Volkswagen TDI 2.5L 120 Diesel Engine Manuals

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Volkswagen TDI 2.5L 120 Manual

Volkswagen TDI 2.5L 120 Manual (83 pages)

Diesel Inboard Engine

Brand: Volkswagen | Category: Engine | Size: 4 MB

Table of Contents

Table of Contents
5
Section 1 - Warranty
9
Warranty Information
10
- Warranty Registration United States and Canada
  10
- Warranty Registration-Outside the United States and Canada
  10
Warranty Policy-Diesel Models
10
- High-Output Recreational Use Worldwide Limited Warranty
  10
Warranty Policy-Australia and New Zealand
15
- Mercruiser Limited Warranty-Australia and New Zealand Policy
  15
Identification
20
TDI 4.2L Engine Description
20
ZF Marine Transmissions
20
Audio Warning System
21
- Testing the Audio Warning System
  22
Lanyard Stop Switch
21
Instrumentation
22
- Individual Instrumentation
  22
  - Tachometer
    22
  - Coolant Temperature Gauge
    23
  - Information Panel
    23
  - Engine Oil Pressure Gauge
    24
  - Voltmeter
    24
  - Engine Oil Pressure Monitoring
    25
  - Optional Instrumentation Panel
    25
Remote Controls
26
Switches
26
- Ignition Lock Switch
  26
- Emergency Stop (E-Stop) Switch
  26
Engine Electrical System Overload Protection
28
Emissions Information
31
- Exhaust Gas Emissions Certificate (Europe Only)
  31
- Owner Responsibility
  31
Section 3 - on the Water

33
- Safe Boating Suggestions
  34
- Be Alert to Carbon Monoxide Poisoning
  35
  - Good Ventilation
    35
  - Poor Ventilation
    35
- Duty Cycle
  35
  - Basic Boat Operation
    35
    
    Duty Cycle Rating
    36
    
    Pleasure Duty Rating
    36
- Basic Boat Operation
  37
- Starting, Shifting, and Stopping
  38
  - Before Starting the Engine
    38
  - Starting the Engine
    38
    
    Restarting the Engine
    38
    
    Starting a Cold Engine
    38
    
    Engine Shutdown (Stopping)
    39
    
    Shifting
    39
- Protecting People in the Water
  39
  - While Boat Is in Operation
    39
  - While the Boat Is Stationary
    39
- High-Speed and High-Performance
  39
- Passenger Safety in Pontoon Boats and Deck Boats
  40
  - Boats Having an Open Front Deck
    40
  - Boats with Front-Mounted, Raised Pedestal Fishing Seats
    40
- Wave and Wake Jumping
  40
- Impact with Underwater Hazards
  41
- Conditions Affecting Operation
  41
- Break-In
  42
  - Initial Break-In Procedure
    42
  - Engine Break-In
    43
    
    20-Hour Break-In Period
    43
    
    After the 20-Hour Break-In Period
    43
    
    End of First Season Checkup
    43
Section 4 - Specifications

45
- Fuel Requirements
  46
  - Nonferrous Metals and the Fuel System
    46
  - Winter Operation and Biodiesel
    46
- Diesel Fuel in Cold Weather
  46
- Antifreeze/Coolant
  46
- Engine Oil
  47
- Engine Specifications
  47
- Fluid Specifications
  48
  - Engine
    48
  - Transmission
    48
- Approved Paints
  48
- Owner and Operator Responsibilities
  50
- Dealer Responsibilities
  50
- Maintenance
  50
- Replacement Parts Warning
  51
- Engine Components
  51
- Inspection
  52
- Routine Maintenance
  52
  - Start of Season
    52
  - Each Day Start
    53
  - Each Day End
    53
  - Weekly
    53
  - End of Season
    53
- Scheduled Maintenance
  53
- Maintenance Log
  54
Section 5 - Maintenance

54
- Engine Oil
  56
  - Checking
    56
  - Filling
    56
  - Changing Oil and Filter
    57
- ZF Marine Transmission Fluid
  58
  - Check Fluid Level
    58
  - Add Fluid
    59
  - Change Fluid
    59
- Engine Coolant
  61
  - Checking the Coolant Level
    61
  - Adding Coolant
    61
- Air Filter
  61
  - Removal
    61
  - Inspection and Cleaning
    62
  - Installation
    62
- Water-Separating Fine Element Fuel Filter
  62
  - Draining
    63
  - Replacing
    63
  - Filling
    64
- Fuel Prefilter
  65
  - Draining
    65
  - Replacing
    66
  - Filling
    66
- Purging the Fuel System
  67
- Seawater System
  67
- Corrosion Protection
  69
  - General Information
    69
  - Sacrificial Anode
    70
  - Antifouling Paint
    70
- Drive Belts
  70
  - Drive Belt
    70
  - Drive Belt Failure Identification
    71
- Battery
  72
- Battery Precautions for Multiple Engines
  72
  - Alternators
    72
  - Engine Control Unit (ECU)
    72
  - Batteries
    72
  - Battery Switches
    72
  - Battery Isolators
    73
  - Generators
    73
  - Section 6 - Storage
    75
- Cold Weather or Extended Storage
  76
  - Preparing Your Power Package for Seasonal or Extended Storage
    76
- Battery Storage
  76
- Recommissioning the Power Package
  76
- Section 7 - Troubleshooting
  77
- Troubleshooting
  78
- Troubleshooting Charts
  78
- Owner Service Assistance
  80
  - Local Repair Service
    80
  - Service Away from Home
    80
  - Stolen Power Package
    80
  - Attention Required after Submersion
    80
  - Replacement Service Parts
    80
  - Parts and Accessories Inquiries
    80
  - Resolving a Problem
    80
- Customer Service Literature
  81
  - English Language
    81
  - Other Languages
    81
  - Andre Sprog
    81
  - Andere Talen
    81
  - Muut Kielet
    81
  - Autres Langues
    81
  - Andere Sprachen
    81
  - Altre Lingue
    81
  - Andre Språk
    81
  - Otros Idiomas
    82
  - Andra Språk
    82
  - Allej Glþssej
    82
- Ordering Literature
  82
  - United States and Canada
    82
  - Outside the United States and Canada
    82

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