VOLKSWAGEN TDI 4.2L V8 DIESEL MARINE ENGINE Service Repair Manual PDF

3
Workshop Manual
Marine Boat Engine 2011 ▶
8-cylinder diesel engine (4.2 l engine, com-
mon rail)
Edition 05.2011
Engine code CEM
3
Repair Group overview for workshop manual
8-cylinder diesel engine (4.2 l engine, common rail)
Edition 05.2011
When filing a Technical Bulletin, enter the bulletin number in the column adjacent to the Repair
Group. When using the Maintenance Manual you can then see at a glance whether Technical Bul-
letins have been published which refer to the Repair Group you are looking for.
Repair Group Technical Bulletins

00 Technical data
01 Self-diagnosis
10 Removing and installing engine
13 Crankshaft group
15 Cylinder head, valve gear
17 Lubrication
19 Cooling
20 Fuel supply system
21 Turbocharging/supercharging
23 Mixture preparation - injection
26 Exhaust system
27 Starter motor, alternator
48 Hydraulic system
90 Instrument panel
97 Central electrics
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness
and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as
a matter of course, be observed.
All rights reserved.

Not to be modified, used, sold, distributed, made public or reproduced without the
consent of the publisher.
Copyright © 2011 Volkswagen AG, Wolfsburg Printed in Germany
8-cylinder diesel engine (4.2 l engine, common rail) 05.2011
3
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine codes / engine numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Health and Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 General repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Rules for cleanliness when working on fuel supply system, injection system and turbocharg-
er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Routing and securing lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 Checking for leaks in the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.4 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
01 - Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1 Features of self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1 Technical data of self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Selectable functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 Connecting the fault reader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4 Fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2 Fault table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1 B0271…17083/P0699 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2 17428/P1020…18316/P1908 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.3 18512/P2080…18727/P2295 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.4 19463/P3007…19464/P3008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3 Final control diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.1 Conduct final control diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.2 Adapting idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4 Measured value blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.2 Read data blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.3 Evaluating measured value blocks with ignition ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.4 Evaluating measured value blocks at idling speed (engine warm, coolant temperature not
below 73 °C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5 Evaluating measured value blocks at full throttle (sea test with warm engine, coolant
temperature not below 73 °C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5.1 Display group 100 -Quantity injected- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5.2 Display group 101 -starting conditions- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
5.3 Display group 102 -Temperatures- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
5.4 Display group 103 -Activation of common rail injectors- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
5.5 Display group 104 -Torque limit moments- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
5.6 Display group 105 -Limiting factors- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
5.7 Display group 106 -Charge pressure control I- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5.8 Display group 107 -Charge pressure control II- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5.9 Display group 108 -Exhaust temperature- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
5.10 Display group 109 -Fuel consumption- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Contents iii
3 Marine Boat Engine 2011 ▶
5.11 Display group 110 -Fuel rail pressure regulation l- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

5.12 Display group 111 -Fuel rail pressure regulation II- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5.13 Display group 112 -Fuel rail pressure regulation Ill- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5.14 Display group 113 -Quantities injected, specification- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
5.15 Display group 114 -Activation period of pilot injection 1- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
5.16 Display group 115 -Activation period of pilot injection 2- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
5.17 Display group 116 -Injection coordinator- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
5.18 Display group 117 -idling speed- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
5.19 Display group 118 - Rotational speed registration- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.2 Securing engine on engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
1.3 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1.4 Securing gearbox bell housing to engine (reverse gear gearbox) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
1.5 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.6 Assembly mounting/engine mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1.7 Engine with connection for external heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
1.1 Assembly overview - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
1.2 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.3 Removing and installing tensioning element for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
1.4 Removing and installing idler roller (left and right) for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1.5 Assembly overview - vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1.6 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1.7 Assembly overview - shaft oil seal and sealing flange at belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . 106
1.8 Replacing oil seal for crankshaft at belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.9 Removing and installing sealing flange at belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
2 Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
2.1 Assembly overview - drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
2.2 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
2.3 Renewing oil seal for crankshaft at gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2.4 Removing and installing engine speed sender -G28- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
3.2 Allocation of main bearing shells for new crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
3.3 Allocation of crankshaft bearing shells for retaining frame without visible colour coding . . . . . . . 118
3.4 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
3.5 Measuring axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
3.6 Measuring radial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
4.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
4.2 Measuring piston projection at „TDC“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
4.3 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
iv Contents
3
4.4 Measuring radial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
4.5 Allocation of conrod bearing shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

1 Timing chain covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
1.1 Assembly overview - timing chain covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
1.2 Renewing oil seal for toothed belt pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1.3 Removing and installing timing chain cover (left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
1.4 Removing and installing timing chain cover (right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
1.5 Removing and installing timing chain cover (bottom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
2 Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
2.1 Assembly overview - camshaft timing chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
2.2 Removing camshaft timing chains from camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
2.3 Removing and installing camshaft timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
2.4 Assembly overview - drive chain for valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
2.5 Removing and installing drive chain for valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
2.6 Assembly overview - drive chain for auxiliary drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
2.7 Removing and installing drive chain for auxiliary drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
2.8 Assembly overview - auxiliary drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
2.9 Renewing oil seal for vane pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
2.10 Removing and installing spur gear drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
3 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
3.1 Assembly overview - cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
3.2 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
3.3 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
3.4 Removing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
3.5 Installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
3.6 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
3.7 Assembly overview - vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
3.8 Removing and installing vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
4 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
4.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
4.2 Measuring axial clearance of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
4.3 Measuring radial clearance of camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
4.4 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
4.5 Checking hydraulic compensation elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
4.6 Renewing valve stem seals with cylinder head installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
4.7 Renewing valve stem seals with cylinder head removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
4.8 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
4.9 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
4.10 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
4.11 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1.1 Engine oil specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1.2 Oil capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Contents v
1.3 Checking engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

1.4 Draining engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
2 Oil pump, lower part of sump, upper part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
2.1 Assembly overview - oil pump, lower part of sump, upper part of sump . . . . . . . . . . . . . . . . . . . . . . . . 204
2.2 Removing and installing lower part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
2.3 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
2.4 Removing and installing upper part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
3 Engine oil cooler, pressure regulating valve for crankcase breather, oil filter housing . 212
3.1 Assembly overview - engine oil cooler, pressure regulating valve for crankcase breather, oil
filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
3.2 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
3.3 Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
3.4 Removing and installing pressure regulating valve for crankcase breather system . . . . . . . . . . . . 215
3.5 Removing and installing mounting plate for engine oil cooler, pressure regulating valve for
crankcase breather system and oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
3.6 Removing and installing oil pressure switch -F1- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
3.7 Removing and installingoil temperature sender -G8- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
3.8 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
1 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
1.1 Assembly overview - cooling system plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
1.2 Parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
1.3 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
1.4 Assembly overview - main heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
1.5 Assembly overview - servo/gearbox oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
1.6 Assembly overview - charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
1.7 Assembly overview - seawater filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
1.8 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
2 Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
2.1 Draining coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
2.2 Filling with coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
2.3 Draining seawater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
2.4 Assembly overview - coolant pump and thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
2.5 Removing and installing coolant temperature sender -G62- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
2.6 Assembly overview - seawater pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

1 Parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
1.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
1.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
1.3 Assembly overview - fuel system microfilter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
1.4 Assembly overview - circulation pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
2 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
2.1 Assembly overview - right turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
vi Contents
3
2.2 Assembly overview - left turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
3 Charge air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
3.1 Assembly overview - air ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
4 Checking components and functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
4.1 Checking turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
252
4.2 Check charge pressure control solenoid valve -N75- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
4.3 Checking bank 1 exhaust gas temperature sender -G235- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
4.4 Checking bank 2 exhaust gas temperature sender -G236- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
4.5 Checking charge air pressure sender -G31- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

1 Safety precautions and rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
1.2 Rules for cleanliness and instructions for working on fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
2 Overview of fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
3 Diesel direct injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
3.1 Schematic overview of fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
3.2 Assembly overview - fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
3.3 Assembly overview - injectors and high-pressure lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
3.4 Removing and installing fuel temperature sender -G81- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
3.5 Removing and installing fuel pressure regulating valve -N276- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
3.6 Removing and installing fuel pressure sender -G247- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
3.7 Assembly overview - toothed belt for high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
3.8 Removing and installing toothed belt for high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
3.9 Assembly overview - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
3.10 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
3.11 Bleeding fuel system after installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
3.12 Intake manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
3.13 Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
4 Checking components and functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
4.1 Checking voltage supply for diesel direct injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
4.2 Checking engine speed sender -G28- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
4.3 Checking coolant temperature sender -G62- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
4.4 Checking oil temperature sender -G8- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
4.5 Checking fuel temperature sender -G81- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
4.6 Checking intake air temperature sender -G42- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
4.7 Checking Hall sender 2 -G40- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
4.8 Checking fuel pressure sender -G247- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
4.9 Checking fuel pressure regulating valve -N276- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
4.10 Checking injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
4.11 Checking and setting injector correction values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
5 Engine control units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
5.1 Removing and installing master engine control unit and slave engine control unit . . . . . . . . . . . . . 316
5.2 Checking matching resistor for data bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
Contents vii
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318

1 Exhaust manifold and exhaust pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
1.1 Assembly overview - exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
1.2 Assembly overview - exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
27 - Starter motor, alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322

1 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
1.1 Removing and installing starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
2 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
2.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
2.2 Assembly overview - alternator with bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
2.3 Removing and installing alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
2.4 Removing and installing poly V-belt pulley with freewheel, manufacturer: Bosch . . . . . . . . . . . . . . 326
2.5 Removing and installing poly V-belt pulley with freewheel, manufacturer: Valeo . . . . . . . . . . . . . . . 328
2.6 Voltage regulator for alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
2.7 Specified torques: Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
48 - Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333

1 Parts of hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
1.1 Functional overview: Hydraulic pump, oil cooler, hydraulic pipes, reservoir . . . . . . . . . . . . . . . . . . . . 334
1.2 Checking hydraulic pump delivery pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
1.3 Removing and installing vane pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
90 - Instrument panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338

1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
1.1 Overview of individual instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
1.2 Overview of operating unit for individual instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
1.3 Overview of contact assignment of individual instrumentation multi-pin connectors . . . . . . . . . . . 341
1.4 Individual instrumentation connector assignment to engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
1.5 Changing a fuse of the individual instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
1.6 Overview of optional instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
1.7 Optional instrumentation connector assignment to engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
1.8 Overview of terminal strip -A- contact assignment, optional instrumentation . . . . . . . . . . . . . . . . . . . 346
1.9 Overview of multipin connector assignment of optional instrumentation . . . . . . . . . . . . . . . . . . . . . . . . 346
1.10 Connection variants of optional instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
1.11 DIP switch on optional instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
1.12 Neutral position with Z-drive or reverse gear gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
97 - Central electrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349

1 Central electrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
1.1 Removing and installing central electrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
1.2 Removing and installing component/circuit board of central electrics . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
1.3 Connector assignment to central electrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
1.4 Removing and installing relay/fuse carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
1.5 Diagnosis connection for system tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
1.6 Wiring harness variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
1.7 Wiring harness and connector repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
viii Contents
3
2 Electronic propulsion system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
2.1 Electronic throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
2.2 Assembly overview - components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
Contents ix
x Contents
3
00 - Technical data
1 Technical data
1.1 Engine codes / engine numbers
The engine code consists of three characters (e.g. CEM) fol-
lowed by the engine number consisting of six digits.. The en-
gine code and engine number are stamped onto the left side of
the cylinder block. In addition, they are also located on the type
plate.
1.2 Engine data

Engine codes CEM
Emissions fulfil 2003/44/EC
Capacity l
Output kW at rpm 257 / 4200
Torque Nm at rpm 700 / 2000 - 3250
Bore Ø mm 83,0
Stroke mm 95,5
Compression ratio 16,4
CN min. 51
Firing order 1-5-4-8-6-3-7-2
Turbocharging/su- 2 turbochargers
percharging with variable tur-
bine geometry.
Self-diagnosis yes
Charge air cooling yes
Weight kg 368
(the weight is for a
dry engine with an-
cillaries, cooling
system and clutch
flange)
Power to weight ra- kg/PS 1,05
tio
(weight compared
to output, to allow
comparisons of effi-
ciency of engines
of different weight
and output)
Certificate No. ac- M1 03 3 08 04
cording to BSO 2
1 Technical data 1
2 Health and Safety Precautions

Introduction
This workshop manual contains technical data, descriptions and
repair instructions for the 8 cylinder TDI boat engine.
The table of contents shows all the individual repair groups of
the boat engine.
General information
Replacement parts for the electrical systems and fuel systems
comply with legal requirements. Genuine parts comply with
these requirements. Any damage caused by the use of non-
genuine parts would not be covered by the warranty.
The boat engine is certified according to BSO 2 under certifi-
cate number: M1 03 3 08 04.
Note
Carefully read all safety precautions before starting repairs. All
danger and safety precautions which must always be complied
with when operating and maintaining the engine are listed in the
following.
General notes
◆ Maintenance work may only be undertaken when the engine

is not running. Some adjustments must be carried out when
the engine is running. Ensure when engine is running that no
loose clothing, long hair or tools become caught in rotating
parts. This could result in serious injury.
◆ Ensure correct shoes (deck shoes) and clothing are worn
when undertaking maintenance work or tests
◆ If the engine is to be turned at starter speed, without starting,
e.g. when checking compression, disconnect connector from
injection pump.
◆ Only use engine oils authorised by Volkswagen Marine ⇒
Operating instructions for Volkswagen Marine Boat Engines.
◆ Start engine only in a well ventilated area. When starting en-
gine in a closed room ensure, exhaust gases are piped a
away from the work area with a suitable ventilation system.
Torque
◆ Always use a torque wrench to tighten nuts / bolts etc. to

specified torque. All torques in this repair manual are for
cleaned threads, bolt heads and contact surfaces.
◆ When tightening components, first tighten to prescribed tor-
que using a torque wrench then turn further to required an-
gle.
When working on the fuel system note the following warn-
ings:
2 Repair Group 00 - Technical data

3
WARNING
Risk of injury - fuel system operates under high pressure.
◆ Wrap a clean cloth around the connection before open-
ing the fuel system. Then release pressure by carefully
loosening the connection.
◆ Extreme care is required when working on a leaking fuel
system. Wear eye protection when testing injectors. The
high pressure of the injecting fuel can cause serious in-
juries.
◆ Wear protective gloves.
◆ Wear eye protection.
Observe the following points to prevent personal injuries

and damage to the injection system:
◆ The ignition must be switched off before connecting or dis-

connecting electrical wiring of the injection system or tester
cables.
◆ Faults are stored in engine control unit if electrical connec-
tors have been disconnected:
– Connecting vehicle diagnosis, testing and information sys-
tem, ScanDi tool or VAS 5052.
– Start „Vehicle self-diagnosis“ mode.
– Read fault memory ⇒ Page 9.
When working on the battery note the following:
Caution
◆ Danger of destroying electronic components when dis-

connecting battery or danger of battery exploding when
reconnecting battery.
◆ Observe notes on procedure for disconnecting the bat-
tery.
◆ Always switch off ignition before disconnecting battery.
◆ Incorrectly reconnecting the battery can cause sparks
which can cause an explosion. Avoid naked flames or
welding operations in the vicinity of the battery.
◆ When charging the battery, hydrogen gas escapes
which when mixed with oxygen produces a highly ex-
plosive gas. Therefore wear eye protection and respec-
tive protective clothing. The gases are heavier than air
and can collect in the bilges. Use only onboard chargers
and, if possible, gel batteries.
Note the following if testers and measuring instruments
have to be used during a sea test:
2 Health and Safety Precautions 3

WARNING
Accidents can be caused by distractions and insufficiently
secured test equipment.
◆ The use of test equipment while driving causes distrac-
tion.
◆ There is an increased risk of injury if test equipment is
not secured.
When working on the cooling system note the following:
WARNING
Hot steam / coolant can escape - risk of scalding!
◆ When working on cooling system - switch off engine
and close sea valves
◆ The cooling system is under pressure when the engine
is hot.
◆ Use extreme caution when unscrewing cap on cooling
system when engine is hot or even warm. Risk of scald-
ing Cover cap of cooling system expansion tank with a
cloth and open cap carefully to allow pressure to es-
cape. Only remove cap when pressure has dissipated.
3 General repair notes

3.1 Rules for cleanliness when working on
fuel supply system, injection system
and turbocharger
Even small amounts of contamination / soiling can lead to de-
fects. For this reason, when working on the fuel supply system,
the injection system or the turbocharger, please observe the fol-
lowing basic rules carefully:
◆ Carefully clean connection points and the surrounding area

with engine cleaner or brake cleaner and dry thoroughly be-
fore opening. When tightening components, first tighten to
prescribed torque using a torque wrench then turn further to
required angle.
◆ Immediately seal off open pipes and connections with suita-
ble caps.
◆ Place removed parts on a clean surface and cover. Use only
lint-free cloths.
◆ Install clean parts only: Only unpack replacement parts im-
mediately prior to fitting. Do not use parts that have been
previously unpacked and stored away loose (e.g. in toolbox-
es, etc.).
◆ When the system is open: Do not work with compressed air.
Do not move boat unless absolutely necessary.
4 Repair Group 00 - Technical data

3
◆ Protect detached electrical connections against dirt and
moisture and only connect when they are dry.
3.2 Routing and securing lines

Mark hydraulic lines, vacuum lines and electrical wiring before
removal so they can be re-installed in the original positions and
correctly connected. Make sketches or take photographs if nec-
essary.
3.3 Checking for leaks in the fuel system

Proceed as follows:
– Allow engine to run at average revs for a few minutes.
– Switch off ignition.
– Check complete fuel system for leaks.
– If leaks are found although the connections have been tight-
ened to the correct torque, the relevant component must be
renewed.
– Carry out a sea test and accelerate with full throttle at least
once.
– Then inspect high-pressure section of fuel system again for
leaks.
3.4 Contact corrosion

Contact corrosion can occur if unsuitable fastening elements
(screws, bolts, nuts, washers etc.) are used. For this reason,
only fasteners with a special surface coating are used. Addition-
ally, all rubber and plastic parts and all adhesives are made of
non-conductive materials.
Always install new parts if you are not sure whether used parts
can be re-fitted ⇒ Parts catalogue.
Note
◆ We recommend using only genuine replacement parts;

these have been tested and are compatible with aluminium.
◆ We recommend the use of Volkswagen Marine accessories.
◆ Damage caused by contact corrosion is not covered under
warranty.
3 General repair notes 5

01 - Self-diagnosis
1 Features of self-diagnosis
The diesel direct injection system control unit is equipped with a
fault memory.
If faults occur in the monitored sensors or components, they are
stored in the memory together with an indication of the type of
fault.
Faults which occur temporarily (sporadically), are printed out
with the addendum „fault occurred sporadically“. These faults
are indicated on display by the addendum „/SP“. The cause of
sporadic faults can be e.g. a loose contact or a brief open cir-
cuit. If a sporadic fault does not occur again within 50 engine
starts, it will be erased from the fault memory.
If faults are recognised which affect the Multifunction indicator
„Service“ is displayed.
The stored faults can be read using the ScanDi tool
⇒ Page 9.
The fault memory must be erased after the faults have been
eliminated ⇒ Page 10.
Note
General information for fault finding is located in the operating
manual of the ScanDi tool
1.1 Technical data of self-diagnosis

Equipment
◆ Fault memory: Non-volatile and volatile memories1).

Read control unit version
The control unit version is displayed when the ScanDi tool is
connected and engine electronics control unit is selected
⇒ Page 7.
Selectable functions on ScanDi tool when address word 01 „En-
gine electronics“ is entered.
1.2 Selectable functions

Note
The prerequisites for selecting the desired functions can be de-
termined from the following table.
1) Will be cancelled after 50th engine start if fault has not occurred again.
6 Repair Group 01 - Self-diagnosis

3
Function Prerequisite
Functions on ScanDi tool / Engine stationary, ig- Engine running at
Boat underway
VAS 5052 nition switched on idling speed
01 Read control unit ver- yes yes yes
sion
02 Read fault memory yes1) yes yes
03 Final control diagnosis yes no no
05 Clear fault memory yes yes yes
06 End output yes yes yes
08 Reading measured val- yes yes yes
ue block
34 Adaption yes yes no
1) Only carry out with ignition switched on, when engine does not start.
1.3 Connecting the fault reader

All functions which can be carried out on the ScanDi tool can al-
so be carried out using the VAS 5052.
Connecting ScanDi tool
Special tools and workshop equipment required
◆ ScanDi tool
Test prerequisites:
◆ The battery voltage must be at least 11.5 V.

◆ Fuse 190 OK.
Procedure
– Unscrew cover of diagnosis connection on operating unit.
– Connect ScanDi tool.
Note
The ScanDi tool can also be connected to the diagnosis con-
nection in the central electrics ⇒ Page 353.
You must, depending on the function required:
– Switch on ignition
or
– Start engine ⇒ Page 6, Selectable functions.
Note
◆ If display remains blank, check voltage supply for diagnosis

connector according to fault finding programme: ⇒ Current
flow diagram TDI 350-8.
◆ If the display is not as shown in the procedure or if „Connec-
tion problems“ are displayed: ⇒ Operating manual of Scan-
Di tool.
1 Features of self-diagnosis 7
Indicated on display: ► W-Marine v1.71

Enter address word XX
– Operate ScanDi tool taking into account the information on
the display:
– Press keys 0 and 1 for address word „Engine electron-
ics“ and confirm entry with Q key.
The control unit identification appears on the ScanDi tool dis- 06V910401 TDI 225-6 MD 000AG 0010
play, e.g.: ▶ Code xxxxxxx WSC xxxxx
◆ 06V910401 = Part no. of control unit (for up-to-date control

unit version see parts catalogue)
◆ TDI = Turbo Diesel Injection
◆ MD 0000AG = Injection system (Marine Diesel Electronic
Control)
◆ 0010 = Control unit software version
◆ Code xxxxxxx (ignore)
◆ WSC xxxxx = Workshop code
– Press → key.
Indicated on display: ► 01-Engine electronics +/- Q

Select function XX K-Ltg 2000
– Refer to repair operations for further procedure.
Connecting VAS 5052

◆ Fault reader -VAS 5052-
Test prerequisites

◆ Fuse 190 OK.
Procedure
– Unscrew cover of diagnosis connection on operating unit.
– Connect fault reader -VAS 5052-.
Note
The VAS 5052 can also be connected to the diagnosis connec-
tion in the central electrics ⇒ Page 353.
Select operating mode
– Press key on display for „Vehicle self-diagnosis“.
Select vehicle system:

– Press „01 - Engine electronics“ key on display.
On the display, the control unit ID of the engine control unit is

shown.
Select diagnosis function:
All the available diagnosis functions are shown on the display.
– Press key on display for the desired function.

3
Note
◆ The display fields will be displayed from top to bottom in

functions 04 - Basic settings or 08 - Read measured value
block.
◆ The following test procedures are described for the ScanDi
tool.
1.4 Fault memory
1.4.1 Read fault memory

◆ ScanDi tool or Fault reader -VAS 5052-
Procedure
– Connect ScanDi tool or Fault reader -VAS 5052- and select
engine electronics control unit with „address word“ 01. The
engine should be idling, for this.
Connect fault reader and select engine control unit ⇒ Page 7.
Only when engine does not start:
– Switch on ignition.

– Operate fault reader taking into account the information on
the display:
– Press keys 0 and 2 for function „Read fault memory“ and
confirm entry with Q key.
The display shows the number of stored faults or „No fault rec- X faults recognised!
ognised“.
If one or more faults are stored:
Using the → key you can now display the individual fault num-
bers along with the respective text.
– Rectify faults using fault table ⇒ Page 11.
– Afterwards erase fault memory ⇒ Page 10.
If there are no faults stored:

– Press Q key.

– Press keys 0 and 6 for function „End data transfer“ and
1 Features of self-diagnosis 9
1.4.2 Clear fault memory

Test prerequisite
◆ Fault eliminated
Note
After eliminating faults the fault memory must be read again as
follows and then cleared.
Procedure
– Connect ScanDi tool or Fault reader -VAS 5052- and select
engine electronics control unit with „address word“ 01. The
engine should be idling, for this.
Connect fault reader and select engine control unit ⇒ Page 7.
– Press keys 0 and 2 for function „Read fault memory“ and
– Press → key until all faults still stored have been displayed
and the display shows.
– Press keys 0 and 5 for function „Clear fault memory“ and
Indicated on display ▶ 05 Clear fault memory
Fault memory erased
– If the fault memory will not erase there is a fault still in the
system and this must be rectified.
– Press → key.
Indicated on display: ► No fault recognized
– Press → key.


3
2 Fault table
Note
◆ The fault table is listed in ascending order according to the

4-digit P-code.
◆ In the following tables, the 5-digit VAG fault code is also lis-
ted next to the 4-digit SAE P-code.
◆ Explanation of the fault types (e.g. open circuit / short circuit
to earth): ⇒ Fault reader operating instructions.
◆ If components are shown as faulty: First check the wiring
and connectors to these components as well as the system
earth connections referring to current flow diagram. Only
when no fault can be located here should the component be
renewed. This is particularly important if faults are indicated
as being sporadic.
◆ Erase fault memory after rectifying faults.
Output on ScanDi tool e.g.
◆ Fault number: P0118

◆ Coolant temperature sender -G62-
◆ Fault type: Sporadic, signal too high
Note
◆ Fault number: P0118 = P-code fault code

◆ Coolant temperature sender -G62- = faulty current path or
fault location
◆ Fault type: Sporadic = Fault that is not always present e.g.
loose contact
◆ Signal too high = Fault type as text
B0271…17083/P0699 ⇒ Page 11.

17428/P1020…18316/P1908 ⇒ Page 19.
18512/P2080...18727/P2295 ⇒ Page 25.
19463/P3007…19464/P3008 ⇒ Page 26.
2.1 B0271…17083/P0699
Output on ScanDi tool / Possible cause of Possible effects Fault remedy
VAS 5052 fault
xxxxx B0271 ◆ Max./Min. recovery ◆ Engine stalls – Erase fault and try
ECU occurred to start again
– Replace control unit
if fault appears
again
2 Fault table 11

VAS 5052 fault
xxxxx B0273 ◆ Max./Min. recovery ◆ Engine stalls – Erase fault and try
ECU occurred to start again
– Replace control unit
if fault appears
again
16496 P0112 ◆ -G42- defective ◆ Replacement value – Check wiring and
Intake air temperature sender ◆ Wiring defective 50 °C -G42- ⇒ Page 302
-G42- signal too low ◆ Possible formation of – Check central earth
smoke point / earth connec-
tions
Intake air temperature sender ◆ Wiring defective 50 °C -G42- ⇒ Page 302
-G42- signal too high ◆ Possible formation of – Check central earth
smoke point / earth connec-
tions
Coolant temperature sender 90 °C -G62- ⇒ Page 297
◆ Wiring defective
-G62- signal too low ◆ Poor cold starting – Check central earth
point / earth connec-
◆ „Knocking“ tions
Coolant temperature sender ◆ Wiring defective 90 °C -G62- ⇒ Page 297
-G62- signal too high ◆ Poor cold starting – Check central earth
◆ „Knocking“ tions
Fuel temperature sender 40 °C -G81- ⇒ Page 300
-G81- implausible signal ◆ Increased exhaust – Check central earth
emissions point / earth connec-
tions
-G81- short to earth ◆ Increased exhaust – Check central earth
emissions point / earth connec-
tions
-G81- open circuit / short to ◆ Increased exhaust – Check central earth
positive emissions point / earth connec-
tions

3
VAS 5052 fault
16575 P0191 ◆ -G247- defective ◆ Reduced perform- – Check wiring and
Fuel pressure sender -G247- ◆ Wiring defective ance -G247- ⇒ Page 306
signal voltage too low or too ◆ Exceeded max. fuel – Check central earth
high rail pressure of 1150 point / earth connec-
bar tions
◆ Exceeded min. fuel
rail pressure of 300
bar
short to earth ◆ Exceeded max. fuel – Check central earth
rail pressure of 1150 point / earth connec-
bar tions
bar
Oil temperature sender -G8- ance -G8- ⇒ Page 299
implausible signal ◆ Replacement value – Check central earth
140 °C point / earth connec-
tions
– Measure oil temper-
ature manually
signal too low ◆ Replacement value – Check central earth
tions
ature manually
signal too high ◆ Replacement value – Check central earth
tions
ature manually
16584 P0200 ◆ Wiring defective ◆ Reduced perform- – Check wiring of in-
Injectors ance jectors ⇒ Page 310
◆ One or more injec-
electrical fault in current cir- tors defective ◆ Lumpy engine (not
cuit running smoothly)
◆ Poor starting char-
acteristics
2 Fault table 13

VAS 5052 fault
16603 P0219 ◆ Reaches 5250 rpm
Maximum engine revs sur-
passed
static
16610 P0226 ◆ Signal voltage from ◆ Increased idling – Check EMMA (see
Throttle position sender EMMA for engine speed 1000 rpm note1))
-G79- and throttle position control unit implausi-
sender -2- -G185- (see ble
note1)) implausible signal ◆ Wiring defective
16618 P0234 ◆ Turbocharger defec- ◆ Charge pressure too – Check turbocharger
Charge pressure control tive high ⇒ Page 252
regulating limit surpassed ◆ Air in fuel system ◆ Reduced perform- – Check charge pres-
static ance sure control
⇒ Page 253.
◆ Fuel system leaking
Charge pressure control tive low ⇒ Page 252
regulating limit not achieved ◆ Leaks between tur- ◆ Reduced perform- – Check charge pres-
static bocharger and in- ance sure control
take manifold ⇒ Page 253.
(charge air routing)
◆ Air in fuel system
Charge pressure sender ance -G31- ⇒ Page 258
-G31- implausible signal ◆ Replacement value = – Check central earth
ambient pressure point / earth connec-
tions
-G31- signal too low ◆ Replacement value = – Check central earth
tions
-G31- signal too high ◆ Replacement value = – Check central earth
tions
16627 P0243 ◆ -N75- defective ◆ Reduced perform- – Check wiring and
Charge pressure control sol- ance -N75- ⇒ Page 253
enoid valve -N75- open cir- ◆ Charge pressure – Check central earth
cuit/ ◆ Vacuum line defec-
control is switched point/earth connec-
short to earth tive tions
off
– Check vacuum line

3
VAS 5052 fault
short to earth tive tions
off
short to positive tive tions
off
16645 P0261 ◆ -N30- defective ◆ Reduced perform- – Check wiring of in-
Injector, cylinder 1 -N30- ance jectors ⇒ Page 310
short to positive ◆ Lumpy engine (not – Check central earth
running smoothly) point / earth connec-
tions
short to earth ◆ Lumpy engine (not – Check central earth
tions
tions
tions
tions
tions
2 Fault table 15

VAS 5052 fault
tions
tions
tions
tions
tions
tions
tions
tions
tions

3
VAS 5052 fault
tions
16705 P0321 ◆ -G28- defective ◆ Engine will not start – Check wiring and
Engine speed sender -G28- -G28- ⇒ Page 295
◆ Wiring defective ◆ Engine stalls
implausible signal – Check central earth
static point / earth connec-
tions
Engine speed sender -G28- -G28- ⇒ Page 295
◆ Wiring defective ◆ Engine stalls
implausible signal – Check central earth
static point / earth connec-
tions
Camshaft position sensor ance -G40- ⇒ Page 304
sender -G40- implausible sig- ◆ Lumpy engine (not – Check central earth
nal running smoothly) point / earth connec-
static tions
◆ Engine starts using
test injection
16928 P0544 ◆ -G235- defective ◆ Replacement value: t – Check wiring and
Bank 1 exhaust temperature = G236 + 20 °C -G235- ⇒ Page 255
sender -1- -G235- electrical ◆ Replacement value: – Check central earth
fault 720 °C when -G235- point / earth connec-
static and -G236- defective tions
Bank 1 exhaust temperature = G236 + 20 °C -G235- ⇒ Page 255
sender -1- -G235- short to ◆ Replacement value: – Check central earth
earth 720 °C when -G235- point / earth connec-
static and -G236- defective tions
Bank 2 exhaust temperature = G236 - 20 °C -G236- ⇒ Page 257
sender -1- -G236- electrical ◆ Replacement value: – Check central earth
fault 720 °C when -G235- point / earth connec-
and -G236- defective tions
Bank 2 exhaust temperature = G236 - 20 °C -G236- ⇒ Page 257
sender -1- -G236- short to ◆ Replacement value: – Check central earth
earth 720 °C when -G235- point / earth connec-
and -G236- defective tions
16988 P0604 ◆ Control unit internal- ◆ Various running – Renew engine con-
Control unit defective ly defective problems including trol unit ⇒ Page 315
DPRAM fault engine will not start
2 Fault table 17

VAS 5052 fault
Control unit defective ly defective problems including trol unit ⇒ Page 315
analogue digital converter engine will not start
Control module implausible ly defective problems including trol unit ⇒ Page 315
engine will not start
17018 P0634 ◆ NPL excessive tem- ◆ Reduced perform- – Check engine room
Control unit - temperature perature in end ance temperature
switch-off stage of measuring – Renew engine con-
◆ Various running
unit trol unit ⇒ Page 315
problems including
17026 P0642 ◆ Terminal 15 or 30 ◆ Reduced perform- – Check voltage sup-
Sender reference voltage voltage supply de- ance ply for engine con-
„A“ of control unit too low fective trol unit ⇒ Page 293
◆ Increased idling
◆ Voltage supply in speed
engine control unit
defective
◆ Relay -J219- defec-
tive
„A“ of control unit too high fective trol unit ⇒ Page 293
engine control unit
defective
tive
„B“ of control unit too low fective trol unit ⇒ Page 293
engine control unit
defective
tive
„B“ of control unit too high fective trol unit ⇒ Page 293
engine control unit
defective
tive

3
VAS 5052 fault
„C“ of control unit too low fective trol unit ⇒ Page 293
engine control unit
defective
„C“ of control unit too high fective trol unit ⇒ Page 293
engine control unit
defective
1) G79 and G185 are not physically present and are emulated by the Electronic Marine Engine Adaption „EMMA“. The signals cre-
ated are passed directly to both engine control units (master and slave) to control the engine.
2.2 17428/P1020…18316/P1908
VAS 5052 fault
17428 P1020 ◆ Fuel pressure regu- ◆ Reduced perform- – Check wiring and
Fuel pressure regulation lating valve -N276- ance -N276- ⇒ Page 307
-N276- control limit exceeded defective – Check central earth
◆ Air in fuel system point / earth connec-
tions
17448 P1040 ◆ Wiring defective ◆ Reduced perform- – Check wiring / lines
Supply for injectors of bank 1 ◆ Solenoid valve fault ance ⇒ Page 310
of master control unit, electri- on all solenoids of ◆ Lumpy engine (not – Check central earth
cal fault in current circuit bank 1 for master running smoothly) point / earth connec-
control unit tions
of master control unit, electri- on all solenoids of ◆ Lumpy engine (not – Check central earth
cal fault in current circuit bank 2 for master running smoothly) point / earth connec-
short circuit control unit tions
of slave control unit, electri- on all solenoids of ◆ Lumpy engine (not – Check central earth
cal fault in current circuit bank 1 for slave running smoothly) point / earth connec-
control unit tions
of slave control unit, electri- on all solenoids of – Check central earth
cal fault in current circuit bank 2 for slave point / earth connec-
short circuit control unit tions
2 Fault table 19

VAS 5052 fault
17471 P1063 ◆ Air in fuel system ◆ Reduced perform- – Check wiring and
Fuel pressure regulation con- ◆ Fuel filter blocked ance -N276- ⇒ Page 307
trol difference -N276- + – Possibly renew high-
-N290- ◆ Fuel regulating valve pressure pump with
-N276- defective fuel metering valve
◆ Fuel metering valve -N290- ⇒ Page 286
-N290- defective – Check central earth
tions
– Check fuel system
⇒ Page 287
– Check fuel level
open circuit / short to positive ◆ Exceeded max. fuel – Check central earth
rail pressure of 1150 point / earth connec-
bar tions
bar
17602 P1194 ◆ -N276- defective ◆ Measuring unit – Check wiring and
Fuel pressure regulating closed -N276- ⇒ Page 307
valve -N276-Short to positive ◆ Engine stops – Check central earth
tions
Fuel pressure regulating ance -N276- ⇒ Page 307
valve -N276-Open circuit/ ◆ Engine stops – Check central earth
Short to earth point / earth connec-
tions
Injector, cylinder 1 -N30- ance -N30- ⇒ Page 310
electrical fault in current cir- ◆ Lumpy engine (not – Check central earth
cuit running smoothly) point / earth connec-
tions
tions
tions

3
VAS 5052 fault
tions
tions
tions
tions
tions
xxxxx P120A ◆ Injector ◆ Reduced perform- – Check connecting
Injector short circuit to earth ance wiring between in-
◆ Short to earth
or positive on master control jectors and master
◆ Lumpy engine (not
unit ◆ Short to battery control unit and/or
running smoothly)
electrical fault in current cir- check master control
cuit unit injector connec-
tions ⇒ Page 310
xxxxx P120B ◆ Injector ◆ Reduced perform- – Check connecting
Injector short circuit to earth ance wiring between in-
◆ Short to earth
or positive on slave control jectors and slave
unit ◆ Short to battery control unit and/or
running smoothly)
electrical fault in current cir- check slave control
cuit unit injector connec-
tions ⇒ Page 310
open circuit ◆ Lumpy engine (not – Check central earth
tions
2 Fault table 21

VAS 5052 fault
tions
tions
tions
tions
tions
tions
tions
16652 P1250 ◆ Fuel rail pressure ◆ Reduced perform- – Check fuel system
Fuel level too low regulation ance ⇒ Page 287
static ◆ Air in fuel system ◆ Lumpy engine (not – Check fuel level
running smoothly)
◆ Fuel level too low
◆ Engine will not start
17686 P1278 ◆ -N290- defective ◆ Reduced perform- – Possibly renew high-
Fuel metering valve -N290- ance pressure pump with
short to positive fuel metering valve
-N290- ⇒ Page 286

3
VAS 5052 fault
xxxxx P1281 ◆ -N290- defective ◆ Reduced perform- – Possibly renew high-
short to earth fuel metering valve
-N290- ⇒ Page 286
running smoothly)
17690 P1282 ◆ -N290- defective ◆ Reduced perform- – Possibly renew high-
open circuit fuel metering valve
-N290- ⇒ Page 286
running smoothly)
17795 P1387 ◆ Atmospheric pres- ◆ Replacement value – Renew engine con-
Control unit sure sensor in con- from charge pressure trol unit ⇒ Page 315
trol unit defective sensor when stopped
Charge pressure control tive high ⇒ Page 252
Regulating limit not reached ◆ Leaks between tur- ◆ Reduced perform- – Check charge pres-
bocharger and in- ance sure control
(charge air routing) – Check charge air
routing
Charge pressure control tive low ⇒ Page 252
Regulating limit surpassed ◆ Leaks between tur- ◆ Reduced perform- – Check charge pres-
bocharger and in- ance sure control
(charge air routing) – Check charge air
routing
17978 P1570 ◆ Attempted manipula- ◆ Engine starts briefly – Renew engine con-
Engine control unit blocked tion and then stops again trol unit ⇒ Page 315
◆ Incorrect control unit
18009 P1601 ◆ Terminal 30 voltage ◆ Engine will not start – Renew engine con-
Terminal 30 voltage supply supply relay -J317- trol unit ⇒ Page 315
◆ Various running
relay -J317- implausible sig- defective
problems including
nal engine will not start
18011 P1603 ◆ Internal control unit ◆ Engine will not start – Renew engine con-
Defective control unit communications mal- trol unit ⇒ Page 315
◆ Various running
functioning
problems including
xxxxx P160A ◆ Internal voltage ◆ Reduced perform- – Renew engine con-
Defective control unit monitoring engine ance trol unit ⇒ Page 315
control unit
◆ Various running
problems including
2 Fault table 23

VAS 5052 fault
xxxxx P160B ◆ NPL recovery occur- – Erase fault memory
Control unit has been reset red ⇒ Page 10
for internal reasons and reini-
tialised
18018 P1610 ◆ Control unit internal- ◆ Reduced perform- – Renew engine con-
Defective control unit ly defective ance trol unit ⇒ Page 315
◆ Fault in master con-
trol unit caused sys-
tem to switch off
18033 P1625 ◆ Neutral switch de- ◆ Engine will not start – Check wiring / lines
Communication between en- fective – Check central earth
◆ „Neutral“ in instru-
gine control unit and EMMA ◆ Line between engine ment flashes point / earth connec-
(1)) malfunctioning control unit and EM- tions
MA ( 1)) defective – Check EMMA ( 1))
– Check neutral switch
(1))
18034 P1626 ◆ Neutral switch de- ◆ Engine will not start – Check wiring / lines
Communication between en- fective – Check central earth
◆ „Neutral“ in instru-
gine control unit and EMMA ◆ Line between engine ment flashes point / earth connec-
(1)) malfunctioning control unit and EM- tions
MA ( 1)) defective – Check EMMA ( 1))
– Check neutral switch
(1))
18038 P1630 ◆ Signal voltage from ◆ Increased idling – Check EMMA ( 1))
Throttle position sender EMMA ( 1)) for en- speed 1000 rpm – Check wiring / lines
-G79- (1)) signal too low gine control unit im-
– Check central earth
plausible
◆ Wiring defective tions
18039 P1631 ◆ Signal voltage from ◆ Increased idling – Check EMMA ( 1))
Throttle position sender EMMA ( 1)) for en- speed 1000 rpm – Check wiring / lines
-G79- (1)) signal too high gine control unit im-
– Check central earth
plausible
◆ Wiring defective tions
18048 P1640 ◆ Control unit internal- ◆ Engine will not start – Renew engine con-
Defective control unit ly defective trol unit ⇒ Page 315
◆ Engine stalls
18055 P1647 ◆ Data differences be- ◆ Reduced perform- – Check coding in
Check drivetrain control unit tween master and ance control units
coding / variants slave

3
VAS 5052 fault
18315 P1907 ◆ Fault in internal CAN ◆ Reduced perform- – Check matching re-
Engine / engine data bus de- transfer ance sistor ⇒ Page 317
fective ◆ Potential difference ◆ No injection for injec- – Check central earth
between engines tors of slave control point / earth connec-
unit tions
◆ No charge air regula- – On twin engine sys-
tion tems - check earth
wire between both
engines
18316 P1908 ◆ Check limit differ- ◆ Reduced perform- – Check coding in
Engine/engine data bus soft- ence between mas- ance control units
ware version monitoring ter and slave
2.3 18512/P2080…18727/P2295
VAS 5052 fault
Exhaust temperature sender ◆ Wiring defective = G236 + 20 °C -G235- ⇒ Page 255
-1- -G235- implausible signal ◆ Replacement value:
720 °C when -G235-
and -G236- defective
Exhaust temperature sender ◆ Wiring defective = G236 - 20 °C -G236- ⇒ Page 257
-2- -G236- implausible signal ◆ Replacement value:
720 °C when -G235-
and -G236- defective
18584 P2152 ◆ Short circuit two or ◆ Reduced perform- – Check injector wiring
Injector(s) supply more injector wiring ance for short circuit
electrical fault ⇒ Page 310
running smoothly)
Fuel pressure regulating ance -N276- ⇒ Page 307
valve -N276-Short to earth – Check central earth
tions
2 Fault table 25
2.4 19463/P3007…19464/P3008
VAS 5052 fault
Camshaft position sensor -G40- ⇒ Page 304
-G40- no signal – Check central earth
tions
19464 P3008 -G40- defective ◆ Engine will not start – Check wiring and
Camshaft position sensor -G40- ⇒ Page 304
-G40- signal outside toler- – Check central earth
ance point / earth connec-
tions
Note
◆ G79 and G185 are not physically present and are emulated by the Electronic Marine Engine Adaption
„EMMA“. The signals created are passed directly to both engine control units (master and slave) to con-
trol the engine.
◆ Check function of control units of Electronic Marine Engine Adaption „EMMA“ using prescribed diagnosis
software. The details are located in the document for the function and diagnosis of the Electronic Marine
Engine Adaption "EMMA".
3 Final control diagnosis

3.1 Conduct final control diagnosis
Final control diagnosis activates the following components in
the given sequence:
Final control test number 0: Charge pressure control solenoid
valve -N75-
Final control test number 1: Fuel metering valve -N290-
Final control test number 2: Fuel pressure regulating valve
-N276-
Final control test number 3: Activation of service display (MIL)
Note
◆ Activation of individual control elements is limited to 60 s but

can be stopped at any time by pressing the → key.
◆ The ignition must be switched off before repeating the final
control diagnosis.

3
Procedure
– Connect ScanDi tool or -VAS 5052- and select engine elec-
tronics control unit with „address word“ 01. Engine should be
running at idling speed (connect fault reader and select en-
gine control unit ⇒ Page 7).
– Operate ScanDi tool taking into account the information on
the display:
– Press keys 0 and 3 for function „Final control diagnosis“.
Indicated on display: ► 01-Engine electronics C +/- Q

03 Final control diagnosis
– Confirm entry with Q key.
Indicated on display (ignore): ▶ 03-Control test - next? C +/- Q

Fault number: 01410 P0582 003
The first final control test (0) is activated automatically. As the
control of the turbocharger is not performed with electric actua-
tors at the vacuum unit ( -J724- AUTO), but by a PWM guided
solenoid valve ( -N75-), a fault code is created! According to ap-
plication the correct display is: Charge pressure control sole-
noid valve -N75-. The control of the charge pressure valve is
applied correctly and can be checked with the following display.
– Press → key.
Indicated on display (ignore): ▶ 03 Control test runs ->

12.3 V 0/min to
– Press → key.
Indicated on display: ► 03 Control test runs ->

12.3 U 0/min up
– Press → key.
Indicated on display: ► 03 Control test - next ->

Fuel metering valve
– Press → key.

0 rpm 303.6 bar 0.0 bar 35%
03 Control test runs ->

Both display values must change between 35% and 11% every 0 rpm 303.6 bar 0.0 bar 11%
4 seconds. The rod to change the position of the vane on the
turbocharger must move back and forth. If the displays do not
change and the rod does not move:
– Check rod for ease of movement.
– Press → key.
– Press C key.

Fuel pressure regulating valve
– Press → key.

0 rpm 303.6 bar 0.0 bar 0%
03 Control test runs ->

– Press → key.
0 rpm 303.6 bar 0.0 bar 40%
Both display values must change between 0% and 40% every 4

seconds.
3 Final control diagnosis 27


Request for fault lamp ON
Service display (MIL) in display of rev counter is activated.
Indicated on display: ► 03 Control test runs -> ->
12.2 V
– Press → key.

– Switch ignition off.
3.2 Adapting idling speed

The idling speed is set to 650 rpm in the factory and can only
be increased (not lowered).
The maximum idling speed possible is 1900 rpm.
Procedure

– Operate fault reader taking into account the information on
the display.
– Press keys 3 and 4 for the function Long adaption and
confirm input with Q key.
Indicated on display: ► 34- Long adaption
Enter channel number xx
– Press keys 0 and 6 for „channel 6“ and confirm entry with
Q key.
Indicated on display e.g.: ▶ Channel 06 Adaption 00000

660 rpm
– Press → key.
Indicated on display: ► Channel 06 Adaption 00000 +/- Q

Enter adaption value XXXXX
– Enter the required idling speed.
Example:
◆ Required idling speed 720 rpm

– Enter additive value 70.
– Press Q key.

3
Indicated on display: ► Channel 06 Adaption 00000 +/- Q
Enter adaption value 00070
If a non-acceptable adaption value was entered:
Indicated on display: ► VW Marine v1.71 C Q
Outside value range 0x3131
Note
The maximum possible value of 01250 = 1900 rpm is set.
– Press C key and repeat adaption.
– Press Q key.
Indicated on display: ► Channel 06 Adaption 00070 Q

Changed value stored
– Press Q key.
Indicated on display e.g.: ▶ 01-Engine electronics +/- Q

4 Measured value blocks

4.1 Safety precautions
Observe following if test and measuring instruments are re-
quired during a sea test:
◆ Test equipment must always be secured in the boat and op-

erated by a 2nd person.
4.2 Read data blocks

◆ ScanDi tool or -VAS 5052-
Test prerequisites
◆ Fuses must be OK.

◆ Earth connection OK.
◆ Coolant temperature must be at least 73 °C.
◆ All electrical consumers, such as, heater or refrigerator must
be switched off.
◆ No faults must be stored in fault memory ⇒ Page 9.
Procedure

– Press keys 0 and 8 for function „Read measured value
block“ and confirm entry with Q key.
4 Measured value blocks 29

Indicated on display: ► 08-Read measured value block +/- Q

Input display group number XXX
Note
The display group number 001 is an example to illustrate the
sequence.
– Press keys 0 , 0 and 1 for function „Display group number
1“.
Indicated on display: ► Display group 1 C+/-
1 2 3 4
(1…4 = Display zones)
– Press C key twice.

– Press keys 0 and 6 for function „End output“ and confirm
entry with Q key.
Note
To change to another display group proceed as follows:
Display group ScanDi tool

Higher Press key +
Lower Press key -
Skip Press C key
Evaluating measured value blocks with ignition ON

⇒ Page 30.
Evaluating measured value blocks at idling speed ⇒ Page 47.
Evaluating measured value blocks at full throttle ⇒ Page 68.
4.3 Evaluating measured value blocks with

ignition ON
4.3.1 Display group 100 -Quantity injected-
Indicated on display: ► Display group 100

rpm % mg/s bar
Display Operating condition or component Specification Evaluation

zones
1 Engine speed 0 rpm ---
2 Throttle position 0% ⇒ Page 31
3 Quantity injected 0 mg/stroke ---
4 High-pressure fuel pressure 0 bar. ---
Evaluation: Engine speed
Display on Possible cause of fault Fault remedy

ScanDi tool
/ / /

3
Evaluation: Throttle position

ScanDi tool
More than 0% ◆ EMMA has faults – Check EMMA1)
◆ Fault in wiring harness – Check wiring harness1)
◆ Fault in throttle lever – Throttle lever diagnosis EMMA1)
Evaluation: Quantity injected

ScanDi tool
/ / /
Evaluation: High-pressure fuel pressure

ScanDi tool
/ / /
4.3.2 Display group 101 -starting conditions-

rpm mg/s - V

zones
2 Starting quantity 0 mg/stroke ---
3 Starting synchronization 0…2 ⇒ Page 31
4 Battery voltage 11…15 V ⇒ Page 32

ScanDi tool
/ / /
Evaluation: Starting quantity

ScanDi tool
/ / /
Evaluation: Starting synchronization

ScanDi tool
When not 0 or 2 ◆ Speed sender defective – Check speed sender ⇒ Page 295
◆ Contact fault in wiring harness – Check wiring connections

Display „Start synchronization“

0 Basic initialisation of automatic synchronization
2 No synchronization, all sender systems are inactive / defective
3 No synchronization, engine revs too low or crankshaft angle sender system implausible
8 No synchronization, crankshaft angle sender system implausible
32 Crankshaft gap detection successful, system waits for actual position from crankshaft angle sender
33 Synchronization available, but has not been tested
34 No synchronization, position not finalised, restart automatic synchronization, too many re-synchroni-
zation cycles (terminal 15: ON/OFF)
38 No valid camshaft signal, synchronization via evaluation of revolution acceleration
48 Synchronization completed, crankshaft and camshaft signals are synchronized
Evaluation: Battery voltage

ScanDi tool
Less than 12 V ◆ Battery defective – Check battery
◆ Wiring connection defective – Check wiring connections
4.3.3 Display group 102 -Temperatures-

°C °C °C °C

zones
1 Fuel temperature 20…70 °C ⇒ Page 32
2 Oil temperature 20…120 °C ⇒ Page 32
3 Intake air temperature <50 °C ⇒ Page 33
4 Coolant temperature >65 °C ⇒ Page 33
Evaluation: Fuel temperature

ScanDi tool
When replacement ◆ Defective wiring connection or fuel – Check wiring and -G81- ⇒ Page 300
value 40 °C temperature sender -G81- – If a fault is present the measured value
block indicates a constant fuel temper-
ature of 40 °C
Evaluation: Oil temperature

ScanDi tool
When replacement ◆ Defective wiring connection or oil tem- – Check wiring and -G8- ⇒ Page 299
value 140 °C perature sender -G8- – If a fault is present the measured value
block indicates a constant oil tempera-
ture of 140 °C

3
Evaluation: Intake air temperature

ScanDi tool
When replacement ◆ Defective wiring connection or intake – Check wiring and -G42- ⇒ Page 302
value 50 °C manifold temperature sender -G42- – If a fault is present the measured value
Above 50 °C ◆ Raw water (seawater) through flow block indicates a constant intake mani-
too low fold temperature of 50 °C
– Check raw water (seawater) pump
◆ Charge air cooler dirty
– Clean charge air cooler
◆ Engine room temperature too high
– Vent engine room
Evaluation: Coolant temperature

ScanDi tool
Below 65 °C ◆ Coolant temperature outside range of – Bring engine to normal operating tem-
acceptable values perature
◆ Test requirements not fulfilled – Check wiring and -G62- ⇒ Page 297
– Observe test conditions
= 90 °C ◆ Coolant temperature replacement val- – Check wiring and -G62-
ue – If a fault is present the measured value
◆ Defective wiring connection or coolant block indicates a constant coolant tem-
temperature sender -G62- perature of 90 °C
Above 95 °C ◆ Coolant temperature too high – Clean coolant shell-and-tube heat ex-
changer
◆ Coolant shell-and-tube heat exchang-
er dirty
4.3.4 Display group 103 -Activation of common

rail injectors-

rpm °kW ms bar

zones
2 Activation of commencement of primary 0 °CA ---
injection
3 Activation period of primary injection 0 ms ---
4 High-pressure fuel pressure 0 bar. ---

ScanDi tool
/ / /

Evaluation: Activation of commencement of primary injection

ScanDi tool
/ / /
Evaluation: Activation period of primary injection

ScanDi tool
/ / /
Evaluation: High-pressure fuel pressure

ScanDi tool
/ / /
4.3.5 Display group 104 -Torque limit moments-

Nm Nm Nm Nm

zones
1 Actual torque from engine 0…10 Nm ⇒ Page 34
2 Torque limit moment 200…250 Nm ⇒ Page 34
3 Torque limit 200…250 Nm ⇒ Page 34
4 Smoke limit 200…300 Nm ⇒ Page 35
Evaluation: Actual torque from engine

ScanDi tool
/ / /
Evaluation: Torque limit moment

ScanDi tool
Less than 200 Nm ◆ Fault detected by engine control unit – Read fault memory ⇒ Page 9
Evaluation: Torque limit

ScanDi tool

3
Evaluation: Smoke limit

ScanDi tool
◆ Atmospheric pressure implausible
◆ Charge pressure sensor implausible
4.3.6 Display group 105 -Limiting factors-

- - - -

zones
1 Quantity limit correction factor 0,99…1,00 ⇒ Page 35
2 Exhaust temperature quantity limit factor 0,99…1,00 ⇒ Page 35
3 Oil temperature correction factor 0,99…1,00 ⇒ Page 35
4 Fuel temperature correction factor 0,99…1,00 ⇒ Page 36
Evaluation: Quantity limit correction factor

ScanDi tool
Below 0.99 ◆ Fault detected by engine control unit – Read fault memory ⇒ Page 9
◆ Torque limit moment active, see dis- – Display group 105 values 2/3/4
play group 105
Evaluation: Exhaust temperature quantity limit factor

ScanDi tool
◆ Exhaust temperature too high – Check wiring and -G235- ⇒ Page 255
◆ Exhaust temperature sender – Check wiring and -G236- ⇒ Page 257

-G235/G236- defective
Evaluation: Oil temperature correction factor

ScanDi tool
◆ Oil temperature too high – Check oil temperature sender -8-
⇒ Page 299
◆ Oil temperature sender -G8- defective

Evaluation: Fuel temperature correction factor

ScanDi tool
◆ Fuel temperature too high – Check oil temperature sender -81-
⇒ Page 300
◆ Fuel temperature sender -G81- defec-
tive
4.3.7 Display group 106 -Charge pressure con-

trol I-

mbar mbar mbar %

zones
1 Atmospheric pressure 900…1100 mbar ---
2 Charge pressure, specified value 900…1100 mbar ---
3 Charge pressure, actual value Display group 106/1 ⇒ Page 36
±50 mbar
4 Charge pressure actuator, activation 80 % ⇒ Page 36
Evaluation: Atmospheric pressure

ScanDi tool
/ / /
Evaluation: Charge pressure, specified value

ScanDi tool
/ / /
Evaluation: Charge pressure, actual value

ScanDi tool
Different display ◆ Charge air pressure sender -G31- im- – Read fault memory ⇒ Page 9
group 106 plausible – Check charge air pressure sender
value 1 ±50 mbar
◆ Charge air pressure sender -G31- de- -G31- ⇒ Page 258
fective
Evaluation: Charge pressure actuator, activation

ScanDi tool
Below 80% ◆ Charge air pressure sender -G31- de- – Read fault memory ⇒ Page 9
fective – Check charge air pressure sender
-G31- ⇒ Page 258

3
trol II-

rpm % Bit V

zones
2 Charge pressure actuator activation be- 101 % ⇒ Page 37
fore linearisation
3 Charge pressure regulation status 0000 0001 ⇒ Page 37

ScanDi tool
/ / /
Evaluation: Charge pressure actuator activation before linearisation

ScanDi tool
Below 80% ◆ Fault detected by engine control unit – Read fault memory ⇒ Page 9
– Check charge air pressure sender
-G31- ⇒ Page 258
Evaluation: Charge pressure regulation status

ScanDi tool
◆ 0000 0000 Charge pressure control/

regulation fault-free
◆ XXXX XXX1 Cold start regulation, off
◆ XXXX XX1X System switch-off re-

quest/system fault
→ ◆ XXXX X1XX Charge pressure control/
regulation, active, permanent regulat-
ing deviations occurred
◆ X1XX XXXX Control unit running in
emergency mode
Evaluation: Battery voltage

ScanDi tool
Battery voltage ◆ Battery defective – Check battery

4.3.9 Display group 108 -Exhaust temperature-

rpm - °C °C

zones
1 Engine speed ---
3 Exhaust temperature from EGT bank 1 -20…200 °C ⇒ Page 38
4 Exhaust temperature from EGT bank 2 -20…200 °C ⇒ Page 38

ScanDi tool
/ / /

ScanDi tool
See display group ◆ See display group 105 value 2 – See display group 105 value 2
105 value 2 ⇒ Page 35 ⇒ Page 35
⇒ Page 35
Evaluation: Exhaust temperature from EGT bank 1

ScanDi tool
More than 200 °C ◆ Exhaust temperature sensor implausi- – Read fault memory ⇒ Page 9
ble – Check wiring and -G235- ⇒ Page 255
◆ Exhaust temperature sensor defective

ScanDi tool
More than 200 °C ◆ Exhaust temperature sensor implausi- – Read fault memory ⇒ Page 9
ble – Check wiring and -G236- ⇒ Page 257
◆ Exhaust temperature sensor defective
4.3.10 Display group 109 -Fuel consumption-

rpm mg/s l/h %

zones

3
zones
3 Fuel consumption 0 l/h ---

ScanDi tool
/ / /

ScanDi tool
/ / /
Evaluation: Fuel consumption

ScanDi tool
/ / /

ScanDi tool
4.3.11 Display group 110 -Fuel rail pressure regu-

lation l-

rpm bar bar %

zones
2 High-pressure fuel pressure (specified) 0 bar. ---
3 High-pressure fuel pressure (actual fig- 0 bar. ---
ure)
4 Activation of fuel regulating valve for high- 0…10 % ---
pressure


ScanDi tool
/ / /
Evaluation: High-pressure fuel pressure (specified)

ScanDi tool
/ / /
Evaluation: High-pressure fuel pressure (actual figure)

ScanDi tool
/ / /
Evaluation: Activation of fuel regulating valve for high-pressure

ScanDi tool
/ / /

lation II-

rpm bar bar %

zones
2 High-pressure fuel pressure (specified) 0 bar. ---
ure)
4 Activation of fuel metering valve 10…20 % ---

ScanDi tool
/ / /

ScanDi tool
/ / /

3

ScanDi tool
/ / /
Evaluation: Activation of fuel metering regulation valve

ScanDi tool
/ / /

lation Ill-

rpm °C - °C

zones
3 Fuel rail pressure regulation, status 0 ⇒ Page 42

ScanDi tool
/ / /

ScanDi tool
= 40 °C Defective wiring connection or fuel tem- – Check wiring and -G81- ⇒ Page 300
perature sender -G81-
– If a fault is present the measured value
ature of 40 °C (ambient air tempera-
ture must also be read as reference)
– Conspicuous deviations signify a pos-
sible faulty sender value (40 °C)
– Check central earth point / earth con-
nections

Evaluation: Fuel rail pressure regulation, status

ScanDi tool
0 Control operation - Active initialisation or fault
1 Control operation - Start speed threshold exceeded
2 Regulating operation - Pressure regulation valve active, fuel rail pressure monitor
off
3 Regulating operation - Measuring unit active, fuel rail pressure monitor off
→ 4 Regulating operation - Pressure regulation valve active, normal operation, fuel rail
pressure monitor active
5 Regulating operation - Measuring unit active, normal operation, fuel rail pressure
monitor active
6 Regulating operation - Switch-over from fuel pressure regulating valve to measur-
ing unit, fuel rail pressure monitor off
7 Control operation - Rapid pressure reduction in fuel rail, engine is shut-down
8 Control operation - New initial initialisation, pre-control values
9 - 14 n.v.
15 Regulating operation - CPC (pressure regulating valve and measuring unit), fuel
rail pressure monitor PCV on, MeUn off
16 Regulating operation- Switch-over via pressure regulating valve after a regulating
operation, fuel rail pressure monitor min/max
17 Regulating operation - Switch-over after a CPC regulating operation, fuel rail
pressure monitor min/max
18 Regulating operation - Switch-over after a measuring unit regulating operation,
fuel rail pressure monitor min/max

ScanDi tool
= 90 °C ◆ Coolant temperature replacement val- – Check wiring and -G62- ⇒ Page 297
changer
er dirty
4.3.14 Display group 113 -Quantity injected, spec-

ification-

mg/s mg/s mg/s mg/s

3
zones
2 Quantity injected for primary injection, 0 mg/stroke ---
specification
3 Pilot injection 1 0 mg/stroke ---
quantity injected, specification
4 Pilot injection 2 0 mg/stroke ---

ScanDi tool
/ / /
Evaluation: Quantity injected for primary injection, specification

ScanDi tool
/ / /
Evaluation: Pilot injection 1, quantity injected, specification

ScanDi tool
/ / /

ScanDi tool
/ / /
4.3.15 Display group 114 -Activation period of pi-

lot injection 1-

mg/s mg/s ms bar

zones
1 Quantity injected (specified) 0 mg/stroke ---
2 Quantity injected (actual) 0 mg/stroke ---
3 Pilot injection 1 0 ms ---
activation period (actual)
ure)

Evaluation: Quantity injected (specified)

ScanDi tool
/ / /
Evaluation: Quantity injected (actual)

ScanDi tool
/ / /
Evaluation: Pilot injection 1 activation period (actual value)

ScanDi tool
/ / /

ScanDi tool
/ / /

lot injection 2-

mg/s mg/s ms bar

zones
1 Quantity injected (specified) 0 mg/stroke ---
2 Quantity injected (actual) 0 mg/stroke ---
ure)

ScanDi tool
/ / /

ScanDi tool
/ / /

3

ScanDi tool
/ / /

ScanDi tool
/ / /
4.3.17 Display group 116 -Injection coordinator-

mg/s - Bit Bit

zones
2 Permitted number of injections 3 ---
3 Switch-off request, injectors 0000 0100 ---
4 Number of fault entries 0000 0000…1111 1111 ---

ScanDi tool
/ / /
Evaluation: Permitted number of injections

ScanDi tool
/ / /
Evaluation: Switch-off request, injectors

ScanDi tool
/ / /
Evaluation: Number of fault entries

ScanDi tool
/ / /
4.3.18 Display group 117 -idling speed-

rpm rpm Bit %


zones
2 Idling speed, specification 640…660 rpm ---
3 Gear information 0000 0000 ---

ScanDi tool
/ / /
Evaluation: Idling speed, specification

ScanDi tool
/ / /
Evaluation: Gear information

ScanDi tool
→ 0000 0000 gear 0 active /
0000 0001 gear 1 active

ScanDi tool
◆ Fault in throttle lever – Throttle lever diagnosis1)
4.3.19 Display group 118 - Rotational speed regis-

tration-

rpm rpm rpm -

zones
2 Crankshaft speed 0 rpm ---
3 Camshaft speed 0 rpm ---
4 Starting synchronization 0…2 ⇒ Page 47

3

ScanDi tool
/ / /
Evaluation: Crankshaft speed

ScanDi tool
/ / /
Evaluation: Camshaft speed

ScanDi tool
/ / /

ScanDi tool
2 No synchronization, all crankshaft/camshaft sender systems are inactive/defective
→ 3 No synchronization, Engine speed too low or crankshaft sender system implausible
8 No synchronization, crankshaft sender system implausible
32 Crankshaft gap detection successful, system waiting for final position from cam-
shaft signal
33 Synchronization available, is still being tested
34 No synchronization, Position not finalised, restart of automatic synchronization,
too many resynchronization cycles (terminal 15: OFF/ON)
35 Synchronization available, rotational angle between crankshaft and camshaft too
high
38 No valid camshaft signal, synchronization performed via evaluation of accelera-
tion of engine revolutions
48 Synchronization completed, crankshaft and camshaft are synchronized
4.4 Evaluating measured value blocks at

idling speed (engine warm, coolant tem-
perature not below 73 °C)
4.4.1 Display group 100 -Quantity injected-

rpm % mg/s bar

zones
1 Engine speed 630…670 rpm1) ---
3 Quantity injected 3…5 mg/stroke ⇒ Page 48
4 High-pressure fuel pressure 280…350 bar ⇒ Page 48

1) All measurements at idling speed may only be carried out within a rev range of 630…670 rpm If an idling speed of 630 rpm is not
achieved or the max. permissible idling speed of 670 rpm is exceeded, the idling speed must be reset to the factory default of 650
rpm before the measured value blocks are evaluated. The idling speed cannot be reduced, only increased whereby the max. pos-
sible idling speed is 1900 rpm.
Evaluation: Engine speed display

ScanDi tool
/ / /
Evaluation: Throttle position display

ScanDi tool
Evaluation: Quantity injected display

ScanDi tool
Above 5 mg/stroke ◆ Engine too cold – Run engine at increased speed to
warm up and repeat check
◆ Engine strained due to consumers
– Switch consumers off
Evaluation: High-pressure fuel pressure display

ScanDi tool
Below 280 bar ◆ Air in fuel system
◆ Fuel or circulation filter blocked
◆ Fuel pressure regulating valve -N276-
defective
◆ Fuel metering valve -N290- defective
– Check wiring and -N276- ⇒ Page 307
◆ Defective fuel pressure sender -G247-
– Check wiring and -G247- ⇒ Page 306
◆ High-pressure system leaking
Over 350 bar ◆ Fuel pressure regulating valve -N276-
defective
◆ Engine too cold
4.4.2 Display group 101 -starting conditions-

rpm mg/s - V

3
zones
1 Engine speed 630…670 rpm1)
2 Starting quantity 19…22 mg/stroke ⇒ Page 49
3 Starting synchronization 48 ⇒ Page 49

ScanDi tool
/ / /
Evaluation: Starting quantity display

ScanDi tool
Larger than 22 mg/ ◆ Engine too cold – Check coolant temperature sender
stroke -G62- ⇒ Page 297
◆ Defective coolant temperature sender
-G62-
Evaluation: Start synchronization display

ScanDi tool
When 38 ◆ Voltage supply under 10 V – The battery is checked
– Check charging system
– Check wiring connections
– Check consumers
◆ Hall sender -G40 - defective – Check wiring and -G40- ⇒ Page 304
8 (not always) ◆ Voltage supply under 10 V – The battery is checked
– Check charging system
– Check wiring connections
– Check consumers
Defective engine speed sender -G28- – Check wiring and -G28- ⇒ Page 295

Evaluation: Battery voltage display

ScanDi tool
Less than 12 V ◆ Alternator defective – Check battery
◆ Battery defective – Check charging system
◆ Consumer current draw too high – Check consumers
Greater than 12 V ◆ Voltage regulator defective – Check regulator
4.4.3 Display group 102 -Temperatures-

°C °C °C °C

zones
2 Oil temperature 20…120 °C ⇒ Page 50
Evaluation: Fuel temperature display

ScanDi tool
ature of 40 °C
Evaluation: Oil temperature display

ScanDi tool
When replacement ◆ Defective wiring connection or oil tem- – Check wiring and -G8- ⇒ Page 299
value 140 °C perature sender -G8- – If a fault is present the measured value
ture of 140 °C

3
Evaluation: Intake air temperature display

ScanDi tool
block indicates a constant intake mani-
fold temperature of approx. 50 °C
Above 50 °C ◆ Raw water (seawater) through flow – Check raw water (seawater) pump
too low – Clean charge air cooler
◆ Charge air cooler dirty – Vent engine room
Evaluation: Coolant temperature display

ScanDi tool
◆ Test requirements not fulfilled – Check coolant temperature sender
-G62- ⇒ Page 297
= 90 °C ◆ Coolant temperature replacement val- – Check coolant temperature sender
ue -G62- ⇒ Page 297
◆ Defective wiring connection or coolant – If a fault is present the measured value
temperature sender -G62- block indicates a constant coolant tem-
perature of 90 °C
changer
er dirty
4.4.4 Display group 103 -Activation of common

rail injectors-

U/ °kW ms bar

zones
1 Engine speed 630…670 rpm1) ---
2 Activation of commencement of primary -5 … -3 °crank angle ⇒ Page 52
injection
3 Activation period of primary injection 0.35…0.45 ms ⇒ Page 52


ScanDi tool
/ / /
Evaluation: Commencement of primary injection display

ScanDi tool
Outside value ◆ Coolant temperature outside range of – Bring engine to normal operating tem-
range acceptable values perature
◆ Test requirements not fulfilled – Check coolant temperature sender
-G62- ⇒ Page 297
– The general prerequisites must be ful-
filled for the specified references (op-
erating temperature = min. 73 °C,
idling speed value range = 630…670
rpm)
Evaluation: Primary injection activation period display

ScanDi tool
Outside value ◆ Rail pressure implausible – Check rail pressure, display group
range 103, value 4
Evaluation: Primary injection, fuel pressure display

ScanDi tool
defective
◆ Fuel metering valve -N290- defective
Over 350 bar ◆ Fuel pressure regulating valve -N276- – Check central earth point / earth con-
defective nections
◆ Engine too cold
4.4.5 Display group 104 -Torque limit moments-

Nm Nm Nm Nm

3
zones

ScanDi tool
Above 80 Nm ◆ Engine too cold – Run engine at increased speed to
warm up and repeat check
Evaluation: Torque limit moment display

ScanDi tool
Evaluation: Torque limit display

ScanDi tool
Evaluation: Smoke limit display

ScanDi tool
◆ Read fault memory
◆ Atmospheric pressure implausible
◆ Charge pressure sensor implausible
4.4.6 Display group 105 -Limiting factors-

- - - -

zones

Evaluation: Quantity limit correction factor display

ScanDi tool
◆ Torque limit moment active, see dis- – Check display group 105, values 2/3/4
play group 105
Evaluation: Exhaust temperature quantity limit factor display

ScanDi tool
◆ Exhaust temperature too high – Check wiring and -G235- ⇒ Page 255
◆ Exhaust temperature sender – Check wiring and -G236- ⇒ Page 257

-G235/G236- defective
Evaluation: Oil temperature quantity limit factor display

ScanDi tool
◆ Oil temperature too high – Check oil temperature sender -G8-
⇒ Page 299
◆ Oil temperature sender defective
Evaluation: Fuel temperature quantity limit factor display

ScanDi tool
◆ Fuel temperature too high – Check fuel temperature sender -G81-
⇒ Page 300
tive

trol I-

mbar mbar mbar %

zones
2 Charge pressure, specified value 900…1150 mbar ---
3 Charge pressure, actual value 900…1150 mbar ⇒ Page 55
4 Charge pressure actuator, activation 25…32% ⇒ Page 55

3
Evaluation: Atmospheric pressure display

ScanDi tool
/ / /
Evaluation: Charge pressure, specified value display

ScanDi tool
/ / /
Evaluation: Charge pressure, actual value display

ScanDi tool
Less than 900 ◆ Charge pressure sensor implausible – Read fault memory ⇒ Page 9
mbar
Larger than 1150 ◆ Charge pressure sensor defective – Check charge pressure sensor
mbar
Evaluation: Charge pressure actuator, activation display

ScanDi tool
Over 32% / under ◆ Rods of guide vane on turbocharger – Check rods of guide vane on turbo-
25% are difficult to move/sticking charger for ease of movement
⇒ Page 253

trol II-

rpm % Bit V

zones
1 Engine speed 630…670 rpm ---
2 Charge pressure actuator activation be- 23…30 % ⇒ Page 56
fore linearisation

ScanDi tool
/ / /

Evaluation: Charge pressure actuator activation before linearisation display

ScanDi tool
Over 42% / under ◆ Rods of guide vane on turbocharger – Check rods of guide vane on turbo-
23% are difficult to move/sticking charger for ease of movement
⇒ Page 253
Evaluation: Charge pressure regulation status display

ScanDi tool
0000 0000 Charge pressure control /charge pressure control regulation fault-free
XXXX XXX1 Cold start, regulation off
XXXX XX1X Switch-off request / system fault
→
XXX X1XX Charge pressure control /charge pressure control regulation active, per-
manent regulation deviations have occurred
X1XX XXXX Control unit in emergency mode

ScanDi tool
◆ Consumer current draw too high – Check consumers
4.4.9 Display group 108 -Exhaust temperature-

rpm - °C °C

zones
3 Exhaust temperature from EGT bank 1 80…120 °C ⇒ Page 57

ScanDi tool
/ / /

3

ScanDi tool
105 value 2 ⇒ Page 35 ⇒ Page 35
⇒ Page 35

ScanDi tool
Display group 108 / Defective wiring connection or bank 1 ex- – Check wiring and -G235- ⇒ Page 255
3 (-G235-) haust temperature sender -G235-
+ 20 °C
nections
– When -G235- and -G236- are defec-
tive, a constant replacement value of
720 °C is used and displayed

ScanDi tool
- 20 °C
nections
4.4.10 Display group 109 -Fuel consumption-

rpm mg/s l/h %

zones
3 Fuel consumption 0.5…0.7 l/h ⇒ Page 58

ScanDi tool
/ / /


ScanDi tool
warm up, and repeat test

ScanDi tool
Above 0.7 l/h ◆ Engine too cold – Run engine at increased speed to

ScanDi tool

lation l-

rpm bar bar %

zones
2 High-pressure fuel pressure (specified) 290…320 bar ⇒ Page 59
3 High-pressure fuel pressure (actual fig- 280…350 bar ⇒ Page 59
ure)
4 Activation of fuel regulating valve for high- 15-25% ---
pressure

ScanDi tool
/ / /

3

ScanDi tool
Over 320 bar ◆ Engine too cold – Run engine at increased speed to

ScanDi tool
defective
◆ Fuel metering valve -N290- defective – Check wiring and -N276- ⇒ Page 307
nections
defective
◆ Engine too cold
Evaluation: High-pressure fuel pressure regulating valve

ScanDi tool
/ / /

lation II-

rpm bar bar %

zones
ure)
4 Activation of fuel metering valve 25-35% ⇒ Page 60

ScanDi tool
/ / /


ScanDi tool
Over 320 bar ◆ Engine too cold – Run engine at increased speed to

ScanDi tool
defective
nections
defective
◆ Engine too cold

ScanDi tool
Below 25 % ◆ Defective wiring connection or fuel – Check central earth point / earth con-
pressure regulating valve -N290- nections
– Possibly renew high-pressure pump
with fuel metering valve -N290-
⇒ Page 286

lation -Ill-

rpm °C - °C

zones

3

ScanDi tool
/ / /

ScanDi tool
– Conspicuous deviations signify a pos-
sible faulty sender value ⇒ 40 °C
nections

ScanDi tool
off
monitor active
9 - 14 n.v.


ScanDi tool
changer
er dirty
4.4.14 Display group 113 -Quantity injected, spec-

ification-

mg/s mg/s mg/s mg/s

zones
2 Quantity injected for primary injection, 3…5 mg/stroke ⇒ Page 62
specification
3 Pilot injection 1 1.85…2.15 ms ---
4 Pilot injection 2 280…350 bar ---

ScanDi tool

ScanDi tool

3

ScanDi tool
/ / /

ScanDi tool
/ / /

lot injection 1-

mg/s mg/s ms bar

zones
1 Quantity injected (specified) 2…6 mg/stroke ⇒ Page 63
2 Quantity injected (actual) 3…5 mg/stroke ⇒ Page 63
ure)

ScanDi tool

ScanDi tool

ScanDi tool
/ / /


ScanDi tool
defective
nections
defective
◆ Engine too cold

lot injection 2-

mg/s mg/s ms bar

zones
ure)

ScanDi tool

ScanDi tool

3

ScanDi tool
/ / /

ScanDi tool
defective
nections
defective
◆ Engine too cold
4.4.17 Display group 116 -Injection coordinator-

mg/s - Bit Bit

zones
3 Switch-off request, injectors 0000 0000 ⇒ Page 66
4 Number of fault entries 0000 0000…1111 1111 ⇒ Page 66

ScanDi tool
◆ Engine too cold – Run engine at increased speed to

Above 5 mg/stroke warm up, and repeat test
Display Possible cause of Fault remedy

on fault
ScanDi
tool
/ / //


ScanDi tool
> 0000 0000 ◆ Fault detected by engine control unit – Read fault memory ⇒ Page 9

ScanDi tool
> 0000 0000 ◆ Fault detected by engine control unit – Read fault memory ⇒ Page 9
4.4.18 Display group 117 -idling speed-

rpm rpm Bit %

zones
2 Idling speed, specification 640…660 rpm ⇒ Page 66
3 Gear information 0000 0000 ---

ScanDi tool
/ / /

ScanDi tool
> 660 rpm ◆ Fault detected by engine control unit – Read fault memory ⇒ Page 9
◆ Fault detected by EMMA – EMMA diagnosis 1)

ScanDi tool
→ 0000 0000 gear 0 active /

3

ScanDi tool
◆ Fault in throttle lever – Throttle lever diagnosis1)
4.4.19 Display group 118 - Rotational speed regis-

tration-

rpm rpm rpm -

zones
2 Crankshaft speed 630…670 rpm ---
3 Camshaft speed 315…335 rpm ---

ScanDi tool
/ / /

ScanDi tool
/ / /

ScanDi tool
/ / /


ScanDi tool
shaft signal
high
5 Evaluating measured value

blocks at full throttle (sea test
with warm engine, coolant tem-
perature not below 73 °C)
Note
◆ Gearbox and propeller design must be correct to archive the

nominal revolutions.
◆ When testing, accelerate the boat at full throttle.
◆ The measured values must be printed out or read (2nd per-
son required) when the revolutions reach specifications.
5.1 Display group 100 -Quantity injected-

rpm % mg/s bar

zones
2 Throttle position 100 % ⇒ Page 69

ScanDi tool
/ / /

3
Evaluation: Throttle position display

ScanDi tool
Less than 100% ◆ EMMA has faults – Check EMMA1)
Evaluation: Quantity injected display

ScanDi tool
Below 60 mg/H ◆ Oil temperature too high – Check wiring and oil temperature
sender -G8- ⇒ Page 299
◆ Exhaust temperature too high
◆ Coolant temperature too high
◆ Error: PWG not 100%
– Check coolant temperature/coolant
◆ Charge pressure is too low temperature sender ⇒ Page 297
– Check EMMA1)
– Check charge pressure control
⇒ Page 252.
Evaluation: High-pressure fuel pressure display

ScanDi tool
Below 1580 bar ◆ Air in fuel system – Bleeding fuel system
◆ Fuel or circulation filter blocked – Clean circulation filter
◆ Fuel pressure regulating valve -N276- – Renewing fuel filter

defective – Check wiring and -N276- ⇒ Page 307
◆ High-pressure system leaking – Check vacuum lines for leaks
Over 1650 bar ◆ Air in fuel system – Bleeding fuel system
◆ Fuel pressure regulating valve -N276- – Check wiring and -N276- ⇒ Page 307
defective
5.2 Display group 101 -starting conditions-

rpm mg/s - V

zones
2 Starting quantity 19…22 mg/stroke ---
5 Evaluating measured value blocks at full throttle (sea test with warm engine, coolant temperature 69
not below 73 °C)

zones
3 Starting synchronization 48 ---

ScanDi tool
/ / /
Evaluation: Starting quantity display

ScanDi tool
Value stored after engine start
Evaluation: Start synchronization display

ScanDi tool
/ / /

ScanDi tool
Less than 13V ◆ Alternator defective – Check battery
5.3 Display group 102 -Temperatures-

°C °C °C °C

zones
2 Oil temperature 80-140 °C ⇒ Page 71
Evaluation: Fuel temperature display

ScanDi tool
ature of 40 °C

3
Evaluation: Oil temperature display

ScanDi tool
When replacement ◆ Defective wiring connection or oil tem- – Check wiring and oil temperature
value 140 °C perature sender -G8- sender -G8- ⇒ Page 299
ture of 140 °C
Evaluation: Intake air temperature display

ScanDi tool
block indicates a constant intake mani-
fold temperature of approx.50 °C
Above 50 °C ◆ Raw water (seawater) through flow – Check raw water (seawater) pump
too low – Clean charge air cooler
◆ Charge air cooler dirty – Vent engine room
Evaluation: Coolant temperature display

ScanDi tool
changer
er dirty
5.4 Display group 103 -Activation of com-

mon rail injectors-
rpm °kW ms bar
not below 73 °C)

zones
2 Activation of commencement of primary -19 … -21 °crank angle ⇒ Page 72
injection
3 Activation period of primary injection 0.75…0.85 ms ⇒ Page 72

ScanDi tool
/ / /
Evaluation: Commencement of primary injection display

ScanDi tool
Outside value ◆ Coolant temperature outside range of – Bring engine to normal operating tem-
range acceptable values perature
– The general test prerequisites must be
fulfilled for the referencing of the speci-
fications. (operating temperature =
min. 73 °C, idling speed value range =
4150…4250 rpm)
Evaluation: Primary injection activation period display

ScanDi tool
Outside value ◆ Rail pressure implausible – Check rail pressure
range display group 103 / 4
Evaluation: Primary injection, fuel high-pressure display

ScanDi tool
defective
nections
Over 1650 bar ◆ Air in fuel system
defective

3
5.5 Display group 104 -Torque limit mo-
ments-
Nm Nm Nm Nm

zones

ScanDi tool
Above 690 Nm ◆ Oil temperature too high – Check wiring and oil temperature
Evaluation: Torque limit moment display

ScanDi tool
◆ Torque limit moment active – Check display group 105 ⇒ Page 74
◆ Revolutions not achieved
Evaluation: Torque limit display

ScanDi tool
◆ Torque limit moment active – Check display group 105 ⇒ Page 74
Evaluation: Smoke limit display

ScanDi tool
◆ Charge pressure is too low – Check charge pressure control
⇒ Page 252.
not below 73 °C)
5.6 Display group 105 -Limiting factors-

- - - -

zones
Evaluation: Quantity limit correction factor display

ScanDi tool
◆ Torque limit moment active – Check display group 105, values 2/3/4
Evaluation: Exhaust temperature quantity limit factor display

ScanDi tool
◆ Exhaust temperature too high – Check exhaust gas temperature send-
er -G235/G236-
◆ Exhaust temperature sender
-G235/G236- defective – Check exhaust gas back pressure
– Check coolant temperature
Evaluation: Oil temperature quantity limit factor display

ScanDi tool
◆ Oil temperature too high – Check wiring and oil temperature
◆ Oil temperature sender -G8- defective
– Check coolant temperature
Evaluation: Fuel temperature quantity limit factor display

ScanDi tool
◆ Fuel temperature too high – Check wiring and -G81- ⇒ Page 300

tive

3
5.7 Display group 106 -Charge pressure
control I-
mbar mbar mbar %

zones
2 Charge pressure, specified value 2450…2550 mbar ⇒ Page 75
3 Charge pressure, actual value 2450…2520 mbar ⇒ Page 75
4 Charge pressure actuator, activation 34…42 % ⇒ Page 75
Evaluation: Atmospheric pressure

ScanDi tool
/ / /
Evaluation: Charge pressure, specified value

ScanDi tool
Below 2450 ◆ Fault detected by engine control unit – Read fault memory ⇒ Page 9
◆ Limit active – Check display group 105 ⇒ Page 74
Evaluation: Charge pressure, actual value

ScanDi tool
Below 2450 mbar ◆ Turbocharger defective
◆ Leaks between turbocharger and in-
take manifold (charge air routing)
◆ Air in fuel system – Check charge pressure control
◆ Adjustment linkage etc. for VTG regu- ⇒ Page 252.
lation sticking/tight – -N75- Check. ⇒ Page 253
Over 2520 mbar ◆ Turbocharger defective – Bleeding fuel system

◆ Adjustment linkage etc. for VTG regu-
lation sticking/tight
Evaluation: Charge pressure actuator, activation

ScanDi tool
Above 42% ◆ Rods of guide vane on turbocharger
– -N75- Check. ⇒ Page 253
are difficult to move/sticking
– Renew air filter
◆ Air filter blocked
not below 73 °C)
5.8 Display group 107 -Charge pressure

control II-
rpm % Bit V

zones
2 Charge pressure actuator activation be- 42…52 % ⇒ Page 76
fore linearisation
4 Battery voltage 13…15 V ⇒ Page 76-

ScanDi tool
/ / /
Evaluation: Charge pressure actuator activation before linearisation

ScanDi tool
Above 52% ◆ Rods of guide vane on turbocharger – -N75- Check. ⇒ Page 253
are difficult to move/sticking – Renew air filter
◆ Air filter blocked
Evaluation: Charge pressure regulation status

ScanDi tool
◆ 0000 0000 Charge pressure control/

regulation fault-free
◆ XXXX XXX1 Cold start regulation, off
◆ XXXX XX1X System switch-off re-

quest/system fault
→ ◆ XXXX X1XX Charge pressure control/
regulation, active, permanent regulat-
ing deviations occurred
◆ X1XX XXXX Control unit running in
emergency mode

ScanDi tool

3
5.9 Display group 108 -Exhaust tempera-
ture-
rpm - °C °C

zones

ScanDi tool
/ / /

ScanDi tool
105 value 2 ⇒ Page 74

ScanDi tool
+ 20 °C
nections

ScanDi tool
- 20 °C
nections
not below 73 °C)
5.10 Display group 109 -Fuel consumption-

rpm mg/s l/h %

zones
3 Fuel consumption 0.5…0.7 l/h ⇒ Page 78

ScanDi tool
/ / /

ScanDi tool
◆ Charge pressure is too low
– Check EMMA1)
⇒ Page 252.

ScanDi tool
Below 72 l/h ◆ Oil temperature too high – Check wiring and oil temperature
– Check EMMA1)
⇒ Page 252.

3

ScanDi tool
5.11 Display group 110 -Fuel rail pressure

regulation l-
rpm bar bar %

zones
ure)
4 Activation of fuel regulating valve for high- 58-68% ---
pressure

ScanDi tool
/ / /

ScanDi tool
Below 1580 bar ◆ Oil temperature too high – Check wiring and oil temperature
– Check EMMA1)
not below 73 °C)

ScanDi tool
defective
nections
defective
Evaluation: High-pressure fuel pressure regulating valve

ScanDi tool
Over 68% / under ◆ Defective wiring connection or fuel – Check wiring and -N276- ⇒ Page 307
58% pressure regulating valve -N276- – Check central earth point / earth con-
◆ Air in fuel system nections

regulation II-
rpm bar bar %

zones
ure)
4 Activation of fuel metering valve 20-35% ⇒ Page 81

ScanDi tool
/ / /

3

ScanDi tool
Below 1580 bar ◆ Oil temperature too high – Check wiring and oil temperature
– Check EMMA1)

ScanDi tool
defective
nections
defective

ScanDi tool
Over 35% or under ◆ Defective wiring connection or fuel – Possibly renew high-pressure pump
20% pressure regulating valve -N290- with fuel metering valve -N290-
⇒ Page 286
◆ Fuel system leaking nections

regulation Ill-
rpm °C - °C

zones
not below 73 °C)

ScanDi tool
/ / /

ScanDi tool
⇒ Conspicuous deviations signify a pos-
sible faulty sender value ⇒ 40 °C
nections

ScanDi tool
off
monitor active
9 - 14 n.v.

3

ScanDi tool
changer
er dirty
5.14 Display group 113 -Quantities injected,

specification-
mg/s mg/s mg/s mg/s

zones
2 Quantity injected for primary injection, 1.2…1.7 mg/stroke ---
specification
3 Pilot injection 1 61…63 mg/stroke ⇒ Page 84
4 Pilot injection 2 60…65 mg/stroke ⇒ Page 84

ScanDi tool
not below 73 °C)

ScanDi tool
– Check EMMA1)
Evaluation: Pilot injection 1 quantity injected, specification

ScanDi tool
/ / /
Evaluation: Pilot injection 2 quantity injected, specification

ScanDi tool
/ / /
5.15 Display group 114 -Activation period of

pilot injection 1-
mg/s mg/s ms bar

zones
ure)

3

ScanDi tool
– Check EMMA1)
⇒ Page 252.

ScanDi tool
– Check EMMA1)
⇒ Page 252.

ScanDi tool
/ / /

ScanDi tool
defective
nections
defective
not below 73 °C)
5.16 Display group 115 -Activation period of

pilot injection 2-
mg/s mg/s ms bar

zones
ure)

ScanDi tool
– Check EMMA1)
⇒ Page 252.

ScanDi tool
– Check EMMA1)

ScanDi tool
/ / /

3

ScanDi tool
defective
nections
defective
5.17 Display group 116 -Injection coordina-

tor-
mg/s - Bit Bit

zones
3 Switch-off request, injectors 0000 0000 ⇒ Page 88
4 Number of fault entries 0000 0000…1111 1111 ⇒ Page 88

ScanDi tool
– Check EMMA1)

ScanDi tool
/ / /
not below 73 °C)

ScanDi tool
>0 ◆ Fault detected by engine control unit – Read fault memory ⇒ Page 9

ScanDi tool
>0 ◆ Fault detected by engine control unit – Read fault memory ⇒ Page 9
5.18 Display group 117 -idling speed-

rpm rpm Bit %

zones
2 Idling speed, specification 640…660 rpm ---
3 Gear information 0000 0000 ⇒ Page 88
4 Throttle position 100 % ⇒ Page 88

ScanDi tool
/ / /

ScanDi tool
/ / /

ScanDi tool
→ 0000 0000 gear 0 active /

ScanDi tool

3
5.19 Display group 118 - Rotational speed
registration-
rpm rpm rpm -

zones
2 Crankshaft speed 4150…4250 rpm ---
3 Camshaft speed 2075…2125 rpm ---

ScanDi tool
/ / /

ScanDi tool
/ / /

ScanDi tool
/ / /

ScanDi tool
shaft signal
high
not below 73 °C)
10 - Removing and installing engine
1 Removing and installing engine

◆ Engine and gearbox support -VAS 6095- with universal
mounting -VAS 6095/1- and bracket for V6 TDI engine
-VAS 6095/1-3-
◆ Workshop hoist -V.A.S 6100-

◆ Torque wrench (5…50 Nm) -V.A.G 1331-
◆ Torque wrench (40…200 Nm) -V.A.G 1332-
◆ Spring-type clip pliers -VAS 5024-
◆ Hose clamps -3093- or hose clamps -3094-
◆ Wiring harness key, large -T01906-
◆ Cable ties
1.1 Removing engine
WARNING
When doing any repair work, especially in the engine com-
partment, pay attention to the following due to the cramped
conditions:
◆ Install all lines (e.g. for fuel, coolant, vacuum) as well as
electric cables in such a way that the original routing is
restored.
◆ Ensure that there is sufficient clearance to all moving or
hot components.
Note
Before carrying out further work, disconnect battery earth strap.
– With the ignition switched off, disconnect battery earth strap.
90 Repair Group 10 - Removing and installing engine

3
– All cable ties which are opened or cut through when engine
is removed must be replaced in the same position when en-
gine is installed.
Note
◆ Before carrying out repair work, we recommend that the en-

gine be secured on the engine and gearbox support
-VAS 6095- using universal mounting -VAS 6095/1- and
brackets -6095/1-3- ⇒ Page 93.
◆ The subsequently described procedure for the removal and

installation of the engine may deviate slightly, depending on
the equipment of the boat.
◆ The engine oil must pumped out first before starting repairs
on the engine ⇒ Page 202.
◆ The engine can be removed out upwards, with or without the
gearbox, depending on the equipment of the boat.
◆ Use an appropiate engine crane when removing or installing

the engine.
The figure on the right shows an example for the removal of the
engine using an engine crane.
– Disconnect battery earth cable at engine earth connection -1

- next to flywheel cover.
1 Removing and installing engine 91

– Disconnect positive cable from battery main wiring harness -

battery -2- on starter motor -1-.
– Turn union nut -A- on multipin connection, below the central

electrics, in -direction of arrow- using wiring harness key
-T01905- and pull connector off forwards.
– Move wiring harness to side.
Note
◆ Before removing fuel supply line, clamp with hose clamp

-VAS 3094-.
◆ Observe environmental regulations for disposal.
WARNING
Before loosening fuel line connections, wrap a cloth
around the connection.
Then carefully pull off line and collect leaking fuel.
– Disconnect fuel supply line -1- on fuel filter -2-.

– Seal line so that fuel system is not contaminated by dirt.
– Disconnect fuel return line -1- at union -2- on high-pressure

accumulator (fuel rail) for cylinder bank 1.
– Seal union with a plug so that no dirt can enter the high-
pressure accumulator (fuel rail) for cylinder bank 1.
– Observe rules for cleanliness ⇒ Page 4.
– Close seawater shut-off valve (sea cock).

3
– Open drain plug -2- on heat exchanger approx. one turn and
drain seawater.
Note
◆ Do not completely remove the drain plug!

◆ If possible, slide a suitable hose over the drain plug union
and collect the seawater in a container.
– Loosen clamp -1- and pull coolant hose -2- off seawater
pump -3-.
– Collect escaping seawater.
Engine with connection for external heater

– On boats with an external warm water heater, mark both
connecting lines and disconnect from engine.
Continuation
– Open and close expansion tank cap to release pressure in
cooling system.
– Remove exhaust hoses from exhaust pipe unions.
– Unscrew assembly mountings/engine mountings from boat
hull.
– Unscrew nuts -arrow- on assembly mountings/engine
mountings for this.
– Pull off or disconnect all other necessary connection/unions
on engine.
– Carefully lift engine out of boat using an appropiate crane.
1.2 Securing engine on engine and gearbox

support
Before carrying out repair work, secure engine on assembly
stand with engine and gearbox support -VAS 6095/1- using uni-
versal mounting -VAS 6095/1-3- and bracket for V6 TDI engine
-VAS 6095-.

Procedure
– Secure engine to a workshop crane and lift engine slightly.
– Before removal of gearbox, disconnect hydraulic hoses and
seal unions against ingress of dirt.
Note
Before installing engine on engine and gearbox support
-VAS 6095-, remove all additional components on engine.
– Now disconnect gearbox.
– Remove exhaust manifold, with attachments, on both sides
of engine.
– Bolt bracket -VAS 6095/1-3- to cylinder block.
– Attach engine to universal mounting -VAS 6095/1-3- with
bracket -VAS 6095/1- as shown.
1.3 Installing engine

Note
◆ The tightening torques listed on this page apply only to light-

ly greased, oiled, phosphated, or black-finished nuts and
bolts.
◆ Additional lubricant such as engine or gearbox oil may be

used, but do not use graphite lubricant.
◆ Do not use de-greased parts.
◆ Tolerance for specified torques is ± 15%.
◆ Torque settings for assembly mountings ⇒ Page 96.
◆ Renew all bolts tightened with specified tightening angle.
◆ To secure torque converter on drive plate, use only new
bolts of the correct type (same as original equipment) as
specified in ⇒ Parts catalogue.
◆ Renew self-locking nuts and bolts when performing assem-
bly work.
◆ Renew bolts which are tightened to a specified angle as well
as oil seals and gaskets.
◆ Hose connections and hoses for charge air system must be
free of oil and grease before assembly.
◆ Secure all hose connections with the correct type of hose
clips (same as original equipment) ⇒ Parts catalogue.
◆ Fit all cable ties in the original position when installing.
Install in reverse order.

3
1.4 Securing gearbox bell housing to en-
gine (reverse gear gearbox)
– Secure gearbox bell housing to engine.
1 - Gearbox bell housing
2 - Hexagon head collar bolt M12x70 (qty 2) 40 Nm ± 10%
Note
Bolts are screwed into the intermediate housing from the back.
1 - Gearbox bell housing

3 - Multi-point socket head bolt M12x60 (qty 4) 60 Nm ± 10%
Note
Bolts are screwed into the intermediate housing from the front.

1.5 Assembly mountings
1.5.1 Assembly overview - assembly mountings
1 - M10 hexagon collared

nut
q 105 ± 5 Nm
2 - Washer
3 - Nut for adjustment of
height
4 - Assembly mounting
with base plate
q To secure base
plate to boat hull:
use bolts with a Ø of
min. 10 mm and
suitable washers.
5 - Left engine mounting
6 - Right engine mount-
ing
7 - M8 x12 hexagon head
collar bolt
8 - Gearbox support
9 - Gearbox
10 - Gearbox support

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3

Repair Group Technical Bulletins

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5.11 Display group 110 -Fuel rail pressure regulation l- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

1.3 Checking engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318

27 - Starter motor, alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322

48 - Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333

90 - Instrument panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338

97 - Central electrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349

1.2 Engine data

2 Health and Safety Precautions

◆ Maintenance work may only be undertaken when the engine

◆ Always use a torque wrench to tighten nuts / bolts etc. to

2 Repair Group 00 - Technical data

Observe the following points to prevent personal injuries

◆ The ignition must be switched off before connecting or dis-

When working on the battery note the following:

◆ Danger of destroying electronic components when dis-

2 Health and Safety Precautions 3

When working on the cooling system note the following:

3 General repair notes

◆ Carefully clean connection points and the surrounding area

4 Repair Group 00 - Technical data

3.2 Routing and securing lines

3.3 Checking for leaks in the fuel system

3.4 Contact corrosion

◆ We recommend using only genuine replacement parts;

3 General repair notes 5

1.1 Technical data of self-diagnosis

◆ Fault memory: Non-volatile and volatile memories1).

1.2 Selectable functions

6 Repair Group 01 - Self-diagnosis

1.3 Connecting the fault reader

◆ The battery voltage must be at least 11.5 V.

◆ If display remains blank, check voltage supply for diagnosis

Indicated on display: ► W-Marine v1.71

◆ 06V910401 = Part no. of control unit (for up-to-date control

Indicated on display: ► 01-Engine electronics +/- Q

Connecting VAS 5052

◆ The battery voltage must be at least 11.5 V.

Select vehicle system:

On the display, the control unit ID of the engine control unit is

8 Repair Group 01 - Self-diagnosis

◆ The display fields will be displayed from top to bottom in

1.4 Fault memory

1.4.1 Read fault memory

Indicated on display: ► 01-Engine electronics +/- Q

If there are no faults stored:

Indicated on display: ► 01-Engine electronics +/- Q

1.4.2 Clear fault memory

Indicated on display: ► No fault recognized

Indicated on display: ► 01-Engine electronics +/- Q

10 Repair Group 01 - Self-diagnosis

◆ The fault table is listed in ascending order according to the

◆ Fault number: P0118

◆ Fault number: P0118 = P-code fault code

B0271…17083/P0699 ⇒ Page 11.