Volkswagen Marine SDI 55-5 User Manual Download | Manualshive

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Superior

Technology

Two-spring nozzle holder

Smooth increase in pressure in the combustion
chamber reduces combustion noise and
mechanical stress.

The two-spring nozzle holder developed for the
Volkswagen direct injection diesel engines
enables fuel injection in two stages. As a result, it
plays an important part in ensuring "smooth"
combustion.

Functional description

There are two springs of different thickness fitted
in the nozzle holder. Due to the geometry of the
springs, the nozzle needle is raised only against
the force of the first spring at the start of
injection. A small gap is produced, allowing a
small quantity of fuel to be pre-injected at low
pressure. This pre-injection ensures a smooth
increase in the combustion pressure and creates
the ignition conditions for the main volume of
fuel. The pressure in the injection nozzle
increases due to the fact that the injection pump
delivers more fuel than escapes through the
small gap. The nozzle needle is further raised
against the force of the second spring. The main
injection now takes place at high pressure.

Combustion system

MSSP_001_017

Spring 1

Spring 2

Nozzle needle

Lift 1

Lift 1 and lift 2

Lift 2

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Summary of Contents for SDI 55-5

Page 1: ...Design and function Self study programme M001 Boat engines from Volkswagen Marine TDI 100 5 TDI 120 5 TDI 150 5 TDI 150 5D SDI 55 5 SDI 75 5 ...

Page 2: ...velopment 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 Boat engines from Volkswagen are developed by skippers for skippers The easy to service components as well as a worldwide parts org...

Page 3: ...ion system 20 Two spring nozzle holder 21 Engine electronic systems 22 Overview of installation locations 22 System overview 24 Glow plug system 26 Intake manifold pressure and intake air temperature sender 27 Needle lift sender 28 Modulating piston movement sender 29 Engine speed sender 30 Coolant temperature sender 31 Fuel temperature sender 32 Throttle lever position sender 33 Metering adjuster...

Page 4: ...th variable turbine geometry 56 Control of variable guide vanes 58 Guide vane adjustment 59 Cooling system 60 Introduction to cooling system 60 Overview of cooling circuit for SDI engines 60 Overview of cooling circuit for TDI engines 62 Design of cooler assembly 64 Intercooler 64 Main heat exchanger 65 Exhaust header 65 Exhaust manifold 66 Combined cooler 66 Seawater pump 67 Sacrificial anode 68 ...

Page 5: ...de memory entries 76 Monitored sensor e g coolant temperature sender 78 Adaptation kits 80 Gearbox bell housing for Volvo SP E DP E 80 Gearbox bell housing for reversing gearbox SAE 7 80 Gearbox bell housing for Mercruiser 81 Gearbox bell housing for Volvo SX DP S 81 Abbreviations 82 List of abbreviations used 82 ...

Page 6: ...d components Ultramodern electronics for monitoring engine functions Warnings with visual and acoustic alarm Water cooled turbocharger with Variable Turbine Geometry VTG for high propelling power in a wide speed range Powerful three phase alternators for reliable power supply and fast battery charging All engines comply with the currently valid and most stringent pollution standard the Bodensee Sc...

Page 7: ...eliability An emergency running program with a regeneration function ensures reliable engine operation should contrary to expectations a malfunction occur a wide effective engine speed range with high propelling power extensive corrosion protection for the engine housing and all add on components a dual mass flywheel to absorb drive and transmission vibrations Fundamentals MSSP_001_003 ...

Page 8: ...r use in displacement boats The engines well proven a million times over offer Quiet operation despite high pressure direct injection Low engine speed level and low vibration operation High torque and low fuel consumption Low pollutant emission Compact installation dimensions Ease of maintenance and Ultramodern technology Fundamentals MSSP_001_004 ...

Page 9: ...kW l 22 3 kW l Min specific fuel consumption 233 g kWh 233 g kWh Weight dry with ancillary components cooling system and clutch flange not including gearbox 260 kg 260 kg Alternator 120 A Electrical system 12 V not earthed Exhaust emission legislation certified in accord ance with Bodensee Schifffahrtsverordnung Stufe 2 Lake Constance Shipping Ordinance Stage 2 45 40 35 30 25 1000 1500 2000 2500 2...

Page 10: ...iance 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 The TDI engines feature a turbocharger with a water cooled VTG turbocharger Variable Turbine Geometry The engines develop a wide effective speed range offering high propelling power without the characteristic...

Page 11: ...hp 4000 rpm Max torque at engine speed 270 Nm 2500 rpm 275 Nm 2500 rpm 310 Nm 1900 rpm 310 Nm 1900 rpm Specific power output 30 1 kW l 35 8 kW l 45 1 kW l 43 9 kW l Min specific fuel consumption 217 g kWh 217 g kWh 203 g kWh 203 g kWh Weight dry with ancillary components cooling system and clutch flange not includ ing gearbox 275 kg 275 kg 280 kg 280 kg Alternator 120 A Electrical system 12 V not ...

Page 12: ... When the oil filter cover is opened a valve also opens so that the oil can flow out of the filter housing through a separate line back into the oil pan Engine mechanical systems MSSP_001_011 MSSP_001_073 Oil filter Oil cooler Oil spray nozzle for piston cooling Oil pump Turbocharger with variable turbine geometry Injection nozzle Hydraulic tappet Marine oil pan Electric oil extractor pump for oil...

Page 13: ...ntilation system with oil separator serves the purpose of keeping the air clean to minimize oil burning and prevents oil deposits forming on the intercooler The oil vapours pass through the crankcase ventilation system into the oil separator The fabric element contained in the oil separator separates oil droplets and blow by gas The oil droplets are collected on the base and returned to the oil pa...

Page 14: ...ey Toothed belt drive for the distributor injection pump The toothed belt drive for the distributor type injection pump consists of the tension pulley deflection pulley drive gearwheel that is driven by the camshaft injection pump gearwheel as well as the toothed drive belt Engine mechanical systems MSSP_001_007 MSSP_001_006 Tension pulley Deflection pulley Camshaft Tension pulley Coolant pump Cam...

Page 15: ... The seawater pump via a separate ribbed V belt drive The belt drives are equipped with automatic belt tensioners and therefore require little maintenance Engine mechanical systems MSSP_001_008 To avoid damage to the vibration damper and the engine the engine must not be run without the alternator belt drive Please refer to the current Workshop Manual for instructions on all adjustment and repair ...

Page 16: ...nnected gearbox The dual mass flywheel divides the flywheel mass into two parts One part is the primary flywheel or centrifugal mass it belongs to the mass moment of inertia of the engine The other part the secondary mass increases the mass moment of inertia of the drive Connected by means of a spring damping system both decoupled masses isolate the vibrations They absorb the vibrations at low eng...

Page 17: ...ss flywheel Engine and drive train vibrations at low engine speed Engine mechanical systems MSSP_001_065 MSSP_001_064 Flywheel Primary flywheel mass Secondary flywheel mass MSSP_001_085 MSSP_001_084 Vibrations generated by the engine Vibrations absorbed by the drive train Engine and drive train vibration in idle speed range Engine and drive train vibration in idle speed range ...

Page 18: ...ntially comprise Bucket tappet with piston Cylinder Non return valve Engine mechanical systems Valve noise after starting the engine is a normal occurrence Oil is forced out of the bucket tappet while the engine is inoperative As soon as the engine is running the high pressure chamber is filled with oil again and the valve noise disappears MSSP_001_012 Bucket tappet Piston Cylinder Compression spr...

Page 19: ...le oil escapes via the leakage gap so that the tappet compresses by max 0 1 mm Valve clearance compensation Compensation of the valve clearance lash begins after the valve has closed The pressure in the high pressure chamber drops as the cam no longer presses against the tappet The spring forces the cylinder and bucket apart to such an extent that there is no clearance between the bucket tappet an...

Page 20: ...egard to noise development smooth operation and pollutant emissions Intake swirl port The special design of the intake port induces a swirling motion in the drawn in air Piston recess The swirling motion of the intake air is continued in the piston recess that is optimally adapted to this engine Injection nozzle The five hole injection nozzle fuel injector injects the fuel in two stages into the p...

Page 21: ...ozzle needle is raised only against the force of the first spring at the start of injection A small gap is produced allowing a small quantity of fuel to be pre injected at low pressure This pre injection ensures a smooth increase in the combustion pressure and creates the ignition conditions for the main volume of fuel The pressure in the injection nozzle increases due to the fact that the injecti...

Page 22: ...f the MDC The components are described in detail in the following chapters Needle lift sender at injection nozzle of 5th cylinder Intake manifold pressure and intake air temperature sender Indicator lamp for glow plug system monitoring and engine electronics Throttle lever position sender Diagnosis interface Acoustic warner Coolant temperature sender ...

Page 23: ...23 Superior Technology Engine electronic systems MSSP_001_019 Fuel temperature sender Modulating piston movement sender Distributor injection pump MDC control unit Engine speed sender ...

Page 24: ...formation on the current operating status of the engine Engine electronic systems 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: ...ng situation Engine electronic systems MSSP_001_020 The corresponding actuators are activated following evaluation of the sensor information in the engine control unit The injection volume and start of injection as well as the preheater system are controlled and monitored in this way Metering adjuster Indicator lamp for glow plug system monitoring and engine electronics Valve for fuel shut off Val...

Page 26: ...lug is only activated at temperatures below 9 C The engine control unit receives the signal for the engine temperature from the coolant temperature sender The preheating procedure is started automatically The preheating time depends on the current engine temperature An indicator lamp in the panel informs the skipper that preheating is active Engine electronic systems MSSP_001_045 Engine speed Pin ...

Page 27: ... intake air The signal is required for limiting smoke in the dynamic range and to monitor the function of the turbocharger TDI only Functional description The piezoelectric crystals in the intake manifold pressure sender are changed by the pressure of the air drawn in and thus send a voltage signal to the engine control unit Substitute function None Effect In the event of failure there are no malf...

Page 28: ... thrust pin The change distorts the applied voltage a pulse peak is created The engine control unit calculates the actual start of injection from the time difference between the pulse peak and the TDC signal from the engine speed sender The actual start of injection is compared with the set start of injection specified in the characteristic map of the engine control unit and is corrected by the co...

Page 29: ...centric shaft moves along the iron core This movement influences the magnetic field The engine control unit evaluates this change and thus obtains the current position of the metering adjuster Substitute function If the engine control unit receives no signal from the modulating piston movement sender the engine will be shut down for safety reasons Effect Engine operation is not possible Engine ele...

Page 30: ...erate an alternating voltage in the sender coil From this signal the engine control unit can accurately calculate the angular position and the current engine speed Substitute function If the engine control unit receives no signal from the engine speed sender an activated emergency operation program uses the signal from the needle lift sender as a substitute signal Effect The injection volume is re...

Page 31: ...n The coolant temperature sender features an NTC bead An NTC Negative Temperature Coefficient changes its resistance corresponding to temperature When the temperature increases the resistance value drops When the temperature drops the resistance values increases The engine control unit can detect the current engine temperature from this resistance value Substitute function If the engine control un...

Page 32: ...ty changes with the change in the fuel temperature The injection volume must be correspondingly adapted to ensure an optimum combustion process Substitute function In the event of the fuel temperature sender failing the last temperature value is stored in the MDC control unit Effect The injection volume can no longer be determined correctly The MDC now determines the injection volume according to ...

Page 33: ... a voltage value corresponding to the throttle position From this value the engine control unit recognizes the throttle lever position and the skipper s choice In connection with the fuel volume control of the distributor injection pump the control unit regulates the fuel volume to be injected Substitute function If the engine control unit receives no signal a fixed stored value is used as the sub...

Page 34: ...ontrol shaft the electromagnetic actuator changes the position of the control slide valve When activated by the engine control unit the position of the control slide valve is changed axially thus constantly varying the injection volume between minimum idle speed and maximum full throttle Substitute function None Effect If the metering adjuster fails due to a defect the engine is shut down by means...

Page 35: ...rolled depending on the clock pulse pulse duty factor of the start of injection valve The engine control unit can adjust infinitely variable between retarded start of injection fully open and advanced start of injection fully closed Activation takes place by means of a ground pulse from the engine control unit Substitute function Control is no longer possible in the event of the start of injection...

Page 36: ...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 In this way it keeps the inlet hole to the high pressure chamber open When power is applied to the solenoid the valve closes the inlet hole The fuel supply is shut off so that the high pressure piston can no longer deliver fuel Substitut...

Page 37: ...owing components Needle lift sender Engine speed sender Modulating piston movement sender Metering adjuster Start of injection valve Turbocharger Boost pressure outside set range TDI only Substitute function None Effect The effect depends on the type of component that has failed Activation The engine control indicator lamp is activated by the engine control unit Engine electronic systems MSSP_001_...

Page 38: ...signals the correct injection volume is determined in the engine control unit and an electrical signal is sent to the metering adjuster in the injection pump The metering adjuster varies the position of the control slide valve corresponding to the electrical signal Overview of sensors and actuators MSSP_001_033 Throttle lever position sender Coolant temperature sender Engine speed sender MDC contr...

Page 39: ...ng variables illustrated in the following the engine control unit calculates the start of injection and sends a corresponding electrical signal to the start of injection valve in the distributor type injection pump Start of injection characteristic map The engine control unit calculates the optimum start of injection from the stored start of injection characteristic map and the input variables MSS...

Page 40: ...interior changes corresponding to the pulse duty factor One start of injection operation is assigned to each clock pulse This facilitates infinitely variable control of the start of injection from maximum advance to retard setting Engine control unit From the incoming sensor signals the engine control unit calculates the set start of injection and sends the signals for the necessary pulse duty fac...

Page 41: ...41 Superior Technology Engine electronic systems MSSP_001_035 Start of injection valve Pressure roller Start of injection valve Eccentric disc Piston of injection timing device ...

Page 42: ...in such a way as to avoid output differences between the individual cylinders This function is monitored by means of the signal from the engine speed sender that supplies the engine control unit with five signals per crankshaft revolution If the signals are received in uniform rhythm this means all cylinders are performing the same amount of work If the output of one cylinder is weaker the cranksh...

Page 43: ... starting is determined by the engine control unit corresponding to the coolant temperature As a result exhaust emission is kept low while still ensuring very good starting characteristics Signal monitoring During operation the engine control unit monitors itself as well as the functions of the sensors and actuators Occurrence of a malfunction is indicated visually by the indicator lamp illuminati...

Page 44: ...der G71 Intake manifold pressure sender G72 Intake manifold temperature sender G79 Throttle lever position sender G80 Needle lift sender G81 Fuel temperature sender G149 Modulating piston movement sender J17 Fuel pump relay J 52 Glow plug relay J248 Diesel direct injection system control unit J317 Terminal 30a voltage supply relay J593 Fuel shut off valve control relay K29 Glow period indicator la...

Page 45: ...e electronic systems J G G80 6 G62 4 G G D D D Y19 J 28 72 G71 593 E190 E354 K29 3 4 3 2 1 2 1 1 2 1 34 70 109 101 65 32 40 4 5 102 110 20 52 73 31 71 112 104 16 6 7 28 27 120 37 24 F36 248 30 30a 15 M ϑ ϑ S81 10A J17 MSSP_001_048 ...

Page 46: ...lectrics It is arranged between the circulation filter and the fuel microfilter The fuel return is routed via the combined cooler In this way the return fuel is cooled and the fuel temperature in the fuel tank kept low Fuel system MSSP_001_036 Fuel tank Pressure roller Eccentric disc Distributor piston Plunger valve Injection nozzle Circulation preliminary filter with water separator Fuel microfil...

Page 47: ...isc executes one lift movement per cylinder During the delivery phase the control slot opens the feed channel as the result of the rotary motion of the distributor piston and allows fuel to flow into the high pressure chamber Start of injection The distributor piston continues to turn so that the control slot closes the feed hole The following list movement exerts pressure on the fuel As the distr...

Page 48: ...iltered out Owing to its higher weight water collects in the base of the filter A high proportion of water in the diesel fuel poses the risk of the water entering the fuel injection system This would lead to internal corrosion and engine failure 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 ...

Page 49: ...urrounded by diesel fuel Water level dangerous If the water level rises up to the contact pins a higher current flows due to the better conductivity of the water The engine control unit detects the higher current flow and by way of the indicator lamp in the control panel signals the high water level to the skipper Drain fuel microfilter A drainage facility is located on the underside of the fuel m...

Page 50: ...ust pass through the guide vane system positioned on the outer housing Due to the different lengths of the deflection vanes and the double change in direction of flow smaller water droplets and fine particles are expelled and also collect on the base of the bowl The considerable increase in cross section below the filter element causes the fuel to settle while the finest water droplets and particl...

Page 51: ...51 Superior Technology Notes ...

Page 52: ...combusting fuels containing carbon It is odourless and colourless explosive and highly toxic Carbon monoxide inhibits erythrocytes red blood corpuscles from transporting oxygen and is lethal even in small concentrations in breathing air In the open it oxidizes to form carbon dioxide within a short space of time Carbon dioxide is a constituent part of air Gaseous hydrocarbons HC They occur in the e...

Page 53: ...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 Electronically controlled and monitored engine management and variable start of injection control further ensure optimum combustion and low exhaust emissions ...

Page 54: ...e movement and pressure energy contained in the exhaust gas is used to drive the turbine wheel of the turbocharger that is connected via a shaft to the compressor wheel The compressor wheel compresses the air and forces it into the combustion chamber Since the air temperature increases during compression and the density thus decreases the engine output can be further increased by cooling the air i...

Page 55: ...e wheel does not reach the rotary speed necessary to sufficiently compress the air The exhaust gas energy is very high in the upper engine speed range The speed of the turbine wheel is therefore higher than necessary The air is compressed too much Intake air Intercooler Intake manifold Exhaust gas flow Exhaust manifold Exhaust turbocharging MSSP_001_052 Engine Boost pressure Turbocharger ...

Page 56: ... optimum boost pressure is made available virtually over the entire engine speed range This ensures improved combustion and lower exhaust emission values as well as high propelling power over the entire engine speed range Exhaust turbocharging Variable guide vanes Oil inlet Exhaust turbine wheel Exhaust turbine housing MSSP_001_061 Pressure cell for adjusting the guide vanes Compressor Intake air ...

Page 57: ...Low engine speed The volume and speed of the exhaust gas are low The cross section of the exhaust pipe is constricted before the turbine wheel by the guide vanes The narrowed cross section forces the exhaust gas to flow faster thus increasing the speed of the turbine wheel The high rotary speed of the turbine guarantees optimum boost pressure also at low engine speed High engine speed The exhaust ...

Page 58: ...back by the force of the spring The guide vanes are set to a small inlet cross section This control always makes available the boost pressure necessary for ensuring optimum power output At high intake manifold pressure the pressure acting on the diaphragm in the pressure cell increases The guide vanes are set to a large inlet cross section Turbocharger with variable guide vanes Boost pressure Inte...

Page 59: ...n the flow of the exhaust gas the constricted inlet cross section results in a higher turbine speed The flow rate of the exhaust gas increases as the engine speed increases The inlet cross section becomes larger so that the boost pressure and turbine output remain constant over a wide speed range Exhaust turbocharging MSSP_001_049 Carrier ring Guide vanes Pressure cell Control linkage Guide pin of...

Page 60: ...a closed circuit The heat is transferred in a heat exchanger through which seawater flows The seawater circuit secondary circuit is an open circuit in which the seawater is drawn in and after having flowed through the heat exchangers it is expelled again Overview of cooling circuit for SDI engines The coolant circuit consists of Small coolant circuit primary red closed freshwater circuit Large coo...

Page 61: ... the exhaust gas flow through the exhaust manifold wet exhaust Small coolant circuit Driven by the coolant pump during the warm up phase the coolant circuit passes through the engine block oil cooler exhaust header and via the bypass back to the coolant pump This ensures the engine quickly reaches its operating temperature Large coolant circuit Once the engine has reached its operating temperature...

Page 62: ...r hydraulic oil and fuel Seawater pump Thermostat 80 C and coolant pump Cooler assembly housing Oil cooler Coolant expansion tank Exhaust header Main heat exchanger Exhaust manifold Intercooler 111 kW only Turbocharger Seawater circuit Small coolant circuit freshwater Large coolant circuit freshwater Bypass Ventilation line ...

Page 63: ...pump and the main heat exchanger In order to increase the air density the compressed charge air from the turbocharger is cooled by the seawater 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 For this reason the large coolant circuit cools the turbocharg...

Page 64: ...he seawater pump pumps the seawater through the intercooler thus cooling the air compressed by the turbocharger The air density increases Cooling system MSSP_001_100 Intercooler Main heat exchanger Seawater inlet Seawater to main heat exchanger Expansion tank Exhaust header Intake pipe MSSP_001_072 Intake air Cooling tubes Seawater outlet Seawater inlet ...

Page 65: ...iesel 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 Cooling system MSSP_001_105 MSSP_001_099 Seawater outlet Seawater inlet Exhaust header Tube assembly for main heat exchanger coolant circuit...

Page 66: ...al electrics on the engine on the side of the oil pan Due to its split design it cools the fuel flowing back to the fuel tank and depending on the boat s equipment the hydraulic oil of the power assisted steering or the gear oil of the reversing gearbox Cooling system MSSP_001_102 Seawater inlet Exhaust gasses Engine cooling water Seawater MSSP_001_069 Fuel outlet Fuel inlet Oil outlet Oil inlet C...

Page 67: ...e connection pieces need only be unclipped in order to disconnect the seawater hoses from the pump The springs lock in again automatically when reconnecting the hoses The pump is made up of the following components Cooling system MSSP_001_060 Pump Impeller Seal Rubber seal Pump cover The rubber impeller of the seawater pump should be inspected at the end of the season and replaced as required Plea...

Page 68: ...nge occurs between different metals in the presence of water As the result of this exchange the lower grade of both metals disintegrates The electrochemical series is obtained by arranging the metals in a series from the lower grade to the higher grade metal The further the metals are apart in the series the higher the charge carrier exchange and thus the disintegration Cooling system MSSP_001_070...

Page 69: ...ical terminals connect the unit to the engine In addition there is also an oil and water resistant connecting cable leading to the control panel Earth cutout relay The engine is earth free in order to protect the drive train from galvanic corrosion The earth cutout relay closes when the engine is started The engine is thus temporarily connected to earth for the purpose of powering the starter Elec...

Page 70: ...displayed in Litres l Gallons g Current fuel consumption average It can be displayed in l km l nm l m g km g nm g m Range It can be displayed in Kilometres km l Nautical miles nm l Miles m l Speed It can be displayed in Kilometres per hour km h Knots kn Miles per hour mph Electrical systems MSSP_001_077 SUPERIOR MARINE TECHNOLOGY marine 0 10 20 30 40 C F VOLT 40 80 0 0 15 29 44 58 72 2 bar psi 1 3...

Page 71: ...collects the data of any number of individual journeys up to 9999 operating hours 9999 nautical miles 9999 litres fuel consumed The individual functions can be selected via the control switch All memory data are deleted except for total operating hours when the control switch is pressed for longer than 5 seconds or when the battery is disconnected Electrical systems MSSP_001_078 MSSP_001_079 marin...

Page 72: ...n on the current engine oil pressure The information comes from the oil pressure sensor on the engine The engine oil pressure should be between 1 bar and 5 bar If the oil pressure drops below 1 bar the oil pressure warning lamp comes on and an acoustic warning signal sounds The engine should be shut off in order to avoid engine damage Electrical systems MSSP_001_080 MSSP_001_081 MSSP_001_082 0 10 ...

Page 73: ...arine on the control panel Another diagnosis connector is located in the central electrics unit After connecting the diagnosis system tester to the diagnosis interface fast data transmission ensures the system diagnosis function is used optimally The diagnostic connection to the engine control unit is established by entering the address word 01 The system diagnosis contains the following functions...

Page 74: ...e buttons 0 and 3 the actuators are activated in a defined sequence Function 04 Basic setting The basic setting of the distributor type injection pump is initiated with the function 04 Self diagnosis Please refer to the current Workshop manual for a detailed description of the basic setting function The faults are output in text form and with a fault ID code You will find detailed information on t...

Page 75: ...disconnecting the diagnosis interface can cause temporary malfunctions in the engine control unit and is therefore not permitted Function 07 Not used Function 08 Read measured value block The engine operating data e g current engine temperature can be read out with the diagnosis system tester after pressing the button 0 and 8 and then entering a display group number The engine operating data are p...

Page 76: ...agnosis function alternately measures the battery voltage and earth Fault display in fault code memory Short to positive Functional description There is a short to positive in the wiring harness connector or in the component The self diagnosis functions always measures positive Self diagnosis MSSP_001_091 MSSP_001_090 Solenoid valve Control unit Self diagnosis Switching output stage Solenoid valve...

Page 77: ...ways measures 0 Volt Fault display in fault code memory Break short to earth Functional description There is a short to earth The self diagnosis function always measures 0 Volt Self diagnosis MSSP_001_093 MSSP_001_092 Solenoid valve Control unit Self diagnosis Switching output stage Solenoid valve Control unit Self diagnosis Switching output stage MPU MPU ...

Page 78: ...usible signal voltage from the temperature sender between approx 0 5 and 4 5 Volt Fault display in fault code memory Short to earth Functional description There is a short to earth The self diagnosis function always measures 0 Volt Self diagnosis MSSP_001_095 MSSP_001_094 Control unit Self diagnosis Sensor MPU R Control unit earth Control unit Self diagnosis Sensor MPU R Control unit earth ...

Page 79: ...ion always measures 4 5 Volt Fault display in fault code memory Break short to positive Functional description There is a short to positive The self diagnosis function always measures 4 5 Volt Self diagnosis MSSP_001_097 MSSP_001_096 Control unit Self diagnosis Sensor MPU R Control unit earth Control unit Self diagnosis Sensor MPU R Control unit earth ...

Page 80: ...ousings The following gearbox bell housings are available for the purpose of using different drive systems Gearbox bell housing for Volvo SP E DP E Gearbox bell housing for reversing gearbox SAE 7 Adaptation kits MSSP_001_087 MSSP_001_086 ...

Page 81: ... Gearbox bell housing for Mercruiser Gearbox bell housing for Volvo SX DP S Adaptation kits MSSP_001_089 MSSP_001_088 Please refer to the technical documentation of your Volkswagen Marine dealer for the current order numbers ...

Page 82: ...teratur Service literature kg Kilograms km Kilometre kn Knots kW Kilowatt I l Litre M m Miles MDC Marine Diesel Control min Minute mm Millimetre mph Miles per hour N nm Nautical miles Nm Newton meters NOx Nitrogen oxide NTC Negative Temperature Coefficient O OT Top dead centre P Pb Lead Pkw Passenger vehicle PME Vegetable oil methyl ester PS Horse power R RME Rape seed oil fatty acid methyl ester ...

Page 83: ...83 Superior Technology Notes ...

Page 84: ...ranslation 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 Subject to modification without notice Copy deadline 04 01 P O Box 31 11 76 38231 Salzgitter Edition 04 01 Publication number 065 991 T05 20 This paper was manufactured from pulp bleached without using chlorine...

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