OXE 30-0101-200 Service Manual
  1. Manuals
  2. Brands
  3. OXE Manuals
  4. Engine
  5. 30-0101-200
  6. Service manual

OXE 30-0101-200 Service Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
DIESEL ENGINE
SERVICE MANUAL 1.0
Publication No: ODM1004

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 30-0101-200 and is the answer not in the manual?

Questions and answers

Related Manuals for OXE 30-0101-200

Summary of Contents for OXE 30-0101-200

  • Page 1 DIESEL ENGINE SERVICE MANUAL 1.0 Publication No: ODM1004...
  • Page 2 OXE 150/200 HP SERVICE MANUAL...

  • Page 3: Preface

    Since our products are in continuous development, we reserve the right to make technical modifications. Reprinting, copying or translation, even of extracts, is not allowed without written permission from Cimco Marine AB. All rights under the copyright law are strictly reserved by Cimco Marine AB. OXE 150/200 HP SERVICE MANUAL...
  • Page 4 OXE 150/200 HP SERVICE MANUAL...

  • Page 5: Table Of Contents

    Fuel system description _________________________________________________________________ 50 Evacuating air from fuel system ______________________________________________________ 51 Transmission component description _________________________________________________ 52 Hydraulic SYSTEM description _______________________________________________________ 53 Repetitive instructions ___________________________________________________________________ 54 Replacing gaskets _________________________________________________________________ 54 Remove and install the top cowling ___________________________________________________ 55 OXE 150/200 HP SERVICE MANUAL...
  • Page 6 Engine oil and oil filter installation ____________________________________________________ 89 Oil filter adapter and oil cooler assembly replacement ________________________________________ 90 Oil filter adapter and oil cooler assembly removal ________________________________________ 90 Oil filter adapter and oil cooler assembly installation______________________________________ 92 OXE 150/200 HP SERVICE MANUAL...
  • Page 7 Camshaft cover inspection _________________________________________________________ 117 Camshaft housing installation ______________________________________________________ 119 Valve rocker arm cover replacement ______________________________________________________122 Valve lifter roller replacement ___________________________________________________________123 Valve lifter roller removal __________________________________________________________ 123 Valve lifter roller installation ________________________________________________________ 123 Camshaft sprocket replacement __________________________________________________________124 OXE 150/200 HP SERVICE MANUAL...
  • Page 8 Intake manifold cleaning and inspection ______________________________________________ 158 Intake manifold assemblY __________________________________________________________ 159 Intake manifold installation ________________________________________________________ 160 Dry sump and Oil pan baffle replacement __________________________________________________162 Oil pan baffle removal _____________________________________________________________ 162 Oil pan baffle installation ___________________________________________________________ 162 OXE 150/200 HP SERVICE MANUAL...
  • Page 9 Upper belt replacement _________________________________________________________________204 Replace belt pulley seals ___________________________________________________________ 205 Replace zinc anodes ______________________________________________________________ 205 Seawater pump impeller replacement _____________________________________________________206 Clean Seawater strainer ________________________________________________________________207 Replace Seawater outlet nipple __________________________________________________________208 Drain and fill coolant ___________________________________________________________________209 Fill coolant ______________________________________________________________________ 210 OXE 150/200 HP SERVICE MANUAL...
  • Page 10 Service at 200 hours ______________________________________________________________ 249 Service at 800 hours ______________________________________________________________ 251 Service record - Lower belt ________________________________________________________ 253 Service record - Lower belt ________________________________________________________ 254 Troubleshooting _______________________________________________________________________255 Operating faults and possible causes _________________________________________________ 255 Fault table ______________________________________________________________________ 256 OXE 150/200 HP SERVICE MANUAL...

  • Page 11: Safety Regulations

    The engine may only be started and operated by authorised personnel. When the engine is running, keep a safe distance to the rotating parts. Wear close-fitting working clothes. OXE 150/200 HP SERVICE MANUAL...

  • Page 12: Regulations To Prevent Damage To Engine And Prevent Wear

    Always use genuine OXE Diesel parts only. Installation of “equally” good parts from other suppliers may cause severe damage Any warranty is void, and the installing workshop is held liable for costs of damage to outboard and people..

  • Page 13: Prevention Of Environmental Damage

    For this reason do not let engine oil get into the ground, waterways, the drains or the sewers. Violations of local environmental legislation are punishable by law. Carefully collect and dispose of used engine oil. Information on collection points can be obtained from retailers, the supplier or the local authorities. OXE 150/200 HP SERVICE MANUAL...

  • Page 14: Cleanliness

    (industrial type vacuum cleaners). Use only fluff-free cleaning cloths on the fuel system. Only tools without any damage may be used. NOTE! Avoid using cracked chrome coatings due to the risk of flaking and contamination. OXE 150/200 HP SERVICE MANUAL...
  • Page 15 Work on removed components may be carried out only at a workplace specially equipped for it. If removed parts are are to be transported, always use the original packing material of the new part. OXE 150/200 HP SERVICE MANUAL...

  • Page 16: Repetitive Alerts

    Protective goggles and glove DANGER Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges from worn exhaust components could result in serious personal injury. OXE 150/200 HP SERVICE MANUAL...
  • Page 17 This engine is equipped with torque-to-yield or single use fasteners. Install a NEW torque-to-yield or single use fastener when installing this component. Failure to replace the torque-to-yield or single use fastener could cause damage to the outboard or component. OXE 150/200 HP SERVICE MANUAL...

  • Page 18: Specifications

    Compression Ratio 16.5:1 Idle Speed 850 RPM Firing Order 1-3-4-2 Engine Height - Total Dimensions Oil Pan to Cover 708 mm 28 in Engine Length - Mounting Bracket to Thermostat Housing 701 mm 27.6 in OXE 150/200 HP SERVICE MANUAL...
  • Page 19 1.9997 - 1.9999 in Crank Pin Journal Diameter - Class C 50.787 - 50.793 mm 1.9995 - 1.9997 in Crank Pin Journal Diameter Oversize - Class A 50.672 - 50.678 mm 1.995 - 1.9952 in OXE 150/200 HP SERVICE MANUAL...
  • Page 20 Piston Ring End Gap - 0.20-0.35 mm 0.0078-0.0137 in First Compression Ring - @ 10 mm (0.393 in) down Piston Ring End Gap - 0.60-0.80 mm 0.0236-0.0 Second Compression Ring - @ 18 mm (0.708 in) down OXE 150/200 HP SERVICE MANUAL...
  • Page 21 Connecting Rod Bearing Thickness Oversize (Black) 1.597-1.601 mm 0.06287-0.06303 in Cooling System Coolant Refer to Recommended fluids and grease Capacity Refer to Recommended fluids and grease Thermostat Start to Open 75°C 167°F Fully Open 77°C 170°F OXE 150/200 HP SERVICE MANUAL...

  • Page 22: Engine Threshold Values

    2500 Gearbox Oil Pressure Low [kPa abs] Manifold Air Pressure [kPa abs] Manifold Air Temp [˚C] Battery Voltage High [V] 14.7 Battery Voltage Low [V] We reserve the right to change values without further notice. OXE 150/200 HP SERVICE MANUAL...

  • Page 23: General Tightening Torques

    Thread (metric) Tightening torque lb ft lb ft M8x1 15.49 19.91 M10x1.25 30.98 38.35 M12x1.25 56.79 70.80 M14x1.5 88.50 110.63 M16x1.5 140.13 177.00 M18x1.5 199.13 250.75 M20x1.5 287.63 361.38 M22x1.5 390.88 494.13 M24x1.5 516.26 641.64 OXE 150/200 HP SERVICE MANUAL...

  • Page 24: Fastener Tightening Specifications

    - First Pass 25 Nm 18 lb ft - Final Pass 100 degrees Crankshaft Main Bearing Bolt – Side - First Pass 25 Nm 18 lb ft - Final Pass 100 degrees (1) = Use new fastener. OXE 150/200 HP SERVICE MANUAL...
  • Page 25 9 Nm 80 lb in - Bolt – M8 25 Nm 18 lb ft Exhaust Camshaft Sprocket Bolt - First Pass 40 Nm 30 lb ft - Final Pass 55 degrees (1) = Use new fastener. OXE 150/200 HP SERVICE MANUAL...
  • Page 26 18 lb ft Oil Feed Pipe to Cylinder Block 15 Nm 11 lb in Oil Filter Cap 15 Nm 11 lb ft Oil Filter Cover 25 Nm 18 lb ft (1) = Use new fastener. OXE 150/200 HP SERVICE MANUAL...
  • Page 27 18 lb ft Turbocharger Oil Feed Pipe Fastener 20 Nm 15 lb ft Turbocharger Oil Return Pipe to Turbocharger 9 Nm 80 lb in Water Pump Bolt 25 Nm 18 lb ft (1) = Use new fastener. OXE 150/200 HP SERVICE MANUAL...

  • Page 28: Recommended Fluids And Grease

    Diesel fuels The composition of the fuels is vital for operation of the OXE diesel engine, its service life, and emissions. To meet the performance specified and to run the boat cleanly and quietly, it is important that fuel as recommended in table Recommended fluids and grease is used.

  • Page 29: Tools And Equipment

    Compressed air supply Trays or storage containers to keep parts and fasteners organized Adequate set of hand tools Approved engine repair stand Approved engine lifting device that will adequately support the weight of the components. OXE 150/200 HP SERVICE MANUAL...

  • Page 30: Special Tools

    TOOLS AND EQUIPMENT SPECIAL TOOLS Illustration Tool Number/Description 30-0160-014 ODT Puller 30-0160-015 ODT Extension 30-0160-016 ODT Crankshaft Fixing Tool 30-0160-017 ODT Camshaft Locking Tool OXE 150/200 HP SERVICE MANUAL...
  • Page 31 TOOLS AND EQUIPMENT Illustration Tool Number/Description 30-0160-018 ODT Camshaft Sprocket Holding Tool 30-0160-019 ODT Fuel Injection Pump Sprocket Holder 30-0160-020 ODT Remover/Installer Glow Plugs 9 mm 30-0160-021 ODT Angle Meter OXE 150/200 HP SERVICE MANUAL...
  • Page 32 TOOLS AND EQUIPMENT Illustration Tool Number/Description 30-0160-023 ODT Fitting tool, oil pump seal 30-0160-025 ODT Remover Oil Seal 30-0160-060 ODT Propshaft bearing fixing tool 30-0160-001 ODT Gauge bar OXE 150/200 HP SERVICE MANUAL...
  • Page 33 TOOLS AND EQUIPMENT Illustration Tool Number/Description 30-0160-002 ODT Hooking tool 30-0160-003 ODT M6 Allen screw, rounded 30-0160-004 ODT Sleeve removal tool 30-0160-005 ODT Sleeve seating tool OXE 150/200 HP SERVICE MANUAL...
  • Page 34 TOOLS AND EQUIPMENT Illustration Tool Number/Description 30-0160-006 ODT Seal forming tool 30-0160-008 ODT 50mm Nut removing tool 30-0160-009 ODT Bearing race driver 30-0160-010 ODT OBD OXE 150/200 HP SERVICE MANUAL...
  • Page 35 TOOLS AND EQUIPMENT Illustration Tool Number/Description 30-0160-034 ODT Flywheel blocking tool 30-0160-110 Propeller shaft bearing remove/mount tool 30-0160-112 50 mm nut removing tool 30-0160-118 Crankshaft fixing tool OXE 150/200 HP SERVICE MANUAL...

  • Page 36: Engine Component Description

    The oil dry sump includes an oil return pipe, which is connected to the oil pump. The dry sump is attached at the bottom of the engine block and the associated oil reservoar is integrated in the outboard rigg. OXE 150/200 HP SERVICE MANUAL...
  • Page 37 There are 2 intake and 2 exhaust valves per cylinder with “minilash” hydraulic adjusters with roller fingers. Valve lash adjusters The valve train uses a roller finger follower acted on by a hydraulic lash adjuster. The roller finger follower reduces friction and noise. OXE 150/200 HP SERVICE MANUAL...

  • Page 38: Outboard Overviews

    Air filter Turbo charger Expansion tank Seawater Intercooler strainer Exhaust pipe/hose Heat exchanger Hydraulic oil cooler Belt housing Transom mount Hydraulic oil pump and filter Upper housing Gear box Lower housing Fig. 1 OXE 150/200 HP SERVICE MANUAL...
  • Page 39 (ECU) Fuel filter Engine connector Battery connectors Engine oil Seawater dip stick pump Alternator Engine oil filter Transom mount and tilt and trim cylinders Anti cavitation plate Water intake Propeller axis Fig. 2 OXE 150/200 HP SERVICE MANUAL...

  • Page 40: System And Assembly Overviews

    7. Engine water pump 1. Seawater strainer 8. Engine 2. Seawater pump 9. Exhaust manifold 3. Heat exchanger and hydraulic oil cooler 10. Thermostat 4. Intercooler 11. Expansion tank 5. Exhaust pipe 12. Turbocharger 6. Belt housing cooler OXE 150/200 HP SERVICE MANUAL...

  • Page 41: Engine Lubrication System

    An engine oil pressure switch or sensor is installed at the oil filter adapter. The turbocharger is lubricated with oil via a feed pipe and drained by a return pipe. Oil returns to the oil pan through cast passages in the engine block. OXE 150/200 HP SERVICE MANUAL...

  • Page 42: Camshaft Timing Components

    19. Timing Belt Cover Bolt 8. Timing Belt Tensioner Bracket 20. Timing Belt Cover 9. Timing Belt Tensioner Special Screw 10. Timing Belt Idler Pulley 11. Timing Belt Idler Pulley Washer 12. Timing Belt Idler Pulley Bolt OXE 150/200 HP SERVICE MANUAL...

  • Page 43: Dry Sump, Filter, And Tube

    7. Turbocharger Oil Feed Pipe 17. Oil Pan Bolt 8. Turbocharger Oil Feed Pipe – Bolt 18. Oil Pan Baffle Bolt 9. Turbocharger Oil Feed Pipe – O-Ring 10. Turbocharger Oil Return Pipe – Bolt Engine Block OXE 150/200 HP SERVICE MANUAL...

  • Page 44: Cylinder Head Assembly

    11. Camshaft Rear Cover Bolt 5. Camshaft Cover Housing Bolt – Medium 12. Camshaft Housing Gasket 6. Camshaft Cover Housing Bolt – Long 13. Intake Camshaft Sprocket Wheel 7. Oil Filler Cap 14. Intake Camshaft Sprocket Wheel Bolt OXE 150/200 HP SERVICE MANUAL...
  • Page 45 53. Engine Lift Bracket Bolt – High Pressure Pump 32. Threaded Plug 54. Plug Gasket 33. Valve Guide 55. Plug 34. Valve Retainer 56. Lid 35. Valve Spring 57. Retainer 36. Valve Retainer 58. Screw OXE 150/200 HP SERVICE MANUAL...

  • Page 46: Engine Block Assembly

    Water Passage Plug Piston Pin Retainer Engine Flywheel Bolt Piston Pin Centaflex CF-R dual stage coupling Connecting Rod Centaflex Bolt Connecting Rod Bolt Engine Flywheel Plug Flywheel Dowel Crankshaft Rear Oil Gasket Increment Wheel Bolt OXE 150/200 HP SERVICE MANUAL...
  • Page 47 Piston Oil Nozzle Crankshaft Lower Bearing Plug Crankshaft Bearing Cap Engine Block Crankshaft Bearing Cap Bolt Water Passage Plug Crankshaft Cylinder Head Locating Pin Crankshaft Upper Bearing Connecting Rod Bearing Caps Piston Oil Nozzle Bolt OXE 150/200 HP SERVICE MANUAL...

  • Page 48: Intake Manifold

    INTAKE MANIFOLD Fig. 9 Intake manifold 1. Intake Manifold Bolt 2. Intake Manifold 3. Manifold Temperature & Pressure Sensor 4. Manifold Absolute Pressure Sensor Bolt 5. EGR-plug retainer 6. Bolt 7. EGR-plug 8. Actuating Drive OXE 150/200 HP SERVICE MANUAL...

  • Page 49: Turbo Charger Assembly

    SYSTEM AND ASSEMBLY OVERVIEWS TURBO CHARGER ASSEMBLY Fig. 10 Turbo charger assembly 1. Air filter 2. Turbo actuator 3. Turbo charger 4. Oil hose 5. Exhaust tube 6. Water pipe 7. Thermostat housing 8. Water cooled exhaust manifold OXE 150/200 HP SERVICE MANUAL...

  • Page 50: Fuel System Description

    The fuel injection pump is a mechanical high pressure pump. Fuel is pumped to to the fuel rail at a specific pressure. Fuel pressure is regulated by the fuel pressure regulator, which is controlled by the ECU. OXE 150/200 HP SERVICE MANUAL...

  • Page 51: Evacuating Air From Fuel System

    Bleeding fuel system Turn the ignition key ON. The fuel pump will run for 20 seconds. NOTE! Do not turn the ignition key to START. This could damage the injection pump. Repeat three times. OXE 150/200 HP SERVICE MANUAL...

  • Page 52: Transmission Component Description

    SYSTEM AND ASSEMBLY OVERVIEWS TRANSMISSION COMPONENT DESCRIPTION Fig. 12 Transmission Propeller shaft Output shaft assembly Input shaft assembly Upper belt Reverse gear assembly Lower belt OXE 150/200 HP SERVICE MANUAL...

  • Page 53: Hydraulic System Description

    Accumulator Proportional pressure relief valve Directional valve Hydraulic pump and filter Clutches Accumulator Directional valve Pressure relief valve Filter Heat exchanger Pressure switch Pump Lubrication circuit Pressure relief for lubrication circuit Fig. 13 Hydraulic system OXE 150/200 HP SERVICE MANUAL...

  • Page 54: Repetitive Instructions

    When applying sealant to a component, apply the amount specified in the service procedure. Do not allow the sealant to enter into any blind threaded holes, as it may prevent the bolt from clamping properly or cause component damage when tightened. OXE 150/200 HP SERVICE MANUAL...

  • Page 55: Remove And Install The Top Cowling

    Close the hatches. Make sure that the top cowling is securely closed and that there are no gaps. A loose or improperly fitted cowling could allow water to enter the engine. Check the fitting of the top cowling. Reinstall if the fit is not complete. OXE 150/200 HP SERVICE MANUAL...
  • Page 56 DANGER Failure to follow these precautions may result in personal injury and/or damage to the outboard or its components. Power cables max 600 mm, min 50 mm 100 A fuse Engine OXE 150/200 HP SERVICE MANUAL...

  • Page 57: Fuel Injection Pump Replacement

    Do not allow smoking or the use of open flames in the area where work on the fuel or EVAP system is taking place. Anytime work is being done on the fuel system, switch off the battery main switch, except for those tests where battery voltage is required. OXE 150/200 HP SERVICE MANUAL...

  • Page 58: Fuel Injection Pump Removal

    Store the components so that contaminants cannot enter. Switch off the battery main switch. Refer to Battery disconnect. Remove the upper timing cover bolts (1). OXE 150/200 HP SERVICE MANUAL...

  • Page 59: Fuel Injection Pump Bracket Removal

    FUEL INJECTION PUMP REPLACEMENT FUEL INJECTION PUMP BRACKET REMOVAL Remove the 6 fuel injection pump bracket bolts (1, 3, 4). Remove the fuel injection pump bracket (2). NOTE! Have a cloth on hand to catch any fuel spill. OXE 150/200 HP SERVICE MANUAL...
  • Page 60 Turn the engine so it is possible to fit 2 Allen bolts (1) M6 x 40 (30 mm unthreaded and 10 mm threaded) through the holes in the pulley and to threads in the high-pressure pump bracket. Remove the pulley nut (2). OXE 150/200 HP SERVICE MANUAL...
  • Page 61 30-0160-014 puller (1). Counterhold with a 30 mm wrench (2). Remove the puller. Remove the high-pressure pump: Remove the nuts and any washers (1). Use a magnet so as not to drop the washers. Lift out the pump. Pay attention to the wedge. OXE 150/200 HP SERVICE MANUAL...

  • Page 62: Fuel Injection Pump Installation

    (1). It is important that the wedge fits into the groove on the pulley. Tighten to 25 Nm (18 lb ft). Install the nut (2) to the high-pressure pump pulley. Tighten to 50 Nm (37 lb ft) . Remove the bolts (1) holding the pulley in place. OXE 150/200 HP SERVICE MANUAL...
  • Page 63 Remove the plug and attach the fuel supply hose (1) and clamp to the pump. Attach the fuel pressure sensor connector (3) to the pump. NOTE! Take note of the bolt locations. Attach the return fuel line. OXE 150/200 HP SERVICE MANUAL...
  • Page 64 Install the upper timing belt belt cover with 7 bolts (2). Switch on the battery main switch. DANGER See Battery disconnect. To evacuate air from the fuel system, see Bleed fuel system. Start the engine and turn it off. OXE 150/200 HP SERVICE MANUAL...

  • Page 65: Fuel Filter

    Remove bolts (3) and nuts (2) including washers. Remove the fuel filter (4) from the bracket. Fuel filter installation Reinstall the new fuel filter in opposite order. Tighten bolts to xx Nm (xx lb ft). Reconnect fuel lines (1). OXE 150/200 HP SERVICE MANUAL...
  • Page 66 Loosen the draining screw (1) and release the fuel-water mixture into the container. Tighten the draining screw (1). NOTE! Also drain the fuel prefilter in boat! Refer to Fuel System description. OXE 150/200 HP SERVICE MANUAL...

  • Page 67: Replacing Fuel Filter Element

    Remove the filter element (1) and discard according to Local environmental legislation. Insert a new filter element (1) and reinstall the fuel filter bowl. Tighten by hand. NOTE! Also replace fuel prefilter element in boat! Refer to Fuel System description. OXE 150/200 HP SERVICE MANUAL...

  • Page 68: Fuel Injector Feed Pipe Replacement

    Always wear safety goggles when working with fuel in order to protect the eyes from fuel splash. Switch off the battery main switch. DANGER See Battery disconnect. Remove the 2 fuel feed pipe nuts (2). Remove the fuel feed pipe (1). OXE 150/200 HP SERVICE MANUAL...

  • Page 69: Feed Pipe Installation (Fuel Pump To Rail)

    Tighten the fuel feed pipe nuts (1, 2): Fuel feed pipe to fuel rail (4) nut (1) tighten to 19 Nm (14 lb ft) . Fuel feed pipe to fuel injection pump nut (2) tighten to 25 Nm (18 lb ft). OXE 150/200 HP SERVICE MANUAL...

  • Page 70: Feed Pipe Removal (Rail To Injectors)

    Have a dry chemical (Class B) fire extinguisher nearby. Switch off the battery main switch. DANGER See Battery disconnect. Remove the 8 fuel injector fuel feed pipe nuts (1, 2). Remove the 4 fuel injector fuel feed pipes (3). OXE 150/200 HP SERVICE MANUAL...

  • Page 71: Feed Pipe Installation (Rail To Injectors)

    Install the 8 fuel injector fuel feed pipe nuts (1, 2) and hand tighten. Tighten the 4 fuel injector fuel feed pipe nuts (1) to 25 Nm (18 lb ft) . Tighten the 4 fuel injector fuel feed pipe nuts (2) to 19 Nm (14 lb ft). OXE 150/200 HP SERVICE MANUAL...

  • Page 72: Fuel Rail Assembly Replacement

    NOTE! Place caps on the open fuel rail connectors to avoid contamination from dirt as soon as the fuel rail pipes are removed. Disconnect the fuel rail pressure sensor wiring harness plug (3). Remove the fuel rail bolts (1). Remove the fuel rail (2). OXE 150/200 HP SERVICE MANUAL...

  • Page 73: Fuel Rail Assembly Installation

    Install the fuel rail (1). WARNING See Fastener. Install the fuel rail bolts (2) and tighten to 25 Nm (18 lb ft). Connect the fuel rail pressure sensor wiring harness plug (3). Switch on the battery main switch. OXE 150/200 HP SERVICE MANUAL...

  • Page 74: Fuel Rail Pressure Sensor Replacement

    Disconnect the fuel rail pressure sensor harness connector. Detach the fuel rail pressure sensor. Install a new fuel rail pressure sensor. Tighten 70 Nm (52 lb ft). Connect the fuel rail pressure sensor harness connector. OXE 150/200 HP SERVICE MANUAL...

  • Page 75: Glow Plug Replacement

    Clean around each of the glow plugs to avoid dirt from entering the engine. WARNING Use care when disconnecting the glow plug electrical connector. Use of excessive force may damage the electrical connector. Remove the glow plugs (1). OXE 150/200 HP SERVICE MANUAL...

  • Page 76: Glow Plug Installation

    GLOW PLUG REPLACEMENT GLOW PLUG INSTALLATION WARNING See Component fastener tightening. NOTE! Be sure that you not interchange the electrical connectors. Install the 4 glow plugs (1). OXE 150/200 HP SERVICE MANUAL...

  • Page 77: Draining And Filling Coolant

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

  • Page 78: Draining Coolant

    NOTE! Don’t open the cooling system when the engine is at operating temperature. This causes a pressure loss in the cooling system. The cooling system must only be filled up when the engine is cold. OXE 150/200 HP SERVICE MANUAL...

  • Page 79: Check Coolant System

    8. Engine necessary. 9. Exhaust manifold – Check that the telltale is not blocked. 10. Thermostat – Check hydraulic oil cooler water outlet for 11. Expansion tank clogging. Clean with pipe cleaner or similar. 12. Turbocharger OXE 150/200 HP SERVICE MANUAL...

  • Page 80: Thermostat Replacement

    Remove thermostat (8) and gasket (9). Install a new thermostat. NOTE! Install a new gasket. Reinstall the thermostat housing lid with 4 screws and washers. Tighten to 9 Nm (14 lb ft). Fill up according to Filling coolant. OXE 150/200 HP SERVICE MANUAL...

  • Page 81: Heat Exchanger Replacement

    Drain the coolant. Refer to Draining and filling coolant. NOTE! Dispose of coolant fluid according to local environmental legislation. Loosen nuts (3) on bracket (2) and remove the strainer by lifting it upwards. Bend the Seawater strainer (1) forward. OXE 150/200 HP SERVICE MANUAL...
  • Page 82 Refer to Thermostat replacement, step 1 to 3. Remove the pressure pipe intercooler retainer (4). Remove the pressure pipe assembly (3). Remove clamp (5) and flex hose (6). Remove clamp (8) and exhaust hose assembly (7). OXE 150/200 HP SERVICE MANUAL...
  • Page 83 Disconnect the quick release connectors (8, 9) of the hydraulic oil hoses. Cut the hoseclamps (3) and remove the coolant hoses. Remove screws and washers (10). Pull the heat exchanger (1) down and outwards. OXE 150/200 HP SERVICE MANUAL...

  • Page 84: Cleaning The Heat Exchanger

    7.5 to 8.5 with the aid of caustic soda. Once the precipitation has settled to the bottom of the container, the clear fluid above can be tipped into the sewer system. CAUTION Risk of contamination of drinking water. Dispose of the sludge at the bottom according to local environmental legislation. OXE 150/200 HP SERVICE MANUAL...

  • Page 85: Heat Exchanger Installation

    Reinstall the Seawater strainer. Reinstall the oil plug and tighten to 20 Nm (14.8 lb ft). Refill hydraulic oil according to Lower belt replacement, Refill hydraulic oil. Refill coolant, according to Draining and filling coolant. OXE 150/200 HP SERVICE MANUAL...

  • Page 86: Freshwater Pump Replacement

    See Fastener. Install the 3 water pump bolts (2) and tighten to 25 Nm (18 lb ft). Fill up coolant, refer to Draining and filling coolant. refer to Timing belt installation. Reinstall the timing belt, OXE 150/200 HP SERVICE MANUAL...

  • Page 87: Engine Oil And Oil Filter Replacement

    ENGINE OIL AND OIL FILTER REPLACEMNET ENGINE OIL AND OIL FILTER REPLACEMENT ENGINE OIL AND OIL FILTER REMOVAL Change engine oil Open the oil filler cap. OXE 150/200 HP SERVICE MANUAL...
  • Page 88 Fit a new washer and tighten the oil draining plug to 9 Nm (6.6 ft-lb). Place a suitable container below the oil filter.. NOTE! Use a 6-point socket to remove the oil filter cap. Remove the oil filter cap (1). Remove and discard the oil filter cartridge. OXE 150/200 HP SERVICE MANUAL...

  • Page 89: Engine Oil And Oil Filter Installation

    Install the new oil filter cartridge. Install the oil filter cap and tighten to 25 Nm (18 lb ft). Fill the engine with the appropriate oil type and quantity. Refer to Recommended fluids and grease. Install the oil filler cap. OXE 150/200 HP SERVICE MANUAL...

  • Page 90: Oil Filter Adapter And Oil Cooler Assembly Replacement

    Remove the engine oil cooler coolant outlet hose clamps (1, 2). Remove the engine oil cooler coolant outlet hose (3) and the snap lock (4). Remove the oil filter cap, refer to Engine oil and oil filter replacement. OXE 150/200 HP SERVICE MANUAL...
  • Page 91 Remove the oil filter adapter and oil cooler assembly bolts (2) from engine block and place in a clean environment. Remove the oil filter adapter and oil cooler assembly (1). Remove and discard the oil filter adapter and oil cooler assembly gasket. OXE 150/200 HP SERVICE MANUAL...

  • Page 92: Oil Filter Adapter And Oil Cooler Assembly Installation

    Fit the oil cooler using new seals greased with Vaseline. Check the oil level and top up if necessary. Switch on the battery main switch. DANGER See Battery Disconnect. Start the engine and check that the oil cooler is not leaking. OXE 150/200 HP SERVICE MANUAL...

  • Page 93: Oil Pump Replacement

    Remove the timing belt, see Timing belt removal. Remove the dry sump, see Oil pan baffle removal. NOTE! The bolt has a left hand thread. Remove the belt pulley using 30-0160-022 Holder (1) in combination with 30-0160-015 Extension (2). OXE 150/200 HP SERVICE MANUAL...
  • Page 94 Remove the eight oil pump bolts (9). Unscrew the stud from 30-0160-016 fixing tool. Remove the oil pump (1). Remove the oil pump gasket (2). Remove and discard the front radial seal. Clean the threads and all of the gasket surfaces. OXE 150/200 HP SERVICE MANUAL...

  • Page 95: Oil Pump Installation

    Use locking agent Loctite on the 8 M6x20 oil pump bolts (3) and tighten to 9 Nm (80 lb in). NOTE! Moisten the gasket sealing lip with a little silicone grease (white). Fit the oil pump seal using 30-0160-023 fitting tool (3). OXE 150/200 HP SERVICE MANUAL...
  • Page 96 30-0160-015 Extension (2). Tighten bolt to 380 Nm (280 lb ft). NOTE! The bolt has a left-hand thread. Remove30-0160-022 holder (1) and EN-977 holding tool (2). Fit the dry sump. See Dry sump and Oil pan baffle replacement. OXE 150/200 HP SERVICE MANUAL...

  • Page 97: Filling Up With Engine Oil

    Then shut down the engine. After about 20 minutes, check the oil level. The oil level should be between the two notches in the dipstick and must never fall below the lower notch. Top up oil as necessary. Do not overfill. OXE 150/200 HP SERVICE MANUAL...

  • Page 98: Positive Crankcase Ventilation Oil Separator Replacement

    Install the positive crankcase ventilation oil separator bolts (2, 5) and tighten to 9 Nm (80 lb in). Install the positive crankcase ventilation oil separator hose. Install the positive crankcase ventilation oil separator hose clamp (1). OXE 150/200 HP SERVICE MANUAL...

  • Page 99: Turbocharger Oil Feed Pipe Replacement

    Install the new turbocharger oil feed pipe gaskets. Install the turbocharger oil feed pipe (2). WARNING See Fastener. Install the 2 turbocharger oil feed pipe bolts (1) and tighten to 9 Nm (80 lb in). OXE 150/200 HP SERVICE MANUAL...

  • Page 100: Turbocharger Oil Return Pipe Replacement

    See Fastener. Install the 2 turbocharger oil return pipe bolts (2) and tighten to 9 Nm (80 lb in). Install the turbocharger oil return pipe bolt (4) and tighten to 25 Nm (18 lb ft). OXE 150/200 HP SERVICE MANUAL...

  • Page 101: Alternator Belt Replacement

    ALTERNATOR BELT REPLACEMENT ALTERNATOR BELT REPLACEMENT ALTERNATOR DRIVE BELT REMOVAL Remove upper cowling. Switch off the battery main switch. DANGER See Battery disconnect. Remove fuel hoses from fuel filter and pull the filter off the bracket. OXE 150/200 HP SERVICE MANUAL...
  • Page 102 ALTERNATOR BELT REPLACEMENT Loosen seawater hoses (2) from seawater pump (1). Unscrew the seawater pump bracket (3). Release the tension on the drive belt by rotating the tensioner pulley fastener clockwise. OXE 150/200 HP SERVICE MANUAL...
  • Page 103 ALTERNATOR BELT REPLACEMENT Remove the alternator belt. Rotate tensioner pulley fastener clockwise to mount the belt. Install removed parts in reverse order OXE 150/200 HP SERVICE MANUAL...

  • Page 104: Alternator Belt Tensioner Replacement

    ALTERNATOR BELT TENSIONER REPLACEMENT Remove the alternator drive belt. See Alternator belt replacement. WARNING See Fastener. Unscrew bolts (1). Lift off the alternator belt tensioner (2). Install in reverse order. Tighten 22 Nm (16 lb ft). OXE 150/200 HP SERVICE MANUAL...

  • Page 105: Alternator Replacement

    Install the alternator support bolt (4) and tighten to 60 Nm (44 lb ft). Install the alternator. Install the alternator bolts (1) and tighten to 60 Nm (44 lb ft). Install the alternator drive belt. OXE 150/200 HP SERVICE MANUAL...

  • Page 106: Camshaft Timing Belt Replacement

    CAMSHAFT TIMING BELT REPLACEMENT WATER PUMP AND CRANK SHAFT BALANCER REMOVAL Remove seawater pump nuts (1). Take off seawater pump (2), seawater pump drive flange (3), and sealing (4). Take off the crankshaft balancer (5). OXE 150/200 HP SERVICE MANUAL...

  • Page 107: Timing Belt Removal

    Check condition of timing belt for signs of damage to help determine the root cause of the failure. The timing belt cannot be reused. Avoid the contact with cooling fluid and oil, it will damage the timing belt. A damaged timing belt can not be reused. OXE 150/200 HP SERVICE MANUAL...

  • Page 108: Timing Belt Inspection

    Rough and/or scored cam sprockets Clean break across fibers Kinked belt before and/or during assembly Foreign material under the belt Oil/Coolant impregnated and/or Poor oil sealing swollen belt Coolant leak at pump Poor belt cover seal OXE 150/200 HP SERVICE MANUAL...

  • Page 109: Timing Belt Removal

    Remove the timing belt front covers upper and lower, see Timing belt front cover removal. Set cylinder one to TDC: Remove the camshaft housing bolt (2). Install the 30-0160-017 locking tool (3) in the camshaft housing. OXE 150/200 HP SERVICE MANUAL...
  • Page 110 Lock the crankshaft, using the 30-0160-016 fixing tool (4). Loosen the timing belt tensioner bolt (1) to release tension from the timing belt. Remove the belt idler pulley bolt (2) and the idler pulley (3). Remove the timing belt (4). OXE 150/200 HP SERVICE MANUAL...

  • Page 111: Installing A New Timimg Belt

    Second the timing belt tensioner (2). Third the water pump (3). Fourth the high pressure pump sprocket (4). Fifth the camshaft sprocket (5). Install a new belt idler pulley (6) and fit the timing belt. OXE 150/200 HP SERVICE MANUAL...
  • Page 112 Install the alternator belt. Rotate tensioner pulley fastener clockwise to mount the belt. Install the seawater pump. Refer to Water pump and crank shaft balancer removal. Reinstall seawater pump bracket and connect seawater hoses to the pump. Refer to Alternator drive belt removal. OXE 150/200 HP SERVICE MANUAL...

  • Page 113: Timing Belt Idler Pulley Replacement - Lower

    Remove the timing belt idler pulley (2). Install the new timing belt idler pulley (2) in reverse order. WARNING See Fastener. Tighten the timing belt idler pulley bolt (2) to 50 Nm (37 lb ft). OXE 150/200 HP SERVICE MANUAL...

  • Page 114: Camshaft Housing Replacement, Cleaning And Inspection

    This will cause the solution to spew out over the engine, the fenders, and the person removing the cap. Serious bodily injury may result. OXE 150/200 HP SERVICE MANUAL...
  • Page 115 Fold away the engine wiring harness. Remove the fuel delivery pipe (2) between the pump and the fuel rail, see Fuel injector fuel feed pipe removal (fuel pump to rail). OXE 150/200 HP SERVICE MANUAL...
  • Page 116 Remove the injectors (1). See Fuel injector fuel feed pipe replacement. Refer to Fuel Injector Replacement. Remove the fuel rail and hose, see Fuel injection fuel rail assembly replacement. Undo and remove the camshaft housing and guide sleeves. Loosen bolts alternately in order as illustrated. OXE 150/200 HP SERVICE MANUAL...

  • Page 117: Camshaft Cover Cleaning

    Inspect the exterior of the camshaft cover for the following conditions: Damage to the camshaft cover bolt holes (1, 2). Damage to the camshaft sensor mounting hole (3). Damage to the under pressure hose bracket bolt holes (4). OXE 150/200 HP SERVICE MANUAL...
  • Page 118 CAMSHAFT HOUSING REPLACEMENT, CLEANING AND INSPECTION Inspect the interior of the camshaft cover for the following conditions: Inspect the camshaft cover bolt holes (3, 4). Inspect the camshaft cover for cracks or damage (1, 2, 5). OXE 150/200 HP SERVICE MANUAL...

  • Page 119: Camshaft Housing Installation

    Clean the cylinder head and camshaft housing sealing surfaces from any gasket residue. Fit the guide sleeves (1) and fit a new gasket onto the cylinder head. Check that all the rocker arms are positioned correctly on the valve stems. OXE 150/200 HP SERVICE MANUAL...
  • Page 120 Fit the timing belt, see Timing belt removal. Fit the fuel rail and hose, see Fuel injection fuel rail assembly replacement. Fit the fuel delivery pipe between the pump and the fuel rail. Tighten 25 Nm (18 lb ft). OXE 150/200 HP SERVICE MANUAL...
  • Page 121 Fold the engine wiring harness back in place and fit the following connectors: Camshaft position sensor (2) Injectors (3) Fuel pressure control valve (4) Throttle body actuator unit (5) Intake air sensor (6) Glow plug connector (7) Coolant temperature sensor (8). OXE 150/200 HP SERVICE MANUAL...

  • Page 122: Valve Rocker Arm Cover Replacement

    Lubricate the rocker arm with engine oil. Fit the rocker arms to the hydraulic valve tappets and the valves. Mark up the valve rocker arm covers position, to ensure that the same position will be used when refitting. OXE 150/200 HP SERVICE MANUAL...

  • Page 123: Valve Lifter Roller Replacement

    VALVE LIFTER ROLLER INSTALLATION Install the valve lifter roller (2) on the top of the valve stem and on the lash adjuster (1). Lubricate the roller followers (2). See Camshaft housing replacement, cleaning and inspection. OXE 150/200 HP SERVICE MANUAL...

  • Page 124: Camshaft Sprocket Replacement

    Install the 30-0160-018 holding tool (2) with 30-0160-015 extension (3). Remove the camshaft sprocket bolt. Remove the camshaft sprocket (1). WARNING See Fastener. Install the camshaft sprocket bolt and tighten to 130 Nm (96 lb ft). OXE 150/200 HP SERVICE MANUAL...

  • Page 125: Camshaft Rear Cover Replacement

    CAMSHAFT REAR COVER INSTALLATION Install the camshaft rear cover gasket. Install the camshaft rear cover (2). WARNING See Fastener. Install the 3 camshaft rear cover bolts (1) and tighten to 9 Nm (80 lb in). OXE 150/200 HP SERVICE MANUAL...

  • Page 126: Camshaft Replacement

    2. Timing Belt Sprocket 3. Camshaft Sprocket Fastener 4. Camshaft Sprocket 5. Camshaft Plug 6. Camshaft Sealing Ring 7. Camshaft Special tools 30-0160-021 angle meter EN-46789 camshaft fixing tool For equivalent regional tools, see Special tools. OXE 150/200 HP SERVICE MANUAL...

  • Page 127: Intake Camshaft Removal

    Install the EN-46789 fixing tool . Remove and discard the intake camshaft sprocket bolt (2). Remove the intake camshaft sprocket (1). Remove the EN-46789 fixing tool . Remove the intake camshaft plug (2). Remove the intake camshaft (1). OXE 150/200 HP SERVICE MANUAL...

  • Page 128: Intake Camshaft Installation

    Install the intake camshaft (1). Install the intake camshaft sealing ring (2). Remove the hole plug (3). Install the EN-46789 fixing tool (4). Turn the camshaft until the EN-46789 fixing tool audibly engages. Install the intake camshaft sprocket (1). OXE 150/200 HP SERVICE MANUAL...
  • Page 129 Tighten the new intake camshaft sprocket bolt a final pass to an additional 55 degrees, using the 30-0160-021 meter. Remove the EN-46789 fixing tool (4). Install the hole plug (3) and tighten to 25 Nm (18 lb ft). OXE 150/200 HP SERVICE MANUAL...

  • Page 130: Exhaust Camshaft Removal

    Install the EN-46789 fixing tool . Remove the exhaust camshaft sprocket bolt (2). Remove the exhaust camshaft sprocket (1). Remove the EN-46789 fixing tool . Remove the exhaust camshaft sealing ring (1). Remove the exhaust camshaft (2). OXE 150/200 HP SERVICE MANUAL...

  • Page 131: Exhaust Camshaft Installation

    WARNING See Torque-to-yield fastener. Install the new exhaust camshaft sprocket bolt (2) and tighten in 2 passes: First pass to 40 Nm (30 lb ft). Second pass an additional 55 degrees, using the 30-0160-021 meter. OXE 150/200 HP SERVICE MANUAL...

  • Page 132: Camshaft Position Sensor Replacement

    Remove the camshaft position sensor (2). Remove the camshaft position sensor O-ring. Install the camshaft position sensor (2). WARNING See Fastener. Install the camshaft position sensor bolt (1) and tighten to 10 Nm (89 lb in). OXE 150/200 HP SERVICE MANUAL...

  • Page 133: Cylinder Head Replacement

    Remove the upper belt drive. Refer to Upper belt assembly removal Undo and remove the crankcase ventilation hose (1) from the oil trap and the bolts (2) holding the oil trap bracket and remove the cooling hose (3). OXE 150/200 HP SERVICE MANUAL...
  • Page 134 Remove the cable duct retaining screws (1). Remove the following connectors: Camshaft position sensor (2) Injectors (3) Fuel pressure control valve (4) Throttle body actuator unit (5) Intake air sensor (6) Glow plug connector (7) Coolant temperature sensor (8). OXE 150/200 HP SERVICE MANUAL...

  • Page 135: Fold Away The Engine Wiring Harness

    Remove the bolt (1) between the fuel pump bracket and cylinder head, screw out the spacer bolt a few turns. Undo and remove the camshaft housing and guide sleeves. Loosen bolts alternately in order as illustrated. OXE 150/200 HP SERVICE MANUAL...
  • Page 136 Carefully lift off the cylinder head. NOTE! Do not confuse the engine block guide sleeves with the camshaft guide sleeves. Remove the engine block guide sleeves. Remove the 10 cylinder head bolts as shown in sequence. Discard the bolts. OXE 150/200 HP SERVICE MANUAL...
  • Page 137 Wear safety glasses when using compressed air in order to prevent eye injury. When cleaning the cylinder head bolt holes use a suitable commercial spray liquid solvent and compressed air from an extended-tip blow gun to reach the bottom of the holes. OXE 150/200 HP SERVICE MANUAL...

  • Page 138: Cylinder Head Installation

    NOTE! For the measurement, the piston has to stay on TDC. Install the EN-301 measurement bridge (2) in compound with the GE-571–B dial (1). NOTE! The largest measured piston overhang value is determining for the choice of the cylinder head gasket. OXE 150/200 HP SERVICE MANUAL...
  • Page 139 Piston overhang 0.331 mm - 0.425 mm (0.0131 in - 0.0167 in) , choose cylinder head gasket with two holes. NOTE! Do not use any sealing material. Install the new cylinder head to block gasket (2) at the engine block (3). Install the cylinder head. OXE 150/200 HP SERVICE MANUAL...
  • Page 140 Fourth pass in sequence to an additional 90 degrees, using the 30-0160-0021 meter. Fifth pass in sequence to an additional 90 degrees, using the 30-0160-0021 meter. Sixth pass in sequence to an additional 90 degrees, using the 30-0160-0021 meter. OXE 150/200 HP SERVICE MANUAL...

  • Page 141: Piston, Connecting Rod, And Bearing Replacement

    Remove any ridge at the top of the cylinder bore to avoid damage to the piston ring lands. Remove the connecting rod bolts (2). Remove the connecting rod cap (1). Remove the connecting rod bearing (3). Remove the piston and connecting rod assembly (4). OXE 150/200 HP SERVICE MANUAL...

  • Page 142: Piston And Connecting Rod Disassemble/Assemble

    Install the piston pin retainers using the 30-0160-026 remover/installer. DANGER Handle the piston carefully. Worn piston rings are sharp and may cause bodily injury. Assemble the new piston rings to the piston (2). Use a suitable tool to expand the rings. OXE 150/200 HP SERVICE MANUAL...

  • Page 143: Piston, Connecting Rod, And Bearing Installation

    Tighten the new connecting rod bolts (2) a final pass to an additional 60 degrees using the 30-0160-021 meter. Assemble the caps and connecting rods in the marked position. Rotate the crankshaft to a position where the connecting rod bolts are in the best situation for install. OXE 150/200 HP SERVICE MANUAL...

  • Page 144: Engine Flywheel Replacement

    Install the 30-0160-034 flywheel blocking tool in order to hold the crankshaft. Remove the flexible coupling (2), 6 bolts (3). WARNING The flexible coupling must not be diassembled. If so, it is important to reassemble it according to specification, otherwise it will break and warranty void. OXE 150/200 HP SERVICE MANUAL...

  • Page 145: Engine Flywheel Installation

    Install the 6 new engine flywheel bolts (2). Install 30-0160-034 flywheel blocking tool locking tool (1) to fix the engine flywheel. WARNING See Fastener. WARNING See Torque-to-yield fastener. Tighten the 6 new engine flywheel bolts to 105 Nm (77 lb ft). OXE 150/200 HP SERVICE MANUAL...

  • Page 146: Crankshaft Oil Seal Replacement

    Remove the 5 crankshaft rear oil seal bolts (2). Remove the crankshaft rear oil seal (1). NOTE! Be careful do not damage the sealing surfaces. Use 30-0160-025 remover (1) to remove the crankshaft rear oil seal (2). OXE 150/200 HP SERVICE MANUAL...

  • Page 147: Crankshaft Oil Seal Installation

    Use the EN-48251 installer (2) to install a new crankshaft rear oil seal (1). Install the new crankshaft rear oil seal (1). WARNING See Fastener. Install the 5 crankshaft rear oil seal bolts (2) and tighten to 9 Nm (80 lb in). OXE 150/200 HP SERVICE MANUAL...

  • Page 148: Crankshaft And Bearing Replacement

    Specifications. Replace the thrust bearing or crankshaft as necessary. WARNING See Crankshaft oil seal replacement. CRANKSHAFT AND BEARING REMOVAL Loosen the 10 crankshaft bearing cap bolts in sequence. OXE 150/200 HP SERVICE MANUAL...
  • Page 149 Remove the 10 crankshaft bearing halves (4) from the cylinder block and the crankshaft. Note the position of the thrust bearing. Place the 10 crankshaft bearing (4) on the cardboard in the correct positions. Remove the 3 increment wheel bolts (2). Remove the increment wheel (1). OXE 150/200 HP SERVICE MANUAL...

  • Page 150: Crankshaft And Bearing Installation

    NOTE! If the crankshaft bearings have been used in a running engine, you must replace them with new crankshaft bearings for reassembly. Clean the crankcase crank bore with a lint-free cloth. Clean all the oil from the backside of new bearing halves. OXE 150/200 HP SERVICE MANUAL...
  • Page 151 Tighten the 10 new crankshaft bearing cap bolts in sequence (1-10) in 2 passes: First pass in sequence to 25 Nm (19 lb ft). Second pass in sequence to an additional 100 degrees using the 30-0160-021 meter. WARNING Refer to Crankshaft oil seal replacement. OXE 150/200 HP SERVICE MANUAL...

  • Page 152: Piston Oil Nozzle Replacement

    PISTON OIL NOZZLE INSTALLATION Install the 4 piston oil nozzles (1). Install the 4 piston oil nozzle bolts (2). WARNING See Fastener. Tighten the 4 piston oil nozzle bolts (2) to 9 Nm (80 lb in). OXE 150/200 HP SERVICE MANUAL...

  • Page 153: Intake Manifold Replacement

    INTAKE MANIFOLD REPLACEMENT INTAKE MANIFOLD REPLACEMENT INTAKE MANIFOLD REMOVAL Remove the fuel pump. See Fuel injection pump replacement. Unplug the intake air sensor connector (1) and the glow plug connector (2). OXE 150/200 HP SERVICE MANUAL...
  • Page 154 Disconnect the upper hose connection (6) from the PCV oil separator. Remove the retaining clips (7). Remove the PCV oil separator retaining bolts (8). Remove the PCV oil separator from the engine block and move the oil trap aside. OXE 150/200 HP SERVICE MANUAL...
  • Page 155 INTAKE MANIFOLD REPLACEMENT Unplug the connector (1) of the combustion circulation actuator. Remove the fuel injection pump bracket stud (1) holding the pump in place. Lock two M8 nuts with each other and remove the bolt. OXE 150/200 HP SERVICE MANUAL...
  • Page 156 Remove the bolt towards the lifting eye (1). Remove the nine intake manifold nuts (2). Remove the four manifold gaskets. Remove the intake manifold. WARNING Plug the intake passages so that no obstacles can enter the engine. OXE 150/200 HP SERVICE MANUAL...

  • Page 157: Intake Manifold Disassembly

    INTAKE MANIFOLD REPLACEMENT INTAKE MANIFOLD DISASSEMBLY Remove the absolute pressure sensor bolt (4). Remove the absolute pressure sensor (3) from the intake manifold (3). Remove the the seal ring (1). OXE 150/200 HP SERVICE MANUAL...

  • Page 158: Intake Manifold Cleaning And Inspection

    29 psi. When there is a risk for particulate exposure, always wear goggles or a face shield over safety glasses to protect the eyes. High pressure injection of particles or liquids may damage eyes or skin. OXE 150/200 HP SERVICE MANUAL...

  • Page 159: Intake Manifold Assembly

    172 kPa (25 psi) of air pressure. Replace the intake manifold as necessary. INTAKE MANIFOLD ASSEMBLY Install the absolute pressure sensor (3) to the intake manifold (2). Install the absolute pressure sensor bolt (4). Install a new seal ring (1). OXE 150/200 HP SERVICE MANUAL...

  • Page 160: Intake Manifold Installation

    WARNING See Intake manifold removal. Install the fuel injection pump bracket stud (1). WARNING See Intake manifold removal, step 13. Plug the connector (1) of the combustion circulation actuator, see Intake manifold removal, step 13. OXE 150/200 HP SERVICE MANUAL...
  • Page 161 Plug in the intake air sensor connector (1) and the glow plug connectors (2). Fit the fuel pump, see Fuel injection pump replacement. Connect an exhaust hose and start the engine. Check there are no leaks. Connect the diagnostic tool and clear any DTCs. OXE 150/200 HP SERVICE MANUAL...

  • Page 162: Dry Sump And Oil Pan Baffle Replacement

    OIL PAN BAFFLE INSTALLATION Install the oil pan baffle (2). WARNING See Fastener. Install the 4 oil pan baffle bolts (1) and tighten to 9 Nm (80 lb in). Reinstall the drysump (3) and tighten 8 bolts (4).. OXE 150/200 HP SERVICE MANUAL...

  • Page 163: Propeller Replacement

    Do not use any body parts to hold the propeller when loosening or tightening the propeller nut. Place a wooden block between the anti-cavitation plate and the propeller in order to prevent the propeller from moving. OXE 150/200 HP SERVICE MANUAL...
  • Page 164 Straighten the cotter pin (2) and pull it out using a pair of pliers. Remove the propeller nut (1). NOTE! Some engines are equipped with a Nyloc-lock nut (1) and do not have a cotter pin. Never reuse a Nyloc-locking nut! OXE 150/200 HP SERVICE MANUAL...
  • Page 165 PROPELLER REPLACEMENT Remove the propeller and thrust washer. Check the oil seals for leakage. NOTE! If the oil seal looks leaks, is damaged, or worn, refer to Lower belt replacement, No 16, for sealant replacement. OXE 150/200 HP SERVICE MANUAL...

  • Page 166: Propeller Installation

    Replace the thrust washer, the propeller and the nut. Fit a new cotter pin and secure or fit a new locking-nut. CAUTION Be sure to use a new cotter pin and bend the ends over securely. Otherwise OXE 150/200 HP SERVICE MANUAL...
  • Page 167 NOTE! Some outboards are equipped with a Nyloc locking nut (1) and do not have a cotter pin. Do NOT reuse a Nyloc locking nut! NOTE! Some models use a retainer (1) and a castlelated nut (2) combined with a cotter pin (3). OXE 150/200 HP SERVICE MANUAL...
  • Page 168 Ensure that the propeller is undamaged and rotates freely of the lower housing. NOTE! Always have an extra propeller including necessary tools on board. OXE 150/200 HP SERVICE MANUAL...

  • Page 169: Lower Belt Replacement

    LOWER BELT REPLACEMENT LOWER BELT REPLACEMENT COWLING REMOVAL Remove the top cowling. Refer to Remove and install the top cowling. Remove the screws and washers of the back cowl. Remove the back cowl. OXE 150/200 HP SERVICE MANUAL...

  • Page 170: Upper Belt Housing Removal

    LOWER BELT REPLACEMENT UPPER BELT HOUSING REMOVAL Disconnect the cooling water hoses from the upper belt housing. OXE 150/200 HP SERVICE MANUAL...
  • Page 171 CAUTION Risk of contamination of drinking water. Dispose of oil according to local environmental legislation! Remove the magnetic plug and O-ring. Drain any remaining gear oil into a suitable container. OXE 150/200 HP SERVICE MANUAL...

  • Page 172: Draining Hydraulic Oil In Lower Housing

    LOWER BELT REPLACEMENT DRAINING HYDRAULIC OIL IN LOWER HOUSING Remove the magnetic plug and washer (1). Remove the magnetic plug and washer (2). Drain the lower belt oil into a suitable container. OXE 150/200 HP SERVICE MANUAL...

  • Page 173: Lower Housing Disassembly

    Remove the outer bearing using (2) the Propshaft bearing remove/mount tool (1). Remove the propeller shaft spring washer (3) and propeller shaft spacer (4). Remove the belt pulley (5). NOTE! The use of one or two M6 screws might facilitate removing the belt pulley. OXE 150/200 HP SERVICE MANUAL...

  • Page 174: Gearbox Disassembling

    Remove the port shaft (1) and the starboard input shaft (2). Make sure to cover the hole at the bottom of the gear case, not to drop any tools or impurities into the belt housing. OXE 150/200 HP SERVICE MANUAL...
  • Page 175 Remove shaving and foreign debris. CAUTION Ensure to remove any material shavings in order not to enter the lower housing or remain in the gearbox. Lean the pulley downwards before removing it from belt and housing. OXE 150/200 HP SERVICE MANUAL...
  • Page 176 Remove 8 short nuts and washers. Leave the 2 long bolts, not to drop the lower housing. Remove the 2 long bolts and pull down the lower housing including belt and adapter plate. Propeller shaft removal Loosen the nose cone bolt and remove the nose cone. OXE 150/200 HP SERVICE MANUAL...
  • Page 177 Pull out the propeller shaft and bearing. Remove the divider plate. Use a tool that fits into the holes in the upper end of the plate to pull it up. Pull up the lower belt. OXE 150/200 HP SERVICE MANUAL...

  • Page 178: Lower Belt Installation

    LOWER BELT REPLACEMENT LOWER BELT INSTALLATION Install a new anode (1). Clean oil plugs (2), Fit new washers (3) and install. Tighten to 9 Nm (6.63 lb ft). Fit new O-rings. OXE 150/200 HP SERVICE MANUAL...
  • Page 179 Never reuse a belt. Always install a new belt! Install the divider plate. Use some tool to fit into the holes (1) in order to ease the mounting. CAUTION The divider plate is very tightly seated. Grinding for easier mounting is allowed! OXE 150/200 HP SERVICE MANUAL...
  • Page 180 Reinstall the nose cone. Slide the propeller belt through the adapter into the upper housing. The resilience of the belt will make it stay in place. OXE 150/200 HP SERVICE MANUAL...
  • Page 181 Tighten the bolts from the center and outwards, refer to gearbox lid. Tighten to 25 Nm (18.44 lb ft). OXE 150/200 HP SERVICE MANUAL...
  • Page 182 Joggle the upper and the lower belt pulley up and down until the belt fits properly on both pulleys. OXE 150/200 HP SERVICE MANUAL...

  • Page 183: Reinstalling Bearing Housing In Gearbox

    NOTE! This procedure is tricky. Guide the bearing housing in position with one of the bolts, alternately hammering with a plastic mallet until the bearing housing slides into places. When in place, cross-tightem the bolts to 25 Nm (18.44 lb ft). OXE 150/200 HP SERVICE MANUAL...

  • Page 184: Reinstalling Propellershaft Components

    Check that the oil seals are undamaged. Replace if necessary. Use the Propshaft bearing mounting tool (2) to reinstall the propeller shaft outer bearing (1). Use the 50mm Nut removing tool (4) and reinstall the retainer (3). OXE 150/200 HP SERVICE MANUAL...

  • Page 185: Reassembling The Gearbox Components

    Reinsert the gearbox shafts in the following order: Port shaft (1), starboard input shaft (2) and output shaft (3). Apply marine grease to shafts and gear wheels. Refer to Recommended fluids and grease. Clean the the gear box and the gear box lid mounting surface. OXE 150/200 HP SERVICE MANUAL...
  • Page 186 Reinstall the gear box lid. Put Loctite on the 14 screws, fit washers on each and tighten with 25 Nm (18.44 lb ft). Fit the hydraulic pump coupling to the port shaft and install the pump. NOTE! Rotate the input shaft until the hydraulic pump coupling snaps into place. OXE 150/200 HP SERVICE MANUAL...

  • Page 187: Refill Hydraulic Oil

    Use an oil filling device (1) and refill gear box oil up to sight glas (3). Refer to Recommended Grease and Fluids. NOTE! Clean the magnetic oil plugs. Install new washers. Remove the filling hose and tighten oil plug (2) to 9 Nm (6.6 ft-lb). OXE 150/200 HP SERVICE MANUAL...

  • Page 188: Reinstall The Upper Belt Housing

    Add plenty of paste to the starboard/input shaft (1). Paste the inner splines with the output shaft (4). Add more paste before greasing the second inner spline. Add silicon (3) on the gearbox side of the insulation (2) and place it on the starboard/input shaft, silicon towards the gearbox. OXE 150/200 HP SERVICE MANUAL...
  • Page 189 NOTE! Tightening the upper bolts first will ensure that no offset angle will stress the mounting points. Tighten the lower bolt (1) to 23 Nm (16.963 lb ft). Connect the cooling water hoses to the upper belt housing. OXE 150/200 HP SERVICE MANUAL...

  • Page 190: Propeller Shaft Bearing Replacement

    Bend up the tab of the lock washer (1) and loosen the nut (2) from the propeller shaft. Take off the nut (1) and lock washer (2). Heat up the spherical bearing (3) until it comes off. DANGER Risk of burns. OXE 150/200 HP SERVICE MANUAL...
  • Page 191 Fit the lock washer (2) and nut (3) when the bearing has cooled down enough to handle. Tighten the nut (1) and bend up a tab (2) against one of the slots of the nut. OXE 150/200 HP SERVICE MANUAL...

  • Page 192: Shims, Shaft Sleeves And Radial Seals Replacement In Gearbox

    Inspect the gearbox sleeves, gearbox radial seals and gearbox shafts for wear and damage. Replace gearbox sleeves and radial seals if damaged. If gearbox shafts are damaged, take a photo of the damage and contact Cimco OXE 150/200 HP SERVICE MANUAL...

  • Page 193: Removing And Installing The Inner Gearbox Bearings

    LOWER BELT REPLACEMENT Marine Technical Support or your OXE Diesel retailer. REMOVING AND INSTALLING THE INNER GEARBOX BEARINGS Refer to Gearbox disassembling. 1. Inner bearing race 2. 30-0160-004 A ODT Puller 25 mm 3. 30-0160-014 ODT Puller tool Remove the inner bearing races with the puller tool equipped with a 25 mm puller.
  • Page 194 Insert the bearing race driver flange on the shaft. Put the bearing race driver flange on the shaft. Place the driver handle on top of the flange and on to the shaft. Softly hammer until the race is properly seated. OXE 150/200 HP SERVICE MANUAL...

  • Page 195: Removing And Installing Bearings And Oil Seals In The Bearing Housing

    Remove the O-ring (3) and replace with a new. Turn the bearing housing up-side-down. Remove bearing (4). Use the Oil seal remover (6) to remove the oil seals (5), 2 pcs. Check bearings (2, 4). for wear and/or damage. Replace if necessary. OXE 150/200 HP SERVICE MANUAL...

  • Page 196: Removing And Installing The Sleeves

    Mark the new sleeve accordingly. NOTE! It is important to align these marks with each other in order to seat the new sleeve so it does not restrict the hydraulic oil supply to the gear house shaft. OXE 150/200 HP SERVICE MANUAL...

  • Page 197: Removing And Installing Bearing Races And Shims In The Gearbox Lid

    Use a hydraulic press to reinsert the bearing races and press them all the way to the bottom of the casting cut out. Check the radial seals of the gearbox shafts. If damaged, remove O-rings and radial seals and repalce with new. OXE 150/200 HP SERVICE MANUAL...
  • Page 198 (Part No. 30-0122-230) into their holes respectively aswell as the O-ring. Tighten the lid with the gauge bar (2) in the middle. Tighten the lid with at least 6 screws evenly distributed with 25 Nm (18.44 lb ft). OXE 150/200 HP SERVICE MANUAL...

  • Page 199: Measuring The Axial Free Play

    Record the findings and note the average gap. Measure the gap on the port shaft NOTE! The port shaft bearing race tolerances have the same span as the starboard shaft bearing races. OXE 150/200 HP SERVICE MANUAL...
  • Page 200 If the free play is not within tolerance, repeat the shims procedure on the shaft in question. If satisfactory results are obtained, continue with reassembling. Remove the gauge bar and the 4 additional screws. Take off the lid. OXE 150/200 HP SERVICE MANUAL...

  • Page 201: Change Lower Belt Oil

    If the oil looks milky and foamy, water has entered the lower housing. Check for leakage! NOTE! Clean the magnetic oil plugs. Install new washers. CAUTION Dispose of the belt oil according to local, environmental legislation! Reinstall and tighten oil plug (2) to 9 Nm (6.6 ft-lb) OXE 150/200 HP SERVICE MANUAL...
  • Page 202 (2) until oil comes out at oil plug hole (1). NOTE! Clean the magnetic oil plugs. Install new washers. Remove the filling hose and tighten oil plug (2) and (1) to 9 Nm (6.6 ft-lb). OXE 150/200 HP SERVICE MANUAL...

  • Page 203: Change Upper Belt Oil

    Inject 0,33 L belt oil into the sight glass/oil level plug hole, using a pressurised filling device. For oil quality, see Recommended fluids and grease. Clean oil plugs and put new sealings on. Tighten to 16 Nm (11.80 lb in). OXE 150/200 HP SERVICE MANUAL...

  • Page 204: Upper Belt Replacement

    Remove 10 bolts and lift off the belt housing bracket. Lift up the belt pulleys and belt. NOTE! The belt pulleys fit in just one hole respectively. Guide pins ensure correct belt housing assembling. Replace the belt and mount in reverse order. OXE 150/200 HP SERVICE MANUAL...

  • Page 205: Replace Belt Pulley Seals

    Reinstall upper belt housing. Refer to Reinstall the upper belt housing. REPLACE ZINC ANODES Remove the bolt holding the anode and the O-ring. Replace with new anode and new O-ring. Tighten bolts to 20 Nm (14.8 lb ft). OXE 150/200 HP SERVICE MANUAL...

  • Page 206: Seawater Pump Impeller Replacement

    REPLACEMENT Remove 4 screws and lid. Take off used impeller and sealing. Install a new sealing. WARNING Rotate impeller clockwise until it fits! Lubricate new impeller and install. Tighten to 2 Nm (1.47 lb in). OXE 150/200 HP SERVICE MANUAL...

  • Page 207: Clean Seawater Strainer

    CLEAN SEAWATER STRAINER CLEAN SEAWATER STRAINER Remove the lid. Pull out the filter element (1). Clean the filter element, check that the o-ring (2) stays in place. Replace O-ring if damaged. Reinstall and close the strainer. OXE 150/200 HP SERVICE MANUAL...

  • Page 208: Replace Seawater Outlet Nipple

    NOTE! Do not overtighten. Reinstall hose assembly and connect hoses. CAUTION Connect water to drive if on land. Start engine. Check for water leaks. Check for water circulation from the outlet jet on the engine cowling. OXE 150/200 HP SERVICE MANUAL...

  • Page 209: Drain And Fill Coolant

    Fit a hose (4) to the coolant drain adapter (3). Drain the coolant/water-mixture into a suitable container. CAUTION Risk of contamination of drinking water. Dispose of used coolant/water- mixture according to local environmental legislation. Remove the hose from the drain adapter. OXE 150/200 HP SERVICE MANUAL...

  • Page 210: Fill Coolant

    If, in an exceptional case, the coolant level has to be checked in an engine that has reached operating temperature, first carefully turn the cap (large cap) with safety valve to the first stop, let off pressure, then open carefully. OXE 150/200 HP SERVICE MANUAL...
  • Page 211 Premature simmering and loss of coolant result. To avoid damage to the engine, this cover should as a general rule only be opened in exceptional cases and then replaced by a new one. OXE 150/200 HP SERVICE MANUAL...

  • Page 212: Antifreeze Preservation Of Seawater System

    Tilt the outboard to a 45⁰ angle to drain as much as possible of the seawater out of the system. When in this position, steer the outboard fully to starboard and port. Repeat if necessary. OXE 150/200 HP SERVICE MANUAL...

  • Page 213: Long-Term Storage

    Run the outboard with the water-intake point in the front of the lower housing lowered into a coolant fluid mixture of sufficient grade. Run the outboard until the entire sea-water part of the system is filled with coolant fluid and thus protected from freezing and corrosion. OXE 150/200 HP SERVICE MANUAL...

  • Page 214: Hydraulic Oil Filter Replacement

    Risk of contamination of drinking water. Dispose of oil according to local environmental legislation! Clean and reinstall the hydraulic oil filter element. If the filter is damaged, install a new filter. Tighten the hydraulic oil filter end cover. OXE 150/200 HP SERVICE MANUAL...
  • Page 215 If the hydraulic oil pressure i s low the propotional valve or the hydraulic pump has to be replaced. If you discover water in the oil (the oil is milky) all hydraulic seals have to be replaced. Refere to Hydraulic system description and Hydraulic pump replacement. OXE 150/200 HP SERVICE MANUAL...

  • Page 216: Hydraulic Pump Replacement

    HYDRAULIC OIL PUMP REPLACEMENT HYDRAULIC PUMP REPLACEMENT Remove 4 screws and washers of hydraulic pump end cover. Remove the pump unit. Install new pump unit in opposite order. Tighten bolts to 20 Nm (14.8 lb ft). OXE 150/200 HP SERVICE MANUAL...

  • Page 217: Air Filter Replacement

    CLEAN THE TURBO CHARGER Clean the inside of the main tube, inlet hose and inlet of the turbo charger with a cloth moistened with solvent. AIR FILTER INSTALLATION Install a new air filter. Tighten clamp. OXE 150/200 HP SERVICE MANUAL...

  • Page 218: Check Power Tilt And Trim System

    Tilt up the outboard and check that the tilt rod and trim rods are extended completely. Check that the tilt rod and trim rods are free from corrosion or other flaws. Activate the tilt-down switch until the rods have retracted completely into the cylinders. OXE 150/200 HP SERVICE MANUAL...
  • Page 219 NOTE! Check if the Power-tilt-and-trim (PTT) motors make abnormal sounds. CAUTION! The outboard can belowered by carefully turning manual valve, should the electric system fail. Ensure that the manual valve is tightened before starting the outboard. Tilt and trim rods, manual valve OXE 150/200 HP SERVICE MANUAL...
  • Page 220 Make sure to support the outboard with the transom tilt saver. Otherwise the outboard can fall down accidentally if the power tilt and trim unit looses pressure. Remove the filling plug (3) and seal (2). Check the fluid level in the reservoir. OXE 150/200 HP SERVICE MANUAL...
  • Page 221 If necessary, fill up with fluid of recommended type until it comes out of the filling hole. See Recommended fluids and grease. NOTE! Install new O-rings and filling plug. Tighten the plug to 2 Nm (1.5 lb ft). Tighten reservoir cap: 7 Nm (5.1 lb ft) OXE 150/200 HP SERVICE MANUAL...
  • Page 222 CHECK POWER TILT AND TRIM UNIT LUBRICATING AND GREASING THE PPT-UNIT Use a grease gun and fill up with recommended grease until the grease comes out at the joints or ends of shaft. Refer to Recommended fluids and grease. OXE 150/200 HP SERVICE MANUAL...
  • Page 223 CHECK POWER TILT AND TRIM UNIT Fill the seatings with grease for smoother tilt operation. Use grease according to Recommended fluids and grease. OXE 150/200 HP SERVICE MANUAL...

  • Page 224: Electrical System

    Air filter restriction sensor Glow plug harness connector Gearbox oil pressure switch connector Injector (4 pcs) Engine oil temperature sensor Exhaust gas temperature sensor connector Water-in-fuel sensor Injector harness connector Water-in-fuel sensor connector Engine coolant temperature sensor/connector OXE 150/200 HP SERVICE MANUAL...
  • Page 225 15. Gearbox output speed sensor 8. Power cable connector 16. Gearbox oil pressure sensor a) GND 17. Trolling valve b) ECU & Helm power 18. Starboard gear coil c) Engine starter power 19. Port gear coil OXE 150/200 HP SERVICE MANUAL...

  • Page 226: Engine Control Unit (Ecu)

    3. PSU control and feedback 4. PSU OK LED-indicator 5. ECU and helm 6. Glow plug control module 7. PTT up 8. PTT down 9. ECU connectors 10. Glow module, control, feedback, supply 11. Glow module, output OXE 150/200 HP SERVICE MANUAL...

  • Page 227: Wiring

    Power trim and tilt unit power cable assembly Use an arrow head clip (1) on cyclon in order to fasten the PTT power cable. Route the ppt power cable (2) behind the cooling fluid return pipe (3) from the oil cooler. OXE 150/200 HP SERVICE MANUAL...
  • Page 228 It is very importent that the harness branches are layed out as shown in picture above, to avoid fretting at exposed critical areas (2) and to ensure correct cabling length. Always double check wiring layout after the ECU bracket assembly is mounted on the engine to ensure that there is no fretting risk. OXE 150/200 HP SERVICE MANUAL...
  • Page 229 ELECTRICAL SYSTEM Rear view Fasten and secure wiring with clips (1). OXE 150/200 HP SERVICE MANUAL...
  • Page 230 Place the engine block ground cable (1) closest to the bracket . Secure/fasten all cables and the harness within the cable clip (2). Cable (3) and cable (4) should be mounted in parallell with bracket edges. OXE 150/200 HP SERVICE MANUAL...
  • Page 231 Power connectors, long starter motor cable (>170 mm, 6.72 in) Mount the starter motor cable (1) in an right angle to the bracket edge. Power connectors, PSU Mount the power cables at recommended angles as shown in picture above. OXE 150/200 HP SERVICE MANUAL...
  • Page 232 Mounting the ECU bracket assembly on the engine First connect the swirl valve (1). NOTE! Ensure it click's. Slide the secondary lock (yellow) in place. Fit the ECU bracket in place and secure loosely with screws/nuts. NOTE! Rear side of engine only. OXE 150/200 HP SERVICE MANUAL...
  • Page 233 Ensure that the contact surface is free from paint. Connect the engine oil pressure sensor connector (2). NOTE! Ensure it click's. Mount the alternator supply (3) on the alternator. NOTE! Route the cable towards the engine. OXE 150/200 HP SERVICE MANUAL...
  • Page 234 Mount the starter motor supply cable (3) to the starter motor solenoid (1) and lead it as vertical as possible. CAUTION Ensure no fretting on starter motor cables (4). Recommended clearance >10 mm (>0.394 in). Connect the crankcase sensor connector (5). NOTE! Ensure it click's. Slide the secondary lock (yellow) in place. OXE 150/200 HP SERVICE MANUAL...
  • Page 235 ELECTRICAL SYSTEM Tighten 3 screw-nuts (1). Adjust the ECU bracket assembly to ensure not fretting. CAUTION Ensure that fretting is not possible. Recommended clearance >10 mm (>0.394 in). OXE 150/200 HP SERVICE MANUAL...
  • Page 236 Mount the PTT-power cables. blue cable (1) closest to the rear end of the engine black/green cable (2) second closest to the rear end of the engine Connect the fuel pressure control valve (1). NOTE! Ensure it click's. OXE 150/200 HP SERVICE MANUAL...
  • Page 237 5. Cable ties 6. Starboard selctor coil connector, REV gear WARNING! Make sure the cables are tightly secured so that no contact with the flywheel is possible! Recommended clearance: >15 mm. Ensure that all connectors click. OXE 150/200 HP SERVICE MANUAL...
  • Page 238 ELECTRICAL SYSTEM 1. Cable tie Connect the propeller speed sensor connector (2). Make sure it clicks! OXE 150/200 HP SERVICE MANUAL...
  • Page 239 Connect the PTT sensor adapter to the engine harness. Make sure it clicks! Connect the PTT cowl switch (2). Make sure it clicks! Connect the PTT sensor adapter to the PTT sensor (3). Make sure it clicks! OXE 150/200 HP SERVICE MANUAL...
  • Page 240 7. Cam shaft angle sensor connector 8. Fuel rail pressure sensor connector 9. Cable tie 10. FSM connector 11. Clips NOTE! Make sure all connectors click and push the yellow or red secondary lock in place! OXE 150/200 HP SERVICE MANUAL...
  • Page 241 ELECTRICAL SYSTEM Exhaust manifold Intercooler ECT connector NOTE! Make sure The ECT connector clicks when connecting. OXE 150/200 HP SERVICE MANUAL...
  • Page 242 ELECTRICAL SYSTEM 1. Clip 2. Water-in-fuel sensor connector 3. Clip 4. Cable tie connector with a cable tie (4). Fix the Water-in-fuel sensor OXE 150/200 HP SERVICE MANUAL...
  • Page 243 ELECTRICAL SYSTEM with a cable tie (1). Fix the Gearbox lubricating oil pressure switch connector Secure the cacle with a clip (3). OXE 150/200 HP SERVICE MANUAL...
  • Page 244 ELECTRICAL SYSTEM Alternator belt Engine oil pressure sensor connector Connect the Engine oil pressure sensor connector (2). Make sure it clicks! OXE 150/200 HP SERVICE MANUAL...
  • Page 245 ELECTRICAL SYSTEM OXE 150/200 HP SERVICE MANUAL...
  • Page 246 PSU Slim Temperature Pressure Port side Swirl Valve T-MAP Star Board Switch Coil Coil 07-9 W87\R2 0,5 Red 07-5 W73\R2 0,5 Red 07-4 W33\R2 0,5 Blue/white 07-3 W39\R2 0,75 Yellow/Red ECU connector, 105 way Engine harness OXE 150/200 HP SERVICE MANUAL...
  • Page 247 Restriction GPCM output Trolling Valve Starter Solenoid Control Signal 06-8 W37\R2 0,75 Black/White 06-10 06-2 W77\R2 0,75 Orange W107\R2 0,5 Yellow/Green Glow plug harness ECU connector, 91 way Main electrical closet 30-0116-003B Scheme 07 2016-08-30 OXE 150/200 HP SERVICE MANUAL...

  • Page 248: Maintenance Schedules

    - Magnetic plug, Upper belt oil Change upper belt oil Lower belt oil Change lower belt oil - Magnetic oil plug, Lower belt oil Change lower belt oil Seawater outlet nipple Replace seawateroutlet nipple Display/gauges, function Display Manual OXE 150/200 HP SERVICE MANUAL...

  • Page 249: Service At 200 Hours

    Fuel filter replacement Gearbox, oil and filter, washer, plug and O-ring Hydraulic oil filter replacement Upper belt oil - magnetic plug, washer Change Upper Belt Oil, Lower belt oil - magnetic plug, washer Change lower belt oil OXE 150/200 HP SERVICE MANUAL...
  • Page 250 Replace Owner's Manual Painting Check painted surfaces Inspection, exhaust hose and cooling hoses Outboard view Hoses/pipes, connections, hose clamps Outboard view Condition of rubber hoses Outboard view Hydraulic hoses, connections (leakage, wear, Outboard view aging) OXE 150/200 HP SERVICE MANUAL...

  • Page 251: Service At 800 Hours

    Hoses, hydraulic hoses, connections. Leakage, Outboard view wear, aging Steering, Function See Steering System's Manual Steering pistons, hoses, hydraulic hoses. See Steering System's Leakage Manual Upper belt oil, packing, plug Change upper belt oil Upper belt Upper belt replacement OXE 150/200 HP SERVICE MANUAL...
  • Page 252 Date of replacement, part No and batch No. Seawater strainer Clean Seawater strainer Seawater pump, impeller Seawater pump impeller replacement Air filter Air Filter Replacement Owner's Manual Painting Check painted surfaces Cowling. Hatches, mounting Remove/install cowling OXE 150/200 HP SERVICE MANUAL...

  • Page 253: Service Record - Lower Belt

    Engine run time / engine hours Belt part No. OBSERVATIONS Batch No. DATE Engine run time / engine hours Belt part No. OBSERVATIONS Batch No. DATE Engine run time / engine hours Belt part No. OBSERVATIONS Batch No. OXE 150/200 HP SERVICE MANUAL...

  • Page 254: Service Record - Lower Belt

    Engine run time / engine hours Belt part No. OBSERVATIONS Batch No. DATE Engine run time / engine hours Belt part No. OBSERVATIONS Batch No. DATE Engine run time / engine hours Belt part No. OBSERVATIONS Batch No. OXE 150/200 HP SERVICE MANUAL...

  • Page 255: Troubleshooting

    The precondition for this, however, is that the experts are familiar with the Service Manual for the engine as well as the accompanying Operating Instructions. OXE 150/200 HP SERVICE MANUAL...

  • Page 256: Fault Table

    Fuel low pressure system: Fuel tank, pre lter, water trap faulty / clogged / mould / fungal attack, fuel unsuitable / contaminated (para n added) x x x x x x Fuel low pressure system: fuel lines leaking, broken, clogged likely to apply might apply OXE 150/200 HP SERVICE MANUAL...
  • Page 257 Coolant entering combustion chamber (cylinder head / gasket leaking) x x o Power supply to ECU control unit interrupted or battery voltage too low Thermostat defective Engine bearings worn x = likely to apply o = might apply OXE 150/200 HP SERVICE MANUAL...
  • Page 258 OXE 150/200 HP SERVICE MANUAL...
  • Page 259 OXE 150/200 HP SERVICE MANUAL...
  • Page 260 Cimco Marine AB, Metallgatan 19 A Ängelholm, SE-262 72 Ängelholm, SWEDEN +46 (0)431-37 11 30, www.oxe-diesel.com Printed in Sweden 2016. Copyright © 2016 Cimco Marine AB.

This manual is also suitable for:

30-0100-17530-0201-20030-0200-15030-0100-12530-3100-30030-3200-300 ... Show all

Table of Contents

Save PDF