Volkswagen SDI 1.9L Series Manual page 49

Table of Contents
Owner and Operator Responsibilities................................... 42
Dealer Responsibilities......................................................... 42
Maintenance......................................................................... 42
Replacement Parts Warning................................................. 43
Engine Components............................................................. 43
Inspection............................................................................. 44
Routine Maintenance............................................................ 44
Start of Season ............................................................. 44
Each Day Start ............................................................. 45
Each Day End ............................................................... 45
Weekly .......................................................................... 45
End of Season .............................................................. 45
Scheduled Maintenance....................................................... 45
Once a Year or Every 200 Operating Hours (Whichever
Occurs First) ................................................................. 45
Every 500 Hours or 5 Years (Whichever Occurs First)
...................................................................................... 46
Every 5 Years or 1,000 Operating Hours (Whichever
Occurs First) ................................................................. 46
Every 5 Years or 2,000 Operating Hours (Whichever
Occurs First) ................................................................. 46
Maintenance Log.................................................................. 46
Engine Oil............................................................................. 48
Checking ....................................................................... 48
Filling ............................................................................ 48
Changing Oil and Filter ................................................. 49
ZF Marine Transmission Fluid.............................................. 50
Check Fluid Level.......................................................... 50
Add Fluid........................................................................ 51
Change Fluid................................................................. 51
Engine Coolant..................................................................... 53
Checking the Coolant Level .......................................... 53
Adding Coolant ............................................................. 53
90-8M0070920 AUGUST 2012
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Section 5 - Maintenance
Air Filter................................................................................ 53
Water-Separating Fine Element Fuel Filter.......................... 54
Fuel Prefilter......................................................................... 57
Purging the Fuel System...................................................... 59
Seawater System................................................................. 59
Corrosion Protection............................................................. 61
Drive Belts............................................................................ 62
Battery.................................................................................. 64
Battery Precautions for Multiple Engines.............................. 64
Removal ....................................................................... 53
Inspection and Cleaning ............................................... 54
Installation .................................................................... 54
Draining ........................................................................ 55
Replacing ...................................................................... 55
Filling ............................................................................ 56
Draining ........................................................................ 57
Replacing ...................................................................... 58
Filling ............................................................................ 58
Seawater Pump Impeller Inspection.............................. 59
Flushing and Draining the Seawater System................. 60
Checking the Seawater Pickups.................................... 60
Cleaning the Seawater Strainer, if Equipped................. 61
General Information....................................................... 61
Sacrificial Anode............................................................ 62
Antifouling Paint............................................................. 62
Drive Belt....................................................................... 62
Drive Belt Failure Identification...................................... 63
Alternators .................................................................... 64
Engine Control Unit (ECU) ........................................... 64
Batteries ....................................................................... 64
Battery Switches ........................................................... 64
Battery Isolators ............................................................ 65
Generators .................................................................... 65
Section 5 - Maintenance
5
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