STEYR MOTORS Marine Engine 2012 Series Service Manual
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STEYR MOTORS Marine Engine 2012 Series Service Manual

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General
STEYR TURBO DIESEL ENGINES
Steyr Marine Engine Family 2012
Z001138-0
www.steyr-motors.com
1/65
SERVICE MANUAL
st
1
Edition
February 2013
STEYR MOTORS GmbH
Im Stadtgut B1,
A-4407 Steyr-Gleink,
AUSTRIA
Z001138-1_2013-02-01

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  • Page 1 General STEYR TURBO DIESEL ENGINES Steyr Marine Engine Family 2012 SERVICE MANUAL Z001138-0 Edition February 2013 STEYR MOTORS GmbH Im Stadtgut B1, www.steyr-motors.com A-4407 Steyr-Gleink, AUSTRIA 1/65 Z001138-1_2013-02-01...
  • Page 2 General Preliminary Service Manual MARINE 2012 THIS PAGE IS INTENTIONALLY BLANK Z001138-1_2013-02-01 2/65...
  • Page 3 General PREFACE STEYR MOTORS GmbH has developed high-performance diesel engines with modulated high-pressure direct injection, especially for special vehicles. STEYR engines are designed to be adapted to various propulsion systems. This SERVICE MANUAL is published with the main intention.to provide information in...
  • Page 4 Illustrations in this manual may not always correspond to actual implements or components and are mainly intended as reference. STEYR MOTORS GmbH reserves the right to make changes at any time, without notice, on technical data or models and / or to discontinue models. The right is also reserved to change technical data or components at any time, without incurring any obligation to retrofit new parts on models produced prior to date of such change.
  • Page 5 General TABLE OF CONTENTS (MAIN ASSEMBLY GROUP ENGINE) GENERAL ENGINE COUPLING FUEL SYSTEM EXHAUST SYSTEM COOLING SYSTEM ELECTRICAL EQUIPMENT HYDRAULIC PUMP ENGINE PREHEATING 5/65 Z001138-1_2013-02-01...
  • Page 6 General Preliminary Service Manual MARINE 2012 Components Engine 01.00 01.01 01.02 Mount Bracket, Crankcase Crankshaft, Bearing, Lifting Eye, Damper Gasket Set 01.03 01.04 01.05 Flywheel Piston, Camshaft, Housing Rings and Pin, Connection Rod 01.06 01.08 (Page 1 & 2) 01.13 Oil pump, Oil pipe, Intake Manifold Oil cooler, Filter...
  • Page 7 General Exhaust System 04.00 Connection to Turbo Charger Cooling System 05.03 05.04 05.05 Water pipe, Water pump Fan Assy. Thermostat 05.06 (Page 1 & 2) Drive Belt, Pulleys, Tensioner-Belt 1 & 2 Electrical System 06.01 06.03 06.05 Alternator, Bracket Starter Engine Harness 06.06 Harness, ECU...
  • Page 8 General Preliminary Service Manual MARINE 2012 VERSIONS OF MANUAL Version Date Modification 01.02.2013 New edition Z001138-1_2013-02-01 8/65...

  • Page 9: Table Of Contents

    General GENERAL Table of Contents GENERAL REMARKS .................. 11 Model and Serial Number ..................11 Documentation ......................12 Technical Data and Overview ................. 13 A 3.2 Overview engine M16 TCA ..................22 Specification ....................23 Fuel Requirements ....................23 Motor oil ........................25 Maintenance and Service ................
  • Page 10 General Preliminary Service Manual MARINE 2012 Testing of torque wrenches ..................61 Non-destructive material testing ................61 Use of adhesive and sealing materials ..............61 Solvent-free sealing materials ................. 61 Wear Limits ....................64 Adjustment information for service and maintenance ..........65 I.1.1 Engine timing (measured with dial indicator No.

  • Page 11: Ageneral Remarks

    General A GENERAL REMARKS A 1 Model and Serial Number The primary model and serial number is located on the engine as illustrated. These numbers are required for warranty claims and ordering parts. 11/65 Z001138-1_2013-02-01...

  • Page 12: A 2 Documentation

    SE266S36 P/N Z011847-0 spare parts catalogue SE286E40 P/N Z011848-0 spare parts catalogue SE306J38 P/N Z011849-0 Optional equipment (IFG, SCC) P/N xxxxxxxxxx tool catalogue for STEYR MOTORS ENGINES P/N Z001125-0 general technical documentation CD – ROM P/N Z 001009/0 Z001138-1_2013-02-01 12/65...

  • Page 13: A 3 Technical Data And Overview

    General A 3 Technical Data and Overview engine SE126E25 SE156E26 SE196E35 SE236E40 SE236S36 SE266E40 SE266S36 SE286E40 SE306J38 type Number of Cylinders bore (mm) stroke (mm) displacement 3200 3200 3200 3200 3200 3200 3200 3200 3200 (cm³) rated power (kW) rated speed 2500 2600 3500...
  • Page 14 General Preliminary Service Manual MARINE 2012 engine SE126E25 SE156E26 SE196E35 SE236E40 SE236S36 SE266E40 SE266S36 SE286E40 SE306J38 type Upper tolerance of maximum power (%) Fuel rate at 54,5 65,9 65,2 71,3 75,9 81,1 86,4 86,3 93,4 rated speed (mm³/stroke) Fuel rate at Maximum 66,8 78,9...
  • Page 15 General engine SE126E25 SE156E26 SE196E35 SE236E40 SE236S36 SE266E40 SE266S36 SE286E40 SE306J38 type Fuel cons. @ 20,1 25,4 33,7 42,5 40,9 47,3 46,1 52,2 rated power (kg/h) exhaust mass flow @ 510,1 545,4 743,7 1007,5 848,9 1027,3 906,1 1091 1072,2 rated power (kg/h) max.
  • Page 16 General Preliminary Service Manual MARINE 2012 engine SE126E25 SE156E26 SE196E35 SE236E40 SE236S36 SE266E40 SE266S36 SE286E40 SE306J38 type MAP at rated 2130 2200 2280 2790 2560 2840 2740 2990 3060 power (mbar) Map Toleranz (+/-) [mbar] 2180 2240 2440 2900 2690 2840 2800 3000...
  • Page 17 General engine SE126E25 SE156E26 SE196E35 SE236E40 SE236S36 SE266E40 SE266S36 SE286E40 SE306J38 type min. fuel supply 3500 3500 3500 3500 3500 3500 3500 3500 3500 pressure block inlet [mbar] - rel. max. engine coolant outlet temperature [°C] raw water flow (l/min) raw water supply 0,37...
  • Page 18 General Preliminary Service Manual MARINE 2012 engine SE126E25 SE156E26 SE196E35 SE236E40 SE236S36 SE266E40 SE266S36 SE286E40 SE306J38 type valve timing adjustment + 3,59±0,02 3,59±0,02 3,59±0,02 3,59±0,02 3,59±0,02 3,59±0,02 3,59±0,02 3,59±0,02 3,59±0,02 tolerance (mm) valve 0,25 / 0,25 0,25 / 0,25 0,25 / 0,25 0,25 / 0,25 0,25 / 0,25 0,25 / 0,25...
  • Page 19 General engine SE126E25 SE156E26 SE196E35 SE236E40 SE236S36 SE266E40 SE266S36 SE286E40 SE306J38 type 85,36 106,7 135,8 164,9 164,9 184,3 184,3 198,85 208,55 86,68 108,35 137,9 167,45 167,45 187,15 187,15 201,925 211,775 2176554-0 2176554-0 2176554-0 2176554-0 2176554-0 2176554-0 2176554-0 2176554-0 2176554-0 Unit Injector 2180996-0 2180996-0 2180996-0...
  • Page 20 General Preliminary Service Manual MARINE 2012 engine SE126E25 SE156E26 SE196E35 SE236E40 SE236S36 SE266E40 SE266S36 SE286E40 SE306J38 type air filter / 2180286-0 2180286-0 2180286-0 2180286-0 2180286-0 2180286-0 2180286-0 2180286-0 2180286-0 mark / type electric 12V /24V 12V /24V 12V /24V 12V /24V 12V /24V 12V /24V 12V /24V...
  • Page 21 General engine SE126E25 SE156E26 SE196E35 SE236E40 SE236S36 SE266E40 SE266S36 SE286E40 SE306J38 type gear box ZF 45 ZF 45 ZF 45 ZF 45 ZF 45 ZF 45 ZF 45 ZF 45 ZF 45 description gearbox torque of 0,0427 0,0427 0,0427 0,0427 0,0427 0,0427 0,0427...

  • Page 22: A 3.2 Overview Engine M16 Tca

    General Preliminary Service Manual MARINE 2012 A 3.2 Overview engine M16 TCA Item Designation Boost Pressure Sensor Zinc Anode (3 Units) Intercooler Fuel Cooler Engine Oil cooler Model and Serial Number Oil Separator Raw Water Drain Plug Valve Crankshaft Housing Ventilation Fuel Filter Fuel Pump Oil Filter...

  • Page 23: B Specification

    General B Specification B 1 Fuel Requirements The STEYR Marine Engines are designed for maximum fuel economy. To maintain optimum performance use diesel fuel according to EN 590 or equivalent to meet this specification. When temperatures are below -7° C (20° F), use diesel fuels with additives for low temperature operation.
  • Page 24 General Preliminary Service Manual MARINE 2012 Fuel Oil Selection Chart properties UNIT Minimum Maximum ASTM Test procedure Cetane number 52,2 DIN 51773 Gravity at 15°C (kg/l) Kg/ m³ EN ISO 3675, EN ISO 12185 Distillation 250°C % (V/V) <65% EN ISO 3405 350°C % (V/V) End point 360°C...

  • Page 25: B 2 Motor Oil

    General B 2 Motor oil To obtain the best engine performance and engine life, only motor oils of know manufacturers are to be used, with ACEA, API service code and specified SAE viscosity. Refer to oil identification symbol on the container. MARINE 2012 17,0 Litre (Oil filling, incl.

  • Page 26: C Maintenance And Service

    General Preliminary Service Manual MARINE 2012 C Maintenance and Service C 1 Trouble Check Chart ATTENTION: After following the “Action” described in chart, and before cranking the engine, make sure there are no loose fuel connections. Make sure engine compartment is free of fuel vapours.

  • Page 27: C1 Trouble Check Chart Continued

    General Trouble Check Chart continued SYMPTOM POSSIBLE CAUSE ACTION Engine vibrates Unit injector Check Performance loss 1. System error or failure Check Engine Management System display for service code. Engine coolant temperature; audible alarm. 2. Fuel incorrect Fill tank with correct fuel. Check fuel filter and fuel flow condition.
  • Page 28 General Preliminary Service Manual MARINE 2012 Items to Check / Troubled Systems General Fault Finding [Factors/Cause of Trouble] • • low battery / Overdischarge • • Connection failure / Terminal / Main Cable • • Battery Main Switch not connected low battery Capacity (wrong capacity-size •...
  • Page 29 General Items to Check / Troubled Systems General Fault Finding [Factors/Cause of Trouble] • • • Breakdown of injection pump • • • • no hydraulic pressure to build up stuck unit injector / spring remains • • compressed • •...

  • Page 30: Service- And Maintenance Schedule

    General Preliminary Service Manual MARINE 2012 After first Every Every 50 hours 300 h. 600 h. Service- and Maintenance Schedule Daily notes or 6 or 12 or 24 months months months -For leakage Check Engine -oil level Lubrication -oil filter Change -motor oil -for leakage...
  • Page 31 General After first Every Every 50 hours 300 h. 600 h. Service- and Maintenance Schedule Daily notes or 6 or 12 or 24 months months months for wear Every 1500 hours Change -poly V-belt or every 48 months Check Poly V-Belt Lubricate Tensioner Every 1500 hours...
  • Page 32 General Preliminary Service Manual MARINE 2012 *refer to manufacturer specification. *drain/clean water from separator bowl. NOTE: Oil exchange interval must be adapted acc. application and utilisation of vehicle, respectively quality of engine lubricant in use. Z001138-1_2013-02-01 32/65...

  • Page 33: D General Information

    General D General Information D 1 Electronic Engine Management System The STEYR Marine engine is equipped with an Electronic Management System (EMS) that performs the following:  controls engine functions to ensure maximum efficiency.  self-diagnostic to protect the engine mechanical components against severe damage if operating parameter exceed limit(s).
  • Page 34 General Preliminary Service Manual MARINE 2012 Operating Effect Panel Indication Additional Action or Parameter noticed Tool- possible reason Readings Insufficient Reduction Steyr Diag See table trouble boost pressure of engine Power shooting; Air or defective speed limitation charge system sensor Engine speed Engine NO RPM...
  • Page 35 General Trouble Indication 35/65 Z001138-1_2013-02-01...
  • Page 36 General Preliminary Service Manual MARINE 2012 Z001138-1_2013-02-01 36/65...

  • Page 37: Diagnostic System

    General Diagnostic system The electronic management system monitors the following engine parameters: oil pressure, boost pressure, coolant temperature, sensor control rack, potentiometer accelerator, speed signal The electronic management system carries out self-diagnostic and/or plausibility checks for all input values and sensor connections. In case of irregularities, there is an optical or audible warning signal.
  • Page 38 Preliminary Service Manual MARINE 2012 Starting the Engine Starting procedure for the STEYR MOTORS engine is the same for both cold and warm engines. The engine control unit automatically regulates the fuel supply and the preheating period, for any given temperature.
  • Page 39 General Instrument indication during normal operation 1. Ignition ON (...before starting) System check - see light indication Note: At low temperature condition (cold weather) the combined light for glow plug preheating & engine oil pressure will not extinguish after 0,7 sec. (glow plug preheating phase) In this case start engine immediately after the light extinguishes.
  • Page 40 General Preliminary Service Manual MARINE 2012 Engine Break-In procedure The following procedure must be used on new and rebuilt STEYR Diesel Engines. You must follow the Engine Break-In instructions during the first 20 running hours to ensure maximum performance and longest engine life. NOTE: NONOBSERVANCE OF BREAK-IN INSTRUCTIONS MAY CAUSE SEVERE ENGINE FAILURE.
  • Page 41 General Final Ten Hours of Break-in During the final ten hours of break-in, the engine may run at full speed for five to ten minutes. Operate engine to with specified temperature, at moderate engine speed increase to cool down engine, occasionally reduce the engine speed and load. NOTE: DURING THE BREAK-IN PERIOD, THE ENGINE MUST NOT BE OPERATED AT CONSTANT RPM FOR LONGER PERIODS.

  • Page 42: Operation After Break - In

    General Preliminary Service Manual MARINE 2012 D 2 Operation after Break – In The engines specified in this manual are intended to be operated at different speeds and loads, but not allowing full load of the engine for more than one hour per 12 running hours. Economic driving may be achieved at the following speeds: MARINE 2012 2000 - 3200 rpm...
  • Page 43 Spray on all outside metal parts of engine SHELL ENSIS T (part number 50322) and let it vent by air for 24 hours (bad smell!). Store engine again as in the condition delivered from STEYR MOTORS. The engine is now preserved for one more year. This preservation procedure must be done every year and ensures that all of the air ways systems, raw water systems, oil system and the cylinders are protected against corrosion.

  • Page 44: E Quality Guidelines For Repair

    - Appropriate test and measuring equipment - Receptacles for operating agents. Depending on the repair step to be carried out, the tools indicated in the STEYR MOTORS TOOL catalogue have to be used. Furthermore special care is to be taken in case of purchasing and stock of required operating material, spare parts and wear parts (e.g.

  • Page 45: E 3 Nomenclature

    General E 3 Nomenclature Term Description Example disassemble Removal of an assembly of a main assembly or remove of a component of an assembly without other unscrew assemblies having been removed before de flange dismantle assemble Putting on of an assembly on a main assembly put on, place or a component of an assembly without further screw on...
  • Page 46 General Preliminary Service Manual MARINE 2012 readjust Devices or tools refill Adding and replenishing of operating agents renew Replacing an auxiliary material by a new one Corrosion protection agent, sealing material, paint gauge Reading in actual positions in programming memory replace Exchanging of a device, a main assembly, an assembly or a component by the same, new or...

  • Page 47: E 4 Si - System

    General E 4 SI – System The following measuring units are used: Linear Pressure and Stress km = kilometre bar = bar m = meter Pa = Pascal mm = millimetre KPa = Kilopascal " = inch N/mm = Newton per square millimetre Area Energy = square meter...

  • Page 48: E 5 Abbreviations

    General Preliminary Service Manual MARINE 2012 E 5 Abbreviations ill. illustration copper MAssy main assembly max. maximum top dead center (POWER TAKE OFF) power transmission at front of crankshaft end Wrench Size Electronic Management System Electronic Control Unit extender ECU FlexDef Electronic Management System for DPF min.

  • Page 49: F Operating Material And Information On Disposal

    Z050316/0 - STEYR Turbo Diesel motor oil SAE 10W-40 (4l. canister) Mobil 1 5W50/ Shell Helix Ultra Racing 10W60 Z011785/0 - STEYR MOTORS engine coolant (5l. can.) 9000190/0 - hydraulic oil ATF (1l. bottle) Z012222/0 - grease, Never – Seeze; NS-160 B (1 kg can.) Z909570/0 - caoutchouc sealing/ electric contacts (148 ml can.)

  • Page 50: F 2 Disposal Of Automotive Waste Products

    General Preliminary Service Manual MARINE 2012 F 2 Disposal of automotive waste products Used operating material is to be collected in special containers to enable possible subsequent treatment. ATTENTION: All operating materials for the engine are subject to the Special Waste Act for disposal.

  • Page 51: G Notes On Safety

    General G Notes on safety 51/65 Z001138-1_2013-02-01...

  • Page 52: G 1 General Notes On Safety

    General Preliminary Service Manual MARINE 2012 G 1 General notes on safety The general knowledge and training of the personnel and the contents of the "general regulations of safety technology" and machine safety regulations (Machine safety regulations - Maschinen Sicherheitsverordnung - MSV) is not subject of this chapter. Inappropriate behaviour and insufficient knowledge of hazard during repair works may cause injury to persons.

  • Page 53: G 4 Safety In The Use Of Operating Material

    General G 4 Safety in the use of operating material Dangerous operating materials, in the sense of accident prevention, are all operating materials potentially explosive, fire-provoking, easily flammable, poisonous, injurious to health and corrosive. Especially the following material belong to this group: - Spirit - Mineral oils - Battery acid...

  • Page 54: H Tightening Torques

    General Preliminary Service Manual MARINE 2012 H Tightening Torques H 1 Listing of Tightening Torques Camshaft housing Screw joint to cylinder block 1. step: 15 Nm +/- 2 2. step: 25 Nm +/- 1 Tighten screws of camshaft housing in two steps in precedence of numbering on bearings (from the inside outwards).
  • Page 55 General Flywheel screws (apply oil to screw head support) 75 Nm +/- 5 (Loctite 243) 45 Nm +/- 4 23 Nm +/- 2 (Loctite 620) 1. step: 200 Nm +/- 10 2. step: 860 Nm +/- 40 Vibration damper screws (apply oil to thread and screw head support) M12x90 Allen screw –...
  • Page 56 General Preliminary Service Manual MARINE 2012 Screw tooth, belt tensioner 45 Nm +/- 4 Valve adjustment element 55 Nm +/- 3 Screw, linkage lever CAUTION: left-hand thread 7 Nm +/- 0,5 Stud, unit injector 21 Nm +/- 2 Z001138-1_2013-02-01 56/65...
  • Page 57 General Collar nut for unit injector 18 Nm - 2 Nut, adjustment screw of unit injector 30 Nm +/- 3 Plug screw for control rack in camshaft housing 50 Nm +/- 5 Hex. flange nut, exhaust manifold 28 Nm +/- 2 (Copper paste) 57/65 Z001138-1_2013-02-01...
  • Page 58 General Preliminary Service Manual MARINE 2012 Exhaust turbocharger 23 Nm +/- 2 50 Nm +/- 5 (greased with NEVER SEEZ) 23 Nm +/-2 Screws, intake manifold 28 Nm +/- 2 Engine oil cooler 12 Nm +/- 2 15 Nm +/- 2 Crankcase ventilation 23 Nm +/- 2 9,5 Nm +/- 1...
  • Page 59 General Thermostat 9,5 Nm +/- 1 Water pump 23 Nm +/- 2 9,5 Nm +/- 1 AC-Compressor (optional) 45 Nm +/- 4 23 Nm +/- 2 9,5 Nm +/- 1 45 Nm +/- 4 (LOCTITE 243) Alternator 59/65 Z001138-1_2013-02-01...

  • Page 60: H 2 General Tightening Torques

    General Preliminary Service Manual MARINE 2012 H 2 General Tightening Torques Values in this table refer to industrial standard and are applicable, if no specific torques are indicated. For studs, tightening torques are to be reduced by 50%. If the tightening torque of a screw connection is not reached, the tightness of the screw/nut too low or the ratio of friction do not correspond.

  • Page 61: H 3 Testing Of Torque Wrenches

    General H 3 Testing of torque wrenches The torque wrenches are subject to regular tests of the set values. By doing so, the tripping value of signalling torque wrenches and the scale accuracy of measuring torque wrenches are tested. H 4 Non-destructive material testing For the detection of surface cracks, the non-destructive test according to colour penetration test procedure is recommended.
  • Page 62 General Preliminary Service Manual MARINE 2012 General guidelines of application for the of use of anaerobic sealing materials Cleanliness of components Non-metallic surface protection must be removed. In case of repair, soiled and oily components are to be cleaned and residues of adhesive plastic material are to be removed.
  • Page 63 General Hardening time Securing Fixing Sealing Class Product Loctite Loctite 243 Loctite 262 Loctite 620 Loctite 5900 Loctite 5910 5182 Hand tightness 15 – 30 15 – 30 5 – 10 0,5- 48 h 30 min 30 min reached after Functional tightness 0,5 h...

  • Page 64: I Wear Limits

    Wear Limits Remark Part. resp. part union New part tolerance Wear Limit 0,032 – 0,099 0,15 Main bearing clearance radial Main bearing clearance axial 0,080 – 0,263 0,30 0,10 0,024 – 0,073 Connect rod bearing clear. radial Connect rod bearing clear. axial 0,064 –...

  • Page 65: I 1 Adjustment Information For Service And Maintenance

    General I 1 Adjustment information for service and maintenance I.1.1 Engine timing (measured with dial indicator No. 2300899/0) Setting instruction: 3,59 +/- 0,04 mm Maintenance instruction: In case the measurements are not within the specified limits of 3,14 to 3,26 mm - than the settings needs to be reset to the original specified value I.1.2 Tension timing belt (measured with tool VR00515/0) Tension instruction:...
  • Page 66 Engine 01 Engine Table of Contents 01.00 Engine Timing, Engine Mount .............. 3   01.00.01 Lock Crank Shaft (Piston No. 1 at TDC) ........5   01.00.02 Camshaft housing cover and seal ........... 8   01.00.03 Maintenance timing belt exchange ..........9  ...
  • Page 67 Engine 01.05.06 Replace radial shaft seal of camshaft ........... 59     01.05.07 Replace cam follower ..............60     01.05.08 Replace retainer of cam follower ........... 61     01.05.09 Replace valve adjusting element ........... 62     01.06 Engine Housing, Oil Pump, Oil Suction Pipe ......
  • Page 68 Engine Items to Check / Troubled Systems Piston / Combustion - Mechanical system [Factors/Cause of Trouble]          Too much oil in the oil pan / oil level too high • • • • • •            ...
  • Page 69 Engine Kapitel MOUNT BRACKET, COVER T-BELT, GASKET SET Z001138-1_2013-02-01 4/87...

  • Page 70: Engine Timing, Engine Mount

    Engine 01.00 Engine Timing, Engine Mount 01.00.01Lock Crank Shaft (Piston No. 1 at TDC) Preparation: Put engine out off operation Disconnect battery Remove camshaft housing cover, 01.00.02 Special tool: for vibration damper screws No. 2300700/0 Locking pin No. 2300551/2 1. Unscrew Allen head plug screw (ill.1) (SW10).
  • Page 71 Engine 4. Continue to turn crankshaft slowly manually in direction of rotation until locking pin engages to slot at the counter weight land of crank shaft ATTENTION: Never actuate starter engine as long as locking pin is inserted. Removal of crank shaft lock pin 1.
  • Page 72 Engine The marked tooth of the camshaft timing belt sprocket stays in line with the upper edge (sealing surface) of the camshaft housing. The notch on the timing belt sprocket of crankshaft is opposite to the arrow marker on the oil pump housing. 7/87 Z001138-1_2013-02-01...

  • Page 73: Camshaft Housing Cover And Seal

    Engine 01.00.02 Camshaft housing cover and seal Remove camshaft housing cover and instruction to exchange cover seal 1. Release 14 hexagon screw SW 10. 2. Remove camshaft housing cover. 3. Release camshaft housing cover sealing by means of screwdriver and remove. 4.
  • Page 74 Engine 01.00.03Maintenance timing belt exchange Preparation: put engine out of operation disconnect battery remove camshaft housing cover Special tool: for vibration damper screws No. 2300700/0 1 Loosen hexagon screws SW10 remove timing belt covering NOTE: See for arrows markings on used timing belt;...
  • Page 75 Engine 6. Adjust eccentric shaft with special tool kit 2300736/0 as shown in illustration before. 7. Mount dial gauge rail with brackets 2306031/6 on studs at intake side of camshaft housing. 8. Insert dial gauge 2300899/0 with probe pin 2300641/1 in dial gauge rail and put probe pin onto unit injector plunger guide cylinder 1.
  • Page 76 Engine 12. Loosen Allen head screw SW 8 of belt tensioner and remove tensioner. 13. Loosen 3 Torx screws M12 x 90 from vibration damper by means of special tool 2300700/0 and remove vibration damper. 14. Remove timing belt. ATTENTION: With loose and/or removed timing belt, the camshaft or crankshaft must not be turned.
  • Page 77 Engine ATTENTION: Pay attention to arrow marker (direction of rotation) on timing belt. 16. Mount vibration damper. Slightly lubricate thread of 3 Torx screws (Lubricant P/N VR00207/0) and tighten with torque wrench to 135 Nm +/-7. NOTE: Recheck torque after first test run. 17.
  • Page 78 Engine ATTENTION: When putting on tension gauge No. VR00515/0, consider the following: The two stop trunnions (ill.20/pos.2)should rest on the forehead of timing belt and must not rest on the back of timing belt Put measuring bow onto tooth. During measuring, completely push in measuring bow and relax quickly.
  • Page 79 Engine 24. Put on tension gauge No. VR00515/0 between camshaft sprocket and tensioner, as described, and read measured value. Timing belt tension should be 600 N +/- 30 N for a new timing belt. NOTE: If timing belt tension does not correspond to specified tension, loosen tensioner and repeat adjustment according to instructions under item 22 through 25.
  • Page 80 Engine 28. Remove camshaft sprocket from conical seat by one hammer blow on puller screw. NOTE: To correct the setting of engine timing follow further instructions as per item 30. Readjustment of camshaft position in case timing needs to be corrected. NOTE: This is to be carried out, if the index value of the engine timing is not within the allowed adjustment tolerance.
  • Page 81 Engine 33. Turn crankshaft by 2 further turns, and at the second turn fix crankshaft with locking pin in TDC position (cylinder 1; in TDC). See chapter 01.00.01. With locked crankshaft, the plunger guide stroke of unit injector at first cylinder should show the following dial gauge value: Index value of engine timing 3.59 mm +/- 0,02 mm (plunger guide stroke - unit...

  • Page 82: Remove Timing Belt

    Engine 01.00.04 Remove timing belt Preparation: put engine out of operation disconnect battery remove camshaft housing cover Special tool: for vibration damper screws No. 2300700/0 1. Loosen 3 Allen screws M12 x 90 (Pos 18) from vibration damper by means of special tool 2300700/0 and remove vibration damper.
  • Page 83 Engine 3. Lock crankshaft, refer 01.00.01 4. Loosen Allen head screw SW 8 of belt tensioner and remove tensioner. 5. Remove timing belt. ATTENTION: With loose and/or removed timing belt, the camshaft or crankshaft must not be turned. This could result in a collision of pistons and valves 6.
  • Page 84 Engine 01.00.05Timing adjustment procedure for dismantled engine Function description: Time control of injection and valves are consistent due to the special camshaft design (3 cams per cylinder). During adjustment, pay attention to essential functional elements, such as unit injector, timing belt tension and sense of rotation of engine, in order to achieve the required setting accuracy of injection.
  • Page 85 Engine 1. Adjust eccentric shaft with special tool 2300736/1 as shown. (ill.4 ) (Tool Kit 2300736/0) 2. Mount dial gauge rail with brackets 2306031/6 on studs at intake side of camshaft housing. 3. Insert dial gauge 2300899/0 with probe pin 2300641/1 in dial gauge rail and put probe pin onto unit injector plunger guide cylinder 4.
  • Page 86 Engine 7. Continue to turn crankshaft in direction of rotation and position it with locking pin in crank shaft. TDC (piston; cylinder 1; in TDC, Reference TDC chapter 01.00.01.) 8. Continue to turn camshaft slowly in direction of rotation until a total distance of 3.32 mm can be read on the dial gauge (plunger stroke at unit injector).
  • Page 87 Engine 12. Mount vibration damper. Slightly lubricate thread of 3 TORX screws (Lubricant P/N VR00207/0) and tighten with torque wrench to 135 +/-7 Nm. NOTE: Recheck torque after first test run. 13. Tightly put on timing belt from crank shaft sprocket over water pump drive wheel and camshaft sprocket, and position camshaft sprocket with marked tooth towards upper...
  • Page 88 Engine should rest on the forehead of timing belt and must not rest on the back of timing belt. Put measuring bow onto tooth. During measuring, completely push in measuring bow and relax quickly. When attaining the required timing belt tension, tighten the Allen head screw (SW 8) with torque wrench to 45 Nm +/-4, and hold up at the same time with wrench (SW32).
  • Page 89 Engine 20. Put on tension gauge No. VR00515/0 between camshaft sprocket and tensioner, as described under item 15, and read measured value. Timing belt tension should be 600 +/- 30 Nm for a new timing belt. NOTE: In case of used belt adjust timing belt tension should be 520 +/- 30 Nm.
  • Page 90 Engine 22. In case of a correct index value of engine timing, remove locking pin on crankshaft and tighten the hexagon nut of the camshaft sprocket SW 30 with 240 Nm by holding up with special tool No. 2300711/0. 23. ATTENTION: The following torques are to be checked again.
  • Page 91 Engine 27. Remove camshaft sprocket from conical seat by one hammer blow on puller screw. NOTE: To correct the setting of engine timing, follow further instructions as per item 32. Readjustment of camshaft position in case of correction of set engine timing NOTE: This is to be carried out, if the index value of the engine timing is not within the allowed adjustment tolerance.
  • Page 92 Engine (cylinder 1; at TDC ) with locking pin in fly wheel bore). See chapter 01.00.01. With locked crankshaft, the plunger guide stroke of unit injector at first cylinder should show the following dial gauge value: Index value of engine timing 3,59 mm +/- 0,04 mm (plunger guide stroke - unit injector) NOTE: If the index value of engine timing should not correspond to the allowed value,...

  • Page 93: Replace Engine Bracket

    Engine 01.00.06 Replace engine bracket ATTENTION: Slightly lift the engine by means of suspension VR 00130/0 at lifting shackles. (approx. 3500 N). Replace engine bracket “Exhaust side” Note: 1 For detailed information refer to vehicle manufacturer. Example: 2 Loosen hexagon screws SW 17, remove bracket and washers.

  • Page 94: Cylinder Block

    Engine Cylinder Block 01.01.01 Replace valves Preparation: Disassemble engine housing, 01.06.01, Disassemble crankshaft, 01.02.01, Disassemble pistons, 01.04.01. 1 Insert special tool No. VR00104/0 in cylinder bore and tighten sturdily with two hexagon screws SW19. 2 Mount valve spring retainer No. VR00105/1 . 3 Pre-stress valve spring with hexagon nut SW28.
  • Page 95 Engine 7 Pull out valve stem gasket with special tool No. 2300758/0. NOTE: When inserting the valves, lubricate valve stem with motor oil. 8 Put special tool No. V000152/0 onto valve stem end and pull on new valve stem over sleeve.

  • Page 96: Adjust Valve Clearance

    Engine 01.01.02 Adjust valve clearance Preparation: Remove camshaft housing cover Valve clearance is adjusted by means of special tool No. VR 00125/0 and adjusting gauge 2300712/3 (ill.1/pos.1) between camshaft base circle (ill.1/pos.2) and cam follower (ill.1/pos.3). NOTE: index value outlet valve 0.25 mm index value intake valve 0.25 mm 31/87 Z001138-1_2013-02-01...

  • Page 97: Replace Valve Guide

    Engine 01.01.03 Replace valve guide Preparation: Disassemble valves, 01.01.01. 1. Press out valve guide with special tool VR00154/0. 2. Insert valve guide with special tool VR00109/0. Z001138-1_2013-02-01 32/87...

  • Page 98: Replace Pressure Regulating Valve For Oil Cooling Jet

    Engine 01.01.04 Replace pressure regulating valve for oil cooling jet Preparation: Disassemble engine casing 01.06.01 Remove pressure regulating valve with open- end wrench (WS13). ATTENTION: Screw in pressure regulating valve until front collar is seated in bore. Screw in pressure regulating valve sturdily.

  • Page 99: Replace Stud Bolt For Unit Injector

    Engine 01.01.05 Replace stud bolt for unit injector Preparation: Remove camshaft housing cover, 01.05.01 Remove unit injector, 03.02.02 1. Tighten threaded pin with a torque of 21 +/- 1 Nm. Z001138-1_2013-02-01 34/87...

  • Page 100: Replace Dowel Pin For Positioning Of Unit Injector

    Engine 01.01.06 Replace dowel pin for positioning of unit injector Preparation: Disassemble camshaft housing, 01.05.01. 1. Insert new dowel pin by means of pressing tool. 35/87 Z001138-1_2013-02-01...

  • Page 101: Replace Dowel Pin For Positioning Of Camshaft Housing

    Engine 01.01.07 Replace dowel pin for positioning of camshaft housing Preparation: Disassemble camshaft housing, 01.05.01. Insert new dowel pin by means of pressing tool. ATTENTION: Do not close oil supply duct with dowel pin in front. (see illustration below) ENGINE DAMAGE! Z001138-1_2013-02-01 36/87...

  • Page 102: Replace O-Ring At Oil Entry To Block

    Engine 01.01.08 Replace O-ring at oil entry to block Preparation: Disassemble coolant manifold Put on new O-ring. Into groove and apply a film of grease to O-ring. Tighten screw M8 with 23 Nm +/- 2. 37/87 Z001138-1_2013-02-01...

  • Page 103: Mount Frame Seal

    Engine 01.01.09 Mount frame seal 1. Clean and degrease groove in cylinder block. 2. Position tool no. V000306/0 over cylinder block, apply on metal surface of tool a film of cleaning agent. Slide frame seal over tool as shown in picture. NOTE: For easier installation of frame seal apply alcohol on sealing profile, or ultra clean agent tool V000306/0 metal surface.
  • Page 104 Engine 3. Apply activator 7649 to groove in the cylinder block. After waiting 2 minutes for the activator to cure, apply construction adhesive LOCTITE 620 (green) on both sides of first profile groove in the frame seal. 4. Press frame seal into cylinder block groove, beginning at the cylinder block corner and then along side of the block.

  • Page 105: Crankshaft, Bearing, Vibration Damper

    Engine 01.02 Crankshaft, Bearing, Vibration Damper 01.02.01 Replace crankshaft Preparation: Disassemble flywheel housing and flywheel, 01.03.01 und 01.03.02, Disassemble timing belt and vibration damper, Disassemble engine housing, 01.06.01, Disassemble oil suction pipe, 01.06.03. Disassemble oil pump housing, 01.06.02, 1. Turn crankshaft in such a way that piston of first cylinder is located at TDC.
  • Page 106 Engine 5. Remove main bearing blocks. 6. Pull out oil nozzles for piston cooling. 7. Remove main bearing shells from bearing blocks. NOTE: For assembly, lubricate all bearing with engine oil. All pistons with connecting rods are inserted in the cylinder bore. Mount injection oil nozzles with new O-rings.
  • Page 107 Engine 10. Insert the two upper thrust bearing segments onto main bearing cap and mount main bearing cap. Install remaining main bearing caps with bearing shells and tighten main bearing screws sturdy. 11. Mount connecting rod cap with bearing shell. (pay attention to numbering). Tightening specification for connecting rod screws (thread and screw head support lubricated):...
  • Page 108 Engine Measuring of end clearance Put on magnetic holder with dial gauge, put dial gauge / calliper onto crankshaft end. Move crankshaft in forward direction and set dial gauge to zero. Move crankshaft backwards and read measured value. Clearance should be between 0.07 and 0.25 mm.

  • Page 109: Replace Gear For Oil Pump Drive

    Engine 01.02.02 Replace gear for oil pump drive Preparation: Disassemble engine housing, 01.06.01, Disassemble timing belt, Disassemble oil pump, 01.06.02, Disassemble oil suction pipe, 01.06.03. 1. Remove woodruff key.(ill.1/pos.1) 2. Pull off gear (ill.1/pos.2) with sleeve ring (ill.1/pos.3). NOTE: Apply surface sealing agent 5182 contact surfaces of gear towards crankshaft and sleeve ring.

  • Page 110: Flywheel

    Engine 01.03 Flywheel 01.03.01 Replace flywheel Preparation: refer to 02.00.01 Consult the manufacturer of the generator to receive instructions on how to remove respectively disassembly the generator from the engine 1. after proper removal of generator open hex head screw M24 and extract flange with special tool (P/No 2300962-0) Refer to 2.00.01 2.

  • Page 111: Piston And Connecting Rod

    Engine 01.04 Piston and Connecting Rod 01.04.01 Dismantle piston and connecting rod Preparation: Dismantle engine housing, 01.06.01 Disassemble crankshaft, 01.02.01. 1. Pull out piston with connecting rod. 2. Remove retainer ring of piston pin by means of a fine blade screwdriver. 3.
  • Page 112 Engine ATTENTION: For assembly of piston and connecting rod, take care that positioning notch of connecting rod bearing is opposite to the clearance recess for oil injection nozzle. NOTE: For best result position rings with piston gap about one third of a turn a part from each others gap.

  • Page 113: Camshaft, Housing, Valve Gear

    Engine 01.05 Camshaft, Housing, Valve Gear 01.05.01 Replace camshaft housing Preparation: Empty fuel system, 03.02.02 item 2 Disconnect battery Disconnect crankshaft from TDC, 01.00.01 Dismantle unit injectors, 03.02.02 Remove cover timing belt, 01.00.04 1. Release timing belt tensioner, remove tensioner pulley entirely 2.
  • Page 114 Engine 7. Dismantle oil supply line - turbocharger at camshaft housing SW 10. 8. Disconnect speed sensor (ill.7/pos.1) Speed sensor 9. Dismantle bracket exhaust manifold, 2x M8 nut. 10. Dismantle oil supply pipe injection timing device. (ill.9) 49/87 Z001138-1_2013-02-01...
  • Page 115 Engine 11. Loosen hexagon screws SW 13 (7x M8x135 & 7x M8x110) 12. Remove camshaft housing upwards. Remove sealing. Assembly of camshaft housing 1. Clean sealing surfaces of motor block (ill.11/pos.1) and camshaft housing (ill.11/pos.2). 2. Put on camshaft housing sealing (ill.11/pos.3).
  • Page 116 Engine 5. Tighten screws of camshaft housing in two steps as illustrated. (ill.14) (from inside outwards). 15 Nm +/- 1 Torque: 1. Step 25 Nm +/- 2 2. Step 6. Assembly unit injectors; refer 03.02.02 7. Adjust unit injectors, refer to 03.02.06. 8.

  • Page 117: Replace Gas Stem Gasket (On Engine Assembly)

    Engine 01.05.02 Replace gas stem gasket (on engine assembly) Preparation: Disassemble camshaft housing, 01.05.01. ATTENTION: Set piston of respective cylinder on TDC. 1. Mount valve spring retainer No. VR00105/1 ill.1). 2. Compress valve spring (ill.2) with hexagon socket SW28. 3. Remove wedges. 4.
  • Page 118 Engine 6. Put special tool No. V000152/0 onto valve stem end and push new valve stem gasket over sleeve. 7. Remove sleeve and press on valve stem gasket with special tool No. V000166/0 until valve stem is supported on collar of valve guide.

  • Page 119: Replace Control Rack

    Engine 01.05.03 Replace control rack Preparation: Drain fuel system, 03.02.02 item 2. Disassemble camshaft housing cover, 01.05.01. Disassemble control solenoid, 03.08.01. 6-cylinder Disassemble unit injector of 1st cylinder, 03.02.02. 1. loosen 2x hex socket head cap screw M8x25 and remove Torsion Arm Assy. Refer to injection timing device 03.08.04 2.
  • Page 120 Engine 4. Remove locking pin (ill.4/pos.1) from last bulkhead. 5. Loosen plug screw SW22 (ill.5), remove sealing ring, pull out control rod to the back. Rear site of engine housing. 6. Assembly in reverse order. NOTE: 7. Adjust control, refer to 01.00.04 8.

  • Page 121: Replace Camshaft

    Engine 01.05.04 Replace camshaft Preparation: disassemble camshaft housing, refer to 01.05.01. 1. Loosen hexagon nut SW30. (ill.1/pos.1) Retaining at hexagon camshaft. 2. Disassemble camshaft sprocket with special tool No. VR00113/0 (ill.2), remove nut & washer. 3. Remove axial pin and retainer plate for camshaft.

  • Page 122: Replace Eccentric Shaft

    Engine 01.05.05 Replace eccentric shaft Preparation: Disassemble camshaft housing cover, 01.05.01. Loosen set screws of unit injector on rocker arm. NOTE: Keep sliding cups below each rocker arm set screw matched to each cylinder. 1. Remove circlips on both sides of rocker arms.
  • Page 123 Engine NOTE: Make sure camshaft lobe is clear of Shaft linkage arrangement. 5. Extract axial half-moon rings (ill.5) of eccentric-shaft (2x) (same as for rocker arms) 6. Displace rocker arm, remove slide rings, remove rocker arms one by one and pull out eccentric shaft towards cylinder.

  • Page 124: Excentric Shaft

    Engine EXCENTRIC SHAFT 01.05.06 Replace radial shaft seal of camshaft Preparation: Lock crankshaft, 01.00.01. Remove timing belt. Disassemble camshaft sprocket 1. Disassemble radial shaft seal. 2. Mount new radial shaft seal with special tool No. VR00122/0. NOTE: Radial shaft seal is waxed; therefore needs not to be oiled.

  • Page 125: Replace Cam Follower

    Engine 01.05.07 Replace cam follower Preparation: disassemble camshaft housing cover. 1. Loosen adjusting screw (ill.1/pos.1) with special tool No. VR00125/0. 2. Lift cam follower spring (ill.1/pos.2) with special tool No. V000121/0. 3. Compress valve spring (ill.1/pos.3) with special tool No. VR00106/0. NOTE: Crankshaft is first to be turned in a position which prevents collision between valve - piston bottom.

  • Page 126: Replace Retainer Of Cam Follower

    Engine 01.05.08 Replace retainer of cam follower Preparation: disassemble cam follower, 01.05.08 1. Turn retainer spring (ill.1/pos.1) sideward’s and removes by means of screwdriver from valve adjusting element towards centre. NOTE: Adjust valves, refer to 01.01.02. 61/87 Z001138-1_2013-02-01...

  • Page 127: Replace Valve Adjusting Element

    Engine 01.05.09 Replace valve adjusting element Preparation: Disassemble retainer spring of cam follower, 01.05.09 1. Unscrew valve adjusting element with hexagon socket SW21. NOTE: Apply thread protection LOCTITE 243 to valve adjusting element and tighten with a torque of 55 Nm +/-3. NOTE: Adjust valves, refer to 01.01.02.

  • Page 128: Engine Housing, Oil Pump, Oil Suction Pipe

    Engine 01.06 Engine Housing, Oil Pump, Oil Suction Pipe Oil Schematic 01.06.01 Replace engine housing Preparation: disconnect battery close fuel feed- and return line, drain engine oil, refer 01.13.02. Dismantle wiring harness, 06.05.02. dismantle exhaust manifold, remove protection-plate frame seal, refer 01.08.06 63/87 Z001138-1_2013-02-01...
  • Page 129 Engine 1. Lift engine with special tool No. VR00130/0 and crane (min. 3500 N). 2. Dismantle oil separator and crank case ventilation hose 3. Remove oil filter and oil hose entirely 4. Remove intake manifold. 5. Disconnect oil pipe from coolant distribution pipe and remove coolant distribution pipe.
  • Page 130 Engine 8. Loosen hexagon screws SW10 remove timing belt covering NOTE: See for arrows markings on used timing belt; mark timing belt if necessary. Consider change intervals – see chart "maintenance". 9. Remove poly for poly-V-belt and front vibration damper. 10.
  • Page 131 Engine 12. Unscrew frame sealing from engine housing. NOTE: Do not puncture frame seal. Z001138-1_2013-02-01 66/87...
  • Page 132 Engine 13. First loosen 16 allen head screws SW 5, then 7 hexagon screws SW15 14. Force apart housing half’s and remove. Assembly 1. Check membranes of frame sealing and rubber pads for damage, replace if necessary. 2. Clean and degrease all sealing surfaces. 3.
  • Page 133 Engine 6. Tighten 7 hexagon screws SW17 (ill.16/pos.2) with a torque of 50 Nm +/-5 Nm. Fasten 16 Allen head screws SW5 (ill.16/pos.1) with a torque of 10 +/-1 Nm. 7. From engine no: Screw together frame sealing with housing halves. Tighten with a torque of 5,5 Nm +/- 0,5.

  • Page 134: Replace Rear Ring Carrier

    Engine 01.06.02 Replace rear ring carrier Preparation: Dismantle engine housing, 01.06.01 1. Loosen 7 hexagon screws, SW 13. Remove support ring. 2. Clean and degrease all sealing surfaces. 3. Clean surface on mounting bosses of block. 4. Apply LOCTITE to sealing area of block with surface sealing agent LOCTITE 5182.

  • Page 135: Replace Rear Radialshaft Sealing Ring

    Engine 01.06.03 Replace rear radial shaft sealing ring Preparation: Remove flywheel, refer 01.03 Remove radial shaft sealing ring 1. Mount special tool No. VR00107/0 to press in the rear radial shaft sealing ring. NOTE: Specified tool enables a replacement of the radial shaft seal with assembled engine housing.

  • Page 136: Replace Oil Pump (Front Ring Carrier)

    Engine 01.06.04 Replace oil pump (front ring carrier) Preparation: dismantle engine housing, 01.06.01. remove timing belt remove vibration damper remove oil pipes 01.06.05 1. Pull of timing belt sprocket by means of special tool No. 2300636/0. 2. Loosen 6 hexagon screws SW13, remove oil pump housing.
  • Page 137 Engine NOTE: Replace friction enhancement washer every time you open the front assembly of crankshaft timing sprocket and vibration damper. Z001138-1_2013-02-01 72/87...

  • Page 138: Replace Oil Suction Pipe/ Oil Return Pipe

    Engine 01.06.05 Replace oil suction pipe/ oil return pipe Preparation: Exchange engine housing, 01.06.01. 1. Loosen 2 hexagon screws SW10 on main bearing block and remove. 2. Pull of oil suction pipe (ill.2/pos.2). Check O-ring or gasket (ill.2/pos.3), replace if necessary. Remark for assembly: 3.

  • Page 139: Intake Manifold/ Exhaust Manifold

    Engine 01.08 Intake Manifold/ Exhaust Manifold 01.08.01 Remove intake manifold 1. Unscrew hexagon screw (ill.2/pos.1) (SW10) of clamp of oil dipstick tube carefully turn away oil dipstick tube. 2. Dismantle ground cable (ill.3/pos.1) at engine housing (if necessary) 3. Remove plug from boost pressure sensor 4.
  • Page 140 Engine 7. Remove plug from magnetic-valve (ill.4/pos.1) and linear-sensor (ill.4/pos.2) 8. Remove mounts of wiring harness on the bottom of intake manifold and turn away wiring harness. 9. Remove oil supply pipe injection timing device. 10. Loosen 12 (6 M8x140, 6 M8x25) Allen head screws from intake manifold and remove intake manifold.

  • Page 141: Mount Intake Manifold

    Engine 01.08.02 Mount intake manifold 1. Clean sealing surfaces on motor block (ill.1). 2. Fix 2 seals (ill.1/pos.1) with grease Staburax NB04 on marked surfaces of mono block. 3. Clean sealing surfaces on intake manifold (ill.1/pos.2). 4. Fix intake manifold on engine block by means of 2 Allen head screws (ill.1/pos.3).

  • Page 142: Disassemble Exhaust Manifold Complete With Turbo Chargers

    Engine 01.08.03 Disassemble exhaust manifold complete with turbo chargers Preparation: remove turbo charger; refer 03.05.01 1. Remove 2 hex head screws M8 (SW13) at exhaust manifold bracket. Loosen 2 hex head nuts M8 (SW13). 2. Remove exhaust temperature sensor (T30) 3.

  • Page 143: Mount Exhaust Manifold

    Engine 01.08.04 Mount exhaust manifold 1. Clean sealing surfaces on motor block. 2. Place 6 exhaust gaskets onto studs. 3. Grease studs with high temp. grease (SMO PN 12222) 4. Place exhaust manifold and mount 2 connecting plates on outside manifold section and place washers on remaining studs.
  • Page 144 Engine 01.08.06 Remove oil supply pipe of turbo charger Preparation 01.08.05 1. Loosen double length hollow screw at lubricant pressure sensor and remove oil supply pipe. 2. Remove cupper washer and dispose Assembly done in reverse order. Note:  Use new cupper washers only. ...

  • Page 145: Engine Oil Cooler

    Close coolant circuit with plug screw in coolant distribution manifold with a torque of 23 Nm +/-2. Refill coolant circuit with coolant liquid STEYR MOTORS engine coolant P/No. Z011785/0 Note: Make sure to bleed coolant system properly to avoid overheating of engine or consequently...

  • Page 146: Change Motor Oil (General)

    Engine 01.13.02 Change motor oil (general) 1. Bring engine to operating temperature and stop engine. 2. Pull oil dipstick off O-Ring seal. 3. Open oil filler cap, but do not remove because of possible contamination. 4. Loosen oil drain plug and drain oil. Dispose sealing rings.
  • Page 147 Engine 7. Fill in STEYR turbo diesel engine oil SAE 10W-40 (No. Z010058/0) (ill.3) or equivalent motor oil with characteristic ACEA E4/E5/E7 or B4/02 resp. API code CF or higher. ATTENTION: Oil filling must not exceed the maximum marker. Overfilling results in high operating temperatures, foaming (air in oil), loss in efficiency and a...
  • Page 148 Engine 01.13.03 Change oil filter 1. Loosen the oil filter with oil filter wrench 2300713/0 and. Dispose the oil filter acc. automotive waste disposal regulation. 2. Clean sealing surface of oil filter head. 3. Oil the seal of new oil filter and screw it onto oil filter head until the seal easily rests against.
  • Page 149 Engine 01.13.04 Coolant distribution manifold 1. Preparation: drain coolant 2. Remove hose clamps from oil cooler connection. 3. Remove 2 hex head bolts M6 (SW10) and pull off oil hose. 4. Loosen clamps of coolant pipe (mounting bolt A/C compressor). 5.
  • Page 150 Engine 10. Remove 4 pieces O-Ring from brace inserts. Messing sleeve 01.13.05 Assemble of coolant distribution manifold Cleaning of flange surface on block Install new O-rings and grease O-rings (SMO-P/No. 10107) for easier assembling. Install new O-ring on oil supply passage. Apply a slight film of LOCTITE 5910 on flange surface at block.
  • Page 151 Engine Apply LOCTITE 5910 on flange surface at coolant distribution manifold. ??????? Tighten 3 hex head screws M8 (SW13) with a torque of 23 Nm +/-2. Install new O-ring and grease O-ring (SMO-P/No. 10107) for easier assembling. Install hose for main engine oil supply from engine oil cooler.
  • Page 152 Engine Refill coolant circuit with coolant liquid STEYR MOTORS engine coolant P/No. Z011785/0 Note: Make sure to bleed coolant system properly to avoid overheating of engine or consequently damage of internal engine components 87/87 Z001138-1_2013-02-01...
  • Page 153 Fuel System 03 Fuel System Table of Contents 03.00 Fuel System.................... 3   03.00.01 General Schematic ................5     03.00.02 Functional description ..............5     03.00.03 Unit injector ..................7     03.00.04 Air system M16 VTI ................8  ...

  • Page 154: Fuel System

    Fuel System Z001138-1_2013-02-01 2/51...

  • Page 155: Fuel System

    Fuel System Items to Check / Troubled Systems Injection System [Factors/Cause of Trouble] Fuel leakage from nozzle body • • • • • • • Air trapped in the fuel system at ignition ON • • • • • • •...
  • Page 156 Fuel System Items to Check / Troubled Systems Air Intake, Fuel Supply & Injection System [Factors/Cause of Trouble] Running out of Fuel  • • Fuel Supply Line Valve closed  • • • • Clogging of fuel filter or water separator • • • • • • Breakdown of fuel feed pump •...

  • Page 157: Fuel System

    Fuel System 03.00 Fuel System 03.00.01 General Schematic 03.00.02 Functional description When the ignition switch is turned, an electric fuel pump 3 is put into operation and the fuel flows from the fuel tank through the pre-filter 2. From the fuel pump, fuel is pumped to the engine fuel gallery at the rear inlet 5 and the unit injectors 6.
  • Page 158 Fuel System Specification for fuel pipes Minimum inside diameter: 16 mm Recommended material: stainless steel NOTE: Min. inside diameter for hosepipes or PA-pipes is 16 mm. Rate of flow: 350 l/h (measurement on continuously operated fuel pump) If additional filters getting installed, the requirements of higher flow in the fuel gallery circuit must to be considered.

  • Page 159: Unit Injector

    Fuel System 03.00.03 Unit injector 7/51 Z001138-1_2013-02-01...

  • Page 160: Air System M16 Vti

    Fuel System 03.00.04 Air system M16 VTI Permissible low pressure for air filter and in air intake pipe before of turbo charger:  Permissible low pressure before TC - intake = 30 mbar  Max. low pressure with loaded air filter element – 50 mbar ...

  • Page 161: Exhaust Pipe And Muffler Marine 2012

    Fuel System 03.00.05 Exhaust pipe and muffler MARINE 2012 ID Exhaust pipe must be properly dimensioned to meet requirements at rated speed gas flow Engine type MARINE 2012 Back pressure 200 mbar Permissible tolerance +/- 50 mbar Exhaust mass flow 840kg/h @ 3550rpm full load.

  • Page 162: Schema - Variable Geometry Turbochargers

    Fuel System 03.00.06 Schema – Variable Geometry Turbochargers Function turbo charging system Turbocharger consists of two fundamental components, a turbine and a compressor. The function of the turbine is to scavenge waste exhaust heat and translate it into rotational motion. This rotational motion is then used to drive the compressor, which compresses air for the consumption of the engine.
  • Page 163 Fuel System Variable Geometry Turbocharger (VGT) Variable Geometry Turbochargers are turbochargers whose geometry and thus effective aspect ratio (A/R) can be altered as needed while in use. The most common design includes several adjustable vanes around a central turbine. As the angle of the vanes change, the angle of air flow onto the turbine blades changes, which changes the effective area of the turbine, and thus the aspect ratio (A/R) changes.

  • Page 164: Fuel Pump, Unit Injector, Lines

    Fuel System 03.02 Fuel Pump, Unit Injector, Lines 03.02.01 Replace fuel pump (Example) NOTE: Fuel pump operation is controlled by EMS. NOTE: The fuel pump in a vehicle installation may vary in location. Please refer to vehicle manufacturer information to locate this device in a car. Preparation for disassembly RECOMMENDET TYPE OF FUELPUMP 2173396-6...
  • Page 165 Fuel System Assembly (Example) 1. Mount pump into bracket at correct position of rubber sleeve. Tighten screws of bracket. 2. Attach fuel hoses to pump and tighten hose clamps. 3. Connect cables to negative terminal (-) and to positive terminal (+). Cover the two terminals with neoprene lacquer sealing No.

  • Page 166: Disassembly And Assembly Of Unit Injector

    Fuel System 03.02.02 Disassembly and assembly of unit injector Preparation: Remove camshaft housing cover. Clean sealing surface of rubber seal and check for hardening and damage. Replace seal, if required. Example: (P/No. Unit injector 2176560-B) NOTE: When replacing or adjusting injectors 555-5 make sure to identify the type of injector marked on the injector housing as shown.
  • Page 167 Fuel System - First turn eccentric shaft towards intake manifold until lever of eccentric shaft is free. Lift lever above injection-timing-device. Then turn shaft towards exhaust-system. NOTE: Make sure camshaft lobe is clear of shaft-linkage arrangement. 1. Turn crankshaft until injector cam is at base circle as well intake and exhaust valve are open, in order to permit a lateral shifting of rocker arm for the following disassembly...
  • Page 168 Fuel System 3. Remove nuts on unit injector flange (2 nuts SW 13). 4. Loosen left-handed hexagon socket securing the control link on the control rack by using 4 mm hexagon socket wrench (P/N 2300908/0). Turn control link against bulk head.
  • Page 169 Fuel System 7. Move the rocker arm towards timing belt side of engine and remove the slide cup. NOTE: Adjusting screw and slide cup match exactly and thus have to be kept matched. 8. Check position of control link(s) against bulkhead as illustrated.
  • Page 170 Fuel System 11. Remove copper seal washer from bottom side of copper insert by means of hook- and lifting tool (No. VR 00116/0). NOTE: Avoid scratches on the sealing surface of the copper insert. Assembly 1. In order to secure an appropriate tight fit, recheck tighten stud bolt with a torque of 20 Nm +/- 1 2.
  • Page 171 Fuel System 4. Clean conical part of copper insert with cleaning mandrel No. 2300565/0. For this purpose, turn cleaning mandrel several times in both directions and then clean copper insert with cleaning tissue. Insert new special copper 5. ATTENTION: seal washer (ill.22/pos.2), from seal kit Z002031/0, with a screwdriver into copper insert.
  • Page 172 Fuel System 8. Push unit injector firmly downwards in order to position it correctly with the O-rings. 9. Lubricate slide cup with motor oil, put it onto adjustment screw, as shown, and shift it together with rocker arm onto unit injector. 10.
  • Page 173 Fuel System 12. Fix control rack, refer 03.02.03 13. Attach control link to control rack and adjust. Refer to 03.02.04, Adjusting Control Link. 14. Connect eccentric-shaft linkage with injection-timing device (parallel pin, retainer c-clip). 15. Adjust unit injection start of delivery. Refer to 03.02.06, 16.
  • Page 174 Fuel System Screw the sliding hammer into the insert and, using force, hammer the insert out. It will be necessary to clean the seating surface extremely well, removing all traces of the old loctite with a strong degreasing agent on a cloth, as below. Clean the new insert also with a degreasing agent and fit a new o-ring.

  • Page 175: Fix Control Rack

    Fuel System 03.02.03 Fix control rack Preparation: Remove camshaft housing cover, refer to 01.00.02 1. Unscrew setpin of control rack (ill.1/pos.1) at the rear bulkhead of camshaft housing, as shown. 2. Position bore (diameter 4 mm) in control rack(ill.2/pos.2) over reference bore (ill.2/pos.3) in the bulkhead wall.

  • Page 176: Adjust Control Link (Injection Quantity)

    Fuel System 03.02.04 Adjust control link (injection quantity) Prior to adjustment, unit injector must be tightened properly, and control rack must be fixed in position with set pin. (refer 03.02.03) NOTE: Readjust all control links even if only one link has been opened. STARTING POSITION: Slacken left-handed setscrew of control link (use special tool P/N 2300908/0).

  • Page 177: Release Fixing Of Control Rod

    Fuel System 03.02.05 Release fixing of control rod 1. Unscrew setpin (ill.3/pos.2) from bulkhead wall. Hold control rack while removing setpin. Slowly release common rack towards the rear to take off applied spring load from the unit injector. (ill.3/pos.1). 2. Reinstall setpin in rear bulkhead bore of camshaft housing (ill.3/pos.1) 3.

  • Page 178: Adjustment Of Unit Injector - Start Of Fuel Delivery

    Fuel System 03.02.06 Adjustment of unit injector – start of fuel delivery Preparation: Remove camshaft housing cover; refer to 01.00.02. Adjustment of unit injector – start of fuel delivery is recommended to perform prior to engine timing adjustments. NOTE: This adjustment is necessary: - if unit injector was removed - periodically according to maintenance (chart)
  • Page 179 Fuel System Connect tool VR00236-0 to valve solenoid and connect power on + and – to cable to release hydraulic pressure from device. NOTE: With the tool connected the injection timing device and eccentric shaft can be moved easily. 4. Turn camshaft until bearing roller of rocker arm, for unit injector being adjusted, is situated on the base circle of the injector cam.
  • Page 180 Fuel System 9. Turn adjusting screw (ill.7/pos.1) with torx screwdriver (2300873/0) and set the adjustment value as listed in table below. Hold adjusting screw in this position and tighten hexagon nut (ill.7/pos.2) by means of torque wrench No. 2300743/0 and tee- handled socket wrench SW17 (2300773/0) with a torque of 30 Nm +/-3.

  • Page 181: Exchange Pressure Check Valve At Fuel Outlet On Block

    NOTE: Use new Cu-sealing rings for assembly. Tighten with a torque of 40 Nm +/-4. ATTENTION: This part is of importance for the proper function of fuel system. Use only genuine STEYR MOTORS spare part in case of replacement. 29/51 Z001138-1_2013-02-01...

  • Page 182: Turbo Charger

    Fuel System 03.05 Turbo charger 03.05.01 Replace Variable Geometry Turbochargers (VGT) Remove air intake pipe. Remove charge air pipe & air filter. Remove exhaust elbow at turbo charger Loosen 3x M8 hex head screws (SW13). Z001138-1_2013-02-01 30/51...
  • Page 183 Fuel System Loosen Heat Protection Turbo. Loosen exhaust elbow clamp and remove exhaust elbow. Loosen hollow screw M12x1,5. Loosen 2xM8x20 hex screw of oil feed line on turbocharger. Remove flange gasket. Dispose gasket. 31/51 Z001138-1_2013-02-01...
  • Page 184 Fuel System Loosen hose clamp. Remove Heat Protection Turbo. Loosen 4xM8 hex flange nut (heat resistant). Remove Turbo-Charger Assembly is done in reverse order. Z001138-1_2013-02-01 32/51...
  • Page 185 Fuel System Assembly in reverse order: Note: 1. Tighten clamp with a torque of 25 Nm +/-2. 2. Tighten 2 hex head screws and hexagon nut (M8) with a torque of 23 +/-2 Nm. 3. Tighten hollow screw (restricted bore) of oil feed line with a torque of 25 Nm +/-2 Use new sealing rings.

  • Page 186: Check Bearing Clearance (Example)

    Fuel System 03.05.02 Check bearing clearance (Example) Measure end clearance: 1. Put test prod of dial gauge onto face of turbine wheel hub. 2. Push cursor downwards and set dial gauge to "0". 3. Push cursor against dial gauge and note deflection of pointer.

  • Page 187: Control Solenoid, Injection Timing Device (Itd)

    Fuel System 03.08 Control Solenoid, Injection Timing Device (ITD) 03.08.01 Remove control solenoid Preparation: 1. Disconnect battery. Remove intake manifold, refer to 01.08.01. 2. Loosen plug connection (ill.2/pos.1) for control rack potentiometer. 3. Remove plug from control solenoid (ill.2/pos.2). 4. Loosen 4 hexagon screws SST (SW13) on control solenoid housing, remove control solenoid assembly.

  • Page 188: Install Rack Control Solenoid

    Fuel System 03.08.02 Install rack control solenoid Assembly onto camshaft housing, proceed as follows: NOTE: Use new O-ring to seal control solenoid. 1. Remove camshaft housing cover. 2. Put O-ring into groove of control solenoid 3. Shift control rack by hand (ill.1) to front position and hold.

  • Page 189: Replace Potentiometer, Indication Of Control Rack Position

    Fuel System 03.08.03 Replace potentiometer, indication of control rack position Preparation: remove intake manifold, refer 01.08.01 1. Loosen 2 Allen head screws SW 3 (ill.1/pos.1). Remove potentiometer. Assembly 2. Insert potentiometer in such a way that rod of potentiometer (ill.2/pos.1) is positioned in front of solenoid rod (ill.2/pos.2).
  • Page 190 Fuel System Schema - Injection Timing Device (ITD) Z001138-1_2013-02-01 38/51...

  • Page 191: Remove Injection Timing Device (Itd)

    Fuel System 03.08.04 Remove injection timing device (ITD) Preparation: remove intake manifold, refer 01.08.01 remove camshaft housing cover, refer 01.00.02 1. Disconnect battery. 2. Remove c-clip (ill.1/pos.1) and pull pin out (ill.1/pos.2). 3. Remove plug from magnetic-valve. 4. Remove connector from linear position sensor.
  • Page 192 Fuel System 5. Loosen 4 hexagon socket head cap screws on ITD housing and remove ITD-assy. Remove O-rings. Z001138-1_2013-02-01 40/51...

  • Page 193: Install Injection Timing Device (Itd)

    Fuel System 03.08.05 Install injection timing device (ITD) NOTE: Use new O-rings. 1. Put new O-rings onto ITD-housing and lubricate rings with motor oil. 2. Mount ITD on camshaft housing. Re-install lever of eccentric-shaft (ill.1) 3. Mount 4 screws and tighten with a torque of 23 +/-2 Nm.

  • Page 194: Change Fuel "Pre-Filter" And "Fine-Filter" (General Description)

    Fuel System 03.09 Change fuel “pre-filter” and “fine-filter” (general description) Water or other fuel contaminations may form deposits which clog the fuel filter and may lead to consequently damage in the injection system. Change fuel filter on a regular schedule is highly recommended every 300 hours of operation and/or every 2 years at least.
  • Page 195 Fuel System electric fuel pump. Turn ignition ON a few times for max. 10 sec. ATTENTION: Do not dry run fuel pump. 7. Start engine and check fuel system for leakage. 8. Remove possibly spilled fuel residues. Dispose fuel filter according EPA regulation.

  • Page 196: Replace Glow Plug

    Fuel System 03.11 Replace Glow Plug Preparation: for glow plug of first cylinder, remove control solenoid - refer to 03.08.01 for glow plug of second to sixth cylinder, remove intake manifold - refer to 01.08.01 Disconnect battery. 1. Remove connector from glow plug. 2.

  • Page 197: Measurement Of Compression Pressure

    Fuel System 03.12 Measurement of Compression Pressure Preparation: remove glow plug, refer to 03.11 1. Install special tool glow plug adaptor 2300638/2 (ill.1) into cylinder to be checked (ill.2). NOTE: During this compression pressure test the control rack “device-Y20” connector must be unplugged.

  • Page 198: Fuel System Check

    Fuel System Compression pressure chart nominal value/lower boundary value Refer to engine table Marquart, aschaber, gmainer MODEL TYPE NOM. VALUE LOWER BOUNDARY VALUE M16TCA M160029/3 21,0 +/- 1,0 bar 18,0 +/- 1,0 bar M16TCA M160029/5 21,0 +/- 1,0 bar 18,0 +/- 1,0 bar M16TCA M160029/6 21,0 +/- 1,0 bar...
  • Page 199 Fuel System 3. Move control rack by means of special tool No.VR00148/0 into idle injection position (approx.5-6 mm) (ill.3) and remain in this position. 4. Put tool (unit injector withdrawing lever No. VR00126/0) onto rocker arm of individual unit injectors (ill. 4) and move upper end of lever in direction of air intake manifold.

  • Page 200: Manual Check Of Unit Injector Without Tool No. Vr 00148/0

    Fuel System defects on an injector must be undertaken this injectors with such symptoms needs to be exchanged. 6. Repeat test on each unit injector 7. Assembly is done in reverse order. ATTENTION: Absolutely make sure to remove special tool No. VR 00148/0 from camshaft housing.

  • Page 201: Disengagement Methode Of Injection

    Fuel System 03.14.03 Disengagement methode of injection NOTE: Disengagement method of injection is a simple and effective method to detect defective unit injectors with regard to formation of air bubbles in both the fuel system and the engine cooling system or lack of power if related to deficiencies in injection equipment.

  • Page 202: Air Bubble Formation In Fuel System (Example)

    Fuel System 03.14.04 Air bubble formation in fuel system (Example) Preparation: Change fuel filter, if necessary refer to 03.09 (item 1, bleed fuel system) Testing device for fuel return 2300719/1 1. Disconnect hose from fuel return on block fuel cooler outlet to fuel cooler. 2.
  • Page 203 Fuel System Result: If it comes to air bubble formation, search for the problem in the area of unit injectors. Control: Defective unit injector(s) is/are to be detected definitely by means of "Disengagement method of injection" (manual injection test method, refer to 03.14.01 and 03.14.02) If there is still air bubble formation, continue with check 4.
  • Page 204 Exhaust System 04 Exhaust System Disassemble / assemble of Turbocharger & Exhaust Elbow 1. Remove air intake pipe. 2. Remove charge air pipe & air filter. 3. Remove exhaust elbow at turbo charger 4. Loosen 3x M8 hex head screws (SW13). Z001138-1_2013-02-01...
  • Page 205 Exhaust System 5. Loosen Heat Protection Turbo. 6. Loosen exhaust elbow clamp and remove exhaust elbow. 7. Loosen hollow screw M12x1,5. 8. Loosen 2xM8x20 hex screw of oil feed line on turbocharger. 9. Remove flange gasket. Dispose gasket. Z001138-1_2013-02-01...
  • Page 206 Exhaust System 10. Loosen hose clamp (oil feed line). 11. Remove Heat Protection Turbo. 12. Loosen 4xM8 hex flange nut (heat resistant). 13. Remove Turbo-Charger Assembly is done in reverse order. Z001138-1_2013-02-01...
  • Page 207 Cooling System 05 Cooling System Table of Contents 05.00 Functional Description Engine Cooling Circuit ......4 05.00.03 Error detection cooling system ............6 05.00.04 Check points for problems in cooling system ........ 7 05.00.06 Component checks of engine cooling system ....... 8 05.00.07 Drain the coolant from engine............
  • Page 208 Cooling System Items to Check / Troubled Systems Raw Water & Fresh Water Coolant System [Factors/Cause of Trouble] • • • Poly V-belt slip or breakage • • Water leaks due to defective seal packing Air is picked in bevor Raw Water Pump •...
  • Page 209 Cooling System Items to Check / Troubled Systems Raw Water & Fresh Water Coolant System [Factors/Cause of Trouble] • • Insufficient air supply / volume to Compartment • • • Air ventilation passage obstructed • • • Contamination of intercooler fins 3/21 Z001138-1_2013-02-01...

  • Page 210: Functional Description Engine Cooling Circuit

    Cooling System 05.00 Functional Description Engine Cooling Circuit In the closed (primary) cooling circuit of the engine, the coolant circulates by centrifugal pump (circulating pump) mounted at the front of engine block. The pulley of the pump is driven from the back of the timing belt. The pump is maintenance- free.
  • Page 211 Cooling System 5/21 Z001138-1_2013-02-01...

  • Page 212: Error Detection Cooling System

    Cooling System 05.00.03 Error detection cooling system 1. Ask for the following information: - Model and serial number of engine? - Engine operating hours? (wear and corrosion) - How long does the problem already exist? (gradual or sudden occurrence) - Operating conditions prior to occurrence of problem - What repair- or service works have already been carried out (thermostat, etc.)? - At what engine speed does the problem occur?

  • Page 213: Check Points For Problems In Cooling System

    Cooling System - Result: Temperature on hose slowly rises simultaneously with temperature of coolant, but does not reach operating temperature (80°C opening temperature of thermostat). - Conclusion: - Thermostat blocked in partially open or completely open state. - Sealing ring of thermostat defective. - Control: - Thermostat got stuck in open or closed position.

  • Page 214: Component Checks Of Engine Cooling System

    Cooling System 05.00.06 Component checks of engine cooling system 1. Hoses and clamps, drain plug etc. For all models: no special tool required. Control works: Check all external components of cooling system for leakage, wear and damages. Check all connections for tightness. Check hoses for cracks, breaks or wear. Repair works: Repair or exchange 2.
  • Page 215 Cooling System 3. Water pump (coolant circulating pump) No special tools required. Control works: If with running engine leakage at the pump housing relief bore is noticed, the slide- ring seal may be worn out or damaged inside the pump. To repair this damage the entire pump must be replaced.
  • Page 216 Cooling System 5. Coolant loss in engine cooling system 5.1 Coolant loss: Control works: - (item 4) check cooler cap - defective monoblock (due to combustion pressure, gases enter the engine cooling system). 5.2 Gas-air mixtures enter the cooling system. 5.2.1 - Defective monoblock This fault only can be stated with using special tool VR 00147/0 (test equipment for CO²...

  • Page 217: Drain The Coolant From Engine

    Cooling System 05.00.07 Drain the coolant from engine To drain the closed cooling circuit, lift or lower the engine in such a way that the engine is in horizontal position, which permits an ideal drainage of engine block. ATTENTION: Approx. 1 litre of coolant will remain in the engine block which is to be considered for refilling.

  • Page 218: Fill Cooling System (Example)

    Cooling System 05.00.08 Fill cooling system (Example) Closed cooling system 1. Fill cooling circuit with specified coolant (SMO Z011785/0)) only. Coolant level should reach the lower edge of the filler neck in the expansion tank, refer to vehicle manufacturer specification. NOTE: Cooling system purges automatically while filling.

  • Page 219: Exchange Thermostat

    Cooling System 05.03.02 Exchange thermostat Preparation: Drain closed cooling circuit refer to 05.00.02.01 Loosen both hose clamps at thermostat housing and pull off both coolant hoses. DISASSEMBLY: 1. Loosen 3 Allen screw M6 holding the thermostat housing. Remove thermostat housing including thermostat. 2.

  • Page 220: Replace Coolant Supply Manifold

    Cooling System 05.03.03 Replace coolant supply manifold Preparation: Drain closed cooling circuit refer to 05.00.02.01 Loosen both hose clamps at thermostat housing and pull off both coolant hoses. Disconnect battery. Disassemble control solenoid, 03.08. 1. Loosen 3 hex head screws (SW10) at bracket.

  • Page 221: Coolant Pump

    Cooling System 05.04 Coolant Pump 05.04.01 Exchange coolant pump Preparation: Remove poly-V-belt remove timing belt, see 01.00.02 drain closed cooling system, refer to 05.00.02 1. Loosen 3 hex flangebolts M8x25 (SW) and remove hoses from front cover. 2. Loosen 3 pcs M8 hexagon head screws one pc M8 Allen screw and one pc M6 Allen screw at coolant pump housing.
  • Page 222 Cooling System 5. Loosen 3 Hex screws (M8x25). 6. Remove Cooling Pipe 7. Loosen 3 Hex screws M8x30, one Nut M8 and two hex socket head cap screws (M6x60, M6x30). Z001138-1_2013-02-01 16/21...
  • Page 223 Cooling System 8. Extract coolant water pump by hand. 9. Put off the gasket. 10. All parts of water pump. 17/21 Z001138-1_2013-02-01...

  • Page 224: Install Coolant Pump

    Cooling System 05.04.02 Install coolant pump 1. Clean and grease sealing surfaces on water pump and on engine block. 2. Put on new gasket (ill.2/pos.1). 3. Align water pump on engine block. Mount screws and tighten with standard torque for its size.
  • Page 225 Cooling System 9. Place gasket. 10. Place coolant water pump. 11. Fix coolant water pump with 3 hex head screws M8x30, one hex nut M8 and two hex socket head cap screws(M6x60, M6x30). 19/21 Z001138-1_2013-02-01...
  • Page 226 Cooling System Preparation: Loosen Poly V-Belt, Drain Water All parts of raw water pump: Change Impeller: Disassemble: 1. Loosen 3x hex socket head cap screws M8x25 (SW?????) 2. Put off Water Pump Assembly 3. Loosen 6x hex head screws M4x8 SW 4.
  • Page 227 Cooling System Change Pulley Disassemble: 1. Loosen 3x hex socket head cap screws M8x16 (SW?????) 2. Pull off pulley Assembly is done in reverse order 21/21 Z001138-1_2013-02-01...
  • Page 228 Electrical System 06 Electrical Systems Table of Contents 06.00 General ..................5     06.01 Generator ..................6     06.01.01 Exchange / Replace Alternator ............6     06.02 Starter motor ................10     06.02.01 Replace starter motor ..............10  ...
  • Page 229 Electrical System   06.10 Actor and Sensor ............... 35     06.10.01 Component configuration engine ..........35     06.10.03 Calibration of rack position ............36     06.10.04 Replace senders, sensors ............38     06.10.04.01 ACT - Air charge temperature sensor, B07 ....38  ...
  • Page 230 Electrical System Items to Check / Troubled Systems Electrical System [Factors/Cause of Trouble] • • • Overdischarge of battery Connection failure • • • low battery Capacity • • • • Defective Key Switch • • • Emergency Cut Off Switch •...
  • Page 231 Electrical System Z001138-1_2013-02-01 4/47...

  • Page 232: General

    Electrical System 06.00 General Wiring For the STEYR Marine Engines wiring and plug connections have been designed according to standard DIN 72 552. In case of necessary repair of a cable connection, take special care that cable quality, isolation, crimping, strand end soldering of cable sockets as well as protective varnish iso lation and/or connector locks meet the respective requirements.

  • Page 233: Generator

    Electrical System 06.01 Generator 06.01.01 Exchange / Replace Alternator All parts of alternator Remove Alternator: 1. Disconnect the wiring cables (SW8/SW10/SW13) 2. Loosen hex head screw M10x80 (SW17) Z001138-1_2013-02-01 6/47...
  • Page 234 Electrical System 3. Loosen hex head screw M10x100 (SW17) Assembly is done in reverse order Funktionsbeschreibung: Artikelnummern + Übersetzungsverhältnis 7/47 Z001138-1_2013-02-01...
  • Page 235 Electrical System Z001138-1_2013-02-01 8/47...
  • Page 236 Electrical System 9/47 Z001138-1_2013-02-01...

  • Page 237: Starter Motor

    Electrical System 06.02 Starter motor 06.02.01 Replace starter motor 1. Disconnect battery. 2. Loosen terminal +30 (battery main cable) on magnetic switch by means of SW13. 3. Remove start signal wiring (terminal 50) from blade terminal resp. M4 screw (depending on model). 4.
  • Page 238 Electrical System 11/47 Z001138-1_2013-02-01...

  • Page 239: Check Starter Motor (Principal Example)

    Electrical System 06.02.02 Check starter motor (principal example) Beschreibung neu für permanent magnet starter  steinek Trouble features Cause Relief When switching on battery discharged and/or charge battery and/or replace the starter (actuation defective of starter key), starter shaft not turning or terminals of starter battery are clean terminals and tighten, only slowly;...
  • Page 240 Electrical System armature not turning; bearings of starter pinion clean bearing surfaces and starter not engaging soiled slightly oil them starter keeps on starter not interrupting; starter immediately turn off ignition, running after starter key, starter relay, actuating immediately disconnect key was released relay (on starter) defective battery;...

  • Page 241: Cables, Wiring Harness - General

    Electrical System 06.05 Cables, Wiring Harness – General Cable / wiring In case of necessary repair of a cable connection, take special care that cable quality, isolation, crimping, strand end soldering of cable sockets as well as protective varnish isolation and/or connector locks meet the respective requirements.

  • Page 242: Engine Harness

    Electrical System 06.05.02 Engine harness Device Designation Component Description connector 80-pole-plug M1CU 3-pole-plug Rack Position Sensor 3-pole-plug Injection Timing Position Sensor 3-pole-plug Speed Sensor 3-pole-plug Manifold Absolute Pressure Sensor 3-pole-plug Lubricant Pressure Sensor 2-pole-plug Engine Coolant Temperature Sensor 2-pole-plug Air Charge Temperature Sensor 2-pole-plug Exhaust Temperature Sensor 6-pole-plug...
  • Page 243 Electrical System Device Designation Component Description connector 20 Amp  VBATT 25 Amp  Fuel Pump 20 Amp  M1CU3 50 Amp  Glow Plugs 50 Amp  Glow Plugs 12,5 Amp  Alternator 3-pole-plug Alternator 4-pole-plug Main Relay 4-pole-plug Fuel Pump Relay 4-pole-plug Glow Plug Relay...

  • Page 244: Wiring Diagram - E-Box Wiring Diagram 2181123-0

    Electrical System 06.05.03 Wiring Diagram – E-Box Wiring Diagram 2181123-0 17/47 Z001138-1_2013-02-01...

  • Page 245: Wiring Diagram - E-Box Wiring Diagram 2181134-0

    Electrical System 06.05.04 Wiring Diagram – E-Box Wiring Diagram 2181134-0 Z001138-1_2013-02-01 18/47...

  • Page 246: Wiring Diagram - External E-Box Diagram 2181141-0

    Electrical System 06.05.05 Wiring Diagram – External E-Box Diagram 2181141-0 19/47 Z001138-1_2013-02-01...

  • Page 247: Wiring Instrument Harness / Marine

    Electrical System 06.05.06 Wiring Instrument Harness / Marine NOTE: For power supply harness to instruments, protecting circuits, fuses and relays, please consult marine manufacturer. Z001138-1_2013-02-01 20/47...
  • Page 248 Electrical System Glow Plug Lamp The GPL shall be turned on when the glow plugs are on before cranking or when the oil pressure drops below the level defined by SMO or Lubricant Pressure Sensor is defective (GPL shall blink with 1Hz). At ignition on, the lamp shall be turned on for approx.

  • Page 249: Warning And Parameter Limits From Engine Management System

    Electrical System 06.05.07 Warning and Parameter Limits from Engine Management System Actual Software Status January 2013 V50000.10C ECT- Characteristic Parameter (TBTLim) Note: Current Value: Limiting starts app. 105°C; Values may get changed during course of development Z001138-1_2013-02-01 22/47...

  • Page 250: Description To Circuit Diagram

    Electrical System 06.06 Description to circuit diagram Designation Description Air charge temperature Controller area network +- GND Cruise control conn. Check engine lamp Crank indicator Diagnostic in / out DIAG Engine coolant temperature Fuel metering solenoid Fuel pump relay Fuel Supply Pressure GND_REF Sensor - Earth Earth...

  • Page 251: Electronics - General

    Electrical System TACHO Tachometer drive signal TEMP Temperature gauge drive Battery voltage (Terminal 30) VBAT VPROT Protected battery voltage VREF Reference voltage Variable turbo geometry Exhaust gas temperature probe MET (T30) Manifold Exhaust Temperature sensor BARO (P0) Absolute Ambient Pressure Sensor 06.07 Electronics –...

  • Page 252: Electronic Engine Management System

    Electrical System 06.07.01 Electronic engine management system The STEYR marine engine is equipped with an Electronic Management System (EMS) that performs the following: * controls engine functions to ensure maximum efficiency. * self-diagnostic to protect the engine from damage if operating parameter are exceeded.

  • Page 253: Diagnostic System

    Electrical System 06.07.02 Diagnostic system The electronic engine management system controls the following parameters: Oil pressure, boost pressure, coolant temperature, air charge temperature, exhaust temperature. The electronic engine management system has an automatic self-test program checking all data of electronic sensors. As soon as a fault is found, there is an optical or audible signal (refer to chart "Service Codes").

  • Page 254: Principle Service Code Table

    Electrical System 06.07.03 Principle service code table NOTE: Some codes may not apply due to different application! DTC List / Error Code List - SE Engines V50000.10D Dec. Hex. ABBREV. INVOLVED DEVICE POSSIBLE CAUSE Variable Limits VTGHBRIDGE_E-MIN Turbocharger output control signal voltage too low, possible short circuit to ground (X25) VTGHBRIDGE_E-MAX Turbocharger output control signal voltage too high, possible short circuit to battery (X25) Barometric Pressure...
  • Page 255 Electrical System DTC List / Error Code List - SE Engines V50000.10D Dec. Hex. ABBREV. INVOLVED DEVICE POSSIBLE CAUSE Variable Limits RPOS_E-MAX Rack Position Sensor signal voltage too high, possible short circuit to battery (B1) 1020 cnts 4,985 V AdcCountRPOS_u16 RPOS_E-MIN Rack Position Sensor signal voltage too low, possible short circuit to ground...
  • Page 256 Electrical System DTC List / Error Code List - SE Engines V50000.10D Dec. Hex. ABBREV. INVOLVED DEVICE POSSIBLE CAUSE Variable Limits Position Sensor Injection Timing Device 4098 1002 ITP_E-MAX signal voltage too high, possible short circuit to battery (B2) 1000 cnts 4,888 V Position Sensor <20/>1000...
  • Page 257 Electrical System 06.07.10 Explanations of the “BLimDiag” – “Bit” to limit Beta _max. BLDqm BETA_max limited on max. Injection Quantity Table (FN_QM) BLDact BETA_max limited by Air Charge Temperature (TBACT) BLDla BETA_max limited on insufficient boost pressure at given load & speed (TBLA*TBACT) Note: During transient driving condition BLimDiag parameter must be ignored because this “Bit”...

  • Page 258: Configuration Engine Ecu-M1Cu3 With Connector A1

    Electrical System 06.07.11 Configuration engine ECU-M1CU3 with connector A1 Use Special Tool Nr. 2301446-0 for measurements. Designation Explication VRACK Hi Side Protected Output RES2 High Current Output RPOS Rack Position Input PT200 Temperature Senor Input Analogue Input PullUp / Down PF20 Analogue Input PullUp / Down NTC Input...
  • Page 259 Electrical System Designation Explication VREF3 5V Analogue Voltage Reference VREF2 5V Analogue Voltage Reference Analogue Input PullUp / Down C_OI Analogue Input PullUp / Down Overside Analogue Input PullUp / Down ------------------ -------------------------------------------------------------------- NFIX2 NTC Input ------------------ -------------------------------------------------------------------- ------------------ -------------------------------------------------------------------- HYB_A1 High Current Output Me / Hi Current Output...

  • Page 260: Potentiometer Accelerator And Voltage Regulator

    Electrical System 06.08 Potentiometer Accelerator and Voltage regulator 06.08.01 Potentiometer Accelerator 2180847-0, B09 33/47 Z001138-1_2013-02-01...

  • Page 261: Voltage Regulator 24V-12V Equalizer 2179789-0

    Electrical System 06.08.02 Voltage regulator 24V-12V equalizer 2179789-0 löschen 2176897-0 DC-DC converter 24/12 Power supply to equalizer recommended wire gauge size. Starter must be connecting by customer use a wire min. AWG 0 (50 mm²) connect a red wire AWG 8 (6 mm²) at battery "A" positive terminal +12V connect a red wire AWG 6 (10 mm²) at battery "B"...

  • Page 262: Actor And Sensor

    Electrical System 06.10 Actor and Sensor 06.10.01 Component configuration engine 35/47 Z001138-1_2013-02-01...

  • Page 263: Calibration Of Rack Position

    Electrical System 06.10.03 Calibration of rack position This procedure must be carried out if any of the following has been done: - Control solenoid has been disassembled or replaced, refer to 03. 08. 01. - Rack position sensor has been disassembled or replaced, refer to 03. 08. 03. - Engine control unit has been replaced.
  • Page 264 Electrical System Turn Ignition “OFF” when eccentric shaft is at correct position (Ill 4) 4. Turn “ON” ignition switch (min. 20 seconds). NOTE: With fixed rack, rack position will be automatically stored by ECU-M1CU3. Storage process will take approx. 20 sec. 5.

  • Page 265: Replace Senders, Sensors

    Electrical System 06.10.04 Replace senders, sensors 06.10.04.01 ACT - Air charge temperature sensor, B07 1. Unscrew temperature sensor (SW19) Grease O-rings before replacing sensor. 06.10.04.02 ECT - Engine Coolant temperature sensor, B06 Preparation: Drain the coolant system 1. Remove plug housing. 2.

  • Page 266: Map - Manifold Absolut Pressure Sensor, B04

    Electrical System 06.10.04.04 MAP – Manifold Absolut Pressure Sensor, B04 1. Pull off plug by turning counterclockwise. 2. Loosen sensor (SW27). Remove sensor. Assembly is done in reverse order off disassembly. For replacing the sensor use LOCTITE 243. 06.10.04.05 RPos - Sensor for rack position, B01 1.

  • Page 267: Itp - Injection Timing Position Sensor, B02

    Electrical System 06.10.04.08 ITP – Injection Timing Position Sensor, B02 1. Remove plug from sensor. 2. Loosen 2 hexagon nuts, remove sensor. 3. Don’t forget the washers 06.10.04.09 ITV – Ignition Timing Valve, Y2 1. Remove intake manifold, refer 01. 08. 01. 2.

  • Page 268: Met- Manifold Exhaust Temperature Sensor X21

    Electrical System 06.10.04.011 FDS-Fuel density Sensor  included in Kit Fuel Compensation MS1205010 1. Remove plug from sensor. 2. Unscrew Fuel density Sensor M14x1.5 (SW30) and remove sensor. NOTE: Use only in combination with MET Software-version: min. V50000.10D Tighten with a torque of 27Nm +/-3 Renew o-ring &...

  • Page 269: T2- Compressor Outlet Temperature Sensor

    Electrical System 06.10.04.014 T2- Compressor Outlet Temperature Sensor 1. Remove plug from sensor. 2. Unscrew Compressor Outlet Temperature Sensor box nut M14x1.5 and remove sensor. 06.10.04.015 EXT – Exhaust Gas Temperature Sensor 1. Remove plug housing. 2. Unscrew Exhaust Gas Temperature Sensor (SW 17).

  • Page 270: Connectors, Helpful Hints

    Electrical System 06.10.05 Connectors, helpful hints Pulling lightly on the wire after it is snapped in place will assure the contact is locked. A contact removal tool taped or tie wrapped to the harness will make it easily available should repairs be needed. Tie wraps and tape away from the rear of the connector will allow the wire to be sealed properly.

  • Page 271: Connectors, Assembly Instructions

    Electrical System 06.10.06 Connectors, assembly instructions Contact insertion Grasp contact Hold connector with rear Push contact straight into approximately (25,4mm) grommet facing you. connector grommet until a one inch behind the positive stop is felt. A slight contact crimp barrel. NOTE: For unused wire tug will confirm that it is cavities, insert sealing...
  • Page 272 Electrical System Contact insertion Grasp contact approximately Hold connector with rear Push contact straight into (25,4mm) one inch behind grommet facing you. connector grommet until a the contact crimp barrel. positive stop is felt. A slight tug will confirm that it is properly locked in place.

  • Page 273: Battery

    Electrical System 06.12 Battery Battery - Acid Test (when using Acid batteries!) The battery provides the starter engine with energy and supplies the required voltage for lighting and other electrical equipment when the engine is not running. During the starting procedure and when the generator does not generate any current, the battery provides the electronic engine management system with voltage.
  • Page 274 Electrical System 2. The battery should always be charged as full as possible. Regularly check the state of charge with the battery acid tester. We recommend checking the acid density and acid level periodically every two weeks. If the density is 0.04 kg/dm³ below the value of full charge, the battery is to be removed and recharged.

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