Volkswagen Marine SDI Series User manual

4-Cyl. SDI
Operating Manual
Volkswagen Marine
Boat Engines
© 2003 Volkswagen Marine
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. Subject to change.
Postfach 31 11 76, 38231 Salzgitter
4-Cyl. SDI I Operation I Art.-No. 064.991.B04.20
Editorial Deadline: 05.2003 I Edition: English 05.2003
❀This paper was produced of woodpulp bleached without chlorine.
M04_BA_Umschlag_0503_20.qxd 10.07.2003 13:54 Uhr Seite 1

Youhavedecidedona
Volkswagen Marine Boat Engine
- Thank you for putting your trust in us.
Volkswagen Marine boat engines
have been developed for the special
requirements in boats.
Volkswagen Marine offers a broad
range of variants to meet any specific
requirements.
Volkswagen Marine boat engines are
characterised by many advantages:
OCompact design and low weight
create the conditions for universal
installation.
OA long life and low fuel consump-
tion ensure economy and environ-
mental friendliness.
You have decided on a Volkswagen
Marine boat engine that is advanced
in every regard. Your boat engine has
been developed to put the least
possible strain on the environment.
VW-Marine Service Partner are avail-
able for support:
The VW-Marine Service Partner
The VW-Marine Service Partner works
at low cost and professionally accord-
ing to factory specifications. It also
guarantees that everything on your
Volkswagen Marine boat engine is in
proper working order. In addition,
VW-Marine Service Partner offer an
extensive package of warranties and
services.
VW Marine Service Partners will be
happy to provide details on the services
and any processing in individual
countries.
Volkswagen Marine

CONTENTS
MANUAL STRUCTURE
What you should know
before you read this manual 3......
OPERATION
General view of engines 4..........
Starting engine 5..................
Stopping the engine 6.............
Instruments 7....................
Warning lamps 10.................
Switch 14........................
Stop switch 15....................
Ignition switch 16.................
Driving lever 16...................
DO-IT-YOURSELF
Safety precautions for working
in the engine compartment 17......
Diesel 19.........................
Changes and parts replacement 20..
SELF-HELP
Self-help 21......................
Fuses 25.........................
INSPECTION SERVICE
Service and care 26...............
Daily checks 27...................
End of season 28.................
Start of season 29.................
Service scope
once yearly
or every 200 operating hours 30.....
Additional work
every 5 years
or every 1,000 operating hours 31...
Engine oil 32.....................
Check engine oil level 33...........
Changing engine oil 34.............
Circulation filter* 37...............
Fuel supply filter 40................
Seawater filter* 42................
Cleaning air filter element 43.......
Cooling system 45................
Seawater pump 48................
Reactive anode 50.................
Reversing-gearbox oil level 51.......
Ribbed V-belt 52..................
Battery* 53.......................
Engine test run 58.................
Preserving engine 59..............
Winter operation 62...............
Tropical operation 64...............
TECHNICAL DATA
SDI 40-4 Diesel Engine 65..........
SDI 50-4 Diesel Engine 66..........
SDI 60-4 Diesel Engine 67..........
Engine characteristic data 68.......
INDEX
Index 69........................

OPERATION
MANUAL STRUCTURE 33
This manual
contains important information on using
your Volkswagen Marine Boat Engine. You
should read this manual carefully prior to
initial operation to quickly become familiar
with the engine and to know how to operate
and handle the engine.
Along with regular service and mainten-
ance, proper operation and use of the Volks-
wagen Marine Boat Engine make an import-
ant contribution to maintaining its value.
Additional warranty information are
contained in the service schedule.
For safety reasons, please also be
sure to follow the safety precautions
on page 17 and the information on
changes and part replacement on
page 20.
Equipment
This manual contains information covering
the full range of options available as we
went to press. Some of the equipment may
not be available until a later time.
Equipment marked with an asterisk
are not part of the standard equip-
ment of the Volkswagen Marine
Boat Engine.
Notes on environmental
protection
Texts which follow this symbol
and are printed in italics are
important notes on environ-
mental protection.
Table of Contents
The first page contains a list of contents in
which all the subjects dealt with in this
manual are given in the order that they
appear.
Index
At the back of the Owner’s Manual is a com-
prehensive alphabetically ordered index.
The required information can be located
quickly using key words.
Warnings
Attention
Blocks of text written in bold
print and with this background
refer to potential accident or
injury risks.
The passages in this bold print pro-
vide useful information on using and
caring for your Volkswagen Marine
engine and call your attention to
potential sources of damage to it.
One final request:
When you sell your boat or your Volkswagen
marine boat engine, please pass on this
manual to the new owner, as the literature
is part of the Volkswagen marine boat
engine!
4
C
What you should know
before you read this manual

OPERATION
4OPERATION
4
Description of engines
SDI-40-4, SDI 50-4 and SDI-60-4
-Four-stroke diesel engine
-4-cylinder in-line
-1.9 litre displacement
-Crankshaft mounted on five bearings
-Valve control by toothed belt and over-
head cam
-Hydraulically adjusted bucket tappets
-Engine lubrication as pressure circulation
lubrication with geared 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
gearbox radiator, 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 tempera-
ture, via the main heat exchanger.
Attention
Refer to the safety instructions
provided on Page 17 onwards
before carrying out any work on
the engine or in the engine
compartment.
General view of engines
BM4-001M

OPERATION
OPERATION 55
Important
ONever allow the engine to run
with the vehicle standing in an
enclosed area - asphyxiation
hazard!
The engine exhaust gases
contain carbon monoxide, which
is colourless and odourless.
Inhaling these gases can be
damaging to your health.
ORefer to the safety instructions
provided on Page 17 onwards
before carrying out any work on
the engine or in the engine
compartment.
ONever start the engine when
the driving lever(s) has/have been
removed.
Accident danger!
OWhen the driving level is correctly
installed, the engine cannot be started
when the lever is not in the neutral position.
A corresponding message appears in the
display of your rev. counter.
OBefore starting the engine, check the
engine oil, coolant and gear oil levels, the
fuel supply and the seawater filter, and
make sure that the seawater valve for the
seawater cooling circuit is open.
OAs soon as the engine starts, release the
ignition key immediately, as the starter may
not continue to run with the engine.
OWhen restarting the engine, restarting is
not possible until the key has been turned
back completely. The non-repeat mechan-
ism is designed to prevent the starter from
engaging while the engine is running, thus
incurring damage.
OAvoid high engine speeds and full throttle
until the engine has reached its operating
temperature.
OYou may hear a small amount of noise in
the first few seconds after starting. This
noise will disappear once oil pressure builds
up in the hydraulic tappets. This phenom-
enon is normal with this type of tappet and
does not indicate a defect or malfunction.
Starting engine

OPERATION
6OPERATION
6
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
compartment.
Stopping the engine

OPERATION
OPERATION 77
The illustration shows the instruments of
the navigating stand panel*.
The illustration shows the navigating stand
panel
Item Page
1 - Coolant temperature gauge 8.......
2 - Rev. counter 8....................
3- Voltmeter 8.......................
4 - Multifunction indicator (MFI) 8......
5 - Engine-oil pressure gauge 9........
A - Warning lamp
Instruments
5
1
4
2
BM4-022M

OPERATION
8OPERATION
8
1 - Coolant temperature
gauge*
The display appears when you switch on the
ignition.
When the ignition is switched on, the warn-
ing lamp Alights up for a few seconds as an
operating check.
Note
Avoid high engine speeds and do not sub-
ject the engine to heavy loads while the
coolant temperature is still below 40°C.
Under normal operating conditions the
needle should remain in the middle of the
scale range.
At heavy engine loads and high outside
temperatures, the needle may also move
far into the upper range.
This is not a cause for concern as
long as the warning lamp A does not
light up and the acoustic signal does
not sound.
A-Warninglamp
If the lamp lights up during driving, first
check the coolant temperature gauge.
If the gauge is in the normal range, coolant
must be added as soon as possible.
If the needle is above 105°C, the coolant
temperature is too high. Stop the engine
and determine the cause of the fault - see
page 11.
Attention
Refer to the safety instructions
provided on Page 17 onwards
before carrying out any work on
the engine or in the engine
compartment.
2 - Rev. counter
Never run the cold engine at high speeds -
either at idle or during driving.
If the needle of the rev. counter goes
above 4,000 rpm, you should cut
back on the throttle to prevent en-
gine damage.
3 - Voltmeter*
The voltmeter indicates the voltage in the
on-board electrical system. Normal value:
between 12 and 16 volts. If the gauge drops
below 12 volts with the engine running,
have the power supply (battery and alterna-
tor) checked by a VW-Marine Service
Partner.
During starting the voltage gauge may drop
below 8 volts.
4 - Multi-function indicator
(MFI)
The multi--function indicator (MFI) provides
a great deal of information. For information
on the operation and functions, please see
the additional operating manual for the
multi-function indicator.

OPERATION
OPERATION 99
5 - Engine-oil
pressure gauge*
The engine-oil pressure gauge only func-
tions with the engine running and indicates
the existing engine oil pressure.
During driving the engine oil pressure is
between approx. 2 and 5 bar.
At an engine oil pressure below 2 bar the
engine oil-pressure warning lamp can light
up and an acoustic signal can sound.
If the engine oil-pressure warning lamp
lights up (see page 13) and the acoustic
signal sounds.
Switch off engine! Check the oil level -
see page 33.
The engine oil-pressure warning
lamp is not an engine oil level indica-
tor! Therefore, check the engine oil
level at regular intervals, preferably
before each trip.
Attention
Refer to the safety instructions
provided on Page 17 onwards
before carrying out any work on
the engine or in the engine
compartment.

OPERATION
10 OPERATION
10
The illustration shows the warning lamps of
the optional navigating stand panel*.
The illustration shows the navigating stand
panel
Item Page
1 - Coolant temperature/
coolant level 11...................
2 - Display for multi-function indicator 12
3 - Alternator 12.....................
4 - Glow plug system and engine fault 13
5 - Engine oil pressure 13.............
A- Switch
Warning lamps
13
2
54 A
BM5-015M
3
5 A
1
4
2BM5-016M

OPERATION
OPERATION 11 11
1 - Coolant temperature
The warning lamp lights up when the cool-
ant temperature is too high.
As an additional warning, an acoustic signal
sounds at the same time, which can be
switched off with the switch A.
Should the fault not be eliminated, 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 sea valve is open.
-sufficient coolant is present. Check the
cooling system for leaks.
-the ribbed V-belt of the seawater pump
is OK.
-the impeller of the seawater pump is OK
- see page 48.
Important
OExercise caution when
opening the coolant cap! When
the engine is hot, the cooling
system is pressurised - danger of
scalding! Therefore, allow the
engine to cool down before
unscrewing the cap.
OExercise particular caution
when working in the engine
compartment!
ORefer to the safety instructions
provided on Page 17 onwards
before carrying out any work on
the engine or in the engine
compartment.
If the fault cannot be eliminated, please con-
tact the nearest VW Marine Service Partner.

OPERATION
12 OPERATION
12
2 - Multi-function indicator
(MFI)
The following faults may be indicated in the
left-hand area of the MFI:
Coolant level
If a fault occurs in the closed cooling system
while driving, this is indicated by a flashing
symbol in the left-hand area of the multi-
function indicator.
In this case, switch off the engine
immediately and check whether ...
-sufficient coolant is present.
-the coolant system is leaky.
Important
OExercise caution when
opening the coolant cap! When
the engine is hot, the cooling
system is pressurised - danger of
scalding! Therefore, allow the
engine to cool down before
unscrewing the cap.
OExercise particular caution
when working in the engine
compartment!
ORefer to the safety instructions
provided on Page 17 onwards
before carrying out any work on
the engine or in the engine
compartment.
If the fault cannot be eliminated, consult the
nearest VW Marine Service Partner.
Water separator
This symbol appears when water has col-
lected in the fuel filter on the engine.
In this case, switch off the engine and drain
the water from the fuel filter
- see page 40.
Attention
Refer to the safety instructions
provided on Page 17 onwards
before carrying out any work on
the engine or in the engine
compartment.
3 - Alternator
This warning lamp lights up when you
switch on the ignition. It should go out again
once the engine is running.
If the alternator warning lamp lights
up during operation:
-Switch off the engine immediately and
check the ribbed V-belt.
If the ribbed V-belt is OK, the fault is prob-
ably in the alternator or the regulating
switch. If the damage cannot be repaired,
please contact the nearest VW Marine Ser-
vice Partner.
Note
The engine may not:
-be operated with the battery dis-
connected, as otherwise the alter-
nator will be damaged.
-operated without the alternator
ribbed V-belt, as otherwise the
front vibration damper will be
damaged.

OPERATION
OPERATION 13 13
4 - Glow plug system and
engine fault
Glow plug system
When the engine is cold, the warning lamp
lights up when the driving position is acti-
vated (ignition on).
Should the warning lamp fail to light up, a
fault is present in the glow plug system -
please obtain professional help.
Start the engine immediately after the lamp
goes out – see page 5.
The engine can also be started immediately
without preheating, however then a
slightly poorer starting behaviour must be
expected.
When the engine is at operating tem-
perature, the preheating warning lamp
does not light up - the engine can be star-
ted immediately.
engine fault
If a fault occurs in the engine control system
during drivin g, this is indicated by the warn-
ing lamp flashing - the engine should be
checked immediately by a VW-Marine
Service Partner.
5 - Engine oil pressure
This warning lamp lights up when the igni-
tion is switched on and must go out after the
engine starts.
If the engine oil-pressure warning
lamp lights up or flickers during
operation:
1 - Switch off the engine immediately, as
the engine lubrication may be inter-
rupted.
2 - Then check the engine oil level (see
page 33).
If the oil level is OK, please contact the
nearest VW Marine Service Partner.
As an additional warning, an acoustic signal
sounds at the same time, which can be
switched off with the switch A.
Should the fault not be eliminated, the
acoustic signal sounds again after a short
time.
On the other hand, occasional flickering of
the warning lamp at idle with the engine is
warm is meaningless if the lamp goes out
again when the engine speed is increased.
The oil-pressure warning lamp is not
an oil level indicator! Therefore, the
oil level should be checked at reg-
ular intervals, preferably before
each trip.

OPERATION
14 OPERATION
14
The illustration shows the switches of the
navigating stand panel.
Item Page
1- Instrumentlighting/dimmer .........
LEERER MERKER
2 - Acknowledgement button for
acoustic signal 15.................
3 - Buttons for multi-function
indicator (MFI) 15.................
4 - Stop engine 15....................
5 - Start engine 15...................
The illustration shows the switches of the
navigating stand panel*.
Item Page
1- Instrumentlighting/dimmer .........
LEERER MERKER
2 - Acknowledgement button for
acoustic signal 15.................
3 - Buttons for
Multi-function indicator (MFI) 15.....
Switch
2
1
3
45
BM5-017M
12 3
BM5-004M

OPERATION
OPERATION 15 15
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.
3- ButtonforMFI
The MFI is operated with this button. Each
time the button is pressed, the display in the
MFI is advanced.
4 - Stop engine
To stop the engine from the flying bridge,
press the Stop button.
5 - Start engine
When the ignition key is inserted and the
ignition is switched on in the navigation
stand panel, you can start the engine by
pressing the Start button.
Important
Always remove the ignition key if
you leave the boat - even for a
short time. This is particularly
important when children remain
on the boat. Otherwise they
could start the engine or operate
the electrical equipment.
Accident danger!
Stop switch
You can stop the engine in case of danger
with the Stop switch on the fuse box/relay
plate.
After the Stop switch is actuated it must be
released again, as otherwise the engine
cannot be started.
To release the Stop switch, turn it in the
direction of the arrow shown on the switch.
Stop switch
BM4-003M

OPERATION
16 OPERATION
16
1 - Fuel supply interrupted, engine
off
2 - Preheating and driving position
As long as the engine is being preheated, no
major consumers should be switched on -
otherwise this will place an unnecessary
load on the starting battery.
3 - Starting engine
Important
Always remove the ignition key if
you leave the boat - even for a
short time. This is particularly
important when children remain
on the boat. Otherwise they
could start the engine or operate
the electrical equipment.
Accident danger!
The illustration shows the pattern of the
driving lever.
1 - Forward driving
2 - Shifting during forward driving
3 - Neutral
4 - Shifting during reverse driving
5 - Reverse driving
Always make sure that the driving lever is in
the Neutral position 3before starting the
engine.
Ignition switch Driving lever
2
31
BM4-013M
5
4
1
3
2
BM5-030M

DO-IT-YOURSELF
OPERATING INFORMATION 17 17
When performing any work on the
engine or in the engine compart-
ment, e.g. checking and topping up
the operating fluids, there may by a
danger of scalding, injuries, acci-
dents and fire.
Important
Exercise particular caution when
working on the engine or in the
engine compartment!
Protect yourself with suitable
work clothing, e.g. gloves, eye
protection etc.
ONever open the engine
compartment cover or perform
work on the engine when you
notice that steam or coolant is
escaping – danger of scalding!
Wait until steam or coolant no
longer escapes and the engine
has cooled down.
OStop the engine, remove the
ignition key and press the Stop
button.
OMove the driving lever into the
Neutral position.
OAllow the engine to cool.
OKeep children away from the
engine compartment.
ODo not open the cap of the
coolant reservoir while the
engine is at operating
temperature, as the cooling
system is pressurised.
OBe sure not to spill liquids over
the hot engine. These liquids
could ignite.
OAvoid short circuits in the
electrical system, and in
particular at the battery.
OIf maintenance, testing,
repairs or adjustments must be
carried out with the engine
running, there is an additional
danger from rotating parts – e.g.
ribbed V-belt and alternator -
danger to life and limb!
Please also observe the warnings
on the following page.
Safety precautions for working
in the engine compartment

DO-IT-YOURSELF
18 OPERATING INFORMATION
18
OIf work on the fuel system or
the electrical system is required:
-Always disconnect the battery
from the engine.
-Do not smoke.
-Never work near an open
flame.
-Always keep a fire
extinguisher close at hand.
Avoid contact with operating
materials. Should operating
materials get into the eyes, flush
the eyes immediately with clean
water and see a doctor at once.
Take along the original container
to the doctor in these cases. You
should be particularly aware of
the following when you if to
carry out work on open water:
-Swells may put you off
balance.
-The danger of spilling
operating materials is
increased by swells.
-If you 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 other-
wise 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 soiling by oil or other
operating fluids can be seen there,
the engine should be checked by a
VW Marine Service Partner.
Important note
Of course, coolant additives and
motor oil are constantly being
further developed. Therefore, the
information contained in this
manual can only reflect the status at
the time of printing. The VW Marine
Service Partner will always be kept
up to date on any changes by the
factory. Therefore, it is best to have
operating materials changed by a
VW Marine Service Partner.
C

DO-IT-YOURSELF
OPERATING INFORMATION 19 19
The diesel fuel must comply with the stan-
dard DIN EN1) 590.
CN2) no lower than 49.
RME fuel (biodiesel)
in accordance with DIN 51 606.
Volkswagen Marine boat engines can also
be operated with RME fuel (rape-oil fatty
acids methylester).
Important
It must be ensured that the fuel
tank and the fuel hoses to the
engine are also suitable for RME
fuel.
Special features of RME
ORME is a plant-based oil (primarily
rapeseed), manufactured using a chemical
process in which a catalytic element is
employed to transform a mixture with
methanol into RME fuel.
ORME is virtually sulphur-free. This means
that practically no sulphur dioxide
emissions (SO2) are generated when it
combusts.
OThe exhaust gas contains
-less carbon monoxide,
-fewer hydrocarbons and
-fewer particles (e.g. soot)
compared to the emissions produced by
conventional diesel fuels.
All emission levels are lower than those laid
down by law.
1) Euro Standard
2) Cetan Number. Measure of the ignitability of
diesel fuel.
OThe RME fuel is biodegradable.
OIts use may be accompanied by slight
reductions in performance.
OFuel consumption may be slightly higher.
ORME is suitable for winter use at tem-
peratures down to about –10 oC.
OAt outside temperatures below approx.
–10 oC diesel fuel must be added to prevent
the RME fuel from flocculating. The mixing
ratio of diesel fuel to RME fuel should be
approx. 50 : 50.
If RME percentage is higher than
50%, more smoke may be produced.
ORME can be mixed with diesel fuel in any
desired ratio during the warm season.
Winter operation
When using summer diesel, malfunctions
may occur at outside temperatures below
0oC, as the fuel also becomes too thick due
to paraffin precipitation.
Therefore, “winter” diesel fuel is available
in Germany at roadside petrol stations dur-
ing the cold season which - depending on
the fuel brand - is also safe for operation at
approximately -15 oCto-22oC.
In countries with other climatic conditions,
diesel fuels with a different temperature
behaviour are offered.
Diesel