M05 BA Umschlag 0503 00 - Volkswagen Marine · 2 FOREWORD You have decided on a VOLKSWAGEN Marine Boat Engine - Thank you for putting your trust in us. VOLKSWAGEN Marine boat …

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8 Cylinder TDI

TDI 350-8

2 FOREWORD

You have decided on aVOLKSWAGEN Marine Boat Engine

- Thank you for putting your trust in us.

VOLKSWAGEN Marine boat engineshave been specially developped foruse in boats.VOLKSWAGEN Marine offers a widemodel range to meet your specificrequirement.VOLKSWAGEN Marine boat enginesare characterised by manyadvantages:

Compact design and low weightcreate the conditions for universalinstallation.

A long life and low fuelconsumption ensure economy andenvironmental friendliness.You have decided on aVOLKSWAGEN Marine boat enginethat is advanced in every regard. Yourboat engine has been developed toput the least possible strain on theenvironment.

VOLKSWAGEN Marine ServicePartners are at your disposal to takecare of your VOLKSWAGEN Marineboat engine.

The VOLKSWAGEN Marine ServicePartner

The VOLKSWAGEN Marine ServicePartners provide a competitive andprofessional service, with all workconforming to factory guidelines.They also ensure that yourVOLKSWAGEN Marine boat engine isin complete working order. Inaddition, VOLKSWAGEN MarineService Partners offer an extensivepackage of warranties and serviceoffers.VOLKSWAGEN Marine ServicePartners will be happy to providedetails on the services and possibledevelopments in individual countries.

VOLKSWAGEN Marine

OPERATION

MANUAL STRUCTURE 3

This manualcontains important information on usingyour VOLKSWAGEN Marine engine. Youshould read this manual carefully beforefirst use of your engine to quicklyfamiliarise yourself with the engine and sothat you know how to operate and handleit correctly.In addition to regular care andmaintenance, the proper treatment of theVOLKSWAGEN Marine engine helpspreserve its value and is in many casesalso one of the conditions for warrantyclaims.Additional warranty information iscontained in the service schedule.For safety reasons, please observe thesafety precautions on page 17 and theinformation on changes and partsreplacement on page 19.

Supplied equipmentThe supplied equipment described here isas complete as possible at the time ofgoing to print. Some of the equipmentmay not be available until a later time.

Equipment marked with a * is not part ofthe standard equipment of VOLKS-WAGEN Marine boat engines.

Environmental protectioninformation

Text in italics marked with thissymbol provides importantinformation on environmentalprotection.

ContentsOn the first pages you will find a table ofcontents that shows all topics describedin this manual in the order of theiroccurrence.

IndexAt the end of the manual an extensive,alphabetical index is provided.With search terms you can specificallyfind the desired information.

Warnings

WarningTexts written in this bold print and onthis shaded background indicate thepossible danger of accidents andinjuries.

Text in this bold print indicates either risksthat can lead to the marine engine beingdamaged, or indicates particularlyimportant information on the proper useof your engine.

And finally, we have a request:When selling your boat or yourVOLKSWAGEN marine boat engine,please give this manual to the new owner,as the literature is part of theVOLKSWAGEN Marine boat engine.

What you should knowbefore you read this manual

OPERATION

4 MANUAL STRUCTURE

NoteWhen your boat is craned or slipped,water can enter the exhaust system ofyour engine.Make sure that the exhaust system ofthe engine is drained of any remainingwater before craning or slipping toavoid damage.

CONTENTS

MANUAL STRUCTUREWhat you should knowbefore you read this manual 3. . . . .

OPERATIONGeneral view of the engine 6. . . . . .Starting the engine 7. . . . . . . . . . . . . .Engine break-inngine 7. . . . . . . . . . . .Switching off the engine 7. . . . . . . .Instruments / Switches 8. . . . . . . . . .Warning lamps 11. . . . . . . . . . . . . . . .Ignition lock 12. . . . . . . . . . . . . . . . . . .Midipanel instrumentation* 12. . . . .Start button 13. . . . . . . . . . . . . . . . . . .Throttle lever 13. . . . . . . . . . . . . . . . . .Stop switch 16. . . . . . . . . . . . . . . . . . .

TIPS AND HINTSSafety precautions for workingin engine compartment 17. . . . . . . . .Diesel 18. . . . . . . . . . . . . . . . . . . . . . . . .Changes and parts replacement 19.

SELF-HELPSelf-help 20. . . . . . . . . . . . . . . . . . . . . .Fuses 24. . . . . . . . . . . . . . . . . . . . . . . . .

INSPECTION SERVICEService and care 26. . . . . . . . . . . . . . .Start of season 27. . . . . . . . . . . . . . . .Daily checks 28. . . . . . . . . . . . . . . . . .End of season 29. . . . . . . . . . . . . . . . .Service scope once yearlyor every 200 operating hours 30. . .

Additional workevery 1,000 operating hours 31.Additional work every 5 yearsor every 3,000 operating hours 32.Engine oil 33. . . . . . . . . . . . . . . . . . . . .Engine oil level checking 34. . . . . . . .Engine oil top-up 35. . . . . . . . . . . . . . .Engine oil renewal 36. . . . . . . . . . . . .Oil filter element replacement 37. . .Circulation filter* 38. . . . . . . . . . . . . .Fuel fine filter 39. . . . . . . . . . . . . . . . .Seawater filter* 41. . . . . . . . . . . . . . .Air filter cleaning 42. . . . . . . . . . . . . .Cooling system 43. . . . . . . . . . . . . . . .Seawater pump 45. . . . . . . . . . . . . . . .Sacrificial anode 46. . . . . . . . . . . . . . .Reverse gearbox-oil level 46. . . . . . .Power steering hydraulic-oil levelchecking (only for Z-drive) 47. . . . .Ribbed V-belts and toothed belts 48Battery* 49. . . . . . . . . . . . . . . . . . . . . .Engine test run 53. . . . . . . . . . . . . . . .Engine preservation 53. . . . . . . . . . . .Winter operation 55. . . . . . . . . . . . . . .Tropical operation 57. . . . . . . . . . . . .

TECHNICAL DATATDI 350-8 Diesel Engine 58. . . . . . . .Engine characteristic data 59. . . . . .

KEYWORD INDEXIndex 60. . . . . . . . . . . . . . . . . . . . . . . .* Does not form part of the standard scope of supply for VOLKSWAGEN Marine boat engines.

OPERATION

6 OPERATION

BM8-- 001M

Engine description TDI 350-8

-- Four-stroke diesel engine

-- Common-rail direct injection

-- V8 cylinder arrangement

-- 4.2 litre displacement

-- Crankshaft mounted on 4 bearings

-- Valves control by chain connected tooverhead cam

-- Hydraulically adjusted bucket tappets

-- Engine lubrication as forced-feedcirculatory lubrication with geared oilpump and replaceable oil filter in mainflow

-- Dry air filter

The engine has two separate coolingcircuits.1 The open seawater circuit runs via the

oil cooler, the main heat exchangerand the exhaust manifold.

2 The coolant circuit runs as a closedpressurised system through theengine block, oil cooler, exhaustcollector, and, after reaching theoperating temperature, via the mainheat exchanger.

WarningObserve the safety precautionsbeginning on page 17 beforeperforming any work on the engine orin the engine compartment.

General view of engine

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OPERATION

OPERATION 7

WarningNever start or operate the engine in

an unventilated or enclosed space.The engine exhaust contains,amongst other gases, odourless andcolourless carbon monoxide, apoisonous and life-threatening gas!Carbon dioxide can cause uncon-sciousness and death.

Observe the safety precautionsbeginning on page 17 beforeperforming any work on the engine orin the engine compartment.

Never start the engine when thethrottle lever(s) has/have beenremoved.Risk of accident!

When the throttle lever is correctlyinstalled, the engine cannot be startedunless the lever is in neutral position.This is indicated in your rev. counterdisplay (Neutral blinking). Before starting the engine, check the

motor oil-, coolant- and hydraulic oillevels, the fuel gauge and the seawaterfilter, and make sure that the seawatervalve for the seawater cooling circuitsupply is open. As soon as the engine starts, release

the ignition key immediately, as thestarter must not continue to run with theengine. When restarting the engine, restarting

is not possible until the key has beencompletely turned back. The restarting-lock prevents the starter from engagingwith the engine running, which coulddamage the starter. After starting a cold engine, increased

running noises may occur for a briefperiod, as oil pressure must first build upin the hydraulic valve clearancecompensation unit. This is normal andshould thus be ignored.

Even modern engines need a break-in period. Be careful to drive moderately untilan optimum operating temperature of90°C is reached and always avoid highrpm when the engine is cold.Do not accelerate too fast at the beginning and drive moderately to break inthe engine not exceeding 2/3 of the nominal rotation speed for approximatelythe first five hours.After the approximate five-hour periodyou may gradually run up the rpm.This is to ensure that the plain bearings ofthe engine all perfectly benefit from aproper engine break-in.The result: frictional resistance, long-termwear, and oil and fuel consumption are significantly reduced whereas the engineservice life is prolonged and the performance increases.As a result of an improper break-in procedure, fuel and oil consumption will generally increase with normal service life accompanied by poor engine performance.

Switch off engineFollowing longer periods at high engineloads, do not switch off the engineimmediately, but instead allow it to idlefor approx. 2 minutes to prevent heataccumulation.


Starting the engine Engine break-in

OPERATION

8 OPERATION

The figure shows the control unit buttonsfor the individual instrumentation.

1 - Control unitItem1 Button for dimmer regulation and

instrument lightingThe brightness of the instrument lightingcan be adjusted by pressing the button.

2 Acknowledge button for acousticsignal

The acoustic signal of a fault message canbe acknowledged with this button.

3 Button for multifunction displayThe multifunction display is operated withthis button. Each time the button ispressed, the display in the MFD isadvanced.NoteA comprehensive instruction manualcontaining descriptions of the individualfunctions of the multifunction display iscontained in the bookletAdditional operating manual for themultifunction display

4 Access to diagnostic interface5 without function

WarningBefore mounting components of the individual instrumentation, please read theinstallation description.It contains important safety instructionsfor mounting..

BM6--018M

Instruments / Buttons

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OPERATION

OPERATION 9

BM6--027M

2 - Coolant temperature gaugeThe gauge works once the ignition isturned on.When the ignition is switched on, thewarning lamp -1- lights up for a fewseconds as an operating check.NoteAvoid high engine speeds and do notsubject the engine to heavy loading aslong as the coolant temperature is stillbelow 40 °C.The needle should, during normal running,oscillate about the central scale area.At heavy engine loads and high outsidetemperatures, the needle may also movefar into the upper range.This is not a cause for concern as long asthe warning lamp -1- does not light up andthe acoustic signal does not sound.

1 - Warning lampWarning lamp -1- lights up when thecoolant temperature is too high.As an additional warning, an acousticsignal sounds at the same time, which canbe switched off with the confirmationbutton -7- (see figure on page 12).Should the fault not be cleared, theacoustic signal sounds again after a shorttime.In this case, switch off the engineimmediately and check whether ...

- the seawater filter is clogged.- the seawater valve is open.- sufficient coolant is present. Check the

cooling system for leaks.- The ribbed V-belt of the seawater

pump is OK.- The impeller of the seawater pump is

OK -see page 50.

Please contact the nearest VOLKS-WAGEN Marine Service Partner if thefault cannot be eliminated.

If the lamp lights up during running, firstcheck the coolant temperature gauge.If the gauge is in the normal range,coolant must be added as soon aspossible.If the needle is above 110 °C, the coolanttemperature is too high. Stop the engineand determine the cause of the fault - seepage 23.

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OPERATION

BM5--048M

3 - Rev. counterNever run the cold engine at high speeds- either when idling or during running.If the needle of the rev. counter goesabove 4500 rpm, you should cut back onthe throttle to prevent engine damage.In the case of a system error the multifunction display of the rev.counter showsthe message -SERVICE-.If this message appears, the programstored in the engine control unit willenable you to safely continue your triphowever if necessary with a reducedengine output.Please contact a VOLKSWAGEN MarineService Partner for system failure analysisand troubleshooting.

BM6--020M

4 - VoltmeterThe voltmeter indicates the voltage in theelectrical onboard supply. Normal value:between 12 and 16 volts. If the generatorcharging indicator lights up or the gaugedrops below 12 volts with the enginerunning, have the power supply (batteryand alternator) checked by aVOLKSWAGEN Marine Service Partner.During starting, the indicated voltage canfall beneath 8 V.


10 OPERATION

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OPERATION

OPERATION 11

BM6--026M

5 - AlternatorThe warning lamp -1- illuminates whenthe ignition is switched on. It must go outafter the engine starts.If the alternator warning lamp lilluminatesduring running:

- Switch off the engine immediately andcheck the ribbed V-belt.

If the ribbed V-belt is OK, the fault isprobably in the alternator or the regulatingswitch. If the damage cannot be repaired,please contact the nearestVOLKSWAGEN Marine Service Partner.NoteThe engine must not:

- be operated with the batterydisconnected, as otherwise thealternator will be damaged.

- operated without the alternator ribbedV-belt, as otherwise the front vibrationdamper will be damaged.


BM6--029M

6 - Engine oil pressure gauge(installation optional)

The engine oil pressure gauge onlyfunctions with the engine running andindicates the existing engine oil pressure.During driving the engine oil pressure isbetween approx. 1 and 5 bar. At anengine oil pressure lower than 1 bar theengine oil pressure warning lamp can lightup and an acoustic signal can sound.If the engine oil-pressure warning lampilluminates or flickers during operation:

- Switch off the engine immediately, asengine lubrication may be interrupted.

- Then check the engine oil level (seepage 34).

You can switch off the acoustic signal bypushing the acknowledgement key -7-(see page 12).Should the fault not be eliminated, theacoustic signal sounds again after a shorttime.Occasional flickering of the warning lampat idle when the engine is warm is meaningless if the lamp goes out again whenthe engine speed is increased.The oil pressure warning alamp is not anoil level display ! Therefore the oil levelshould be checked at regular intervals,preferably before each trip.

Warning lamps

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OPERATION

BM5--019M

1 - Fuel supply interrupted, engine off2 - Running position3 - Starting the engine

WarningAlways remove the ignition key if youleave the boat - even for a short time.This is particularly important whenchildren remain in the boat. Otherwisethey could start the engine or operatethe electrical equipment. Risk ofaccident!

Emergency stop switchAn emergency stop switch with lanyardhelps to prevent accidents. If there is anemergency situation with risk ofendangering personal (man overboard),the complete power supply of the enginewill be stopped immediately by pulling thelanyard. Therefore the installation and useis stringently required by VOLKSWAGENMarine. An emergency stop switch mustbe located at all control panels (for furtherdetails please follow the “Installation description EB08”, page 41).To restart the engine, the toggle switchhas to be moved back to the -ON-position.

BM5--019M

As an alternative to the individualinstrumentation, which is included in thedelivery, a midi panel instrumentation*may be used instead.Pos.

1 - Rev. counter with multifunctional display

2 - Indicator light for coolant temperature

3 - Indicator light for motor control

4 - Indicator light for alternator

5 - Indicator light for emgine oilpressure

6 - Button for multifunction display

7 - Acknowledgement button foracoustic signal

8 - Start button

9 - Ignition lock / Engine stop* Does not form part of the standardscope of supply for VOLKSWAGENMarine boat engines.

WarningBefore installing the midi panelinstrumentation please read the in-stallation description.It contains important safety instruc-tions concerning the installation.

Ignition lock Midi panel instrumentation12 OPERATION

12 OPERATION

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OPERATION

OPERATION 13

BM6--042M

When midipanel instrumentation* isinstalled, the engine can be started usingthe start button* -8- (see figure above).Insert the ignition key in the ignition lockturn to the running position (see page 12).Press the start button to start the engine.

* Does not form part of the standard scope of supply for VOLKSWAGEN Marine boat engines.

BM8--027M

1 - Forward direction2 - Shift to forward direction3 - Neutral4 - Shift to reverse direction5 - Reverse direction

Starting an enginewith a single control stand1 Switch the ignition on.- You will hear a short acoustic signal andthe throttle lever control light (see Item Aon the illustration) flashes twice a second.2 Make sure that the throttle lever is at

neutral -3-.3 Press the -CONTROL- button (see

Item B on the illustration).- The throttle lever control light (ItemA) stays on.

4 Make sure that the message-NEUTRAL- appears in themultifunction display of the revcounter and that there is no signalflashing up.

5 Start the engine.

Start button*Throttle lever function for asingle-engine system

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OPERATION

Starting an enginewith two control stands1. Switch the ignition on.- You will hear a short acoustic signal andthe throttle lever control light of the selected control stand (see Item A on theillustration) flashes twice a second.2. Make sure that the throttle levers of

both control stands are at neutral -3-.3. Push the -CONTROL- button (see Item

B) of the selected control stand.- the throttle lever control light of theselected control stand stays on whereasthe control light of the other control standswitches off.4. Start the engine.

Control stand changeover1. Make sure that the throttle levers of

both control stands are at neutral -3-.2. Press the -CONTROL- button of the

control stand taking over.- The throttle lever control light of thecontrol stand taking over (Item A) stayson.The control stand is now activated.

Speed setting with the gears inneutral1. Make sure that the throttle lever is at

neutral -3-.2. Press the -CONTROL- button (see

Item B on the illustration) andsimultaneously set the throttle leverto position -2-.

3. Release the -CONTROL- button- The control light (see Item A)continuously flashes twice a second.4. You may now, with the gears in

neutral, increase the speed asrequired (throttle lever positions -2- to-1-).

5. To terminate the function, set thethrottle lever to neutral -3-.The control light stays on.

BM8--027M

Throttle lever function for asingle-engine system

14 OPERATION

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OPERATION

OPERATION 15

BM8--029M

Starting the engines with a singlecontrol stand.Start the engines one after the other asdescribed below:stand1. Switch the ignition of the selected

engine on.- You will hear a short acoustic signal andthe throttle lever control light of theselected engine (see Item A or Item C onthe illustration) flashes twice a second.2. Make sure that the throttle lever of

the selected engine is at neutral -3-.3. Press the -CONTROL- button (see

Item B on the illustration).The throttle lever control light (Item A- orItem C-) stays on4. Make sure that the message

-NEUTRAL– appears in the multi-function display of the rev counterand that there is no signal flashing up.

5. Start the engine.

Repeat steps 1. to 5. on the secondengine.

Starting the engines with two controlstandsStart the engines one after the other asdescribed below:1. Switch the ignition of the selected

engine on.- You will hear a short acoustic signal andthe throttle lever control light of theselected control stand (see Item A on theillustration) flashes twice a second.2. Make sure that the throttle levers of

both engines are at neutral -3-.3. Press the -CONTROL- button (see

Item B) of the selected control stand.- The throttle lever control light of theselected control stand stays on whereasthe control light of the other control standswitches off.4. Start the engine

Repeat steps 1. to 5. on the secondengine.

Speed setting with the gears inneutral1. Make sure that the throttle lever is at

neutral -3-.2. Press the -CONTROL- button (see

Item B on the illustration) andsimultaneously set the respectivethrottle lever to position -2- (ahead) orposition -4- (astern).

3. Release the -CONTROL- button.- The throttle lever control light (see ItemA) continuously flashes twice a second.4. You may now, with the gears in

neutral, increase the speed asrequired (throttle lever positions -2- to-1- or -4- to -5-).

5. To terminate the function, set thethrottle lever to neutral -3-.

- The control light stays on.

Throttle lever function for atwo-engine system

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Synchronous operation is possible from5% to 95% of the set speed range.Provided that the throttle levers are notmore than 10% apart from each other inthis range, the synchronous operationlamp –D- (see fig. on page 15) lights upand the engines are controlled to run atsynchronous speed.The synchronization can be deactivatedand activated again respectively by pushing the -CONTROL- button -B- (see fig.on page 15), provided that the button ispushed for a second and the abovementioned conditions are complied with.

BM8--008M

You can stop the engine in case of dangerusing the stop switch -1- on theright-hand side of the central electricalunit.After pressing the stop switch it must beunlocked again, as otherwise the enginecannot be started.To release the stop switch, turn it in thedirection shown by the arrow on theswitch.

Synchronous operation oftwo engines Stop switch

16 OPERATION

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TIPS AND HINTS

OPERATING INSTRUCTIONS 17

When performing any work on the engineor in the engine compartment, e. g. checking and topping up the operating fluids,there is a risk of scalding, injuries, accidents- and fire.

WarningWhen carrying out any work on theengine or in the engine room useextreme care!Protect yourself with suitable workclothing, e.g. gloves, eye protectionetc.

Never open the enginecompartment cover or perform workon the engine when you notice thatwater vapour or coolant is escaping -danger of scalding!Wait until water vapour or coolant isno longer escaping and the engine hascooled down.

Stop the engine, remove theignition key and press the Stop button.

Move the throttle lever into theNeutral position.

Allow the engine to cool.Keep children away from the

engine compartment.Do not open the cap of the coolant

reservoir while the engine is still atoperating temperature, as the coolingsystem is pressurised.

Never pour liquids over the hotengine. The liquids could ignite.

If work on the electrical system isnecessary:-- Never conduct fault finding with

the engine running - danger to lifeand limb!

-- If work on or repairs to the electricalsystem are not carried out properlyor professionally, other areas in theon-board electrical system couldalso be damaged - risk of accidentand fire!Avoid short circuits in the electrical

system, and in particular at thebattery.

If maintenance, testing, repairs oradjustments must be carried out withthe engine running, there is anadditional danger from rotating parts,e. g. ribbed V-belt and alternator.Danger to life and limb!

Please also observe the warnings onthe following page.

Safety precautions when working in the engine compartment

TIPS AND HINTS

18 OPERATING INSTRUCTIONS

If work on the fuel system or theelectrical system is required:

-- Always disconnect the batteryfrom the engine.

-- Do not smoke.

-- Never work near to an open flame.

-- Always have a fire extinguisher atthe ready.

Avoid contact with operatingmaterials. Should operating materialsget into the eyes, flush the eyesimmediately with clean water and seea doctor at once. Take the originaloperating material container with youto the doctor in these cases. Youshould be particularly aware of thefollowing when you want to carry outwork on open water:-- Swell could cause you to become

unbalanced.

-- The risk of spilling operatingmaterials is increased by swell.

-- If you require a doctor in anemergency, there will be a delay.

The warnings in this manual and thegenerally applicable safety rules mustbe observed.

When topping up fluids, make sure thatthey are not confused, as otherwiseserious malfunctions and engine damagewill result.

To ensure that leaks are detected indue time, the bilge under the engine

should be kept clean and should bechecked regularly. If soiling by oil or otheroperating fluids can be seen there, theengine should be checked by aVOLKSWAGEN Marine Service Partner.

Important noteOf course, coolant additives and motor oilare, of course, under constantdevelopment. Therefore this informationonly reflects the status at the time ofprinting. VOLKSWAGEN Marine ServicePartners will always be kept up to datewith any changes by the factory.Therefore, it is best to have operatingmaterials changed by a VOLKSWAGENMarine Service Partner.

TIPS AND HINTS

OPERATING INSTRUCTIONS 19

Diesel used must comply with DIN EN1)

590 .

CN2) not lower than 51.

Notes on the fuel systemDuring the installation of fuel systemcomponents, it has to be made sure thatnon-ferrous metals such as copper lines,brass nipples or galvanized tanks are notused.The use of non-ferrous metals may resultin a power loss of the engine or failure ofthe injection nozzles.

Winter operationWhen using summer diesel, malfunctionsmay occur when exterior temperaturesfall below 0 °C, as the fuel becomes toothick due to paraffinĆseparation.In Germany "winter" diesel fuel is readilyavailable from roadside petrol stationsduring the cold season and - dependent onfuel brand - is safe for operation atapproximately -15 °C to -22 °C.In countries with other climaticconditions, diesel fuels with a differenttemperature behaviour are offered.The addition of petrol (gasoline) or othersubstances will cause severe damage tothe engine and is therefore strictlyforbidden.Biodiesel must not be used.1) EuroStandard

2) Cetane-Number. Measure of the ignitability ofdiesel fuel.

Do not change the as-supplied conditionof VOLKSWAGEN Marine boat engineswithout careful consideration. Therefore,if technical changes are to be made to theengine, or if parts must be renewed later,the following instructions must beobserved:

BEFORE purchasing parts and beforemaking technical changes, a consultationwith a VOLKSWAGEN Marine ServicePartner should always take place becauseVOLKSWAGEN Marine Service Partnersare well qualified to advise in thesematters due to their close cooperationwith us.

WarningIn your own interest we

recommend using only genuineVOLKSWAGEN Marine parts for yourVOLKSWAGEN Marine boat engine.The reliability, safety and suitability ofthese parts especially for the boatengine is ensured.

Despite ongoing observation of themarket, we cannot evaluate or provideany form of guarantee for otherproducts, even if in isolated cases anapproval by an officially recognisedtechnical testing and monitoringassociation or a government approvalhas been granted.

Other products can have a negativeeffect on the service life of yourVOLKSWAGEN Marine boat engine.

Diesel Changes and Parts

TIPS AND HINTS

20 OPERATING INSTRUCTIONS

Genuine VOLKSWAGEN Marine partsare available from a VW Marine ServicePartner. Obviously they will also be ableto ensure installation is carried outcorrectly. If modifications are carried out, always

observe our specifications. This ensuresthat no damage to the engine occurs,operating safety is maintained and thechanges are permissible. AVOLKSWAGEN Marine Service Partnerwill also carry out this work correctly orrefer you to a specialised workshop inspecial cases.

The broad network of VOLKSWAGENMarine Service Partners with trainedprofessionals, modern equipment and allrequired special tools is available to youfor the care and service of yourVOLKSWAGEN Marine boat engine.Here you will receive professional adviceand find fast, effective help.

If, for example, the engine should fail tostart or idling faults occur, faults and theirremedies are described in detail in thefollowing chapter. Should the individualremedies not solve the problem, yourVOLKSWAGEN Marine Service Partnerwill be happy to provide additionalassistance.If repairs must be made, the engine shouldbe brought to a VOLKSWAGEN MarineService Partner. It is in good hands there.


NoteTo find your local VOLKSWAGENMarine Service Partner, visit ourwebsite atwww. volkswagen - marine.de.

If you have special questions, pleasedo not hesitate to contact our free ofcharge Service Hotline at 0800-89 6274 63 or 0800-VWMARINE. We willbe more than happy to help you in anyway we can.

Self-help

TIPS AND HINTS

SELF-HELP 21

Fault

Engine does not start

Starter does not turn

Cause Remedy

Throttle lever is not in neutralposition

Move throttle lever into neutral

Throttle lever neutral switch doesnot generate an output signal (onlywith Z drive)

Check operation of neutral switch

Neutral switch in gearbox does notoutput a signal(only with ZF reverse gearbox)

Check operation of neutral switch

Stop switch activated Unlock stop switch

Ignition switched off Switch on ignition

Battery discharged or defective Check battery and charge;replace if necessary

Starter connections loose orcorroded

Check connections and cleanor replace if necessary

Connections to ignition/starterswitch loose or corroded

Check connections and cleanor replace if necessary

Air inside fuel system See section on fuel system

Should the individual remedies not solve the problem, your VOLKSWAGEN MarineService Partner will be happy to provide additional assistance.


TIPS AND HINTS

22 SELF-HELP

Fault

No or faulty fuel supply

Cause Remedy

Fuel cock closed Open fuel cock

No fuel in tank Fill tank

Tank dirty Clean

Fuel lines clogged Check lines and clean if necessary

Water level in circulation filter* toohigh

Drain water from circulation filter*

Circulation filter* clogged Clean circulation filter*and replace if necessary

Water level in fine element fuelfilter too high

Drain water from fine element fuel filter

Fine element fuel filter clogged Replace fine element fuel filter

Engine shakes

See section on fuel supply

Engine dies

See section on fuel supply



* Does not form part of the standard scope of supply for VOLKSWAGENMarine boat engines

TIPS AND HINTS

SELF-HELP 23

Fault

Engine becomes too hot

Cause Remedy

Seawater valve closed Open seawater valve

Seawater filter is clogged Close seawater valve and clean seawaterfilter.

Seawater pump aspirates air Check cover of seawater filter for properseating and leaks andcheck suction hose.

Oil cooler clogged Check oil cooler, clean if necessary

Impeller of seawater pumpdefective

Renew impeller

Insufficient coolant in coolingsystem - engine circuit

Add coolant (pure water in an emergency).Check cooling system for leaks and seal ifnecessary.

Coolant pump for engine circuitdefective

This fault should always be checked andeliminated by a VOLKSWAGEN MarineService Partner, as special tools arerequired.



* Does not form part of the standardscope of supply for VOLKSWAGEN

Marine boat engines

TIPS AND HINTS

24 SELF-HELP

BM8--007M

The individual circuits are protected byfuses.It is advisable to always carry a fewreplacement fuses available fromVOLKSWAGEN Marine Service Partners.

WarningObserve the safety precautions

beginning on page 17 beforeperforming any work on the engine orin the engine compartment.

Never "repair" fuses or replace withfuses of a higher amperage, as thismay result in damage at another pointin the electrical system. It may evencause a fire.

NoteIf a recently fitted fuse blows again aftera short time, the electrical system mustbe checked as soon as possible by aVOLKSWAGEN Marine Service Partner.

The fuses are located in the centralelectric unit behind the cover (fig.BM8-004M), as well as on the rear side ofthe control unit of the individualinstrumentation (fig. BM6-023M, page25).

BM6--004M

In the case of a two-engine system, thecentral electrical system shown inillustration BM8-004M is applied.The circuit board presented in illustrationBM8-007M is provided in duplicate wherethe boards are mounted side by side withthis type of central electrical system.

Changing a fuse in the central electric unit

Switch off the ignition and the affectedconsumer.

Press down the Stop switch on thecentral electric unit (see fig. on page 16).

Unscrew the screws and remove thecover from the central electric unit.

Determine which fuse belongs to thefailed consumer using the fuse table.Fuse assignmentNo. Consumer A1)

1 Main fuse 20. . . . . . . . . . . . . . . . . . . . .2 Oil extraction pump 5. . . . . . . . . . . . .3 Terminal 15 (ignition on) 15. . . . . . .4 Accessory (ignition on) 5. . . . . . . . . .5 Accessory (permanent positive) 5. .

1) Amps

Fuses

AV01WMH

Kreis

AV01WMH

Kreis

AV01WMH

Kreis

AV01WMH

Kreis

AV01WMH

Kreis

TIPS AND HINTS

SELF-HELP 25

Colour code for fuses:orange: 5 amps. . . . . . . . . . . . . . . . . . . . . .blue: 15 amps. . . . . . . . . . . . . . . . . . . . . . .green: 30 amps. . . . . . . . . . . . . . . . . . . . . . Pull out the appropriate fuse. Replace blown fuse (recognisable by

melted metal strip) with a new fuse of thesame rating. Secure the cover of the central electric

unit again with the screws. Unlock the Stop switch.

Relaybox

BM8--030M

1 - Main fuse (terminal 30) 30 amps2 - Main relay

BM6--023M

Changing a fuse in the control element ofthe individual instrumentation

Switch off the ignition and the affectedconsumer. Press down the Stop switch on the

central electric unit. Loosen the screws and pull the control

unit off in a forwards direction. Determine which fuse belongs to the

failed consumer using the fuse table.Fuse assignmentNo. Consumer A1)

1 Ignition on (terminal 15) 2. . . . . . . . .2 Permanent positive (terminal 30) 2

Pull out the appropriate fuse. Replace blown fuse (recognisable by

melted metal strip) with a new fuse of thesame rating. Replace the control element and

tighten the screws again. Unlock the Stop switch.

1) Amps

Fuses

AV01WMH

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av01wmh

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INSPECTION

26 INSPECTION

The broad network of VOLKSWAGENMarine Service Partners with trainedprofessionals, modern equipment and allrequired special tools is available to youfor the care and service of yourVOLKSWAGEN Marine boat engine.If an inspection service is required, allchecking and adjustment to be carried outin this context are described in detail inthe following chapter.Some of the work must be carried outprior to each engine start..Other work is only required on an annualbasis, at the end of the season or after200 operating hours.

The work described here is used tomaintain your VOLKSWAGEN Marineboat engine.The specified service intervals arematched to normal operating conditions.Under more extreme conditions it isnecessary to have some work carried outbefore the next service is due or betweenthe specified service intervals. Thisapplies above all to the cleaning of the airfilter element when operating in verydusty conditions.

Service and care

INSPECTION

INSPECTION 27

Work at start of seasonAt the start of the season, visually check and inspect the engine.You should have the service work on your VOLKSWAGEN Marine boat engineconducted by your VOLKSWAGEN Marine Service Partner, as the work requiresspecialised knowledge and special tools.

Scope of work Page

Ribbed V-belt for alternator, power steering pump: check condition 48

Toothed belt for common rail injection system: check condition 48

Check operation of seawater valve*

Check battery voltage and charge battery* if necessary 52

NoteMaintenance must be performed on thereverse gearbox or the Sterndrive inaccordance with the specifications oftheir respective manufacturers.



Start of Season

INSPECTION

28 INSPECTION

Visual inspection before each sailingBefore sailing check and visually inspect the engine.

Scope of work Page

Visual inspection for leaks and damage

Check engine oil level 32

Check circulation filter* (bowl) and drain off water if necessary 36

Check coolant level and top up if necessary 43

Check seawater filter* and clean if necessary 40

Check hydraulic oil level* for Sterndrives 47

Check reverse-gearbox oil level 46




Daily checks

INSPECTION

INSPECTION 29

Work at end of seasonAt the end of the season you should subject the engine to a check and visualinspection.You should have the service work on your VOLKSWAGEN Marine boat engineconducted by your VOLKSWAGEN Marine Service Partner, as the work requiresspecialised knowledge and special tools.

WarningObserve the safety precautions

beginning on page 17 beforeperforming any work on the engine orin the engine compartment.

Please be sure to observe theworking sequences and informationon engine preservation from page 53.

Scope of work Page

Visual inspection for leaks and damage

Interrogate fault memory of engine electronics

Change engine oil and oil filter 33,35

Replace fine element fuel filter 39

Check air filter element and clean if necessary 41

Check seawater filter* and clean if necessary 40

Check coolant level and top up if necessary 43

Seawater pump: Check impeller and replace if necessary 45

Check sacrificial anode and replace if necessary 46

Clean engine and carry out preservation measures 53

Flush and drain seawater cooling system 54

Fill fuel tank until full



End of season

INSPECTION

30 INSPECTION

Your VOLKSWAGEN Marine boat engine must be serviced once a year at the end ofthe season or every 200 operating hours.You should have the service work on your VOLKSWAGEN Marine boat engineconducted by your VOLKSWAGEN Marine Service Partner, as the work requiresspecialised knowledge and special tools.The following table shows the work required.

Scope of work Page

Visual inspection for leaks from above and below

Interrogate fault memory

Change engine oil 33

Replace oil filter element 35

Replace circulation filter element* 37

Replace fine element fuel filter 39

Check power steering hydraulic oil level* for Sterndrive engines 47

Check coolant level 43

Check air filter element and clean if necessary 41

Ribbed V-belt for alternator, power steering pump: check condition 48

Toothed belt for common rail injection system: check condition 48

Clean seawater filter* 40

Seawater pump: Check impeller and replace if necessary 45

Check sacrificial anode and replace if necessary 46

NoteMaintenance must be performed on thereverse gearbox or the Z-drive inaccordance with the specifications oftheir respective manufacturers.



Service scopeonce a year or every 200 operating hours

INSPECTION

INSPECTION 31

This additional work on your VOLKSWAGEN Marine boat engine must be carried outevery 1,000 operating hours.You should have the additional work on your VOLKSWAGEN Marine boat engineconducted by your VOLKSWAGEN Marine Service Partner, as the work requiresspecialised knowledge and special tools.The following table shows the scope of the additional work.

Scope of work Page

Clean air filter element 41

Check pipe bundles of heat exchanger; remove and clean if necessary



Additional workevery 1,000 operating hours

INSPECTION

32 INSPECTION

This additional work on your VOLKSWAGEN Marine boat engine must be carried outevery 5 years or every 3,000 operating hours.You should have the additional work on your VOLKSWAGEN Marine boat engineconducted by your VOLKSWAGEN Marine Service Partner, as the work requiresspecialised knowledge and special tools.The following table shows the scope of the additional work.

Scope of work Page

Replace toothed belt for common rail injection system



Additional workevery 5 years or every 3,000 operating hours

INSPECTION

INSPECTION 33

SpecificationsA special VOLKSWAGEN Marine longlifeoil that can be used all-year round is usedto fill the engine at the factory.It has special corrosion protectionproperties to protect the engine in anaggressive environment such as salty seaair. It also protects the engine from innercorrosion during long downtimes, e.g.during winter storage.The container must be labelled with thespecifications given on this page.Important noteObviously, engine oils are under constantdevelopment. Therefore, the informationin this manual can only reflect the statusat the time of printing.VOLKSWAGEN Marine Service Partnersare always kept up to date with anychanges by the factory. Therefore, it isalways best to have the oil change carriedout by a VOLKSWAGEN Marine ServicePartner.

Multigrade light oil:Specification VOLKSWAGEN LonglifeVW 507 00

Important notes

The engine oil named above is aspecified for the given maintenanceintervals. Only this oil should be used fortopping up.

Avoid mixing with other oils, asotherwise the condition for themaintenance intervals specified in theservice schedule will no longer be met.

Engine oil

INSPECTION

34 INSPECTION

A02--0018

During normal running, the engineconsumes oil. Therefore, the engine oillevel must be checked at regular intervals.Conditions for checking the oil level

Engine oil temperature must be at least60 0C

The boat must be at rest whenmeasuring the oil level.

Wait a few minutes after switching offthe engine to permit the oil to run backinto the oil pan.Sequence of work

Pull the dipstick out, wipe it with aclean cloth and push the dipstick backagain into the tube making sure that itgoes all the way in.

Pull the dipstick out again and checkthe oil level.Using the markings on the dipstick as anindicatora – Oil must not be added.b – Oil can be added.c – Oil must be added.Sufficient oil is provided if the oil level isthereafter within the –b- range (serratedarea).

NoteThe oil level must not exceed the maxmark –a- and must not be below the minmark –c-.

In the case of heavy engine loading, suchas during longer engine operation(10 - 12 hours), the oil level should atleast lie in the middle of the two markings(min/max).The quantity difference between min. andmax. marks is 1.3 litre..

Checking engine oil level

INSPECTION

INSPECTION 35

A10--10372

Remove the cap of the oil filler neck–arrow- and pour in small quantities ofengine oil. Make sure that you also checkthe oil level by using the dipstick.illustration above).The oil level must never be above range A(see figure on page 34). Otherwise oilmay be sucked via the crankcaseventilation.

WarningWhen topping-up, do not allow any oilto fall onto hot engine components -risk of fire.

Carefully close the oil filler cap and pushthe dipstick in as far as the stop.Otherwise, oil could escape with theengine running.


The properties of VOLKSWAGEN Longlifeoil not only worsen due to loading duringoperation, but also due to ageing. The oilchange date is therefore dependent onboth the mileage and the running time.If the engine is constantly operated underextreme operating conditions, the motoroil should be changed at shorter intervals.The motor oil must be changed at theintervals specified on page 29 and 30.Have the oil change carried out by aVOLKSWAGEN Marine Service Partner.

WarningIf you want to change the motor oilyourself, then please be sure toobserve the following points:

To prevent the risk of burns fromhot motor oil, allow the engine to coolfirst.

Use a suitable container of asufficient size to hold the oil fillingquantity of your engine when drainingthe oil.

Wear eye protection.If your hands come into contact

with motor oil, they must then bewashed thoroughly.

Used oil must be stored in a safeplace away from children until itsproper disposal.

Refilling engine oil Engine oil renewal

INSPECTION

36 INSPECTION

A24- 10 558

Loosen the protective cap -1- of theoil filter housing -2- (see illustrationabove) using a 32 mm socket wrench, sothat the return valve opens and the usedoil can flow back into the oil sump.

The supplied oil change hose -3- isalready connected on to the union of theoil extraction pump -4- (see illustrationbelow) .

Route the other end of the hose into thecontainer being used for the oil change.

BM8--022M

BM8-- 015M

With the engine stopped and theignition switched on, press and hold thebutton -1- at the right front side of theengine and wait until the engine oil hasbeen fully extracted

Engine oil renewal

AV01WMH

Rechteck

INSPECTION

INSPECTION 37

A17--10093

Loosen the protective cap -1- of the oilfilter housing -6- (see illustration above)using a 32 mm socket wrench and removethe cap together with the filter element-3-.

Remove the filter element -3- from thecap -1- and wipe the cap with a cleancloth

Replace the filter element -3- and thegasket -2- and lightly coat the new gasketwith oil.

Replace the O-ring -5-. Fit the cap -1- together with the new

filter element -3- into the oil filter housingand tighten the cap with a tighteningtorque of 35 Nm.

When proceeding with the fitting makesure that the neck – 4-, below at the oilfilter element, is inserted into therespective drilling -5- of the oil filterhousing (see fig. right ).

Use a 32 mm socket wrench to tightenthe cap.

BM6--014M

For filling quantities see the chapter"Technical data".

Check the oil level with the oil dipstick -also see page 34.

The oil level must be between the twomarkings and should never be above themax. mark.

WarningUsed oil must be stored in a safe placeaway from children until its properdisposal.

Oil must never get into waterways,the sewer system or the ground.Due to the disposal problem, it is best

to have the motor oil and filter change carried out by a VOLKSWAGEN MarineService Partner.

Engine oil additivesDo not mix additives with the engine oil.Damage resulting from the use of suchadditives, will not be covered by theguarantee.

Replacing the oil filterelement

INSPECTION

38 INSPECTION

BM5--026M

WarningIf you wish to change the circulation filterelement*, always follow the guidelinesand instructions provided by the manufacturer as well as the following notes.

Close the cut-off valve if present. If theengine is equipped with a single filter,switch off the engine. With a double filterit is sufficient to switch over to the otherfilter.

Please make sure that no diesel fuelgets onto the hoses. Clean hosesimmediately if necessary.

Wear eye protection.

If your hands come into contact withdiesel fuel, they must then be washedthoroughly.

The used circulation filter element mustbe stored in a safe place away fromchildren until its proper disposal.

Observe the safety precautionsbeginning on page 17 before performingany work on the engine or in the enginecompartment.

Back-flushingSwitch off the engine (single filter) or

switch over to the second filter (doublefilter).

Unscrew the bleeder screw -1-.Open the drain valve -2- below the

bowl and catch fuel in a suitable containeruntil all dirt is rinsed out of the bowl.

Close the drain valve -2-.Pour clean fuel into the filter via the

bleed hole.Screw the bleed screw -1- back in.Start the engine and conduct a visual

inspection of the fuel system for leaks.

Notes

After draining the fuel it is notnecessary to bleed the fuel system.

Should a loss of power or excessivelyhigh intake resistance not be eliminatedby back-flushing, the filter element mustbe replaced.

Diesel fuel must never get intowaterways, the sewer system or the

ground.Due to the disposal problem, it is best tohave the filter change carried out by aVOLKSWAGEN Marine Service Partner.

* Does not form part of the standardscope of supply for VOLKSWAGENMarine boat engines

Circulation filter*water drainage

AV01WMH

Rechteck

INSPECTION

INSPECTION 39

WarningIf you wish to change the circulationfilter element, always follow theguidelines and instructions providedby the manufacturer.

Fine element fuel filterwater drainage

WarningIf you want to drain the water from thefine element fuel filter, then please besure to observe the following points:

Please make sure that no diesel fuelgets onto the coolant hoses. Clean hoses immediately if necessary.


with diesel fuel, they must then bewashed thoroughly.

Used fuel must be stored in a safeplace away from children until its proper disposal.

Observe the safety precautions beginning on page 17 before performingany work on the engine or in the engine compartment.

BM8--002M

Open the drain screw -1- (see fig.above) by a few turns and catch about100 cm3 fuel in a suitable container.

Screw the bleed screw -1- back in.

NoteAfter draining the water from the fineelement fuel filter it is not necessary tobleed the fuel system.

The fine element fuel filter provides ahand pump -2- (see fig. above).After draining the water from the fineelement fuel filter, pump it until youdetect an increased resistance. The fuelsystem has been filled with diesel.Finally, visually check the fuel system forleaks.

Diesel fuel must never get intowaterways, the sewer system or theground.

Due to the disposal problem, it is best tohave the filter change carried out by aVOLKSWAGEN Marine Service Partner.

Replacement of circulationfilter element*

Fine element fuel filterwater drainage

INSPECTION

40 INSPECTION

BM6--017M

WarningIf you want to change the fine elementfuel filter yourself, then please be sureto observe the following points:

Please make sure that no diesel fuelgets onto the coolant hoses. Cleanhoses immediately if necessary.


with diesel fuel, they must then bewashed thoroughly.

The old fine element fuel filter mustbe stored in a safe place away fromchildren until its proper disposal.


Remove the connector -2-.Unscrew the old fine element fuel

supply filter -3- and clean the sealingsurface of the bracket

Empty the fine element fuel supplyfilter into an appropriate container andunscrew and remove the drain plug -1-.

Remove the drain plug of the new fineelement fuel supply filter and make sureto replace it with the drain plug of the oldfilter

Lightly coat the rubber ring of the newfine element fuel supply filter with dieselfuel.

Fill the fine element fuel filter withclean diesel. This enables the engine to bestarted more quickly.

Screw in the new filter andfinger-tighten it

Fit the connector -2- back inNoteAfter replacing the filter element it is notnecessary to bleed the fuel system.

The fine element fuel filter provides ahand pump. After changing the fineelement fuel filter, pump it until youdetect an increased resistance. The fuelsystem has been filled with diesel.

Finally, visually check the fuel systemfor leaks.

Diesel fuel must never get intowaterways, the sewer system or the

ground.Due to the disposal problem, it is best tohave the filter change carried out by aVOLKSWAGEN Marine Service Partner.

Replacement of fine elementfuel filter

INSPECTION

INSPECTION 41

BM5--006M

WarningNever open the filter housing with

the seawater valve open to preventwater from entering.


As the degree of soiling of the seawaterfilter is depending on the water the engineis operated in, you should check the filterfor soiling each time before starting theengine. As the cover of the filter housingis transparent, you do not need to openthe cover.


If you detect soiling, proceed as follows: Close the seawater valve. Unscrew the screws -see left figure-

and remove the cover. Remove the filter element, flush it

thoroughly with clean water and refit it. Before screwing on the filter cover, the

sealing ring should be lubricated, e.g. withsilicone oil or Teflon spray.

Check the cover and the gasket forcorrect seating.

WarningIf a cover is not seated correctly, aircan be sucked in, causing the engineto overheat.

Open the seawater valve again. Start the engine and conduct a visual

inspection of the seawater filter* forleaks.

Cleaning of seawater filter*

INSPECTION

42 INSPECTION

BM8--021M

The air filter must be regularly cleaned.A dirty air filter can be detected in that thedirt particles will have settled in the smallopenings of the filter (see figure).If the engine is operated in very dustyareas, clean the filter more frequently.

Removing the air filter Remove the two hoses of the

crankcase ventilation system -A- and -B-at the left and right protective cap of theair filter.

Loosen the hose clips -1- and -2- (seetop left and top right illustration) and pullthe two protective caps of the air filtertogether with the air filter off the intakepipes of the two turbochargers.

Loosen the two mounting screws -3-and -4- at the metal rings and remove thetension springs -5- from the metal rings(4x).

Remove the metal rings from theprotective caps.

Remove the caps from the air filter. Blow-out the filter from the inside

towards the outside with max. 2.0 barcompressed air.

BM8--009M

WarningWear protective goggles when blowing

out the filter. Flying dirt particles can enterthe eyes -risk of injury.


Clean the filter as described in theinstructions on the special cleaning and servicekit available from a VOLKSWAGEN MarineService Partner.

Note

Never use petrol, thinner or other agents forcleaning! The filter could be destroyed.

Installing the air filterInstallation of the air filter is carried out inreverse sequence

WarningWhen installing the protective caps make surethat the marking at the rim of the caps is properly aligned with the silver metal strip of one ofthe air filter ribs. (see - arrows). Arrange themounting screws of the metal rings in such away that the screwed connection is alsoaligned with the marking. This is necessary toensure that the two protective caps are fittedto the intake pipes of the two turbo chargers.

Air filter cleaningAir filter blow-out andwashing

AV01WMH

Rechteck

AV01WMH

Rechteck

INSPECTION

INSPECTION 43

The cooling system must be filled with amixture of water and our coolant additiveG12++ (corrosion inhibitor andethylene-based antifreeze) at a ratio of60% (water) to 40% (coolant additive).This ratio provides the necessaryantifreeze protection down to approx.-25°C and, most of all, protects the lightmetal components of the cooling systemagainst corrosion. In addition to this, scaledeposits are avoided and the boiling pointof the coolant is significantly increased.Therefore, even in summer or in warmercountries, the water/additive ratio mustnot be changed by refilling the systemwith water. The coolant additive portionmust always be at least 40%.For climatic reasons, the G12++ portionmay be increased to 50% (antifreezeprotection down to about -35°C).An increase to 60% coolant additivecontent provides antifreeze protectiondown to -50°C.

CautionThe less water and the higher thecoolant additive portion in the system,the higher the danger of a heatbuild-up. Beginning at a coolantadditive portion of around 65%,antifreeze protection deterioratesdramatically. The result is an erratictemperature rise in the system, as theheat conductivity of the coolant dropsextremely.

Coolant lossCoolant loss is mainly a result of leakages.In such an event, the cooling systemshould be inspected immediately by aVOLKSWAGEN Marine Service partner.It is not sufficient to just add coolant.With the system sealed, coolant losseswill only be experienced when the coolantboils as a result of overheating and is thenpressed out of the system.

Only our G12++ (corrosion inhibitor andethylene-based antifreeze) or an additivewith the specification TL 774-F (N 052774 F0, check the description on thecontainer, bottle or drum) must be used ascoolant additive. The coolant additive isavailable from VOLKSWAGEN MarineService Partners.Any other coolant additive mayconsiderably influence the corrosionprotection effect.Any such resulting corrosion damage mayinvolve the loss of coolant and,subsequently, cause considerabledamage to the engine.

WarningThe coolant additive and the coolantpresent a health hazard!The coolant additive must thereforebe stored in a particularly safe placeout of reach of children. If the coolantmust be drained, it must be caughtand also stored in a safe place.

Drained coolant should normally notbe reused; it must be disposed of

under observance of the applicableenvironmental protection regulations.

Cooling system Coolant additive

INSPECTION

44 INSPECTION

BM8-- 003M

The coolant level can only be properlychecked with the engine stopped.The right coolant level is important for theproper operation of the cooling system.Therefore, the coolant level should bechecked regularly. With the engine cold,the coolant must be above the min markand below the max mark (see fig. above).NoteThe coolant level is measured using asensor. If the coolant level is too low, thenthis is displayed in the multifunctiondisplay and an acoustic warning tone issounded.

Visual inspectionCheck the coolant hoses for leaks andporosity.When operating the engine in the tropics, thenotes on page 56 must also be observed!

WarningNever open the engine compartment

cover when you see water vapour orcoolant escaping from the enginecompartment - risk of scalding! Wait untilwater vapour or coolant no longer escapes.

Do not open the cooling system capwhile the engine is hot - danger of scalding:The coolant system is pressurised!


Use only new coolant for topping up.First stop the engine and allow to cool.Then cover the cap with a cloth and care-fully unscrew in an anti-clockwise direction.If no G12++ or an additive with the specification TL 774-F (N 052 774 F0 see label on container, bottle or drum) isavailable, no other coolant additive shouldbe used. In this case only use water andrestore the proper mixing ratio with thespecified coolant additive (see page 39)as soon as possible.In case of a major loss of coolant, only addcoolant with the engine cooled down toprevent engine damage.

Never fill the system above the max.mark:Excess coolant is forced out of the coolingsystem when it heats up by theoverpressure valve in the cap!

Screw the cap firmly on.

Important notePlease observe the following whentopping up:G12++ can be mixed with G13 at anyratio. Mixing with any other coolantadditives must be avoided as this woulddeteriorate the corrosion protection andaffect service life.G12++ is violet. If the fluid shows anyother colour, then G12++ has beenmixed with another coolant additive!In this case be sure to change the coolantas soon as possible!If this is not done, severe engine damageor malfunction may result!

Checking coolant level Coolant top-up

AV01WMH

Rechteck

INSPECTION

INSPECTION 45

BM6--011M


In accordance with the specifications inthe service schedule, the impeller must bechecked and replaced if necessary.Note

Close the seawater valve. Remove the screws -1- (see figure

above)- on the front side of the seawaterpump and take off the cover.

Mark the direction of rotation of theimpeller -7- (see fig. BM6-012M) andremove the rubber seal -5- from themiddle of the impeller.

Pull the impeller downwards off theshaft with a suitable puller.

Check the impeller for damage.

Notes

The impeller must always be replaced, even if there is only minor damage.

Make sure you always have a reserve impeller on board.

BM6--012M

Before reinstalling the impeller, greaseit with silicone spray or glycerine.

Push the impeller onto the shaft andpress the rubber protection cap into theimpeller.

Replace the housing sealing ring -6-(see fig. above).

Replace the cover on the housing andscrew the screws -1- (see fig.BM6-011M)) back in.

Open the seawater valve. Start the engine and check the cooling

system for leaks.

Seawater pump impeller checkingand replacement where necessary

AV01WMH

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AV01WMH

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INSPECTION

46 INSPECTION

BM8--012M

The sacrificial anode in the coolingsystem must be checked in accordancewith the specifications in the serviceschedule and replaced if necessary.Check the sacrificial anode, as it protectsthe engine from galvanic corrosion.ăClose the seawater valve.ăScrew out the sacrificial anode.

NoteThe reactive anode is located at the backof the intercooler (see illustration above).

ăCapture any escaping water(approx. 2-2.5 l) with a suitable container.ăAfter checking, screw the sacrificial

anode back in.ăOpen the seawater valve.

A new sacrificial anode has a length ofdimension A = 20 millimetres - seefigure.The anode must be replaced with a newone when more than 50 % (10millimetres) of it has been used.Use only original VOLKSWAGEN Marineparts, as an incorrect composition of theanode can result in serious corrosiondamage to the engine.

BM5--007M


NoteThe oil of a reverse gear engine must bechanged according to the instructionsprovided by the respective gearmanufacturer. With every oil change, thefilter element must also be replaced.Please make sure that you always followthe instructions provided in the operationmanual of the manufacturer.

In order to properly check the oil level, theboat must be lying calmly. Afterswitching off the engine, wait a fewminutes to permit the oil to run back intothe oil pan. The oil level can be checkedeither hot or cold.

WarningMaintenance work on the gearbox hasto be carried out only with engineswitched off. Always wear gloveswhen working on a hot gearbox.

Checking sacrificial anodeand replacement if necessary

Reverse gearboxoil level checking

AV01WMH

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AV01WMH

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INSPECTION

INSPECTION 47

BM5--034M

Sequence of work1. Remove the dipstick by rotating its gripanticlockwise (see fig. BM5-007, p. 46) BM5-007M)before withdrawing the dipstick from thehousing.2. Wipe the dipstick off with a clean anddust-free cloth ensuring all oil is removed.3. Insert the dipstick back into the hole ofthe housing, making sure that you push itdown to the end without screwing it in because otherwise the reading of the oillevel will not be correct.4. Then pull out the dipstick again andread off the oil level:A- If the oil level is within range -A-, no

oil should be added.B- If the oil level is within the range -B-,

oil may be added.When doing so, the oil level may endup in range -A-.

C - If the oil level is within the range -C-or below, oil must be added. There issufficient oil when the oil level iswithin range -B-.

However, the oil level must never beabove range -A-.In the case of heavy gearbox loading,such as during longer engine operation(10 - 12 hours), the oil level should atleast lie in the middle of the two markings(min/max).

BM6--005M


You should not leave the steering wheelat lock for longer than 15 seconds withthe engine running. The hydraulic oilheats up considerably when the wheel iscontinually at full lock.The power assisted steering system couldbe damaged as a result.Noise also indicates the fact that thewheel is in the steering lock position whilethe boat is stationary, as the servo pumpis heavily loaded in the process. It will alsobriefly reduce the idling speed of theengine.The power-steering hydraulic oil levelmust be checked at regular intervals.This test must be conducted with theengine running and the rudder in thestraight-ahead position.

Reverse gearboxoil level checking

Hydraulic power steeringoil level checking (only Z-drive)

AV01WMH

Rechteck

AV01WMH

Rechteck

INSPECTION

48 INSPECTION

BM5--033M

Screw out the oil dipstick -1-, wipe witha clean cloth and screw in the dipstickagain up to the stop.Then screw out the dipstick again andread off the oil level:A - If the oil level is within range A,

no oil should be added.B - If the oil level is within range B,

oil may be added.When doing so, the oil level may endup in range A.

C - If the oil level is within the range C orbelow, oil must be added. There issufficient oil when the oil level iswithin range B.

In the case of heavy steering loading,such as during longer operation (10 - 12hours), the oil level should at least lie inthe middle of the two markings(min/max).

Power-steering hydraulic oil renewalThe power-steering hydraulic oil must bechanged in accordance with thespecifications of the respectivemanufacturer.

WarningThe ribbed V-belt and the toothed

belt should only be checked orreplaced with the engine stopped - riskof injury!


Check the ribbed V-belt and toothed beltfor wear, separations and cracks.Ribbed V-belts and toothed belts in poorcondition must be replaced.If you are not sure whether the ribbedV-belt or toothed belt is damaged, pleasecontact a VOLKSWAGEN Marine ServicePartner.NoteIt is always advisable to keep areplacement ribbed V-belt and toothedbelt on board.

Hydraulic power steering oillevel checking (only Sterndrive)

Checking the ribbed V-beltand toothed belt

AV01WMH

Rechteck

INSPECTION

INSPECTION 49

WarningThe following warnings and safetyprecautions must be observed whenworking on the battery.

Wear eye protection. Do notallow acidic or lead-con-taining particles to get intothe eyes or on to the skin or

clothing.

Battery acid has a highlycorrosive. Wear protectivegloves and eye protection. Donot tilt the battery as acid may

escape from the ventilation openings.Flush the eyes with clean water forseveral minutes if acid splashes intothem. Then seek medical assistanceimmediately. Immediately neutralizeany acid splashes on the skin orclothing with soap suds and then rinseoff with lots of water. If acid isswallowed, seek medical assistanceimmediately.

During battery charging, ahighly-explosive gas mixtureis generated.

Fire, sparks, naked flamesand smoking are forbidden.Avoid spark formation whenhandling cables and electrical

devices. Prevent short circuits. Nevershort circuit battery poles. Risk ofinjury due to high-energy sparks.

Keep acid and batteries awayfrom children.

Always switch off the engine, theignition and all electrical consumersand press the Stop button beforeworking on the electrical system. Thenegative cable must be disconnectedat the battery.

When disconnecting the battery,first disconnect the negative cable andthen the positive cable.The battery should not bedisconnected with the engine runningor with the ignition switched on, asotherwise the electrical system(electronic components) will bedamaged.

When reconnecting the battery,first connect the positive cable andthen the negative cable. Theconnection cables must never beswapped over - risk of electrical cablefire!

Do not connect the battery with theignition switched on or with the enginerunning, as otherwise the electricalsystem (electronic components) can bedamaged.To protect the case from UV radiation, donot place the battery in direct daylight.

* Does not form part of the standardscope of supply for VOLKSWAGENMarine boat engines

Battery - Warnings and safety precautions

INSPECTION

50 INSPECTION


Recommended starter batteryNominal voltage: 12VCold starting power: 520ACapacity: 110Ah

Cable diameters<50 mm2

Acid level

Please observe the warnings on theprevious page.

The battery is virtually maintenance-freeunder normal operating conditions.However, at high outside temperatures orwith long, daily operating hours it isadvisable to check the acid level fromtime to time. Similarly, the acid level mustalso be checked after each chargingprocess. Add distilled water if necessaryup to the acid level marking or up to a level5 mm above the separators.

Charging stateDetermine the battery charging state bychecking the acid density or the batteryvoltage.Acid density (specific gravity)charged = 1.285,discharged = 1.12

Total voltageDetermine the total voltage only byconnecting a voltage tester to the battery:- test duration: 5 to 10 seconds- nominal voltage: 12 Volt- discharged: 9.6 Volt.

Battery terminalsClean and grease terminals and noteexternal condition of battery, e.g. raisedplates, cracked case.


Battery* Battery* checking

INSPECTION

INSPECTION 51

The acid level is always to be at the max.mark on the long side. Never fill above themax. mark and do not allow the acid levelto drop below the min. mark.The concerned battery cells must be filledup to the max.- mark before the acid levelreaches the min.- mark.Do not overfill the battery cells, asotherwise battery acid will escape via thevent opening. This can lead to injury andcorrosion damage.After filling, the battery cells affectedmust be sealed tightly with the batteryplugs.We recommend having the acid levelchecked and corrected by aVOLKSWAGEN Marine Service Partner.NoteThe use of gel batteries on board isrecommended.

BIM--023M

A round inspection window (see arrow) isprovided on top of the battery. This"magic eye" changes its colour dependingon the charging state and acid level of thebattery. The colour display servesVOLKSWAGEN Marine Service Partnersas a diagnostic aid.Air bubbles can falsify the colour display.Carefully tap the magic eye.If the indication in the inspection windowis colourless or light yellow, the batterylevel is too low. Distilled water must beadded. With batteries older than 5 yearswe recommend replacement.We recommend having the acid levelchecked and corrected by aVOLKSWAGEN Marine Service Partner.

Battery removalBefore removing the battery, switch offthe ignition and all current consumers.To remove the battery, first disconnectthe negative cable (usually black orbrown) and then the positive cable(usually red). Then unscrew the batterymounting.


Battery* without magic eye Battery* with magic eye

12V 330A 61Ah DINETN 561 019 054

540A EN/SAE

6EO 915 105Betriebsanleitung beachten!See owners manual!

DANGER/POISON

BIM-023M

INSPECTION

52 INSPECTION

BIM--022M

Battery replacementIf the battery is replaced, the new batterymust have the same voltage (12 V),design and safety characteristics such ascentral venting and an O-ring seal for thebattery plugs.The amperage and capacity shouldmatch. VOLKSWAGEN Marine ServicePartner offer a range of suitable batteries.When installing the battery, make surethat the ignition and all current consumersare switched off.

Due to the disposal problem regardingused batteries, it is best to have a

battery replaced by a VOLKSWAGENMarine Service Partner. Batteries containsulphuric acid, lead etc and should neverbe disposed of in household refuse.

Battery connectionBefore connecting the battery, switch offthe ignition and all current consumers.Place the battery in the installationlocation provided and secure the batterywith the battery bracket.To connect the battery, first connect thepositive cable (usually red) and then thenegative cable (usually black or brown).

Battery charging

WarningObserve the warnings on page 48 andthe information provided by thecharger manufacturer.

NoteTo charge the battery of the on-boardelectrical system, the use of special boatchargers that prevent gassing of thebattery is recommended.

WarningKeep children away from the

battery, battery acid and the charger.Only charge the battery in a well

ventilated area. Do not smoke or usenaked flames and ensure no electricalsparks are produced when chargingbatteries, as a highly explosivemixture of gases is given off duringbattery charging.

Protect your eyes and face. Do notbend over the battery.

Rinse battery acid from eyes or skinimmediately for several minutes withclear water. Then seek medical careimmediately.

Quick charging of a battery isdangerous and should only be carriedout by a VOLKSWAGEN MarineService Partner, as special chargersand knowledge are required.

Never charge a frozen battery - riskof explosion! A discharged battery canfreeze at temperatures just less than0 °C. A frozen battery must alwaysbe allowed to thaw prior to charging.

We do not recommend the continued useof thawed batteries, as the batteryhousing can be cracked by the formationof ice and battery acid can leak out as aresult.

Battery* with magic eye

Betriebsanleitung beachten!See owners manual!

12V 330A 61Ah DINETN XXX XXX XXX

540A EN/SAE

6EO 915 105

DANGER/POISON

BIM-022M

INSPECTION

INSPECTION 53


Warning lampsCheck the warning lamps for the coolant,the alternator and the engine oil pressure.The warning lamps light up when theengine is shifted into the operatingposition and must go out again after theengine is started.

Starting the engineCheck the starting behaviour of theengine when doing so.

LeaksCheck the cylinder head cover, oil filter,fuel system and cooling system for leaks.

Exhaust systemCheck the exhaust system for leaks anddamage.

Engine oil and the oil filter elementrenewal (see page 35 and 36).

For units to be shut down for longerperiods - e.g. after the end of the season -please carry out preservation in thespecified order:1 - Thoroughly clean all parts to be

preserved.2 - Allow the engine to warm up.3 - After switching off the engine,

replace the oil filter element and pumpoff the motor oil - see page 36 and 37.

4 - Add engine oil and run the engine forapproximately 30 seconds at a highidling speed.

5 - Switch the engine off.6 - Plug all openings (e.g. exhaust pipe,

air filter) to prevent the penetration ofdirt or moist air.

7 - Spray the engine with ananti-corrosion agent from theoutside.

NoteOn engines that run at least 20 minutesunder load every two weeks, no corrosionprotection is required. However, the oilmust be changed at the intervals specifiedin the service schedule.


Engine test run Engine preservation

INSPECTION

54 INSPECTION

BM8--024M


Flushing and subsequent draining of theseawater cooling system with fresh wateris very important for preventing corrosionand frost damage.The flushing process should be carried outtogether with the engine oil change.Conduct flushing in the specified order:1 - Close the seawater valve -1-.2 - Open and clean the seawater filter

-see page 42.3 - Fill the seawater filter with fresh

water and run the engine at idle.Make sure that the seawater filter isalways filled with fresh water to preventthe seawater pump from running dry. Thiswould result in the pump becomingdefective.It is important that the engine runs for awhile so that all sludge and salt residuesare flushed away that could otherwisepromote corrosion.

4 - Switch off the engine again.5 - Screw on the cover of the seawater

filter.6 - Push a suitable hose onto the

connection of the drain screw -2-.7 - Open the drain screw, to which you

have connected the hose, andcapture the water in a suitablecontainer.

8 - After completing draining, removethe hose from the drain screw andclose the two drain screws again.

Seawater cooling systemflushing and draining

BM6--007M

INSPECTION

INSPECTION 55

NoteThere is a possibility that the engine willnot start if the fuel system of the boat hasnot yet been completely bled. Make sureto properly bleed the fuel system in orderto avoid engine starting problems.

The fuel system can be bled as follows:

1. First make sure that the fuel filter isfilled with fuel.

2. Remove the pressure sensor from theback part of the left “rail” in order to openthe “rail” and allow the entrapped air toescape.

3. Start the engine and let it run for approx. 20 - 30 seconds.

4. Wait a few seconds and repeat theabove procedure two more times. Nowthe fuel system of the boat should beproperly bled.

5. Attach the pressure sensor to theback part of the left “rail”.

6. Start the engine.

At the end of the season, the fuel systemalso requires maintenance and inspection.Please observe the following:

To prevent condensation water in thetank, completely fill the tank before theend of the season.

Check the fuel system for leaks.Drain water from the circulation filter

- see page 38.Replace the fine element fuel filter

- see page 40.An inspection service should always be

conducted on the VOLKSWAGEN Marineboat engine before the start of the coldseason. In addition, please observe thefollowing instructions when operating theVOLKSWAGEN Marine boat engine atextremely low temperatures.


BatteryThe battery capacity decreases as thetemperature drops. This is due to itschemical and physical properties. This iswhy an extremely cold battery, which isalso not well charged, only has a fractionof the starting power it has at normaltemperatures.We recommend recharging the batteryevery 6 to 8 weeks in the winter. The acidlevel and density must be checked. Thevoltage of the cells must be measuredwith the battery loaded.It is best to have this work conducted bya VOLKSWAGEN Marine Service Partner.

Bleeding the fuel system Winter operation

INSPECTION

56 INSPECTION

If the engine is not used for several weeksat extremely low sub-zero temperatures,the battery should be removed and storedin a frost-proof room to prevent it fromfreezing and being destroyed.

Cable connectionsCheck and clean all cable connections, asoxidised connections lead to voltagedrops and starting difficulties.

Cooling system(please observe the notes on page 43)

To protect the engine against heat, dustand corrosion, the following measures arerequired:


EngineIf the unit is not operated for a longerperiod, the engine should be protectedagainst possible corrosion damage.See the chapter "Engine preservation".

BatteryCheck the battery acid level above theupper edge of the plates weekly. It isapprox. 5 mm or can be read off at theexisting acid level marks. In case of lossesdue to evaporation, only distilled watershould be added.Observe the instructions about this onpage 49.

Air filterIf the engine is to be operated in verydusty areas, check the filter element morefrequently.Observe the instructions about this onpage 42.Cooling systemThe coolant level must be checked daily.If a coolant loss is detected, the coolingsystem must be checked for leaks, asnormally coolant losses hardly occur inthe closed cooling system.Observe the instructions on the pages9, 43 and 54.

Fine element fuel filterDrain the water from the filter weekly.The fine element fuel filter should bechanged earlier than specified in theservice schedule if necessary.Observe the instructions on pages 39and 40.

Winter operation Tropical operation

TECHNICAL DATA

DIESEL ENGINES 57

Engine data

Engine code CEMA

Output at rpm 257 kW (350 bhp) / 4200

Maximum torque in Nm at rpm 700 / 2000 - 3250

Number of cylinders, displacement 8 cylinder, 4.134 cm3

Compression 16.4

Bore/stroke in mm 83.0 / 95.5

Turbocharging 2 exhaust-gas turbochargers VTG2)

Charge-air cooling Seawater-pipe-bundle heat exchanger

Weight in kg1) 368

Efficiency weight in kg/bhp4) 1.05

Diesel fuel at least CN 51 as per DIN EN 590

Complies with the following emissionlegislationCertificate No. as per BSO 2

EG 2003/44

M1 03 3 08 04

Fuel consumption

Min. specific in g/kWh 215

Filling quantities

Coolant in litres approx. 9.0 G12++

Hydraulic oil

Power steering in litres approx. 1.0 ATF

Dependent on reversegearbox model in litres approx. 2.5 - 3.5

Engine oil3) with filter change in litresThe oil level must be checkedwhen topping up.Do not overfill!

9.0

VOLKSWAGEN Longlife oil Specification VW 504 00 und 507 00

1) The weight corresponds to a dry engine,with ancillary units, cooling system and clutchflange.

2) Turbocharger with variable turbine geometry

3) For additional information see "Engine oil"on page 35.

4) Weight specification based on output, inorder to compare engines with different sizesand output relative to their efficiency.

TDI 350-8 Diesel Engine with 2 exhaust-gas turbochargers

TECHNICAL DATA

58 CHARACTERISTIC DATA

Important notePlease always specify the model with theengine number or the engine code whenmaking all queries, any complaints andwhen ordering spare parts.This will prevent misunderstanding whenprocessing your query.

Before you read of the characteristic data,stop the engine and allow it to cool down.


The name plateThe name plate is located to the front onthe intercooler.

Engine codeEngine numberThe engine code is a series of four letters(e.g. CEMA), which is followed by theengine number, a six-digit number. Theengine code and the engine number arepunched into the left side of the cylinderblock.In addition to this, they are shown on thenameplate.

Engine characteristic data

INDEX

AAir filter, - cleaning 42. . . . . . . . . . . .Alternator 11. . . . . . . . . . . . . . . . . . . . .Antifreeze 43. . . . . . . . . . . . . . . . . . . . .

BBattery 50. . . . . . . . . . . . . . . . . . . . . . .

- charging 53. . . . . . . . . . . . . . . . . . .- removal 52. . . . . . . . . . . . . . . . . . . .- replacement 52. . . . . . . . . . . . . . . .- tropical operation 59. . . . . . . . . . .- winter operation 59. . . . . . . . . . . .

Battery voltage gauge 10. . . . . . . . . .

CCare 26. . . . . . . . . . . . . . . . . . . . . . . . . .Cetane number 19. . . . . . . . . . . . . . . .Changes 19. . . . . . . . . . . . . . . . . . . . . .Characteristic data 61. . . . . . . . . . . . .Circulation filter elementreplacement 39. . . . . . . . . . . . . . . . . . .Circulation filter water drainage 38.Coolant additive 43. . . . . . . . . . . . . . .Coolant level 44. . . . . . . . . . . . . . . . . .Coolant temperature 10. . . . . . . . . . .Coolant temperature gauge 10. . . . .Cooling system 43. . . . . . . . . . . . . . . .

- sacrificial anode 47. . . . . . . . . . . .

DDaily checks 29. . . . . . . . . . . . . . . . . .Dipstick

- engine 36. . . . . . . . . . . . . . . . . . . . .- Power steering hydraulics 54. . .- reverse gearbox 53. . . . . . . . . . . .

EEnd of season 29. . . . . . . . . . . . . . . . .Engine

- check oil level 35. . . . . . . . . . . . . .- oil 33. . . . . . . . . . . . . . . . . . . . . . . . .- oil consumption 34. . . . . . . . . . . .- oil level 34. . . . . . . . . . . . . . . . . . . .- oil renewal intervals 35. . . . . . . . .- preservation 54. . . . . . . . . . . . . . . .- safety precautions 17. . . . . . . . . .- starting 7. . . . . . . . . . . . . . . . . . . . .- switching off 7. . . . . . . . . . . . . . . .- test run 52. . . . . . . . . . . . . . . . . . . .

Engine characteristic data 61. . . . . .Engine code 61. . . . . . . . . . . . . . . . . . .Engine control unit 8. . . . . . . . . . . . . .Engine description 6. . . . . . . . . . . . . .Engine number 61. . . . . . . . . . . . . . . .Engine oil renewal 35. . . . . . . . . . . . .Engine preservation 54. . . . . . . . . . . .Environment

- battery 50. . . . . . . . . . . . . . . . . . . . .- diesel fuel 19. . . . . . . . . . . . . . . . . .- engine oil 33. . . . . . . . . . . . . . . . . .- operating fluids 19. . . . . . . . . . . . .- used oil 35. . . . . . . . . . . . . . . . . . . .

FFine element fuel filter 39. . . . . . . . . .

- renewal 40. . . . . . . . . . . . . . . . . . . .- water drainage 39. . . . . . . . . . . . .

Freshwater filter, - clean 41. . . . . . . .Freshwater pump 46. . . . . . . . . . . . . .Fuel 19. . . . . . . . . . . . . . . . . . . . . . . . . .Fuel anti-knock properties 19. . . . . .Fuel system 57. . . . . . . . . . . . . . . . . . .Fuses 25. . . . . . . . . . . . . . . . . . . . . . . . .

INDEX

GGeneral view of engine 6. . . . . . . . . .Glow plug system 12. . . . . . . . . . . . .

IIgnition lock 13. . . . . . . . . . . . . . . . . . .Inspection intervals 30. . . . . . . . . . . .Inspection service

- air filter cleaning 42. . . . . . . . . . . .- check engine oil level 34. . . . . . .- Circulation filter element

replacement 39. . . . . . . . . . . . . . . .- Circulation filter

water drainage 38. . . . . . . . . . . . .- cooling system 43. . . . . . . . . . . . .- drain water from fine element

fuel filter 39. . . . . . . . . . . . . . . . . . .- engine oil level checking 34. . . . .- engine oil renewal 35. . . . . . . . . .- engine test run 53. . . . . . . . . . . . .- impeller 45. . . . . . . . . . . . . . . . . . . .- power steering hydraulic oil level

checking 48. . . . . . . . . . . . . . . . . . .- replace fine element fuel filter 40- reverse gearbox oil level

checking 47. . . . . . . . . . . . . . . . . . .- ribbed V-belt checking 49. . . . . .- Seawater filter cleaning 41. . . . .- toothed belt checking 49. . . . . . .

Instrument lighting 8. . . . . . . . . . . . . .Instruments 8. . . . . . . . . . . . . . . . . . . .

LLighting for controls andinstruments 15. . . . . . . . . . . . . . . . . . .

Lubricant additives 36. . . . . . . . . . . . .Lubricants 33. . . . . . . . . . . . . . . . . . . . .

MMaintenance 26. . . . . . . . . . . . . . . . . .

NName plate 61. . . . . . . . . . . . . . . . . . . .

OOil 33. . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil consumption 36. . . . . . . . . . . . . . .Oil filter 37. . . . . . . . . . . . . . . . . . . . . . .Oil filter element 37. . . . . . . . . . . . . . .Oil renewal intervals 36. . . . . . . . . . .Oil specification 35. . . . . . . . . . . . . . .Operation in cold countries 59. . . . .Operation in warm countries 59. . . .Overview 6. . . . . . . . . . . . . . . . . . . . . .

PPart replacement 19. . . . . . . . . . . . . . .Power steering hydraulics- oil level checking 48. . . . . . . . . . . . .

RReplacement parts 19. . . . . . . . . . . . .Rev. counter 9. . . . . . . . . . . . . . . . . . .Reverse gearbox

- oil level 47. . . . . . . . . . . . . . . . . . . .- oil level checking 47. . . . . . . . . . .

Ribbed V-belt 49. . . . . . . . . . . . . . . . . .

INDEX

SSacrificial anode 47. . . . . . . . . . . . . . .Safety precautions 17. . . . . . . . . . . . .Seawater cooling system 56. . . . . . .Seawater filter, - clean 41. . . . . . . . .Seawater pump 46. . . . . . . . . . . . . . . .Self-help 20. . . . . . . . . . . . . . . . . . . . . .Service 26. . . . . . . . . . . . . . . . . . . . . . .Service scope 27. . . . . . . . . . . . . . . . .Start button 13. . . . . . . . . . . . . . . . . . .Start of season 27. . . . . . . . . . . . . . . .Starting the engine 7. . . . . . . . . . . . . .Stop switch 16. . . . . . . . . . . . . . . . . . .Switches 8. . . . . . . . . . . . . . . . . . . . . . .Switching off the engine 7. . . . . . . .

TTechnical changes 19. . . . . . . . . . . . .Technical description 6. . . . . . . . . . . .Test run 54. . . . . . . . . . . . . . . . . . . . . .Throttle lever (single engine) 13. . . .Throttle lever (two engines) 14. . . . .Toothed belt 49. . . . . . . . . . . . . . . . . .Tropical operation 59. . . . . . . . . . . . .

UUnleaded fuel 19. . . . . . . . . . . . . . . . .

VVoltmeter 10. . . . . . . . . . . . . . . . . . . . .

WWarning and control lamps 10. . . . .Warning lamps 10. . . . . . . . . . . . . . . .Winter operation 55. . . . . . . . . . . . . . .

- battery 50. . . . . . . . . . . . . . . . . . . . .- cooling system 43. . . . . . . . . . . . .- diesel fuel 19. . . . . . . . . . . . . . . . . .- engine oil 33. . . . . . . . . . . . . . . . . .

© 2009 VVOOLLKKSSWWAAGGEENN MMaarriinnee

VOLKSWAGEN Marine is constantly working on the further development of all types andmodels. Please be aware, therefore, that changes in the equipment supplied in terms ofshape, accessories and technology may occur at any time. Therefore no claims should bemade based on the information, figures and descriptions given in this manual.

Text, figures and standards in this manual are based on information current at the time ofprinting. Reprinting, reproduction or translation, in whole or in part, is not permitted with-out the written approval of VOLKSWAGEN Marine. All rights according to the applicablecopyright laws are expressly reserved for VOLKSWAGEN Marine. Subject to alterations.Printed in Germany

Postfach 31 11 76, 38231 SalzgitterHotline: +49 1800-89 62 74 63

+49 1800-VWMARINEwww.volkswagen-marine.com

8 Cyl. TDI 350-8 I Operation I Art.-Nr. 066.991.B08.20Editorial Deadline: 08.2009 I Edition: english 08.2009

� This paper was produced from wood pulp bleached without chlorine.

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