Volkswagen SDI 1.9L 40 User Manual

© 2012 Mercury Marine
TDI 4.2L Diesel Inboard Models
*8M0070920*
90-8M0070920 812
Declaration of Conformity—Mercury Diesel Inboard (VW)
This inboard engine when installed in accordance to Mercury Marine’s instructions complies with the requirements of the
following directives by meeting the associated standards, as amended:
Recreational Craft Propulsion Engines with the Requirements of Directive 94/25/EC as amended by 2003/44/EC
Name of engine manufacturer: Volkswagen Antriebssysteme
Address: HMA‑E/1, PO 7962, Industriestraße Nord
Town: Salzgitter Post Code: 38231 Country: Germany
Name of Authorized Representative: Brunswick Marine in EMEA Inc.
Address: Parc Industriel de Petit‑Rechain
Town: Verviers Post Code: 4800 Country: Belgium
Name of Notified Body for exhaust emission assessment: International Marine Certification Institute (IMCI)
Address: Rue Abbé Cuypers 3
Town: Bruxelles Post Code: B‑1040 Country: Belgium ID Number: 0609
Conformity assessment module used for exhaust emissions:
☒ B+C ☐ B+D ☐ B+E ☐ B+F ☐ G ☐ H
Other Community Directives applied: Electromagnetic Compatibility Directive 2004/108/EC
Description of Engines and Essential Requirements
Engine Type:
Fuel Type: Combustion Cycle:
☒ Inboard engine ☒ Diesel ☒ 4 stroke
Identification of Engines Covered by this Declaration of Conformity
Name of engine model or engine family:
Unique engine identification number(s) or engine
family code(s)
EC Type–examination
certificate or type‑approval
certificate number
SDI 1.9L 40/50/60 SDI 40‑4/SDI 50‑4/SDI 60‑4 EXVWM001
SDI 2.5L 75 SDI 75‑5 EXVWM002
TDI 2.5L 100/120 TDI 100‑5/TDI 100‑5 SE EXVWM003
TDI 2.5L 140/150/165 TDI 150‑5/TDI 150‑5 D/TDI 165‑5 EXVWM004
R4 TD; TDI 1.9L 75 TDI 75‑4 EXVWM006
TDI 3.0L 225/230/265 TDI 225‑6/TDI 230‑6/TDI 265‑6 EXVWM007
TDI 4.2L 285/350 TDI 285‑8/TDI 350‑8 EXVWM008
Essential requirements
Standards
Other
normative
document/
method
Technical
file
Please specify in more detail
(* = mandatory standard)
Annex I.B – Exhaust Emissions
B.1 engine identification ☐ ☐ ☒
B.2 exhaust emission
requirements
☒* ☐ ☐ *EN ISO 8178‑1:1996
B.3 durability ☐ ☐ ☒
B.4 owner’s manual ☒ ☐ ☐ ISO 8665:1995
Annex I.C – Noise Emissions
see Declaration of Conformity of the craft in which the engine(s) has (have) been
installed

Volkswagen SDI 1.9L 40 Specifications

General

Fuel Type	Diesel
Fuel System	Direct injection
Turbocharged	No
Bore x Stroke	79.5 mm x 95.5 mm
Compression Ratio	19.5:1
Aspiration	Naturally aspirated
Displacement	1896 cc
Valvetrain	SOHC
Engine Type	Inline-4

Summary

Declaration of Conformity

Section 1 - Warranty

Warranty Registration Procedures

Procedures for registering the product and updating contact information.

Diesel Models Worldwide Limited Warranty

Details of the worldwide limited warranty for diesel models.

High-Output Recreational Warranty

Warranty terms for high-output recreational use.

Light-Duty Commercial Warranty

Warranty terms for light-duty commercial use.

3-Year Corrosion Warranty

Warranty against corrosion for diesel models.

Section 2 - Getting to Know Your Power Package

Lanyard Stop Switch Operation

Purpose and operation of the lanyard stop switch.

Section 3 - On The Water

Safe Boating Practices

General recommendations for safe boating and regulations.

Carbon Monoxide Poisoning Awareness

Hazards of carbon monoxide and prevention methods.

Engine Duty Cycle Ratings

Understanding engine duty cycles and ratings for applications.

Basic Boat Operation Procedures

Step-by-step procedures for basic boat operation and shutdown.

Cold Weather Operation Precautions

Precautions for operating the engine in cold weather.

Engine Starting, Shifting, and Stopping

Procedures for starting, shifting gears, and stopping the engine.

Safety with People in Water

Safety measures for people in or near the water.

Impact With Underwater Hazards

Precautions when encountering underwater hazards.

Propeller Selection Importance

Importance of correct propeller selection for performance.

Engine Break-In Procedures

Steps for properly breaking in the engine.

Section 4 - Specifications

Fuel Requirements and Handling

Antifreeze/Coolant Information

Engine Specifications

Engine Oil Specifications

Section 5 - Maintenance

Scheduled Maintenance Intervals

Engine Oil Maintenance

ZF Marine Transmission Fluid Service

Engine Coolant Service

Air Filter Maintenance

Fuel Filter Service

Maintenance of the water-separating fine element fuel filter.

Fuel Prefilter Service

Fuel System Purging

Seawater System Maintenance

Corrosion Protection Measures

Sacrificial Anode Inspection

Drive Belts Maintenance

Battery Handling and Precautions

Section 6 - Storage

Cold Weather or Extended Storage

Preparing for Storage

Recommissioning After Storage

Section 7 - Troubleshooting

Troubleshooting Charts

Charts to help diagnose common engine issues.

Engine Will Not Start Issues

Common causes and remedies for engine starting problems.

Fuel Supply Problems

Troubleshooting fuel supply issues like no fuel or faulty supply.

Excessive Engine Temperature

Diagnosing and fixing engine overheating issues.

Section 8 - Customer Assistance Information

Owner Service Assistance

Replacement Service Parts

Resolving Product Problems