Volkswagen TDI 350-8 Operating Manual
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Volkswagen TDI 350-8 Operating Manual

Volkswagen TDI 350-8 Operating Manual

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Operating Manual
8 Cylinder TDI
8
TDI 350-8
TDI 350-8

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Summary of Contents for Volkswagen TDI 350-8

  • Page 1 Operating Manual 8 Cylinder TDI TDI 350-8 TDI 350-8...
  • Page 2 VOLKSWAGEN Marine Service have been specially developped for Partners are at your disposal to take use in boats. care of your VOLKSWAGEN Marine VOLKSWAGEN Marine offers a wide boat engine. model range to meet your specific requirement. VOLKSWAGEN Marine Service...

  • Page 3: Manual Structure

    Contents contains important information on using On the first pages you will find a table of your VOLKSWAGEN Marine engine. You contents that shows all topics described should read this manual carefully before in this manual in the order of their first use of your engine to quickly occurrence.
  • Page 4 OPERATION Note When your boat is craned or slipped, water can enter the exhaust system of your engine. Make sure that the exhaust system of the engine is drained of any remaining water before craning or slipping to avoid damage. MANUAL STRUCTURE...

  • Page 5: Table Of Contents

    ......Service scope once yearly or every 200 operating hours . . . * Does not form part of the standard scope of supply for VOLKSWAGEN Marine boat engines.

  • Page 6: General View Of The Engine

    OPERATION General view of engine BM8- - 001M Engine description TDI 350-8 The engine has two separate cooling circuits. Four-stroke diesel engine The open seawater circuit runs via the oil cooler, the main heat exchanger Common-rail direct injection and the exhaust manifold.

  • Page 7: Starting The Engine

    OPERATION Starting the engine Engine break-in Even modern engines need a break-in pe­ Warning riod. Be careful to drive moderately until Never start or operate the engine in an optimum operating temperature of an unventilated or enclosed space. 90°C is reached and always avoid high engine exhaust contains,...
  • Page 8 OPERATION Instruments / Buttons The figure shows the control unit buttons for the individual instrumentation. BM6- -018M 1 - Control unit Item Button for dimmer regulation and instrument lighting The brightness of the instrument lighting can be adjusted by pressing the button. Acknowledge button for acoustic signal The acoustic signal of a fault message can...
  • Page 9 OPERATION the seawater filter is clogged. the seawater valve is open. sufficient coolant is present. Check the cooling system for leaks. BM6- -027M 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 the fault cannot be eliminated.
  • Page 10 Warning however if necessary with a reduced Observe safety precautions engine output. beginning page before Please contact a VOLKSWAGEN Marine performing any work on the engine or Service Partner for system failure analysis in the engine compartment. and troubleshooting. OPERATION...

  • Page 11: Warning Lamps

    If the damage cannot be repaired, illuminates or flickers during operation: please contact nearest Switch off the engine immediately, as VOLKSWAGEN Marine Service Partner. engine lubrication may be interrupted. Note Then check the engine oil level (see The engine must not: page 34).

  • Page 12: Ignition Lock

    * Does not form part of the standard lanyard. Therefore the installation and use scope of supply for VOLKSWAGEN is stringently required by VOLKSWAGEN Marine boat engines. Marine. An emergency stop switch must...

  • Page 13: Start Button

    4 - Shift to reverse direction Press the start button to start the engine. 5 - Reverse direction * Does not form part of the standard scope of supply for VOLKSWAGEN Marine boat engines. Starting an engine with a single control stand Switch the ignition on.
  • Page 14 OPERATION Throttle lever function for a single-engine system Starting an engine with two control stands 1. Switch the ignition on. - You will hear a short acoustic signal and BM8- -027M the throttle lever control light of the selec­ ted control stand (see Item A on the illustration) flashes twice a second.
  • Page 15 OPERATION Throttle lever function for a two-engine system Starting the engines with two control stands Start the engines one after the other as described below: 1. Switch the ignition of the selected BM8- -029M engine on. - You will hear a short acoustic signal and the throttle lever control light of the selected control stand (see Item A on the illustration) flashes twice a second.

  • Page 16: Stop Switch

    OPERATION Synchronous operation of two engines Stop switch Synchronous operation is possible from 5% to 95% of the set speed range. Provided that the throttle levers are not more than 10% apart from each other in this range, the synchronous operation BM8- -008M lamp –D- (see fig.

  • Page 17: Tips And Hints

    TIPS AND HINTS Safety precautions when working in the engine compartment When performing any work on the engine If work on the electrical system is or in the engine compartment, e. g. check­ necessary: ing and topping up the operating fluids, Never conduct fault finding with there is a risk of scalding, injuries, acci­...
  • Page 18 Therefore, it is best to have operating Swell could cause you to become materials changed by a VOLKSWAGEN unbalanced. Marine Service Partner. risk spilling operating materials is increased by swell.

  • Page 19: Diesel

    Changes and Parts Diesel used must comply with DIN EN Do not change the as-supplied condition 590 . of VOLKSWAGEN Marine boat engines without careful consideration. Therefore, ) not lower than 51. if technical changes are to be made to the...

  • Page 20: Self-Help

    VOLKSWAGEN Marine Service Partner will be happy to provide additional assistance. If repairs must be made, the engine should be brought to a VOLKSWAGEN Marine Service Partner. It is in good hands there. Warning Observe safety...
  • Page 21 Air inside fuel system See section on fuel system Should the individual remedies not solve the problem, your VOLKSWAGEN Marine Service Partner will be happy to provide additional assistance. Warning Observe safety...
  • Page 22 Replace fine element fuel filter Engine shakes See section on fuel supply Engine dies See section on fuel supply Should the individual remedies not solve the problem, your VOLKSWAGEN Marine Service Partner will be happy to provide additional assistance. Warning Observe safety...
  • Page 23 This fault should always be checked and defective eliminated by a VOLKSWAGEN Marine Service Partner, as special tools are required. Should the individual remedies not solve the problem, your VOLKSWAGEN Marine Service Partner will be happy to provide additional assistance. Warning Observe safety...

  • Page 24: Fuses

    BM8-004M is applied. replacement fuses available from The circuit board presented in illustration VOLKSWAGEN Marine Service Partners. BM8-007M is provided in duplicate where the boards are mounted side by side with this type of central electrical system. Warning Observe the safety precautions...
  • Page 25 TIPS AND HINTS Fuses Colour code for fuses: orange: ..... . 5 amps blue: ..... . . 15 amps green: .

  • Page 26: Service And Care

    INSPECTION Service and care The broad network of VOLKSWAGEN The work described here is used to Marine Service Partners with trained maintain your VOLKSWAGEN Marine professionals, modern equipment and all boat engine. required special tools is available to you specified...

  • Page 27: Start Of Season

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

  • Page 28: Daily Checks

    Warning Observe safety precautions beginning page before performing any work on the engine or in the engine compartment. * Does not form part of the standard scope of supply for VOLKSWAGEN Marine boat engines INSPECTION...

  • Page 29: End Of Season

    At the end of the season you should subject the engine to a check and visual inspection. You should have the service work on your VOLKSWAGEN Marine boat engine conducted by your VOLKSWAGEN Marine Service Partner, as the work requires specialised knowledge and special tools.

  • Page 30: Or Every 200 Operating Hours

    Service scope once a year or every 200 operating hours Your VOLKSWAGEN Marine boat engine must be serviced once a year at the end of the season or every 200 operating hours. You should have the service work on your VOLKSWAGEN Marine boat engine conducted by your VOLKSWAGEN Marine Service Partner, as the work requires specialised knowledge and special tools.
  • Page 31 INSPECTION Additional work every 1,000 operating hours This additional work on your VOLKSWAGEN Marine boat engine must be carried out every 1,000 operating hours. You should have the additional work on your VOLKSWAGEN Marine boat engine conducted by your VOLKSWAGEN Marine Service Partner, as the work requires specialised knowledge and special tools.
  • Page 32 Additional work every 5 years or every 3,000 operating hours This additional work on your VOLKSWAGEN Marine boat engine must be carried out every 5 years or every 3,000 operating hours. You should have the additional work on your VOLKSWAGEN Marine boat engine conducted by your VOLKSWAGEN Marine Service Partner, as the work requires specialised knowledge and special tools.

  • Page 33: Engine Oil

    VOLKSWAGEN Marine Service Partners are always kept up to date with any changes by the factory. Therefore, it is always best to have the oil change carried out by a VOLKSWAGEN Marine Service Partner. INSPECTION...

  • Page 34: Checking Engine Oil Level

    INSPECTION Checking engine oil level In the case of heavy engine loading, such as during longer engine operation (10 - 12 hours), the oil level should at least lie in the middle of the two markings (min/max). A02- -0018 The quantity difference between min. and max.

  • Page 35: Engine Oil Renewal

    INSPECTION Refilling engine oil Engine oil renewal The properties of VOLKSWAGEN Longlife oil not only worsen due to loading during operation, but also due to ageing. The oil change date is therefore dependent on both the mileage and the running time.
  • Page 36 INSPECTION Engine oil renewal A24- 10 558 BM8- - 015M Loosen the protective cap -1- of the With the engine stopped and the oil filter housing -2- (see illustration ignition switched on, press and hold the above) using a 32 mm socket wrench, so button -1- at the right front side of the that the return valve opens and the used engine and wait until the engine oil has...

  • Page 37: Replacing The Oil Filter

    When proceeding with the fitting make to have the motor oil and filter change sure that the neck – 4-, below at the oil carried out by a VOLKSWAGEN Marine filter element, is inserted into the Service Partner. respective drilling -5- of the oil filter housing (see fig.

  • Page 38: Circulation Filter

    The used circulation filter element must * Does not form part of the standard be stored in a safe place away from scope of supply for VOLKSWAGEN children until its proper disposal. Marine boat engines Observe safety...
  • Page 39 Observe the safety precautions be­ Due to the disposal problem, it is best to ginning on page 17 before performing have the filter change carried out by a any work on the engine or in the en­ VOLKSWAGEN Marine Service Partner. gine compartment. INSPECTION...

  • Page 40: Fuel Fine Filter

    Diesel fuel must never get into waterways, the sewer system or the ground. Due to the disposal problem, it is best to have the filter change carried out by a VOLKSWAGEN Marine Service Partner. INSPECTION...
  • Page 41 As the cover of the filter housing is transparent, you do not need to open the cover. * Does not form part of the standard scope of supply for VOLKSWAGEN Marine boat engines. INSPECTION...

  • Page 42: Air Filter Cleaning

    Remove hoses instructions on the special cleaning and service crankcase ventilation system -A- and -B- kit available from a VOLKSWAGEN Marine at the left and right protective cap of the Service Partner. air filter. Note...

  • Page 43: Cooling System

    60% (water) to 40% (coolant additive). coolant additive. The coolant additive is This ratio provides necessary available from VOLKSWAGEN Marine antifreeze protection down to approx. Service Partners. -25°C and, most of all, protects the light other coolant additive...

  • Page 44: Checking Coolant Level

    INSPECTION Checking coolant level Coolant top-up 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 direc­ tion. BM8- - 003M If no G12++ or an additive with the spe­...

  • Page 45: Seawater Pump

    INSPECTION Seawater pump impeller checking and replacement where necessary BM6- -011M BM6- -012M Before reinstalling the impeller, grease Warning it with silicone spray or glycerine. Observe safety precautions beginning page before Push the impeller onto the shaft and performing any work on the engine or press the rubber protection cap into the in the engine compartment.

  • Page 46: Reverse Gearbox-Oil Level

    Warning millimetres) of it has been used. Maintenance work on the gearbox has Use only original VOLKSWAGEN Marine to be carried out only with engine parts, as an incorrect composition of the switched off. Always wear gloves anode can result in serious corrosion when working on a hot gearbox.
  • Page 47 INSPECTION Reverse gearbox Hydraulic power steering oil level checking oil level checking (only Z-drive) BM5- -034M BM6- -005M Sequence of work Warning 1. Remove the dipstick by rotating its grip Observe safety precautions anticlockwise (see fig. BM5-007, p. 46) BM5-007M) beginning page before...

  • Page 48: Ribbed V-Belts And Toothed Belts

    V-belt or toothed belt is damaged, please Then screw out the dipstick again and contact a VOLKSWAGEN Marine Service read off the oil level: Partner. A - If the oil level is within range A, Note no oil should be added.
  • Page 49 Avoid spark formation when handling cables and electrical * Does not form part of the standard devices. Prevent short circuits. Never scope of supply for VOLKSWAGEN short circuit battery poles. Risk of Marine boat engines injury due to high-energy sparks.

  • Page 50: Battery

    - nominal voltage: 12 Volt - discharged: 9.6 Volt. Battery terminals Clean and grease terminals and note external condition of battery, e.g. raised plates, cracked case. * Does not form part of the standard scope of supply for VOLKSWAGEN Marine boat engines. INSPECTION...
  • Page 51 To remove the battery, first disconnect the negative cable (usually black or brown) and then the positive cable (usually red). Then unscrew the battery mounting. * Does not form part of the standard scope of supply for VOLKSWAGEN Marine boat engines. INSPECTION...
  • Page 52 Due to the disposal problem regarding immediately for several minutes with used batteries, it is best to have a clear water. Then seek medical care battery replaced by a VOLKSWAGEN immediately. Marine Service Partner. Batteries contain sulphuric acid, lead etc and should never Quick charging of a battery is be disposed of in household refuse.

  • Page 53: Engine Test Run

    INSPECTION Engine test run Engine preservation Engine oil and the oil filter element Warning renewal (see page 35 and 36). Observe safety precautions beginning page before For units to be shut down for longer performing any work on the engine or periods - e.g.
  • Page 54 INSPECTION Seawater cooling system flushing and draining 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-. BM8- -024M BM6- -007M 7 - Open the drain screw, to which you have...

  • Page 55: Bleeding The Fuel System

    - see page 40. An inspection service should always be 2. Remove the pressure sensor from the conducted on the VOLKSWAGEN Marine back part of the left “rail” in order to open boat engine before the start of the cold the “rail”...

  • Page 56: Tropical Operation

    INSPECTION Winter operation Tropical operation To protect the engine against heat, dust If the engine is not used for several weeks and corrosion, the following measures are at extremely low sub-zero temperatures, required: the battery should be removed and stored in a frost-proof room to prevent it from Warning freezing and being destroyed.

  • Page 57: Technical Data

    TECHNICAL DATA TDI 350-8 Diesel Engine with 2 exhaust-gas turbochargers 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 cm Compression 16.4...
  • Page 58 TECHNICAL DATA Engine characteristic data Important note Please always specify the model with the engine number or the engine code when making all queries, any complaints and when ordering spare parts. This will prevent misunderstanding when processing your query. Before you read of the characteristic data, stop the engine and allow it to cool down.

  • Page 59: Index

    INDEX Air filter, - cleaning ... . End of season ....Alternator ..... Engine Antifreeze .
  • Page 60 INDEX Lubricant additives ... . . Lubricants ..... General view of engine .
  • Page 61 INDEX Sacrificial anode ....Warning and control lamps ..Safety precautions ... . . Warning lamps .
  • Page 64 © 2009 V V O O L L K K S S W W A A G G E E N N M M a a r r i i n n e e VOLKSWAGEN Marine is constantly working on the further development of all types and models.

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