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Volkswagen Marine TDI 100-5 User Manual

Volkswagen Marine TDI 100-5
84 pages
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Design and function
Self-study programme M001
Boat engines from
Volkswagen Marine
TDI 100-5
TDI 120-5
TDI 150-5
TDI 150-5D
SDI 55-5
SDI 75-5

Table of Contents

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Volkswagen Marine TDI 100-5 Specifications

General IconGeneral
Engine TypeDiesel
Number of Cylinders5
Displacement2.5 L
Power Output100 HP
Fuel SystemDirect injection
Engine ConfigurationInline
AspirationTurbocharged
Cooling SystemWater-cooled

Summary

Fundamentals

Features

Describes key characteristics of the boat engines, including quiet operation, low weight, and advanced electronics.

The SDI engine

Details the naturally aspirated diesel engines designed for displacement boats with direct injection.

Engine data SDI

Presents technical specifications and performance curves for the SDI engine models.

The TDI engine

Explains the turbocharged direct injection engines designed for various boat types.

Engine data TDI

Provides technical specifications and performance curves for the TDI engine models.

Engine mechanical systems

Engine oil circuit

Illustrates the system for circulating engine oil, including filter and extractor pump.

Cup-type oil filter

Describes the upright, easily serviceable cup-type oil filter and its function.

Electric oil extractor pump

Explains the electric pump for environmentally friendly engine oil changes.

Oil pan

Details the specially designed oil pan with baffle plates for stability in rough seas.

Crankcase ventilation with oil separator

Describes the system for cleaning crankcase air and preventing oil deposits.

Belt drives

Covers toothed belt drives for camshaft, coolant pump, and injection pump.

Ribbed V-belt drives for ancillary components

Details V-belt drives for alternator, power steering, and seawater pump.

Dual-mass flywheel

Explains the function of the dual-mass flywheel in reducing torsional vibrations.

Hydraulic bucket tappet

Describes the hydraulic tappets that reduce noise and simplify servicing.

Combustion system

The combustion system

Explains direct fuel injection into the combustion chamber and its advantages.

Intake swirl port

Details the intake port design that creates a swirling motion in the intake air.

Piston recess

Describes how the piston recess continues the swirling air motion for optimal combustion.

Injection nozzle

Covers the five-hole injection nozzle and its two-stage injection process.

Two-spring nozzle holder

Explains the two-spring nozzle holder for smooth, two-stage fuel injection.

Engine electronic systems

Overview of installation locations

Provides a general layout of the Marine Diesel Control (MDC) system components.

System overview

Shows how sensors supply information to the engine control unit for operating status.

Glow plug system

Details the integrated glow plug control system functions: preheating, post-heating, standby.

Intake manifold pressure and intake air temperature sender

Describes the sensor in the intake manifold measuring pressure and air temperature.

Needle lift sender

Explains the sender on the injection nozzle that signals the start of injection.

Modulating piston movement sender

Covers the sender that signals the position of the metering adjuster in the injection pump.

Engine speed sender

Describes the sensor that detects engine speed using the induction principle.

Coolant temperature sender

Explains the NTC sensor that provides engine temperature data to the control unit.

Fuel temperature sender

Details the sender measuring fuel temperature to adapt injection volume.

Throttle lever position sender

Covers the sender that informs the control unit of the throttle lever position.

Metering adjuster

Describes the electromagnetic actuator controlling injection volume in the distributor injection pump.

Start of injection valve

Explains the valve controlling the start of fuel injection based on pulse duty factor.

Fuel shut-off valve

Details the solenoid valve that interrupts fuel supply to shut down the engine.

Indicator lamp for glow plug system monitoring and engine electronics

Explains the self-diagnosis indicator lamp for malfunctions.

Fuel volume control

Describes how sensor signals determine injection volume and control the metering adjuster.

Start of injection control

Explains how the control unit determines correct fuel delivery timing.

Injection timing device

Details the mechanical device that adjusts injection timing based on fuel pressure.

Idle speed control

Covers how the control unit maintains a constant idle speed by adjusting the metering adjuster.

Smooth running control

Explains how injection volume per cylinder is controlled for uniform engine operation.

Maximum engine speed governing

Describes how injection volume is reduced to protect the engine at maximum speed.

Start volume control

Details how starting injection volume is determined based on coolant temperature.

Signal monitoring

Explains the self-monitoring of sensors and actuators with visual/acoustic warnings.

Function diagram

Presents a schematic diagram illustrating electrical system connections and components.

Fuel system

Fuel supply

Describes the system for supplying fuel from the tank to the injection pump.

Diesel fuel microfilter with water warning facility

Explains the filter for impurities and its water level warning system.

Circulation preliminary filter with water separator (optional)

Details the filter that separates water and particles from the fuel.

Emission characteristics

Emission characteristics

Discusses the importance of low environmental pollution and engine design.

Pollutants in exhaust gas

Identifies and describes common exhaust gases like CO, HC, soot, and NOx.

Reducing pollutants

Explains measures taken to reduce exhaust gas constituents like soot and HC.

Exhaust turbocharging

Fundamental principle of exhaust turbocharging

Explains how turbochargers increase engine torque and output by compressing intake air.

Turbocharger with variable turbine geometry

Details the turbocharger with variable guide vanes for optimal boost pressure.

Control of variable guide vanes

Describes how the pressure cell controls guide vane positions based on intake manifold pressure.

Guide vane adjustment

Explains the mechanism for adjusting guide vanes via a control linkage.

Cooling system

Introduction to cooling system

Explains the dual-circuit cooling system used in boats to transfer heat to seawater.

Overview of cooling circuit for SDI engines

Illustrates the cooling circuit design for SDI engines.

Seawater circuit

Describes the flow of seawater through the system for cooling the engine.

Small coolant circuit

Details the primary coolant circuit used during engine warm-up.

Large coolant circuit

Explains the primary coolant circuit used once the engine reaches operating temperature.

Overview of cooling circuit for TDI engines

Illustrates the cooling circuit design for TDI engines, including the intercooler.

Design of cooler assembly

Shows the layout of the intercooler, main heat exchanger, and expansion tank.

Intercooler (TDI 150-5/150-5D only)

Describes the intercooler that cools compressed charge air using seawater.

Main heat exchanger

Explains how heat is transferred from coolant to seawater.

Exhaust header

Details the exhaust header that is cooled by the coolant circuit.

Exhaust manifold

Describes how seawater is fed to the exhaust manifold for cooling.

Combined cooler

Explains the cooler that cools fuel, hydraulic oil, or gear oil.

Seawater pump

Details the pump driven by a V-belt that circulates seawater.

Sacrificial anode

Explains the anode in the heat exchanger that prevents corrosion.

Electrical system

Central electrics unit

Describes the unit housing the engine control unit, relays, and fuses.

Earth cutout relay

Explains the relay that temporarily connects the engine to earth for starting.

Multifunction display

Details the display showing operating hours, distance, fuel consumption, and speed.

Memory

Describes the automatic memory function of the multifunction display.

Displays/indicators

Covers information provided by the rev counter, voltmeter, and oil pressure gauge.

Self-diagnosis

Diagnosis

Explains the system diagnosis function for reading malfunctions from the fault code memory.

Function 01 – Check control unit version

Describes how to check the control unit identification.

Function 02 – Check fault code memory

Details how to check and read stored fault codes from the memory.

Function 03 – Actuator diagnosis

Explains how to check the functionality of engine actuators.

Function 04 – Basic setting

Covers the initiation of basic settings for the injection pump.

Function 05 – Delete fault code memory

Describes how to delete entries from the fault code memory.

Function 06 – End output

Explains how to end communication with the engine control unit.

Function 08 - Read measured value block

Details how to read engine operating data using the diagnosis system.

Examples of fault code memory entries

Illustrates common fault displays and their functional descriptions.

Monitored sensor, e.g. coolant temperature sender

Explains how sensors are monitored for plausible signal voltages.

Adaptation kits

Gearbox bell housings

Lists available gearbox bell housings for different drive systems.

Abbreviations

List of abbreviations used

Provides a comprehensive list of abbreviations and their meanings used in the manual.

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