Volkswagen Marine SDI Series Operating Manual
  1. Manuals
  2. Brands
  3. Volkswagen Marine Manuals
  4. Engine
  5. SDI Series
  6. Operating manual

Volkswagen Marine SDI Series Operating Manual

Boat engine
Hide thumbs Also See for SDI Series:
Table of Contents

Advertisement

Quick Links

Operating Manual
4-Cyl. SDI

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the SDI Series and is the answer not in the manual?

Questions and answers

Related Manuals for Volkswagen Marine SDI Series

Summary of Contents for Volkswagen Marine SDI Series

  • Page 1 Operating Manual 4-Cyl. SDI...
  • Page 2 It also Volkswagen Marine boat engines are guarantees that everything on your characterised by many advantages: Volkswagen Marine boat engine is in Compact design and low weight proper working order. In addition, create the conditions for universal VW-Marine Service Partner offer an installation.

  • Page 3: Table Of Contents

    CONTENTS MANUAL STRUCTURE What you should know Engine oil ..... before you read this manual ..Check engine oil level .

  • Page 4: Manual Structure

    Volkswagen Marine manual to the new owner, as the literature Boat Engine. is part of the Volkswagen marine boat engine! Notes on environmental protection Texts which follow this symbol...

  • Page 5: General View Of Engines

    OPERATION General view of engines BM4-001M Description of engines The engine has two separate cooling circuits. SDI-40-4, SDI 50-4 and SDI-60-4 1 - The open seawater circuit runs via the gearbox radiator, main heat Four-stroke diesel engine exchanger and the exhaust manifold. 2 - The coolant circuit runs as a closed 4-cylinder in-line pressurised system through the engine...

  • Page 6: Starting Engine

    OPERATION Starting engine When restarting the engine, restarting is Important not possible until the key has been turned Never allow the engine to run back completely. The non-repeat mechan- with the vehicle standing in an ism is designed to prevent the starter from enclosed area - asphyxiation...

  • Page 7: Stopping The Engine

    OPERATION Stopping the engine Do not immediately switch off the engine after a lengthy period of heavy load, but rather allow it to run at idle speed for about 2 minutes to prevent a build-up of engine heat. Attention Refer to the safety instructions provided on Page 17 onwards before carrying out any work on the engine or in the engine...

  • Page 8: Instruments

    OPERATION Instruments The illustration shows the instruments of Item Page the navigating stand panel*. 1 - Coolant temperature gauge ..2 - Rev. counter ....3 - Voltmeter .
  • Page 9 OPERATION 1 - Coolant temperature 2 - Rev. counter gauge* Never run the cold engine at high speeds - either at idle or during driving. The display appears when you switch on the ignition. If the needle of the rev. counter goes above 4,000 rpm, you should cut When the ignition is switched on, the warn- back on the throttle to prevent en-...
  • Page 10 OPERATION 5 - Engine-oil Switch off engine! Check the oil level - see page 33. pressure gauge* The engine oil-pressure warning The engine-oil pressure gauge only func- lamp is not an engine oil level indica- tions with the engine running and indicates tor! Therefore, check the engine oil the existing engine oil pressure.

  • Page 11: Warning Lamps

    OPERATION Warning lamps BM5-015M The illustration shows the warning lamps of Item Page the optional navigating stand panel*. 1 - Coolant temperature/ coolant level ....2 - Display for multi-function indicator 12 3 - Alternator .
  • Page 12 OPERATION 1 - Coolant temperature Important The warning lamp lights up when the cool- Exercise caution when ant temperature is too high. opening the coolant cap! When As an additional warning, an acoustic signal the engine is hot, the cooling sounds at the same time, which can be system is pressurised - danger of switched off with the switch A.
  • Page 13 OPERATION 2 - Multi-function indicator Water separator (MFI) This symbol appears when water has col- lected in the fuel filter on the engine. The following faults may be indicated in the left-hand area of the MFI: In this case, switch off the engine and drain the water from the fuel filter - see page 40.
  • Page 14 OPERATION 4 - Glow plug system and 5 - Engine oil pressure engine fault This warning lamp lights up when the igni- tion is switched on and must go out after the Glow plug system engine starts. When the engine is cold, the warning lamp If the engine oil-pressure warning lights up when the driving position is acti- lamp lights up or flickers during...

  • Page 15: Switch

    OPERATION Switch BM5-004M BM5-017M The illustration shows the switches of the The illustration shows the switches of the navigating stand panel. navigating stand panel*. Item Page Item Page 1 - Instrument lighting/dimmer ..1 - Instrument lighting/dimmer .

  • Page 16: Stop Switch

    OPERATION Stop switch 1 - Instrument lighting The brightness of the instrument lighting can be adjusted by pressing the button. 2 - Acknowledgement button for acoustic signal The acoustic signal of a fault message can be acknowledged with this button. BM4-003M 3 - Button for MFI Stop switch...

  • Page 17: Ignition Switch

    OPERATION Ignition switch Driving lever BM4-013M BM5-030M 1 - Fuel supply interrupted, engine The illustration shows the pattern of the driving lever. 2 - Preheating and driving position 1 - Forward driving As long as the engine is being preheated, no 2 - Shifting during forward driving major consumers should be switched on - 3 - Neutral...

  • Page 18: Do-It-Yourself

    DO-IT-YOURSELF Safety precautions for working in the engine compartment When performing any work on the Do not open the cap of the engine or in the engine compart- coolant reservoir while ment, e.g. checking and topping up engine operating the operating fluids, there may by a temperature, cooling danger of scalding, injuries, acci-...
  • Page 19 DO-IT-YOURSELF When topping up fluids, make sure If work on the fuel system or that they are not confused, as other- the electrical system is required: wise serious malfunctions Always disconnect the battery engine damage will result. from the engine. ensure that leaks...

  • Page 20: Diesel

    RME fuel (biodiesel) peratures down to about –10 in accordance with DIN 51 606. At outside temperatures below approx. Volkswagen Marine boat engines can also –10 C diesel fuel must be added to prevent be operated with RME fuel (rape-oil fatty the RME fuel from flocculating.

  • Page 21: Changes And Parts Replacement

    DO-IT-YOURSELF Changes and parts replacement The state of the Volkswagen Marine boat Genuine Volkswagen Marine parts are engines when shipped from the factory available from a VW-Marine Service Partner. may not be changed without careful con- Of course, proper fitting is also carried out sideration.

  • Page 22: Self-Help

    Volkswagen Marine boat engine. Here you will receive professional advice and find fast, effective help. If, for example, the engine should fail to start...
  • Page 23 DO-IT-YOURSELF Fault Engine does not start Starter does not turn Cause Remedy Driving lever is not in neutral position Move driving lever into Neutral position Neutral position Neutral switch in gearbox does not Check operation of neutral switch output signal (only with ZF reversing gear) STOP button pressed Release Stop button...
  • Page 24 DO-IT-YOURSELF Fault No or insufficient fuel supply Cause Remedy Fuel cock closed Open fuel cock No fuel in tank Refuel Tank dirty Clean Fuel lines clogged Check lines and clean if necessary Water level in circulation filter too Drain water from circulation filter high Circulation filter clogged Clean circulation filter and renew...
  • Page 25 DO-IT-YOURSELF Fault Engine becomes too hot Cause Remedy Seawater valve closed Check impeller and renew if necessary. Then open seawater valve. Seawater filter is clogged Close seawater valve, check impeller and renew if necessary. Then clean seawater filter and open seawater valve.

  • Page 26: Fuses

    DO-IT-YOURSELF Fuses BM4-008M BM4-004M individual electrical circuits The fuses are located in the fuse box/relay protected by fuses. plate behind the cover. It is advisable to always carry a selection of Switch off the ignition and corresponding replacement fuses available VW Marine electrical equipment.

  • Page 27: Service And Care

    The far-reaching network of VW Marine The work described here is used to maintain service partners with specially trained your Volkswagen Marine boat engine. experts, modern equipment and all necess- The specified service intervals are matched ary special tools is available to support your to normal operating conditions.

  • Page 28: Daily Checks

    INSPECTION Daily checks Visual inspection before going out Before going out you should subject the engine to a check and visual inspection. Work required Page Visual inspection for leaks and damage Check engine oil level Check circulation filter* (Bowle) and drain off water if necessary Checking coolant level and top up if necessary Check seawater filter* and clean if necessary Note...

  • 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 VW Marine Service Partner, as the work required specialised knowledge and special tools.

  • Page 30: Start Of Season

    At the start 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 VW Marine Service Partner, as the work required specialised knowledge and special tools.

  • Page 31: Service Scope

    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 VW Marine Service Partner, as the work required specialised knowledge and special tools.

  • Page 32: Additional Work

    Additional work every 5 years or every 1,000 operating hours This additional work on your Volkswagen Marine boat engine must be carried out every 5 years or every 1,000 operating hours. You should have the additional work on your Volkswagen Marine boat engine conducted by your VW Marine Service Partner, as the work required specialised knowledge and special tools.

  • Page 33: Engine Oil

    INSPECTION Engine oil Specifications Multi-grade light-running oil: VW Marine Longlife specification A special VW Marine Longlife oil that can be VW 506 00 (0W30) ran as an all-year oil is used in the engine at the factory. Important notes It has special corrosion protection prop- The engine oil named above is a erties to protect the engine in an aggressive condition for the specified mainten-...

  • Page 34: Check Engine Oil Level

    INSPECTION Check engine oil level Then pull out the dipstick again and read off the oil level: A - If the oil level is within the range A, no oil may be added. B - If the oil level is within the range B, oil may be added.

  • Page 35: Changing Engine Oil

    INSPECTION Changing engine oil Changing engine oil Observe the safety precautions beginning on page 17 before performing out any work on the engine engine compartment. The properties of VW Marine Longlife oil not only worsen due to loading during opera- tion, but also due to ageing.
  • Page 36 INSPECTION BM4-023M BM4-009M Remove the cover of the oil filter so that Press and hold the button 2 fuse box/ the return valve opens and the used oil can relay plate with the engine stopped and the flow back into the oil sump. ignition switched on until all engine oil is completely pumped out.
  • Page 37 INSPECTION Pouring in engine oil For filling quantities, see the chapter ”Technical data”. Check the oil level with the oil dipstick - also see page 33. The oil level must be between the two markings and may never be above the max. mark. Important Used oil must be stored in a safe place out of reach of children...

  • Page 38: Circulation Filter

    INSPECTION Circulation filter* Please make sure that no diesel fuel gets onto the hoses. Clean the hoses with water immediately if necessary. Wear eye protection. your hands come into contact with diesel fuel, they must washed thoroughly afterwards. Used fuel must be stored in a safe place away from children BM5-026M until its proper disposal.
  • Page 39 INSPECTION Start the engine and conduct a visual Renewing circulation filter* inspection of the fuel system for leaks. Important Notes want change After draining the fuel it is not necessary circulation filter element* to bleed the fuel system. yourself, then please be sure to observe the following points: Should a power drop or excessively high intake resistance not be eliminated by back-...
  • Page 40 INSPECTION Renewing filter element Fit the cover with the gasket and tighten the screws diagonally. Switch off the engine (single filter) or switch over to the second filter (double Note filter). After renewing the filter element, it is not necessary to bleed the fuel system. Unscrew the 4 cover screws and take off the cover.

  • Page 41: Fuel Supply Filter

    INSPECTION Fuel supply filter Unscrew the bleeder screw 1. Open the drain screw 2 by a few turns and can approx. 100 cm of fuel with a suit- able container. Screw in the drain screw 2 again. Screw in the bleeder screw 1 again. Note After renewing the filter element, it is not necessary to bleed the fuel system.
  • Page 42 INSPECTION Disconnect the connector 1 on the cable below the fuel supply filter. Screw out the old fuel supply filter 2 and clean the sealing surface of the bracket. Moisten the rubber ring of the new filter with diesel fuel. Fill the fuel supply filter with clean diesel fuel.

  • Page 43: Seawater Filter

    INSPECTION Seawater filter* If you determine soiling, proceed as follows: Close the seawater valve. Unscrew the screws - see left illustration - and remove the cover. Remove the filter element, flush it thor- oughly with clean water and refit it. Before screwing on the filter cover, the sealing ring should be lubricated, e.g.

  • Page 44: Cleaning Air Filter Element

    INSPECTION Cleaning air filter element BM4-016M BM5-035M Cleaning air filter element Cleaning air filter element Wash out and oil the filter element as speci- Blow out the filter insert with a maxi- fied in the service schedule. mum of 2.0 bar compressed air from the inside outward.
  • Page 45 INSPECTION BM4-017M Installing air filter element Guide the air filter housing over the air filter element and tighten the screw 2 - see left-hand illustration on page 43 - again. Push the air filter element with the air filter housing over the intake manifold again. Secure the air filter housing with the two screws 1 - see left-hand illustration on page 43.

  • Page 46: Cooling System

    INSPECTION Cooling system The cooling system must be filled with a Coolant additive mixture of water and a 33 % share of our Only G 12 A8D coolant additive coolant additive G 12 A8C (glycol-based (antifreeze on glycol basis with antifreeze with corrosion inhibitors).
  • Page 47 INSPECTION To obtain correct readings you should check the coolant level with the engine switched off. Correct coolant level is important for ensur- ing your coolant system functions at an optimum. You should therefore check the coolant level regularly! With the engine cold, the coolant must be above the min mark and below the max mark -arrow-.
  • Page 48 INSPECTION Topping up the coolant To avoid engine damage you should refrain from adding large amounts Important of coolant with the engine hot - wait until it has cooled (thermal shock). Never open engine compartment cover when you Never fill the coolant to beyond steam coolant the MAX mark:...

  • Page 49: Seawater Pump

    INSPECTION Seawater pump BM4-014M BM4-015M Unscrew the screws 5. Checking seawater pump Pull the seawater pump out of the impeller and renewing if bracket on the side. necessary Remove the screws 3 - left-hand illustra- In accordance with the specifications in the tion - on the back of the seawater pump service schedule, the impeller must be from the housing and take off the cover.
  • Page 50 INSPECTION BM4-014M BM4-015M Before reinstalling the impeller, grease it Insert the seawater pump in the bracket with silicone spray or glycerine. and secure it with the screws 5 on the bracket. Push the impeller onto the shaft and press the rubber protection cap into the Press in the retaining clip 2 - left-hand impeller.

  • Page 51: Reactive Anode

    The anode must be replaced with a new one when more than 50 % (10 millimetres) of it has been used. Use only genuine Volkswagen Marine parts, as an incorrect composition of the anode can result in serious corrosion damage in the engine.

  • Page 52: Reversing-Gearbox Oil Level

    INSPECTION Reversing-gearbox oil level BM5-007M BM5-034M Then pull out the oil dipstick again and read Check reversing-gearbox oil off the oil level: level A - If the oil level is within the range A, no oil may be added. Important Observe the safety precautions B - If the oil level is within the range B, oil beginning on page 17 before...

  • Page 53: Ribbed V-Belt

    INSPECTION Ribbed V-belt Checking ribbed V-belt Important The ribbed V-belt may only be checked or renewed with the engine stopped danger injury! Observe the safety precautions beginning on page 17 before performing out any work on the engine engine compartment. Check the ribbed V-belt for wear, separ- ations and cracks.

  • Page 54: Battery

    INSPECTION Battery* Important Keep children well away from batteries following warnings battery acid. safety precautions must observed when working on the battery. Always switch off the engine, the ignition and all electrical Wear protection. consumers and press the Stop Avoid allowing acid or button before working on the lead particles to come electrical system.
  • Page 55 INSPECTION Total voltage Important Determine the total voltage only when the Observe the safety precautions battery is loaded with a voltage tester: beginning on page 17 before performing out any work on the - test duration: 5 to 10 seconds engine engine - nominal voltage 12 volts...
  • Page 56 INSPECTION Checking acid level Removing battery Start by making certain that the ignition and Please observe the warnings on all vehicular electrical equipment and the previous page. systems are switched off. The battery is virtually maintenance-free To remove the battery, first disconnect the under normal operating conditions.
  • Page 57 INSPECTION Renewing battery Connecting battery If the battery is renewed, the new battery Before connecting the battery, switch off must have the same voltage (12 V), design the ignition and all current consumers. and safety characteristics, such as central Place the battery in the location provided venting and an O-ring seal for the battery and secure the battery with the battery plugs.
  • Page 58 INSPECTION Charging battery Flush acid splashes in the eyes or on the skin with clean water Important for several minutes. Then consult Observe the warnings on the a doctor immediately. pages 53 and the information of Rapidcharging a battery is the charger manufacturer.

  • Page 59: Engine Test Run

    INSPECTION Engine test run Important Observe the safety precautions beginning on page 17 before performing out any work on the engine engine compartment. Warning lamps Check the warning lamps for the coolant, the alternator and the engine oil pressure. The warning lamps light up when the engine is shifted into the operating position and must go out again after the engine is started.

  • Page 60: Preserving Engine

    6 - Plug all openings (e.g. exhaust pipe, air filter) to prevent the penetration of dirt Depending on the operating conditions, or moist air. Volkswagen Marine boat engines must 7 - Spray the engine with an anti-corrosion be protected against possible corrosion agent from the outside.
  • Page 61 INSPECTION BM4-018M BM4-021M It is important that the engine runs for a Flushing and draining seawater while so that all sludge and salt residues are cooling system flushed away that could otherwise promote corrosion. Important 4 - Switch off the engine again. Observe the safety precautions beginning on page 17 before 5 - Screw on the cover of the seawater...
  • Page 62 INSPECTION Fuel system Important The fuel system also requires an inspection There is fire danger with a leaky and care at the end of the season. fuel system. Please observe the following: If you want to drain the water from the circulation filter and To prevent condensation water in the renew the fuel supply filter tank, completely fill the tank before the end...

  • Page 63: Winter Operation

    INSPECTION Winter operation An inspection service should always be Cable connections conducted on the Volkswagen Marine boat Check and clean all cable connections, as engine before the start of the cold season. oxidised connections lead to voltage drops In addition, please observe the following and starting difficulties.
  • Page 64 INSPECTION Other coolant additives can lead to considerable reduction in corrosion protection. The resulting corrosion damage can lead to coolant loss and subse- quently to major engine damage. Important note Please observe the following when topping off: Never mix G12 with other coolant additives (including not with G11).

  • Page 65: Tropical Operation

    INSPECTION Tropical operation To protect the engine against heat, dust and Cooling system corrosion, the following measures are The coolant level must be checked daily. If required: a coolant loss is determined, the cooling system must be checked for leaks, as Important normally coolant losses hardly occur in the Observe the safety precautions...

  • Page 66: Technical Data

    TECHNICAL DATA SDI 40-4 Diesel Engine Engine data at rpm 29 kW (40 bhp)/2,600 Output in Nm at rpm 125 / 2000 Maximum torque Number of cylinders, displacement 4 cylinders, 1,900 cm Compression ratio 19.5 Bore/stroke in mm 79.5/95.5 Weight in kg Diesel fuel at least CN 49 as per DIN EN 590 or bio-diesel as per DIN 51606 EU3...

  • Page 67: Sdi 50-4 Diesel Engine

    TECHNICAL DATA SDI 50-4 Diesel Engine Engine data at rpm 37 kW (50 bhp)/3000 Output in Nm at rpm 125/2,000 Maximum torque Number of cylinders, displacement 4 cylinders, 1,900 cm Compression ratio 19.5 Bore/stroke in mm 79.5/95.5 Weight in kg Diesel fuel at least CN 49 as per DIN EN 590 or bio-diesel as per DIN 51606 EU3...

  • Page 68: Sdi 60-4 Diesel Engine

    TECHNICAL DATA SDI 60-4 Diesel Engine Engine data at rpm 44 kW (60 bhp)/3,600 Output in Nm at rpm 125/2,000 Maximum torque Number of cylinders, displacement 4 cylinders, 1,900 cm Compression ratio 19.5 Bore/stroke in mm 79.5/95.5 Weight in kg Diesel fuel at least CN 49 as per DIN EN 590 or bio-diesel as per DIN 51606 EU3...

  • Page 69: Engine Characteristic Data

    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 misunderstandings when processing your query. Before you read off the character- istic data, stop the engine and allow it to cool down.

  • Page 70: Index

    INDEX Additional lubricant, 35 Care, 26 Air filter element, 43 Cetane Number, 19 Alternator, 12 Changing engine oil, 34 Anti-knock properties of the fuel, 19 Characteristic data, 68 Antifreeze, 45 Start of season, 29 Cleaning raw water filter, 42 Coolant additive, 45 Coolant level, 46 Coolant temperature, 11 Battery, 53...
  • Page 71 INDEX Engine General view, 4 - Checking oil level, 33 General view of engines, 4 - Oil, 32 Glow-plug warning lamp, 13 - Oil change intervals, 34 - Oil consumption, 33 - Oil level, 33 - Oil pressure, 13 Identification plate, 68 - Safety precautions, 17 Ignition switch, 16 - Starting, 5...
  • Page 72 INDEX Lubricants, 32 Coolant system, 50 Reactive anode, 50 Renewing circulation filter element, 38 Renewing fuel filter, 41 Maintenance, 26 Replacement parts, 20 Modifications, 20 Rev counter, 8 Multi-function indicator, 8 Reversing-gear, - Oil level, 51 Reversing-gearbox - Checking oil level, 51 - Oil level, 51 Oil change intervals, 34 Reversing-gearbox oil level,...
  • Page 73 INDEX Technical description, 4 Voltmeter, 8 Technical modifications, 20 Test run, 58 Tropical operation, 64 Warning lamps, 10 Winter operation, 62 - Battery, 62 Unleaded fuel, 19 - Cooling system, 45 - Diesel fuel, 19 - Engine oil, 32 INDEX...
  • Page 74 The texts, illustrations and standards of this manual are based on the state of information at the time of printing. Reprinting, reproduction or translation, in whole or in part, is not permitted without the written approval of Volkswagen Marine. All rights according to the applicable copyright laws are expressly reserved for Volkswagen Marine.

This manual is also suitable for:

Sdi-40-4Sdi 50-4Sdi-60-4

Table of Contents

Save PDF