Textron MPE 850 MARINE Page 47 Service Manual Download

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SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

8 Service tasks in the workshop

8.2 Tools and accessories

Textron Motors offers a diagnostic case that

contains the Textron Motors Diagnostic Tool. The

Textron Motors Diagnostic Tool is designed for fault

diagnostics and service tasks for Textron engines

using a Synerject engine management system.

Visit your local vehicle dealer or our web site

www.textronmotors.com for more information.

8.2.2 Textron Motors diagnostic case

Summary of Contents for MPE 850 MARINE

Page 1: ...C 80 TC 120 408014 I2 846 MAR TC 120 408090 I2 846 MAR TC 155 408246 I2 846 MAR NA 80 This service manual is valid for the following engine models Read this service manual thoroughly before operating...

Page 2: ......

Page 3: ...to make continual improvements as part of the ongoing technical development of its products All documentation is therefore subject to technical modifications Reprints and translations in whole or in...

Page 4: ...pment 24 3 10 1 Lights in vehicle 24 4 Operation 26 4 1 Service intervals 26 4 2 Operation during the break in period 28 4 3 Operating engine 29 4 3 1 Inspecting the exhaust and fuel system 29 4 3 2 C...

Page 5: ...ing and adjusting valve lash 59 8 5 1 Checking valve lash 59 8 5 2 Adjusting valve lash 63 8 6 Replacing spark plugs and ignition coils 66 8 7 Checking spark plugs 68 8 8 Replacing rubber mount 71 8 9...

Page 6: ...Make sure that all persons using the vehicle have access to this service manual If you sell the vehicle always pass on this service manual to the new owner The latest version of the servicew manual i...

Page 7: ...ddition to the information in this service manual Accident prevention Environmental protection Handling of hazardous materials Personal safety equipment Traffic laws 2 Safety 2 1 Meaning of safety ale...

Page 8: ...lfill strict quality and safety requirements Textron Motors offers spare parts to the highest quality Ensure that equivalent spare parts corresponds with this quality requirements Engine modifications...

Page 9: ...Do not smoke in the vicinity of the engine and do not allow open flames or sparks near the engine or the fuel system Always turn off the engine before fueling Never fill with fuel while the engine is...

Page 10: ...ion numbers Both numbers are printed on a label 1 affixed to the engine The part number Part No 2 is the number of the engine model The serial number Serial No 3 is an unique number for each individua...

Page 11: ...ted on the expansion tank 6 The serial number is also engraved on the crankcase 7 The Emission Control Information label is located on the expansion tank Engine model I2 846 MAR NA 80 The label with t...

Page 12: ...of power and or increased fuel consumption 91 ROZ or 82 5 MOZ USA Regular 87 Permissible share of ethanol NOTICE A greater concentration can deteriorate the engine s fuel system and starting performan...

Page 13: ...es may trigger a chemical reaction and they may lose their effectiveness The suggested coolant additives are laboratory tested for compatibility If you use another coolant additive verify the compatib...

Page 14: ...tion Information The wire harness is not shown in the figures Sacrificial anode 8 Exhaust manifold 9 Exhaust side Exhaust pipe 10 Sea water return 11 Engine models I2 846 MAR TC 80 TC 100 and TC 120 O...

Page 15: ...e components and information 1st cylinder 12 Sensor camshaft 13 2nd cylinder Fuel supply 14 Engine rotation direction 15 Stub shaft 16 Power take off Engine cover 17 Oil tank 18 Coolant expansion tank...

Page 16: ...components and information Sacrificial anode 7 Exhaust manifold 8 Exhaust side Exhaust pipe 9 Sea water return 10 Engine model I2 846 MAR TC 155 Oil filter 1 Drainage for storage 2 Waste gate valve 3...

Page 17: ...ponents and information 1st cylinder 11 Sensor camshaft 12 2nd cylinder Fuel supply 13 Fuse Box 14 Engine rotation direction 15 Stub shaft 16 Power take off Engine cover 17 Oil tank 18 Coolant expansi...

Page 18: ...ial anode 5 Exhaust manifold 6 Exhaust side Exhaust pipe 7 Sea water return 8 Engine model I2 846 MAR NA 80 Oil filter 1 Drainage for storage 2 Heat exchanger 3 Connection for sea water cooling circui...

Page 19: ...ft 10 2nd cylinder Fuel supply 11 Fuse Box 12 Engine rotation direction 13 Stub shaft 14 Power take off Engine cover 15 Oil tank 16 Coolant expansion tank 17 Engine Chassis vehicle connector 18 Sea wa...

Page 20: ...15 A fuse IGK terminal 30 key switch 4 15 A fuse VBD terminal 30 battery 5 15 A fuse SERVICE electric circuit for ignition coils injectors 6 10 A spare fuse SPARE 7 10 A fuse FUEL fuel pump 8 15 A fus...

Page 21: ...red See chapter 3 10 1 Lights in vehicle Engine speed limitations If a speed limitation is active the engine speed cannot be exceeded even at full throttle In the following operation conditions speed...

Page 22: ...1 rpm Engine speed limit 8000 min 1 rpm Idle speed 1600 min 1 rpm Fuel system Sequential multipoint manifold injection Lubrication system Dry sump Cooling system Closed coolant circuit and open sea w...

Page 23: ...m Idle speed 1450 min 1 rpm Fuel system Sequential multipoint manifold injection Lubrication system Dry sump Cooling system Closed coolant circuit and open sea water cooling circuit Engine management...

Page 24: ...t illuminates after the engine is started until the required oil pressure is achieved NOTICE Serious engine damage due to insufficient lubrication If the oil pressure light remains on after starting t...

Page 25: ...repair possible faults by a qualified workshop All Textron Motors authorized workshops are qualified to repair your engine The temperature warning light is flashing Check the coolant level See chapter...

Page 26: ...ition Perform all engine and vehicle related service tasks as described in this service manual and the vehicle manufacturer s documentation Following service tasks you can perform yourself All activit...

Page 27: ...y 4 years Changing engine oil and oil filter Checking and adjusting valve lash 3 Replacing spark plugs Replacing ignition coils Replacing rubber mount Maintaining waste gate valve all engine models I2...

Page 28: ...disassembled first minutes until the engine is warm Observe the following guidance to achieve optimal break in Avoid engine speeds over 6000 min 1 rpm long periods of idle operation long periods of o...

Page 29: ...st system 2 hose clamps bolts and metal parts for corrosion Ensure hoses are properly mounted and free of cracks Fuel system WARNING Fuel is highly flammable Vapors may explosively ignite Check fuel s...

Page 30: ...w the MIN marking follow instructions in Refilling coolant section NOTICE Overfilled coolant increases the cooling system pressure and may cause leaks in hoses If coolant level exceeds the MAX marking...

Page 31: ...ngine damage caused by overheating If you operate the engine without sea water the optimal engine cooling is no longer provided Observe chapter 5 2 Operating engine without sea water The vehicle is pl...

Page 32: ...during the break in period Turn off the engine CAUTION Scalding caused by hot engine oil Wear protective gloves Unscrew the oil dipstick 1 from the oil tank Wipe the oil dipstick and insert into the o...

Page 33: ...oil in small quantities with repeatedly checking The difference between the MIN marking 7 and the MAX marking 6 is approximately 0 5 liter 0 5 qt US engine oil Fill engine oil through the opening 5 o...

Page 34: ...cle manufacturer s documentation Put the throttle control in neutral position Turn off ignition or Turn the ignition switch in the OFF position If your vehicle has a battery isolator switch or similar...

Page 35: ...vice is attached at this connection Connect the flushing device See the vehicle manufacturer s documentation NOTICE Engine damage due to water in the engine When the engine is turned off the water may...

Page 36: ...ection If you operate your vehicle in salt water regularly use a corrosion protection spray See chapter 4 1 Service intervals Information For information about suitable products and their using please...

Page 37: ...for 30 days or more prepare the engine for storage See chapter 5 1 Engine storage for more than 30 days Transport and store the vehicle on a preferably stable and flat surface If you do not have any...

Page 38: ...r 5 3 Towing vehicle in water Engine damage caused by overheating If you operate the engine without sea water the optimal engine cooling is no longer provided Select one of the following procedures Op...

Page 39: ...gh the exhaust system if your vehicle has been capsized and or the engine compartment has been flooded It can still happen even if the engine has been partially flooded The longer you postpone the nec...

Page 40: ...the vehicle there are several options Read the vehicle manufacturer s documentation for more information For example Insert the safety lanyard Put the throttle control in neutral position Switch on t...

Page 41: ...ry is discharged or defective Contact a qualified workshop All Textron Motors authorized workshops are qualified to repair your engine The engine stalls but can be started again Lack of fuel Fill up f...

Page 42: ...ocated in the fuse box on the engine See chapter 3 6 Engine components and information Remove the cover 1 from the fuse box Risk of fire caused by incorrect or bridged fuse The fuse protects the cable...

Page 43: ...gine fuses Insert the fuse 5 Repeat the procedure with other fuses Insert the cover 6 into the fuse box Connect the power supply to the engine See the vehicle manufacturer s documentation Check the fu...

Page 44: ...extronmotors com for a list of all authorized Textron Motors workshops 7 2 Tools and parts Textron Motors offers a selection of accessories to prepare you for the most important situations Visit your...

Page 45: ...safety of persons Read the vehicle manufacturer s documentation for more information Disconnect the engine from the power supply before performing any servicing tasks Only reconnect the power supply...

Page 46: ...in the workshop 8 2 Tools and accessories Figure Description Oil filter O rings for oil filter change Spark plug Champion RC7PYCBX Feeler gauge 0 05 2 mm Sealing kit valve cover Figure Description Va...

Page 47: ...stic case that contains the Textron Motors Diagnostic Tool The Textron Motors Diagnostic Tool is designed for fault diagnostics and service tasks for Textron engines using a Synerject engine managemen...

Page 48: ...rx screwdriver socket T30 Hexagon nut driver 7 In addition to the service case you will require the following tools and accessories for service tasks The figures are only examples of suitable tools Fi...

Page 49: ...49 SHB MPE850 Rev F 408014 408090 408101 408246 8 Service tasks in the workshop 8 2 Tools and accessories Figure Description Oil suction pump Drain tray Hose clamp pliers for spring band clamps...

Page 50: ...igh Tech ASW 040 P Loctite 8150 Engine internal preservative Liqui Moly Germany Fuel stabilizer Liqui Moly Germany Sealing surface cleaner Liqui Moly brake and parts cleaner AIII Germany Corrosion pro...

Page 51: ...out from the oil tank The remaining engine oil will be pumped out with the suction pump in the dry sump CAUTION Scalding caused by hot engine oil Wear protective gloves Unscrew the oil dipstick 2 from...

Page 52: ...supplied with electricity through the service fuse When the service fuse is removed you can rotate the engine using the starter avoiding starting the engine Remove the service fuse 6 8 Service tasks i...

Page 53: ...NOTICE Breakage risk due to work on the oil tank When removing the hose from the oil tank you need to move the oil tank This can brake the oil tank pins Put the oil tank beside 10 the oil tank bracket...

Page 54: ...Close the hose clamp 15 Tightening torque 5 Nm 0 5 Nm 3 7 lbf ft 0 4 lbf ft Replacing oil filter Hold the oil filter 19 Unscrew the banjo bolt 20 Remove the oil filter 8 Service tasks in the workshop...

Page 55: ...2 Nm 10 3 lbf ft 1 5 lbf ft Insert the service fuse 28 8 Service tasks in the workshop 8 3 Changing engine oil and oil filter Clean the sealing surface 23 with sealing surface cleaner Replace the oil...

Page 56: ...Lift the oil tank 30 and insert it into the oil tank bracket 31 Screw in the bolts 32 at the oil tank Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft 8 Service tasks in the workshop 8 3 Changing en...

Page 57: ...t See the Textron Motors Diagnostic Tool manual Update the engine control unit calibration See the Textron Motors Diagnostic Tool manual Test drive the vehicle 8 Service tasks in the workshop 8 3 Chan...

Page 58: ...ve cathodic protection Check the sacrificial anode 2 At least half of the original size 60 mm 2 4 in 16 mm 0 6 in remains If the sacrificial anode is less than half of the original size replace the sa...

Page 59: ...s from the gear on the camshaft when the engine is started Disconnect the engine from the power supply Disconnect the wire harness connectors from the ignition coils 2 and sensor camshaft 3 8 5 1 Chec...

Page 60: ...f the camshaft Check the valve lash 10 of all valves on the cylinder using a feeler gauge Required valve lash 0 2 0 3 mm If the valve lash of one or more valves is not right continue with chapter 8 5...

Page 61: ...h Checking valve lash on the 1st cylinder Turn the camshaft until the position of the camshaft is as illustrated See the vehicle manufacturer s documentation The camshaft is marked at the 2nd cylinder...

Page 62: ...ashers 22 and serrated lock washers as illustrated Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft Connect the wire harness connectors to the ignition coils 23 and sensor camshaft 24 Touch up paintw...

Page 63: ...mation The camshaft is turned by turning the crankshaft Read the vehicle manufacturer s documentation for instructions Always turn the crankshaft in the same direction as the engine rotates See chapte...

Page 64: ...ngine or cylinder head Operating the engine when there are small components in the crankcase and cylinder head can result in serious damage and cause the crank drive to seize Cover the chain channel 6...

Page 65: ...e slide plate 15 slightly using the rocker arm pusher Slide the pin 16 forward by hand Slowly release the rocker arm pusher The valve spring slides the slide plate upwards again 8 Service tasks in the...

Page 66: ...s and ignition coils Remove the spark plugs with a cold engine Disconnect the wire harness connectors from the ignition coils 2 Unscrew the bolts 3 Pull the ignition coils 4 out 8 Service tasks in the...

Page 67: ...ors to the ignition coils 10 Touch up paintwork defects Clear the service counter to reset service light See the Textron Motors Diagnostic Tool manual Update the engine control unit calibration See th...

Page 68: ...Checking spark plugs Remove the spark plugs with a cold engine Disconnect the wire harness connectors from the ignition coils 2 Unscrew the bolts 3 Pull the ignition coils 4 out 8 Service tasks in the...

Page 69: ...s 6 are extremely sooty clean carefully using a spark plug brush Check the spark plug gap 7 using a feeler gauge Required spark plug gap 0 69 0 84 mm 0 028 0 032 in If the spark plug gap is not satisf...

Page 70: ...drive the vehicle 8 Service tasks in the workshop 8 7 Checking spark plugs Insert the ignition coils 9 Replace the serrated lock washers 10 Assemble the bolts 11 washers 12 and serrated lock washers a...

Page 71: ...g rubber mount 8 8 Replacing rubber mount Open the spring band clamps 4 Remove the hose 5 Engine models I2 846 MAR TC 80 TC 100 TC 120 and NA 80 Remove the rubber mount with a cold engine Mark 2 the h...

Page 72: ...3 and throttle body 12 8 Service tasks in the workshop 8 8 Replacing rubber mount Remove the throttle body 9 Unscrew the bolts 10 Remove the rubber mount 11 Replace the rubber mount Hold the rubber mo...

Page 73: ...nd clamps 15 Touch up paintwork defects Clear the service counter to reset service light See the Textron Motors Diagnostic Tool manual Update the engine control unit calibration See the Textron Motors...

Page 74: ...8 Replace the rubber mount Hold the rubber mount in position Screw in the bolts Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft 8 Service tasks in the workshop 8 8 Replacing rubber mount Disconnect...

Page 75: ...t Hold the the connecting pipe 13 in position Close the hose clamps 12 Tightening torque 3 Nm 0 5 Nm 2 2 lbf ft 0 4 lbf ft Touch up paintwork defects Clear the service counter to reset service light S...

Page 76: ...HB MPE850 Rev F 408014 408090 408101 408246 1 2 8 Service tasks in the workshop 8 9 Maintenance waste gate valve 8 9 Maintenance waste gate valve Waste gate valve version 1 1 Waste gate valve version...

Page 77: ...ve the indicated directions of rotation 1 One nut 4 has a left hand thread Hold the spanner nut 3 with a wrench Open the two nuts 2 4 in direction of rotating Open the spanner nut 5 in the indicated d...

Page 78: ...marking 8 Close the spanner nut with two full turns in the indicated direction of rotation Close the two nuts 10 11 in direction of rotation 9 Touch up paintwork defects Clear the service counter to r...

Page 79: ...e spanner nut 3 with a wrench Open the two nuts 2 4 in direction of rotating Open the spanner nut 5 in the indicated direction of rotation until no longer pretensioning exists 8 9 2 Maintaining waste...

Page 80: ...tion Close the two nuts 10 11 in direction of rotation 9 Touch up paintwork defects Clear the service counter to reset service light See the Textron Motors Diagnostic Tool manual Update the engine con...

Page 81: ...ster Open the clamp 3 The clamp built in by the engine manufacturer in these place is destroyed during removal After removing the clamp must be replaced by a hose clamp Remove the hose 2 Engine models...

Page 82: ...h the flame arrester Close the hose clamp 6 Tightening torque 4 5 Nm 1 Nm 3 3 lbf ft 0 7 lbf ft Replace the clamp 8 Insert the hose 7 Close the hose clamp Tightening torque 3 Nm 0 5 Nm 2 2 lbf ft 0 4...

Page 83: ...e arrester 3 The fabric must be visible When the fabric filter is no longer visible continue with section Cleaning the flame arrestor 8 Service tasks in the workshop 8 10 Checking flame arrester Clean...

Page 84: ...Tightening torque 4 5 Nm 1 Nm 3 3 lbf ft 0 7 lbf ft Touch up paintwork defects Clear the service counter to reset service light See the Textron Motors Diagnostic Tool manual Update the engine control...

Page 85: ...g coolant Place the drain tray under the fitting 3 on heat exchanger Open the hose clamp 2 Remove the hose and keep it over the drain tray Coolant drains off Drain the coolant with a cold engine Unscr...

Page 86: ...ing torque 5 Nm 0 5 Nm 3 7 lbf ft 0 4 lbf ft Flushing coolant circuit Fill the expansion tank 4 with clean fresh water Water drains off through the heat exchanger Repeat the procedure until only clear...

Page 87: ...of coolant When coolant level is below the MIN marking 7 wait until the engine has cooled down Refill coolant until the coolant level is between the MIN marking and the MAX marking NOTICE Leaks in the...

Page 88: ...88 SHB MPE850 Rev F 408014 408090 408101 408246 8 12 Replacing fuel filter See the vehicle manufacturer s documentation 8 Service tasks in the workshop 8 12 Replacing fuel filter...

Page 89: ...ugs See chapter 8 7 Checking spark plugs Spray engine internal preservative into the cylinder through the spark plug bores 1 according to the manufacturer s instructions Do not start the engine again...

Page 90: ...ion Open the hose clamp 4 Remove the plug 5 Place the hose 6 at the lowest point of the engine compartment Do not start the engine again NOTICE Water inside the engine due to open drainage hose Inform...

Page 91: ...to operation Close the hose clamp 2 Tightening torque 3 Nm 0 5 Nm 2 2 lbf ft 0 4 lbf ft Insert the plug 1 Mount the drainage hose 4 on the hose clip 3 Turn on the ignition wait a moment and then turn...

Page 92: ...014 408090 408101 408246 8 14 Disposal When disposing of engine fluids replaced parts or the whole engine always comply with the relevant applicable national laws and guidelines 8 Service tasks in the...

Page 93: ...s Date Work carried out Engine oil and oil filter changed Sacrificial anode checked Valve lash checked Spark plugs replaced Rubber mount replaced Waste gate valve maintained Flame arrester checked Coo...

Page 94: ...ed Waste gate valve maintained Flame arrester checked Coolant changed Fuel filter replaced Status hours of operation Company seal signature Date Work carried out Engine oil and oil filter changed Sacr...

Page 95: ...5 SHB MPE850 Rev F 408014 408090 408101 408246 Appendix Engine manufacturer Textron Motors GmbH Kautexstra e 52 53229 Bonn Germany www textronmotors com Engine manufacturer Appendix Engine manufacture...

Page 96: ...ace 66 Initial operation 91 Inspection before use 29 Intake side engine 14 16 18 Intended use engine 10 L Lights vehicle 24 Locating a workshop 44 M Malfunction indicator light 24 Malfunctions 40 Manu...

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