Self-Study Programme

Self-study programme M001
Design and function
Boat engines from Volkswagen Marine
TDI 100-5 TDI 120-5 TDI 150-5 TDI 150-5D
SDI 55-5 SDI 75-5
Foreword
Volkswagen diesel engines have been providing dependable service in passenger vehicles and transporters since 1976. The development of TDI engines is a signicant step in the direction of high technology. With their sophisticated mechanical and electronic systems, low fuel consumption values and outstanding power ratings, these diesel engines represent peak performance in diesel technology.
MSSP_001_002
Boat engines from Volkswagen are developed by skippers for skippers. The easy-to-service components as well as a worldwide parts organisation ensure reliable and efcient operation over many years.
NEW
Attention Note
The self-study programme is not a workshop manual!
Please refer to the corresponding service literature for inspection, adjustment and repair instructions.
Table of Contents
Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 The SDI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 The TDI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Engine mechanical systems . . . . . . . . . . . . . . . . . . . . . 12

Engine oil circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Cup-type oil lter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Electric oil extractor pump for oil change . . . . . . . . . . . . . . . . . . .13 Marine oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Crankcase ventilation with oil separator . . . . . . . . . . . . . . . . . . . .13 Toothed belt drive for the camshaft . . . . . . . . . . . . . . . . . . . . . . . 14 Toothed belt drive for the distributor injection pump. . . . . . . . . 14 Ribbed V-belt drives for ancillary components . . . . . . . . . . . . . .15 Dual-mass ywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Hydraulic bucket tappet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Combustion system . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Two-spring nozzle holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Engine electronic systems . . . . . . . . . . . . . . . . . . . . . . .22

Overview of installation locations . . . . . . . . . . . . . . . . . . . . . . . . 22 System overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Glow plug system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Intake manifold pressure and intake air temperature sender . 27 Needle lift sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Modulating piston movement sender . . . . . . . . . . . . . . . . . . . . . 29 Engine speed sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Coolant temperature sender. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 Fuel temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Throttle lever position sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Metering adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Start of injection valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Fuel shut-off valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Indicator lamp for glow plug system monitoring and engine electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Fuel volume control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Start of injection control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Internal functions in the engine control unit . . . . . . . . . . . . . . . . 42 Function diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
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Table of Contents
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Diesel fuel microlter with water warning facility . . . . . . . . . . . 48 Circulation preliminary lter with water separator (optional). . 50
Emission characteristics . . . . . . . . . . . . . . . . . . . . . . . . 52
Pollutants in exhaust gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Reducing pollutants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Exhaust turbocharging . . . . . . . . . . . . . . . . . . . . . . . . . 54
Fundamental principle of exhaust turbocharging . . . . . . . . . . . Turbocharger with variable turbine geometry . . . . . . . . . . . . . . Control of variable guide vanes . . . . . . . . . . . . . . . . . . . . . . . . . Guide vane adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 56 58 59
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

Introduction to cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Overview of cooling circuit for SDI engines . . . . . . . . . . . . . . . . 60 Overview of cooling circuit for TDI engines . . . . . . . . . . . . . . . . 62 Design of cooler assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Intercooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Main heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Exhaust header . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Combined cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Seawater pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Sacricial anode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

Central electrics unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Earth cutout relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Multifunction display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Displays/indicators rev counter, voltmeter and oil pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
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Table of Contents
Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Function 01 to 08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Examples of fault code memory entries . . . . . . . . . . . . . . . . . . . Monitored sensor e.g. coolant temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . 73 74 76 78
Adaptation kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80

Gearbox bell housing for Volvo SP-E/DP-E . . . . . . . . . . . . . . . . 80 Gearbox bell housing for reversing gearbox (SAE-7) . . . . . . . . 80 Gearbox bell housing for Mercruiser . . . . . . . . . . . . . . . . . . . . . 81 Gearbox bell housing for Volvo SX/DP-S . . . . . . . . . . . . . . . . . . 81
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
List of abbreviations used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
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Fundamentals
Features
Quiet-running 5-cylinder engines Low weight and compact dimensions 2-pole electrical system: To avoid galvanic corrosion, the engine is not connected to ground Electric oil intake pump and upright cup-type oil lter for clean and efcient oil change at the push of a button Oil pan with support feet and bafe plates for increased protection when listing and in rough seas Low-maintenance belt drives with automatic tensioning elements to ensure long service life of belts and components Ultramodern electronics for monitoring engine functions Warnings with visual and acoustic alarm Water-cooled turbocharger with Variable Turbine Geometry (VTG) for high propelling power in a wide speed range Powerful three-phase alternators for reliable power supply and fast battery charging All engines comply with the currently valid and most stringent pollution standard, the Bodensee Schifffahrtsverordnung (Lake Constance Shipping Ordinance) BSO II also with twin motorisation Complete instrumentation with economy control Suitable for PME/RME fuel
Particular care must be taken to ensure that the fuel tank and the fuel hoses leading to the engine are also suitable for PME/RME fuel.
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Fundamentals
The Volkswagen Marine boat engines feature a special Marine Diesel Control (MDC) system specically adapted to boat operation and which is characterized by maximum reliability. An emergency running program with a regeneration function ensures reliable engine operation should, contrary to expectations, a malfunction occur. a wide effective engine speed range with high propelling power. extensive corrosion protection for the engine housing and all add-on components. a dual-mass ywheel to absorb drive and transmission vibrations.
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Fundamentals
The SDI engine
The Volkswagen Marine boat engines are designed as naturally aspirated diesel engines with direct injection for use in displacement boats.
The engines, well-proven a million times over, offer: Quiet operation despite high pressure direct injection Low engine speed level and low-vibration operation High torque and low fuel consumption Low pollutant emission Compact installation dimensions Ease of maintenance and Ultramodern technology
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Fundamentals
Engine data
Marine Type Engine code letter Engine design Fuel injection system Displacement Compression ratio Power rating at engine speed Max. torque at engine speed Specic power output Min. specic fuel consumption Weight (dry, with ancillary components, cooling system and clutch ange) not including gearbox Alternator Electrical system Exhaust emission legislation, certied in accordance with SDI 55-5 BCT SDI 75-5 ANF
5-cylinder in-line naturally aspirated diesel engine Diesel direct injection with electronically controlled distributor-type injection pump 2461 cm3 19.0 : 1 40 kW (55 bhp) 2500 rpm 155 Nm 16.3 kW/l 233 g/kWh 260 kg 120 A 12 V not earthed Bodensee Schifffahrtsverordnung Stufe 2 (Lake Constance Shipping Ordinance, Stage 2) 2250 rpm 55 kW (75 bhp) 3600 rpm 155 Nm 22.3 kW/l 233 g/kWh 260 kg 2250 rpm
SDI 55-5
45
SDI 75-5
60
Output (kW)
40
55
Output (kW)
50 160 45
35
30
150
40
Output (kW)
Output (kW)
Torque (Nm)
25
140
35 30 25
150 140 130
20
130
15 20 10 15 10 1000 1500 2000 2500 1000 1500 2000 2500 3000 3500
Engine speed (rpm)
Engine speed (rpm)
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Torque (Nm)
Torque (Nm)
Torque (Nm)
160
Fundamentals
The TDI engine
Volkswagen Marine boat engines are designed as direct injection engines with turbocharging for use in displacement and hydroglider boats. The TDI 150-5 is particularly suitable for use in fast hydroplanes. The TDI 150-5D variant is certied for use as twin motorisation in compliance with BSO II. The TDI 100-5 and 120-5 engines are perfectly adapted to use in touring and sailing boats. They are both also certied for use as twin motorisation in compliance with BSO II. The TDI engines feature a turbocharger with a water-cooled VTG turbocharger (Variable Turbine Geometry). The engines develop a wide effective speed range offering high propelling power without the characteristic propulsion weakness of turbocharged engines in the lower engine speed range.
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TDI 100-5
90
80
Output (kW)
70
60
280
Output (kW)
50
Torque (Nm)
240
40
200
30
160
20
10
1500
2000
2500
3000
Engine speed (rpm)
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Torque (Nm)
Fundamentals
Engine data
Marine Type Engine code letter Engine design Fuel injection system Supercharging Displacement Compression ratio Power rating at engine speed Max. torque at engine speed Specic power output Min. specic fuel consumption Weight (dry, with ancillary components, cooling system and clutch ange) not including gearbox Alternator Electrical system Exhaust emission legislation, certied in compliance with TDI 100-5 BCU TDI 120-5 ANG TDI 150-5 ANH TDI 150-5D BCV
5-cylinder in-line turbocharged diesel engine Diesel direct injection with electronically controlled distributor-type injection pump Variable turbocharger (VTG) 2461 cm3 19.0 : 1 74 kW (100 bhp) 2600 rpm 270 Nm 2500 rpm 30.1 kW/l 217 g/kWh 275 kg 88 kW (120 bhp) 3250 rpm 275 Nm 2500 rpm 35.8 kW/l 217 g/kWh 275 kg 111 kW (150 bhp) 4000 rpm 310 Nm 1900 rpm 45.1 kW/l 203 g/kWh 280 kg 108 kW (147 bhp) 4000 rpm 310 Nm 1900 rpm 43.9 kW/l 203 g/kWh 280 kg
120 A 12 V not earthed Bodensee Schifffahrtsverordnung Stufe 2 (Lake Constance Shipping Ordinance, Stage 2)
TDI 120-5
100
TDI 150-5
120 110
90
Output (kW)
Output (kW)
100 90 280 80 320 290 260
80
70
Torque (Nm)
Output (kW)
60
Torque (Nm)
240
Output (kW)
70 60 50 40 30
50
200
Torque (Nm)
230
40
30 20 20 10 0 1500 2000 2500 3000
10
1000
1500
2000
2500
3000
3500
4000
Engine speed (rpm)
Engine speed (rpm)
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Torque (Nm)
Engine mechanical systems

Engine oil circuit
Injection nozzle Turbocharger with variable turbine geometry Oil lter Hydraulic tappet
Oil spray nozzle for piston cooling Oil pump Oil cooler Electric oil extractor pump for oil change
Marine oil pan

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Cup-type oil lter

The cup oil lter is arranged upright. The paper lter that can be replaced from the top ensures the lter is easy to service and environmentally compatible. When the oil lter cover is opened, a valve also opens so that the oil can ow out of the lter housing through a separate line back into the oil pan.
Filter element
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Electric oil extractor pump
The electric oil extractor pump can be used to extract the engine oil in an environmentally friendly manner and free of drips. The pump is switched on by the switch on the central electrics unit.
From oil pan To collection reservoir
Electric connection
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Oil pan
The oil pan is designed specially for use in Volkswagen Marine boat engines. Bafe plates ensure reliable oil supply to the engine also when listing heavily and in rough seas.
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Crankcase ventilation with oil separator

The crankcase ventilation system with oil separator serves the purpose of keeping the air clean (to minimize oil burning) and prevents oil deposits forming on the intercooler. The oil vapours pass through the crankcase ventilation system into the oil separator. The fabric element contained in the oil separator separates oil droplets and blow-by gas. The oil droplets are collected on the base and returned to the oil pan. The blow-by gas is routed back into the intake manifold of the engine. The fabric element need not be replaced.
To intake pipe
From crankcase ventilation
To oil pan
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Belt drives
Camshaft
Toothed belt drive for the camshaft The toothed belt drives the camshaft and the coolant pump. The mechanical tension of the toothed belt is controlled by a tension pulley.
Coolant pump
Tension pulley
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Toothed belt drive for the distributor injection pump The toothed belt drive for the distributor-type injection pump consists of the tension pulley, deection pulley, drive gearwheel that is driven by the camshaft, injection pump gearwheel as well as the toothed drive belt.
Camshaft Tension pulley
Deection pulley
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Ribbed V-belt drives for ancillary components The ancillary components are driven by ribbed V-belts. The following components are driven: The alternator (12 V) for engine operation and battery charging Optional The power steering pump for boats with Z-drive and optional An additional 12 V, 24 V or 230 V alternator The seawater pump via a separate ribbed V-belt drive
To avoid damage to the vibration damper and the engine, the engine must not be run without the alternator belt drive. Please refer to the current Workshop Manual for instructions on all adjustment and repair work.
The belt drives are equipped with automatic belt tensioners and therefore require little maintenance.
Belt tensioner
12 V alternator
Deection pulley Seawater pump Belt tensioner Power steering pump 2nd alternator
Vibration damper
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Dual-mass ywheel
Due to irregularities in combustion, displacement engines produce torsional vibrations at the crankshaft and the ywheel. The use of a dual-mass ywheel prevents these torsional vibrations being transmitted into the drive train where they would produce resonance, resulting in disturbing noise in the boat. The dual-mass ywheel therefore also avoids excessive stress in the subsequently connected gearbox.
The dual-mass ywheel divides the ywheel mass into two parts. One part is the primary ywheel or centrifugal mass; it belongs to the mass moment of inertia of the engine. The other part, the secondary mass, increases the mass moment of inertia of the drive. Connected by means of a spring damping system, both decoupled masses isolate the vibrations. They absorb the vibrations at low engine speeds thus ensuring "drive rattle" no longer occurs.
Secondary ywheel mass
Vibration insulation
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Vibration damper
Primary ywheel mass of the dual-mass ywheel Crankshaft drive

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Conventional power transmission structure without dual-mass flywheel Engine and drive train vibrations at low engine speed
Flywheel Engine and drive train vibration in idle speed range
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Power transmission with dual-mass flywheel Engine and drive train vibrations at low engine speed
Primary ywheel mass
Secondary ywheel mass
Engine and drive train vibration in idle speed range
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Vibrations generated by the engine Vibrations absorbed by the drive train

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Hydraulic bucket tappet
All Volkswagen Marine boat engines are equipped with hydraulic bucket tappets. In addition to reducing noise, they also simplify servicing: No need to check and adjust valve clearance Precision valve timing
Camshaft
Bucket tappet Oil reservoir Non-return valve Oil feed Piston Cylinder Compression spring
High pressure chamber
Valve stem
MSSP_001_012
The hydraulic bucket tappets essentially comprise: Bucket tappet with piston Cylinder Non-return valve
Valve noise after starting the engine is a normal occurrence. Oil is forced out of the bucket tappet while the engine is inoperative. As soon as the engine is running, the high pressure chamber is lled with oil again and the valve noise disappears.
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Functional description Beginning of valve stroke The cam turns on the bucket tappet, the non-return valve closes and pressure builds up in the high pressure chamber. The oil trapped in the high pressure chamber cannot be compressed. The bucket tapped acts as a rigid element.
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Valve stroke The pressure in the high pressure chamber increases due to the force the cam exerts on the tappet. A little oil escapes via the leakage gap so that the tappet compresses by max. 0.1 mm.
Leakage gap
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Valve clearance compensation Compensation of the valve clearance (lash) begins after the valve has closed. The pressure in the high pressure chamber drops as the cam no longer presses against the tappet. The spring forces the cylinder and bucket apart to such an extent that there is no clearance between the bucket tappet and cam. Oil ows out of the supply reservoir through the now opening non-return valve into the high pressure chamber.
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Combustion system
The combustion system
In Volkswagen Marine boat engines, the fuel is injected directly into the main combustion chamber.
The advantages include: More efcient combustion Improved fuel utilization Lower fuel consumption and Low pollutant emission
The special design of the pistons, injection nozzles and of the intake port optimises the combustion process with regard to noise development, smooth operation and pollutant emissions.
Intake swirl port The special design of the intake port induces a swirling motion in the drawn-in air.
Piston recess The swirling motion of the intake air is continued in the piston recess that is optimally adapted to this engine.
Injection nozzle The ve-hole injection nozzle (fuel injector) injects the fuel in two stages into the piston recess where it ignites on the hot air. The two-stage injection prevents a "harsh" increase in pressure thus avoiding the characteristic diesel "knock".
MSSP_001_016
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Combustion system
Two-spring nozzle holder
Smooth increase in pressure in the combustion chamber reduces combustion noise and mechanical stress. The two-spring nozzle holder developed for the Volkswagen direct injection diesel engines enables fuel injection in two stages. As a result, it plays an important part in ensuring "smooth" combustion.
Spring 1 Lift 1
Spring 2
Functional description There are two springs of different thickness tted in the nozzle holder. Due to the geometry of the springs, the nozzle needle is raised only against the force of the rst spring at the start of injection. A small gap is produced, allowing a small quantity of fuel to be pre-injected at low pressure. This pre-injection ensures a smooth increase in the combustion pressure and creates the ignition conditions for the main volume of fuel. The pressure in the injection nozzle increases due to the fact that the injection pump delivers more fuel than escapes through the small gap. The nozzle needle is further raised against the force of the second spring. The main injection now takes place at high pressure.
Nozzle needle Lift 1 and lift 2
Lift 2
MSSP_001_017
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Engine electronic systems

Overview of installation locations
This general layout provides an overview of the components of the MDC. The components are described in detail in the following chapters.
Throttle lever position sender
Needle lift sender at injection nozzle of 5th cylinder
Intake manifold pressure and intake air temperature sender
marine
Acoustic warner
Indicator lamp for glow plug system monitoring and engine electronics
Diagnosis interface Coolant temperature sender
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Fuel temperature sender
Modulating piston movement sender
Distributor injection pump
MDC control unit
Engine speed sender
MSSP_001_019
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System overview
Sensors supply the engine control unit with information on the current operating status of the engine.
Needle lift sender
Engine speed sender
Coolant temperature sender
Intake manifold and intake air temperature sender
Modulating piston movement sender Fuel temperature sender
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The corresponding actuators are activated following evaluation of the sensor information in the engine control unit. The injection volume and start of injection as well as the preheater system are controlled and monitored in this way. For monitoring purposes, the engine control unit makes use of several characteristic maps and characteristic curves while ensuring the best torque output, the most favourable fuel consumption and the best exhaust emission characteristics for every operating situation.
MDC control unit
Acoustic warner
Metering adjuster Valve for fuel shut-off Diagnosis connector Valve for start of injection
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Glow plug system
A glow plug system control is integrated in the Volkswagen Marine engine control unit. The glow plug control contains the following functions: Preheating Post-heating Standby heating
Functional description Preheating In view of the outstanding starting characteristics of the Volkswagen Marine direct injection boat engines, preheating (glow plug) is only activated at temperatures below +9 C. The engine control unit receives the signal for the engine temperature from the coolant temperature sender. The preheating procedure is started automatically. The preheating time depends on the current engine temperature. An indicator lamp in the panel informs the skipper that preheating is active.
Engine speed Coolant temperature
Pin 8 Pin 14
Pin 26 Pin 50 MDC control unit
Indicator lamp for glow plug system monitoring and engine electronics Relay for glow plugs Fuse
Q6
Q6
Q6
Q6
Q6
MSSP_001_045
Glow plugs
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The intake manifold pressure and intake air temperature sender is located in the intake manifold. From the signal, the engine control unit recognizes the pressure and temperature of the intake air. The signal is required for limiting smoke in the dynamic range and to monitor the function of the turbocharger (TDI only).
MSSP_001_098
Functional description The piezoelectric crystals in the intake manifold pressure sender are changed by the pressure of the air drawn in and thus send a voltage signal to the engine control unit.
Substitute function None
Effect In the event of failure, there are no malfunctions in engine operation
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Needle lift sender
The needle lift sender is located on the injection nozzle of the 5th cylinder. It signals the actual start of injection to the engine control unit. The signal is used to ensure the characteristic map for start of injection is adhered to.
Nozzle holder
Magnet coil
Functional description The voltage applied at the magnet coil of the needle lift sender is controlled by the engine control unit such that a constant current always ows. In this way, a magnetic eld is generated in the magnet coil (solenoid). The magnetic eld changes with the movement of the nozzle needle that is connected to the thrust pin. The change distorts the applied voltage; a pulse peak is created. The engine control unit calculates the actual start of injection from the time difference between the pulse peak and the TDC signal from the engine speed sender. The actual start of injection is compared with the set start of injection specied in the characteristic map of the engine control unit and is corrected by the control unit in the event of deviations.
Thrust pin
MSSP_001_018
Substitute function An emergency operation program is started in the event of the needle lift sender failing. The start of injection is controlled according to xed setpoints from the characteristic map. In addition, the injection volume is reduced.
Effect The power output of the engine is reduced.
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The modulating piston movement sender signals to the engine control unit the current position of the metering adjuster in the injection pump.
Distributor injection pump Coil with alternating voltage
Iron core Moving metal ring Eccentric shaft
Functional description An alternating voltage generates an alternating magnetic eld in a special iron core. A metal ring that is secured to the eccentric shaft moves along the iron core. This movement inuences the magnetic eld. The engine control unit evaluates this change and thus obtains the current position of the metering adjuster.
Fixed metal ring
MSSP_001_021
Substitute function If the engine control unit receives no signal from the modulating piston movement sender, the engine will be shut down for safety reasons.
Effect Engine operation is not possible.
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Engine speed sender
The engine speed sender is located in the vicinity of the starter crown gear. It scans ve marks on the sender wheel for engine speed. The engine control unit uses the signal to detect the engine speed.
Functional description The sender operates in accordance with the induction principle. The marks on the sender wheel generate an alternating voltage in the sender coil. From this signal, the engine control unit can accurately calculate the angular position and the current engine speed.
MSSP_001_022
Substitute function If the engine control unit receives no signal from the engine speed sender, an activated emergency operation program uses the signal from the needle lift sender as a substitute signal.
Effect The injection volume is reduced thus also reducing the engine power output. The engine is shut down if the signal from the needle lift sender also fails.
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The coolant temperature sender is located on the connection coupling for the coolant above the coolant pump. Its signal serves as a variable for determining the engine temperature and for detecting whether preheating, post-heating, standby heating or increased idle speed is required when the engine is cold (90 sec). The signal is additionally used in the event of engine overheating to reduce the power output.
MSSP_001_023
Functional description The coolant temperature sender features an NTC bead. An NTC (Negative Temperature Coefcient) changes its resistance corresponding to temperature. When the temperature increases the resistance value drops. When the temperature drops the resistance values increases. The engine control unit can detect the current engine temperature from this resistance value.
Substitute function If the engine control unit receives no signal from the coolant temperature sender, a xed value stored in the engine control unit is used as the substitute signal.
Effect The MDC control unit receives no engine temperature value from the coolant temperature sender.
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The fuel temperature sender is located in the upper housing of the distributor-type injection pump. Its signal informs the engine control unit of the coolant temperature and the control unit adapts the fuel volume accordingly.
Distributor injection pump
Functional description The fuel density changes with the change in the fuel temperature. The injection volume must be correspondingly adapted to ensure an optimum combustion process.
MSSP_001_024
Substitute function In the event of the fuel temperature sender failing, the last temperature value is stored in the MDC control unit.
Effect The injection volume can no longer be determined correctly. The MDC now determines the injection volume according to the value last stored.
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The throttle lever position sender is located in the vicinity of the central electronics unit. Its signal informs the engine control unit of the throttle lever position. This signal is also used to determine the injection volume.
Shaft
Coil spring
Functional description The shaft in the sender is turned when accelerating. The potentiometer mounted on the end of the shaft sends to the engine control unit a voltage value corresponding to the throttle position. From this value, the engine control unit recognizes the throttle lever position and the skipper's choice. In connection with the fuel volume control of the distributor injection pump, the control unit regulates the fuel volume to be injected.
Potentiometer with idle switch
MSSP_001_025
Substitute function If the engine control unit receives no signal, a xed stored value is used as the substitute signal.
Effect The engine runs at increased idle speed (1400 rpm) so that the skipper can reach the next mooring. Acceleration is no longer possible.
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Metering adjuster
The metering adjuster with an electromagnetic actuator for controlling the injection volume is located in the distributor-type injection pump.
Functional description With the aid of a control shaft, the electromagnetic actuator changes the position of the control slide valve. When activated by the engine control unit, the position of the control slide valve is changed axially thus constantly varying the injection volume between "minimum" (idle speed) and "maximum" (full throttle).
Metering adjuster
Control slide valve
MSSP_001_026
Effect If the metering adjuster fails due to a defect, the engine is shut down by means of the fuel shut-off valve.
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Start of injection valve
The start of injection valve is positioned on the underside in the housing of the distributor-type injection pump. The inner chamber pressure of the pump acts on the injection control piston via this cyclically clocked solenoid valve.
Functional description The start of injection is controlled depending on the clock pulse (pulse duty factor) of the start of injection valve. The engine control unit can adjust innitely variable between retarded start of injection (fully open) and advanced start of injection (fully closed). Activation takes place by means of a ground pulse from the engine control unit.

MSSP_001_030
Substitute function Control is no longer possible in the event of the start of injection valve failing. A xed value is used.
Effect The engine runs with reduced power output due to the now limited volume of fuel.
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Fuel shut-off valve
The fuel shut-off valve is installed on the upper side of the distributor-type injection pump in the vicinity of the fuel injection lines. This solenoid valve interrupts the fuel supply when the engine is shut down.
Functional description The valve is open when no power is applied. In this way, it keeps the inlet hole to the high pressure chamber open. When power is applied to the solenoid, the valve closes the inlet hole. The fuel supply is shut off so that the high pressure piston can no longer deliver fuel.
Fuel shut-off valve
Supply hole Valve Valve seat
MSSP_001_031
Effect The engine is shut down by the metering adjuster.
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The self-diagnosis concept of Volkswagen Marine boat engines comprises a self-monitoring function for sensors, actuators and mircoprocessors by the engine control unit.
marine
Functional description The self-diagnosis system uses an indicator lamp to inform the skipper of any malfunctions. In this way he is requested to call at the nearest service centre. A warning is given in the event of a malfunction in the following components: Needle lift sender Engine speed sender Modulating piston movement sender Metering adjuster Start of injection valve Turbocharger: Boost pressure outside set range (TDI only)
Start
MSSP_001_032
SUPERIOR MARINE TECHNOLOGY
20 10 0 30 40
m 3.7 l/h
marine
Stop

MSSP_001_067
Effect The effect depends on the type of component that has failed.
Activation The engine control indicator lamp is activated by the engine control unit.
When the indicator lamp is activated by the engine control unit, an acoustic warning signal additionally sounds. This signal can be turned off after pressing the acknowledging button.
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Fuel volume control
Following evaluation of the received sensor signals, the correct injection volume is determined in the engine control unit and an electrical signal is sent to the metering adjuster in the injection pump. The metering adjuster varies the position of the control slide valve corresponding to the electrical signal. The engine control unit monitors the change in the valve position with the aid of the modulating piston movement sender. If there is insufcient air in the system, the injection volume is limited by the smoke characteristic map.
Overview of sensors and actuators
MDC control unit
Engine speed sender
Metering adjuster

MSSP_001_033
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Start of injection control
A large number of engine properties such as the starting characteristic, fuel consumption, engine output, smooth engine operation as well as exhaust emission are inuenced by the start of injection. The task of the start of injection control is to determine the correct timing for fuel delivery. Based on the inuencing variables illustrated in the following, the engine control unit calculates the start of injection and sends a corresponding electrical signal to the start of injection valve in the distributor-type injection pump.
MDC control unit
Engine speed sender
Needle lift sender
MSSP_001_034
Start of injection characteristic map The engine control unit calculates the optimum start of injection from the stored start of injection characteristic map and the input variables.
Start of injection
Throttle lever position
Engine speed
MSSP_001_046
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Functional description Injection timing device The mechanical injection timing device in the distributor-type injection pump operates with the aid of the speed-dependent fuel pressure in the pump interior. It is necessary to inject fuel earlier as the engine speed increases. The start of injection is varied by the turning movement of the rolling ring. This is controlled by the change in the fuel pressure in the pump interior. The fuel pressure increases as the engine speed increases. The control unit controls the start of injection valve by means of a clock pulse (pulse duty factor). The pressure in the pump interior changes corresponding to the pulse duty factor. One start of injection operation is assigned to each clock pulse. This facilitates innitely variable control of the start of injection from maximum advance to retard setting.
Note To provide a clear illustration, the objects in the enlargements have been turned through 90!
Rolling ring Advance Pressure roller
Retard
Engine control unit From the incoming sensor signals, the engine control unit calculates the set start of injection and sends the signals for the necessary pulse duty factor to the start of injection valve.
To intake side of vane pump Spring Pin Fuel pressure in pump interior
Start of injection valve The valve converts the pulse duty factor into a change in the pump interior pressure (control pressure).
Piston of injection timing device
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Eccentric disc
Pressure roller
Piston of injection timing device
MSSP_001_035
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Internal functions in the engine control unit
With additional functions, the engine control unit ensures the engine runs smoothly during operation.
Idle speed control Based on the engine speed signal that is supplied 5 times per crankshaft revolution, the engine control unit recognizes even the smallest deviation from the specied idle speed. By way of changes in the metering adjuster control, the engine control unit can maintain a constant idle speed under all operating conditions.
MSSP_001_106
Smooth running control In order to achieve particularly smooth, uniform engine operation, the injection volume of each cylinder is controlled in such a way as to avoid output differences between the individual cylinders. This function is monitored by means of the signal from the engine speed sender that supplies the engine control unit with ve signals per crankshaft revolution. If the signals are received in uniform rhythm this means all cylinders are performing the same amount of work. If the output of one cylinder is weaker, the crankshaft will be accelerated to a lesser extent. If the output of one cylinder is higher, it will accelerate the crankshaft to a greater extent. Once the engine control unit has recognized an irregularity, a higher or lower injection volume is immediately supplied to the corresponding cylinder until the engine runs smoothly and uniformly again. The injection volume deviation is indicated in the measured value block.
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Maximum engine speed governing On reaching the maximum engine speed, the engine control unit reduces the injection volume in order to protect the engine.
Start volume control The injection volume required for starting is determined by the engine control unit corresponding to the coolant temperature. As a result, exhaust emission is kept low while still ensuring very good starting characteristics.
Signal monitoring During operation, the engine control unit monitors itself as well as the functions of the sensors and actuators. Occurrence of a malfunction is indicated visually by the indicator lamp illuminating and acoustically by a warning tone.
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MSSP_001_032
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Function diagram
E190 - Emergency stop button E354 - Oil extractor pump button F36 - Neutral switch F60 - Idling switch G6 G28 G62 G71 G72 G79 G80 G81 G149 Fuel pump (presupply pump) Engine speed sender Coolant temperature sender Intake manifold pressure sender Intake manifold temperature sender Throttle lever position sender Needle lift sender Fuel temperature sender Modulating piston movement sender
30 30a 15
J 52
J 317 S 190
15 A
S 125
50 A
N 108
G81
G149
N 146
J17 - Fuel pump relay J 52 - Glow plug relay J248 - Diesel direct injection system control unit J317 - Terminal 30a voltage supply relay J593 - Fuel shut-off valve control relay K29 - Glow period indicator lamp N108- Start of injection valve N146 - Metering adjuster Q6 - Glow plugs (engine) S81 - Fuel pump fuse S125 - Glow plug fuse S190 - Terminal 30 voltage supply fuse Y19 - Multifunction display with engine speed
42
114
18
103
111
108
106
99
121
116
51
63
50
12
69
80
33
Q6
F60
G 79
31a 31
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30 30a 15
S 81
10A
J 17
G 80
G6
34
70
109
101
J 248
65 32 40 4 5 102 110 20 52 73 31 71 112 104 16 6 7 28 27 120 37 24
D
4
Y19
F 36
G28
G72
G71
G62
J 593 E190 K 29 E354
MSSP_001_048
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Fuel system
Fuel supply
The fuel pump sucks the fuel out of the fuel tank directly via the circulation preliminary lter. The electric presupply pump supports the fuel pump located in the injection pump housing. The fuel presupply pump is mounted on the engine below the central electrics. It is arranged between the circulation lter and the fuel microlter. The fuel return is routed via the combined cooler. In this way, the return fuel is cooled and the fuel temperature in the fuel tank kept low.
Fuel presupply pump
Fuel microlter with additional water separation chamber and sensor
Pressure roller Eccentric disc Distributor piston Plunger valve
Injection nozzle
Combined cooler
Fuel tank
Circulation preliminary lter with water separator

MSSP_001_036
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Fuel system
Functional description
Fuel intake The vane pump sucks in the fuel and forces it into the pump housing. The rotor is mounted directly on the drive shaft. A pressure control valve is tted for the purpose of maintaining the pressure increase within the permissible range as the engine speed increases.
Pressure control valve
Vane pump
MSSP_001_037
Filling high pressure chamber With the aid of a claw clutch, the drive shaft of the vane pump causes the distributor piston to rotate and lift by means of an eccentric disc. The eccentric disc executes one lift movement per cylinder. During the delivery phase, the control slot opens the feed channel as the result of the rotary motion of the distributor piston and allows fuel to ow into the high pressure chamber.
Distributor piston

MSSP_001_038
Start of injection The distributor piston continues to turn so that the control slot closes the feed hole. The following list movement exerts pressure on the fuel. As the distributor piston continues to rotate, the distributor groove is aligned ush with the outlet hole. The fuel under high pressure is forced to the injection nozzle.
Control slot Distributor groove
Distributor channel
MSSP_001_039
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Fuel system
Diesel fuel microlter with water warning facility
The task of the fuel microlter is to lter out the nest impurities in the fuel. Thoroughly ltered fuel is of great signicance for ensuring reliable operation. Condensation water or water that enters the system while refuelling must be ltered out. Owing to its higher weight, water collects in the base of the lter. A high proportion of water in the diesel fuel poses the risk of the water entering the fuel injection system. This would lead to internal corrosion and engine failure. For this reason, diesel fuel microlters in Volkswagen Marine boat engines feature a water warning facility. It informs the skipper of high water level in the fuel microlter before it can place operational reliability at risk.
Drain channel Fuel microlter
Warning switch
MSSP_001_040
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Fuel system
Water level safe The engine control unit sends a voltage to the contact pins of the warning switch located in the fuel microlter. Only a low current ows if the contact pins are surrounded by diesel fuel.
Filter
Contact pins Diesel fuel Water
MSSP_001_041
Water level dangerous If the water level rises up to the contact pins, a higher current ows due to the better conductivity of the water. The engine control unit detects the higher current ow and by way of the indicator lamp in the control panel signals the high water level to the skipper.
MSSP_001_042
Drain fuel microfilter A drainage facility is located on the underside of the fuel microlter.
Water drain valve
Please refer to the Owner's Handbook or the current Workshop Manual for the exact description of the water drainage procedure.
MSSP_001_043
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Fuel system
Circulation preliminary lter with water separator (optional)
The circulation water separator is installed between the fuel tank and fuel presupply pump. The exact installation location depends on the type of boat.
Alternative outlet opening Outlet opening Filter element Cross section enlargement Alternative inlet opening Inlet opening
Functional description The fuel ows through the inlet opening and an internal system of guide vanes. An intensive rotary motion is induced which forces the fuel into the bowl section. Water droplets and heavy particles are expelled by the centrifugal force, they collect on the bowl walls and nally settle on the base of the bowl. During the further course of the lter process, the fuel must pass through the guide vane system positioned on the outer housing. Due to the different lengths of the deection vanes and the double change in direction of ow, smaller water droplets and ne particles are expelled and also collect on the base of the bowl. The considerable increase in cross section below the lter element causes the fuel to settle while the nest water droplets and particles are expelled. The remaining particles and water are subsequently ltered out by a replaceable lter element.
Bowl base
Guide vane Guide vane Bowl section
Waster drain
MSSP_001_044
Please refer to the Owner's Handbook or the current Workshop Manual for instructions on the maintenance and water draining procedure.
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Notes
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Emission characteristics
The lowest possible level of environmental pollution renders necessary sophisticated design as well as extensive matching and tuning work. In doing so, it is often necessary to consolidate conicting requirements such as low pollutant emission and high engine power output. All Volkswagen Marine boat engines comply with the Bodensee Schifffahrtsverordnung Stufe 2 (Lake Constance Shipping Ordinance, Stage 2) (BSO II).
Pollutants in exhaust gas

The following exhaust gasses mainly occur in the exhaust emissions of diesel engines: Carbon monoxide (CO) Carbon monoxide is produced by combusting fuels containing carbon. It is odourless and colourless, explosive and highly toxic. Carbon monoxide inhibits erythrocytes (red blood corpuscles) from transporting oxygen and is lethal even in small concentrations in breathing air. In the open it oxidizes to form carbon dioxide within a short space of time. Carbon dioxide is a constituent part of air. Gaseous hydrocarbons (HC) They occur in the exhaust gas following incomplete combustion. Hydrocarbons irritate the sense organs and, depending on the type, can also cause cancer. Soot particles Soot particles are produced by the combustion process in a diesel engine. The effects on the human body are currently not fully claried. Nitrogen oxide (NOx) Nitrogen oxide is produced by high pressure, high temperature and surplus oxygen during combustion.
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Reducing pollutants
Measures designed to reduce soot particles and the formation of HC increase the percentage of nitrogen oxides. Attempts to reduce the nitrogen emission increase the proportion of other exhaust gas constituents. In Volkswagen Marine boat engines, the lowest possible exhaust emission has been achieved by specic design of the combustion chamber and of the piston recess as well as the matching and coordination of the injection nozzles. Electronically controlled and monitored engine management and variable start of injection control further ensure optimum combustion and low exhaust emissions.
MSSP_001_075
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Exhaust turbocharging
Fundamental principle of exhaust turbocharging
The aims of supercharging by means of a turbocharger are: Higher torque and Increased engine output By compressing the intake air, more air and thus increased levels of oxygen enter the combustion chamber with each intake stroke. The higher share of oxygen enables improved combustion. The power output is increased. The movement and pressure energy contained in the exhaust gas is used to drive the turbine wheel of the turbocharger that is connected via a shaft to the compressor wheel. The compressor wheel compresses the air and forces it into the combustion chamber. Since the air temperature increases during compression and the density thus decreases, the engine output can be further increased by cooling the air in an intercooler. The air density increases again.
Intercooler Heat Exhaust gas from the engine drives the exhaust turbine.
The compressed, heated air is routed to the intercooler.
Air inlet
Exhaust
Compressor
Exhaust turbine
MSSP_001_051
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There are two specic problems involved in the use of a conventional turbocharger. The energy of the exhaust gas is too low in the lower engine speed range. The turbine wheel does not reach the rotary speed necessary to sufciently compress the air. The exhaust gas energy is very high in the upper engine speed range. The speed of the turbine wheel is therefore higher than necessary. The air is compressed too much.
Turbocharger Intake air Exhaust gas ow
Intercooler
Boost pressure
Intake manifold
Exhaust manifold
Engine
MSSP_001_052
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Turbocharger with variable turbine geometry
The turbocharger installed in Volkswagen Marine boat engines operates with variable guide vanes.
Advantage By correspondingly inuencing the exhaust ow, the optimum boost pressure is made available virtually over the entire engine speed range. This ensures improved combustion and lower exhaust emission values as well as high propelling power over the entire engine speed range.
Pressure cell for adjusting the guide vanes
Exhaust turbine housing Oil inlet
Compressor
Exhaust turbine wheel
Intake air
Variable guide vanes To intake manifold Coolant
MSSP_001_061
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Fundamental principle A gas ows through a narrow pipe faster than through a pipe without a constriction. The prerequisite is that the same pressure is applied in both pipes. This physical principle is utilized by the turbocharger with variable turbine geometry for the purpose of achieving a constant boost pressure in virtually all engine speed ranges.
MSSP_001_053
Low engine speed The volume and speed of the exhaust gas are low. The cross section of the exhaust pipe is constricted before the turbine wheel by the guide vanes. The narrowed cross section forces the exhaust gas to ow faster thus increasing the speed of the turbine wheel. The high rotary speed of the turbine guarantees optimum boost pressure also at low engine speed.
Guide vane
Turbine wheel
Boost pressure
Exhaust gas pressure
MSSP_001_054
High engine speed The exhaust volume and speed are high. The guide vanes enable a larger cross section. The maximum boost pressure is not exceeded.
Exhaust gas pressure
Boost pressure
MSSP_001_055
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Exhaust gas turbocharing

Control of variable guide vanes
The pressure cell is connected via a hose line to the intake pipe. The pressure in the pressure cell changes depending on the intake manifold pressure.
Turbocharger with variable guide vanes Low speed High speed Exhaust gas ow
Intake air
Boost pressure
Pressure cell Guide vanes Intercooler Cylinder head
MSSP_001_057
At low intake manifold pressure, the diaphragm of the pressure cell is pushed back by the force of the spring. The guide vanes are set to a small inlet cross section.
At high intake manifold pressure, the pressure acting on the diaphragm in the pressure cell increases. The guide vanes are set to a large inlet cross section.
This control always makes available the boost pressure necessary for ensuring optimum power output.
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Guide vane adjustment
The guide vanes together with their shafts are mounted on the carrier ring. The guide vanes are connected by means of a shaft to the guide pin. This guide pin engages in the adjustment ring such that all guide vanes are adjusted simultaneously as the adjustment ring rotates. The adjustment ring is turned by the vacuum cell in connection with the control linkage.
Pressure cell Carrier ring Guide vanes Adjustment ring Guide pin Shaft
Control linkage Guide pin of control linkage

MSSP_001_049
Flat guide vane setting = Narrow inlet cross section of exhaust gas ow
Steep guide vane setting = Large inlet cross section of exhaust gas ow Direction of rotation of adjustment ring
MSSP_001_074
In connection with the acceleration in the ow of the exhaust gas, the constricted inlet cross section results in a higher turbine speed.
The ow rate of the exhaust gas increases as the engine speed increases. The inlet cross section becomes larger so that the boost pressure and turbine output remain constant over a wide speed range.
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Cooling system
Introduction to cooling system
While in a road vehicle the engine heat is given off via the cooling water to the air drawn in on the airstrain, the engine heat in a boat is transferred to the seawater. In order to keep the engine clear of aggressive media such as saltwater, the Volkswagen Marine boat engines feature a dual-circuit cooling system. In the same way as in passenger vehicles, the coolant in the primary circuit is made up of antifreeze, corrosion inhibitor and water and is designed as a closed circuit. The heat is transferred in a heat exchanger through which seawater ows. The seawater circuit (secondary circuit) is an open circuit in which the seawater is drawn in and after having owed through the heat exchangers, it is expelled again. Overview of cooling circuit for SDI engines
The coolant circuit consists of Small coolant circuit (primary) red closed freshwater circuit Large coolant circuit (primary) blue closed freshwater circuit Seawater circuit (secondary) green
Exhaust manifold
Main heat exchanger
Exhaust header
Coolant expansion tank
Oil cooler
Cooler assembly housing
Thermostat 80 C and coolant pump
Seawater lter
Combined cooler (gear oil and fuel)
Seawater pump
MSSP_001_058
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Cooling system
Seawater circuit Drawn in by the seawater pump, the seawater enters the system via the boat's hull. The seawater lter lters the impurities out of the incoming seawater. The downstream combined cooler is a two-piece assembly. It cools the fuel owing back to the fuel tank. On boats with power-assisted steering, the other part cools the hydraulic oil in the steering system as well as the gearbox oil on boats with a reversing gearbox. In the heat exchanger, the seawater absorbs the heat of the coolant circuit and thus cools the engine. The seawater outlet takes place in the exhaust gas ow through the exhaust manifold (wet exhaust). Provided the engine is running, the seawater always ows through the main heat exchanger and the exhaust manifold.
Small coolant circuit Driven by the coolant pump during the warm-up phase, the coolant circuit passes through the engine block, oil cooler, exhaust header and via the bypass back to the coolant pump. This ensures the engine quickly reaches its operating temperature.
Large coolant circuit Once the engine has reached its operating temperature, the thermostat opens the "large coolant circuit". The coolant now additionally ows through the main heat exchanger where it gives off the heat to the seawater.
Seawater circuit Small coolant circuit (freshwater) Large coolant circuit (freshwater) Bypass Ventilation line
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Cooling system
Overview of cooling circuit for TDI engines
Turbocharger Exhaust manifold
Intercooler (111 kW only)
Main heat exchanger
Exhaust header
Coolant expansion tank
Oil cooler
Cooler assembly housing
Thermostat 80 C and coolant pump
Seawater lter
Combined cooler (hydraulic oil and fuel)
Seawater pump
MSSP_001_068
Seawater circuit Small coolant circuit (freshwater) Large coolant circuit (freshwater) Bypass Ventilation line
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Cooling system
Seawater circuit Apart from the following changes, the seawater circuit of the TDI engines is the same as that of the SDI engines. Changes On the TDI 150-5/150-5D, 108 kW and 111 kW TDI engines, the intercooler is located between the seawater pump and the main heat exchanger. In order to increase the air density, the compressed charge air from the turbocharger is cooled by the seawater. The TDI 120-5, 88 kW engines as well as the TDI 100-5, 74 kW engines are not equipped with an intercooler.
Large coolant circuit High temperatures occur at the turbocharger during engine operation. For this reason, the "large coolant circuit" cools the turbocharger instead of the exhaust manifold as on the SDI.
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Cooling system
Design of cooler assembly
Expansion tank
Intercooler
Seawater inlet Seawater to main heat exchanger Intake pipe Exhaust header
Main heat exchanger
MSSP_001_100
Intercooler (TDI 150-5/150-5D only)

The intercooler consists of the cooling pipe assembly and the housing. The seawater pump pumps the seawater through the intercooler, thus cooling the air compressed by the turbocharger. The air density increases.
Intake air
Cooling tubes
Seawater outlet
Seawater inlet
MSSP_001_072
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Cooling system
Main heat exchanger
The heat from the engine is transferred via the coolant in the main heat exchanger to the seawater. The main heat exchanger and the expansion tank form one unit.
Expansion tank
Exhaust header Main heat exchanger

MSSP_001_105
Exhaust header
Exhaust gas temperatures of a diesel engine can reach up to 800C. In order to keep the surface temperature at a low level, the exhaust header in Volkswagen Marine boat engines is cooled by the coolant circuit. The dissipated heat is then transferred in the main heat exchanger to the seawater.
Exhaust header Seawater inlet
Tube assembly for main heat exchanger (coolant circuit)
Seawater outlet
MSSP_001_099
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Cooling system
Exhaust manifold
In the exhaust manifold, the seawater required for cooling is fed to the exhaust gas and routed via the exhaust system out of the boat (wet exhaust).
Seawater Exhaust gasses Seawater inlet
Engine cooling water
MSSP_001_102
Combined cooler
The combined cooler is located below the central electrics on the engine on the side of the oil pan. Due to its split design, it cools the fuel owing back to the fuel tank and, depending on the boat's equipment, the hydraulic oil of the power-assisted steering or the gear oil of the reversing gearbox.
Fuel outlet Fuel inlet
Oil outlet Oil inlet
Seawater to pump
Seawater from lter
Cooling tubes
MSSP_001_069
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Cooling system
Seawater pump
The seawater pump is driven by a ribbed V-belt. The star-shaped impeller pumps the seawater into the seawater circuit.
Quick-release coupling of seawater hoses The design of the hose couplings ensures easy assembly and disassembly. The retaining springs on the connection pieces need only be unclipped in order to disconnect the seawater hoses from the pump. The springs lock in again automatically when reconnecting the hoses.
The pump is made up of the following components:
Seal Seawater outlet Pump Impeller
Pump cover
Rubber seal
MSSP_001_060
Seawater inlet
The rubber impeller of the seawater pump should be inspected at the end of the season and replaced as required. Please refer to the Owner's Handbook and the current Workshop Manual.
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Cooling system
Sacricial anode
Due to the incoming seawater, disintegration in accordance with electrochemical series can occur on the materials with which the seawater comes in contact. To ensure no engine component is affected, a reactive or sacricial anode is located in the main heat exchanger. It disintegrates (sacrices) itself, thus protecting the other components.
Electrochemical series Charge carrier exchange occurs between different metals in the presence of water. As the result of this exchange, the lower grade of both metals disintegrates. The electrochemical series is obtained by arranging the metals in a series from the lower grade to the higher grade metal. The further the metals are apart in the series the higher the charge carrier exchange and thus the disintegration.
Sacricial anode
MSSP_001_070
Aluminium H2 O Al
Iron Fe
Lead Pb
Copper Cu
Gold Au
Magnesium
MSSP_001_071
Please refer to the Owner's Handbook or the current Workshop Manual for instructions on how to replace the sacricial anode.
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Electrical system
Central electrics unit
The central electrics unit based on pc-board design is located on the engine. It accommodates the engine control unit, relays, diode group, fuses for the glow plugs and the fuse for the fuel pump as well as the MDC main fuse. Two electrical terminals connect the unit to the engine. In addition, there is also an oil and water resistant connecting cable leading to the control panel.
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MSSP_001_050
Earth cutout relay

The engine is earth-free in order to protect the drive train from galvanic corrosion. The earth cutout relay closes when the engine is started. The engine is thus temporarily connected to earth for the purpose of powering the starter.
MSSP_001_101
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Electrical systems
Multifunction display
The rev counter in the control panel is equipped with a multifunction display.
C
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80 40
175 105
100 120
210
12 8
14 16
250
20 10 0 30 40
VOLT
It contains the following information:

1 0
150 km 3.7 l/h

bar 2 3 4
15 29 44 0
Operating hours Gearbox in neutral position Distance It can be displayed in - Kilometres (km) - Nautical miles (nm) - Miles (m) Fuel consumption Can be displayed in - Litres (l) - Gallons (g) Current fuel consumption/average It can be displayed in - l/km - l/nm - l/m - g/km - g/nm - g/m Range It can be displayed in - Kilometres (km/l) - Nautical miles (nm/l) - Miles (m/l) Speed It can be displayed in - Kilometres per hour (km/h) - Knots (kn) - Miles per hour (mph)
psi
58 72
marine
MSSP_001_077
3.7 m
15 m 3.7kn
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Electrical systems
Memory The multifunction display is also equipped with an automatic memory. It stores information relating to: Operating hours Distance covered Amount of fuel consumed Fuel consumption Range Speed
The memory collects the data of any number of individual journeys up to 9999 operating hours 9999 nautical miles 9999 litres fuel consumed
40
500 3.7
o l m
marine
MSSP_001_079
The individual functions can be selected via the control switch.
All memory data are deleted (except for total operating hours) when the control switch is pressed for longer than 5 seconds or when the battery is disconnected.
marine
MSSP_001_078
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71 Technology
Electrical systems
Displays/indicators
Rev counter The rev counter provides information on the current engine speed. It receives the engine speed signal from the engine control unit.
20 10 0 30 40 o o
3.7l/h 3.7 l/h

marine
MSSP_001_080
Voltmeter The voltmeter provides information on the current system voltage. The information is provided by terminal 15 at the ignition starter switch.
8
12
EIN
14 16
AUS ST ART
VOLT
15
MSSP_001_081
Oil pressure gauge

1
bar 2 3 0
15 29 44 0
It provides information on the current engine oil pressure. The information comes from the oil pressure sensor on the engine. The engine oil pressure should be between 1 bar and 5 bar. If the oil pressure drops below 1 bar, the oil pressure warning lamp comes on and an acoustic warning signal sounds. The engine should be shut off in order to avoid engine damage.
psi
58 72
MSSP_001_082
Superior
72 Technology
Self-diagnosis
Diagnosis
The engine control unit features a system diagnosis function. Malfunctions that occur during operation are stored in the fault code memory and can then be read out with the Volkswagen diagnosis system tester V.A.G 1552. Diagnosis with the fault readout unit V.A.G 1551 and the diagnosis system tester VAS 5051 is also possible. It will also be possible to read out the data with the diagnosis system VAS 5052 that will be introduced at a later point in time. The diagnosis interface is located behind the cover with the lettering "Marine" on the control panel. Another diagnosis connector is located in the central electrics unit.
MSSP_001_083
V.A.G 155 2
After connecting the diagnosis system tester to the diagnosis interface, "fast data transmission" ensures the system diagnosis function is used optimally.
V.A.G SELF-DIAGNOSIS 1. Fast data transmission* 2. Flash code output*
HELP
The diagnostic connection to the engine control unit is established by entering the "address word 01". The system diagnosis contains the following functions: Function 01 Check control unit version Function 02 Check fault code memory Function 03 Actuator diagnosis Function 04 Basic setting Function 05 Delete fault code memory Function 06 End output Function 07 Not used Function 08 Read measured value block
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Self-diagnosis
Function 01 Check control unit version The control unit identication is shown on the display.
Fast data transmission Select function XX
HELP
Function 02 Check fault code memory This function serves to check the entries in the fault code memory. After pressing the buttons 0 and 2, the number of stored fault codes is shown on the display. The stored fault codes are displayed in succession by pressing the button. The faults are output in text form and with a fault ID code. You will nd detailed information on the fault codes under fault identication in the Workshop Manual for the engine control.
Function 03 Actuator diagnosis This functions serves to check the actuators. After pressing the buttons 0 and 3 the actuators are activated in a dened sequence. Please refer to the current Workshop Manual for the exact description of the function check procedure of the actuators and the activation sequence.
Function 04 Basic setting The basic setting of the distributor-type injection pump is initiated with the function 04. Please refer to the current Workshop manual for a detailed description of the basic setting function.
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Self-diagnosis
Function 05 Delete fault code memory The fault code memory can be deleted by pressing the buttons 0 and 5. It is only possible to delete the fault code memory if it was checked beforehand.
Function 06 End output Communication with the engine control unit is ended by pressing the buttons 0 and 6. Ending communication by disconnecting the diagnosis interface can cause temporary malfunctions in the engine control unit and is therefore not permitted.
Function 07 Not used
Function 08 Read measured value block The engine operating data, e.g. current engine temperature, can be read out with the diagnosis system tester after pressing the button 0 and 8 and then entering a display group number. The engine operating data are provided in display groups. Refer to the Workshop Manual for the list of display group numbers and the values shown on the display.
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75 Technology
Self-diagnosis
Examples of fault code memory entries
Solenoid valve controlled on negative side
Fault display in fault code memory: No fault detected

Solenoid valve
Functional description Depending on the activation of the solenoid valve by the computer, the self-diagnosis function alternately measures the battery voltage and earth
Control unit Self-diagnosis
MPU
Switching output stage

MSSP_001_090
Fault display in fault code memory: Short to positive
Solenoid valve
Functional description There is a short to positive in the wiring harness, connector or in the component. The self-diagnosis functions always measures positive.
Control unit
Self-diagnosis
MPU

MSSP_001_091
Superior
76 Technology
Self-diagnosis
Fault display in fault code memory Break/short to earth
Solenoid valve
Functional description There is a wire break. The self-diagnosis functions always measures 0 Volt.
MPU Control unit Self-diagnosis

MSSP_001_092
Fault display in fault code memory: Break/short to earth
Solenoid valve
Functional description There is a short to earth. The self-diagnosis function always measures 0 Volt.
Control unit
Self-diagnosis
MPU

MSSP_001_093
Superior
77 Technology
Self-diagnosis
Monitored sensor, e.g. coolant temperature sender
Fault display in fault code memory: No fault detected

Control unit R MPU Self-diagnosis
Functional description The self-diagnosis functions measures a plausible signal voltage from the temperature sender between approx. 0.5 and 4.5 Volt.
Control unit earth Sensor
MSSP_001_094
Fault display in fault code memory: Short to earth

Functional description There is a short to earth. The self-diagnosis function always measures 0 Volt.
MSSP_001_095
Superior
78 Technology
Self-diagnosis
Fault display in fault code memory: Break/short to positive
Functional description There is a wire break. The self-diagnosis function always measures > 4.5 Volt.
MSSP_001_096
Fault display in fault code memory: Break/short to positive

Functional description There is a short to positive. The self-diagnosis function always measures > 4.5 Volt.
MSSP_001_097
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79 Technology
Adaptation kits
Gearbox bell housings
The following gearbox bell housings are available for the purpose of using different drive systems.
Gearbox bell housing for Volvo SP-E/DP-E
MSSP_001_086
Gearbox bell housing for reversing gearbox (SAE-7)
MSSP_001_087
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80 Technology
Adaptation kits
Gearbox bell housing for Mercruiser
MSSP_001_088
Gearbox bell housing for Volvo SX/DP-S
MSSP_001_089
Please refer to the technical documentation of your Volkswagen Marine dealer for the current order numbers.
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81 Technology
Abbreviations
List of abbreviations used
A A Al Au - Ampere - Aluminium - Gold M m MDC min mm mph Miles Marine Diesel Control Minute Millimetre Miles per hour
B BSO - Bodensee Schifffahrtsverordnung (Lake Constance Shipping Ordinance)
N C cm3 - Cubic centimetre Co - Carbon monoxide Cu - Copper nm Nm NOx NTC Nautical miles Newton meters Nitrogen oxide Negative Temperature Coefcient
F Fe - Iron
O OT - Top dead centre
G g - Grams or gallons
P Pb Pkw PME PS Lead Passenger vehicle Vegetable oil methyl ester Horse power
H H2O - Water h - Hours HC - Hydrocarbon R RME - Rape-seed oil fatty acid methyl ester
K KD-Literatur - Service literature kg - Kilograms km - Kilometre kn - Knots kW - Kilowatt
U rpm - Revolutions per minute
V V - Volt VTG - Variable Turbine Geometry
I l - Litre
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82 Technology
Notes
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83 Technology
Self-study programme M001
2001 Volkswagen Marine The texts, illustrations and standards in these instructions are based on the information available at the time of printing. Reprinting, duplication or translation, in whole or in part, is not permitted without the written approval of Volkswagen Marine. All rights in accordance with the copyright law are reserved expressly by Volkswagen Marine. Subject to modification without notice. Copy deadline 04/01 P.O. Box 31 11 76, 38231 Salzgitter Edition 04/01, Publication number 065.991.T05.20
This paper was manufactured from pulp bleached without using chlorine.

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Self-study programme M001

Design and function

Boat engines from Volkswagen Marine

TDI 100-5 TDI 120-5 TDI 150-5 TDI 150-5D

SDI 55-5 SDI 75-5

The self-study programme is not a workshop manual!

Engine mechanical systems . . . . . . . . . . . . . . . . . . . . . 12

Combustion system . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Engine electronic systems . . . . . . . . . . . . . . . . . . . . . . .22

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

Adaptation kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80

150 140 130

Engine speed (rpm)

Engine speed (rpm)

Engine speed (rpm)

100 90 280 80 320 290 260

30 20 20 10 0 1500 2000 2500 3000

Engine speed (rpm)

Engine speed (rpm)

Engine mechanical systems

Marine oil pan

Cup-type oil lter

Engine mechanical systems

Crankcase ventilation with oil separator

From crankcase ventilation

Engine mechanical systems

Engine mechanical systems

Engine mechanical systems

Secondary ywheel mass

Primary ywheel mass of the dual-mass ywheel Crankshaft drive

Engine mechanical systems

Primary ywheel mass

Secondary ywheel mass

Engine and drive train vibration in idle speed range

Vibrations generated by the engine Vibrations absorbed by the drive train

Engine mechanical systems

High pressure chamber

Engine mechanical systems

Nozzle needle Lift 1 and lift 2

Engine electronic systems

Throttle lever position sender

Needle lift sender at injection nozzle of 5th cylinder

Intake manifold pressure and intake air temperature sender

Diagnosis interface Coolant temperature sender

Engine electronic systems

Fuel temperature sender

Modulating piston movement sender

Distributor injection pump

MDC control unit

Engine speed sender

Engine electronic systems

Needle lift sender

Engine speed sender

Coolant temperature sender

Intake manifold and intake air temperature sender

Throttle lever position sender

Modulating piston movement sender Fuel temperature sender

Engine electronic systems

MDC control unit