OXE 30-0100-125 Service Manual Download Page 5

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OXE 150/200 HP SERVICE MANUAL

CONTENTS

CONTENT

Preface

________________________________________________________________________________ 3

Safety regulations

______________________________________________________________________11

Important!

_______________________________________________________________________ 11

Warning signs / levels of warnings

___________________________________________________ 11

Regulations for prevention of accidents with personal injury

_______________________________ 11

Regulations to prevent damage to engine and prevent wear

________________________________ 12

prevention of environmental damage

__________________________________________________ 13

Cleanliness

______________________________________________________________________ 14

Repetitive alerts

__________________________________________________________________ 16

Specifications

__________________________________________________________________________18

Engine mechanical specifications

_____________________________________________________ 18

Engine Threshold values

____________________________________________________________ 22

General tightening torques

__________________________________________________________ 23

Fastener tightening specifications

____________________________________________________ 24

Recommended fluids and grease

_____________________________________________________ 28

Tools and equipment

____________________________________________________________________29

Special tools

_____________________________________________________________________ 30

Engine component description

___________________________________________________________36

Outboard overviews

_____________________________________________________________________38

System and assembly overviews

__________________________________________________________40

Cooling system

___________________________________________________________________ 40

Engine lubrication system

__________________________________________________________ 41

Camshaft timing components

________________________________________________________ 42

Dry sump, filter, and tube

___________________________________________________________ 43

Cylinder head assembly

____________________________________________________________ 44

Engine block assembly

_____________________________________________________________ 46

Intake manifold

___________________________________________________________________ 48

Turbo charger assembly

____________________________________________________________ 49

Fuel system description

_________________________________________________________________50

Evacuating air from fuel system

______________________________________________________ 51

Transmission component description

_________________________________________________ 52

Hydraulic SYSTEM description

_______________________________________________________ 53

Repetitive instructions

___________________________________________________________________54

Replacing gaskets

_________________________________________________________________ 54

Remove and install the top cowling

___________________________________________________ 55

Summary of Contents for 30-0100-125

Page 1: ...SERVICE MANUAL 1 0 Publication No ODM1004 DIESEL ENGINE ...

Page 2: ...2 OXE 150 200 HP SERVICE MANUAL ...

Page 3: ...ne AB regulations Otherwise the manufacturer s liability for defects will not apply For basic information on the fuels see table Recommended Fluids and Grease Any repair of components such as injection pump alternator etc ought to be left to Cimco certified distributors or OEM service departments Best regards Cimco Marine AB Metallgatan 19a SE 262 72 Ängelholm Sweden 46 0 431 371130 info oxe diese...

Page 4: ...4 OXE 150 200 HP SERVICE MANUAL ...

Page 5: ...Special tools______________________________________________________________________ 30 Engine component description ____________________________________________________________36 Outboard overviews______________________________________________________________________38 System and assembly overviews___________________________________________________________40 Cooling system_________________________...

Page 6: ...removal_________________________________________________________________ 75 Glow plug installation_______________________________________________________________ 76 Draining and filling coolant________________________________________________________________77 Draining coolant___________________________________________________________________ 78 Filling coolant______________________________________...

Page 7: ...________________________________________________105 Alternator removal________________________________________________________________ 105 Alternator installation______________________________________________________________ 105 camshaft Timing belt replacement ________________________________________________________106 Water pump and crank shaft balancer removal___________________________________...

Page 8: ... removal___________________________________________________________ 144 Engine flywheel installation_________________________________________________________ 145 Crankshaft oil seal replacement___________________________________________________________146 Crankshaft oil seal removal_________________________________________________________ 146 Crankshaft oil seal installation_______________________...

Page 9: ...__________________________________________________ 190 Remove the propeller shaft bearing___________________________________________________ 190 Shims shaft sleeves and radial seals replacement in gearbox__________________________________192 800 h service_____________________________________________________________________ 192 Removing and installing the inner gearbox bearings_____________________...

Page 10: ..._________________________________ 218 Electrical system_______________________________________________________________________224 Electrical Components_____________________________________________________________ 224 Engine control unit ECU ___________________________________________________________ 226 wiring__________________________________________________________________________ 227 Maintenanc...

Page 11: ...rating procedures which must be complied with in order to avoid personal injury WARNING This refers to working and operating procedures which must be complied with in order to prevent damage to or destruction of material NOTE Explanatory descriptions which help in understanding the relevant work or operating procedure to be carried out REGULATIONS FOR PREVENTION OF ACCIDENTS WITH PERSONAL INJURY I...

Page 12: ... Clean the engine thoroughly prior to repairs Ensure that dirt sand or foreign matter will not enter the engine during repair work If engine operation is abnormally immediately Determine the cause of the disruption rectify the cause prior to restart in order to prevent further damage to the outboard Always use genuine OXE Diesel parts only Installation of equally good parts from other suppliers ma...

Page 13: ...ances that have caused skin cancer in tests on animals If the basic principles of work safety and hygiene are followed handling used engine oil does not represent a health hazard Precautionary measures to protect your health Avoid prolonged or repeated skin contact with used engine oil Protect your skin by means of suitable agents creams etc or wear protective gloves Clean skin which has been in c...

Page 14: ...intenance repair Avoid air movements any swirling of dust when starting engines The area of the still closed fuel system must be cleaned and dried with the aid of compressed air Remove detached particles of dirt such as paint chippings and insulation material with a suitable extractor industrial type vacuum cleaner Cover areas of the engine compartment from where dust particles could be detached w...

Page 15: ... side of the fuel system are to be closed immediately with suitable caps see special tools These caps stoppers must be packed protected from dust prior to use and to be disposed of after usage Following this all the components must be carefully stored in a clean closed container Never use used cleaning or testing liquids for these components New parts must not be removed from their original packin...

Page 16: ...here is no system pressure To relieve system pressure follow this procedure Turn the ignition key to IGN ACC Shift in gear a couple of times in order to release the hydraulic pressure Turn off ignition Cleaning solvent DANGER Bodily injury may occur if the cleaning solvent is inhaled or exposed to the skin Ensure proper ventilation Eye protection DANGER Approved safety glasses and gloves should be...

Page 17: ...rect location Replacement fasteners must be the correct part number for that application Do not use paints lubricants or corrosion inhibitors on fasteners or fastener joint surfaces unless specified These coatings affect fastener torque and joint clamping force and may damage the fastener Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to p...

Page 18: ...5 Nm 2500 RPM 306 lb ft 2500 RPM Fuel Diesel Dry weight 340 kg 2459 lb ft Wet weight 358 kg 2589 lb ft Alternator output 130 A Rig length 20 25 or 30 Cooling Closed cooling circuit Starting Electric Shift Electro hydraulic Clutch Hydraulic multi friction plate Gear ratios 1 73 1 or 2 17 1 Dimensions 25 leg LHW 1000 x 1880 x 680 mm 39 37 x 74 02 x 26 77 in Bore 90 0 mm 3 54 in Stroke 90 4 mm 3 56 i...

Page 19: ...1 831 1 837 mm 0 072 0 0723 in Main Bearing Shells Class B Code no 2 blue 1 836 1 844 mm 0 07228 0 0726 in Main Bearing Shells Class C Code no 3 yellow 1 843 1 849 mm 0 07256 0 07279 in Main Bearing Journal Undersize 0 127 mm 0 005 in Main Bearing Journal Diameter Class A Code no 1 brown 59 867 59 982 mm 2 3569 2 3614 in Main Bearing Journal Diameter Class B Code no 2 green 59 861 59 867 mm 2 3567...

Page 20: ...Cylinder Bore Diameter Oversize 0 1 mm 0 0039 in Compression Height 46 63 mm 1 84 in Connecting Rod Length 145 mm 5 7 in Engine Oil Viscosity Refer to Recommended fluids and grease Quality Refer to Recommended fluids and grease Oil Change Including Filter Refer to Recommended fluids and grease Oil Consumption Liter 1 000 engine hours max 0 9 Liter 3200km max 37 cu in 200 miles Standard Oil Pump Oi...

Page 21: ... mm 0 0236 0 0314 in Pin Piston Pin Clearance to Connecting Rod Bore Maximum 0 039 mm 0 0015 in Piston Piston Pin Clearance to Piston Pin Bore 0 005 0 015 mm 0 0002 0 0006 in Connecting Rod Connecting Rod Bearing Thickness Red 1 527 1 531 mm 0 06012 0 06028 in Connecting Rod Bearing Thickness Blue 1 530 1 534 mm 0 06024 0 06039 in Connecting Rod Bearing Thickness Yellow 1 533 1 537 mm 0 06035 0 06...

Page 22: ...90 Exhaust Gas Temp C 800 850 Engine Oil Pressure kPa abs 200 Engine Oil Temp C 130 140 Fuel Rail Pressure Mpa 185 Gearbox Oil Pressure High kPa abs 2400 2500 Gearbox Oil Pressure Low kPa abs 250 200 Manifold Air Pressure kPa abs 330 350 Manifold Air Temp C 60 80 Battery Voltage High V 14 7 15 Battery Voltage Low V 12 11 We reserve the right to change values without further notice ...

Page 23: ... 25 M16 180 132 75 220 162 25 M18 240 177 00 300 221 25 M20 350 258 13 440 324 50 M22 490 361 38 610 449 88 M24 600 442 501 760 560 51 Hexagon nuts and bolts with metric fine thread Thread metric Strength class 8 8 or 8 10 9 or 10 Tightening torque Nm lb ft Nm lb ft M8x1 21 15 49 27 19 91 M10x1 25 42 30 98 52 38 35 M12x1 25 77 56 79 96 70 80 M14x1 5 120 88 50 150 110 63 M16x1 5 190 140 13 240 177 ...

Page 24: ...r Bolt 9 Nm 80 lb in Exhaust Manifold Nut 25 Nm 18 lb ft Connecting Rod Bolt First Pass 25 Nm 18 lb ft Final Pass 60 degrees Coolant Outlet Bolt 9 Nm 80 lb in Crankshaft Balancer Bolt 25 Nm 18 lb ft Crankshaft Increment Wheel Bolts 12 Nm 106 lb in Crankshaft Rear Oil Seal Bolt 9 Nm 80 lb in Crankshaft Sprocket Bolt 340 Nm 251 lb ft Crankshaft Main Bearing Bolt Inner First Pass 25 Nm 18 lb ft Final...

Page 25: ...inder Head Torx T60 Bolts First Pass 20 Nm 1 15 lb ft 1 Second Pass 65 Nm 48 lb ft Third Pass 90 degrees Fourth Pass 90 degrees Final Pass 90 degrees Cylinder Head Core Hole Plug 15 Nm 11 lb ft Alternator Drive Belt Idler Pulley Bolt 22 Nm 16 lb ft Tensioner Bolt 22 Nm 16 lb ft Drive Belt Tensioner Fastener QtNm 2 22 Nm 16 lb ft Engine Flywheel Bolt 160 Nm 118 lb ft Engine Oil Pressure Switch 30 N...

Page 26: ...uel Feed Pipe Nut to High Pressure Pump 25 Nm 18 lb ft Glow Plug without Pressure Sensor 9 mm 10 Nm 89 lb in Generator Bolt 60 Nm 44 lb ft Generator Bracket Bolt Front 60 Nm 44 lb ft Generator Bracket Bolt Side 60 Nm 44 lb ft High Pressure Pump Drive Gear to High Pressure Pump M14x1 5 50 Nm 37 lb ft High Pressure Pump to High Pressure Pump Bracket 25 Nm 18 lb ft Intake Camshaft Sprocket Bolt First...

Page 27: ...Idler Pulley Bolt Upper 25 Nm 18 lb ft Idler Pulley Bolt Lower 50 Nm 37 lb ft Tensioner Bolt 25 Nm 18 lb ft Timing Belt Tensioner Bracket Bolt 25 Nm 18 lb ft Timing Belt Upper Front Cover Bolt 9 Nm 80 lb in Timing Belt Upper Front Cover Fastener 3 Nm 27 lb in Transmission Mount Bolt to Transmission First Pass 50 Nm 37 lb ft Second Pass 60 degrees Final Pass 15 degrees Turbocharger to Exhaust Manif...

Page 28: ... Dexron II 0 5 0 7 liters 0 52 0 73 quarts NOTE Only use fuels lubricants etc in accordance with Cimco Marine AB regulations or warranty will be void Diesel fuels The composition of the fuels is vital for operation of the OXE diesel engine its service life and emissions To meet the performance specified and to run the boat cleanly and quietly it is important that fuel as recommended in table Recom...

Page 29: ...n measuring tools are required for inspection of certain critical components Torque wrenches and a torque angle meter are necessary for the proper tightening of various fasteners To properly service the engine assembly the following items should be readily available Approved eye protection and safety gloves Clean well lit work area Suitable cleaning tank for parts Compressed air supply Trays or st...

Page 30: ... HP SERVICE MANUAL TOOLS AND EQUIPMENT SPECIAL TOOLS Illustration Tool Number Description 30 0160 014 ODT Puller 30 0160 015 ODT Extension 30 0160 016 ODT Crankshaft Fixing Tool 30 0160 017 ODT Camshaft Locking Tool ...

Page 31: ... TOOLS AND EQUIPMENT Illustration Tool Number Description 30 0160 018 ODT Camshaft Sprocket Holding Tool 30 0160 019 ODT Fuel Injection Pump Sprocket Holder 30 0160 020 ODT Remover Installer Glow Plugs 9 mm 30 0160 021 ODT Angle Meter ...

Page 32: ...SERVICE MANUAL TOOLS AND EQUIPMENT Illustration Tool Number Description 30 0160 023 ODT Fitting tool oil pump seal 30 0160 025 ODT Remover Oil Seal 30 0160 060 ODT Propshaft bearing fixing tool 30 0160 001 ODT Gauge bar ...

Page 33: ...P SERVICE MANUAL TOOLS AND EQUIPMENT Illustration Tool Number Description 30 0160 002 ODT Hooking tool 30 0160 003 ODT M6 Allen screw rounded tip 30 0160 004 ODT Sleeve removal tool 30 0160 005 ODT Sleeve seating tool ...

Page 34: ...50 200 HP SERVICE MANUAL TOOLS AND EQUIPMENT Illustration Tool Number Description 30 0160 006 ODT Seal forming tool 30 0160 008 ODT 50mm Nut removing tool 30 0160 009 ODT Bearing race driver 30 0160 010 ODT OBD ...

Page 35: ...MANUAL TOOLS AND EQUIPMENT Illustration Tool Number Description 30 0160 034 ODT Flywheel blocking tool 30 0160 110 Propeller shaft bearing remove mount tool 30 0160 112 50 mm nut removing tool 30 0160 118 Crankshaft fixing tool ...

Page 36: ...roller type and the valve bridges The camshaft sprocket wheel is installed in front of the camshaft Because of the cam follower of the hydraulic type it does not need to adjust for valve clearance The cylinder head is made of aluminium alloy for better strength in hardness with light weight The combustion chamber of plate type of the cylinder head is designed for increased squish and swirl efficie...

Page 37: ...that is created from exhaust gas that passes the turbocharger s exhaust turbine driving the induction side turbine increasing airflow to the engine thus increase the power A water cooled intercooler is used before compressed hot air enters the engine in order to lower the temperature of the induuce air for optimum power for the combustion process During normal engine operation water will flow thro...

Page 38: ...D OVERVIEWS Fig 1 Expansion tank Expansion tank filler cap Intercooler Exhaust pipe hose Belt housing Hydraulic oil pump and filter Transom mount Upper housing Lower housing Hydraulic oil cooler Heat exchanger Seawater strainer Turbo charger Air filter Gear box ...

Page 39: ...ig 2 Transom mount and tilt and trim cylinders Seawater pump Engine connector Engine oil dip stick Engine oil filter Anti cavitation plate Water intake Propeller axis Engine control unit ECU Alternator Battery connectors Fuel filter Engine oil filler cap ...

Page 40: ...YSTEM Fig 3 Schematic diagram of the cooling system 1 Seawater strainer 2 Seawater pump 3 Heat exchanger and hydraulic oil cooler 4 Intercooler 5 Exhaust pipe 6 Belt housing cooler 1 2 3 4 5 6 11 10 7 9 12 8 7 Engine water pump 8 Engine 9 Exhaust manifold 10 Thermostat 11 Expansion tank 12 Turbocharger ...

Page 41: ...l filter should become restricted Oil then enters the gallery where it is distributed to the crankshaft and camshafts The connecting rod bearings are oiled by constant oil flow passages through the crankshaft connecting and the main journals to the rod journals The pressurized oil passes through the cylinder head restrictor orifice into the cylinder head and then into each camshaft feed gallery Ca...

Page 42: ...Tensioner Bracket Spacer 8 Timing Belt Tensioner Bracket 9 Timing Belt Tensioner Special Screw 10 Timing Belt Idler Pulley 11 Timing Belt Idler Pulley Washer 12 Timing Belt Idler Pulley Bolt 13 Timing Belt Tensioner 14 Timing Belt Tensioner Bolt 15 Crankshaft Sprocket Wheel 16 Crankshaft Pulley 17 Crankshaft Pulley Stud 18 Timing Belt Cover Washer 19 Timing Belt Cover Bolt 20 Timing Belt Cover CAM...

Page 43: ...let Pipe 7 Turbocharger Oil Feed Pipe 8 Turbocharger Oil Feed Pipe Bolt 9 Turbocharger Oil Feed Pipe O Ring 10 Turbocharger Oil Return Pipe Bolt Engine Block 11 Turbocharger Oil Return Pipe O Ring 12 Turbocharger Oil Return Pipe 13 Turbocharger Oil Return Pipe Bolt Turbocharger 14 Turbocharger Oil Return Pipe Gasket 15 Oil Pan Baffle 16 Dry sump 17 Oil Pan Bolt 18 Oil Pan Baffle Bolt Fig 6 Dry sum...

Page 44: ...ition Sensor Bolt 5 Camshaft Cover Housing Bolt Medium 6 Camshaft Cover Housing Bolt Long 7 Oil Filler Cap 8 Oil Filler Cap Gasket 9 Camshaft Rear Cover 10 Camshaft Rear Cover Gasket 11 Camshaft Rear Cover Bolt 12 Camshaft Housing Gasket 13 Intake Camshaft Sprocket Wheel 14 Intake Camshaft Sprocket Wheel Bolt SYSTEM AND ASSEMBLY OVERVIEWS Fig 7 Cylinder head assembly ...

Page 45: ...0 Exhaust Valve 31 Intake Valve 32 Threaded Plug 33 Valve Guide 34 Valve Retainer 35 Valve Spring 36 Valve Retainer 37 Valve Stem Oil Seal 38 Roller Followers 39 Hydraulic Valve Lash Adjuster Intake Valve 40 Hydraulic Valve Lash Adjuster Exhaust Valve 41 Fuel Injector Bracket Stud 42 Intake Manifold Stud 43 Cylinder Head Bolt Washer 44 Cylinder Head Bolt 45 Exhaust Camshaft Gasket 46 Camshaft Spro...

Page 46: ...Retainer 4 Piston Pin 5 Connecting Rod 6 Connecting Rod Bolt 7 Plug 8 Crankshaft Rear Oil Gasket 9 Crankshaft Rear Oil Gasket Bolt 10 Water Passage Plug 11 Engine Flywheel Bolt 12 Centaflex CF R dual stage coupling 13 Centaflex Bolt 14 Engine Flywheel 15 Flywheel Dowel 16 Increment Wheel Bolt SYSTEM AND ASSEMBLY OVERVIEWS Fig 8 Engine block assembly ...

Page 47: ...l 18 Crankshaft Lower Bearing 19 Crankshaft Bearing Cap 20 Crankshaft Bearing Cap Bolt 21 Crankshaft 22 Crankshaft Upper Bearing 23 Piston Oil Nozzle Bolt 24 Piston Oil Nozzle 25 Plug 26 Engine Block 27 Water Passage Plug 28 Cylinder Head Locating Pin 29 Connecting Rod Bearing Caps ...

Page 48: ...E MANIFOLD Fig 9 Intake manifold 1 Intake Manifold Bolt 2 Intake Manifold 3 Manifold Temperature Pressure Sensor 4 Manifold Absolute Pressure Sensor Bolt 5 EGR plug retainer 6 Bolt 7 EGR plug 8 Actuating Drive SYSTEM AND ASSEMBLY OVERVIEWS ...

Page 49: ...MANUAL SYSTEM AND ASSEMBLY OVERVIEWS TURBO CHARGER ASSEMBLY Fig 10 Turbo charger assembly 1 Air filter 2 Turbo actuator 3 Turbo charger 4 Oil hose 5 Exhaust tube 6 Water pipe 7 Thermostat housing 8 Water cooled exhaust manifold ...

Page 50: ...er Not provided by Cimco Marine The 30 micron fuel filter is equipped with a water separator and installed after the fuel tank on the suction side of the fuel system between the fuel feed tank and the electric fuel feed pump External fuel pump The electric fuel feed pump is mounted outside the fuel tank and is operated by the engine s ECU An electric pump motor pushes fuel from fuel tank to the en...

Page 51: ...or provide the seal Integral locking tabs inside the female connector hold the fittings together Fuel pipe O rings O rings seal the connections in the fuel system Fuel system O ring seals are made of a special material Service the O rings seals with the correct service part EVACUATING AIR FROM FUEL SYSTEM NOTE In order for the diesel fuel system to work properly the fuel lines must be full of fuel...

Page 52: ...VICE MANUAL SYSTEM AND ASSEMBLY OVERVIEWS TRANSMISSION COMPONENT DESCRIPTION 1 2 3 4 5 6 1 Propeller shaft 2 Output shaft assembly 3 Input shaft assembly 4 Upper belt 5 Reverse gear assembly 6 Lower belt Fig 12 Transmission ...

Page 53: ...ches Accumulator Pump Filter Directional valve Pressure switch Pressure relief valve Heat exchanger Lubrication circuit Pressure relief for lubrication circuit T P P T 1 Pressure sensor 2 Accumulator 3 Proportional pressure relief valve 4 Directional valve 5 Hydraulic pump and filter Fig 13 Hydraulic system ...

Page 54: ...t material from a part Do not use abrasive pads sand paper or power tools to clean the gasket surfaces These methods of cleaning can cause damage to the component sealing surfaces Abrasive pads also produce a fine grit that the oil filter cannot remove from the oil This grit is abrasive and has been known to cause internal engine damage Assembling components When assembling components use only the...

Page 55: ...ng damage and work obstructions Before installing the top cowling check that the seal is not dry broken or worn as this will allow water to enter the engine Lower the cowling carefully into place NOTE Ensure that the hatches are folded outwards Close the hatches Make sure that the top cowling is securely closed and that there are no gaps A loose or improperly fitted cowling could allow water to en...

Page 56: ...witch off the battery main switch to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal DANGER Failure to follow these precautions may result in personal injury and or damage to the outboard or its components Battery GND Cable Control supply cable Common supply cable Main switch min 70 mm2 Power cables Engine max600 mm min 50 mm2 A B A1 B1 A2...

Page 57: ...ug or cap any fuel system openings in order to reduce fuel vapor formation Clean up any spilled fuel immediately Avoid sparks and any source of ignition Use signs to alert others in the work area that fuel system work is in process DANGER Place a dry chemical Class B fire extinguisher nearby before performing any on outboard service procedures Failure to follow these precautions may result in pers...

Page 58: ...ng in the fuel system Malfunctions can also occur due to very small dirt particles Prevent dirt from entering the fuel system by cleaning the hoses and plugging the pipes and lines upon removal Store the components so that contaminants cannot enter 1 Switch off the battery main switch Refer to Battery disconnect 2 Remove the upper timing cover bolts 1 ...

Page 59: ...CE MANUAL FUEL INJECTION PUMP REPLACEMENT FUEL INJECTION PUMP BRACKET REMOVAL 1 Remove the 6 fuel injection pump bracket bolts 1 3 4 2 Remove the fuel injection pump bracket 2 NOTE Have a cloth on hand to catch any fuel spill ...

Page 60: ...uel line 5 Plug the nozzle pipe NOTE Have a cloth on hand to catch any fuel spill NOTE When affixing the pulley use two hex socket head screws M6 X 40 30 mm unthreaded and 10 mm thread The screws must be tightened the whole length of the thread This way the pulley is prevented from moving out of position 4 Remove the pulley nut Turn the engine so it is possible to fit 2 Allen bolts 1 M6 x 40 30 mm...

Page 61: ...pressing the pump out with 30 0160 014 puller 1 Counterhold with a 30 mm wrench 2 Remove the puller 6 Remove the high pressure pump Remove the nuts and any washers 1 Use a magnet so as not to drop the washers Lift out the pump Pay attention to the wedge FUEL INJECTION PUMP REPLACEMENT ...

Page 62: ...tener 1 Install the wedge to the pump and put the pump in place Install any washers and nuts 1 It is important that the wedge fits into the groove on the pulley Tighten to 25 Nm 18 lb ft 2 Install the nut 2 to the high pressure pump pulley Tighten to 50 Nm 37 lb ft 3 Remove the bolts 1 holding the pulley in place ...

Page 63: ...ail fastener 5 Tighten to 19 Nm 14 lb ft If it is difficult to get the fuel pipe in place slacken the fuel rail retaining bolts slightly Tighten fuel pipe fastener 6 to high pressure pump to 25 Nm 18 lb ft Remove the plug and attach the fuel supply hose 1 and clamp to the pump Attach the fuel pressure sensor connector 3 to the pump NOTE Take note of the bolt locations 5 Attach the return fuel line...

Page 64: ...ECTION PUMP REPLACEMENT 6 Install the upper timing belt belt cover with 7 bolts 2 7 Switch on the battery main switch DANGER See Battery disconnect 8 To evacuate air from the fuel system see Bleed fuel system 9 Start the engine and turn it off ...

Page 65: ...l lines or filter CAUTION Risk of contamination of drinking water Dispose of the fuel water mixture according to local environmental legislation 2 Disconnect the fuel lines 1 by disconnecting the quickrelease fuel connectors 3 Remove bolts 3 and nuts 2 including washers Remove the fuel filter 4 from the bracket Fuel filter installation 1 Reinstall the new fuel filter in opposite order Tighten bolt...

Page 66: ...er Dispose of the fuel water mixture according to local environmental legislation 1 Apply a suitable container 2 in order to collect the fuel water mixture that drains from the fuel filter 2 Loosen the draining screw 1 and release the fuel water mixture into the container Tighten the draining screw 1 NOTE Also drain the fuel prefilter in boat Refer to Fuel System description ...

Page 67: ... to local environmental legislation 1 Apply a suitable container 3 in order to collect the fuel water mixture that drains from the fuel filter 2 Unscrew the fuel filter bowl 2 3 Remove the filter element 1 and discard according to Local environmental legislation 4 Insert a new filter element 1 and reinstall the fuel filter bowl Tighten by hand NOTE Also replace fuel prefilter element in boat Refer...

Page 68: ...nition or heat source is present Never drain or store diesel fuel in an open container due to the possibility of fire or explosion Have a dry chemical Class B fire extinguisher nearby DANGER Always wear safety goggles when working with fuel in order to protect the eyes from fuel splash 1 Switch off the battery main switch DANGER See Battery disconnect 2 Remove the 2 fuel feed pipe nuts 2 3 Remove ...

Page 69: ... TO RAIL 1 Install a new fuel feed pipe 3 Do not reuse 2 Install the 2 fuel feed pipe nuts 1 2 and hand tighten WARNING See Fastener 3 Tighten the fuel feed pipe nuts 1 2 Fuel feed pipe to fuel rail 4 nut 1 tighten to 19 Nm 14 lb ft Fuel feed pipe to fuel injection pump nut 2 tighten to 25 Nm 18 lb ft ...

Page 70: ...could occur if an ignition source is present Never drain or store diesel fuel in an open container due to the possibility of fire or explosion Have a dry chemical Class B fire extinguisher nearby 1 Switch off the battery main switch DANGER See Battery disconnect 2 Remove the 8 fuel injector fuel feed pipe nuts 1 2 3 Remove the 4 fuel injector fuel feed pipes 3 ...

Page 71: ...INJECTORS 1 Install 4 new fuel injector fuel feed pipes 3 Do not reuse WARNING See Fastener 2 Install the 8 fuel injector fuel feed pipe nuts 1 2 and hand tighten 3 Tighten the 4 fuel injector fuel feed pipe nuts 1 to 25 Nm 18 lb ft 4 Tighten the 4 fuel injector fuel feed pipe nuts 2 to 19 Nm 14 lb ft ...

Page 72: ...switch DANGER See Battery disconnect 2 Remove the fuel fuel feed pipes see Fuel injector fuel feed pipe replacement NOTE Place caps on the open fuel rail connectors to avoid contamination from dirt as soon as the fuel rail pipes are removed 3 Disconnect the fuel rail pressure sensor wiring harness plug 3 4 Remove the fuel rail bolts 1 5 Remove the fuel rail 2 3 ...

Page 73: ...EMBLY REPLACEMENT FUEL RAIL ASSEMBLY INSTALLATION 1 Install the fuel rail 1 WARNING See Fastener 2 Install the fuel rail bolts 2 and tighten to 25 Nm 18 lb ft 3 Connect the fuel rail pressure sensor wiring harness plug 3 4 Switch on the battery main switch 3 ...

Page 74: ...r See Repetitive Alerts WARNING Prepare for spillage have a clean cloth to collect any fuel nearby Ensure that no dirt enters the engine 1 Disconnect the fuel rail pressure sensor harness connector 2 Detach the fuel rail pressure sensor 3 Install a new fuel rail pressure sensor Tighten 70 Nm 52 lb ft 4 Connect the fuel rail pressure sensor harness connector ...

Page 75: ... 9 mm For equivalent regional tools see Special tools 1 Disconnect the electrical connector at each of the glow plugs 2 Clean around each of the glow plugs to avoid dirt from entering the engine WARNING Use care when disconnecting the glow plug electrical connector Use of excessive force may damage the electrical connector 3 Remove the glow plugs 1 ...

Page 76: ...E 150 200 HP SERVICE MANUAL GLOW PLUG REPLACEMENT GLOW PLUG INSTALLATION WARNING See Component fastener tightening NOTE Be sure that you not interchange the electrical connectors 1 Install the 4 glow plugs 1 ...

Page 77: ...77 OXE 150 200 HP SERVICE MANUAL DRAINING AND FILLING COOLANT DRAINING AND FILLING COOLANT 1 Filler cap 2 Coolant expansion tank 3 Drain adapter 4 Hose ...

Page 78: ...filler neck on expansion tank until fluid level has reached just 4 cm below the filling neck 3 Start the engine and let it run at a speed of 2 000 rpm for approx 15 minutes 4 Switch off engine carefully turn cap with safety valve to the first detent to relieve pressure and then carefully remove cap and top up with coolant DANGER Risk of scalding and burning yourself 5 Before the engine is next put...

Page 79: ...r pump 8 Engine 9 Exhaust manifold 10 Thermostat 11 Expansion tank 12 Turbocharger Check the system regularly Check hoses for fissures and damage Replace if necessary Check that the water intake is not blocked Clean if necessary Check the seawater filter Clean if necessary Check coolant level and mixture Fill up if necessary Check that the telltale is not blocked Check hydraulic oil cooler water o...

Page 80: ...tercooler retainer 3 3 Remove the pressure pipe assembly 4 Remove the turbo water outlet 4 5 Loosen screws 5 washers 6 and thermostat housing lid 7 6 Remove thermostat 8 and gasket 9 7 Install a new thermostat NOTE Install a new gasket 8 Reinstall the thermostat housing lid with 4 screws and washers Tighten to 9 Nm 14 lb ft 9 Fill up according to Filling coolant ...

Page 81: ...e all heat protection cover HEAT EXCHANGER REMOVAL 2 Drain the coolant Refer to Draining and filling coolant NOTE Dispose of coolant fluid according to local environmental legislation 3 Loosen nuts 3 on bracket 2 and remove the strainer by lifting it upwards 4 Bend the Seawater strainer 1 forward ...

Page 82: ... Remove the pressure pipe retainer 1 and the clamp 2 Refer to Thermostat replacement step 1 to 3 6 Remove the pressure pipe intercooler retainer 4 7 Remove the pressure pipe assembly 3 8 Remove clamp 5 and flex hose 6 9 Remove clamp 8 and exhaust hose assembly 7 ...

Page 83: ...the engine by plugging hydraulic oil hose connections 10 Remove the oil plug 2 and drain the hydraulic oil into a suitable container NOTE Dispose of hydraulic oil according to local environmental legislation 11 Remove the hoses 4 8 to and from the intercooler the hose from the seawater pump and the heat exchanger out hose Disconnect the quick release connectors 8 9 of the hydraulic oil hoses 12 Cu...

Page 84: ...ble container made of synthetic material 2 Fill container with undiluted genuine pickling liquid at room temperature until the heat exchanger is completely submerged 3 Allow pickling fluid to soak in for approx 10 hours If this period of time is not sufficient allow another 5 hours 4 The pickling period can be shortened by heating up the pickling fluid up to a maximum of 50 C and by moving heat ex...

Page 85: ... Reinstall all hoses and hose clamps 3 Reinstall the Seawater strainer 4 Reinstall the oil plug and tighten to 20 Nm 14 8 lb ft 5 Refill hydraulic oil according to Lower belt replacement Refill hydraulic oil 6 Refill coolant according to Draining and filling coolant HEAT EXCHANGER REPLACEMENT ...

Page 86: ...three water pump bolts 2 4 Remove the water pump 1 5 Remove the water pump gasket 3 FRESHWATER PUMP INSTALLATION 1 Install a new water pump gasket 3 2 Install the water pump 1 WARNING See Fastener 3 Install the 3 water pump bolts 2 and tighten to 25 Nm 18 lb ft 4 Fill up coolant refer to Draining and filling coolant 5 Reinstall the timing belt refer to Timing belt installation FRESHWATER PUMP REPL...

Page 87: ...87 OXE 150 200 HP SERVICE MANUAL ENGINE OIL AND OIL FILTER REPLACEMNET ENGINE OIL AND OIL FILTER REPLACEMENT ENGINE OIL AND OIL FILTER REMOVAL Change engine oil 1 Open the oil filler cap ...

Page 88: ...CAUTION Risk of contamination of drinking water Dispose of used oil according to local environmental legislation 4 Fit a new washer and tighten the oil draining plug to 9 Nm 6 6 ft lb 5 Place a suitable container below the oil filter NOTE Use a 6 point socket to remove the oil filter cap 6 Remove the oil filter cap 1 7 Remove and discard the oil filter cartridge ...

Page 89: ... 2 WARNING Very iomportant for appropriate sealing Place the seal ring into the correct grove marked with an arrow WARNING Proper oil filter cap tightening is mandatory Failure to tighten the oil filter cap to the proper specification can hinder later removal and cause possible oil filter cap damage NOTE Use an appropriate 6 point socket to remove the oil filter cap 2 Install the new oil filter ca...

Page 90: ...R See Battery Disconnect 2 Drain the coolant see Drain and fill coolant 3 Place a receptacle under the engine to collect oil and coolant 4 Undo the cable clip from the oil cooler 5 Unplug the connector of the oil pressure switch 6 Remove the engine oil cooler coolant outlet hose clamps 1 2 7 Remove the engine oil cooler coolant outlet hose 3 and the snap lock 4 8 Remove the oil filter cap refer to...

Page 91: ...nt inlet hose clamps 1 10 Remove the engine oil cooler coolant inlet hose 2 11 Remove the oil filter adapter and oil cooler assembly bolts 2 from engine block and place in a clean environment 12 Remove the oil filter adapter and oil cooler assembly 1 13 Remove and discard the oil filter adapter and oil cooler assembly gasket ...

Page 92: ...ter adapter and oil cooler assembly replacement 4 Install engine oil cooler coolant inlet hose and clamps 5 Install engine oil cooler coolant outlet hose clamps and the snap lock 6 Carry out cooling system pressure testing 7 Carry out filling and bleeding the cooling system refer to Filling Coolant 8 Fit the oil cooler using new seals greased with Vaseline 9 Check the oil level and top up if neces...

Page 93: ...haft fixing tool 30 0160 017 Camshaft holding tool 30 0160 023 Fitting tool oil pump seal Refer to Special Tools OIL PUMP REMOVAL 1 Remove the timing belt see Timing belt removal 2 Remove the dry sump see Oil pan baffle removal NOTE The bolt has a left hand thread 3 Remove the belt pulley using 30 0160 022 Holder 1 in combination with 30 0160 015 Extension 2 ...

Page 94: ...table tool without damaging the sealing surfaces 4 Remove the oil pump radial seal 8 5 Remove the eight oil pump bolts 9 Unscrew the stud from 30 0160 016 fixing tool 6 Remove the oil pump 1 7 Remove the oil pump gasket 2 8 Remove and discard the front radial seal 9 Clean the threads and all of the gasket surfaces ...

Page 95: ...l pump with a new gasket 1 2 Install the oil pump 2 WARNING See Fastener 3 Use locking agent Loctite on the 8 M6x20 oil pump bolts 3 and tighten to 9 Nm 80 lb in NOTE Moisten the gasket sealing lip with a little silicone grease white 4 Fit the oil pump seal using 30 0160 023 fitting tool 3 ...

Page 96: ... Fit the belt pulley using 30 0160 022 holder crankshaft 1 in combination with 30 0160 015 Extension 2 Tighten bolt to 380 Nm 280 lb ft NOTE The bolt has a left hand thread 6 Remove30 0160 022 holder 1 and EN 977 holding tool 2 7 Fit the dry sump See Dry sump and Oil pan baffle replacement ...

Page 97: ...ine oil at the oil filler neck refer to Outboard overview 2 After filling start the engine and let it run for a few minutes at low speed WARNING If no oil pressure builds up after approx 10 seconds switch off the engine immediately 3 Check oil pressure and leaks 4 Then shut down the engine After about 20 minutes check the oil level 5 The oil level should be between the two notches in the dipstick ...

Page 98: ...eparator drain hose 4 5 Remove the positive crankcase ventilation oil separator 3 6 Check hoses and clamps for wear or damage POSITIVE CRANKCASE VENTILATION OIL SEPARATOR INSTALLATION 1 Install the positive crankcase ventilation oil separator 3 2 Install the positive crankcase ventilation oil separator drain hose to oil pan 4 WARNING See Fastener 3 Install the positive crankcase ventilation oil se...

Page 99: ...urbocharger oil feed pipe bolts 1 2 Remove the 4 turbocharger oil feed pipe gaskets 3 Remove the turbocharger oil feed pipe 2 TURBOCHARGER OIL FEED PIPE INSTALLATION 1 Install the new turbocharger oil feed pipe gaskets 2 Install the turbocharger oil feed pipe 2 WARNING See Fastener 3 Install the 2 turbocharger oil feed pipe bolts 1 and tighten to 9 Nm 80 lb in ...

Page 100: ...arger oil return pipe 3 3 Remove the turbocharger oil return pipe gaskets TURBOCHARGER OIL RETURN PIPE INSTALLATION 1 Install the new turbocharger oil return pipe gaskets 2 Install the turbocharger oil return pipe 3 NOTE Ensure the correct direction of the spacer and gaskets Wide hole towards the turbocharger WARNING See Fastener 3 Install the 2 turbocharger oil return pipe bolts 2 and tighten to ...

Page 101: ...ATOR BELT REPLACEMENT ALTERNATOR BELT REPLACEMENT ALTERNATOR DRIVE BELT REMOVAL 1 Remove upper cowling 2 Switch off the battery main switch DANGER See Battery disconnect 3 Remove fuel hoses from fuel filter and pull the filter off the bracket ...

Page 102: ... SERVICE MANUAL 4 Loosen seawater hoses 2 from seawater pump 1 5 Unscrew the seawater pump bracket 3 6 Release the tension on the drive belt by rotating the tensioner pulley fastener clockwise ALTERNATOR BELT REPLACEMENT ...

Page 103: ...103 OXE 150 200 HP SERVICE MANUAL 7 Remove the alternator belt 8 Rotate tensioner pulley fastener clockwise to mount the belt 9 Install removed parts in reverse order ALTERNATOR BELT REPLACEMENT ...

Page 104: ...IONER REPLACEMENT 1 Remove the alternator drive belt See Alternator belt replacement WARNING See Fastener 2 Unscrew bolts 1 3 Lift off the alternator belt tensioner 2 4 Install in reverse order 5 Tighten 22 Nm 16 lb ft ALTERNATOR BELT TENSIONER REPLACEMENT ...

Page 105: ...bolts 1 3 Remove the alternator support 2 4 Remove the alternator bolt 4 5 Remove the alternator 3 ALTERNATOR INSTALLATION 1 Install the alternator 3 2 Install the alternator support 2 WARNING See Fastener 3 Install the alternator support bolt 4 and tighten to 60 Nm 44 lb ft 4 Install the alternator 5 Install the alternator bolts 1 and tighten to 60 Nm 44 lb ft 6 Install the alternator drive belt ...

Page 106: ...AFT TIMING BELT REPLACEMENT CAMSHAFT TIMING BELT REPLACEMENT WATER PUMP AND CRANK SHAFT BALANCER REMOVAL 1 Remove seawater pump nuts 1 2 Take off seawater pump 2 seawater pump drive flange 3 and sealing 4 3 Take off the crankshaft balancer 5 ...

Page 107: ...rotating it clockwise Lock the tensioner 5 in place by means of a mandrel 4 as it otherwise could clamp the timing belt lower front cover NOTE Check condition of timing belt for signs of damage to help determine the root cause of the failure The timing belt cannot be reused Avoid the contact with cooling fluid and oil it will damage the timing belt A damaged timing belt can not be reused CAMSHAFT ...

Page 108: ...k surface of the belt is cracked worn scratched scored Excessive cold starts Tensioner jamming Overheated engine Interference with the belt cover Side of belt surface is worn Improper installation of the belt Overload or misalignment of the cam drive components Tensioner jamming Heavy thrust loading against the idler guide flanges Damaged idler guide Teeth are worn Poor belt cover sealing Excessiv...

Page 109: ...ixing tool 30 0160 017 camshaft locking tool 30 0160 018 camshaft sprocket holding tool For equivalent regional tools see Special tools 1 Remove the timing belt front covers upper and lower see Timing belt front cover removal 2 Set cylinder one to TDC Remove the camshaft housing bolt 2 Install the 30 0160 017 locking tool 3 in the camshaft housing ...

Page 110: ... engages NOTE Observe the direction of timing belt rotation 2 3 Remove the bolt and install the fixing tool stud 3 4 Lock the crankshaft using the 30 0160 016 fixing tool 4 5 Loosen the timing belt tensioner bolt 1 to release tension from the timing belt 6 Remove the belt idler pulley bolt 2 and the idler pulley 3 7 Remove the timing belt 4 ...

Page 111: ...ence NOTE The marks on the timing belt must fit to the marks on the sprockets see arrows in picture NOTE The timing belt tensioner must be loose NOTE Make sure that the timing belt does not fall out of the sprocket during the installation procedure Start with the crankshaft sprocket 1 Second the timing belt tensioner 2 Third the water pump 3 Fourth the high pressure pump sprocket 4 Fifth the camsh...

Page 112: ...ry to turn the engine clockwise not in another direction 6 Rotate the engine 360 7 Check the engine timing 8 Lock the belt tensioner in place with a mandrel Refer to Timing belt removal 9 Mount at the same time the fuel filter bracket and the lower timing belt cover refer to Timing belt removal 10 Remove the mandrel from the belt tensioner 11 Reinstall the upper timing belt cover Cross tighten bol...

Page 113: ...REPLACEMENT LOWER 1 Remove the timing belt see Timing belt removal 2 Remove the timing belt idler pulley bolt 1 3 Remove the timing belt idler pulley 2 4 Install the new timing belt idler pulley 2 in reverse order WARNING See Fastener 5 Tighten the timing belt idler pulley bolt 2 to 50 Nm 37 lb ft ...

Page 114: ...ng any on outboard service procedures Failure to follow these precautions may result in personal injury WARNING Do not allow smoking or the use of open flames in the area where work on the fuel or EVAP system is taking place Anytime work is being done on the fuel system switch off the battery main switch except for those tests where battery voltage is required WARNING Fuel that flows out at high p...

Page 115: ...mshaft position sensor 2 Injectors 3 Fuel pressure control valve 4 Throttle body actuator unit 5 Intake air sensor 6 Glow plug connector 7 Coolant temperature sensor 8 NOTE If the injectors are to be refitted mark the injectors so that they can be refitted to the same cylinder 4 Fold away the engine wiring harness 5 Remove the fuel delivery pipe 2 between the pump and the fuel rail see Fuel inject...

Page 116: ...Remove the injectors 1 See Fuel injector fuel feed pipe replacement Refer to Fuel Injector Replacement 7 Remove the fuel rail and hose see Fuel injection fuel rail assembly replacement 8 Undo and remove the camshaft housing and guide sleeves Loosen bolts alternately in order as illustrated ...

Page 117: ...pect each camshaft cover for dents or damage to the exterior A dented or damaged camshaft cover may Leak engine oil Affect crankcase ventilation Interfere with the camshafts Interfere with the ignition coil sealing Allow water or condensation to enter the engine 2 Inspect the exterior of the camshaft cover for the following conditions Damage to the camshaft cover bolt holes 1 2 Damage to the camsh...

Page 118: ...MANUAL CAMSHAFT HOUSING REPLACEMENT CLEANING AND INSPECTION 3 Inspect the interior of the camshaft cover for the following conditions Inspect the camshaft cover bolt holes 3 4 Inspect the camshaft cover for cracks or damage 1 2 5 ...

Page 119: ... INSPECTION CAMSHAFT HOUSING INSTALLATION 1 Clean the cylinder head and camshaft housing sealing surfaces from any gasket residue 2 Fit the guide sleeves 1 and fit a new gasket onto the cylinder head 3 Check that all the rocker arms are positioned correctly on the valve stems ...

Page 120: ...ts in sequence 1 18 Make sure the guide sleeves are positioned correctly in the camshaft housing Tighten 25 Nm 18 lb ft 5 Fit the timing belt see Timing belt removal 6 Fit the fuel rail and hose see Fuel injection fuel rail assembly replacement 7 Fit the fuel delivery pipe between the pump and the fuel rail Tighten 25 Nm 18 lb ft ...

Page 121: ...back in place and fit the following connectors Camshaft position sensor 2 Injectors 3 Fuel pressure control valve 4 Throttle body actuator unit 5 Intake air sensor 6 Glow plug connector 7 Coolant temperature sensor 8 CAMSHAFT HOUSING REPLACEMENT CLEANING AND INSPECTION ...

Page 122: ... 1 Remove the camshaft housing see Camshaft housing replacement cleaning and inspection 2 Lubricate the rocker arm with engine oil Fit the rocker arms to the hydraulic valve tappets and the valves 3 Mark up the valve rocker arm covers position to ensure that the same position will be used when refitting ...

Page 123: ...ed the roller followers actuated by the camshaft must also be replaced VALVE LIFTER ROLLER REMOVAL 1 Remove the valve lifter roller from the hydraulic lash adjuster 1 2 Remove the valve lifter roller 2 VALVE LIFTER ROLLER INSTALLATION 1 Install the valve lifter roller 2 on the top of the valve stem and on the lash adjuster 1 2 Lubricate the roller followers 2 See Camshaft housing replacement clean...

Page 124: ...ee Special tools 1 Remove alternator belt see Alternator belt replacement 2 Remove timing belt see Timing belt removal 3 Install the 30 0160 018 holding tool 2 with 30 0160 015 extension 3 4 Remove the camshaft sprocket bolt 5 Remove the camshaft sprocket 1 WARNING See Fastener 6 Install the camshaft sprocket bolt and tighten to 130 Nm 96 lb ft CAMSHAFT SPROCKET REPLACEMENT ...

Page 125: ...MOVAL 1 Remove the 3 camshaft cover bolts 1 2 Remove the camshaft rear cover 2 3 Remove the camshaft rear cover gasket CAMSHAFT REAR COVER INSTALLATION 1 Install the camshaft rear cover gasket 2 Install the camshaft rear cover 2 WARNING See Fastener 3 Install the 3 camshaft rear cover bolts 1 and tighten to 9 Nm 80 lb in ...

Page 126: ...ENT 1 Timing Belt Sprocket Fastener 2 Timing Belt Sprocket 3 Camshaft Sprocket Fastener 4 Camshaft Sprocket 5 Camshaft Plug 6 Camshaft Sealing Ring 7 Camshaft Special tools 30 0160 021 angle meter EN 46789 camshaft fixing tool For equivalent regional tools see Special tools ...

Page 127: ...aft housing replacement cleaning and inspection 2 Install EN 4678 camshaft fixing tool 3 Install the EN 46789 fixing tool 4 Remove and discard the intake camshaft sprocket bolt 2 5 Remove the intake camshaft sprocket 1 6 Remove the EN 46789 fixing tool 7 Remove the intake camshaft plug 2 8 Remove the intake camshaft 1 ...

Page 128: ...MSHAFT INSTALLATION 1 Install the intake camshaft 1 2 Install the intake camshaft sealing ring 2 3 Remove the hole plug 3 4 Install the EN 46789 fixing tool 4 5 Turn the camshaft until the EN 46789 fixing tool audibly engages 6 Install the intake camshaft sprocket 1 ...

Page 129: ...olt 2 and tighten a first pass to 40 Nm 30 lb ft WARNING See Fastener 8 Tighten the new intake camshaft sprocket bolt a final pass to an additional 55 degrees using the 30 0160 021 meter 9 Remove the EN 46789 fixing tool 4 10 Install the hole plug 3 and tighten to 25 Nm 18 lb ft CAMSHAFT REPLACEMENT ...

Page 130: ...EXHAUST CAMSHAFT REMOVAL 1 Install the EN 46789 fixing tool 2 Remove the exhaust camshaft sprocket bolt 2 3 Remove the exhaust camshaft sprocket 1 4 Remove the EN 46789 fixing tool 5 Remove the exhaust camshaft sealing ring 1 6 Remove the exhaust camshaft 2 ...

Page 131: ...xhaust camshaft sealing ring 1 3 Install the EN 46789 fixing tool 4 Install the exhaust camshaft sprocket 1 WARNING See Fastener WARNING See Torque to yield fastener 5 Install the new exhaust camshaft sprocket bolt 2 and tighten in 2 passes First pass to 40 Nm 30 lb ft Second pass an additional 55 degrees using the 30 0160 021 meter ...

Page 132: ...N SENSOR REPLACEMENT 1 Remove the camshaft position sensor bolt 1 2 Remove the camshaft position sensor 2 3 Remove the camshaft position sensor O ring 4 Install the camshaft position sensor 2 WARNING See Fastener 5 Install the camshaft position sensor bolt 1 and tighten to 10 Nm 89 lb in ...

Page 133: ...ays wear safety goggles when working with fuel in order to protect the eyes from fuel splash 1 Remove the air filter See Check lower belt tension 2 Remove the timing belt See Timing belt removal 3 Remove the upper belt drive Refer to Upper belt assembly removal 4 Undo and remove the crankcase ventilation hose 1 from the oil trap and the bolts 2 holding the oil trap bracket and remove the cooling h...

Page 134: ... to the combustion circulation actuator 6 Remove the cable duct retaining screws 1 7 Remove the following connectors Camshaft position sensor 2 Injectors 3 Fuel pressure control valve 4 Throttle body actuator unit 5 Intake air sensor 6 Glow plug connector 7 Coolant temperature sensor 8 ...

Page 135: ...r 8 Remove the injectors see Fuel injection fuel rail assembly replacement Refer to Fuel Injector Replacement 9 Remove the fuel rail and hose see Fuel injection fuel rail assembly replacement 10 Remove the bolt 1 between the fuel pump bracket and cylinder head screw out the spacer bolt a few turns 11 Undo and remove the camshaft housing and guide sleeves Loosen bolts alternately in order as illust...

Page 136: ...d by undoing the bolts in the illustrated order 13 Carefully lift off the cylinder head NOTE Do not confuse the engine block guide sleeves with the camshaft guide sleeves 14 Remove the engine block guide sleeves 15 Remove the 10 cylinder head bolts as shown in sequence Discard the bolts ...

Page 137: ...l of the gasket surface is important not the appearance There will be indentations from the gasket left in the cylinder head after all of the gasket material is removed These small indentations will be filled in by the new gasket Use a new razor blade for each cylinder head and cylinder block NOTE Do not use a tap to clean the cylinder head bolt holes Hold the razor blade as parallel to the gasket...

Page 138: ...es NOTE Ensure that the cylinder head and the cylinder block sealing surfaces are clear of oil grease and old gasket material 2 Inspect the flatness of cylinder head and cylinder block sealing surfaces NOTE For the measurement the piston has to stay on TDC 3 Install the EN 301 measurement bridge 2 in compound with the GE 571 B dial 1 NOTE The largest measured piston overhang value is determining f...

Page 139: ...n choose cylinder head gasket without holes Piston overhang 0 231 mm 0 330 mm 0 0091 in 0 0130 in choose cylinder head gasket with one hole Piston overhang 0 331 mm 0 425 mm 0 0131 in 0 0167 in choose cylinder head gasket with two holes NOTE Do not use any sealing material 5 Install the new cylinder head to block gasket 2 at the engine block 3 6 Install the cylinder head CYLINDER HEAD REPLACEMENT ...

Page 140: ...1 meter Fourth pass in sequence to an additional 90 degrees using the 30 0160 0021 meter Fifth pass in sequence to an additional 90 degrees using the 30 0160 0021 meter NOTE The following tightening order applies to torx T60 cylinder head bolts First pass in sequence to 20 Nm 15 lb ft Second pass in sequence to 65 Nm 48 lb ft Third pass in sequence to an additional 90 degrees using the 30 0160 002...

Page 141: ...s are the most accessible 2 Mark the connecting rod and cap with the cylinder position Also mark their orientation This will ensure the caps and connecting rods are re assembled properly 3 Remove any ridge at the top of the cylinder bore to avoid damage to the piston ring lands 4 Remove the connecting rod bolts 2 5 Remove the connecting rod cap 1 6 Remove the connecting rod bearing 3 7 Remove the ...

Page 142: ...piston rings must not be reused NOTE Two retainers hold the piston pins in place Ensure that the piston pin is not damaged Do not reuse the retainers 2 Remove the piston pin retainers using the 30 0160 026 remover installer 3 Remove the piston pin 1 4 Disassemble the piston from the connecting rod 3 Piston and connecting rod assemble 1 Assemble the piston to the connecting rod 3 2 Install the pist...

Page 143: ...to compress the piston rings 3 Install the piston and connecting rod assembly 4 4 Install the connecting rod bearing 3 5 Install the connecting rod cap 1 WARNING See Fastener WARNING See Torque to yield fastener 6 Install the new connecting rod bolts 2 and tighten a first pass to 25 Nm 19 lb ft 7 Tighten the new connecting rod bolts 2 a final pass to an additional 60 degrees using the 30 0160 021 ...

Page 144: ...nt regional tools see Special tools 1 Install the 30 0160 034 flywheel blocking tool in order to hold the crankshaft 2 Remove the flexible coupling 2 6 bolts 3 WARNING The flexible coupling must not be diassembled If so it is important to reassemble it according to specification otherwise it will break and warranty void ENGINE FLYWHEEL REPLACEMENT ...

Page 145: ...t oil seal replacement ENGINE FLYWHEEL INSTALLATION 6 Install the engine flywheel 1 NOTE Clean the thread before inserting a new bolt with locking compound 7 Install the 6 new engine flywheel bolts 2 8 Install 30 0160 034 flywheel blocking tool locking tool 1 to fix the engine flywheel WARNING See Fastener WARNING See Torque to yield fastener 9 Tighten the 6 new engine flywheel bolts to 105 Nm 77 ...

Page 146: ...8251 installer oil seal For equivalent regional tools see Special tools CRANKSHAFT OIL SEAL REMOVAL WARNING See Engine flywheel replacement 1 Remove the 5 crankshaft rear oil seal bolts 2 2 Remove the crankshaft rear oil seal 1 NOTE Be careful do not damage the sealing surfaces 3 Use 30 0160 025 remover 1 to remove the crankshaft rear oil seal 2 ...

Page 147: ...ACEMENT CRANKSHAFT OIL SEAL INSTALLATION 1 Use the EN 48251 installer 2 to install a new crankshaft rear oil seal 1 2 Install the new crankshaft rear oil seal 1 WARNING See Fastener 3 Install the 5 crankshaft rear oil seal bolts 2 and tighten to 9 Nm 80 lb in ...

Page 148: ...hile monitoring the movement of the dial indicator 3 The crankshaft end play should not exceed specifications see Specifications 4 If the specifications are exceeded inspect the thrust bearing thrust OD and the crankshaft thrust wall for wear and or excessive runout see Specifications 5 Replace the thrust bearing or crankshaft as necessary WARNING See Crankshaft oil seal replacement CRANKSHAFT AND...

Page 149: ...kshaft in a secure place 6 Prepare a piece of cardboard or equivalent numbered 1 5 for bearing identification Main bearing journals are numbered from the front of the engine 7 Remove the 10 crankshaft bearing halves 4 from the cylinder block and the crankshaft Note the position of the thrust bearing 8 Place the 10 crankshaft bearing 4 on the cardboard in the correct positions 9 Remove the 3 increm...

Page 150: ...ial tools 1 Install the increment wheel 1 WARNING See Fastener 2 Install the 3 increment wheel bolts 2 and tighten to 12 Nm 106 lb in NOTE If the crankshaft bearings have been used in a running engine you must replace them with new crankshaft bearings for reassembly 3 Clean the crankcase crank bore with a lint free cloth 4 Clean all the oil from the backside of new bearing halves ...

Page 151: ... must fit flush with the upper crankcase 6 Using two hands install the crankshaft straight up to the engine block 7 Install the 5 crankshaft bearing caps 3 8 Install the 10 new crankshaft bearing cap bolts 1 2 WARNING See Torque to yield fastener 9 Tighten the 10 new crankshaft bearing cap bolts in sequence 1 10 in 2 passes First pass in sequence to 25 Nm 19 lb ft Second pass in sequence to an add...

Page 152: ...move the crankshaft see crankshaft and bearing replacement 2 Remove the 4 piston oil nozzle bolts 2 3 Remove the 4 piston oil nozzles 1 PISTON OIL NOZZLE INSTALLATION 1 Install the 4 piston oil nozzles 1 2 Install the 4 piston oil nozzle bolts 2 WARNING See Fastener 3 Tighten the 4 piston oil nozzle bolts 2 to 9 Nm 80 lb in ...

Page 153: ...VICE MANUAL INTAKE MANIFOLD REPLACEMENT INTAKE MANIFOLD REPLACEMENT INTAKE MANIFOLD REMOVAL 1 Remove the fuel pump See Fuel injection pump replacement 2 Unplug the intake air sensor connector 1 and the glow plug connector 2 ...

Page 154: ...ssure pipe clamp 3 and disconnect the hose 6 Remove the exhaust pressure pipe bracket bolts 4 7 Remove the exhaust pressure pipe from the engine 8 Remove coolant hose quick connection 5 9 Disconnect the upper hose connection 6 from the PCV oil separator 10 Remove the retaining clips 7 11 Remove the PCV oil separator retaining bolts 8 12 Remove the PCV oil separator from the engine block and move t...

Page 155: ... MANUAL INTAKE MANIFOLD REPLACEMENT 13 Unplug the connector 1 of the combustion circulation actuator 14 Remove the fuel injection pump bracket stud 1 holding the pump in place Lock two M8 nuts with each other and remove the bolt ...

Page 156: ...IFOLD REPLACEMENT 15 Remove the bolt towards the lifting eye 1 16 Remove the nine intake manifold nuts 2 17 Remove the four manifold gaskets 18 Remove the intake manifold WARNING Plug the intake passages so that no obstacles can enter the engine ...

Page 157: ...0 HP SERVICE MANUAL INTAKE MANIFOLD REPLACEMENT INTAKE MANIFOLD DISASSEMBLY 1 Remove the absolute pressure sensor bolt 4 2 Remove the absolute pressure sensor 3 from the intake manifold 3 3 Remove the the seal ring 1 ...

Page 158: ...d components are appropriately rated to handle the supplied pressure from the compressor Always use the lowest pressure that will do the job Always use a gun or similar device with an OSHA compliant pressure reducing nozzle if the pressure of your compressed air is greater than 29 psi When there is a risk for particulate exposure always wear goggles or a face shield over safety glasses to protect ...

Page 159: ... an air gun or direct air towards another individual or your skin Compressed air entering the bloodstream through a break in the skin or through a body opening can create an air bubble embolism a dangerous and potentially deadly medical condition Dangling hoses can present a trip hazard 4 Clean the passages 1 with compressed air 2 if necessary Use a maximum of 172 kPa 25 psi of air pressure 5 Repl...

Page 160: ...ings affect fastener torque and joint clamping force and may damage the fastener Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems When using fasteners that are threaded directly into plastic use extreme care not to strip the mating plastic part s Use hand tools only and do not use any kind of impact or power tools Fasten...

Page 161: ...nd tighten the fasteners 8 and tighten to 9 Nm 80 lb in 10 Connect the upper PCV oil separator hose connection 6 11 Install the retaining clips 7 12 Attach the coolant hose quick connection 5 13 Attach the engine control module wiring harness bracket fastener 1 and tighten to 9 Nm 80 lb in 14 Plug in the intake air sensor connector 1 and the glow plug connectors 2 15 Fit the fuel pump see Fuel inj...

Page 162: ... BAFFLE REMOVAL 1 Loosen 8 bolts 4 and remove the drysump 3 2 Remove the 4 oil pan baffle bolts 1 3 Remove the oil pan baffle 2 OIL PAN BAFFLE INSTALLATION 1 Install the oil pan baffle 2 WARNING See Fastener 2 Install the 4 oil pan baffle bolts 1 and tighten to 9 Nm 80 lb in 3 Reinstall the drysump 3 and tighten 8 bolts 4 ...

Page 163: ...OPELLER REMOVAL DANGER Do not use any body parts to hold the propeller when loosening or tightening the propeller nut 1 Place a wooden block between the anti cavitation plate and the propeller in order to prevent the propeller from moving PROPELLER REPLACEMENT ...

Page 164: ...1 Straighten the cotter pin 2 and pull it out using a pair of pliers 2 Remove the propeller nut 1 NOTE Some engines are equipped with a Nyloc lock nut 1 and do not have a cotter pin Never reuse a Nyloc locking nut PROPELLER REPLACEMENT ...

Page 165: ...RVICE MANUAL 3 Remove the propeller and thrust washer 4 Check the oil seals for leakage NOTE If the oil seal looks leaks is damaged or worn refer to Lower belt replacement No 16 for sealant replacement PROPELLER REPLACEMENT ...

Page 166: ... INSTALLATION NOTE A hub kit is recommended when installing a propeller 1 Replace the thrust washer the propeller and the nut 2 Fit a new cotter pin and secure or fit a new locking nut CAUTION Be sure to use a new cotter pin and bend the ends over securely Otherwise ...

Page 167: ...propeller washer and propeller on the propeller shaft NOTE Be sure to install the propeller washer before installing the propeller otherwise the lower case and propeller boss could be damaged NOTE Some outboards are equipped with a Nyloc locking nut 1 and do not have a cotter pin Do NOT reuse a Nyloc locking nut NOTE Some models use a retainer 1 and a castlelated nut 2 combined with a cotter pin 3...

Page 168: ...tter pin ends NOTE Do not reuse the cotter pin or Nyloc nut installed Otherwise the propeller can come off during operation NOTE If the propeller nut does not align with the propeller shaft hole after tightening to the specified torque tighten the nut further to align it with the hole Ensure that the propeller is undamaged and rotates freely of the lower housing NOTE Always have an extra propeller...

Page 169: ...P SERVICE MANUAL LOWER BELT REPLACEMENT LOWER BELT REPLACEMENT COWLING REMOVAL 1 Remove the top cowling Refer to Remove and install the top cowling 2 Remove the screws and washers of the back cowl 3 Remove the back cowl ...

Page 170: ...170 OXE 150 200 HP SERVICE MANUAL UPPER BELT HOUSING REMOVAL 4 Disconnect the cooling water hoses from the upper belt housing LOWER BELT REPLACEMENT ...

Page 171: ...00h service it is necessary to remove the hydraulic pump Refer to Hydraulic pump replacement 6 Remove the magnetic plug and washer Use an oil extractor and extract the hydraulic oil into a suitable container CAUTION Risk of contamination of drinking water Dispose of oil according to local environmental legislation 7 Remove the magnetic plug and O ring Drain any remaining gear oil into a suitable c...

Page 172: ...00 HP SERVICE MANUAL LOWER BELT REPLACEMENT DRAINING HYDRAULIC OIL IN LOWER HOUSING 8 Remove the magnetic plug and washer 1 9 Remove the magnetic plug and washer 2 Drain the lower belt oil into a suitable container ...

Page 173: ...R HOUSING DISASSEMBLY Special tools 30 0160 008 ODT 50mm Nut removing tool 30 0160 110 Propshaft bearing remove mount tool 1 Remove the propeller nut 1 using the 50 mm Nut removing tool 2 2 Remove the outer bearing using 2 the Propshaft bearing remove mount tool 1 3 Remove the propeller shaft spring washer 3 and propeller shaft spacer 4 4 Remove the belt pulley 5 NOTE The use of one or two M6 scre...

Page 174: ...GEARBOX DISASSEMBLING 1 Remove the gearbox shafts starting with the output shaft 3 2 Remove the port shaft 1 and the starboard input shaft 2 3 Make sure to cover the hole at the bottom of the gear case not to drop any tools or impurities into the belt housing ...

Page 175: ...nwards in an alternating fashion half a turn each time in order to keep a parallel motion out of the seat of the bearing 5 Check the O ring replace if damaged or worn 6 Remove shaving and foreign debris CAUTION Ensure to remove any material shavings in order not to enter the lower housing or remain in the gearbox 7 Lean the pulley downwards before removing it from belt and housing ...

Page 176: ... short nuts and washers Leave the 2 long bolts not to drop the lower housing 2 Remove the 2 long bolts and pull down the lower housing including belt and adapter plate Propeller shaft removal 1 Loosen the nose cone bolt and remove the nose cone LOWER BELT REPLACEMENT ...

Page 177: ... behind the nose cone until the bearing is released 3 Pull out the propeller shaft and bearing 12 Remove the divider plate Use a tool that fits into the holes in the upper end of the plate to pull it up 13 Pull up the lower belt LOWER BELT REPLACEMENT ...

Page 178: ...OXE 150 200 HP SERVICE MANUAL LOWER BELT REPLACEMENT LOWER BELT INSTALLATION 1 3 2 3 2 1 Install a new anode 1 2 Clean oil plugs 2 Fit new washers 3 and install Tighten to 9 Nm 6 63 lb ft 3 Fit new O rings ...

Page 179: ...o avoid sharp folds Maintain a loop big enough to freely insert the propeller shaft and bearing CAUTION Sharp folds could damage the lower belt and shorten its life span CAUTION Never reuse a belt Always install a new belt 5 Install the divider plate Use some tool to fit into the holes 1 in order to ease the mounting CAUTION The divider plate is very tightly seated Grinding for easier mounting is ...

Page 180: ...ft and bearing NOTE Every time this operation fails and the bearing skew the area behind the nose cone has to be heated up again Therefor move the belt about 10 cm 4 in prior to each heating operation 18 Insert the propeller shaft bearing fixing tool and spherical bearing into the propeller shaft housing The tool 2 centers the spherical bearing into the bearing race When the bearing is in place re...

Page 181: ...ling the lower housing Start off with the 2 long bolts in order to position the keep the lower housing in place while applying washers and nuts to the short bolts joining the lower and upper housing Tighten the bolts from the center and outwards refer to gearbox lid Tighten to 25 Nm 18 44 lb ft LOWER BELT REPLACEMENT ...

Page 182: ...the belt pulley 1 Reinsert the belt pulley through the upper loop of the belt by leaning the rear of the pulley down and aiming the front of the pulley in to the bearing race 2 Joggle the upper and the lower belt pulley up and down until the belt fits properly on both pulleys LOWER BELT REPLACEMENT ...

Page 183: ...IN GEARBOX 1 Reinstall bearing housing 4 bolts and washers NOTE This procedure is tricky Guide the bearing housing in position with one of the bolts alternately hammering with a plastic mallet until the bearing housing slides into places 2 When in place cross tightem the bolts to 25 Nm 18 44 lb ft LOWER BELT REPLACEMENT ...

Page 184: ...ONENTS 1 Reinstall the propeller shaft distance and spring washer CAUTION Check that the oil seals are undamaged Replace if necessary 2 Use the Propshaft bearing mounting tool 2 to reinstall the propeller shaft outer bearing 1 3 Use the 50mm Nut removing tool 4 and reinstall the retainer 3 ...

Page 185: ...ing tool 3 NOTE that the O rings go into the shaft slots prior to the radial seals Take care not to deform the radial seals excessively when installing them 4 Reinsert the gearbox shafts in the following order Port shaft 1 starboard input shaft 2 and output shaft 3 Apply marine grease to shafts and gear wheels Refer to Recommended fluids and grease 5 Clean the the gear box and the gear box lid mou...

Page 186: ...art No 30 0122 230 into their holes respectively 8 Reinstall the gear box lid Put Loctite on the 14 screws fit washers on each and tighten with 25 Nm 18 44 lb ft 9 Fit the hydraulic pump coupling to the port shaft and install the pump NOTE Rotate the input shaft until the hydraulic pump coupling snaps into place LOWER BELT REPLACEMENT ...

Page 187: ...O ring 3 Reinstall and tighten to 30 Nm 22 127 lb ft 4 Use an oil filling device 1 and refill gear box oil up to sight glas 3 Refer to Recommended Grease and Fluids NOTE Clean the magnetic oil plugs Install new washers 5 Remove the filling hose and tighten oil plug 2 to 9 Nm 6 6 ft lb LOWER BELT REPLACEMENT ...

Page 188: ...02 2 165 in inner outer diameter and 25mm 0 984 in high Silicon marine grade source locally 30 0110 904 Paste 1 Add plenty of paste to the starboard input shaft 1 Paste the inner splines with the output shaft 4 Add more paste before greasing the second inner spline 2 Add silicon 3 on the gearbox side of the insulation 2 and place it on the starboard input shaft silicon towards the gearbox ...

Page 189: ...er mounting points 1 3 Fit the belt housing and tighten the upper bolts to 23 Nm 16 963 lb ft NOTE Tightening the upper bolts first will ensure that no offset angle will stress the mounting points 4 Tighten the lower bolt 1 to 23 Nm 16 963 lb ft 5 Connect the cooling water hoses to the upper belt housing ...

Page 190: ...emove the propeller shaft bearing Refer to Lower belt replacement 10 Bend up the tab of the lock washer 1 and loosen the nut 2 from the propeller shaft 1 Take off the nut 1 and lock washer 2 2 Heat up the spherical bearing 3 until it comes off DANGER Risk of burns LOWER BELT REPLACEMENT ...

Page 191: ...l it fumes 4 Apply the hot bearing to the propeller shaft DANGER Risk of burns 5 Fit the lock washer 2 and nut 3 when the bearing has cooled down enough to handle 6 Tighten the nut 1 and bend up a tab 2 against one of the slots of the nut PROPELLER SHAFT BEARING REPLACEMENT ...

Page 192: ...tom of the casted cut out in the gearbox housing lid and the gearbox housing thus causing deformation of the shims and increasing the axial free play beyond specifications Damage can be inflicted on the sleeves and radial seals of the shafts in turn causing damage to the gear box shafts and malfunction of the gearbox Replace the used shims with shims of correct dimensions Replace the gear box shaf...

Page 193: ...e 2 30 0160 004 A ODT Puller 25 mm 3 30 0160 014 ODT Puller tool 1 Remove the inner bearing races with the puller tool equipped with a 25 mm puller NOTE The inner shims could be damaged during the removal procedure and need to be replaced 2 Shim to 1 5 mm using 1 pcs of each 30 0120 041 30 0120 040 NOTE Apply a thin layer of bearing grease in order to hold the shims in place while assembling the b...

Page 194: ... Puller tool 3 Fit the bearing race driver flange 2 into the sleeve and mount the bearing race 1 4 Insert the bearing race driver flange on the shaft 5 Put the bearing race driver flange on the shaft 6 Place the driver handle on top of the flange and on to the shaft 7 Softly hammer until the race is properly seated ...

Page 195: ... 0160 025 ODT Remover Oil Seal 1 Put the bearing housing on a working bench 2 Use the puller tool 1 to remove the bearing 2 3 Remove the O ring 3 and replace with a new 4 Turn the bearing housing up side down 5 Remove bearing 4 6 Use the Oil seal remover 6 to remove the oil seals 5 2 pcs 7 Check bearings 2 4 for wear and or damage Replace if necessary LOWER BELT REPLACEMENT ...

Page 196: ...ip to expand so that the inwards end of the sleeve is locked against the tool end 3 Use the hammer 3 to remove the sleeve 4 Using a marker pen 1 mark the face of the gearbox sleeve 5 cutout in line with the hydraulic oil supply channel Mark the new sleeve accordingly NOTE It is important to align these marks with each other in order to seat the new sleeve so it does not restrict the hydraulic oil ...

Page 197: ...RACES AND SHIMS IN THE GEARBOX LID 1 Use a bearing puller to remove the bearing races 2 from the gearbox lid 1 2 Use a hooker tool to remove the shims 3 NOTE The inner shims could be damaged during the removal procedure and need to be replaced 3 Use a hydraulic press to reinsert the bearing races and press them all the way to the bottom of the casting cut out 4 Check the radial seals of the gearbo...

Page 198: ...arboard input shaft 2 and output shaft 3 6 Prior to installing the gear house lid 1 insert the two housing lid guide pins Part No 30 0122 230 into their holes respectively aswell as the O ring 7 Tighten the lid with the gauge bar 2 in the middle Tighten the lid with at least 6 screws evenly distributed with 25 Nm 18 44 lb ft ...

Page 199: ...ts in order to make them seat properly 3 Dial in the dial indicator against the endof the shaft so that the pin is actuating the indicator 4 Set the indicator to zero 5 With your own hands pull as hard as you can up and down while noting the gap Repeat this procedure of seating the shaft in its bearing races upa and down three times to confirm the gap 6 Record the findings and note the average gap...

Page 200: ...at the procedure of seating the shaft and measuring the gap three times Record the findings and note the average gap Installing shims in the gearbox housing lid NOTE The axial free play tolerance specification is 0 to 0 05 mm 0 197 in 12 Remove the gauge bar and screws and take off the gearbox lid 13 Remove the bearing races 3 pcs with a puller end pulling tool 14 Install the required shims Shims ...

Page 201: ...he propeller shaft housing Drain the oil into a suitable container 3 Check drained oil quality The oil should be red to dark red If the oil looks milky and foamy water has entered the lower housing Check for leakage NOTE Clean the magnetic oil plugs Install new washers CAUTION Dispose of the belt oil according to local environmental legislation 4 Reinstall and tighten oil plug 2 to 9 Nm 6 6 ft lb ...

Page 202: ...efer to Recommended fluids and grease 6 Clean the sightglass Install a new washer Tighten to 16 Nm 11 8 ft lb 7 Alternatively use an oil filling device and fill up the oil through the oil plug hole 2 until oil comes out at oil plug hole 1 NOTE Clean the magnetic oil plugs Install new washers 8 Remove the filling hose and tighten oil plug 2 and 1 to 9 Nm 6 6 ft lb ...

Page 203: ...lug and sealing 1 4 Remove the lower oil plug and sealing 2 Let all the oil run out into a suitable container 3 CAUTION Risk of contamination of drinking water Dispose of oil according to local environmental legislation 5 Inject 0 33 L belt oil into the sight glass oil level plug hole using a pressurised filling device For oil quality see Recommended fluids and grease 6 Clean oil plugs and put new...

Page 204: ... Drain gear oil refer to Change Upper belt oil 3 Put the unit on a workbench belt housing bracket upwards 4 Remove 10 bolts and lift off the belt housing bracket 5 Lift up the belt pulleys and belt NOTE The belt pulleys fit in just one hole respectively Guide pins ensure correct belt housing assembling 6 Replace the belt and mount in reverse order ...

Page 205: ...e the seals 1 using the oil seal remover 2 Install new seals 2 Reinstall upper belt housing Refer to Reinstall the upper belt housing REPLACE ZINC ANODES 3 Remove the bolt holding the anode and the O ring 4 Replace with new anode and new O ring Tighten bolts to 20 Nm 14 8 lb ft UPPER BELT REPLACEMENT ...

Page 206: ...PELLER REPLACEMENT 1 Remove 4 screws and lid 2 Take off used impeller and sealing 3 Install a new sealing WARNING Rotate impeller clockwise until it fits 4 Lubricate new impeller and install Tighten to 2 Nm 1 47 lb in SEAWATER PUMP IMPELLER REPLACEMENT ...

Page 207: ...ANUAL CLEAN SEAWATER STRAINER CLEAN SEAWATER STRAINER 1 Remove the lid 2 Pull out the filter element 1 3 Clean the filter element check that the o ring 2 stays in place Replace O ring if damaged 4 Reinstall and close the strainer ...

Page 208: ... 5 Remove the nipple from the hose and discard Check the rubber hose surface where the nipple was fastened for any signs of damage or wear Insert and fasten new nipple in order as per figure NOTE The lip on the washer and the nipple face towards the hose for good sealing 6 Tighten the securing nut assembly until it firmly presses against the rubber NOTE Do not overtighten 7 Reinstall hose assembly...

Page 209: ...of the expansion tank 2 2 Fit a hose 4 to the coolant drain adapter 3 3 Drain the coolant water mixture into a suitable container CAUTION Risk of contamination of drinking water Dispose of used coolant water mixture according to local environmental legislation 4 Remove the hose from the drain adapter ...

Page 210: ...ll up with coolant via filler neck on expansion tank 2 until fluid level has reached up to 4 cm beneath the filler neck 3 Let engine run at a speed of 2 000 rpm for approx 15 minutes 4 Switch off engine carefully turn cap with safety valve to the first detent to relieve pressure and then carefully remove cap and top up with coolant DANGER Risk of scalding and burning yourself Before the engine is ...

Page 211: ... to a reduction in the engine output Coolant pressure in the expansion tank is only built up again when the engine has cooled down The cooling system must therefore only be filled up when the engine is cold WARNING When the cover is opened with working valves there is a danger that it is not properly sealed when closed again The required overpressure is no longer set up in the cooling system Prema...

Page 212: ...med to prevent engine issues For both short term and long term storage see instruction below and picture SHORT TERM STORAGE 1 Open connection 1 2 Unscrew the plug on the side of the heat exchanger 2 3 Undo the hose on the seawater pump 3 and drain the seawater 4 Tilt the outboard to a 45 angle to drain as much as possible of the seawater out of the system 5 When in this position steer the outboard...

Page 213: ...d of sufficient grade temperature wise until it exits from connection 1 4 Undo the hose on the seawater pump 3 and drain the seawater Alternative solution for long term storage Water intake 1 Run the outboard with the water intake point in the front of the lower housing lowered into a coolant fluid mixture of sufficient grade 2 Run the outboard until the entire sea water part of the system is fill...

Page 214: ...e of times 2 Tilt the outboard in order to minimize oil spill Carefully clean the area around the gearbox oil filter with pressurised air 3 Remove the filter cap Have a cloth nearby to collect the oil in the filter CAUTION Risk of contamination of drinking water Dispose of oil according to local environmental legislation 4 Clean and reinstall the hydraulic oil filter element If the filter is damag...

Page 215: ...ng device 1 8 Fill with oil up to sight glas See Recommended fluids and grease 9 Clean the magnetic plug 2 and reinstall If the hydraulic oil pressure i s low the propotional valve or the hydraulic pump has to be replaced If you discover water in the oil the oil is milky all hydraulic seals have to be replaced Refere to Hydraulic system description and Hydraulic pump replacement ...

Page 216: ...ICE MANUAL HYDRAULIC PUMP REPLACEMENT 1 Remove 4 screws and washers of hydraulic pump end cover Remove the pump unit 2 Install new pump unit in opposite order 3 Tighten bolts to 20 Nm 14 8 lb ft HYDRAULIC OIL PUMP REPLACEMENT ...

Page 217: ...NT AIR FILTER REMOVAL 1 Remove the clamp 2 Pull off the air filter element CLEAN THE TURBO CHARGER 3 Clean the inside of the main tube inlet hose and inlet of the turbo charger with a cloth moistened with solvent AIR FILTER INSTALLATION 4 Install a new air filter 5 Tighten clamp ...

Page 218: ... clamp bracket when the outboard is trimmed or tilted Check the power trim and tilt unit for any signs of oil leaks Tilt and trim switch on cowling 1 Operate each of the power trim and tilt switches on the remote control and lower cowling to check that all switches work NOTE The ignition key must be in IGN ACC position 2 Tilt up the outboard and check that the tilt rod and trim rods are extended c...

Page 219: ...operates smoothly Check the hydraulic fluid if necessary Also check wear of pistons and joints NOTE Check if the Power tilt and trim PTT motors make abnormal sounds CAUTION The outboard can belowered by carefully turning manual valve should the electric system fail Ensure that the manual valve is tightened before starting the outboard Tilt and trim rods manual valve ...

Page 220: ...e outboard completely and support the tilt cylinder with a transom saver 1 WARNING Make sure to support the outboard with the transom tilt saver Otherwise the outboard can fall down accidentally if the power tilt and trim unit looses pressure 2 Remove the filling plug 3 and seal 2 Check the fluid level in the reservoir ...

Page 221: ...oir due to internal pressure NOTE If the fluid is correctly levelled only a small amount of fluid should come out of the filling hole when the plug is removed 3 If necessary fill up with fluid of recommended type until it comes out of the filling hole See Recommended fluids and grease NOTE Install new O rings and filling plug Tighten the plug to 2 Nm 1 5 lb ft Tighten reservoir cap 7 Nm 5 1 lb ft ...

Page 222: ... MANUAL CHECK POWER TILT AND TRIM UNIT LUBRICATING AND GREASING THE PPT UNIT 1 Use a grease gun and fill up with recommended grease until the grease comes out at the joints or ends of shaft Refer to Recommended fluids and grease ...

Page 223: ...223 OXE 150 200 HP SERVICE MANUAL CHECK POWER TILT AND TRIM UNIT 2 Fill the seatings with grease for smoother tilt operation Use grease according to Recommended fluids and grease ...

Page 224: ... plug harness connector 4 Injector 4 pcs 5 Exhaust gas temperature sensor connector 6 Injector harness connector 7 Engine coolant temperature sensor connector 8 Exhaust gas temperature sensor 9 Air filter restriction sensor 10 Gearbox oil pressure switch connector 11 Engine oil temperature sensor 12 Water in fuel sensor 13 Water in fuel sensor connector ...

Page 225: ...mperature and air mass meter 7 Fuel pressure control valve 8 Power cable connector a GND b ECU Helm power c Engine starter power 9 PTT cowl connector 10 PTT switch 11 PTT sensor connector 12 Engine connector 13 ECU 14 Gearbox output speed sensor connector 15 Gearbox output speed sensor 16 Gearbox oil pressure sensor 17 Trolling valve 18 Starboard gear coil 19 Port gear coil ...

Page 226: ...RICAL SYSTEM ENGINE CONTROL UNIT ECU 1 GND 2 Supply 3 PSU control and feedback 4 PSU OK LED indicator 5 ECU and helm 6 Glow plug control module 7 PTT up 8 PTT down 9 ECU connectors 10 Glow module control feedback supply 11 Glow module output ...

Page 227: ...ELECTRICAL SYSTEM WIRING Power trim and tilt unit power cable assembly 1 Use an arrow head clip 1 on cyclon in order to fasten the PTT power cable 2 Route the ppt power cable 2 behind the cooling fluid return pipe 3 from the oil cooler ...

Page 228: ...with clips 1 CAUTION It is very importent that the harness branches are layed out as shown in picture above to avoid fretting at exposed critical areas 2 and to ensure correct cabling length Always double check wiring layout after the ECU bracket assembly is mounted on the engine to ensure that there is no fretting risk ...

Page 229: ...229 OXE 150 200 HP SERVICE MANUAL ELECTRICAL SYSTEM Rear view 1 Fasten and secure wiring with clips 1 ...

Page 230: ...GND cabling order 1 Starter motor supply 1 Engine harness GND 2 Alternator supply 2 PSU GND cable 3 Engine block GND 1 Place the engine block ground cable 1 closest to the bracket 2 Secure fasten all cables and the harness within the cable clip 2 3 Cable 3 and cable 4 should be mounted in parallell with bracket edges ELECTRICAL SYSTEM ...

Page 231: ...ECTRICAL SYSTEM Power connectors long starter motor cable 170 mm 6 72 in 1 Mount the starter motor cable 1 in an right angle to the bracket edge Power connectors PSU 1 Mount the power cables at recommended angles as shown in picture above ...

Page 232: ...ECU bracket assembly on the engine 1 First connect the swirl valve 1 NOTE Ensure it click s 2 Slide the secondary lock yellow in place 3 Fit the ECU bracket in place and secure loosely with screws nuts NOTE Rear side of engine only ELECTRICAL SYSTEM ...

Page 233: ...le 1 on the engine block NOTE Ensure that the contact surface is free from paint 5 Connect the engine oil pressure sensor connector 2 NOTE Ensure it click s 6 Mount the alternator supply 3 on the alternator NOTE Route the cable towards the engine ELECTRICAL SYSTEM ...

Page 234: ...tor supply cable 3 to the starter motor solenoid 1 and lead it as vertical as possible CAUTION Ensure no fretting on starter motor cables 4 Recommended clearance 10 mm 0 394 in 9 Connect the crankcase sensor connector 5 NOTE Ensure it click s 10 Slide the secondary lock yellow in place ELECTRICAL SYSTEM ...

Page 235: ...E 150 200 HP SERVICE MANUAL 11 Tighten 3 screw nuts 1 Adjust the ECU bracket assembly to ensure not fretting CAUTION Ensure that fretting is not possible Recommended clearance 10 mm 0 394 in ELECTRICAL SYSTEM ...

Page 236: ...L 12 Mount the PTT power cables blue cable 1 closest to the rear end of the engine black green cable 2 second closest to the rear end of the engine 13 Connect the fuel pressure control valve 1 NOTE Ensure it click s ELECTRICAL SYSTEM ...

Page 237: ... 2 Port selector coil connector FWD gear 3 Flywheel 4 Gearbox oil pressure sensor connector 5 Cable ties 6 Starboard selctor coil connector REV gear WARNING Make sure the cables are tightly secured so that no contact with the flywheel is possible Recommended clearance 15 mm 1 Ensure that all connectors click ELECTRICAL SYSTEM ...

Page 238: ...238 OXE 150 200 HP SERVICE MANUAL 1 Cable tie 2 Connect the propeller speed sensor connector 2 Make sure it clicks ELECTRICAL SYSTEM ...

Page 239: ... sensor and actuaror connectors 1 Connect the PTT sensor adapter 1 to the engine harness Make sure it clicks 2 Connect the PTT cowl switch 2 Make sure it clicks 3 Connect the PTT sensor adapter to the PTT sensor 3 Make sure it clicks ELECTRICAL SYSTEM ...

Page 240: ...njector harness connector 5 Air filter restriction connector 6 Turbo actuator connector 7 Cam shaft angle sensor connector 8 Fuel rail pressure sensor connector 9 Cable tie 10 FSM connector 11 Clips NOTE Make sure all connectors click and push the yellow or red secondary lock in place ELECTRICAL SYSTEM ...

Page 241: ...241 OXE 150 200 HP SERVICE MANUAL 1 Exhaust manifold 2 Intercooler 3 ECT connector NOTE Make sure The ECT connector clicks when connecting ELECTRICAL SYSTEM ...

Page 242: ...242 OXE 150 200 HP SERVICE MANUAL 1 Clip 2 Water in fuel sensor connector 3 Clip 4 Cable tie 1 Fix the Water in fuel sensor 3 connector with a cable tie 4 ELECTRICAL SYSTEM ...

Page 243: ...243 OXE 150 200 HP SERVICE MANUAL 2 Fix the Gearbox lubricating oil pressure switch connector 2 with a cable tie 1 3 Secure the cacle with a clip 3 ELECTRICAL SYSTEM ...

Page 244: ...244 OXE 150 200 HP SERVICE MANUAL ELECTRICAL SYSTEM 1 Alternator belt 2 Engine oil pressure sensor connector 4 Connect the Engine oil pressure sensor connector 2 Make sure it clicks ...

Page 245: ...245 OXE 150 200 HP SERVICE MANUAL ELECTRICAL SYSTEM ...

Page 246: ... W66 R2 0 5 Blue Red W66 R2 0 5 Blue Red 49 W67 R2 0 5 Gray Red W67 R2 0 5 Gray Red 1 2 C20 30 0116 209 W68 R2 0 5 Blue Red W69 R2 0 5 White Green 37 W23 R2 0 5 Gray W23 R2 0 5 Gray W24 R2 0 5 Blue 1 2 C23 30 0116 209 34 W76 R2 0 75 White W76 R2 0 75 White 1 2 C28 30 0116 247 33 W85 R2 0 5 Black W85 R2 0 5 Black 32 W84 R2 0 5 White W84 R2 0 5 White 1 2 3 4 5 C30 30 0116 231 27 W89 R2 0 5 Yellow Gr...

Page 247: ... W81 R2 0 5 Red White A B C C29 30 0116 225 23 W88 R2 0 5 Yellow W88 R2 0 5 Yellow 30 W92 R2 0 5 Orange 06 1 31 W93 R2 0 5 Black 06 1 1 F03 30 0116 360 5 W94 R2 0 75 Yellow Red W94 R2 0 75 Yellow Red W95 R2 1 5 Red W96 R2 1 5 Red W97 R2 1 5 Red W98 R2 1 5 Black W100 R2 1 5 Black W99 R2 1 5 Black 42 06 8 W79 R2 0 5 Red 1 S04 W103 R2 0 75 Red 1 S06 W104 R2 0 5 Yellow Green W1 R2 6 0 Red 1 S01 W7 R2 ...

Page 248: ...e Oil pressure and leakage X Display manual Gear box oil and filter X Hydraulic oil filter Replacement Coolant level and mixture X Drain and fill coolant Fluid level power trim X Check the power tilt and trim fluid level Seawater filter X Clean Seawater stariner Upper belt tension X Check upper belt tension Lower belt tension X Check lower belt tension Upper belt oil X Change upper belt oil Magnet...

Page 249: ...n Lower belt tension X Check lower belt tension Coolant level and mixture X Drain and fill coolant Crank case ventilation X Check hoses and clamps Air filter X Air Filter Replacement Display gauges function X Display Manual Turbo charger X Clean the turbo charger Exhaust hose X Outboard views Alternator drive belt tension X Self adjusting check for wear Seawater strainer X Clean Seawater strainer ...

Page 250: ...ill up Clean Change Replace Refer to Painting X Owner s Manual Check painted surfaces Inspection exhaust hose and cooling hoses X Outboard view Hoses pipes connections hose clamps X Outboard view Condition of rubber hoses X Outboard view Hydraulic hoses connections leakage wear aging X Outboard view ...

Page 251: ...er Anodes Intercooler heat exchanger transom mount X User s Manual Inspect anodes Exhaust hose and coolant hoses X Outboard view Hoses pipes connections and hose clamps X Outboard view Condition of rubber hoses X Outboard view Crank case ventilation X Check hoses and clamps Alternator drive belt X Alternator belt replacement Cables connectors and cable glands X Outboard view Coolant X Drain and fi...

Page 252: ...er belt replacement Propeller shaft oil seal X Propeller replacement Lower belt oil packing plug X X Change lower belt oil Lower belt and related parts X Lower belt replacement Please fill in the Service record on the following pages Date of replacement part No and batch No Seawater strainer X Clean Seawater strainer Seawater pump impeller X Seawater pump impeller replacement Air filter X Air Filt...

Page 253: ...Belt part No OBSERVATIONS Batch No DATE Engine run time engine hours Belt part No OBSERVATIONS Batch No DATE Engine run time engine hours Belt part No OBSERVATIONS Batch No DATE Engine run time engine hours Belt part No OBSERVATIONS Batch No DATE Engine run time engine hours Belt part No OBSERVATIONS Batch No ...

Page 254: ...SERVATIONS Batch No DATE Engine run time engine hours Belt part No OBSERVATIONS Batch No DATE Engine run time engine hours Belt part No OBSERVATIONS Batch No DATE Engine run time engine hours Belt part No OBSERVATIONS Batch No DATE Engine run time engine hours Belt part No OBSERVATIONS Batch No SERVICE RECORD ...

Page 255: ...nents Then use a process elimination questions to pin point the probable causes and investigate and eliminate these successively on the basis of the table and your own experience This helps to reduce repairs to the required scale and to counteract claims regarding over eager replacement of parts and complaints about expensive work and down time NOTE The following list is conceived as an aid to mem...

Page 256: ...le connection loose or dam aged x x Starter motor starter interlock relay defective carbon brushes worked loose worn winding damaged short to ground x x x x Engine oil viscosity unsuitable not suitable for ambient temperature lube oil qual ity does not comply with specifications x x Oil level in oil pan too high x Oil level in pan too low oil in oil pan too thin mixed with condensate or fuel x Eng...

Page 257: ...ses Possible causes x x x x x x x Fuel low pressure system Air in system turn on ignition when bleeding system x x x x x x x x Fuel low pressure system Feed pump main filter x x x x x o x x Fuel high pressure system Injectors defective clogged leaking coked x x x x o x x o x x x x o Fuel high pressure system High pressure pump worn x x o ECU rpm sensor polarity reversed x x x x o o o o ECU detects...

Page 258: ...258 OXE 150 200 HP SERVICE MANUAL ...

Page 259: ...259 OXE 150 200 HP SERVICE MANUAL ...

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