Volkswagen SDI 1.9L Series Manual page 6

Duty Cycle.............................................................................. 27
Basic Boat Operation........................................................ 27
Duty Cycle Rating....................................................... 28
Pleasure Duty Rating.................................................. 28
Basic Boat Operation.............................................................. 29
Operation Chart............................................................... 29
Freezing Temperature and Cold Weather Operation...... 29
Drain Plug and Bilge Pump............................................. 30
Starting, Shifting, and Stopping.............................................. 30
Before Starting the Engine.............................................. 30
Starting the Engine.......................................................... 30
Restarting the Engine.................................................. 30
Starting a Cold Engine................................................ 30
Shifting............................................................................ 31
Engine Shutdown (Stopping)........................................... 31
Protecting People in the Water............................................... 31
While Boat is in Operation................................................ 31
While the Boat is Stationary.............................................. 31
High-Speed and High-Performance....................................... 31
Fuel Requirements................................................................. 38
Nonferrous Metals and the Fuel System.......................... 38
Winter Operation and Biodiesel........................................ 38
Diesel Fuel in Cold Weather................................................... 38
Antifreeze/Coolant.................................................................. 38
Engine Oil .............................................................................. 39
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
Page ii
Passenger Safety In Pontoon Boats And Deck Boats............ 32
Wave and Wake Jumping....................................................... 32
Impact With Underwater Hazards........................................... 33
Conditions Affecting Operation............................................... 33
Break-In.................................................................................. 34
Section 4 - Specifications
Engine Specifications............................................................. 39
Fluid Specifications................................................................. 40
Approved Paints..................................................................... 40
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
Boats Having An Open Front Deck................................... 32
Boats With Front-Mounted, Raised Pedestal Fishing Seats
.......................................................................................... 32
Weight Distribution (Passengers and Gear) Inside the
Boat................................................................................. 33
Bottom of Boat................................................................. 34
Elevation and Climate..................................................... 34
Propeller Selection.......................................................... 34
Initial Break-In Procedure................................................ 34
Engine Break-In............................................................... 35
20-Hour Break-In Period............................................. 35
After the 20-Hour Break-In Period............................... 35
End of First Season Checkup.......................................... 35
Engine............................................................................. 40
Transmission................................................................... 40
Checking the Coolant Level.............................................. 53
Adding Coolant................................................................. 53
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
90-8M0070920 AUGUST 2012
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