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SHB MPE850 Rev 1.2 | 408014 | 408090 | 408101 |

6 Malfunctions

6.1 Malfunctions table

Malfunction

Possible cause

Remedy

The engine does not crank.

The ignition is turned off.

Turn on ignition.

The power supply of vehicle is

disconnected for safety reasons.

Depending on equipment of 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 the battery isolator.

After start failure the starter can stay

disabled for a few seconds.

Wait a few seconds and start the

engine again.

A fuse is defective.

Check the engine fuses. (See

chapter 6.2 Checking engine fuses.)

Check the fuses located in

the vehicle. See the vehicle

manufacturer's documentation.

The battery is discharged or

defective.

Contact immediately a workshop

authorized by Weber Motor or the

vehicle manufacturer.

The drive train is blocked.

Remove the blockage. See

the vehicle manufacturer's

documentation.

The engine cranks, but

does not start.

A fuse is defective or the service

fuse is unplugged.

Check the engine fuses or plug in

the service fuse. (See chapter 6.2

Checking engine fuses.)

Check the fuses located in

the vehicle. See the vehicle

manufacturer's documentation.

Lack of fuel.

Fill up fuel. See the vehicle

manufacturer's documentation.

The battery is discharged or

defective.

Contact immediately a workshop

authorized by Weber Motor or the

vehicle manufacturer.

Содержание MPE 850

Страница 1: ...AR TC 100 TC 80 TC 120 408014 I2 846 MAR TC 120 408090 I2 846 MAR TC 155 This service manual is valid for the following engine variants Read this service manual thoroughly before operating the engine...

Страница 2: ......

Страница 3: ...strives 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 whol...

Страница 4: ...fications 20 4 Operation 21 4 1 Service intervals 21 4 2 Operation during the break in period 23 4 3 Service before driving 24 4 3 1 Inspecting the exhaust and fuel system 24 4 3 2 Checking coolant le...

Страница 5: ...al anode 52 8 5 Checking and adjusting valve play 53 8 5 1 Checking valve play 53 8 5 2 Adjusting valve play 57 8 6 Replacing spark plugs and igition coils 60 8 7 Checking spark plugs 62 8 8 Replacing...

Страница 6: ...he vehicle always pass on the service manual to the new owner The latest version of the service manual is available for download in other languages from our web site www weber motor com Always read th...

Страница 7: ...o 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 alert symbol...

Страница 8: ...s use original Weber Motor spare parts The consequences of attaching add on parts and making unauthorized modifications to the engine are unknown and pose a safety risk to personnel Modifications and...

Страница 9: ...even death by asphyxiation When operating the engine in enclosed spaces use exhaust hoses to direct the engine exhaust gases into the open Engine exhaust gases Some service tasks require disconnectio...

Страница 10: ...micals hazardous materials according to the law of the state of California This product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Cal...

Страница 11: ...umber for each individual engine Take the time to enter the part number and serial number in chapter 9 Confirmation of service tasks Both numbers are required when making queries about your engine 3 1...

Страница 12: ...number and the serial number is located on the expansion tank 6 The serial number is also engraved on the crankcase 7 The label Emission Control Information indicates the certification of the engine a...

Страница 13: ...rating of 98 ROZ or 88 MOZ USA Premium 93 unleaded NOTICE Low octane fuel can cause loss of power and or increased fuel consumption Unleaded gasoline with an octane rating of at least 91 ROZ or 82 5 M...

Страница 14: ...topping up the coolant do not change the mixing ratio Always use approved coolant additives when topping up the coolant Coolant additive based on ethylene glycol silicate and nitrite free suitable fo...

Страница 15: ...he engine will not be disconnected from the battery The battery is connected separately to the wire harness The wire harness is not shown in the figures Sacrificial anode 8 Exhaust pipe 9 Sea water re...

Страница 16: ...16 3 Description 3 6 Engine components and information 1st cylinder 11 2nd cylinder 12 Fuel supply 13 Engine rotation direction 14 Stub shaft 15 Engine cover 16 Oil tank 17 Expansion tank coolant 18...

Страница 17: ...3 6 Engine components and information Sacrificial anode 7 Exhaust pipe 8 Sea water return 9 Engine variant I2 846 MAR TC 155 Oil filter 1 Drainage for storage 2 Waste gate valve 3 Flame arrester 4 He...

Страница 18: ...Description 3 6 Engine components and information 1st cylinder 10 2nd cylinder 11 Fuel supply 12 Fuse Box 13 Engine rotation direction 14 Stub shaft 15 Engine cover 16 Oil tank 17 Expansion tank cool...

Страница 19: ...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 fuse V...

Страница 20: ...n 1 rpm 113 kW 7500 min 1 rpm Engine speed limit 8000 min 1 rpm Idle speed 1600 min 1 rpm Carburation Sequential multipoint intake manifold injection Lubrication system Dry sump Cooling system Closed...

Страница 21: ...Following service tasks you can perform yourself before driving daily or after driving every 10 h1 Inspecting exhaust and fuel system Checking coolant level Checking oil level Flushing sea water cooli...

Страница 22: ...y 360 h or at least every 4 years Changing engine oil and oil filter Checking and adjusting valve play Replacing spark plugs Replacing ignition coils Replacing rubber mount Adjusting waste gate valve...

Страница 23: ...life of the engine Observe the following points to ensure that the engine parts break in properly engine speeds over 6000 min 1 rpm long periods of idle operation long operating periods at low engine...

Страница 24: ...tem 2 have noticeable corrosion Check if hoses are mounted properly and if cracks have been formed on hoses Fuel system WARNING Fuel is highly flammable Vapors may ignite and cause an explosion Check...

Страница 25: ...marking continue with the section Refilling coolant NOTICE Leaks in the hoses due to increased pressure When the MAX marking is exceeded pump out excessive coolant with a suction pump 4 Operation 4 3...

Страница 26: ...hicle manufacturer s documentation CAUTION Scalding caused by hot engine oil Wear protective gloves Unscrew the oil dipstick 1 at the oil tank Wipe the oil dipstick and insert into the oil tank Do not...

Страница 27: ...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 of the...

Страница 28: ...ing device See the vehicle manufacturer s documentation NOTICE Engine damage due to water in the engine When the engine is switched off the water may get into the engine through the exhaust system Fir...

Страница 29: ...30 days Transport and store the vehicle on a preferably stable and flat surface If you do not have any flat surface available note for storage necessarily the angles in the figure Do not exceed these...

Страница 30: ...le 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 Operate the engine o...

Страница 31: ...flooded the water may get into the engine through the exhaust system It can still happen even if the engine has been partially flooded The longer you postpone the necessary service tasks the more sev...

Страница 32: ...nate after engine start The engine warning light comes on after starting the engine for a few seconds If the MIL engine warning light is not on an error has occurred The temperature warning light is f...

Страница 33: ...ive Check the engine fuses See chapter 6 2 Checking engine fuses Check the fuses located in the vehicle See the vehicle manufacturer s documentation The battery is discharged or defective Contact imme...

Страница 34: ...facturer s documentation The engine stalls and cannot be started again No fuel Fill up fuel See the vehicle manufacturer s documentation The engine does not provide the full power There is no malfunct...

Страница 35: ...ed 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 fro...

Страница 36: ...ne 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 fuse...

Страница 37: ...tion of accessories to prepare you for the most important situations Visit your local vehicle dealer or our web site www weber motor com for more information 7 3 Repairs Repairs require mechanical kno...

Страница 38: ...cumentation for more information Disconnect the engine from the power supply before performing any servicing tasks Only reconnect the power supply to the engine once all service tasks are complete and...

Страница 39: ...s workshop Serious eye injuries caused by sudden release of spring band clamps Wear protective glasses also people in the nearby working place Use only suitable tools as described in Section 8 2 Tools...

Страница 40: ...om for more information 8 2 1 Weber Motor service parts 8 Service tasks in the workshop 8 2 Tools and accessories Figure Description Oil filter O rings for oil filter change Spark plug Champion RC7PYC...

Страница 41: ...ce tasks in the workshop 8 2 Tools and accessories Weber Motor offers a diagnostic case that contains the Weber Diagnostic Tool The Weber Diagnostic Tool is designed for fault diagnostics and service...

Страница 42: ...ut 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 All tools and accessories are availab...

Страница 43: ...43 SHB MPE850 Rev 1 2 408014 408090 408101 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...

Страница 44: ...Germany Corrosion protection spray W rth corrosion protection spray Germany The product must be salt water resistant and suitable for different surfaces such as metals paintet surfaces plastic and ru...

Страница 45: ...ll be pumped 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 di...

Страница 46: ...pplied 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 in...

Страница 47: ...ICE 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 8...

Страница 48: ...acing oil filter Hold the oil filter 19 Unscrew the banjo bolt 20 Remove the oil filter 8 Service tasks in the workshop 8 3 Changing engine oil and oil filter Open the hose clamps 11 and 13 Hold the h...

Страница 49: ...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 f...

Страница 50: ...ift 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 engi...

Страница 51: ...ight See the Weber Diagnostic Tool manual Update the engine control unit calibration See the Weber Diagnostic Tool manual Test drive the vehicle 8 Service tasks in the workshop 8 3 Changing engine oil...

Страница 52: ...athodic protection Check the sacrificial anode 2 At least half of the original size 60 mm 2 4 in 16 mm 0 6 in exists If the sacrificial anode is less than half of the original size replace the sacrifi...

Страница 53: ...rom 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 Checkin...

Страница 54: ...correspond to one rotation of the camshaft Check the valve play 10 of all valves on the cylinder using a feeler gauge Required valve play 0 2 0 3 mm If the valve play of one or more valves is not rig...

Страница 55: ...cking the valve play 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...

Страница 56: ...washers 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 the p...

Страница 57: ...the crankshaft The vehicle manufacturer has devised a suitable procedure for this Read the vehicle manufacturer s documentation for more information Always turn the crankshaft in the same direction as...

Страница 58: ...e 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 Hol...

Страница 59: ...ide 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 wor...

Страница 60: ...and igition 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 wo...

Страница 61: ...tors to the ignition coils 10 Touch up the paintwork defects Clear the service counter to reset service light See the Weber Diagnostic Tool manual Update the engine control unit calibration See the We...

Страница 62: ...cking 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 wo...

Страница 63: ...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 satisfact...

Страница 64: ...e 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 as il...

Страница 65: ...rubber mount 8 8 Replacing rubber mount Open the spring band clamps 4 Remove the hose 5 Engine variants I2 846 MAR TC 80 TC 100 and TC 120 Remove the rubber mount with a cold engine Mark 2 the hose 1...

Страница 66: ...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 moun...

Страница 67: ...the spring band clamps 15 Touch up the paintwork defects Clear the service counter to reset service light See the Weber Diagnostic Tool manual Update the engine control unit calibration See the Weber...

Страница 68: ...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 th...

Страница 69: ...f ft 0 4 lbf ft 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 the paintwork defects Clear the service counter to res...

Страница 70: ...waste gate valve Adjust the waste gate valve with a cold engine Observe the indicated directions of rotation 1 One nut 4 has a left hand thread Hold the threaded rod 3 with a wrench Open the two nuts...

Страница 71: ...does not move anymore The thread rod 6 has not moved yet Attach the 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...

Страница 72: ...rester 1 The fabric must be visible When the fabric filter is no longer visible continue with section Cleaning the flame arrestor Open the hose clamp 4 Cleaning flame arrester Open the clamp 3 The cla...

Страница 73: ...e flame arrester 5 Clean the flame arrester with cleaning spray according to the manufacturer s instructions Attach the flame arrester Close the hose clamp 6 Tightening torque 4 5 Nm 1 Nm 3 3 lbf ft 0...

Страница 74: ...coolant Put 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 Unscrew t...

Страница 75: ...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 wa...

Страница 76: ...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 hoses due...

Страница 77: ...77 SHB MPE850 Rev 1 2 408014 408090 408101 8 12 Replacing fuel filter See the vehicle manufacturer s documentation 8 Service tasks in the workshop 8 12 Replacing fuel filter...

Страница 78: ...s 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 Pe...

Страница 79: ...n 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 t...

Страница 80: ...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 th...

Страница 81: ...8014 408090 408101 8 14 Disposal When disposing of operating materials replaced parts or the whole engine always comply with the relevant applicable national laws and guidelines 8 Service tasks in the...

Страница 82: ...ks Date Work carried out Engine oil and oil filter changed Sacrificial anode checked Valve play checked Spark plugs replaced Rubber mount replaced Waste gate valve adjusted Flame arrester checked Cool...

Страница 83: ...ed Waste gate valve adjusted 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 Sacrif...

Страница 84: ...manufacturer Appendix Engine manufacturer Exhaust type authorization and certification Exhaust type authorization and certification This engine family complies with U S EPA Exhaust regulation for inbo...

Страница 85: ...O LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERW...

Страница 86: ...ine 11 Ignition coils replace 60 Initial operation 80 Inspection before driving 24 Intended use engine 11 L Locating a workshop 37 M Malfunctions 32 Manufacturer engine 84 O Oil filter replace 45 Oil...

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