Volkswagen TDI 350-8 Operating Manual Download

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DI 350-8

Operating Manual

oat Engines from

age

rin

8 Cylinder TDI

TDI 350-8

Summary of Contents for TDI 350-8

Page 1: ...Bootsmotoren von Volkswagen Marine 8 TDI 350 8 Operating Manual Boat Engines from Volkswagen Marine 8 Cylinder TDI TDI 350 8 ...

Page 2: ...e that is advanced in every regard Your boat engine has been developed to put the least possible strain on the environment VOLKSWAGEN Marine Service Partners are at your disposal to take care of your VOLKSWAGEN Marine boat engine The VOLKSWAGEN Marine Service Partner The VOLKSWAGEN Marine Service Partners provide a competitive and professional service with all work conforming to factory guidelines...

Page 3: ... marked with a is not part of the standard equipment of VOLKS WAGEN Marine boat engines Environmental protection information Text in italics marked with this symbol provides important information on environmental protection Contents On the first pages you will find a table of contents that shows all topics described in this manual in the order of their occurrence Index At the end of the manual an ...

Page 4: ...RUCTURE Note When your boat is craned or slipped water can enter the exhaust system of your engine Make sure that the exhaust system of the engine is drained of any remaining water before craning or slipping to avoid damage ...

Page 5: ...00 operating hours 30 Additional work every 1 000 operating hours 31 Additional work every 5 years or every 3 000 operating hours 32 Engine oil 33 Engine oil level checking 34 Engine oil top up 35 Engine oil renewal 36 Oil filter element replacement 37 Circulation filter 38 Fuel fine filter 39 Seawater filter 41 Air filter cleaning 42 Cooling system 43 Seawater pump 45 Sacrificial anode 46 Reverse...

Page 6: ...red oil pump and replaceable oil filter in main flow Dry air filter The engine has two separate cooling circuits 1 The open seawater circuit runs via the oil cooler the main heat exchanger and the exhaust manifold 2 The coolant circuit runs as a closed pressurised system through the engine block oil cooler exhaust collector and after reaching the operating temperature via the main heat exchanger W...

Page 7: ...ting a cold engine increased running noises may occur for a brief period as oil pressure must first build up in the hydraulic valve clearance compensation unit This is normal and should thus be ignored Even modern engines need a break in pe riod Be careful to drive moderately until an optimum operating temperature of 90 C is reached and always avoid high rpm when the engine is cold Do not accelera...

Page 8: ...function display The multifunction display is operated with this button Each time the button is pressed the display in the MFD is advanced Note A comprehensive instruction manual containing descriptions of the individual functions of the multifunction display is contained in the booklet Additional operating manual for the multifunction display 4 Access to diagnostic interface 5 without function Wa...

Page 9: ...is too high As an additional warning an acoustic signal sounds at the same time which can be switched off with the confirmation button 7 see figure on page 12 Should the fault not be cleared the acoustic signal sounds again after a short time In this case switch off the engine immediately and check whether the seawater filter is clogged the seawater valve is open sufficient coolant is present Chec...

Page 10: ...ssary with a reduced engine output Please contact a VOLKSWAGEN Marine Service Partner for system failure analysis and troubleshooting BM6 020M 4 Voltmeter The voltmeter indicates the voltage in the electrical onboard supply Normal value between 12 and 16 volts If the generator charging indicator lights up or the gauge drops below 12 volts with the engine running have the power supply battery and a...

Page 11: ... gauge installation optional The engine oil pressure gauge only functions with the engine running and indicates the existing engine oil pressure During driving the engine oil pressure is between approx 1 and 5 bar At an engine oil pressure lower than 1 bar the engine oil pressure warning lamp can light up and an acoustic signal can sound If the engine oil pressure warning lamp illuminates or flick...

Page 12: ...s for further details please follow the Installation de scription EB08 page 41 To restart the engine the toggle switch has to be moved back to the ON position BM5 019M As an alternative to the individual instrumentation which is included in the delivery a midi panel instrumentation may be used instead Pos 1 Rev counter with multifunctio nal display 2 Indicator light for coolant tempe rature 3 Indi...

Page 13: ...l 4 Shift to reverse direction 5 Reverse direction Starting an engine with a single control stand 1 Switch the ignition on You will hear a short acoustic signal and the throttle lever control light see Item A on the illustration flashes twice a second 2 Make sure that the throttle lever is at neutral 3 3 Press the CONTROL button see Item B on the illustration The throttle lever control light Item ...

Page 14: ...le levers of both control stands are at neutral 3 2 Press the CONTROL button of the control stand taking over The throttle lever control light of the control stand taking over Item A stays on The control stand is now activated Speed setting with the gears in neutral 1 Make sure that the throttle lever is at neutral 3 2 Press the CONTROL button see Item B on the illustration and simultaneously set ...

Page 15: ...will hear a short acoustic signal and the throttle lever control light of the selected control stand see Item A on the illustration flashes twice a second 2 Make sure that the throttle levers of both engines are at neutral 3 3 Press the CONTROL button see Item B of the selected control stand The throttle lever control light of the selected control stand stays on whereas the control light of the ot...

Page 16: ...again respectively by pu shing the CONTROL button B see fig on page 15 provided that the button is pushed for a second and the above mentioned conditions are complied with BM8 008M You can stop the engine in case of danger using the stop switch 1 on the right hand side of the central electrical unit After pressing the stop switch it must be unlocked again as otherwise the engine cannot be started ...

Page 17: ... cool O Keep children away from the engine compartment O Do not open the cap of the coolant reservoir while the engine is still at operating temperature as the cooling system is pressurised O Never pour liquids over the hot engine The liquids could ignite If work on the electrical system is necessary Never conduct fault finding with the engine running danger to life and limb If work on or repairs ...

Page 18: ... require a doctor in an emergency there will be a delay The warnings in this manual and the generally applicable safety rules must be observed When topping up fluids make sure that they are not confused as otherwise serious malfunctions and engine damage will result To ensure that leaks are detected in due time the bilge under the engine should be kept clean and should be checked regularly If soil...

Page 19: ...used 1 EuroStandard 2 Cetane Number Measure of the ignitability of diesel fuel Do not change the as supplied condition of VOLKSWAGEN Marine boat engines without careful consideration Therefore if technical changes are to be made to the engine or if parts must be renewed later the following instructions must be observed O BEFORE purchasing parts and before making technical changes a consultation wi...

Page 20: ...oat engine Here you will receive professional advice and find fast effective help If for example the engine should fail to start or idling faults occur faults and their remedies are described in detail in the following chapter Should the individual remedies not solve the problem your VOLKSWAGEN Marine Service Partner will be happy to provide additional assistance If repairs must be made the engine...

Page 21: ...h Ignition switched off Switch on ignition Battery discharged or defective Check battery and charge replace if necessary Starter connections loose or corroded Check connections and clean or replace if necessary Connections to ignition starter switch loose or corroded Check connections and clean or replace if necessary Air inside fuel system See section on fuel system Should the individual remedies...

Page 22: ...ine element fuel filter too high Drain water from fine element fuel filter Fine element fuel filter clogged Replace fine element fuel filter Engine shakes See section on fuel supply Engine dies See section on fuel supply Should the individual remedies not solve the problem your VOLKSWAGEN Marine Service Partner will be happy to provide additional assistance Warning Observe the safety precautions b...

Page 23: ...ng system engine circuit Add coolant pure water in an emergency Check cooling system for leaks and seal if necessary Coolant pump for engine circuit defective This fault should always be checked and eliminated by a VOLKSWAGEN Marine Service Partner as special tools are required Should the individual remedies not solve the problem your VOLKSWAGEN Marine Service Partner will be happy to provide addi...

Page 24: ... the cover fig BM8 004M as well as on the rear side of the control unit of the individual instrumentation fig BM6 023M page 25 BM6 004M In the case of a two engine system the central electrical system shown in illustration BM8 004M is applied The circuit board presented in illustration BM8 007M is provided in duplicate where the boards are mounted side by side with this type of central electrical ...

Page 25: ...element of the individual instrumentation O Switch off the ignition and the affected consumer O Press down the Stop switch on the central electric unit O Loosen the screws and pull the control unit off in a forwards direction O Determine which fuse belongs to the failed consumer using the fuse table Fuse assignment No Consumer A1 1 Ignition on terminal 15 2 2 Permanent positive terminal 30 2 O Pul...

Page 26: ...ome of the work must be carried out prior to each engine start Other work is only required on an annual basis at the end of the season or after 200 operating hours The work described here is used to maintain your VOLKSWAGEN Marine boat engine The specified service intervals are matched to normal operating conditions Under more extreme conditions it is necessary to have some work carried out before...

Page 27: ...g pump check condition 48 Toothed belt for common rail injection system check condition 48 Check operation of seawater valve Check battery voltage and charge battery if necessary 52 Note Maintenance must be performed on the reverse gearbox or the Sterndrive in accordance with the specifications of their respective manufacturers Warning Observe the safety precautions beginning on page 17 before per...

Page 28: ...y 43 Check seawater filter and clean if necessary 40 Check hydraulic oil level for Sterndrives 47 Check reverse gearbox oil level 46 Note Maintenance must be performed on the reverse gearbox or the Sterndrive in accordance with the specifications of their respective manufacturers Warning Observe the safety precautions beginning on page 17 before performing any work on the engine or in the engine c...

Page 29: ...l inspection for leaks and damage Interrogate fault memory of engine electronics Change engine oil and oil filter 33 35 Replace fine element fuel filter 39 Check air filter element and clean if necessary 41 Check seawater filter and clean if necessary 40 Check coolant level and top up if necessary 43 Seawater pump Check impeller and replace if necessary 45 Check sacrificial anode and replace if ne...

Page 30: ...ring hydraulic oil level for Sterndrive engines 47 Check coolant level 43 Check air filter element and clean if necessary 41 Ribbed V belt for alternator power steering pump check condition 48 Toothed belt for common rail injection system check condition 48 Clean seawater filter 40 Seawater pump Check impeller and replace if necessary 45 Check sacrificial anode and replace if necessary 46 Note Mai...

Page 31: ...pecial tools The following table shows the scope of the additional work Scope of work Page Clean air filter element 41 Check pipe bundles of heat exchanger remove and clean if necessary Note Maintenance must be performed on the reverse gearbox or the Sterndrive in accordance with the specifications of their respective manufacturers Warning Observe the safety precautions beginning on page 17 before...

Page 32: ...lised knowledge and special tools The following table shows the scope of the additional work Scope of work Page Replace toothed belt for common rail injection system Note Maintenance must be performed on the reverse gearbox or the Sterndrive in accordance with the specifications of their respective manufacturers Warning Observe the safety precautions beginning on page 17 before performing any work...

Page 33: ...ls are under constant development Therefore the information in this manual can only reflect the status at the time of printing VOLKSWAGEN Marine Service Partners are always kept up to date with any changes by the factory Therefore it is always best to have the oil change carried out by a VOLKSWAGEN Marine Service Partner Multigrade light oil Specification VOLKSWAGEN Longlife VW 507 00 Important no...

Page 34: ...dipstick back again into the tube making sure that it goes all the way in O Pull the dipstick out again and check the oil level Using the markings on the dipstick as an indicator a Oil must not be added b Oil can be added c Oil must be added Sufficient oil is provided if the oil level is thereafter within the b range serrated area Note The oil level must not exceed the max mark a and must not be b...

Page 35: ... to loading during operation but also due to ageing The oil change date is therefore dependent on both the mileage and the running time If the engine is constantly operated under extreme operating conditions the motor oil should be changed at shorter intervals The motor oil must be changed at the intervals specified on page 29 and 30 Have the oil change carried out by a VOLKSWAGEN Marine Service P...

Page 36: ...sump O The supplied oil change hose 3 is already connected on to the union of the oil extraction pump 4 see illustration below O Route the other end of the hose into the container being used for the oil change BM8 022M BM8 015M O With the engine stopped and the ignition switched on press and hold the button 1 at the right front side of the engine and wait until the engine oil has been fully extrac...

Page 37: ...lement is inserted into the respective drilling 5 of the oil filter housing see fig right O Use a 32 mm socket wrench to tighten the cap BM6 014M For filling quantities see the chapter Technical data Check the oil level with the oil dipstick also see page 34 The oil level must be between the two markings and should never be above the max mark Warning Used oil must be stored in a safe place away fr...

Page 38: ... or in the engine compartment Back flushing O Switch off the engine single filter or switch over to the second filter double filter O Unscrew the bleeder screw 1 O Open the drain valve 2 below the bowl and catch fuel in a suitable container until all dirt is rinsed out of the bowl O Close the drain valve 2 O Pour clean fuel into the filter via the bleed hole O Screw the bleed screw 1 back in O Sta...

Page 39: ...age 17 before performing any work on the engine or in the en gine compartment BM8 002M O Open the drain screw 1 see fig above by a few turns and catch about 100 cm3 fuel in a suitable container O Screw the bleed screw 1 back in Note After draining the water from the fine element fuel filter it is not necessary to bleed the fuel system O The fine element fuel filter provides a hand pump 2 see fig a...

Page 40: ...nd unscrew and remove the drain plug 1 O Remove the drain plug of the new fine element fuel supply filter and make sure to replace it with the drain plug of the old filter O Lightly coat the rubber ring of the new fine element fuel supply filter with diesel fuel O Fill the fine element fuel filter with clean diesel This enables the engine to be started more quickly O Screw in the new filter and fi...

Page 41: ...en the cover Does not form part of the standard scope of supply for VOLKSWAGEN Marine boat engines If you detect soiling proceed as follows O Close the seawater valve O Unscrew the screws see left figure and remove the cover O Remove the filter element flush it thoroughly with clean water and refit it O Before screwing on the filter cover the sealing ring should be lubricated e g with silicone oil...

Page 42: ...tside with max 2 0 bar compressed air BM8 009M Warning O Wear protective goggles when blowing out the filter Flying dirt particles can enter the eyes risk of injury O Observe the safety precautions beginning on page 17 before performing any work on the engine or in the engine compartment O Clean the filter as described in the instructions on the special cleaning and service kit available from a VO...

Page 43: ...tem as the heat conductivity of the coolant drops extremely Coolant loss Coolant loss is mainly a result of leakages In such an event the cooling system should be inspected immediately by a VOLKSWAGEN Marine Service partner It is not sufficient to just add coolant With the system sealed coolant losses will only be experienced when the coolant boils as a result of overheating and is then pressed ou...

Page 44: ...ne or in the engine compartment Use only new coolant for topping up First stop the engine and allow to cool Then cover the cap with a cloth and care fully unscrew in an anti clockwise direc tion If no G12 or an additive with the spe cification TL 774 F N 052 774 F0 see la bel on container bottle or drum is available no other coolant additive should be used In this case only use water and restore t...

Page 45: ...he middle of the impeller O Pull the impeller downwards off the shaft with a suitable puller O Check the impeller for damage Notes O The impeller must always be replaced even if there is only minor damage O Make sure you always have a reserve impeller on board BM6 012M O Before reinstalling the impeller grease it with silicone spray or glycerine O Push the impeller onto the shaft and press the rub...

Page 46: ...an incorrect composition of the anode can result in serious corrosion damage to the engine BM5 007M Warning Observe the safety precautions beginning on page 17 before performing any work on the engine or in the engine compartment Note The oil of a reverse gear engine must be changed according to the instructions provided by the respective gear manufacturer With every oil change the filter element ...

Page 47: ...ever be above range A In the case of heavy gearbox loading such as during longer engine operation 10 12 hours the oil level should at least lie in the middle of the two markings min max BM6 005M Warning Observe the safety precautions beginning on page 17 before performing any work on the engine or in the engine compartment You should not leave the steering wheel at lock for longer than 15 seconds ...

Page 48: ...steering hydraulic oil renewal The power steering hydraulic oil must be changed in accordance with the specifications of the respective manufacturer Warning O The ribbed V belt and the toothed belt should only be checked or replaced with the engine stopped risk of injury O Observe the safety precautions beginning on page 17 before performing any work on the engine or in the engine compartment Chec...

Page 49: ...short circuit battery poles Risk of injury due to high energy sparks Keep acid and batteries away from children O Always switch off the engine the ignition and all electrical consumers and press the Stop button before working on the electrical system The negative cable must be disconnected at the battery O When disconnecting the battery first disconnect the negative cable and then the positive cab...

Page 50: ...imilarly the acid level must also be checked after each charging process Add distilled water if necessary up to the acid level marking or up to a level 5 mm above the separators Charging state Determine the battery charging state by checking the acid density or the battery voltage Acid density specific gravity charged 1 285 discharged 1 12 Total voltage Determine the total voltage only by connecti...

Page 51: ...arging state and acid level of the battery The colour display serves VOLKSWAGEN Marine Service Partners as a diagnostic aid Air bubbles can falsify the colour display Carefully tap the magic eye If the indication in the inspection window is colourless or light yellow the battery level is too low Distilled water must be added With batteries older than 5 years we recommend replacement We recommend h...

Page 52: ...turer Note To charge the battery of the on board electrical system the use of special boat chargers that prevent gassing of the battery is recommended Warning O Keep children away from the battery battery acid and the charger O Only charge the battery in a well ventilated area Do not smoke or use naked flames and ensure no electrical sparks are produced when charging batteries as a highly explosiv...

Page 53: ...er periods e g after the end of the season please carry out preservation in the specified order 1 Thoroughly clean all parts to be preserved 2 Allow the engine to warm up 3 After switching off the engine replace the oil filter element and pump off the motor oil see page 36 and 37 4 Add engine oil and run the engine for approximately 30 seconds at a high idling speed 5 Switch the engine off 6 Plug ...

Page 54: ... water and run the engine at idle Make sure that the seawater filter is always filled with fresh water to prevent the seawater pump from running dry This would result in the pump becoming defective It is important that the engine runs for a while so that all sludge and salt residues are flushed away that could otherwise promote corrosion 4 Switch off the engine again 5 Screw on the cover of the se...

Page 55: ...before the end of the season O Check the fuel system for leaks O Drain water from the circulation filter see page 38 O Replace the fine element fuel filter see page 40 O An inspection service should always be conducted on the VOLKSWAGEN Marine boat engine before the start of the cold season In addition please observe the following instructions when operating the VOLKSWAGEN Marine boat engine at ex...

Page 56: ...chapter Engine preservation Battery Check the battery acid level above the upper edge of the plates weekly It is approx 5 mm or can be read off at the existing acid level marks In case of losses due to evaporation only distilled water should be added Observe the instructions about this on page 49 Air filter If the engine is to be operated in very dusty areas check the filter element more frequentl...

Page 57: ...sumption Min specific in g kWh 215 Filling quantities Coolant in litres approx 9 0 G12 Hydraulic oil Power steering in litres approx 1 0 ATF Dependent on reverse gearbox model in litres approx 2 5 3 5 Engine oil3 with filter change in litres The oil level must be checked when topping up Do not overfill 9 0 VOLKSWAGEN Longlife oil Specification VW 504 00 und 507 00 1 The weight corresponds to a dry...

Page 58: ...w it to cool down Warning Observe the safety precautions beginning on page 17 before performing any work on the engine or in the engine compartment The name plate The name plate is located to the front on the intercooler Engine code Engine number The engine code is a series of four letters e g CEMA which is followed by the engine number a six digit number The engine code and the engine number are ...

Page 59: ...ks 29 Dipstick engine 36 Power steering hydraulics 54 reverse gearbox 53 E End of season 29 Engine check oil level 35 oil 33 oil consumption 34 oil level 34 oil renewal intervals 35 preservation 54 safety precautions 17 starting 7 switching off 7 test run 52 Engine characteristic data 61 Engine code 61 Engine control unit 8 Engine description 6 Engine number 61 Engine oil renewal 35 Engine preserv...

Page 60: ...e element fuel filter 40 reverse gearbox oil level checking 47 ribbed V belt checking 49 Seawater filter cleaning 41 toothed belt checking 49 Instrument lighting 8 Instruments 8 L Lighting for controls and instruments 15 Lubricant additives 36 Lubricants 33 M Maintenance 26 N Name plate 61 O Oil 33 Oil consumption 36 Oil filter 37 Oil filter element 37 Oil renewal intervals 36 Oil specification 35...

Page 61: ...7 Starting the engine 7 Stop switch 16 Switches 8 Switching off the engine 7 T Technical changes 19 Technical description 6 Test run 54 Throttle lever single engine 13 Throttle lever two engines 14 Toothed belt 49 Tropical operation 59 U Unleaded fuel 19 V Voltmeter 10 W Warning and control lamps 10 Warning lamps 10 Winter operation 55 battery 50 cooling system 43 diesel fuel 19 engine oil 33 ...

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Page 64: ...n this manual are based on information current at the time of printing Reprinting reproduction or translation in whole or in part is not permitted with out the written approval of VOLKSWAGEN Marine All rights according to the applicable copyright laws are expressly reserved for VOLKSWAGEN Marine Subject to alterations Printed in Germany Postfach 31 11 76 38231 Salzgitter Hotline 49 1800 89 62 74 6...

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