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STEYR 4 CYLINDER, Service Manual

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STEYR 4 CYLINDER Service Manual Download Page 157

Z001019/0_7_July 2012

 

Page FUEL SYSTEM - 1

SERVICE MANUAL MARINE ENGINES

03  FUEL SYSTEM

03  FUEL SYSTEM

Table of Contents

Page

03.00 

Fuel system / Functional description  ...................................................

 

2

03.02 

Fuel pump, unit injector, lines  ..............................................................  4 

03.02.01 

Replace fuel pump     ................................................................................  4 

03.02.02 

Disassembly and assembly of unit injector  ..............................................  7

03.02.03 

Fix control rack ........................................................................................  14

03.02.04 

Adjust control link (injection quantity) ......................................................  15

03.02.05 

Loosen fixing of control rod 

 ....................................................................  16

03.02.06 

Adjust start of injection ............................................................................  17

03.02.07 

Exchange check valve for fuel pre-pressure to unit injector  ..................  20

03.04 

Air filter 

 .................................................................................................  21

03.04.01 

Change air filter 

 ......................................................................................  21

03.05 Turbocharger 

 ........................................................................................  22

03.05.01 

Replace turbocharger  ............................................................................  22

03.05.02 

Check bearing clearance ........................................................................  25

03.08 

Control solenoid ...................................................................................  26

03.08.01 

Remove control solenoid ........................................................................  26

03.08.02 

Install control solenoid ............................................................................. 28

03.08.03 

Replace sensor, indication of control rack position .................................  29

03.09 

Change fuel filter  

 .................................................................................  30

03.11 

Replace glow plug  ...............................................................................  31

03.12 

Measurement of Compression Pressure ............................................. 32

03.14 

Fuel system check ................................................................................. 34

03.14.01 

Manual injection test methode ................................................................. 34

03.14.02 

Disengagement methode of injection ....................................................... 36

03.14.03 

Air bubble formation in fuel system .......................................................... 37

Summary of Contents for 4 CYLINDER

Page 1: ...www steyr motors com STEYR MOTORS GmbH Im Stadtgut B1 A 4407 Steyr Gleink AUSTRIA 4 CYLINDERS 6 CYLINDERS STEYR MARINE ENGINES SERVICE MANUAL P N Z001019 0 6th Edition July 2008 4 CYLINDERS 6 CYLINDERS ...

Page 2: ...THIS PAGE IS INTENTIONALLY BLANK ...

Page 3: ...with the main intention to provide information in form of technical data and know how based on our experience in the marine diesel engine business which will enable you in case of possible failure to operate service and repair the engine 4 6 CYLINDER MARINE ENGINES to maintain their operating safety and reliability To achieve continuous improvement with regard to form and contents of the informati...

Page 4: ...nded as reference STEYR MOTORS GmbH reserves the right to make changes at any time without notice on technical data or models and or to discontinue models The right is also reserved to change technical data or components at any time without incurring any obligation to retrofit new parts on models produced prior to date of such change To guarantee proper function of the engine and its attached part...

Page 5: ...Z001019 0_6_July 2008 TABLE OF CONTENTS MAIN ASSEMBLY GROUP ENGINE GENERAL 01 ENGINE 02 COUPLING 03 FUEL SYSTEM 04 EXHAUST SYSTEM 05 COOLING SYSTEM 06 ELECTRICAL EQUIPMENT ...

Page 6: ...1 06 Engine housing oil pump oil suction pipe 01 08 Intake manifold intercooler 01 13 Engine oil cooler 01 09 Auxiliary drive PTO 01 14 Exhaust manifold seals heat exchanger 02 Coupling 03 Fuel system 04 Exhaust system 02 01 Torsion coupling 02 02 Coupler 02 03 Torsion coupling Centa 03 02 Fuel pump unit injector pipes 03 04 Air filter 03 05 Turbo charger 03 08 Control solenoid 03 09 Fuel filter 0...

Page 7: ... 03 Pipes thermostat 05 04 Coolant pump 05 10 Raw water pump side mounted 05 11 Raw water pump front mounted 06 01 Generator alternator 06 03 Starter motor 06 05 Engine harness 06 06 EMS E box diagnosis system fuses 06 07 Instrument panel connecting cable 06 10 Sender sensor 06 12 Battery charge equalization ...

Page 8: ... VERSIONS OF MANUAL Version Date Modification 1 0 01 10 2000 new edition 2 0 01 06 2002 release typ 164 246 3 0 01 07 2005 release typ 256 4 0 01 07 2007 modification 5 0 01 03 2008 modification 6 0 01 07 2008 modification ...

Page 9: ...22 C 1 Trouble Check Chart 22 C 2 Service and Maintenance Schedule 24 D General Information 26 D 1 Electronic Engine Management System ECU 26 D 2 Diagnostic System 27 D 3 Extended Storage Preservation Procedure 28 D 4 Engine Break in procedure 32 D 5 Operation after Break in 34 E Quality Gudelines for Repair 36 E 1 Spare parts specification 36 E 2 Workshop profile 36 E 3 Nomenclature 37 E 4 SI Sys...

Page 10: ...hightening Torques 44 H 1 Listing of Thightening Torques 44 H 2 General Tightening torques 49 H 3 Testing of torque wrench 50 H 4 Non destructive material testing 50 H 5 Use of adhesive and sealing materials 50 H 6 Solvent free sealing materials 50 J Wear Limits 52 J 1 Adjustment information for service and maintenance 53 ...

Page 11: ...ry model and serial number ill 1 or ill 2 is located on the engine as illustrated These numbers are required for warranty claims and ordering parts The model and serial number of the marine gearbox is located on the marine gearbox housing as illustrated To obtain instructions regarding marine gearbox operation refer to marine gearbox owners manual 17 06014 08006 1 1 08007 FOR ALL 6 CYL MARINE ENGI...

Page 12: ...01023 0 STEYR 144 vti td diesel marine P N Z 001005 0 STEYR 164 td diesel marine P N Z 001015 0 STEYR 174 vti diesel marine P N Z 001011 0 STEYR 166 td diesel marine P N Z 011796 1 STEYR 236 FDE P N Z 011796 0 STEYR 236 td diesel marine P N Z 011796 1 Z011769 2 STEYR 246 td diesel marine P N Z 011800 0 STEYR 256 td diesel marine P N Z 011810 0 STEYR 266 td diesel marine P N Z 011805 0 installation...

Page 13: ...A 3 Modell summary A 3 1 Modell summary 4 cylinder engines 03 01 ill 1 03 01 ill 2 03 01 ill 3 Inborder i e ZF 45 Marinegear Down angle Bobtail Version Innenborder i e ZF 63 Marinegear Equipment with side mounted raw water pump or with side mounted raw water pump power steering pump ...

Page 14: ...GENERAL 6 Z001019 0_8_Octobre 2011 SERVICE MANUAL MARINE ENGINES ToC 03 01 ill 4 03 01 ill 5 03 01 ill 6 Equipment Bobtail B Direkt gearbox A down angle gear box Parallel offset gearbox Lifeboat Engine 03 01 ill 7 ...

Page 15: ...AL 7 GENERAL SERVICE MANUAL MARINE ENGINES ToC Stern Drive Jet Drive 03 01 ill 10 03 01 ill 11 TYPE Mercury Alpha Bravo I II III Volvo DP 290 Volvo DP 290 Hydraulic SX Stern Drive TYPE Alamarin Hamilton Castoldi 03 01 ill 8 03 01 ill 9 ...

Page 16: ...NGINES ToC A 3 2 Modell summary 6 cylinder engines 03 02 ill 1 03 02 ill 2 03 02 ill 3 Inborder i e ZF 63 Marine gear Down angle with side mounted raw water pump or with side mounted raw water pump power steering pump and front mounted auxiliary drive PTO Bobtail Version ...

Page 17: ... SERVICE MANUAL MARINE ENGINES ToC 03 02 ill 4 03 02 ill 5 03 02 ill 6 03 02 ill 7 03 02 ill 8 Transmission Lifeboat Engine Equipment Bobtail B Direkt gearbox A down angle gear box Parallel offset gearbox i 2 5V shaft angle 12 i 2 0V shaft angle 12 ...

Page 18: ...ANUAL MARINE ENGINES ToC 03 02 ill 9 03 02 ill 10 03 02 ill 12 Stern drive Mercury Bravo II III Volvo DP 290 Stern Power Drive Volvo DP 290 ZF Hydraulic Pump Volvo SX Drive King Cobra Drive Type Jet Drive TYPE Alamarin Hamilton Castoldi Jet drive 03 02 ill 11 ...

Page 19: ...Z001019 0_8_Octobre 2011 PageGENERAL 11 GENERAL SERVICE MANUAL MARINE ENGINES ToC THIS PAGE IS INTENTIONALLY BLANK ...

Page 20: ...croprocessor controlled filling capacity motor oil approx 8 0 l engine housing incl approx 1 l oil filter contents specification motor oil SAE 5W 50 ACEA B4 02 API CF or 10W 40 ACEA E4 E5 E7 API CF P N0 Z010058 0 oil and oil filter change intervals every 150 operating hours and or once per season oil filter P No 2178582 1 oil filter location pressure sided electric charging system 14 V 90 A altern...

Page 21: ...ne Oilcooler 17 Oil Suction Pipe 18 Oil Dipstick 19 Hydraulic Oil Tank 20 Cooler Cap 21 Potentiometer Accelerator 22 Motor Oil Filler Cap 23 Boost Pressure Sensor 24 Rack Position Sensor 25 Drive Belt 26 Cover T Belt Lower 27 Engine Mount 28 Drive Belt Tensioner 29 Vibration Damper 30 Cover T Belt Upper 31 Engine Lifting Eye 32 Speed Sensor 33 Valve Cover 34 Heat Exchanger 35 Coolant Expansion Tan...

Page 22: ...acity motor oil approx 8 0 l engine housing incl approx 1 l oil filter contents specification motor oil SAE 5W 50 ACEA B4 02 API CF or 10W 40 ACEA E4 E5 E7 API CF P N0 Z010058 0 oil and oil filter change intervals every 150 operating hours and or once per season oil filter P No 2178582 1 oil filter location pressure sided electric charging system 14 V 90 A alternator with transistorized voltage re...

Page 23: ...ne Oilcooler 17 Oil Suction Pipe 18 Oil Dipstick 19 Hydraulic Oil Tank 20 Cooler Cap 21 Potentiometer Accelerator 22 Motor Oil Filler Cap 23 Boost Pressure Sensor 24 Rack Position Sensor 25 Drive Belt 26 Cover T Belt Lower 27 Engine Mount 28 Drive Belt Tensioner 29 Vibration Damper 30 Cover T Belt Upper 31 Engine Lifting Eye 32 Speed Sensor 33 Valve Cover 34 Heat Exchanger 35 Coolant Expansion Tan...

Page 24: ... kPa 60 100 PSI microprocessor controlled filling capacity motor oil approx 10 0 l engine housing incl approx 1 l oil filter contents specification motor oil SAE 5W 50 ACEA B4 02 API CF or 10W 40 ACEA E4 E5 E7 API CF P N0 Z010058 0 oil and oil filter change intervals every 150 operating hours and or once per season oil filter P No 2178582 1 oil filter location suction sided electric charging syste...

Page 25: ...ipstick 18 Rack Position Sensor 19 Engine Lifting Eye 20 Motor Oil Filler Cap 21 Potentiometer Accelerator 22 Drive Belt Raw Water Pump 23 Engine Mount 24 Drive Belt Tensioner 25 Cover T Belt Lower 26 Vibration Damper 27 Drive Belt Alternator Hydr Pump 28 Speed Sensor 29 Cover T Belt Upper 30 Valve Cover 31 Heat Exchanger 32 Coolant Expansion Tank 33 Cooler Cap 34 Diagnostic Outlet 35 Inversion Sw...

Page 26: ...filling capacity motor oil approx 10 0 l engine housing incl approx 1 l oil filter contents specification motor oil SAE 5W 50 ACEA B4 02 API CF or 10W 40 ACEA E4 E5 E7 API CF P N0 Z010058 0 oil and oil filter change intervals every 150 operating hours and or once per season oil filter P No 2178582 1 oil filter location suction sided electric charging system 14 V 90 A alternator with transistorized...

Page 27: ... Position Sensor 18 Engine Lifting Eye 19 Motor Oil Filler Cap 20 Potentiometer Accelerator 21 Drive Belt Raw Water Pump 22 Engine Mount 23 Drive Belt Tensioner 24 Cover T Belt Lower 25 Vibration Damper 26 Drive Belt Alternator Hydr Pump 27 Speed Sensor 28 Cover T Belt Upper 29 Valve Cover 30 Heat Exchanger 31 Coolant Expansion Tank 32 Cooler Cap 33 Diagnostic Outlet 34 Inversion Switch only for S...

Page 28: ...ranceoffuelquality Thepropertieslistedinthefollowingfueloilselectionchart haveprovidedoptimumengine performance Fuel Oil Selection Chart ASTM Test procedure D 613 D 976 D 1298 D86 D 93 EN 116 CEN D 445 D 1266 D 2622 D 2785 D 130 D 189 D 482 D 95 D 1744 D 974 D 2274 General Fuel classification Cetane number Gravity at 15 C kg l Destillation 50 90 End point Flash point CFPP Cloud point Viscosity Kin...

Page 29: ...SAE 10W 40 SMO No Z010058 0 Initial factory fill is a high quality break in oil specified ACEA B4 02 SAE 5W 50 During the break in period 20 hours frequently check the oil level Somewhat higher oil consumption is normal until piston rings are seated The oil level should be maintained between the minimum and maximum marks on the dipstick The space between the marks represents approximately 2 quarts...

Page 30: ...ush with fresh fuel 6 System error or failure Check Engine Management System display for service code 7 Battery output insufficient Charge or replace battery Only for SOLAS 8 Inversion switch actuated Cancelled by ignition OFF ON Starter won t crank 1 Battery connections loose or Check for loose connections engine corroded and corrosions Clean connections and thighten 2 Battery is dead Check level...

Page 31: ... Boatoverloaded Reduceload 3 Boat trim Distribute boat load evenly Adjust trim 4 Excessive water in bilge Drainbilge 5 Boat hull condition Cleaning 6 Improperpropellerselection Select proper propeller pitch and diameter 7 Fuel incorrect Fill tank with correct fuel Check fuel filter and fuel flow condition 8 Throttle not fully open Check throttle command lever for fulltravel 9 Overheating Check coo...

Page 32: ...ir filter element preserve after season FUEL check for leakage SYSTEM hoses drain addtiional fuel filter change fuel filter check additional fuel filter preserve fuel system after season BATTERY check acid level densitiy ELECTRONICS check connections after season ELECTRICAL check connections tighten loose con EQUIPMENT insulation nections Renew cables if required INVERSION check switch every 50 ho...

Page 33: ...enance Schedule GEARBOX check oil level STERNDRIVE for leakage change gear oil ATF see manufacturer s oil filter specifications FRONT VIBRA check torque TION DAMPER ENGINECOM check for leakage water repair or consult PARTMENT AND fuel your STEYR BILGE exhaust gas Marine dealer SHIFTING check smooth action If required to be adjustment replaced by your STEYRMarine Dealer STEERING check lubrication s...

Page 34: ... 2x p sec Gauge reading 107 C Horn ON 2x p sec Gauge reading 120 C Hornandindication light CEL ON 2x p sec Hornandindication light CEL ON 2x p sec Horncontinuousand Oil indication light continous switched ON Oilpressureindication light switched ON 1x p sec Effect noticed Reductionof enginespeed Reductionof enginespeed Reductionof enginespeed Reductionof enginespeed Reductionof enginespeed Reductio...

Page 35: ...essure boost pressure coolant temperature exhaust pipe temperature Hi riser sensor control rack potentiometeraccelerator speedsignal The electronic management system carries out self diagnostic and or plausibility checks for all input values and sensor connections In case of irregularities there is an optical or audible warning signal see page 71 Existing active failures remain stored until the pr...

Page 36: ...approved NOTE Do not crank engine over max 30 40 sec 5 Start the engine and let it run up to temperature 6 Stop the engine and drain the old engine oil and store for future refill and usage 7 Fillinpreservationoil art nr Z050323 0 5litercanister adequate quantity incl in all Preservation Service Kits up to the minimum mark on the dip stick 8 ConnectthefuelsystemtoacanisterZ010014 0filled withprese...

Page 37: ...reservation or engine is put into operation 17 Only by 2nd Preservation Aftertwoyearsenginestoragereplaceenginecoolant water art nr Z011785 0 5 liter canister adequate quantity incl in 2nd Preservation Service Kit and fill between min max level in coolant expansion tank 18 Replaceallpipesandconnectionstooriginalcondition andrestoreengine 19 RecordcarriedoutStoragePreservationProcedure infollowingd...

Page 38: ...ed every year after 3 yearsstockingwithoutBASE ENGINEWARRANTY approval from STEYR MOTORS NOTE When commissioning or running an engine that has been preserved as stated above the engine will run roughlyandsmokeforthefirstfewminutes Donotbe alarmed as this is normal until the deposits of the preservationmaterialshavecleared 68 Sticker of 1st preservation refer to Installation Manual P N Z001007 0 Ch...

Page 39: ...Z001019 0_8_Octobre 2011 PageGENERAL 31 GENERAL SERVICE MANUAL MARINE ENGINES ToC THIS PAGE IS INTENTIONALLY BLANK ...

Page 40: ... speed then increase engine speed again to assist the break in of rings and bearings Maintain planing attitude to avoid excessive engine load NOTE DO NOT RUN ENGINE AT A CONSTANT RPM FOR LONGER PERIODS DURING THIS INITIAL TWO HOURS OF BREAK IN ATTENTION Warning indication engine over load during break in via ECU The ECU controls during the first two hours of engine operation the load on the engine...

Page 41: ...s its position while turning raising the boat or planing check the oil level in the engine housing by means of dipstick If necessary add oil DO NOT OVERFILL In case that the oil pressure control lamp still illuminated with correct oil level have the engine checked by your STEYR Marine dealer as to malfunction of signal or oil pump NOTE During normal operation of engine oil pressure will rise as RP...

Page 42: ...lowingspeeds 3000 rpm 3000 rpm 3000 rpm 3200 rpm 3200rpm 3400rmp 2200rpm 2200rpm 3300rpm 3600rpm 3600rpm which will prolong engine life and reduce sound emissions When starting a cold engine always allow the engine to warm up slowly Never run the engine at full speed until operating temperature is reached During the first 50 running hours check the oil level frequently M084K32 M094K33 M0114K33 M01...

Page 43: ...Z001019 0_8_Octobre 2011 PageGENERAL 35 GENERAL SERVICE MANUAL MARINE ENGINES ToC THIS PAGE IS INTENTIONALLY BLANK ...

Page 44: ...fting gear crane with a lifting capacity of 5 000 N 500 kg minimum Cleaning device wash basin for soiled components Commercialtools Appropriate test and measuring equipment Receptacles for operating agents Depending on the repair step to be carried out the tools indicated in the catalog TOOL KIT are to be provided Furthermore special care is to be taken in case of purchasing and stock of required ...

Page 45: ... a component of an assembly if further assemblies are put on for functional achievement loosen Partial unlocking of fixing elements of a component or of an assembly remove Taking off a fixing element of a component or an assembly secure Putting on a fixing element of a component or an assembly andtightening disassemble Taking apart assemblies into individual components assemble Putting together co...

Page 46: ...emeter J Joule cm2 squarecentimeter kW h kilowatt hour Volume Power m3 cubic meter kW kilowatt cm3 cubic centimeter dm3 cubic decimeter mm3 cubic millimeter l litre Mass Temperature t metric ton K degreesKelvin kg kilogram C degreesCelsius g gram Energy Time N newton h hour kN kilonewton min minute daN dekanewton s second Electricity Velocity A ampere km h kilometer per hour V volt m s meter per s...

Page 47: ...ANUAL MARINE ENGINES ToC E 5 Abbreviations ill illustration Cu copper MAssy main assembly max maximum TDC top dead center PTO POWER TAKE OFF power transmission at front crankshaft end WS wrench size EMS Electronic Management System ECU Electronic Control Unit ...

Page 48: ... 509 315 ml cartridge surface sealing 5910 50 ml cartridge construction adhesive 620 50 ml flask construction adhesive 262 50 ml flask contact grease 100 ml tube corrosion protection spray 400 ml can corrosion protection wax 120 ml can grease STABURAX NBU4 1 kg can fuel rust protection additive 5 lt can electric contact spray silver varnish RAL 9006 1 lt can hardener varnish 0 5 lt can dilution fo...

Page 49: ...100 refers to the required disposal in Austria Respective legal local regulations are to be followed The maintenance and repair personnel has to take care that operating material and other material to be regarded as special waste product is always deposited at collection site Key No Description 31 423 Oil contaminated soil or oil bonding agent 54 102 Waste oil 54 104 Fuels 54 202 Lubricants 54 207...

Page 50: ...elines for damage prevention The general knowledge and training of the workshop personnel and the contents of the general regulationsofsafetytechnology andmachinesafetyregulations Maschinen Sicherheitsverordnung MSV are not subject of this chapter Inappropriate behaviour and insufficient knowledge of hazard during repair works may cause injury to persons In the description of repair works such sou...

Page 51: ...oil or an appropriate bonding agent and to be disposed ATTENTION In order to prevent health hazards take care of the following Avoid direct contact with dangerous operating material as far as possible Change clothes as quickly as possible if they are soiled with dangerous operating material Do not keep oily rags in work clothes Clean oil soiled body parts only with products friendly to skin never ...

Page 52: ...o cylinder block 1 step 15 Nm 2 2 step 25 Nm 1 Tighten screws of camshaft housing in two steps in precedence of numbering on bearings from the inside outwards Plug screw for locking pin in engine housing 50 Nm 5 Connectingrodscrews apply oil to thread and screwhead support 1 step 10 Nm 1 2 step 30 Nm 3 3 step 75 4 Main bearing screws apply oil to thread and screwhead support 1 step 35 Nm 3 2 step ...

Page 53: ... ill 7 08 01 ill 8 Flywheel screws useLOCTITE243onthread 75 Nm 4 Vibration damper screws apply oil to thread and screwhead support 135 Nm 2x 7 Screw rear ring carrier useLOCTITE243onthread 1 step 8 Nm 1 2 step 30 Nm 3 Nut camshaftsprocket taperdegreasedoncamshaft thread lubricated 1 step 80 Nm 4 2 step 240 Nm 12 ...

Page 54: ...bre 2011 SERVICE MANUAL MARINE ENGINES ToC 08 01 ill 9 08 01 ill 10 08 01 ill 11 08 01 ill 12 Valve adjustment element 55 Nm 3 Screw tooth belt tensioner 45 Nm 4 Screw linkage lever CAUTION left handthread 7 Nm 0 5 Stud unit injector 21 Nm 2 ...

Page 55: ...VICE MANUAL MARINE ENGINES ToC 08 01 ill 13 08 01 ill 14 08 01 ill 15 08 01 ill 16 Nut adjustment screw of unit injector 30 Nm 3 Collar nut for unit injector 18 Nm 2 Plug screw for control rack in camshaft housing 50 Nm 5 Screw exhaust manifold 23 Nm 2 ...

Page 56: ... ill 17 08 01 ill 18 08 01 ill 19 08 01 ill 20 Screws intercooler 28 Nm 2 Studs turbocharger M8 23 Nm 2 M10 35 Nm 2 Plug screws zinc anode 50 Nm 5 Crown nut oil cooler useLOCTITE243onthread 55 Nm 5 Nut turbocharger greased with NEVER SEEZ M8 25 Nm 2 M10 45 Nm 2 NOTE for all clamps 3 5 Nm ...

Page 57: ...20 870 M 24 570 800 960 M 24 660 930 1100 M 27 840 1200 1400 M 27 980 1400 1650 M 30 1150 1600 1950 M 30 1350 1850 2250 Nominal Ø Nominal Ø M 8x1 22 30 36 M 8x1 25 35 42 M 10x1 25 42 59 71 M 10x1 25 49 68 82 M 12x1 25 76 105 130 M 12x1 25 88 125 150 M 12x1 5 72 100 120 M 12x1 5 83 115 140 M 14x1 5 120 165 200 M 14x1 5 140 195 235 M 16x1 5 180 250 300 M 16x1 5 210 295 350 M 18x1 5 260 365 435 M 18x...

Page 58: ...rew connections is not necessary Anaerobic sealing materials These are used for securing fixing and sealing and only harden under exclusion of air Solvent containing sealing materials Due to their contents of volatile parts a loss of volume occurs during hardening During repair the hardeningtimeistakenintoconsideration Ifsuchsealingmaterialsareused specialreferenceismade in the description of the ...

Page 59: ...peduring screwing in Screws or nuts which are tightened with a specified torque are slightly oiled on their support surface or housingpart Guidelines for fixing B Designation BM Fixing medium tight Designation BF Fixing tight Application Jointing connections bushings sprockets belt pulleys bearings etc Jointing procedure In case of jointing connections both jointing parts are to be wetted The wett...

Page 60: ...to 3 mm before end of valve guide J Wear Limits Part resp part union Main bearing clearance radial Main bearing clearance axial Connect rod bearing clear radial Connect rod bearing clear axial Cylinder bore Piston travel clearance Piston diameter Gap 1 ring Gap 2 ring Gap 3 ring Axial play 1 ring Axial play 2 ring Axial play 3 ring Camshaft radial Camshaft axial Valve guide Oil pressure idle run O...

Page 61: ...tenance instruction In case the measurements are not within the specified limits of 630 N to 490 N than the settings needs to be reset to the original specified value J 1 3 Start of fuel delivery on the unit injectors measured with dial indicator No 2300899 0 Setting instruction For original settings on your engine please see table 03 02 06 Maintenanceinstruction Incasethemeasurementsarenotwithint...

Page 62: ...GENERAL PageGENERAL 54 Z001019 0_8_Octobre 2011 SERVICE MANUAL MARINE ENGINES ToC THIS PAGE IS INTENTIONALLY BLANK ...

Page 63: ...lace dowel pin for positioning of camshaft housing 34 01 01 08 Replace external screw adaptor for oil cooler 35 01 01 09 Replace coolant supply pipe 35 01 01 10 Mount frame seal 36 01 02 Crankshaft bearing vibration damper 38 01 02 01 Replace crankshaft 38 01 02 02 Replace gear for oil pump drive 42 01 03 Flywheel housing 43 01 03 01 Replace flywheel housing 43 01 03 02 Replace flywheel 44 01 03 0...

Page 64: ... 06 04 Replace oil pump front ring carrier 72 01 06 05 Replace oil suction pipe 73 01 08 Intercooler 74 01 08 01 Remove intercooler 74 01 08 02 Assembly of intercooler 78 01 08 03 Replace intercooler element 79 01 09 Auxiliary drive in front PTO 81 01 13 Engine oil cooler 82 01 13 01 Replace engine oil cooler 82 01 13 02 Repair oil cooler 84 01 13 03 Change motor oil 85 01 13 04 Change oil filter ...

Page 65: ...ver 01 00 02 Special tool for vibration damper screws No 2300767 0 Locking pin No 2300551 2 1 Unscrew allen head plug screw ill 1 SW 10 2 Turn crankshaft by means of special tool 2300767 0 ill 2 until roller of rocker arm cyl 1 runs up the ramp of injection cam ill 3 3 Insert locking pin 2300551 2 into guide hole and slightly press it against crankshaft counter weight 00 01 ill 1 00 01 ill 2 00 01...

Page 66: ... make sure that locking pin has been removed 3 Clean sealing surface of camshaft housing and camshaft housing cover Check seal for hardening and damage Exchange if necessary See 01 00 02 4 Remaining assembly is done in reserve order 4 Continue to turn crankshaft slowly manually in direction of rotation until locking pin engages into slot of crankshaft ATTENTION Never actuate starter engine as long...

Page 67: ... positionsaretobefoundincaseofcorrectadjustment The bearing roller of the rocker arm on cyl 1 is located just before the injection cam cap The marked tooth of the camshaft timing belt sprocketstay sinlinewiththeupperedge sealing surface of the camshaft housing Thenotchonthetimingbeltsprocketof crankshaft is opposite to the arrow marker on the oil pump housing 00 01 ill 8 00 01 ill 9 00 01 ill 10 T...

Page 68: ...surface Remove seal with a scraper and dispose 5 Cleansealingsurfaceofcamshafthousingcoverand camshaft housing 6 For engines with plane sealing surface Position new seal on camshaft housing cover and press it into the groove beginning at the half moon ill 2 7 For engines with bossed sealing surface Apply LOCTITE 5900 to sealing surface of camshaft housing cover position the new sealing on and forc...

Page 69: ...E See for arrows markings on used timing belt mark timing belt if necessary Consider change intervals see chart maintenance 00 03 ill 1 00 03 ill 3 00 03 ill 2 00 03 ill 4 Special tool 2306031 4 dial gauge rail 4 cyl 2306031 1 dial gauge rail 6 cyl with bossed seal surface 2306031 6 dial gauge rail 6 cyl with plane seal surface 2300899 0 dial gauge 2300641 1 probe pin VR00515 0 V belt tightener 23...

Page 70: ... by meansofspecialtool2300767 0andremovevibration damper 12 Remove timing belt ATTENTION Withlooseand orremovedtimingbelt the camshaft or crankshaft must not be turned Thiscouldresultinacollisionofpistons and valves 00 03 ill 7 00 03 ill 8 00 03 ill 6 00 00 00 03 ill 5 8 Pre set dial gauge to position 20 mm stroke small pointer at 20 inside scale big pointer at 0 outside scale or press zero button...

Page 71: ...er direction of rotation on timing belt 14 Mount vibriation damper Slightly grease thread and flange of 3 TORX screws Grease P N Z012222 0 and tighten with torque wrench to 135 Nm 7 NOTE Recheck torque after first test run 15 Tightly put on timing belt from crank shaft sprocket over water pump drive wheel and camshaft sprocket and position camshaft sprocket with marked tooth towards upper sealing ...

Page 72: ...rther counterclockwise turning of tensioner hexagon SW 32 to read 600 N 30 Nm for new timing belt indication on tension gauge between green and red marked field ATTENTION When putting on tension gauge No VR00515 0 consider the following The two stop trunnions ill 15 pos 2 should rest on the forehead of timing belt and must not rest on the back of timing belt Put measuring bow onto tooth Duringmeas...

Page 73: ...ed and read measured value Timing belt tension should be 600 N 30 N for a new timing belt NOTE If timing belt tension does not correspondtospecifiedtension loosen the tensioner and repeat adjustment according to instructions under item 21 through 24 In this case a re positioning of the camshaft sprocket may be required 22 Turn crankshaft further 2 turns and at second turn fix crankshaft with locki...

Page 74: ...ol No 2300711 0 and turn nut by approx 1 4 rotation 24 Mount extractor ill 23 pos 1 camshaft sprocket VR00113 0 and screw in puller screw LEFTHAND THREAD by hand Prestress puller screw with approx 100 Nm 5 NOTE Do not remove camshaft sprocket from conical seat when screwing in the puller screw 25 Remove camshaft sprocket from concial seat by one hammer blow on puller screw NOTE Tocorrectthesetting...

Page 75: ...ins adjusted as described before 28 Remove locking pin from crankshaft Refer 01 00 01 29 Tighten hexagon nut SW 30 of camshaft sprocket to 80 4 Nm by holding up with special tool 2300711 0 at hexagon on camshaft ATTENTION During this operation camshaft sprocketandcamshaftareconnected positively A positive connection is only achieved by tightening the hexagon nut with 240 12 Nm The previously set s...

Page 76: ...ect index value of engine timing tighten hexagon nut of camshaft sprocket SW 30 with 240 12 Nm by holding up with special tool No 2300711 0 32 ATTENTION The following torques are to be checked again 1 Torque on hexagon nut of camshaft sprocket SW 30 240 12 Nm 2 Fillister socket head screw SW 8 of timing belt tensioner at 45 4 Nm 3 3 TORX screws on vibration damper with 135 4 Nm 33 Remove locking p...

Page 77: ...Unscrew hexagon screws SW 10 of lower timing belt covering ill 2 pos 2 and remove timing belt cover NOTE See for arrows markings on used timing belt mark timing belt if necessary Consider change intervals see chart maintenance 5 Lock crankshaft see 01 00 01 6 Loosen Allen head screw SW 8 of belt tensioner and remove tensioner 7 Loosen 3 TORX screws for vibration damper by meansofspecialtool2300767...

Page 78: ...nk angle before TDC piston cylinder 1 in TDC in order to set all pistons in the engine to approximately the same length of stroke thus providinge open space for the valve movement stroke This ensures that the camshaft may be turned to the desired position injection stroke unit injector cylinder 1 without problems Crankshaft position with dismantled vibration damper Crankshaft position with mounted...

Page 79: ...n dial gauge rail and put probe pin onto unit injector plunger guide cylinder 1 3 Turn camshaft until the roller of rocker arm is located on base circle of injection cam 4 Pre set dial gauge to position 20 mm stroke small pointer at 20 inside scale big pointer at 0 outside scale 5 Slowly turn camshaft in direction of rotation until dial gauge shows a stroke of 2 mm injection stroke at unit injecto...

Page 80: ...ON Veryhighforasaretransmittedviathis conical seat Therefore it is extremely important that the two cone surfaces are assembled absolutely clean and grease free 9 Shiftcamshaftsprocketontoconeandslightlylubricate thread at front end of camshaft Slightly turn hexagon nut and washer by hand The camshaft sprocket should only slightly be supported by the cone in this status on easily turning of the ca...

Page 81: ...Z012222 0 and tighten with torque wrench to 135 Nm 7 NOTE Recheck torque after first test run 12 Tightly put on timing belt from crank shaft sprocket over water pump drive wheel and camshaft sprocket and position camshaft sprocket with marked tooth towards upper sealing edge of camshaft housing 13 Clean and degrease contact surface of tensioner and camshaft housing Then mount tensioner 00 05 ill 1...

Page 82: ... the forehead of timing belt and must not rest on the back of timing belt Put measuring bow onto tooth Duringmeasuring completelypushinmeasuring bow and relax quickly Whenattainingtherequiredtimingbelttension tighten the Allen head screw SW 8 with torque wrench to 45 Nm 4 and hold up at the same time with wrench SW32 16 Tighten hexagon nut SW 30 of camshaft sprocket to 80 Nm 4 by holding up with s...

Page 83: ...ead measured value Timing belt tension should be 600 N 15 N for a new timing belt NOTE for a used timing belt 520 N 30 N NOTE If timing belt tension does not correspond to desired value loosen the tensioner and repeat adjustment according to instructions under item 14 to 19 In this case a re positioning of the camshaft sprocket may be required 20 Turn crankshaft further 2 turns and at second turn ...

Page 84: ...ex value of engine timing tightenthehexagonnutofthecamshaftsprocket SW 30 with 240 Nm by holding up with special tool No 2300711 0 22 ATTENTION The following torques are to be checked again 1 Torque on hexagon nut of camshaft sprocket SW 30 240 Nm 12 2 Allen head screw SW 8 of timing belt tensioner at 45 Nm 4 3 3 TORX screws on vibration damper with 135 Nm 7 23 Remove locking pin on crankshaft õ 0...

Page 85: ...extractor ill 26 pos 1 camshaft sprocket VR00113 0 and screw in puller screw LEFTHAND THREAD by hand Prestress puller screw with approx 100 Nm 5 NOTE Do not remove camshaft sprocket from conical seat when screwing in the puller screw 26 Remove camshaft sprocket from concial seat by one hammer blow on puller screw NOTE Tocorrectthesettingof enginetiming follow further instructions as per item 27 00...

Page 86: ... remains adjusted as described before 29 Remove locking pin from crankshaft See 01 00 01 30 Tighten hexagon nut SW 30 of camshaft sprocket to80Nm 4byholdingupwithspecialtool2300711 0 at hexagon on camshaft ATTENTION During this operation camshaft sprocketandcamshaftareconnected positively A positive connection is only achieved by tightening the hexagon nut with 240 Nm 12 The previously set stroke ...

Page 87: ...ect index value of engine timing tighten hexagon nut of camshaft sprocket SW 30 with 240 Nm 12 by holding up with special tool No 2300711 0 33 ATTENTION The following torques are to be checked again 1 Torque on hexagon nut of camshaft sprocket SW 30 240 Nm 12 2 Fillister socket head screw SW 8 of timing belt tensioner at 45 Nm 4 3 3 TORX screws on vibration damper with 135 Nm 4 34 Remove locking p...

Page 88: ...osen two setscrews SW17 of engine mount remove engine mount NOTE Afterassemblyoftheenginemount center the engine to correct axis geometry of drive unit Replace engine bracket 1 For 4 cyl engines Loosen 7 allen head screws SW6 remove bracket and 7 washers NOTE During assembly secure allen head screws with LOCTITE 243 9000059 1 and tighten with a torque of 23 2 Nm 1 For 6 cyl engines Loosen 4 allen ...

Page 89: ... SERVICE MANUAL MARINE ENGINES 00 06 ill 5 Exchange bracket on flywheel housing 1 Loosen 4 allen head screws SW10 and remove support NOTE During assembly secure allen head screws with LOCTITE 243 9000059 1 and tighten with a trorque of 75 5 Nm ToC ...

Page 90: ...mble pistons 01 04 01 1 Insert special tool No VR00104 00 in cylinder bore andtightensturdilywithtwohexagonscrews SW19 2 Mount valve spring retainer No VR00105 1 3 Prestress valve spring with hexagon nut SW28 4 Remove wedges 5 Relax valve spring again remove valve spring sp ring plate and spring washer 6 Remove special tool from cylinder bore remove valves 01 01 ill 1 01 01 ill 2 01 01 ill 3 01 01...

Page 91: ... valve stem over sleeve 9 Remove sleeve and press on valve stem gasket with special tool No V000166 0 until valve stem gasket is supported on collar of valve guide 10 Lubricate valve stem motor oil 11 Mount special tool No VR00104 0 again 12 Put on spring washer valve spring and spring plate and prestress valve spring with special tool No VR00105 1 NOTE The progressively wound end of the valve spr...

Page 92: ...ool No VR 00125 0 and adjusting gauge 2300712 3 ill 1 pos 1 betweencamshaftbasecircle ill 1 pos 2 and cam follower ill 1 pos 3 NOTE index value outlet valve 0 25 mm index value intake valve 0 25 mm 01 02 ill 1 1 3 2 01 03 ill 1 01 01 03 Replace valve guide Preparation Disassemble valves 01 01 01 1 Press out valve guide with special tool VR00154 0 2 Insert valve guide with special tool VR00109 0 To...

Page 93: ...tion Disassemble engine casing 01 06 01 Remove pressure regulating valve with open end wrench WS13 ATTENTION Screwinpressureregulatingvalve until front collar is seated in bore Screw in pressure regulating valve sturdily NOTE Securethreadwithstructuraladhesive LOCTITE 262 ATTENTION Only tested valves with an opening pressure of 1 6 bar 0 15 bar to be used ToC ...

Page 94: ... 0_6_July 2008 SERVICE MANUAL MARINE ENGINES 01 01 05 Replace stud bolt for unit injector Preparation Remove camshaft housing cover 01 05 01 Remove unit injector 03 02 02 1 Tighten threaded pin with a torque of 21 1 Nm 01 05 ill 1 ToC ...

Page 95: ... Page ENGINE 33 01 ENGINE SERVICE MANUAL MARINE ENGINES 01 01 06 Replace dowel pin for positioning of unit injector Preparation Disassemble camshaft housing 01 05 01 1 Insert new dowel pin by means of setter 01 06 ill 1 ToC ...

Page 96: ...01 07 ill 2 01 01 07 Replace dowel pin for positioning of camshaft housing Preparation Disassemble camshaft housing 01 05 01 Insert new dowel pin by means of setter ATTENTION Do not close oil supply duct with dowel pin in front see illustration below ENGINE DAMAGE Cylinder 1 Oil supply duct Dowel pin ToC ...

Page 97: ...1 Screwinexternalscrewpart ill 1 pos 1 withatorque of 100 Nm 5 2 Put on new O ring ill 1 pos 2 2 1 01 08 ill 1 01 08 ill 2 01 09 ill 1 1 2 01 01 09 Replace coolant supply pipe Preparation Disassemble control solenoid 03 08 1 Loosen hose clamp ill 1 pos 1 remove hose 2 Loosen three allen head screws SW5 ill 1 pos 2 remove coolant supply pipe NOTE Use new seal for assembly ToC ...

Page 98: ...frame seal slot variant item 2 7 2 Apply construction adhesive LOCTITE 262 on both sides of first profile groove of frame seal 3 Apply activator 764 to groove in the cylinder block 01 10 ill 1 01 10 ill 2 01 10 ill 3 01 10 ill 4 4 Put frame seal from the bottom over the cylinder block 5 Bourrelet of frame seal profile must be placed at the front coolant pump in the center of the side of cylinder b...

Page 99: ...l into block groove NOTE For easier installation of frame seal apply alcohol on sealing profil The alcohol will serve as a lubrication agent during installation process 9 Clean of the frame seal lip and the block slot using Acetoneoranonoilbasedcleaner purealcohol and give time for this dry before continuing Place Loctite activator 7649 see below on the upper edge of the frame seal lip and in the ...

Page 100: ...onnecting rod bearing caps and the main bearing caps thecrankshaftmaynotbeturned 2 Loosen the two screws of each connecting rod with special tool 2300746 0 remove connecting rod bearingcapswithbearingshell Pushdownallpistons and connecting rods to TDC position NOTE Remain with crank shaft in position during work operation to avaid damange the bearings Never turn crank shaft 3 Remove rocking pin 4 ...

Page 101: ...il All pistons with connecting rods are inserted in the cylinder bore Mount injection oil nozzles with new O rings When inserting the crankshaft take carethatthefirstconnectingrodjournal pin is positioned at TDC 9 Check fotproperinstallationmainbearingshellsand connecting rod bearing shells ATTENTION Main bearing base and main bearing cap are marked with consequential numbers on one side of the be...

Page 102: ...and screw head support lubricated 1st working step all screws 10 Nm 1 2nd working step all screws 30 Nm 3 3rd working step all screws 75 4 Special tool No 2300706 0 ATTENTION Usescrewsonlytwice Aftertightening mark with center punch Tighteningspecificationformainbearingscrews thread and screw head support lubricated 1st working step all screws 35 Nm 3 2nd working step all screws 45 4 3rd working s...

Page 103: ...01 ill 13 Measuring of end clearance Put on magnetic holder with dial gauge put dial gauge caliper onto crankshaft end Move crankshaft in forward direction and set dial gauge to zero Move crankshaft backwards and read measured value Clearance should be between 0 07 and 0 25 mm ToC ...

Page 104: ...ing belt Disassemble oil pump 01 06 02 Disassemble oil suction pipe 01 06 03 1 Remove woodruff key ill 1 pos 1 2 Pulloffgear ill 1 pos 2 withsleevering ill 1 pos 3 NOTE Apply surface sealing agent 509 to contact surfaces of gear towards crankshaft and sleeve ring 3 Placeoilpumpdrivegearwithlargerchamferagainst crank shaft contact surface to clear machined shaft radius ill 2 pos 1 02 02 ill 2 1 ToC...

Page 105: ...ation Dismantle engine mount of flywheel housing 01 00 04 1 Loosen 6 hexagon sockets SW8 and 4 hexagon sockets SW6 2 Remove flywheel housing from adjusting sleeve ill 1 pos 1 3 For SOLAS models only First loosen screw ill 2 pos 1 and fix blow by valve above flywheel housing 4 Assembly is done in reverse order 03 01 ill 1 1 03 01 ill 2 1 ToC ...

Page 106: ...02 Replace flywheel Preparation disassemble torsion coupling 02 01 disassemble intermediate ring 01 03 03 1 Lock crankshaft 01 00 01 2 Loosen eight hexagon head screws SW17 and remove flywheel NOTE Apply thread protection LOCTITE 243 to hexagon head screws and tighten with a torque of 75 Nm 4 ToC ...

Page 107: ...AL MARINE ENGINES 01 03 03 Replace adapter ring Preparation Dismantle flywheel housing 01 03 01 For 6 cyl engines 1 Loosen 9 hexagon head screws SW13 remove adapter ring NOTE Screw tensile strength 10 9 Tightenhexagonscrewswithatorque of 30 Nm 3 03 03 ill 1 ToC ...

Page 108: ... 01 06 01 disassemble crankshaft 01 02 01 1 Pull out piston with connecting rod 2 Remove retainer ring of piston pin by means of a screwdriver 3 Push out piston pin remove piston from connecting rod 4 Remove piston rings by means of piston ring pliers Special tool piston ring pliers 2300906 0 ATTENTION For assembly of piston rings take care of marking TOP In case of a change of cylinder diameter t...

Page 109: ...g groove of connecting rod bearing is opposite to the clearance for injection oil nozzle NOTE Forbestresultpositionringswithpiston gap about one third of a turn a part from each other gap NOTE When inserting the piston into cylinder bore with special tool No 2300714 1 takecarethatarrowmarkingonpiston bottom shows to the front 04 01 ill 6 04 01 ill 5 ToC ...

Page 110: ...t battery Disconnect crankshaft from TDC 01 00 01 Dismantle all unit injectors 03 02 02 1 Loosen all control links and turn to the back ill 1 pos 1 ATTENTION LEFTHAND THREAD ill 1 pos 2 2 Release timing belt dismantle tightener 3 Remove timing belt from gear 4 For 4 cyl engines Loosen 3 hexagon nuts SW13 ill 3 pos 1 and remove Remove indexing plate 05 01 ill 3 1 2 05 01 ill 1 05 01 ill 2 C 1 C 1 T...

Page 111: ...ill 4 pos 3 and remove Remove bracket with potentiometer 8 Remove plug ill 5 pos 1 from control solenoid For 4 cyl engine item 9 12 9 Remove plug ill 6 pos 1 from control solenoid 10 Remove plug ill 6 pos 3 for sensor of control rack 11 Loosen plug ill 6 pos 2 for potentiometer accelerator 12 Dismantle supportig strap ill 7 pos 1 between cam shaft housing and intercooler 05 01 ill 4 õ 05 01 ill 6 ...

Page 112: ...e 14 Loosen hose clamp ill 8 pos 2 and ill 9 pos 1 and dismantle raw water pipe and bend 15 Dismantlecover ill 8 pos 3 tointercoolerbyloosening 5 hexagon screws SW10 16 Disconnect speed sensor ill 10 pos 1 17 Loosen hexagon screws SW13 ill 11 18 Remove camshaft housing upwards Remove sealing 05 01 ill 10 05 01 ill 11 C 1 C 1 C 2 C 3 C 1 05 01 ill 9 05 01 ill 8 ToC ...

Page 113: ...djust control refer to 01 00 03 11 Calibrate sensor for main rack position refer to 06 10 03 12 Assembly engine in reversed order Assembly of camshaft housing 1 Clean sealing surfaces of motorblock ill 12 pos 1 and camshaft housing ill 12 pos 2 2 Put on camshaft housing sealing ill 12 pos 3 ATTENTION Always use new sealing 3 Put on camshaft housing Take care that all cam followers ill 13 pos 1 res...

Page 114: ...housing 01 05 01 ATTENTION Set piston of respective cylinder on TDC 1 Mount valve spring retainer No VR00105 1 ill 1 2 Presstress valve spring ill 2 with hexagon socket SW28 3 Remove wedges 4 Relax valve spring again remove valve spring and spring washer 5 Remove valve stem gasket with special tool No 2300758 0 05 02 ill 1 05 02 ill 2 05 02 ill 3 05 02 ill 4 ToC ...

Page 115: ...0166 0 until valve stem is supported on collar of valve guide 8 Lubricate valve stem motor oil 9 Put on valve spring and spring washer and prestress with special tool No VR00105 1 NOTE Progressively wound end of valve spring is located at cylinder block 10 Put in wedges relax valve spring check correct seat of wedges NOTE In case of replacing other valve stem gaskets take care that respective pist...

Page 116: ...1 Disassemble control solenoid 03 08 01 Disassemble unit injector of 1st cylinder 03 02 02 1 Disassemblehandletocontrolsolenoid byloosening two hexagon screws SW8 ill 2 pos 1 2 Disassemble all control links ill 3 pos 1 by loosening hexagon socket SW4 ill 3 pos 2 ATTENTION LEFTHAND THREAD 3 Remove setpin ill 4 pos 1 from last bulkhead 05 03 ill 2 05 03 ill 3 05 03 ill 4 1 2 1 05 03 ill 1 1 ToC ...

Page 117: ...ng screw SW22 ill 5 remove sealing ring pull out control rod to the back NOTE Connection of lefthand thread screws and control links to be opened three times only 5 Adjust control link mass equalization refer to 03 02 04 6 Adjust control refer to 01 00 03 7 Calibrate rack position refer to 06 10 03 ToC ...

Page 118: ...ble camshaft housing refer to 01 05 01 1 Loosen hexagon nut SW30 ill 1 pos 1 2 Disassemble camshaft wheel with special tool No VR00113 0 ill 2 remove washer 3 Remove axial holder of camshaft and rocker arm shaft ill 3 4 Disassemble all cam followers refer to 01 05 07 05 04 ill 1 05 04 ill 2 05 04 ill 3 05 04 ill 4 1 2 ToC ...

Page 119: ...ith radial shaft seal to the front 6 Pull out camshaft from the front of camshaft housing ATTENTION On all 4 cyl and 6 cyl engines before 68224400 Attherearendofcamshaft ill 1 pos 2 the speed sensor wheel is located When pulling out and pushing in the camshaft take care that bearings of camshaft are not damaged ToC ...

Page 120: ...m 1 Remove half moon rings ill 1 pos 1 on both sides of rocker arms 2 Variant 1 Extract axial holder ill 2 of camshaft and rocker arm shaft 3 Variant 2 Extract axial half moon rings ill 3 of rocker arm shaft 2x same as for rocker arms 4 Displace rocker arm remove slide rings remove rocker arms one by one and pull out rocker arm shaft towards cyl 4 or 6 ill 4 05 05 ill 1 05 05 ill 2 1 05 05 ill 3 0...

Page 121: ... of camshaft Preparation Lock crankshaft 01 00 01 Remove timing belt Disassemble camshaft wheel 1 Disassemble radial shaft seal 2 Mount new radial shaft seal with special tool No VR00122 0 NOTE Radial shaft seal is waxed therefore needs not to be oiled Do not use grease on radial shaft lip seal 05 06 ill 1 ToC ...

Page 122: ... ill 1 pos 3 with special tool No VR00106 0 NOTE Crankshaft is first to be turned in a position which prevents collision between valve piston bottom ATTENTION Before relaxing the valve spring check whether the valve wedges ill 1 pos 4 are still positioned correctly ENGINE DAMAGE 4 Lift cam follower from valve stem end and turn sidewards 5 Lift cam follower from ball pin 6 Lift cam follower by mean...

Page 123: ...ES 01 05 08 Replace retainer of cam follower Preparation disassemble cam follower 01 05 07 1 Turn retainer spring ill 1 pos 1 sidewards and removebymeansofscrewdriverfromvalveadjusting element towards center NOTE Adjust valves refer to 01 01 02 05 08 ill 2 05 08 ill 1 1 ToC ...

Page 124: ...5 09 Replace valve adjusting element Preparation Disassemble retainer spring of cam follower spring 01 05 08 1 Unscrew valve adjusting element with hexagon socket SW21 NOTE ApplythreadprotectionLOCTITE 243 tovalveadjustingelementandtighten with a torque of 55 Nm 3 NOTE Adjust valves refer to 01 01 02 ToC ...

Page 125: ...smantle E box dismantle exhaust manifold heat exchanger refer to 05 01 02 1 LockliftingchainspecialtoolNo VR00103 0ontothe two lifting shackles ill 2 1 2 Lift engine with special tool No VR00130 0 and crane min 3500 N and mount it on No VR00102 0 and trestle No VR00101 0 by means of four hexagon screws M8x30 SW13 ATTENTION thread screwing depth 1 5xD 3 Dismantleoildipsticktube ill 4 pos 1 andventi...

Page 126: ...E ENGINES 5 Dismantle oil hose on engine cooler ill 5 pos 1 6 Disconnect oil hose on oil pump ill 6 pos 1 7 Unscrew hollow screw SW19 ill 7 pos 1 to fuel feed pipe For 4 cyl engines 8 Remove oil filter bracket 06 01 ill 5 06 01 ill 6 06 01 ill 7 06 01 ill 8 1 1 1 ToC ...

Page 127: ...ly refer to 05 10 13 Loosen 11 hexagon screws SW10 remove lower timing belt covering For 6 cyl engines 14 Loosen 6 hexagon screws Remove lower timing belt covering 15 Dismantle flywheel housing refer to 01 03 Dismantle torsion coupling refer to 02 Remove flywheel refer to 01 03 16 Dismantle engine cooler refer to 01 13 Forengineswithscrewedframeseal alusupport 17 Unscrew frame sealing from housing...

Page 128: ...cture frame seal 19 Loosen one hexagon screw SW10 ill 14 pos 1 Remove protective sheet For 4 cyl engines 20 First loosen 11 Allen head screws SW5 ill 15 pos 1 then7hexagonscrews SW17 ill 15 pos 2 For 6 cyl engines 21 First loosen 13 Allen head screws SW5 ill 17 pos 1 then3hexagonscrews SW13 ill 17 pos 2 and at last 4 hexagon screws SW17 ill 17 pos 3 06 01 ill 13 06 01 ill 14 06 01 ill 15 06 01 ill...

Page 129: ... in the area of the parting plane from the engine housing Wet sealing surfaces of screws with surface sealing agent LOCTITE 509 For 6 cyl engines item 4 6 4 Clean sealing profiles from adhesive residues 5 Only for engines with rubber frame seal slot variant Wet sealing profile of frame sealing on both sides with construction adhesive LOCTITE 262 6 Wet sealing ring on front ring carrier with surfac...

Page 130: ...ll 22 pos 2 with a torque of 50 Nm 5 Fasten 11 Allen head screws SW5 ill 22 pos 1 with a torque of 10 Nm 1 10 For 6 cyl engines ATTENTION Tighten 4 hexagon screws SW17 ill 23 pos 3 with a torque of 50 Nm 5 Then fasten 3 hexagon screws with a torque of 23 Nm 2 SW13 ill 23 pos 2 andatlast13Allenheadscrews with a torque of 10 Nm 1 SW5 ill 23 pos 1 11 Forengineswithscrewedframeseal alusupport Screw to...

Page 131: ... For engines with rubber frame seal slot variant Press frame sealing by hand into housing halfs NOTE To avoid an extension of the rubber only push frame seal profil straight into groove of engine housing 13 Further assembly is done in reverse order of disassembly 06 01 ill 25 ToC ...

Page 132: ...Remove support ring 2 Clean and degrease all sealing surfaces 3 Wet sealing area of support ring with surface sealing agent LOCTITE 509 4 Mount new support ring ATTENTION Replace radial shaft sealing ring VR00107 0 5 Tighten flange screws of rear ring carrier with a torque of 28 Nm 3 NOTE Secure flange screws of rear ring carrier with thread protection LOCTITE 243 06 02 ill 1 ToC ...

Page 133: ...rear radialshaft sealing ring Preparation Remove flywheel refer 01 03 Remove radial shaft sealing ring 1 Mount special tool No VR00107 0 to press in the rear radial shaft sealing ring 2 Press radial shaft sealing into rear built in ring carrier by means of special tool No VR00107 0 Assembly engine in reverse order ToC ...

Page 134: ...ENTION Replaceradialshaftsealingring ill 3 pos 1 in oil pump housing Mount oil pumphousing andinsertradialshaft sealing ring with special tool No VR00118 0 NOTE Check sealing ring ill 3 pos 2 on oil pumphousingfordamage exchange if necessary wet new sealing ring with surface sealing agent LOCTITE 5910 ApplyLOCTITE509 toflangesurface to front main bearing block and oil pump front ring carrier Secur...

Page 135: ...ck Remove plate only possible at 4 cyl engines ill 2 pos 2 2 Pull of oil suction pipe Check O ring ill 2 pos 3 replace if necessary ATTENTION During assembly of oil suction pipe take care that no bracings occur Assembly is done in reverse order 3 Grease O ring during assembly 4 Secure the screws with thread protection LOCTITE 243 and tighten with a torque of 10 Nm 1 06 05 ill 2 1 2 3 06 05 ill 1 T...

Page 136: ...andem cooler refer to 05 01 06 or remove triple cooler refer to 05 01 08 or For M16 246 only Remove additional oil cooler refer to 05 01 07 For 4 cyl engines item 3 8 3 Unscrew 3 hexagon nuts ill 3 pos 1 of shift plate and remove 4 Loosen plug connections of boost pressure sensor ill 4 pos 1 loosen accelerator potentiometer ill 4 pos 2 5 Loosen hose clamp ill 4 pos 3 Take off hose and remove shift...

Page 137: ...pports intercooler ill 6 pos 1 8 Loosen hose clamps of hose connection turbocharger intercooler ill 7 pos 1 and remove hose For 6 cyl engines item 9 10 9 Unscrew setscrews ill 8 pos 1 for pipe support of raw water pipe 10 Removecover ill 8 pos 2 tointercoolerbyloosening 5 hexaong screws SW10 08 01 ill 5 08 01 ill 7 08 01 ill 8 08 01 ill 6 A 1 1 C 2 1 ToC ...

Page 138: ...ow screw of boost pressure hose ill 12 pos 4 on air collector and remove 11 For 4 cyl engines Unscrew hexagon screw SW10 ill 9 pos 1 of raw water pipe clamp 12 Open hose clamp ill 9 pos 2 on intercooler 13 Open hose clamp on heat exchanger ill 10 pos 1 and remove raw water pipe For 6 cyl engines item 14 19 14 Loosenhoseclamp ill 11 pos 1 Loosen2hexagon screws SW13 ill 11 pos 2 andremoveconnecting ...

Page 139: ...f wiring harness on the bottom of air collector and turn away wiring harness 21 Only for 4 cyl engines with hydraulic system Loosen 2 hexagon sockets ill 14 pos 1 remove hydraulic tank and fix it laterally in such a way that no oil can leak 22 Unscrew hexagon sockets SW6 from intercooler and remove 08 01 ill 13 08 01 ill 15 08 01 ill 14 C 1 A 1 ToC ...

Page 140: ...f monoblock 3 Clean sealing surfaces on intercooler ill 3 4 For 4 cyl engines Apply a slight film of LOCTITE 5900 to the sealing surfaces ill 3 of intercooler 5 Fixintercooleronengineblockbymeansof2hexagon sockets For 4 cyl engines screw in remaining 6 hexagon sockets SW8 and for 6 cyl engines remaining 10 hexagon sockets and tighten with a torque of 28 Nm 2 6 Further assembly is done in reverse o...

Page 141: ...ler intercooler element and intermediate flange 4 Grease O ring ill 1 pos 5 with Molykote BR 2 PLUS and shift it up to the flange of the intercooler element ill 1 pos 10 Insert intercooler element into intercooler Grease O ring ill 1 pos 6 with Molykote BR 2 PLUS insert it into intercooler cover ill 1 pos 3 fix on intercooler and loosely mount on intercooler with 3 screws ill 1 pos 2 5 Push O ring...

Page 142: ...01 ENGINE PageENGINE 80 Z001019 0_6_July 2008 SERVICE MANUAL MARINE ENGINES THIS PAGE IS INTENTIONALLY BLANK ToC ...

Page 143: ...gon screws SW13 ill 1 pos 1 and remove drive shaft 4 Loosen 3 hexagon screws SW13 ill 1 pos 2 and remove flange ring For 6 cyl engines item 5 7 5 Loosen 6 hexagon screws SW10 ill 2 pos 1 and remove elastic shaft with adapter plate 6 Loosen 3 hexagon screws SW13 and 3 hexagon nuts SW13 ill 2 pos 2 Remove adapter plate from elastic shaft 7 Assembly is done in reverse order 09 01 ill 1 09 01 ill 2 1 ...

Page 144: ...LER 01 13 01 Replace engine oil cooler Preparation Empty closed cooling circuit 05 00 02 Remove tandem cooler 05 01 06 1 Loosen hose clamp ill 1 pos 1 on oil cooler 6 Loosen fixing nut ill 2 of oil line SW22 7 Loosen 4 allen head screws SW6 remove cooler 13 01 ill 2 13 01 ill 3 C 1 13 01 ill 1 ToC ...

Page 145: ...albow of the water pump Take care that the engine oil cooler is led parallel to the assembly surface O ring may be damaged in main oil duct ill 6 pos 1 Replace O rings of oil hoses and grease with Staburax NB04 Filling refer to 05 00 08 Filling closed cooling system NOTE Cover the three contact surfaces with surface sealing agent LOCTITE 5900 Tighten 4 allen head screws with a torque of 23 Nm 2 Se...

Page 146: ...Prior to assembly clean all sealing surfaces Slightly grease the O rings with Staburax NB04 1 Cover sealing surfaces of the two housing halfs with surface sealing agent LOCTITE 5900 special tool No 2300717 0 2 Put together cooler insert and housing halfs with three new O rings ill 1 pos 3 3 Loosely screw in hexagon sockets SW5 ill 1 pos 2 4 Screw in the two slotted round nuts with thread protectio...

Page 147: ...ove oil filler cap ill 2 pos 1 6 Fill in STEYR turbo diesel engine oil SAE 10W 40 No Z010058 0 ill 3 or equivalent motor oil with characteristics ACEA B4 02 or API code CF ATTENTION Oil filling must not exceed the maximum marker Overfilling results in high operating temperatures foaming air in oil loss in efficiency and a reduced engine life As the quantity for an oil change refer to Specification...

Page 148: ...collecting pan below oil filter ill 2 3 Loosen the oil filter with oil filter wrench No 2300713 1 and unscrew by hand Dispose the oil filter acc EPA regulation 4 Clean sealing surface of oil filter head 5 Oil the seal of new oil filter and screw it onto oil filter headuntilthesealeasilyrestsagainst Tightentheoil filter with a 3 4 turn ATTENTION Remove possible oil contaminations from filter head a...

Page 149: ...Z001019 0_6_July 2008 PageENGINE 87 01 ENGINE SERVICE MANUAL MARINE ENGINES 01 14 EXHAUST MANIFOLD SEALS HEAT EXCHANGER Refer to 05 01 02 Exhaust manifold heat exchanger ToC ...

Page 150: ...01 ENGINE PageENGINE 88 Z001019 0_6_July 2008 SERVICE MANUAL MARINE ENGINES THIS PAGE IS INTENTIONALLY BLANK ToC ...

Page 151: ... 2008 Page COUPLING 1 SERVICE MANUAL MARINE ENGINES 02 COUPLING 02 COUPLING Table of Contents Page 02 01 Replace torsion coupling 2 02 01 01 For 6 cyl engines 2 02 01 02 For 4 cyl engines 4 02 01 03 Installation 6 ToC ...

Page 152: ... 01 02 01 01 Remove coupling for 6 cyl engines Remove coupling for gearbox jet drive VOLVO stern drive apllication Variant 1 Loosen 9 screws Remove coupling Variant 2 Loosen 6 screws Remove coupling Variant 3 Loosen9hexagonscrews Removeflywheeladaptor and coupling 01 01 ill 1 01 01 ill 2 01 01 ill 3 Old version replaced by variant 2 Current version replaced variant 1 ToC ...

Page 153: ...e apllication Variant 1 Loosen 3 screws Remove coupling Loosen 9 screws Remove flywheel adaptor if necessary Variant 2 Loosen 6 screws Remove coupling Loosen 9 screws Remove flywheel adaptor if necessary Variant 3 Loosen 6 screws Remove coupling Loosen 9 screws Remove flywheel adaptor if necessary 01 01 ill 5 01 01 ill 6 01 01 ill 7 Current version replaced variant 1 01 01 ill 4 Old version replac...

Page 154: ...VOLVO stern drive apllication Variant 1 Loosen 9 screws Remove coupling Variant 2 Loosen 6 screws Remove coupling Loosen 9 hexagon screws Remove coupling Remove coupling for OMC VOLVO SX stern drive apllication Loosen6screws removewashers Removecoupling 01 02 ill 1 01 02 ill 2 01 02 ill 3 Old version replaced by variant 2 Current version replaced variant 1 ToC ...

Page 155: ...move coupling for MERCURY stern drive apllication Variant 1 Loosen 3 screws Remove coupling Variant 2 Loosen 6 screws Remove coupling Loosen 9 screws Remove flywheel adaptor if necessary 01 02 ill 4 01 02 ill 5 Old version replaced by variant 2 Current version replaced variant 1 ToC ...

Page 156: ...Z001019 0_6_July 2008 SERVICE MANUAL MARINE ENGINES 02 01 03 Installation Description Nm Screw Coupling M8 x 1 25 8 8 23 Screw Coupling M8 x 1 25 10 9 32 Screw Coupling M10 x 1 5 45 Use locking compound LOCTITE 243 on threads ToC ...

Page 157: ...n 17 03 02 07 Exchange check valve for fuel pre pressure to unit injector 20 03 04 Air filter 21 03 04 01 Change air filter 21 03 05 Turbocharger 22 03 05 01 Replace turbocharger 22 03 05 02 Check bearing clearance 25 03 08 Control solenoid 26 03 08 01 Remove control solenoid 26 03 08 02 Install control solenoid 28 03 08 03 Replace sensor indication of control rack position 29 03 09 Change fuel fi...

Page 158: ...alteventil Fuel check valve Kraftstoffrücklauf Fuel return line Kraftstoff Filter Fuel filter Kraftstoffpumpe Fuel pump Rückschlagventil Check valve Kraftstoffzufuhr PD Fuel supply UI Pumpedüse Unit Injector Regelstangensensor Rack position sensor Kipphebel Rocker arm Anlenkhebel Adjustment lever 7 10 9 6 13 3 2 1 1 1 4 1 5 1 2 8 1 4 5 Aktuator Control solenoid Kraftstoffkühler Fuel cooler 03 00 f...

Page 159: ...e is controlled by pressure valve 7 1 8 2 5 bar at idle 8 anti siphon valve 9 baffles depending on tank size For fuel requirements refer to chapter GENERAL Specification for fuel pipes Minimum inside diameter 8 mm Recommended material stainless steel or copper NOTE Min inside diameter for hosepipes or PA pipes is 10 mm Rate of flow 240l h 7 in case of continuously operating pump If additional filt...

Page 160: ...nto the line ATTENTION Closefuelcockontank iftankishigher 2 ATTENTION Prior to disassembly disconnect batterycablesfrombattery toavoid damages to the electronic system 3 Disconnect positive cable and negative cable ill 6 by unscrewing hexagon nuts SW7 8 with washer from terminals of fuel pump 4 Unscrew hollow screw ill 6 pos 1 of fuel feed line Dispose Cu sealing rings 5 Unscrewhollowscrew ill 6 p...

Page 161: ...r plate and holding strap Remove fuel pump For 6 cyl engines only item 7 8 7 Remove two hexagon screws SW10 for fixing fuel pump on filter plate ill 8 pos 1 as well as ground wire ATTENTION Mark position of fuel pump on pump support 8 Remove pump bracket ATTENTION Measure height for assembly of pump because of fitting position of fuel lines 02 01 ill 7 02 01 ill 8 1 ...

Page 162: ...a standard torque of 10 Nm 1 Torque wrench No 2300704 0 Fix ground cable together with bracket 6 Mount adaptor with Cu sealing rings at top face of fuel pump 7 Attach fuel lines between filter and pump as well as pump and block Tighten hollow screws with a torque of 30 Nm 3 ATTENTION Hold up with second wrench on he xagon of pump housing to avoid a damage to the E pump Always use new Cu sealing ri...

Page 163: ...is at base circle as well intake and exhaust valve are open in order to permit a lateral shifting of rocker arm 2 Before loosening flange nuts of unit injectors ven tilate fuel system For this purpose open screw of banjo fitting just enaugh to let air through seal rings between fuel filter and fuel pump ill 4 pos 1 and let pump run approx 6 times for 10 sec Make sure that air is sucked ATTENTION C...

Page 164: ...n socket SW 4 LEFT HAND THREAD per unit injector 5 Loosen adjusting nut with 17 mm socket wrench hexagonnutSW17andscrewdriver Turnadjusting screw to such an extent that the slide cup is loosely attached to the spring plate Do not remove 6 Insert screwdriver with small blade into recess of retainer ring half moon ring for rocker arm lock push retainer ring upwards and remove Fordisassemblyofunitinj...

Page 165: ... position of control link s against bulkhead as illustrated 9 Insert the unit injector lever SMO No VR00126 0 below the camshaft and push upwards against the body of unit injector The unit injector is thus lifted out fromtheengineblockandmayberemovedmanually NOTE For disassembly of the unit injector from cylinder No 1 the control rack is to be moved forward 10 Remove unit injector with mounting fl...

Page 166: ...h a torque of 21 Nm 2 2 Drain possible fuel residues by means of suction de vice No VR 00121 0 from the combustion chamber Suction device must be equipped with a suction hose of at least 250 mm of length in order that possible fuel residues can be sucked from piston recess NOTE Fuelresiduesinthecombustioncham ber may cause severe damage to the engine 3 Check copper insert for possibly remaining se...

Page 167: ...sertnewspecialcoppersealwasher ill 19 pos 2 fromsealkitZ002031 0 with a screwdriver into copper insert Make sure the copper seal washer is plane 6 Install new O rings ill 19 pos 1 from seal kit Z002031 0 and cover O rings with a thin coat of clean motor oil 7 Insert unit injector into bore and align unit injector recess to dowel pin ill 20 pos 1 for positioning Avoid any contact with control link ...

Page 168: ... with motor oil put it onto adju stment screw as shown and shift it together with rocker arm onto unit injector 10 Install retainer ring to secure the rocker arm 11 Screw on flange nuts hexagon nuts SW 13 and tighten evenly Absolutely tighten nuts with a torque of 18 2 Nm ATTENTION Payattentionto horizontalinstallation of mounting flange 02 02 ill 21 02 02 ill 22 02 02 ill 23 02 02 ill 24 ...

Page 169: ...TEM 12 Fix control rack 13 Attach control link to control rack and adjust Refer to 03 02 04 Adjusting Control Link 14 Adjust injection start Refer to 03 02 06 Injection Start unit injector 15 Connect fuel pipes and operate electric fuel pump 3 times for 10 seconds to vent fuel system ...

Page 170: ... 02 1 Unscrewsetpinofcontrolrack ill 1 pos 1 attheback of camshaft housing as shown 2 Position bore diameter 4 mm in control rack ill 2 pos 1 overreferencebore ill 2 pos 2 inthebulkhead wall 3 Pull control rack manually to the front against spring resistance and hold Insert setpin as shown and fasten sturdily 02 03 ill 1 02 03 ill 2 02 03 ill 3 1 02 03 ill 4 2 3 1 1 2 ...

Page 171: ...ully position end of control link on front side of unit injector control rack possibly use screwdriver 2 Turn control link against unit injector control gear until controlgearcompletelypushesagainstuppergauged stop and hold position with screwdriver Hold in this position and tighten left handed setscrew of control link with a torque of 7 Nm 0 5 Repeat steps 1 and 2 for the rest of unit injector co...

Page 172: ... pos 2 from bulkhead wall with removingsetpinandholdcontrolrack Reinstallsetpin in rear camshaft housing bore ill 3 pos 1 2 Tighten setpin with a torque of 7 Nm 3 Check axial flexibility of control rack Control rack is to be moved easily and should automatically return to reverse position due to spring load 02 05 ill 2 02 05 ill 1 02 05 ill 3 1 2 ...

Page 173: ...eal surface 2306031 6 dial gauge rail 6 cyl with plane seal surface 2300899 0 dial gauge 2300641 1 probe pin 1 Unit injector must be installed properly and fastened Control rack and unit injector control gear must be free to move 2 Put dial gauge rail with bracket No 2306031 see list special tool onto stud bolt at intercooler side of camshaft housing and fasten with nuts 3 Turn camshaft until bear...

Page 174: ...th a build date before 2007 48226999 68226999 M094K32 M0114K33 M0144M38 M0144V38 M0164M40 MO174V40 MO126K28 MO166K28 MO236K43 MO246M41 MO256H45 MO256K43 MO266K43 TYPE 2176555 5 2176555 5 2176555 5 2176555 5 2176557 0 2176557 0 2176555 5 2176555 5 2176555 5 2176557 0 2176557 0 2176557 0 2176557 0 Unit Injector 8 27 0 02 8 27 0 02 8 27 0 02 8 27 0 02 8 27 0 02 8 07 0 02 8 27 0 02 8 27 0 02 8 27 0 02...

Page 175: ...2 3 20 0 02 0 25 0 25 MO114K33 2176557 0 8 47 0 02 8 52 0 02 3 20 0 02 0 25 0 25 MO144V38 2176557 0 8 27 0 02 8 32 0 02 3 20 0 02 0 25 0 25 MO144M38 2176557 0 8 47 0 02 8 52 0 02 3 20 0 02 0 25 0 25 MO164M40 2176557 0 8 37 0 02 8 42 0 02 3 20 0 02 0 25 0 25 MO174V40 2176552 1 8 77 0 02 8 82 0 02 3 20 0 02 0 25 0 25 MO126K25 2176552 1 9 29 0 02 9 34 0 02 3 20 0 02 0 25 0 25 MO156K25 2176552 1 9 15 ...

Page 176: ...for fuel pre pressure to unit injector 1 Unscrew valve SW 19 mm ill 1 pos 1 remove 2 Cu sealing rings NOTE Use new Cu sealing rings for assem bly Tightenwithatorqueof 40Nm 4 ATTENTION On account of importance of this valve proper function of fuel system onlyusegenuineSTEYRsparepart for possible exchange 02 07 ill 1 1 ...

Page 177: ...9069 4 cyl and 68219174 6 cyl 1 Open retaining clip 2 Remove air filter and cover 3 Put new air filter together with cover onto filter head and fix with retaining clip From engine serial no 48219070 4 cyl and 68219175 6 cyl 1 Remove hose clamp and air filter 2 Mount new air filter together with hose clamp and tighten clamp solid 04 01 ill 1 04 01 ill 2 04 01 ill 3 ...

Page 178: ...n fastenings of heat protection Remove heat protection ill 2 pos 1 5 Loosen hose clamp ill 2 pos 2 and remove hose for air charge pressure box 6 Loosen screw ill 2 pos 3 for raw water pipe support SW10 7 Loosen hollow screw ill 3 pos 1 of oil feed line on turbocharger 8 Remove plug of oil pressure switch ill 3 pos 2 9 Loosen hollow screw ill 3 pos 3 of oil feed line on motorblock Dispose Cu sealin...

Page 179: ...and remove hose For 6 cyl engines only item 13 17 13 Loosensupportscrew ill 7 pos 1 forraw waterpipe 14 Remove covering ill 7 pos 3 to intercooler by loo sening 5 hexagon screws SW10 ill 7 pos 2 15 Loosenhoseclamp ill 8 pos 1 connectioncompres sion housing 16 Loosen 2 hexagon screws ill 8 pos 2 and remove connecting bend 17 Loosen hollow screw ill 8 pos 3 of cooling system vent pipe SW14 Remove pi...

Page 180: ...etween turbocharger return pipe and engine housing intake for crack and damage Replace if necessary For 4 cyl engines only Clean sealing surface of flange turbo charger and exhaust manifold and lubricate with grease Z012222 0 For 6 cyl engines only Clean sealing surfaces of flange turbo charger and exhaust manifold Replace flange seal Further assembly is done in reverse order ATTENTION Tigthen the...

Page 181: ...easurement by turning cursor by 90 Permissible radial clearance max 0 42 mm 0 04 measuring point measuring strength location point of dial gauge prod For 4 cyl engines only item 1 2 1 Tighten 4 hexagon nuts of turbocharger flange with a torque of 25 Nm 2 2 Tighten 2 screws for fixing the flange of oil return pipe with a torque of 10 Nm 1 Tighten hollow screw with 25 Nm 3 For 6 cyl engines only ite...

Page 182: ...01 1 Disconnect battery For 4 cyl engines only item 2 3 2 Loosen plug connection ill 2 pos 1 for control rack potentiometer 3 Remove plug from control solenoid ill 2 pos 2 For 6 cyl engines only item 4 11 4 Unscrew 3 hexagon screws SW10 ill 3 pos 1 of upper timing belt covering 5 Unscrew 2 hexagon screws SW10 ill 4 pos 1 of front control solenoid covering 08 01 ill 2 08 01 ill 3 08 01 ill 4 08 01 ...

Page 183: ...ket with potentiometer accelerator 9 Remove plug ill 5 pos 4 for sensor of control rod 10 Remove plug ill 6 pos 1 from control solenoid 11 Loosen 4 hexagon screws SW13 ill 6 pos 2 on control solenoid housing Remove control solenoid assembly Remove seal and dispose For 4 cyl engines only 12 Loosen 4 hexagon screws SW13 ill 7 on control solenoidhousing removecontrolsolenoidassembly Remove seal and d...

Page 184: ...only Secure the 4 screws with LOCTITE 243 and tighten with a torque of 23 Nm 2 For 6 cyl engines only item 8 9 7 Cover the two lower screws with LOCTITE 243 and slightly tighen 8 CoverthetwoupperscrewswithLOCTITE243 Bring into position bracket with potentiometer accelerator and fix with upper screws Tighten the 4 screws with a torque of 23 Nm 2 9 Check whether the control rack can be moved over a ...

Page 185: ...ill 2 pos 1 is positioned in front of solenoid rod ill 2 pos 2 2 Secure 2 Allen head screws 3 mm with Loctite 243 and tighten with a torque of 5 Nm 0 5 3 Check whether control rack can be moved over a distance of approx 18 mm ATTENTION Rod of rack rack position sensor is spring loaded and might easily slip off from the face of solenoid rod ill 2 pos 2 during assembly In such a case the control rac...

Page 186: ...ankishigher than fuel filer 2 Unscrew filter ill 2 by means of filter wrench No 2300713 1 Remove filter and dispose Take care that original seal does not adhere to filter housing If so remove seal and dispose 3 Clean sealing surface on filter head ill 3 4 Slightly oil seal of new fuel filter with clean motor oil ill 4 5 Screw on new fuel filter until seal slightly rests on sealing surface of filte...

Page 187: ...oid refer to 03 08 01 For 6 cyl engines only for glow plug of first cylinder remove control solenoid refer to 03 08 01 for glow plug of second to sixth cylinder remove intercooler refer to 01 08 01 1 Remove glow plug 2 Unscrew glow plug s with special tool No VR00146 0 3 Screw in new glow plug s by means of special tool No VR00146 0 and tighten by means of special tool No 2300703 0 with a torque o...

Page 188: ...pressure meter No 2300750 0 ill 3 4 Remove plug J1 Connect special tool No VR00145 0 instead of plug J1 5 Put into operation compression pressure meter ac cording to operating instructions 6 Start engine by pressing the button for 5 to 10 sec of special tool No VR00145 0 until compression pressure rises no more ATTENTION Start with special tool VR00145 0 only Engine may just turn but not feed and ...

Page 189: ...Z001019 0_7_July 2012 Page FUEL SYSTEM 33 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM THIS PAGE IS INTENTIONALLY BLANK ...

Page 190: ...ion Remove camshaft housing cover refer to 01 00 02 1 Remove plug screw ill 1 pos 1 with sealing ring 2 MountspecialtoolNo VR00148 0 ill 2 pos 1 together with sealing ring ill 2 pos 2 3 Move control rack by means of special tool No VR00148 0 into idle injection position approx 5 6 mm ill 3 and remain in this position 14 01 ill 1 14 01 ill 2 14 01 ill 3 1 1 2 ...

Page 191: ...on of return fuel There should be neither air bubbles nor discoloration gray in the fuel 2 Check proper flow quantity i e engine at idle flow rate after engine block 180 to 240 l hr 47 to 63 gal Injector Check To feel the injection activities move the control rack quantity delivery in between its acceptable travel 5 to 14mm while depressing the plunger with the rocker arm For safe and easier handl...

Page 192: ...speed of engine continue with item 3 3 Bring engine to operating temperature and then test the boat under operating conditions and watch for bubbles to form Keeping this operating condition continue with item 4 4 Loosen nut on cover ill 1 pos 1 screw in with fast turns screw ill 1 pos 2 until knocking noise disappears Tighten nut ill 1 pos 1 again As a re sult unit injector is pressed down to such...

Page 193: ...ition ON Observe the sight glass as to complete ventilation of system bubblefree fuel flow Result If a bubblefree fuel flow cannot be achieved search for the problem at the suction side from fuel tank to fuel pump Check 1 Fuel in tank 2 Tank suction pipe and fitting 3 ANTI SIPHON VALVE if installed leckage 4 Water separator leaky or contaminated 5 Check all fuel lines connections and fittings in t...

Page 194: ... during load operation continue with check 3 Check 3 Start the engine bring it to operating temperature test the boat under operating conditions and observe the glass bulb Result If it comes to bubble formation search for the problem in the area of unit injectors Control Defective unit injector s is are to be detected definitely by means of Disengagement methode of injection manual injection test ...

Page 195: ...uly 2008 Page EXHAUST SYSTEM 1 SERVICE MANUAL MARINE ENGINES 04 EXHAUST SYSTEM Page 04 01 Hi Riser 3 04 01 01 Replace Hi Riser 3 04 01 02 Measurement of Exhaust Backpressure 4 04 EXHAUST SYSTEM Table of Contents ToC ...

Page 196: ...04 EXHAUST SYSTEM Page EXHAUST SYSTEM 2 Z001019 0_6_July 2008 SERVICE MANUAL MARINE ENGINES THIS PAGE IS INTENTIONALLY BLANK ToC ...

Page 197: ...clamp ill 3 pos 1 connecting hose heat exchanger hi riser 4 Loosen 2 hose clamp ill 4 pos 2 from exhaust pipe elbow 5 Variant 1 Loosen hexagon screws ill 2 pos 3 of hi riser Remove hi riser 6 Variant 2 Loosen profiled clamp ill 4 pos 1 of hi riser Remove hi riser Assembly 1 Prior to assembly clean sealing surfaces of turbocharger high riser and lubricate with high temperature grease SMO Z012222 0 ...

Page 198: ...g ill 1 pos 3 with pressure gauge connection ill 1 pos 4 onto pressure gauge ill 1 pos 1 Connectpressuregaugetooneendofpressure hose ill 1 pos 5 6 Connect the other end of pressure hose ill 1 pos 5 to double union ill 1 pos 6 MEASUREMENT Drive the boat under operating conditions rated output at rated speed and read off pressure on pressure gauge RESULT With an exhaust pressure below 100 mbar at ra...

Page 199: ...ansion tank 16 05 01 01 Coolant tank 16 05 01 02 Disassembly exhaust manifold heat exchanger 17 05 01 03 Checks 21 05 01 04 Exchange heat exchanger element 23 05 01 05 Assembly of exhaust manifold 24 05 01 06 Exchange tandem cooler 26 05 01 07 Exchange additional oil cooler only type 246 26 05 01 08 Exchange triple cooler 27 05 03 Pipes thermostat 27 05 03 01 Coolant pipes and hoses 27 05 03 02 Ex...

Page 200: ...eering and or transmission oil system Then water flows through the tube stake of intercooler ill 1 5 where the raw water absorbs thermal energy from air charge Through the connecting line above the rear part of the camshaft case the raw water enters the tube stake of heat exchanger ill 1 6 where the raw water still absorbs thermical energy from engine coolant Then raw water flows through the high ...

Page 201: ...STEM 00 01 ill 1 1 Raw water intake 2 Impeller pump 3 Fuel cooler 4 Hydraulic oil and transmission oil cooler 5 Tube stake intercooler 6 Tube stake heat exchanger 7 Hi riser 8 Sensor exhaust gas temperature 9 Raw water outlet 10 Sacrificial anodes 11 Raw water filter 12 Splash water flap ...

Page 202: ... side of coolant pump This circulating circuit ill 2 A is continued until the coolant in the thermostat housing ill 2 6a has achieved the temperature 80 C As soon as the temperature of 80 C in the thermostat housing is achieved the thermostat opens and the coolant is partially thermostat opens according to operating temperature transmitted to the heat exchanger ill 2 B Via the contact channel the ...

Page 203: ...g pump 2 Oil cooler 3 Water jacket block cylinder 4 Water cooled exhaust manifold 5 Turbocharger 6a Thermostat closed 6b Thermostat open 7 Tube stake heat exchanger 8 Water intake pipe 9 Expansion tank 10 Filler cap 11 Coolant temperature sensor 12 Drain plug B Circuit thermostat open A Circuit thermostat closed ToC ...

Page 204: ...ter pump impeller defective broken or strong wear suction pipe from raw water filter to raw water pump clogged or deformed shaft bearing defective Sealing O ring of impeller housing defective impeller plate seal Tandem cooler contaminated e g through a part of broken impeller Tube stake intercooler contaminatd Heat exchanger exhaust contaminated seal in heat exchanger cover defective Ventilation A...

Page 205: ...the outlet of raw water pump ill 2 1 Disconnect hose from pressure side of raw water pump connect pipe stub ill 2 pos 10 and connect raw water hose to pipe stub again 2 Mount intermediate sealing ring ill 2 pos 3 with pressuregaugeconnection ill 2 pos 4 ontopressure gauge ill 2 pos 2 and connect it at one end of pressure hose ill 2 pos 5 3 Connect the other end of pressure hose ill 2 pos 5 to pipe...

Page 206: ...function of thermostat overheating or slow heating of coolant Procedure Let the engine run until indicated temperature exceeds 80 C Feel on hose of front engine water pipe between heat exchanger and water intake pipe Result Hose cold Conclusion Thermostat got stuck in closed state Result Hose warm or hot Conclusion Thermostat opens partially or completely Procedure Let the engine run temperature o...

Page 207: ... seals sand or dross in manifold burned out hoses 1 11 hull state of hull marine vegetation equipment attached to hull NOTE Mountings protruding over the hull may produce cavitations during fast ride which cause air bubbles These are possibly taken at the lower gear box by the drive and mixed with the inflowing cooling water Due to bad refrigerating capacity of the external cooling system an overh...

Page 208: ...new sealings and sealing rings 3 Raw water pump No special tools required Control works With running engine check rotation of pump belt pulley If belt pulley runs out of true this may cause excessive wear of the pulley and damages on the pump itself If with running engine leakages on the pump are stated the shaft sealing ring at the front of the pump is leaky or the spacer is defective Repair work...

Page 209: ...t for correct model and correct rated output corrosion limited mobility or broken spring Repair works No repair possible Exchange thermostat Test procedure Dip the thermostat together with a thermometer into a water tank and heat up the water At a temperature of 80 81 C the thermostat should begin to open and should open for 3 8 4 0 mm at a temperature of 85 88 C ill 1 A At 90 93 C the thermostat ...

Page 210: ...oler cap defective exhaust manifold exhaust gases reach the engine cooling circuit defective monoblock due to combustion pressure gases reach the engine cooling system 5 2 Gas air mixtures reach the cooling system 5 2 1 Defective exhaust manifold Control works 05 01 03 Check exhaust manifold heat exchanger 5 2 2 Defective leaky monoblock Control works Use special tool SMO VR00147 0 by using enclos...

Page 211: ...raw water circuit proceed as follows 3 Lock exhaust pipe with special tool No VR00144 0 ill 4 pos 1 4 Remove plug J 1 Connect special tool No VR00145 0 instead of plug J1 5 Start the engine by pressing the button until raw water system is completly emptied ATTENTION Only start with special tool No VR00145 0 Engine only be cranked by starter motor but not start 6 Aftercompletedrainage assemblyisdon...

Page 212: ...drain plug when the engine is hot This could lead to severe injuries by hot coolant underpressure Assoonastheengine has cooled down the cap may be openedby1 4turntotheleft torelease possibly remaining pressure Then press down the cap turn and remove 7 There are two drain plugs on the engine through which the coolant from the internal cooling circuit can be drained Refer to ill 5 pos 1 and ill 6 po...

Page 213: ...s old version only item 3 4 Remove venting screw ill 2 pos 1 SW6 at the front of heat exchanger Fill cooling circuit with specifiedcoolantonly Coolantlevelshouldreachthe lower edge of the filler neck in the expansion tank 4 Mount venting screw again and tighten ATTENTION For a new filling of the closed cooling circuit make sure that the cooling system is deaerated completely 5 Let the engine run c...

Page 214: ...ICE MANUAL MARINE ENGINES 05 COOLING SYSTEM 01 01 ill 1 05 01 COOLER HEAT EXCHANGER EXPANSION TANK 05 01 01 Coolant tank The coolant tank is an integrated part of the exhaust manifold heat exchanger housing and may not be exchanged in single parts ToC ...

Page 215: ...losed cooling circuit according to instructions in 05 00 07 drain coolant 2 Unscrew three screws ill 1 pos 1 of upper timing belt covering Remove covering 3 Disconnect water hose ill 2 pos 2 to thermostat housing 4 Loosen hose clamp ill 2 pos 1 and remove coolant pipe For 6 cyl engines only item 5 6 5 Loosen hose clamp ill 3 pos 1 and remove coolant pipe 6 Loosen hose clamp ill 3 pos 2 and remove ...

Page 216: ...0 Loosen hose clamp ill 6 pos 2 and remove hose for air charge pressure box 11 Loosen screw SW10 ill 6 pos 3 for raw water pipe support 12 Loosen hollow screw SW14 ill 7 pos 1 of oil feed line on turbocharger 13 Remove plug of oil pressure switch ill 7 pos 2 14 Loosen hollow screw ill 7 pos 3 of oil feed line on motorblock Dispose Cu sealing rings 15 Loosen 2 hexagon screws ill 8 1 of oil return l...

Page 217: ...r intercooler ill 10 pos 1 and remove hose For 6 cyl engines only item 18 21 18 Loosen setscrew ill 11 pos 1 for support of sea water pipe 19 Remove covering ill 11 pos 3 to intercooler by loosening 5 hexagon screws SW10 ill 11 pos 2 20 Loosen hose clamp ill 12 pos 1 compressor housing connection 21 Loosen 2 hexagon screws SW13 ill 12 pos 2 and remove connecting manifold 01 02 ill 9 01 02 ill 10 0...

Page 218: ...14 pos 1 and 2 3 nuts ill 14 pos 2 CAUTION If the exhaust manifold is not secured itmigthfallwhenlooseningthescrews 24 Remove exhaust manifold with turbocharger and high riser CAUTION Heavy unit approx 40 kg DisassemblyONLYwithsuitablelifting device or second person 25 Remove O rings or gaskets from exhaust manifold or cyl block and dispose 01 02 ill 13 01 02 ill 15 01 02 ill 14 1 1 2 1 ToC ...

Page 219: ...nger in a pressure test with closed outlet nipple Pressurize inlet nipple with a pressure gauge and immerse manifold into water At a pressure of 22 25 kPa the manifold should show no leaks ATTENTION Mostly structural cracks are highly dependent on thermal influence In order to achieve a more reliable result of the pressure test the component should be heated up to approx 80 C ToC ...

Page 220: ...Page COOLING SYSTEM 22 Z001019 0_6_July 2008 SERVICE MANUAL MARINE ENGINES 05 COOLING SYSTEM THIS PAGE IS INTENTIONALLY BLANK ToC ...

Page 221: ...ssembly 5 Grease O Ring ill 1 pos 5 with Molykote BR 2 PLUS and push it onto flange of heat exchanger element ill 1 pos 4 Then insert heat exchanger element from front into exhaust manifold Grease O ring ill 1 pos 6 with Molykote BR 2 PLUS and push it onto exposed rear end of heat exchanger element 6 Grease seal ill 1 pos 9 with Molykote BR 2 PLUS and insert it into heat exchanger cover at the bac...

Page 222: ...ock 2 Clean sealing surfaces on exhaust manifold ill 2 pos 1 For 4 cyl engines only item 3 5 3 Insert O ring on cyl bloc ill 3 pos 1 by means of Molykote 4 Insert two O rings ill 4 pos 1 into exhaust manifold by means of Molykote ATTENTION different sizes 5 Thinly cover sealing surfaces ill 4 pos 2 of exhaust manifold with surface sealing agent LOCTITE 5900 01 05 ill 2 01 05 ill 1 01 05 ill 3 01 0...

Page 223: ... means of Molykote 9 Put exhaust manifold onto 3 assembly bolts ill 5 pos 1 Mount manifold screws and tighten sturdily Remove assembly bolts and screw in remaining 3 screw and 3 nuts Tighten screws with a torque of 23 NM 2 nuts with 10 Nm For 4 cyl engines only item 10 11 10 Put exhaust manifold onto the two threaded bolts ill 6 pos 1 11 Tighten 8 hexagon screws SW13 ill 7 pos 1 with a torque of 2...

Page 224: ...ly Assembly is done in reverse order ATTENTION Use new sealing rings 3 5 4 2 6 1 01 06 ill 1 05 01 07 Exchange additional oil cooler used only at type 246 Disassembly Preparation loosen clamp oil dipstick SW10 1 Remove drain plug at tandem cooler to drain the raw water system 2 Loosen union nuts of oil hoses ill 1 pos 1 SW 21 at the additional oil cooler 3 Loosen hose clamp ill 1 pos 2 of hose to ...

Page 225: ... 1 Remove drain plug at triple cooler to drain the raw water system ill 1 pos 1 2 Loosen union nuts of oil hoses ill 1 pos 2 SW 32 at the triple oil cooler 3 Loosen hose clamps ill 1 pos 3 of hose to raw water hoses 4 Loosen fuel lines ill 1 pos 4 SW 19 and hydraulik lines SW 22 5 UnscrewthreeAllenheadscrews SW6 ill 1 pos 5 of clamps and remove triple cooler ill 1 pos 6 Assembly Assembly is done i...

Page 226: ...engines with hydraulic system item 2 3 2 Loosen hexagon screw SW10 fixing the oil tank of hydraulic system ill 3 pos 1 Remove oil tank from mount and fix it laterally to avoid any leaking of hydraulic oil 3 Loosen the two lower hexagon sockets SW5 ill 3 pos 2 fixing the covering of thermostat housing Remove covering of thermostat housing and seal together with mount for hydraulic tank Dispose seal...

Page 227: ...2 Put seal ill 6 pos 1 onto thermostat 4 Insert thermostat into housing ventilation mark ill 7 pos 1 showing upwards ATTENTION Put on new seal 5 Insert spacer 6 Remaing assembly is done in reverse order 7 Tighten screws of thermostat housing cover with a torque of 10 Nm 1 8 Filling of closed cooling circuit refer to 05 00 08 03 02 ill 7 03 02 ill 5 03 02 ill 6 1 1 03 02 ill 8 ToC ...

Page 228: ... are to be removed once a year and checked for galvanic erosion In case of a material loss of 50 the anode needs to be exchanged SW23 1 Anodes 1 and 2 ill 2 pos 1 2 are on the intercooler 2 Anodes 3 is in the high riser elbow 3 Anodes 4 and 5 ill 2 pos 4 5 are on the heat exchanger 4 Illustration 1 shows a new anode NOTE For operation with fresh water magnesium anode sticks are recommended 03 03 i...

Page 229: ...For 6 cyl engines only Loosen hose clamp ill 2 pos 1 and remove hose 2 Loosen hose clamps SW6 and remove hose between thermostat housing and water pump ill 3 pos 1 3 Loosen hose clamp of hose elbow ill 3 pos 2 at oil cooler side 4 Loosen all screws ill 4 and hexagon nut of water pump ill 4 pos 3 5 Loosen water pump by slight knocking with plastic hammer and remove hose elbow 04 01 ill 3 04 01 ill ...

Page 230: ... on motorblock 2 Put on new sealing ill 2 pos 1 3 Align water pump on motorblock Mount screws and nuts and tighen with standard torque for these size 4 Further assembly is done in reverse order in accordance with 01 00 04 remove timing belt 5 Adjust control according to instructions in paragraph 01 00 05 engine timing adjustment procedure 04 02 ill 1 04 02 ill 2 1 ToC ...

Page 231: ...sion inhibiting spray into the spring housing of the belt tensioner 1 Release belt tension by pulling tensioner from V belt oftorquewrenchNo 2300704 0 ill 3 pos 1 Remove Poly V belt 2 Pull the belt tightener counterclockwise by means of torque wrench No 2300704 0 into position as show ill 3 pos 1 Apply the Poly V belt acc to ill 1 for engine with hydraulic pump or ill 2 for engine without hydrauli...

Page 232: ... 1 and alternator ill 4 pos 2 NOTE Always change V belts in pairs only Servopump NOTE The servopump is driven together with the alternator Tension of V belt is done via alternator Raw water pump old version Preparation Remove alternator V belts 1 Loosen setscrews ill 3 pos 1 2 Loosen hexagon nut of clamping bolt ill 3 pos 2 Release V belt by turning the clamping bolt ill 3 pos 3 counterclockwise a...

Page 233: ...on Remove alternator V belts 1 Loosen screw ill 5 pos 1 Turn screw counter ill 6 pos 1 clockwise to reduce of tension V belt 2 Remove V belt 3 Assembly is done in reverse order 4 Adjust V belt tension according 05 07 02 5 Tighten screw ill 5 pos 1 with a Torque of 23 N 2 to secure idler pulley bracket 1 07 02 ill 5 07 02 ill 6 1 ToC ...

Page 234: ...s should be stretched to such an extent that they yield for 10 13 mm when pressing your finger on marked spots 07 01 ill 4 A B This corresponds to a belt tension of 350 Nm 50 If the belt is too loose it may slip through which results in higher wear and bad efficiency of alternator or servo pump Belt tension is to be checked after first 10 operating hours and than every 50 operating hours 07 02 ill...

Page 235: ...4 screws ill 1 pos 4 remove raw water pump ill 1 pos 5 6 Assembly is done in reverse order 7 Torque screws M6 pos 4 with 9 5 Nm screws M8 pos 1 with 23 Nm Secure all threads with LOCTITE 243 For 6 cyl engines only old version 1 Loosen two setscrews SW17 ill 2 pos 1 2 Loosen hexagon nut of clamp bolt ill 2 pos 2 relieve V belt by turning clamp bolt ill 2 pos 3 counterclockwise 3 Remove V belt ill 2...

Page 236: ...y combustion pressure in the cooling system Control works Check tightening torque of unit injectors 03 02 02 ASSEMBLY item 11 and repeat check NOTE If there is no gas entry coolant loss is eliminated If there is still gas entry refer to 03 14 02 to disengagement methode of injection this methode can help to detect a possible transfer of combustion gases into the water jacket NOTE If the defective ...

Page 237: ...ts of E box 29 06 05 03 02 Connection start assist relay K28 and K26 2 29 06 05 03 03 Connection relay socket for K24 K26 1 and K27 29 06 05 03 04 Wiring harness from eng no 482 18 000 682 18 000 SOLAS 30 06 06 Electronics general 36 06 06 01 Electronic Engine Management System 36 06 06 02 Diagnostic system 37 06 06 03 Reading error codes 38 06 06 04 Idication cancellation of memorized sensor and ...

Page 238: ...ition 82 06 10 04 Replace sender sensor 83 06 10 04 01 Sensor exhaust gas temperature B17 83 06 10 04 02 Sensor engine temperature B16 83 06 10 04 03 Sensor engine speed B15 83 06 10 04 04 Sensor boost pressure B12 83 06 10 04 05 Sensor rack position feedback B14 84 06 10 04 06 Sensor oil pressure B18 84 06 10 04 07 Potentiometer accelerator B13 84 06 10 05 Check sensors and switches 85 06 10 05 0...

Page 239: ...ctor locks meet the respective requirements Tools for crimp connections to be found in tool catalog P N Z001002 0 Level 4 06 00 01 Cable numbers principal functions 15000 xx ignition positive from ignition switch 15012 xx 12 volt via main relay and control unit A5 15100 xx 5 volt supply voltage for sensors 30000 xx battery positive not secured 30012 xx battery positive secured 31000 xx battery neg...

Page 240: ...GINES 06 01 ALTERNATOR 06 01 01 Adjust poly V belt tension 1 For 6 cyl engines only As to tension of V belt for alternator refer to chapter 05 07 01 02 For 4 cyl engines only Automatic initial tension of belt tension through spring loaded tightener ill 1 and ill 2 01 01 ill 1 01 01 ill 2 1 ToC ...

Page 241: ...move belt 3 Loosen screws ill 2 pos 1 2 remove alternator NOTE Assembly is done in reverse order For 4 cyl engines only Connections ill 3 1 B battery acc illustration 3 ill 3 2 D charging control L1 ill 3 3 DF D field rotor winding ill 3 4 D on governor For 4 cyl engines only Governor ill 4 1 B acc illustration 4 ill 4 2 DF ill 4 3 D ill 4 4 D 2 01 02 ill 1 01 02 ill 2 1 2 1 01 02 ill 3 2 1 3 4 01...

Page 242: ...integrated base governor Charge capacity at 750 r p m approx 34 A at 2500 r p m maximum charge capacity Condensor capacity 2 2 µF 01 03 ill 1 Charging circuit scheme 1 battery 2 Z2 ground connection on engine 3 red 4 fuse 50 A 5 starter engine 6 red 7 plug engine electrics instrument cable 8 fuse 10 A 9 starter key lock 10 15000 xx 11 red 16 mm 12 generator 13 charging controll L1 14 61000 02 18 p...

Page 243: ...crew so far that it overtravels the specified control range 4 Turn screwdriver clockwise to increase the operating voltage and or anticlockwise to lower the operating voltage Adjust voltage range between 14 0 and 14 2 volt 28 0 to 28 4 volt for 24 volt plants ATTENTION Do not turn adjusting screw so far that it overtravels the stop to prevent damages to the governor 5 After adjustment remove screw...

Page 244: ...A Governor integratedl base governor Excitation winding resistance 2 7 0 27 01 03 ill 4 Error Detection Check battery All connections terminals Acid concentration Filling level check refill if necessary Carry out load test Excessive voltage Governor Loose connections Battery Charging voltage too low Belt tension Output Governor Slip ring Internal components of alternator No charging voltage Belt t...

Page 245: ...gratedl base governor Excitation winding resistance 7 9 0 79 01 03 ill 5 Error Detection Check battery All connections terminals Acid concentration Filling level check refill if necessary Carry out load test Excessive voltage Governor Loose connections Battery Charging voltage too low Belt tension Output Governor Slip ring Internal components of alternator No charging voltage Belt tension Charging...

Page 246: ...gratedl base governor Excitation winding resistance 7 9 0 79 01 03 ill 6 Error Detection Check battery All connections terminals Acid concentration Filling level check refill if necessary Carry out load test Excessive voltage Governor Loose connections Battery Charging voltage too low Belt tension Output Governor Slip ring Internal components of alternator No charging voltage Belt tension Charging...

Page 247: ...Z001019 0_6_July 2008 Page ELECTRICAL SYSTEM 11 06 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES THIS PAGE IS INTENTIONALLY BLANK ToC ...

Page 248: ...urrent 90 A Governor integratedl base governor Charge capacity at 750 r p m ca 34 A at 3000 r p m maximum charge capacity Condensor capacity 2 2 µF 01 03 ill 7 Charging circuit scheme 1 battery 2 Z2 ground connection on engine 3 red 4 fuse 50 A 5 starter engine 6 red 7 plug engine electrics instrument cable 8 fuse 10 A 9 starter key lock 10 15000 xx 11 red 16 mm 12 generator 13 charging control L1...

Page 249: ...ng level check refill if necessary Carry out load test Excessive voltage Governor Loose connections Battery Charging voltage too low Belt tension Output Governor Slip ring Internal components of alternator No charging voltage Belt tension Charging control lamp defective 12V 2W Output Cables and connections Governor Slip ring Internal components of alternator Alternator scheme 01 03 ill 8 Governor ...

Page 250: ...specified 4 amp 0 4 Exciting current is higher than specified 4 amp 0 4 ConnecttesterlampbetweenB and D of generator With engine running tester lamp extinguishes With engine running tester lamp glows With engine stopped install new governor and start engine again Tester lamp between B und D Tester lamp extinguishes Tester lamp still glows Error and or Relief Generator control lamp L1 burned out an...

Page 251: ...s On the other hand diodes with an interruption in forward directionweremostlydestroyedbyexcessivecurrent or excessive heating ill 04 1 Lamp burning diode functional Lamp not burning diode interrupted ill 04 2 Lamp not burning diode functional Lamp burning diode had short circuit b by means of ohmmeter For diode testing only a simple battery powered ohmmeter may be used Measuring bridges are unsui...

Page 252: ...erminal 30 ill 2 pos 1 on magnetic switch by means of SW13 4 Loosen start signal wiring terminal 50 ill 2 pos 2 by means of SW10 5 Loosen two hexagon screws ill 2 pos 3 SW13 of starter bracket 6 Loosentwoscrews SW8 ill 2 pos 4 removestarter NOTE Have starter motor repaired in an authorized STEYR workshop After assembly coat all electric supplies with rubber sealing Z909570 0 03 00 ill 1 03 00 ill ...

Page 253: ...relay on starter defective voltage drop in lines too large lines damaged line connections loose links oxidized starterdoesnotinterrupt starterkey starter relay K28 actuating relay on starter defective short circuit in wiring cable No 50000 xx connected to 12V Relief charge battery and or replace cleanterminalsandtighten treatwith pole grease provide ground connection eliminate earth short circuit ...

Page 254: ...06 ELECTRICAL SYSTEM Page ELECTRICAL SYSTEM 18 Z001019 0_6_July 2008 SERVICE MANUAL MARINE ENGINES THIS PAGE IS INTENTIONALLY BLANK ToC ...

Page 255: ...sary repair of a cable connection take special care that cable quality isolation crimping strand end soldering of cable sockets as well as protective varnish isolation and or connector locks meet the respective requirements Tools for crimp connections to be found in tool catalog P N Z001002 0 KIT 3 In general take care that battery cable lengths are kept as short as possible starter engine 3 kW 12...

Page 256: ...06 ELECTRICAL SYSTEM Page ELECTRICAL SYSTEM 20 Z001019 0_6_July 2008 SERVICE MANUAL MARINE ENGINES 05 02 ill 1 06 05 02 E box base plate to eng no 482 17 000 ToC ...

Page 257: ...tion A5 E box control unit F1 fuse 50 A main fuse F2 fuse 50 A glow plugs F3 fuse 50 A glow plugs F4 fuse 5 A permanent current module F5 fuse 10 A switched current for module K27 F6 fuse 10 A fuel pump K24 J1 plug 23 pole connection engine cable instrument cable K24 relay fuel pump K26 1 relay preheating K26 2 realy preheating K27 relay main circuit K28 relay start assist relay X5 plug 35 pole mo...

Page 258: ...le plug pot rack position X15 B15 3 pole plug engine speed sensor X16 B 16 2 pole plug engine temperature sensor X17 B17 2 pole plug exhaust gas temperature sensor X18 B18 3 pole plug oil pressure sensor X19 B19 1 pole plug oil pressure gauge optional X20 Y20 2 pole plug control solenoid X22 B22 without stop trim sensor optional X23 6 pole plug diagnosis Z1 splice spot earth connection sensor Z2 s...

Page 259: ...Z001019 0_6_July 2008 Page ELECTRICAL SYSTEM 23 06 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 05 02 ill 4 Wiring harness to eng no 482 17 000 ToC ...

Page 260: ...06 ELECTRICAL SYSTEM Page ELECTRICAL SYSTEM 24 Z001019 0_6_July 2008 SERVICE MANUAL MARINE ENGINES Circuit diagram to eng no 482 17 000 05 02 ill 5 ToC ...

Page 261: ...r B12 3 Z3 link splice 15100 06 X14 pot rack position B14 C Z3 link splice 15100 07 X18 oil pressure sensor B18 B Z3 link splice 17415 01 F2 50A fuse glow plugs IN K26 1 relay preheating 87 17415 02 F3 50A fuse glow plugs IN K26 2 relay preheating 87 30000 03 K26 1 relay preheating 30 K28 starter relay 30 30000 04 K26 2 relay preheating 30 K28 starter relay 30 30000 05 F1 50A main fuse IN starter ...

Page 262: ...lice 31100 03 X13 pot accelerator B13 4 Z1 link splice 31100 07 X16 ECT B16 2 Z1 link splice 31100 08 X12 MAP B12 2 Z1 link splice 31100 09 X14 RACK B14 A Z1 link splice 31100 10 X18 oil pressure sensor B18 A Z1 link splice 31100 11 X17 sensor exh gas temp B17 2 Z1 link splice 31409 01 X20 control solenoid Y20 2 X5 control unit A5 35 31554 01 K24 relay fuel pump 85 X5 control unit A5 22 31555 01 K...

Page 263: ...14 60412 01 M2 fuel pump M4 posit K24 relay fuel pump 87 60613 01 J1 plug engine instruments N X5 control unit A5 8 60614 01 J1 plug engine instruments K X5 control unit A5 26 60616 01 J1 plug engine instruments G X5 control unit A5 25 60706 01 J1 plug engine instruments J X5 fixed rotation speed A5 29 60808 01 Z 5 60808 X5 control unit A5 32 60808 02 Z 5 60808 J1 plug engine instruments M 60808 0...

Page 264: ...06 ELECTRICAL SYSTEM Page ELECTRICAL SYSTEM 28 Z001019 0_6_July 2008 SERVICE MANUAL MARINE ENGINES 06 05 03 E box base plate from eng no 482 18 000 682 18 000 SOLAS 05 03 ill 1 ToC ...

Page 265: ...e 50 A main fuse F2 fuse 50 A glow plugs F3 fuse 50 A glow plugs F4 fuse 5 A permanent current module F5 fuse 10 A switched current for module K27 F6 fuse 10 A fuel pump J1 plug 23 pole connection engine cable instrument cable K24 relay fuel pump K26 1 relay preheating K26 2 realy preheating K27 relay main circuit K28 relay start X3 plug 2 pole inversion switch for SOLAS only S3 inversion switch f...

Page 266: ...ing control circuit G1 alternator G2 battery to be provided by customer J1 plug 23 pole connection engine cable instrument cable K24 relay fuel pump K26 1 relay preheating control circuit K26 2 relay preheating load circuit K27 relay main circuit K28 relay start M1 starter M2 fuel pump R10 glow pins X2 S2 plug 2 pole gears switch X3 S3 plug 2 pole inversion switch only SOLAS X5 A5 plug 35 pole mod...

Page 267: ...Z001019 0_6_July 2008 Page ELECTRICAL SYSTEM 31 06 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 05 03 ill 4 Wiring harness from eng no 482 18 000 SOLAS 682 18 000 SOLAS ToC ...

Page 268: ... BASE 4 6 CYLINDER 12V Batt Batt Ign 15 Supplied by Relais Sens ECU Control ECU DIAG Start Charge D Sens 5V Sens B 24V CAN Z5 Z6 EXCEPTIONS ONLY FOR TYP MO 164M40 MO 174V40 MO 246K41 MO 256H45 MO 256K43 MO 266K43 A 31100 08 15100 05 60110 01 60808 01 ISO 60900 01 CAN H 60901 01 CAN L 60 123 01 WS 2179349 0 02 070118_tedoc www steyr motors com R10 5 R10 1 R10 2 R10 3 R10 4 R10 6 6 CYL 6 CYL 4 CYL 4...

Page 269: ...ens ECU Control ECU DIAG Start Charge D Sens 5V Sens B 24V G2 M2 Fuel Pump Fuel Pump Relay K24 Main Relay K27 Preheating Control Relay K26 1 Preheating Load Relay K26 2 Control Solenoid Y20 Start Relay K28 Trim Sensor Option B22 60120 01 R10 60120 01 60808 01 ISO 60900 01 CAN H 60901 01 CAN L 60 123 01 WS G1 Sensor Oil Pressure Gauge Option B19 Gear Switch S2 RPM B15 Map B12 RPOS B14 PED B13 EXT B...

Page 270: ...900 02 60901 02 60808 01 ISO 60900 01 CAN H 60901 01 CAN L 60 123 01 WS Batt Batt Ign 15 Supplied by Relais Sens ECU Control ECU DIAG Start Charge D Sens 5V Sens B 24V CAN Wiring LPS All engines before 2007 A 31100 10 15100 07 60117 01 EXCEPTIONS ONLY FOR TYP MO 164M40 MO 174V40 MO 246K41 MO 256H45 MO 256K43 MO 266K43 A 31100 08 15100 05 60110 01 Wiring MAP All engines before 2007 31100 08 15100 0...

Page 271: ... 5 R10 1 R10 2 R10 3 R10 4 R10 6 Batt Batt Ign 15 Supplied by Relais Sens ECU Control ECU DIAG Start Charge D Sens 5V Sens B 24V CAN Wiring LPS All engines before 2007 A 31100 10 15100 07 60117 01 EXCEPTIONS ONLY FOR TYP MO 164M40 MO 174V40 MO 246K41 MO 256H45 MO 256K43 MO 266K43 A 31100 08 15100 05 60110 01 Wiring MAP All engines before 2007 31100 08 15100 05 60110 01 ALL ENGINE TYPES WITH FOLLOW...

Page 272: ...erature sensor or sensor connection Oil pressure below limit Defect Oil pressure sensor or sensor connection Insufficient boost pressure or defictive sensor Additional Tool Readings Steyr Diag Power limitation Steyr Diag Service code Steyr Diag Power limitation Steyr Diag Service code Steyr Diag Power limitation Steyr Diag Service code Steyr Diag Power limitation Panel Indication Horn ON 2x p sec ...

Page 273: ...automatic self test program checking all data of electronic sensors As soon as a fault is found there is an optical or audible signal refer to chart Error Codes Occurred faults remain stored until cancellation Stored faults may be selected analyzed and cancelled by means of PC via diagnostic outlet A reference to one or several stored faults is the 5 second TESTING of the CHECK ENGINE LAMP and the...

Page 274: ...witch Code indication and indication sequence After entering the error code indication modus the Engine Management System will display a blink code at the Check Engine Light on the dash panel The blinking sequence will always begin and end with control code indication 12 Each ERROR CODE will be repeated 3 times to reassure your correct reading see below bar code illustration Example sequence check...

Page 275: ... must be released close contact after app 2 sec to delete this ERROR CODE Note Any other ERROR CODE have to be selected and cleared individually following the above mentioned procedure to delete a determined ERROR CODE Note An ERROR CODE can only be deleted if no defect exists in this circuit In case of a present active failure the ERROR CODE keeps reappearing until the problem has been repaired a...

Page 276: ...r accelerator rack position sensor rack position sensor lubricant pressure sensor lubricant pressure sensor RPM sensor K28 start assist relay RPM sensor refer to setting rack pos this code is designated for beginning or end of loop signal level too low short circuit or missing contact signal level too high missing connection signal level too low short circuit or missing contact signal level too hi...

Page 277: ...limit exceeded short circuit missing connection or bulb blown Current limit exceeded in relay circuit short circuit no current detected in relay circuit disconnection no current detected in main relay circuit short circuit no current detected in main relay circuit disconnection Current limit exceeded short circuit no current in circuit of oil pressure lamp Nominal actual value difference rack pos ...

Page 278: ...ttery Replace automatic circuit breaker 1 Swing off E box base plate 2 Disconnect cable from automatic circuit breaker 3 Loosen 2 hexagon screws ill 1 pos 1 SW1 4 and take off thermal circuit breaker ill 1 pos 2 NOTE For assembly seal cable screw connections with rubber varnish Replace fuses 1 Remove E box cover 2 Remove fuse protection cap Pull out fuses ill 1 pos 3 Replace defect fuse 3 ToC ...

Page 279: ... 60616 01 lamp oil pressure L3 H 31615 01 warning horn J 60706 01 const speed switch K 60614 01 temperature display L 61000 02 alternator D M blind plug N 60613 01 tachometer speed O 60121 01 oil pressure gauge optional P 60810 01 check engine lamp Q 50000 02 ignition lock start R 50000 03 ignition lock start S 60120 01 trim optional T 61001 02 alternator B 24V DC ifused U 60901 03 CAN low V 60900...

Page 280: ...60900 01 CANH canbus high 16 60901 01 CANL canbus low 17 15012 01 VPROT2 direct supply line to control solenoid 18 15012 02 VPROT protected 12V after K27 and protective wiring in governor 19 15000 03 IGN ignition terminal 15 20 31100 01 Gnd Vref sensor ground connection 21 free free not busy 22 31554 01 FPR fuel pump relay 23 60810 01 CEL check engine lamp 24 31558 01 MR main relay K27 25 31615 01...

Page 281: ...Z001019 0_6_July 2008 Page ELECTRICAL SYSTEM 45 06 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 06 06 09 Fitting main connector J1 properly J1 Fitting Main Connector M1 01 ToC ...

Page 282: ...G blind plug installation option for B engine temperature key switch constant revolution C warning light battery charge H blind plug installation option for D combined light preheating control oil pressure gauge or warning light engine oil pressure voltmeter 12V E warning light check engine I audible warner F ignition key lock installed to rear side of paneel 07 00 ill 1 I ToC ...

Page 283: ...for glow plug preheating warning light engine oil pressure will not extinguish after 0 7 sec glow plug preheating phase In this case start engine immediately after the light extinguishes 2 ignition ON until engine start ON 5 sec ON 0 7 sec ON ON 5 sec Indication active error 3 engine running after start OFF OFF OFF OFF light indication light indication NOTE Further information see Table Error indi...

Page 284: ...e below min limit Remarks check oil level Indication status 80 90 C OFF OFF OFF FLASHING 1x per sec fault oil pressure sensor or sensor connection check oil pressure sensor B18 and connection reduce throttle position until light goes OFF indication during first 2 hours of operation ON engine overload during break in period 07 02 ill 2 07 02 ill 3 NOTE see cap general D3 A C D E B 07 02 ill 1 A tem...

Page 285: ...mperature to high after cooling down check engine coolant level 120 C ON 2x per sec OFF OFF OFF defect engine coolant sensor or sensor connection after cooling down check engine coolant level sensor B16 and connection Indication status 07 02 ill 4 07 02 ill 5 07 02 ill 6 07 02 ill 7 80 90 C ON OFF OFF ON Trouble in governing loop involved components control solenoid rack control gear of unit injec...

Page 286: ...INES Fault Remarks During start attempt ON ON ON OFF Engine will not start Failure in governing circuit Failure in governing circuit Positioning of rack not possible Trouble shooting of control solenoid rack control gear of unit injection rack position sensor Indication status 07 02 ill 9 ToC ...

Page 287: ...Z001019 0_6_July 2008 Page ELECTRICAL SYSTEM 51 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES THIS PAGE IS INTENTIONALLY BLANK ToC ...

Page 288: ... voltmeter 12V warning light engine oil pressure E warning light check engine light I emergency cut off switch F push button ignition ON OFF red J audible warning device installed to rear side of panel NOTE Instrument gauges are automatically illuminated if ignition is turned ON NOTE In case an inversion occured the engine gets shut down automatically to re establish regular running and operation ...

Page 289: ...sure will not extinguish after 0 7 sec glow plug preheating phase In this case start engine immediately after the light extinguishes ON 5 sec Indication active error OFF NOTE Further information see Table Error indication on Instrument Panel Normal condition ON 0 7 sec ON 0 7 sec ON ON 0 7 sec ON 5 sec Instrument indication during normal operation 06 07 04 Chart Operating Status for SOLAS only 07 ...

Page 290: ...mal engine operation or indication in case of sensor defect while ignition is switched ON Event Speed resp performance limitation during engine operation 80 90 C ON OFF Fault oil pressure below min limit Remarks check oil level Indication status OFF ON 80 90 C OFF fault oil pressure sensor or sensor connection check oil pressure sensor B18 and connection OFF OFF FLASHING 1x per sec ON engine overl...

Page 291: ...or connection engine coolant temperature to high after cooling down check engine coolant level defect engine coolant sensor or sensor connection after cooling down check engine coolant level sensor B16 and connection Indication status 07 05 ill 4 07 05 ill 5 07 05 ill 6 07 05 ill 7 Trouble in governing loop involved components control solenoid rack control gear of unit injector rack position senso...

Page 292: ...INES Fault Remarks During start attempt Engine will not start Failure in governing circuit Failure in governing circuit Positioning of rack not possible Trouble shooting of control solenoid rack control gear of unit injection rack position sensor Indication status 07 05 ill 9 ON ON OFF ON ToC ...

Page 293: ...Z001019 0_6_July 2008 Page ELECTRICAL SYSTEM 57 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES THIS PAGE IS INTENTIONALLY BLANK ToC ...

Page 294: ...running time meter P4 gauge trim optional H22 warning horn XS8 1 pin plug to lighting switch instrument panel XS9 2 pin plug charging control relay charging control wiring harness side XS10 2 pin plug charging control relay charging control instrument side X1 S1 4 pin plug ignition X2 L1 10 pin plug charge control lamp X3 L2 10 pin plug cel check engine lamp X4 L3 10 pin plug oil pressure warning ...

Page 295: ...Z001019 0_6_July 2008 Page ELECTRICAL SYSTEM 59 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 07 10 ill 1 6 Cyl Wiring harness instrument panel if alternator PRESTOLITE is used old version ToC ...

Page 296: ...ng time meter P4 gauge trim optional H22 warning horn XS8 1 pin plug to lighting switch instrument panel XS9 2 pin plug charging control relay charging control wiring harness side XS10 2 pin plug charging control relay charging control instrument side X1 S1 4 pin plug ignition X2 L1 10 pin plug charge control lamp X3 L2 10 pin plug cel check engine lamp X4 L3 10 pin plug oil pressure warning lamp ...

Page 297: ...Z001019 0_6_July 2008 Page ELECTRICAL SYSTEM 61 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES 6 Cyl Wiring harness instrument panel if alternator PRESTOLITE is used old version 07 10 ill 2 ToC ...

Page 298: ...tch constant revolution optional L1 lamp charge control L2 lamp cel check engine lamp L3 lamp oil pressure preheating conrol P1 gauge engine coolant temperature P2 gauge oil pressure optional P3 gauge tachometer with running time meter H22 warning horn E10 lighting engine coolant temperature gauge E11 lighting oil pressure gauge optional E12 lighting tachometer gauge X8 1 pin plug connector illumi...

Page 299: ... 30012 07 30012 08 31000 01 3100 02 60616 01 31615 01 60706 01 60614 01 61000 02 31000 16 Ground shield 60613 01 60121 01 60810 01 50000 02 50000 03 60120 01 61001 01 B 24V 60901 03 60900 03 Start Warning Horn H22 _ Charge Control Lamp L1 1 2 Check Engine Lamp L2 1 2 OIL Preheating control Lamp L3 1 2 Engine Coolant Temperature Gauge P1 40 105 175 210 250 F C 40 80 12 0 10 0 G _ Lighting ECT Gauge...

Page 300: ...eld 60613 01 60121 01 60810 01 50000 02 50000 03 60120 01 61001 01 B 24V 60901 03 60900 03 Connector Illumination switch Fuse 10A X8 Z2 Z3 Z4 Z1 F9 Intermediate Cable Charge Indicator 24 V 85 86 87a 87 30 Start Warning Horn H22 _ Charge Control Lamp L1 1 2 Check Engine Lamp L2 1 2 OIL Preheating control Lamp L3 1 2 Engine Coolant Temperature Gauge P1 40 105 175 210 250 F C 40 80 12 0 10 0 G _ Ligh...

Page 301: ...01 61000 02 31000 16 Ground shield 60613 01 60121 01 60810 01 50000 02 50000 03 60120 01 61001 01 B 24V 60901 03 60900 03 Connector Illumination switch Fuse 10A X8 Z2 Z3 Z4 F9 Z1 3 4 START green S2 3 4 IGN red ON OFF S1 M M Emergency CUT OFF Switch S3 Warning Horn H22 _ Charge Control Lamp L1 1 2 Check Engine Lamp L2 1 2 OIL Preheating control Lamp L3 1 2 Engine Coolant Temperature Gauge P1 40 105...

Page 302: ...eyr motors com 0 10 40 20 30 40 105 175 210 250 F C 40 80 12 0 10 0 No colours of shielded wire correspond to individual cable No 15000 01 Connector Illumination switch _ J1 A 1 J1 B 2 J1 C 3 J1 D 4 J1 E 5 J1 F 6 J1 G 7 J1 H 8 J1 J 9 J1 K 10 J1 L 11 J1 M J1 N 13 J1 O 14 J1 P 15 J1 Q 16 J1 R 17 J1 S 18 J1 T 12 J1 U 21 J1 V 22 J1 W 19 J1 X 20 15000 01 15000 02 30012 07 30012 08 31000 01 3100 02 6061...

Page 303: ...Z001019 0_6_July 2008 Page ELECTRICAL SYSTEM 67 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES THIS PAGE IS INTENTIONALLY BLANK ToC ...

Page 304: ...running time Thus the setting procedure is completed Byrepeatedselectionof functionPULSEtheselected pulse rate may be checked The pulse rate appears on the display and the individual digits begin to flash in sequence starting with the last digit 06 07 13 ADJUST INSTRUMENTS 06 07 13 01 Tachometer with running time meter There are 2 possible settings Function PULSE Entry of pulse rate 12 18 per revo...

Page 305: ...er deflection changes downwards At the beginning the pointer deflection changes very slowly which permits a very precise fine adjustment With a short release of the key the procedure is repeated With a longer pressing of the key the pointer deflection will change faster Release the key as soon as the fine adjustment corresponds to the reference rpm The display then changes to counting of running t...

Page 306: ...nce otherwise there is a risk of a short ciruit Short circuits can cause cable fires battery explosions and damage to other electronic storage systems Please note that when the battery is disconnected all transient electronic memories lose the values entered and have to be reprogrammed With petrol engines allow the engine compartment fan to run before beginning work in the engine compartment At th...

Page 307: ...vidual strands are not damaged or cut off New connections should only be made using soft solder or with commercial crimp connectors Crimped connections should only be made using cable crimping pliers The safety instructions of the hand tool manufacturer must be observed Insulate exposed leads in such a way that short circuits cannot occur Caution Risk of short circuit through faulty junctions or d...

Page 308: ...ge ELECTRICAL SYSTEM 72 Z001019 0_6_July 2008 SERVICE MANUAL MARINE ENGINES 06 07 14 02 Audible warner H22 07 14 ill 1 sensor exhaust gas temperature sensor engine coolant sensor oil pressure control unit control unit ToC ...

Page 309: ...al sensor 06 07 14 03 Circuit diagram voltmeter optional 06 07 14 04 Circuit diagram oil pressure gauge optional sensor B19 gauge P2 sensor marking G one sensor for two displays 07 14 ill 2 07 14 ill 3 06 07 14 04 Circuit diagram oil pressure gauge optional sensor B19 gauge P2 sensor marking G one sensor for two displays 07 14 ill 2 07 14 ill 3 ToC ...

Page 310: ...s 23 24 or 29 will flash NOTE First check cables and connections R1 Resistance between terminals 3 and 1 approximately 1 2 kOhm resistance value switch to infinetelyaftermovingthrottleleverfromidleposition Switch contact should open within the first 10 of throttle lever pedal movement R2 Resistance between terminals 5 and 4 1 2 kOhm R3 Resistance between terminals 5 and 2 2 2 kOhm for normal posit...

Page 311: ...ow BLACK AWG 6 RED AWG 6 RED AWG 8 12V Protected Output Note Mainswitsches are mechanically interlinked X21 ARMATUREN PLUG 6 POLE USE ONLY 12 VOLT INSTRUMENTS pin1 60810 check engine lampe 12V 2W pin2 60616 glow lamp 12V 2W pin3 60614 temperature instruments 12V pin4 60613 engine speed instruments 12V pin5 50000 starter terminal 50 detection of start pin6 15000 ignition connect it to the ignition ...

Page 312: ...STEM Page ELECTRICAL SYSTEM 76 Z001019 0_6_July 2008 SERVICE MANUAL MARINE ENGINES 06 08 03 DC DC converter DC DC Converter IVO 8770 CIRCUIT DIAGRAM Batt A Batt B 24VDC 12VDC U2 16A 25A Batt C Engine G U1 IE IA ToC ...

Page 313: ...Z001019 0_6_July 2008 Page ELECTRICAL SYSTEM 77 ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES THIS PAGE IS INTENTIONALLY BLANK ToC ...

Page 314: ...alter Option Connector gear switch optional Inversionsschalter Nur bei SOLAS Inversion switch only for SOLAS Abschaltventil Nur bei SOLAS Blow by only for SOLAS Stecker Ölmanometer Option Connector oil pressure gauge optional Stecker Trimmanzeige Option Connector trim optional Ladedrucksensor Boost pressure sensor Gaspedal Potentiometer accelerator Regelstangensensor Rack position sensor Motordreh...

Page 315: ...sor engine coolant temperature Abgastemperatursensor Sensor exhaust gas temperature Öldrucksensor Lubricant pressure sensor Sensor engine speed BESCHREIBUNG DESCRIPTION Stecker Ölmanometer Option Connector oil pressure gauge optional Stecker Trimmanzeige Option Connector trim optional Haupt Verbindungsstecker Main connector Diagnose Stecker Diagnosis plug Steuermagnet Control solenoid Stecker Getr...

Page 316: ...ption Connector gear switch optional Inversionsschalter Nur bei SOLAS Inversion switch only for SOLAS Abschaltventil Nur bei SOLAS Blow by only for SOLAS Stecker Ölmanometer Option Connector oil pressure gauge optional Stecker Trimmanzeige Option Connector trim optional Ladedrucksensor Boost pressure sensor Gaspedal Potentiometer accelerator Regelstangensensor Rack position sensor Motordrehzahlsen...

Page 317: ...sor engine coolant temperature Abgastemperatursensor Sensor exhaust gas temperature Öldrucksensor Lubricant pressure sensor Sensor engine speed BESCHREIBUNG DESCRIPTION Stecker Ölmanometer Option Connector oil pressure gauge optional Stecker Trimmanzeige Option Connector trim optional Haupt Verbindungsstecker Main connector Diagnose Stecker Diagnosis plug Steuermagnet Control solenoid Stecker Getr...

Page 318: ...ss will take approx 20 sec 4 Turn off ignition 5 Loosen threaded pin and screw it into rear bulkhead wall ill 1 A NOTE If storage in ECU A5 was unsuccessful error code 56 will be detected Refer to Error Codes NOTE Therackpositionsensorismagnetism sensitive All external magnets must be kept away as the may disturb the sensor This procedure must be carried out if any of the following has been done C...

Page 319: ... B15 1 Press catch spring and remove plug 2 Loosen hexagon screw SW10 pull out sensor ATTENTION For assembly use new 0 ring Grease O ring and put it on 10 04 ill 2 10 04 ill 4 10 04 ill 1 1 2 1 1 2 2 10 04 ill 3 06 10 04 04 Boost pressure sensor B12 for engines 94 114 144 126 166 236 only 1 Remove hose from exhaust manifold ATTENTION Do not remove hose from boost pressure sensor 2 Press retaining ...

Page 320: ...el 06 10 04 05 Rack position feedback sensor B14 1 Remove retaining clip remove plug housing ill 6 pos 1 2 Disassemble control solenoid refer to 03 08 01 3 Loosen 2 cylinder screws with hexagon socket SW 3 remove sensor ill 6 pos 2 Assembly is done according to assembly of control solenoid refer to 03 08 10 04 ill 6 2 1 1 2 10 04 ill 7 1 2 3 4 10 04 ill 8 Boost pressure sensor B12 for engines 164 ...

Page 321: ...ensor B14 service codes 35 and 36 will flash NOTE First always check cables and connections Final check Disassemble rack position feedback sensor from control solenoid 1 Check resistance between terminals A and C with a digital ohmmeter Resistance must be between 2 2 kOhm 10 2 Measure resistance between terminals B and C with extended shaft Resistance must be 0 5 kOhm 10 C B 10 05 A ill 3 C A 10 0...

Page 322: ...10 05 01 B Check rack position feedback sensor B14 connector X14 In case of defective rack position feedback sensor B14 service codes 35 and 36 or 186 will flash NOTE First always check cables and connections Final check Disassemble rack position feedback sensor from control solenoid 1 Supply terminals A minus and C plus with 5 0V DC 1 2 Sensor extended Measure between terminal A minus and B signa...

Page 323: ...hrottlepotentiometer B13 accelerator connector X13 In case of defective potentiometer accelerator B13 service codes 23 24 or 29 will flash NOTE First check cables and connections Resistance between terminals 5 and 4 1 2 kOhm Resistance between terminals 5 and 2 2 2 kOhm for normal position of potentiometer accelerator 1 4 kOhm at full speed max impact Resistance between terminals 3 and 1 1 2 kOhm ...

Page 324: ...5 ill 8 Pressure test For a pressure test of the sensor disconnect the sensor hose and connect a pressure gauge with a short piece of hose to the sensor Carefully pressurize the sensor Read and record the values on the gauge input pressure and on the display outputpressure for5spotsbetween0and1 5bar Comparerecordedinputandoutputvalues with the chart If values are not within tolerance limits replac...

Page 325: ...king cancel the error code refer to 06 06 04 Use a standard voltmeter multimeter to measure the supply voltage and or the resistance Supply voltage Ubat 12V 2V ignition ON main relay K27 active measurement point GND on X15 3 against supply voltage on X15 1 Continuity from X15 2 to control unit X5 33 max resistance 2 ohms If supply voltage and transition from X15 2 to X5 33 are connect replace the ...

Page 326: ...n of check cancel the error code refer to 06 06 04 Use a standard voltmeter multimeter to mesure the supply voltage and or the resistance Supply voltage 5V 0 4V ignition ON main relay K27 active measuring point GND on X18 A against 5V on X18 B Continuity from X18 C to control unit X5 10 max resistance 2 ohms Output signal depending on pressure see diagram Remove B18 and admit pressure when X18 is ...

Page 327: ... check the oil pressure gauge before checking the oil pressure sensor To check the oil pressure gauge disconnect cable from sensor turn on ignition key and shortly put the sensor cable to ground connection If gauge functions properly the pointer will shortly deflect to high values If there is no malfunction of the gauge replace the oil pressure sensor Check of oil pressure sensor 1 To check the oi...

Page 328: ...ter and pressurize sensor Read andrecordpressureandresistanceatdifferentspots over the entire pressure range 3 Compare pressure and resistance values with chart If values are not within tolerance range at one spot replace sensor 06 10 05 07 Check coolant temperature sensor B16 To check the coolant temperature sensor make the following test with connected ohmmeter In case of failure replace the sen...

Page 329: ...sensor together with thermometer into a canister with coolant Connect a digital ohmmeter to the sensor and heat the fluid on a heater Monitor ohmmeter und thermometer The ohmmeter should show values corresponding to the values of the resistance curve with a tolerance range of 10 06 10 05 08 Check audible warner 0 7 sec with ignition ON function check and message no error stored ToC ...

Page 330: ...he boat 12V supply of all electric and electronic components on the engine including instrument panel by center tapping Additional charge is guaranteed by charging equalization For 6 cyl engines only Use a 12 V battery with a cold test circuit of 650 ampere at 18 C and a capacity of 115 Ah at 27 C to guarantee the supply of the electric and electronic components Explanation Cold current test The c...

Page 331: ...idered 1 Protect the boat against acid leakage 2 Clean battery 3 Check connections and cables 4 Clean battery contacts neg pos 5 Check holding device of battery 6 Check housing for damages acid leakage 12 01 ill 1 7 Check acid density 8 Disassemble battery for test In case of less than 3 4 charge charge it by means of battery charger carry out charge test 9 Check acid level In case of a bad state ...

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