Related Manuals for Volkswagen Marine TDI 100-5
Summary of Contents for Volkswagen Marine TDI 100-5
- Page 1 Self-study programme M001 Design and function TDI 100-5 TDI 120-5 TDI 150-5 SDI 55-5 SDI 75-5 TDI 150-5D...
- Page 2 Foreword Volkswagen diesel engines have been providing dependable service in passenger vehicles and transporters since 1976. The development of TDI engines is a significant 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.
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Page 3: Table Of Contents
Table of Contents Fundamentals ....... . . 6 Features..........6 The SDI engine . - Page 4 Table of Contents Fuel system ........46 Fuel supply ......... . . 46 Diesel fuel microfilter with water warning facility .
- Page 5 Table of Contents Self-diagnosis ....... . 73 Diagnosis ..........73 Function 01 to 08 .
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Page 6: Fundamentals
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 filter for clean and efficient oil change at the push of a button •... - Page 7 Fundamentals The Volkswagen Marine boat engines feature • a special M arine D iesel C ontrol (MDC) system specifically 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.
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Page 8: The Sdi Engine
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 •... - Page 9 Fundamentals Engine data SDI 55-5 SDI 75-5 Marine Type Engine code letter Engine design 5-cylinder in-line naturally aspirated diesel engine Diesel direct injection with electronically controlled Fuel injection system distributor-type injection pump Displacement 2461 cm 19.0 : 1 Compression ratio 40 kW (55 bhp) 2500 rpm 55 kW (75 bhp) 3600 rpm Power rating at engine speed...
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Page 10: The Tdi Engine
The TDI 150-5D variant is certified 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 certified for use as twin motorisation in compliance with BSO II. -
Page 11: Engine Data
Fundamentals Engine data TDI 100-5 TDI 120-5 TDI 150-5 TDI 150-5D Marine Type Engine code letter Engine design 5-cylinder in-line turbocharged diesel engine Diesel direct injection with electronically controlled Fuel injection system distributor-type injection pump Supercharging Variable turbocharger (VTG) Displacement 2461 cm 19.0 : 1... -
Page 12: Engine Mechanical Systems
Engine mechanical systems Engine oil circuit Injection nozzle Turbocharger with Hydraulic tappet variable turbine geometry Oil filter Oil spray nozzle for piston cooling Oil pump Oil cooler Electric oil extractor pump for oil change Marine oil pan MSSP_001_011 Cup-type oil filter The cup oil filter is arranged upright. -
Page 13: Electric Oil Extractor Pump For Oil Change
Electric connection MSSP_001_107 Oil pan The oil pan is designed specially for use in Volkswagen Marine boat engines. Baffle plates ensure reliable oil supply to the engine also when listing heavily and in rough seas. MSSP_001_104 Crankcase ventilation... -
Page 14: Toothed Belt Drive For The Camshaft
Engine mechanical systems Belt drives Camshaft Toothed belt drive for the camshaft The toothed belt drives • the camshaft and • the coolant pump. Coolant The mechanical tension of the toothed belt is pump controlled by a tension pulley. Tension pulley MSSP_001_006 Toothed belt drive for the distributor injection pump... -
Page 15: Ribbed V-Belt Drives For Ancillary Components
Engine mechanical systems Ribbed V-belt drives for To avoid damage to the vibration ancillary components damper and the engine, the engine must not be run without the The ancillary components are driven by ribbed alternator belt drive. V-belts. Please refer to the current Workshop The following components are driven: Manual for instructions on all •... -
Page 16: Dual-Mass Flywheel
Engine mechanical systems Dual-mass flywheel Due to irregularities in combustion, displacement engines produce torsional vibrations at the crankshaft and the flywheel. The use of a dual-mass flywheel prevents these torsional vibrations being transmitted into the drive train where they would produce resonance, resulting in disturbing noise in the boat. - Page 17 Engine mechanical systems Conventional power transmission structure without dual-mass flywheel Engine and drive train vibrations at low engine speed Engine and drive train vibration in idle Flywheel speed range MSSP_001_065 MSSP_001_085 Power transmission with dual-mass flywheel Engine and drive train vibrations at low engine speed Primary flywheel mass Secondary flywheel mass...
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Page 18: Hydraulic Bucket Tappet
Engine mechanical systems 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... - Page 19 Engine mechanical systems Functional description Beginning of valve stroke High pressure chamber 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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Page 20: Combustion System
Combustion system The combustion system In Volkswagen Marine boat engines, the fuel is injected directly into the main combustion chamber. The advantages include: • More efficient combustion • Improved fuel utilization • Lower fuel consumption and • Low pollutant emission... -
Page 21: Two-Spring Nozzle Holder
Combustion system Two-spring nozzle holder Smooth increase in pressure in the combustion chamber reduces combustion noise and Lift 1 mechanical stress. The two-spring nozzle holder developed for the Spring 1 Volkswagen direct injection diesel engines enables fuel injection in two stages. As a result, it plays an important part in ensuring "smooth"... -
Page 22: Engine Electronic Systems
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... - Page 23 Engine electronic systems Fuel temperature sender Modulating piston movement sender Distributor injection pump MDC control unit Engine speed sender MSSP_001_019 Superior Technology...
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Page 24: System Overview
Engine electronic systems 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 Throttle lever position sender Modulating piston movement sender Fuel temperature sender... - Page 25 Engine electronic systems The corresponding actuators are activated For monitoring purposes, the engine control unit following evaluation of the sensor information in makes use of several characteristic maps and the engine control unit. characteristic curves while ensuring the best torque output, the most favourable fuel The injection volume and start of injection as well consumption and the best exhaust emission as the preheater system are controlled and...
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Page 26: Glow Plug System
• 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. -
Page 27: Intake Manifold Pressure And Intake Air Temperature Sender
Engine electronic systems Intake manifold pressure and intake air temperature sender 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. -
Page 28: Needle Lift Sender
Engine electronic systems Nozzle holder Needle lift sender The needle lift sender is located on the injection nozzle of the 5 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 Magnet coil adhered to. -
Page 29: Modulating Piston Movement Sender
Engine electronic systems Distributor Coil with alternating Modulating piston movement sender injection pump voltage The modulating piston movement sender signals to the engine control unit the current position of the metering adjuster in the injection pump. Iron core Moving Functional description metal ring An alternating voltage generates an alternating Eccentric... -
Page 30: Engine Speed Sender
Engine electronic systems Engine speed sender The engine speed sender is located in the vicinity of the starter crown gear. It scans five marks on the sender wheel for engine speed. The engine control unit uses the signal to detect the engine speed. -
Page 31: Coolant Temperature Sender
Engine electronic systems Coolant temperature sender 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 MSSP_001_023 increased idle speed is required when the engine is cold (90 sec). -
Page 32: Fuel Temperature Sender
Engine electronic systems Distributor injection pump Fuel temperature sender 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. -
Page 33: Throttle Lever Position Sender
Engine electronic systems Shaft Throttle lever position sender 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 Coil spring determine the injection volume. -
Page 34: Metering Adjuster
Engine electronic systems 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. -
Page 35: Start Of Injection Valve
Engine electronic systems 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... -
Page 36: Fuel Shut-Off Valve
Engine electronic systems 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. -
Page 37: Indicator Lamp For Glow Plug System Monitoring
Engine electronic systems Indicator lamp for glow plug system monitoring and engine electronics 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. -
Page 38: Fuel Volume Control
Engine electronic systems Fuel volume control Following evaluation of the received sensor The engine control unit monitors the change in signals, the correct injection volume is the valve position with the aid of the modulating determined in the engine control unit and an piston movement sender. -
Page 39: Start Of Injection Control
Engine electronic systems 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 influenced by the start of injection. The task of the start of injection control is to determine the correct timing for fuel delivery. - Page 40 Engine electronic systems Functional description Injection timing device The mechanical injection timing device in the distributor-type injection pump operates with the Note aid of the speed-dependent fuel pressure in the To provide a clear illustration, the objects in the pump interior. enlargements have been turned through 90°! It is necessary to inject fuel earlier as the engine speed increases.
- Page 41 Engine electronic systems Eccentric disc Pressure roller Start of injection valve Piston of injection Start of injection timing device valve MSSP_001_035 Superior Technology...
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Page 42: Internal Functions In The Engine Control Unit
Engine electronic systems 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 MSSP_001_106 5 times per crankshaft revolution, the engine control unit recognizes even the smallest deviation from the specified idle speed. - Page 43 Engine electronic systems 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.
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Page 44: Function Diagram
Engine electronic systems Function diagram E190 - Emergency stop button E354 - Oil extractor pump button F36 - Neutral switch F60 - Idling switch G6 - Fuel pump (presupply pump) G28 - Engine speed sender G62 - Coolant temperature sender G71 - Intake manifold pressure sender G72 - Intake manifold temperature sender G79 - Throttle lever position sender... - Page 45 Engine electronic systems ϑ ϑ MSSP_001_048 Superior Technology...
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Page 46: Fuel System
Fuel system Fuel supply The fuel pump sucks the fuel out of the fuel tank directly via the circulation preliminary filter. 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. - Page 47 Fuel system Functional description Fuel intake Pressure control valve 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 fitted for the purpose of maintaining the pressure Vane pump increase within the permissible range as the engine speed increases.
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Page 48: Diesel Fuel Microfilter With Water Warning Facility
MSSP_001_040 For this reason, diesel fuel microfilters in Volkswagen Marine boat engines feature a water warning facility. It informs the skipper of high water level in the fuel microfilter before it can place operational reliability at risk. - Page 49 Fuel system Functional description Water level safe Filter The engine control unit sends a voltage to the contact pins of the warning switch located in the fuel microfilter. Only a low current flows if the Contact pins contact pins are surrounded by diesel fuel. Diesel fuel Water MSSP_001_041...
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Page 50: Circulation Preliminary Filter With Water Separator (Optional)
Fuel system Circulation preliminary filter with water separator (optional) The circulation water separator is installed between the fuel tank and fuel presupply pump. Outlet Alternative The exact installation location depends on the opening outlet opening type of boat. Filter element Cross section Functional description enlargement... - Page 51 Notes Superior Technology...
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Page 52: Emission Characteristics
In doing so, it is often necessary to consolidate conflicting 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). -
Page 53: Reducing Pollutants
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 specific design of the combustion chamber and of the piston recess as well as the matching and coordination of the injection nozzles. -
Page 54: Exhaust Turbocharging
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. - Page 55 Exhaust turbocharging There are two specific 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 sufficiently compress the air.
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Page 56: Turbocharger With Variable Turbine Geometry
Exhaust turbocharging Turbocharger with variable turbine geometry The turbocharger installed in Volkswagen Marine boat engines operates with variable guide vanes. Advantage • By correspondingly influencing the exhaust flow, the optimum boost pressure is made available virtually over the entire engine speed range. - Page 57 Exhaust turbocharging Functional description Fundamental principle A gas flows 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.
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Page 58: Control Of Variable Guide Vanes
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 flow Intake air... -
Page 59: Guide Vane Adjustment
Exhaust turbocharging Guide vane adjustment Pressure cell The guide vanes together with their shafts are mounted on the carrier ring. The guide vanes are Carrier ring connected by means of a shaft to the guide pin. Guide vanes Adjustment ring This guide pin engages in the adjustment ring such that all guide vanes are adjusted Guide pin... -
Page 60: Cooling System
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... - Page 61 Cooling system Seawater circuit Drawn in by the seawater pump, the seawater enters the system via the boat's hull. The seawater filter filters the impurities out of the incoming seawater. The downstream combined cooler is a two-piece assembly. It cools the fuel flowing back to the fuel tank.
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Page 62: Overview Of Cooling Circuit For Tdi Engines
Cooling system Overview of cooling circuit for TDI engines Turbocharger Exhaust manifold Intercooler (111 kW only) Oil cooler Thermostat Cooler assembly housing 80 °C and coolant pump Combined cooler Seawater pump Seawater filter (hydraulic oil MSSP_001_068 and fuel) Seawater circuit Small coolant circuit (freshwater) Large coolant circuit (freshwater) Bypass... - Page 63 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.
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Page 64: Design Of Cooler Assembly
Cooling system Design of cooler assembly Intercooler Expansion tank Seawater inlet Main heat exchanger Seawater to main heat exchanger Intake pipe Exhaust header 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. -
Page 65: Main Heat Exchanger
Exhaust gas temperatures of a diesel engine can reach up to 800°C. 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. -
Page 66: Exhaust Manifold
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 Seawater inlet Exhaust gasses 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. -
Page 67: Seawater Pump
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. -
Page 68: Sacrificial Anode
Cooling system Sacrificial 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 sacrificial anode is located in the main heat exchanger. -
Page 69: Electrical System
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. -
Page 70: Multifunction Display
Electrical systems Multifunction display SUPERIOR MARINE TECHNOLOGY The rev counter in the control panel is equipped °C with a multifunction display. VOLT °F It contains the following information: 15 29 44 • Operating hours • Gearbox in neutral position • Distance marine It can be displayed in - Kilometres (km) -
Page 71: Electrical Systems
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 •... -
Page 72: And Oil Pressure Gauge
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. marine MSSP_001_080 Voltmeter ST ART The voltmeter provides information on the current VOLT system voltage. The information is provided by terminal 15 at the ignition starter switch. -
Page 73: Self-Diagnosis
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. -
Page 74: Function 01 To 08
Self-diagnosis Function 01 – Check control unit version Fast data transmission HELP The control unit identification is shown on the Select function XX display. Function 02 – Check fault code memory This function serves to check the entries in the fault code memory. - Page 75 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.
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Page 76: Examples Of Fault Code Memory Entries
Self-diagnosis Examples of fault code memory entries Solenoid valve controlled on negative side Fault display in fault code memory: Solenoid valve No fault detected Functional description Depending on the activation of the solenoid Control unit Self-diagnosis valve by the computer, the self-diagnosis function alternately measures the battery voltage and earth Switching output stage... - Page 77 Self-diagnosis Fault display in fault code memory Solenoid valve Break/short to earth Functional description There is a wire break. Control unit Self-diagnosis The self-diagnosis functions always measures 0 Volt. Switching output stage MSSP_001_092 Fault display in fault code memory: Solenoid valve Break/short to earth Functional description Control unit...
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Page 78: Monitored Sensor
Self-diagnosis Monitored sensor, e.g. coolant temperature sender Fault display in fault code memory: No fault detected Control unit 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... - Page 79 Self-diagnosis Fault display in fault code memory: Break/short to positive Control unit Self-diagnosis Functional description There is a wire break. The self-diagnosis function always measures > 4.5 Volt. Control unit earth Sensor MSSP_001_096 Fault display in fault code memory: Control unit Self-diagnosis Break/short to positive Functional description...
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Page 80: Adaptation Kits
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 Superior Technology... -
Page 81: Gearbox Bell Housing For Mercruiser
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. Superior Technology... -
Page 82: Abbreviations
Abbreviations List of abbreviations used - Ampere - Aluminium - Miles - Gold MDC - Marine Diesel Control - Minute mm - Millimetre mph - Miles per hour BSO - Bodensee Schifffahrtsverordnung (Lake Constance Shipping Ordinance) - Nautical miles Nm - Newton meters - Cubic centimetre NOx - Nitrogen oxide - Carbon monoxide... - Page 83 Notes Superior Technology...
- Page 84 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.