Page 1 STEYR MARINE ENGINES 4 CYLINDERS 4 CYLINDERS + 6 CYLINDERS + 6 CYLINDERS SERVICE MANUAL P/N Z001019/0 Edition July 2008 www.steyr-motors.com STEYR MOTORS GmbH Im Stadtgut B1, A-4407 Steyr-Gleink, AUSTRIA...
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Page 3 PREFACE STEYR MOTORS GmbH has developed high-performance diesel engines with modulated high- pressure direct injection, especially for the marine environment. STEYR marine engines are designed to be adapted to various propulsion systems. SERVICE MANUAL This is published with the main intention -...
Page 4: Z001019/0_6_July
STEYR marine engine or every sold boat with a built-in STEYR marine engine. Part 1 (Warranty Registration Card) is to be handed over to the customer, part 2 (Dealer Record Card) remains with the dealer and part 3 is to be sent to the After Sales Service of STEYR MOTORS GmbH.
Page 5 TABLE OF CONTENTS (MAIN ASSEMBLY GROUP ENGINE) GENERAL ENGINE COUPLING FUEL SYSTEM EXHAUST SYSTEM COOLING SYSTEM ELECTRICAL EQUIPMENT Z001019/0_6_July 2008...
Page 6 Components Engine 01.00 01.01 01.02 Engine timing, Cylinder block Chrankshaft engine mount bearing, vibration damper 01.03 01.04 01.05 Flywheel, Piston, Chamshaft, housing connection rod housing, valve drive 01.06 01.08 01.09 Engine housing, Intake manifold, Auxiliary drive-PTO oil pump, intercooler oil suction pipe 01.13 01.14 Engine oil cooler,...
Page 7 Cooling system 05.01 05.03 05.04 Cooler, Pipes, Coolant pump heat exchanger, thermostat expansions tank 05.10 05.11 Raw water pump, Raw water pump, side mounted front mounted Electrical 06.01 06.03 06.05 system Generator, Starter motor Engine harness alternator 06.06 06.07 06.10 EMS, E-box, Instrument panel, Sender, sensor...
Page 8 VERSIONS OF MANUAL Version Date Modification 01. 10. 2000 new edition 01. 06. 2002 release typ 164, 246 01. 07. 2005 release typ 256 01. 07. 2007 modification 01. 03. 2008 modification 01. 07. 2008 modification Z001019/0_6_July 2008...
Page 9: Table Of Contents
A 3.2 Model summary 6 cylinder engines ............Technical Data and Overview ..............12 A 4.1 Technical Data and Overview 4 cylinder engines........12 A 4.2 Technical Data and Overview 6 cylinder engines........16 Specifications ..................20 Fuel Requirements ................. 20 Motor oil ....................
Page 10 SERVICE MANUAL MARINE ENGINES GENERAL Measures in case of accidents ..............43 Thightening Torques ................44 Listing of Thightening Torques ..............44 General Tightening torques ..............49 Testing of torque wrench ................50 Non-destructive material testing ............... 50 Use of adhesive and sealing materials ............. 50 Solvent-free sealing materials ..............
Page 11: Ageneral Remarks
SERVICE MANUAL MARINE ENGINES GENERAL GENERAL REMARKS Model and Serial Numbers The primary model and serial number (ill.1 or ill.2) is located on the engine as illustrated. These numbers are required for warranty claims and ordering parts. FOR ALL FOR ALL 4 CYL.
Page 12: A 2 Documentation
P/N Z 001022/0 tool catalogue for all marine engines P/N Z 001002/1 spare parts catalogue STEYR 94 td diesel marine P/N Z 001023/0 STEYR 144 vti/td diesel marine P/N Z 001005/0 STEYR 164 td diesel marine...
Page 13: A 3 Model Summary
SERVICE MANUAL MARINE ENGINES GENERAL Modell summary A 3.1 Modell summary 4 cylinder engines Bobtail - Version Equipment: with side mounted raw water pump or, with side mounted raw water pump, power steering pump 03.01 ill.1 Inborder i.e. ZF 45 Marinegear Down angle 03.01 ill.2...
Page 14 SERVICE MANUAL MARINE ENGINES GENERAL Lifeboat Engine Equipment Bobtail "B" 03.01 ill.4 Direkt gearbox 03.01 ill.5 A-down angle gear box 03.01 ill.6 Parallel offset gearbox 03.01 ill.7 Page GENERAL-6 Z001019/0_8_Octobre 2011...
Page 15 SERVICE MANUAL MARINE ENGINES GENERAL Jet Drive TYPE Alamarin Hamilton Castoldi 03.01 ill.8 03.01 ill.9 03.01 ill.10 Stern Drive TYPE Mercury Alpha Bravo I, II & III Volvo DP 290 Volvo DP 290 Hydraulic 03.01 ill.11 SX - Stern Drive Z001019/0_8_Octobre 2011 Page GENERAL-7...
Page 16: A 3.2 Model Summary 6 Cylinder Engines
SERVICE MANUAL MARINE ENGINES GENERAL A 3.2 Modell summary 6 cylinder engines Bobtail - Version with side mounted raw water pump or, with side mounted raw water pump, power steering pump and front mounted auxiliary drive-PTO 03.02 ill.1 Inborder i.e. ZF 63 Marine gear Down angle 03.02 ill.2 03.02 ill.3...
Page 17 SERVICE MANUAL MARINE ENGINES GENERAL Transmission i = 2.5V, shaft angle 12° i = 2.0V, shaft angle 12° 03.02 ill.4 Lifeboat Engine Equipment Bobtail "B" 03.02 ill.5 Direkt gearbox 03.02 ill.6 A-down angle gear box 03.02 ill.7 Parallel offset gearbox 03.02 ill.8 Z001019/0_8_Octobre 2011 Page GENERAL-9...
Page 18 SERVICE MANUAL MARINE ENGINES GENERAL Jet drive 03.02 ill.9 Jet Drive TYPE Alamarin Hamilton 03.02 ill.10 Castoldi 03.02 ill.11 Stern drive Type Mercury Bravo II & III Volvo DP 290 Stern Power Drive 03.02 ill.12 Volvo DP 290 ZF Hydraulic Pump Volvo SX - Drive King Cobra Drive Page GENERAL-10...
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Page 20: Technical Data And Overview
STEYR MOTORS engine coolant - 36 C° P/No. Z011785/0 extended periods to be evaluated upon application and type of usage STEYR MOTORS GmbH. reserves the right to make changes without notice or obligations. Efficiency of gearbox = 97,0%, efficiency of Z-drive = 95,5% Page GENERAL-12...
Page 21 SERVICE MANUAL MARINE ENGINES GENERAL Overview for all STEYR 4 Cyl. Marine Engines Item Designation Zinc Anode (4 Units) Model and Serial Number Intercooler Fuel/Oil Cooler with Raw Water Drain Plug Fuel Pump Oil Seperator Raw Water Drain Plug Valve Crankshaft Housing Ventilation...
Page 22 STEYR MOTORS engine coolant - 36 C° P/No. Z011785/0 extended periods to be evaluated upon application and type of usage STEYR MOTORS GmbH. reserves the right to make changes without notice or obligations. Efficiency of gearbox = 97,0%, efficiency of Z-drive = 95,5% Page GENERAL-14...
Page 23 SERVICE MANUAL MARINE ENGINES GENERAL Overview for all STEYR 4 Cyl. Marine Engines Item Designation Zinc Anode (4 Units) Model and Serial Number Intercooler Fuel/Oil Cooler with Raw Water Drain Plug Fuel Pump Oil Seperator Raw Water Drain Plug Valve Crankshaft Housing Ventilation...
Page 24: A 4.2 Technical Data And Overview 6 Cylinder Engines
STEYR MOTORS engine coolant - 36 C° P/No. Z011785/0 extended periods to be evaluated upon application and type of usage STEYR MOTORS GmbH. reserves the right to make changes without notice or obligations. Efficiency of gearbox = 97,0%, efficiency of Z-drive = 95,5% Page GENERAL-16...
Page 25 SERVICE MANUAL MARINE ENGINES GENERAL Overview STEYR MO126M28, MO166K28, MO196K35, MO236K42 Item Designation Boost Pressure Sensor Zinc Anode (5 Units) Intercooler Fuel- / Hydr. Oil Cooler Engine Oilcooler Model and Serial Number Oil Seperator Raw Water Drain Plug Valve Crankshaft Housing Ventilation...
Page 26 STEYR MOTORS engine coolant - 36 C° P/No. Z011785/0 extended periods to be evaluated upon application and type of usage STEYR MOTORS GmbH. reserves the right to make changes without notice or obligations. Efficiency of gearbox = 97,0%, efficiency of Z-drive = 95,5% Page GENERAL-18...
Page 27 SERVICE MANUAL MARINE ENGINES GENERAL Overview STEYR MO256K43, MO256H45 Item Designation Boost Pressure Sensor Zinc Anode (5 Units) Intercooler Engine Oil / Fuel / Hydr. Oil Cooler Model and Serial Number Oil Seperator Raw Water Drain Plug Valve Crankshaft Housing Ventilation (only...
Page 28: B Specifications
Specifications Fuel Requirements The STEYR Marine Engines are designed for maximum fuel economy. To maintain optimum performance use diesel fuel according to CEC RF-03-A-84 or equivalent to meet this specification. When temperatures are below -7° C (20° F), use diesel fuels with additives for low temperature operation.
Page 29: B 2 Motor Oil
SYNTHETIC OIL 10W-40 Recommended engine oil: STEYR TURBO DIESEL ENGINE OIL - SAE 10W-40 SMO No. Z010058/0 Initial factory fill is a high quality break-in oil specified ACEA B4 - 02, SAE 5W-50. During the break in period (20 hours), frequently check the oil level. Somewhat higher oil consumption is normal until piston rings are seated.
Page 30: C Maintenance And Service
SERVICE MANUAL MARINE ENGINES GENERAL Maintenance and Service 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. Failure to do so could result in fire.
Page 31 SERVICE MANUAL MARINE ENGINES GENERAL Trouble Check Chart - continued SYMPTOM POSSIBLE CAUSE ACTION Engine vibrates Propeller condition Check for bent, broken, or damaged propeller Check for weeds on propeller or sterndrive gearcase. Check for bent propeller shaft. Unit injector Check.
Page 32: C2 Service- And Maintenance Schedule
SERVICE MANUAL MARINE ENGINES GENERAL after first every every C2 Service- and Maintenance Schedule 50 hours 150 h. 300 h. daily *) notes or 6 or 12 or 24 months months months ENGINE check - for leakage LUBRICATION - oil level change - oil filter - motor oil...
Page 33 - oil level specification SAFETY check - remote control local rules EQUIPMENT - emergency cutout and consultation - completeness of your STEYR - condition Marine Dealer SHAFT BEARING check - lubrication consult STEYR GLAND - sealing Marine Dealer ENGINE MOUNT...
Page 34: General Information
GENERAL General Information 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 35: Diagnostic System
70° deg. angle switched ON until ignition reset During break in phase See information break Cel-ON at high Indication light Steyr Diag in procedure accelerator "CEL" is switched Break-in position (more phase than 75%) Optical and accustical warning signals are explained on the following tables.
Page 36: D 3 Extended Storage Preservation Procedure
SERVICE MANUAL MARINE ENGINES GENERAL Extended Storage Preservation Procedure: Use following kit-numbers to have the necessary equipment for an appropriate preservation: Preservation- Service Kit art.nr.Z021003-0 (valid for all 4 and 6 cylinder Marine engine models) Preservation- Service Kit art.nr. Z021004-0 (valid for all 4 and 6 cylinder Marine engine models) Remove the engine from storage and place on a suitable work shop area with access to all sides of the...
Page 37 2) COMMISSIONING REPORT (to find under: Installation Manual Z001007/0 / chapter 19. APPENDIX) Ensure notification in above documents for approval of extended STEYR MOTORS BASE ENGINE WARRANTY. Otherwise BASE ENGINE WARRANTY will end for PLEASURE /COMMERCIAL duty after 1 year starting from STEYR MOTORS manufacturing date.
Page 38 Made by: Made by: (36 months). Date: Date: Date: 600 h Service rvice 750 h Service After 3 years stocking, starting from STEYR Made by: Made by: Made by: MOTORS manufacturing date (see ill. 6), engine Date: Date: Date: Date:...
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Page 40: D 4 Engine Break-In Procedure
SERVICE MANUAL MARINE ENGINES GENERAL 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 If necessary, add oil (DO NOT OVERFILL). In case that the oil pressure control lamp still illuminated with correct oil level, have the engine checked by your STEYR Marine dealer as to malfunction of signal or oil pump. NOTE: During normal operation of engine, oil pressure will rise as RPM increases and fall as RPM decreases.
Page 42: D 5 Operation After Break-In
12 running hours. Economic driving may be achieved at the following speeds: M084K32 3000 rpm. M094K33 3000 rpm. M0114K33 3000 rpm. M0144M38 + BUKH STEYR SOLAS 3200 rpm. M0144V38 + BUKH STEYR SOLAS 3200 rpm M0164M40 + BUKH STEYR SOLAS 3400 rmp M0126M28 2200 rpm...
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Page 44: E Quality Gudelines For Repair
* Operation in very muddy water Only use genuine STEYR MARINE spare parts in order to avoid possible loss of performance. For this reason you should insist on the famous quality of genuine STEYR MARINE spare parts and under no circumstances use spare parts of unknown quality.
Page 45: E 3 Nomenclature
SERVICE MANUAL MARINE ENGINES GENERAL Nomenclature Term Description Example disassemble Removal of an assembly of a main assembly or of a component remove of an assembly without other assemblies having been removed unscrew before deflange dismantle assemble put on, place Putting on of an assembly on a main assembly or a component screw on of an assembly without further assemblies being put on...
Page 46: E 4 Si- System
SERVICE MANUAL MARINE ENGINES GENERAL SI- System The following measuring units are used. Linear Pressure and Stress kilometer meter pascal millimeter Kilopascal " inch N/mm newton per square millimeter Area Energy square meter Joule square centimeter kW/h kilowatt hour Volume Power cubic meter kilowatt...
Page 47: E 5 Abbreviations
SERVICE MANUAL MARINE ENGINES GENERAL Abbreviations ill. illustration copper MAssy main assembly max. maximum top dead center (POWER TAKE OFF) power transmission at front crankshaft end wrench size Electronic Management System Electronic Control Unit Z001019/0_8_Octobre 2011 Page GENERAL-39...
Page 48: F Operating Material And Information On Disposal
Qty. Designation VR00207/0 set of fuel and oil for engine service, consisting of: Z010058/0 - STEYR Turbo Diesel motor oil SAE 5W-50 (4l. can.) Z011785/0 - STEYR MOTORS engine coolant (5l. can.) 9000190/0 - hydraulic oil ATF (1l. bottle) Z012222/0 - grease, Never - Seez;...
Page 49: F 2 Disposal Of Automotive Waste Products
SERVICE MANUAL MARINE ENGINES GENERAL 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. The "Special Waste Catalog"...
Page 50: Gnotes On Safety
SERVICE MANUAL MARINE ENGINES GENERAL NOTES ON SAFETY 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 (Maschinen-Sicherheitsverordnung - MSV) are not subject of this chapter.
Page 51: G 4 Safety In The Use Of Operating Material
SERVICE MANUAL MARINE ENGINES GENERAL Safety in the use of operating material Dangerous operating material, 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 52: H Thightening Torques
SERVICE MANUAL MARINE ENGINES GENERAL Tightening Torques 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 53 SERVICE MANUAL MARINE ENGINES GENERAL Flywheel screws (use LOCTITE 243 on thread) 75 Nm +/- 4 08.01 ill.5 Vibration damper screws (apply oil to thread and screwhead support) 135 Nm (2x) +/- 7 08.01 ill.6 Screw, rear ring carrier (use LOCTITE 243 on thread) 1.
Page 54 SERVICE MANUAL MARINE ENGINES GENERAL Screw tooth, belt tensioner 45 Nm +/- 4 08.01 ill.9 Valve adjustment element 55 Nm +/- 3 08.01 ill.10 Screw, linkage lever CAUTION: left-hand thread 7 Nm +/- 0,5 08.01 ill.11 Stud, unit injector 21 Nm +/- 2 08.01 ill.12 Page GENERAL-46 Z001019/0_8_Octobre 2011...
Page 55 SERVICE MANUAL MARINE ENGINES GENERAL Collar nut for unit injector 18 Nm - 2 08.01 ill.13 Nut, adjustment screw of unit injector 30 Nm +/- 3 08.01 ill.14 Plug screw for control rack in camshaft housing 50 Nm +/- 5 08.01 ill.15 Screw, exhaust manifold 23 Nm +/- 2...
Page 56 SERVICE MANUAL MARINE ENGINES GENERAL Studs, turbocharger M8 - 23 Nm +/- 2 M10 - 35 Nm +/-2 Nut, turbocharger (greased with NEVER SEEZ ) M8 - 25 Nm +/-2 M10 - 45 Nm +/-2 08.01 ill.17 Screws, intercooler 28 Nm +/- 2 08.01 ill.18 Plug screws, zinc anode 50 Nm +/- 5...
Page 57: General Tightening Torques
SERVICE MANUAL MARINE ENGINES GENERAL General Tightening torques Values in this table refer to industrial standard and are applicable, if no specific torques are are indicated. For studs, tightening torques are to be reduced by 50%. µ tot. *) 0.100 µ...
Page 58: H 3 Testing Of Torque Wrench
SERVICE MANUAL MARINE ENGINES GENERAL 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. Non-destructive material testing For the detection of surface cracks, the non-destructive test according to colour penetration test procedure is recommended.
Page 59 SERVICE MANUAL MARINE ENGINES GENERAL 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. Thread bores are recut with the appropriate thread bore and blown out with compressed air.
Page 60: J Wear Limits
SERVICE MANUAL MARINE ENGINES GENERAL Wear Limits New part tolerance Wear Limit Remark Part resp. part union Main bearing clearance radial 0,032 - 0,099 0,15 0,080 . 0,263 0,30 Main bearing clearance axial 0,024 - 0,073 0,10 Connect.rod bearing clear. radial 0,064 - 0,217 0,50 Connect.rod bearing clear.
Page 61: J 1 Adjustment Information For Service And Maintenance
SERVICE MANUAL MARINE ENGINES GENERAL Adjustment information for service and maintenance J 1.1 Engine timing (measured with dial indicator No. 2300899/0) Setting instruction: 3,20 +/- 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.
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Page 63 SERVICE MANUAL MARINE ENGINES 01 ENGINE 01 ENGINE Table of Contents 01.00 Engine timing, engine mount ................. 3 01.00.01 Lock crankshaft ....................3 01.00.02 Exchange camshaft housing cover sealing ............6 01.00.03 Maintenance timing-belt exchange ..............7 01.00.04 Remove timing belt................... 15 01.00.05 Timing adjustment procedure for dismantled engine ........
Page 64 SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.06 Engine housing, oil pump, oil suction pipe ..........63 01.06.01 Replace engine housing .................. 63 01.06.02 Replace support ring rear ................. 70 01.06.03 Replace rear radialshaft sealing ring ..............71 01.06.04 Replace oil pump (front ring carrier) ..............72 01.06.05 Replace oil suction pipe ..................
Page 65: Engine Timing, Engine Mount
SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.00 ENGINE TIMING, ENGINE MOUNT 01.00.01 Lock crankshaft Preparation: Put engine out off operation Disconnect battery Remove camshaft housing cover, 01.00.02 Special tool: for vibration damper screws No. 2300767/0 Locking pin No. 2300551/2 00.01 ill.1 Unscrew allen head plug screw (ill.1) (SW 10).
Page 66 SERVICE MANUAL MARINE ENGINES 01 ENGINE Continue to turn crankshaft slowly manually in direction of rotation until locking pin engages into slot of crankshaft. ATTENTION: Never actuate starter engine as long as locking pin is inserted. 00.01 ill.5 Removal of locking pin Pull out locking pin 2300551/2.
Page 67 SERVICE MANUAL MARINE ENGINES 01 ENGINE Explanation: (for engine timing) If the crankshaft has been locked in position as described (piston; cylinder; in TDC), the following positions are to be found in case of correct adjustment. The bearing roller of the rocker arm on cyl. 1 is located just before the injection cam cap.
Page 68: Exchange Camshaft Housing Cover Sealing
SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.00.02 Exchange camshaft housing cover sealing Release hexagon nuts. Remove camshaft housing cover. For engines with plane sealing surface. Release camshaft housing cover sealing by means of screwdriver and remove. 00.02 ill.1 For engines with bossed sealing surface. Remove seal with a scraper and dispose.
Page 69: Maintenance Timing-Belt Exchange
SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.00.03 Maintenance timing belt exchange Preparation: put engine out of operation disconnect battery remove camshaft housing cover Special tool: for vibration damper screws No. 2300767/0 For 4 cyl. engines Remove Poly-V-belt. See exchange of Poly-V-belt (05.06) For 6 cyl.
Page 70 SERVICE MANUAL MARINE ENGINES 01 ENGINE Pre-set dial gauge to position 20 mm stroke (small pointer at 20 - inside scale, big pointer at 0 - outside scale) or press zero button an digital dial gauge. 00.03 ill.5 Lock crankshaft, refer 01.00.01 00.03 ill.6 Loosen Allen head screw SW 8 of belt tensioner and remove tensioner.
Page 71 SERVICE MANUAL MARINE ENGINES 01 ENGINE Put new timing belt onto crankshaft sprocket and camshaft sprocket (marked tooth of camshaft sprocket points at upper edge of camshaft housing). 00.03 ill.9 ATTENTION: Pay attention to arrow marker (direction of rotation) on timing belt. 00.03 ill.10 Mount vibriation damper.
Page 72 SERVICE MANUAL MARINE ENGINES 01 ENGINE Clean and degrease contact surface of tensioner and camshaft housing. Then mount tensioner. 00.03 ill.13 Pre tension timing belt by turning tensioner on hexagon WS 32 counterclockwise. Tighten hexagon socket SW 8 with torque wrench to 20 Nm +/- 2.
Page 73 SERVICE MANUAL MARINE ENGINES 01 ENGINE Remove locking pin from crank shaft. 00.03 ill.17 Turn crankshaft 4 turns and stop at fourth turn with a plunger guide stroke of unit injector of approx. 3.32 mm (dial gauge reading). Then turn back crank shaft by a stroke measurement of 0.5 mm on the dial gauge.
Page 74 SERVICE MANUAL MARINE ENGINES 01 ENGINE NOTE: If the index value of engine timing should not correspond to the specifical value, follow the instructions as per item 26. Remove camshaft sprocket Loosen hexagon nut of camshaft sprocket SW 30 by holding up with special tool No.
Page 75 SERVICE MANUAL MARINE ENGINES 01 ENGINE 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. Check locking position of crankshaft or lock crank shaft, if necessary.
Page 76 SERVICE MANUAL MARINE ENGINES 01 ENGINE NOTE: If the index value of engine timing should not correspond to the allowed value, follow the instructions as per item 24. In case of correct index value of engine timing, tighten hexagon nut of camshaft sprocket SW 30 with 240 +/-12 Nm by holding up with special tool No.
Page 77: Remove Timing Belt
SERVICE MANUAL MARINE ENGINES 01 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. 2300767/0 For 4 cyl. engines Remove Poly-V-belt. See exchange of Poly-V-belt (05.06) For 6 cyl.
Page 78: Timing Adjustment Procedure For Dismantled Engine
SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.00.05 Timing 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 essen- tial 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 79 SERVICE MANUAL MARINE ENGINES 01 ENGINE Mount dial gauge rail with brackets 2306031/. (see list special tool) on studs at intake side of camshaft housing. Insert dial gauge 2300731/0 with probe pin 2300641/1 in dial gauge rail and put probe pin onto unit injector-plunger guide cylinder 1.
Page 80 SERVICE MANUAL MARINE ENGINES 01 ENGINE Continue to turn crankshaft in direction of rotation and position it with locking pin on TDC (piston; cylinder 1; in TDC). See chapter 01.00.01. 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 81 SERVICE MANUAL MARINE ENGINES 01 ENGINE ATTENTION: Pay attention to arrow marker (direction of rotation) on timing belt. 00.05 ill.11 Mount vibriation damper. Slightly grease thread and flange of 3 TORX screws (Grease P/N Z012222/0) and tighten with torque wrench to 135 Nm +/-7. NOTE: Recheck torque after first test run.
Page 82 SERVICE MANUAL MARINE ENGINES 01 ENGINE Prestress timing belt by turning tensioner on hexagon (WS 32) counterclockwise. Tighten hexagon so- cket (SW 8) with torque wrench to 20 Nm +/- 2. 00.05 ill.15 Put on tension gauge No. VR00515/0 (ill.16/pos.1) between camshaft sprocket and tensioner.
Page 83 SERVICE MANUAL MARINE ENGINES 01 ENGINE Remove locking pin from crank shaft. 00.05 ill.19 Turn crankshaft 4 turns and stop at fourth turn with a plunger guide stroke of unit injector of approx. 3.30 mm (dial gauge reading). Then turn back crank shaft by a stroke measurement of 0.5 mm on the dial gauge.
Page 84 SERVICE MANUAL MARINE ENGINES 01 ENGINE NOTE: If the index value of engine timing should correspond to the desired value, follow the instructions as per item 24. In case of a correct index value of engine timing, tighten the hexagon nut of the camshaft sprocket (SW 30) with 240 Nm by holding up with special tool No.
Page 85 SERVICE MANUAL MARINE ENGINES 01 ENGINE Remove camshaft sprocket Loosen hexagon nut of camshaft sprocket (SW 30) by holding up with special tool No. 2300711/0 and turn nut by approx. 1/4 rotation. 00.05 ill.25 Mount extractor (ill.26/pos.1) camshaft sprocket VR00113/0 and screw in puller screw "LEFTHAND THREAD"...
Page 86 SERVICE MANUAL MARINE ENGINES 01 ENGINE 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. Check locking position of crankshaft or lock crank shaft, if necessary.
Page 87 SERVICE MANUAL MARINE ENGINES 01 ENGINE NOTE: If the index value of engine timing should not correspond to the allowed value, follow the instructions as per item 24. In case of correct index value of engine timing, tighten hexagon nut of camshaft sprocket (SW 30) with 240 Nm +/-12 by holding up with special tool No.
Page 88: Replace Engine Mount And Engine Bracket
SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.00.06 Replace engine mount and engine bracket ATTENTION: Slightly lift the engine by means of suspension VR 00130/0 at lifting shackles (ill.1/pos.1) (approx. 3500 N). Replace engine mount 00.06 ill.1 Loosen hexagon nut (SW24), remove washer. Loosen two setscrews (SW17) of engine mount, remove engine mount.
Page 89 SERVICE MANUAL MARINE ENGINES 01 ENGINE Exchange bracket on flywheel housing Loosen 4 allen head screws (SW10) and remove support. NOTE: During assembly, secure allen head screws with LOCTITE 243 (9000059/1) and tighten with a trorque of 75 +/- 5 Nm. 00.06 ill.5 Z001019/0_6_July 2008 Page ENGINE - 27...
Page 90: Cylinder Block
SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.01 CYLINDER BLOCK 01.01.01 Replace valves Preparation: Disassemble engine housing, 01.06.01, Disassemble crankshaft, 01.02.01, Disassemble pistons, 01.04.01. Insert special tool No. VR00104/00 in cylinder bore and tighten sturdily with two hexagon screws (SW19). 01.01 ill.1 Mount valve spring retainer No.
Page 91 SERVICE MANUAL MARINE ENGINES 01 ENGINE Pull out valve stem gasket with special tool No. 2300758/0. 01.01 ill.5 NOTE: When inserting the valves, lubricate valve stem with motor oil. Put special tool No. V000152/0 onto valve stem end and pull on new valve stem over sleeve. Remove sleeve and press on valve stem gasket with special tool No.
Page 92: Adjust Valve Clearance
SERVICE MANUAL MARINE ENGINES 01 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...
Page 93: Replace Pressure Regulating Valve For Oil Cooling Jet
SERVICE MANUAL MARINE ENGINES 01 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 94: Replace Stud Bolt For Unit Injector
SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.01.05 Replace stud bolt for unit injector Preparation: Remove camshaft housing cover, 01.05.01 Remove unit injector, 03.02.02 Tighten threaded pin with a torque of 21 +/- 1 Nm. 01.05 ill.1 Page ENGINE - 32 Z001019/0_6_July 2008...
Page 95: Replace Dowel Pin For Positioning Of Unit Injector
SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.01.06 Replace dowel pin for positioning of unit injector Preparation: Disassemble camshaft housing, 01.05.01. Insert new dowel pin by means of setter. 01.06 ill.1 Z001019/0_6_July 2008 Page ENGINE - 33...
Page 96: Replace Dowel Pin For Positioning Of Camshaft Housing
SERVICE MANUAL MARINE ENGINES 01 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 setter. 01.07 ill.1 ATTENTION: Do not close oil supply duct with dowel pin in front. (see illustration below) ENGINE DAMAGE! Cylinder 1 Oil supply...
Page 97: Replace External Screw Adaptor For Oil Cooler
SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.01.08 Replace external screw adaptor for oil cooler Preparation: Disassemble oil cooler, 01.06.01. Screw in external screw part (ill.1/pos.1) with a torque of 100 Nm +/-5. Put on new O-ring. (ill.1/pos.2) 01.08 ill.1 01.08 ill.2 01.01.09 Replace coolant supply pipe Preparation:...
Page 98: Mount Frame Seal
SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.01.10 Mount frame seal Preparation: Disassemble engine housing, 01.06.01, Disassemble crankshaft, 01.02.01, Clean and degrease groove in cylinder block. 01.10 ill.1 For engines with rubber frame seal (slot-variant) (item 2-7) Apply construction adhesive LOCTITE 262 on both sides of first profile groove of frame seal.
Page 99 SERVICE MANUAL MARINE ENGINES 01 ENGINE Press frame seal into cylinder block groove, beginning at the cylinder block corner and then along side of the block. NOTE: Only press in the rubber of the frame seal by hand. Do not stretch or displace. Pay attention do least curing time and curing temperature.
Page 100: Crankshaft, Bearing, Vibration Damper
SERVICE MANUAL MARINE ENGINES 01 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, Dissamble engine housing, 01.06.01, Disassemble oil suction pipe, 01.06.03. Disassemble oil pump housing, 01.06.02, 02.01 ill.1 Turn crankshaft in such a way that first cylinder is...
Page 101 SERVICE MANUAL MARINE ENGINES 01 ENGINE Remove main bearing blocks. 02.01 ill.5 Pull out oil nozzles for piston cooling. 02.01 ill.6 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.
Page 102 SERVICE MANUAL MARINE ENGINES 01 ENGINE Insert the two upper thrust bearing segments onto main bearing cap and mount main bearing cap. Install remaining main bearing caps with bearing shalls and tighten main bearing screws sturd. Mount connecting rod cap with bearing shell. (pay attention to numbering).
Page 103 SERVICE MANUAL MARINE ENGINES 01 ENGINE Measuring of end clearance Put on magnetic holder with dial gauge, put dial gauge caliper onto crankshaft end. Move crankshaft in forward direction and set dial gauge to zero. Move crankshaft backwards and read measured value.
Page 104: Replace Gear For Oil Pump Drive
SERVICE MANUAL MARINE ENGINES 01 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. Remove woodruff key.(ill.1/pos.1) Pull off gear (ill.1/pos.2) with sleeve ring (ill.1/pos.3). NOTE: Apply surface sealing agent 509 to contact surfaces of gear towards...
Page 105: Flywheel, Housing
SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.03 FLYWHEEL, HOUSING 01.03.01 Replace flywheel housing Preparation: Dismantle engine mount of flywheel housing, 01.00.04. Loosen 6 hexagon sockets (SW8 and 4) hexagon sockets (SW6). Remove flywheel housing from adjusting sleeve (ill.1/ pos.1). 03.01 ill.1 For SOLAS models only First loosen screw (ill.2/pos.1) and fix blow-by valve above flywheel housing.
Page 106: Replace Flywheel
SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.03.02 Replace flywheel Preparation: disassemble torsion coupling, 02.01 disassemble intermediate ring, 01.03.03 Lock crankshaft, 01.00.01 Loosen eight hexagon head screws (SW17) and remove flywheel. NOTE: Apply thread protection LOCTITE 243 to hexagon head screws and tighten with a torque of 03.02 ill.1 75 Nm +/-4.
Page 107: Replace Adapter Ring
SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.03.03 Replace adapter ring Preparation: Dismantle flywheel housing, 01.03.01. For 6 cyl. engines Loosen 9 hexagon head screws (SW13), remove adapter ring. 03.03 ill.1 NOTE: Screw tensile strength - 10.9 Tighten hexagon screws with a torque of 30 Nm +/-3.
Page 108: Piston And Connecting Rod
SERVICE MANUAL MARINE ENGINES 01 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. Pull out piston with connecting rod. 04.01 ill.1 Remove retainer ring of piston pin by means of a screwdriver.
Page 109 SERVICE MANUAL MARINE ENGINES 01 ENGINE ATTENTION: For assembly of piston and connecting rod, take care that positioning groove of connecting rod bearing is opposite to the clearance for injection oil nozzle. NOTE: For best result position rings with piston gap about one third of a turn a part from each other gap.
Page 110: Camshaft, Housing, Valve Gear
SERVICE MANUAL MARINE ENGINES 01 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 all unit injectors, 03.02.02. Loosen all control links and turn to the back (ill.1/ pos.1).
Page 111 SERVICE MANUAL MARINE ENGINES 01 ENGINE For 6 cyl. engine (item 5-8) Remove plug (ill.4/pos.1) for sensor of control rack. Remove control rack. Loosen plug (ill.4/pos.2) for potentiometer accelerator. Loosen 3 hexagon screws (SW13) (ill.4/pos.3) and remove. Remove bracket with potentiometer. 05.01 ill.4 Remove plug (ill.5/pos.1) from control solenoid.
Page 112 SERVICE MANUAL MARINE ENGINES 01 ENGINE For 6 cyl. engines (item 13-15) Loosen setscrews (ill.8/pos.1) for support of raw water pipe. Loosen hose clamp (ill.8/pos.2 and ill.9/pos.1) and dismantle raw water pipe and bend. Dismantle cover (ill.8/pos.3) to intercooler by loosening 5 hexagon screws (SW10).
Page 113 SERVICE MANUAL MARINE ENGINES 01 ENGINE Assembly of camshaft housing Clean sealing surfaces of motorblock (ill.12/pos.1) and camshaft housing (ill.12/pos.2). Put on camshaft housing sealing (ill.12/pos.3). ATTENTION: Always use new sealing! 05.01 ill.12 Put on camshaft housing. Take care that all cam followers (ill.13/pos.1) rest on valve stems (ill.13/pos.2), are positioned and aligned accordingly.
Page 114: Replace Valve Stem Gasket (On Engine Assembly)
SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.05.02 Replace valve stem gasket (on engine assembly) Preparation: Disassemble camshaft housing, 01.05.01. ATTENTION: Set piston of respective cylinder on TDC. 05.02 ill.1 Mount valve spring retainer No. VR00105/1 (ill.1). Presstress valve spring (ill.2) with hexagon socket (SW28).
Page 115 SERVICE MANUAL MARINE ENGINES 01 ENGINE Put special tool No. V000152/0 onto valve stem end and push new valve stem gasket over sleeve. 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 116: Replace Control Rack
SERVICE MANUAL MARINE ENGINES 01 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. Disassemble unit injector of cylinder, 03.02.02. 05.03 ill.1 Disassemble handle to control solenoid by loosening two hexagon screws (SW8) (ill.2/pos.1).
Page 117 SERVICE MANUAL MARINE ENGINES 01 ENGINE Loosen locking screw (SW22) (ill.5), remove sealing ring, pull out control rod to the back. NOTE: Connection of lefthand thread screws and control links to be opened three times only. 05.03 ill.5 Adjust control link (mass equalization), refer to 03.02.04.
Page 118: Replace Camshaft
SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.05.04 Replace camshaft Preparation: disassemble camshaft housing, refer to 01.05.01. Loosen hexagon nut (SW30). (ill.1/pos.1) 05.04 ill.1 Disassemble camshaft wheel with special tool No. VR00113/0 (ill.2), remove washer. 05.04 ill.2 Remove axial holder of camshaft and rocker arm shaft.
Page 119 SERVICE MANUAL MARINE ENGINES 01 ENGINE Push out camshaft (ill.5) with radial shaft seal to the front. Pull out camshaft from the front of camshaft housing. ATTENTION: On all 4 cyl. and 6 cyl. engines before: 68224400 At the rear end of camshaft (ill.1/pos.2) the speed sensor wheel is located.
Page 120: Replace Rocker Arm Shaft
SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.05.05 Replace rocker arm shaft Preparation: Disassemble camshaft housing cover, 01.05.01. Loosen setscrews of unit injector on rocker arm. Remove half-moon rings (ill.1/pos.1) on both sides of rocker arms. 05.05 ill.1 Variant 1: Extract axial holder (ill.2) of camshaft and rocker arm shaft.
Page 121: Replace Radial Shaft Seal Of Camshaft
SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.05.06 Replace radial shaft seal of camshaft Preparation: Lock crankshaft, 01.00.01. Remove timing belt. Disassemble camshaft wheel. Disassemble radial shaft seal. Mount new radial shaft seal with special tool No. VR00122/0. 05.06 ill.1 NOTE: Radial shaft seal is waxed;...
Page 122: Replace Cam Follower
SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.05.07 Replace cam follower Preparation: disassemble camshaft housing cover. Loosen adjusting screw (ill.1/pos.1) with special tool No. VR00125/0. 05.07 ill.1 Chuck cam follower spring (ill.1/pos.2) with special tool No. V000121/0. 05.07 ill.2 Compress valve spring (ill.1/pos.3) with special tool No.
Page 123: Replace Retainer Of Cam Follower
SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.05.08 Replace retainer of cam follower Preparation: disassemble cam follower, 01.05.07 Turn retainer spring (ill.1/pos.1) sidewards and remove by means of screwdriver from valve adjusting element towards center. 05.08 ill.1 NOTE: Adjust valves, refer to 01.01.02. 05.08 ill.2 Z001019/0_6_July 2008 Page ENGINE - 61...
Page 124: Replace Valve Adjusting Element
SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.05.09 Replace valve adjusting element Preparation: Disassemble retainer spring of cam follower spring, 01.05.08 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.
Page 125: Engine Housing, Oil Pump, Oil Suction Pipe
SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.06 ENGINE HOUSING, OIL PUMP, OIL SUCTION PIPE 01.06.01 Replace engine housing Preparation: disconnect battery close fuel feed- and return line, empty closed cooling circuit, refer to 05.00.02.01. suck off motor oil dismantle wiring harness, 06.05.02. dismantle E-box dismantle exhaust manifold - heat 06.01 ill.1...
Page 126 SERVICE MANUAL MARINE ENGINES 01 ENGINE Dismantle oil hose on engine cooler (ill.5/pos.1). 06.01 ill.5 Disconnect oil hose on oil pump (ill.6/pos.1). 06.01 ill.6 Unscrew hollow screw (SW19) (ill.7/pos.1) to fuel feed pipe. 06.01 ill.7 For 4 cyl. engines Remove oil filter bracket. 06.01 ill.8 Page ENGINE - 64 Z001019/0_6_July 2008...
Page 127 SERVICE MANUAL MARINE ENGINES 01 ENGINE For 6 cyl. engines Loosen two hexagon nuts and two hexagon screws (SW13). Remove filter plate. Remove V-belt. For 4 cyl. engines Remove Poly-V-belt. Dismantle raw water pump laterally, refer to 05.10 06.01 ill.9 Loosen 11 hexagon screws (SW10), remove lower timing belt covering.
Page 128 SERVICE MANUAL MARINE ENGINES 01 ENGINE For engines with rubber frame seal (slot variant) Force out frame sealing from engine housing slot by means of broad screwdriver. NOTE: Do not puncture frame seal. 06.01 ill.13 Loosen one hexagon screw (SW10) (ill.14/pos.1). Remove protective sheet.
Page 129 SERVICE MANUAL MARINE ENGINES 01 ENGINE Force apart housing halfs and remove. 06.01 ill.18 Assembly Check membrans of frame sealing for damage, replace if necessary. Clean and degrease all sealing surfaces. For 4 cyl. engines Wet front and rear ring carrier with construction adhesive LOCTITE 620, in the area of the parting plane from the engine housing.
Page 130 SERVICE MANUAL MARINE ENGINES 01 ENGINE First put suction-sides housing half onto dowel pin, then check for second housing half wether oil suction pipe and oil suction pipe horn do not collide with the housing. Screw together the housing halfs. 06.01 ill.21 For 4 cyl.
Page 131 SERVICE MANUAL MARINE ENGINES 01 ENGINE For engines with rubber frame seal (slot variant) Press frame sealing by hand into housing halfs. NOTE: To avoid an extension of the rubber, only push frame seal profil straight into groove of engine housing. 06.01 ill.25 Further assembly is done in reverse order of disassembly.
Page 132: Replace Support Ring Rear
SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.06.02 Replace support ring rear Preparation: Replace engine housing, 01.06.01 Loosen 7 hexagon screws. Remove support ring. Clean and degrease all sealing surfaces. Wet sealing area of support ring with surface sealing agent LOCTITE 509. 06.02 ill.1 Mount new support ring ATTENTION: Replace radial shaft sealing ring.
Page 133: Replace Rear Radialshaft Sealing Ring
SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.06.03 Replace rear radialshaft sealing ring Preparation: Remove flywheel, refer 01.03 Remove radial shaft sealing ring Mount special tool No. VR00107/0 to press in the rear radial shaft sealing ring. 06.03 ill.1 Press radial shaft sealing into rear built-in ring carrier by means of special tool No.
Page 134: Replace Oil Pump (Front Ring Carrier)
SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.06.04 Replace oil pump (front ring carrier) Preparation: dismantle engine housing, 01.06.01. remove timing belt remove vibration damper Pull of timing belt sprocket by means of special tool No. 2300636/0 (ill.1). 06.04 ill.1 Loosen 6 hexagon screws (SW13) (ill.2), remove oil pump housing.
Page 135: Replace Oil Suction Pipe
SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.06.05 Replace oil suction pipe Preparation: Exchange engine housing, 01.06.01. 06.05 ill.1 Unscrew 2 screws (ill.2/pos.1) on main bearing block. Remove plate (only possible at 4 cyl. engines) - (ill.2/ pos.2). Pull of oil suction pipe. Check O-ring (ill.2/pos.3), replace if necessary.
Page 136: Intercooler
SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.08 INTERCOOLER 01.08.01 Remove intercooler Preparation: remove air filter, 03.04.01 08.01 ill.1 Unscrew hexagon screw (ill.2/pos.1) (SW10) of clamp of oil dipstick tube, carefully turn away oil dipstick tube. Remove tandem cooler, refer to 05.01.06 remove triple cooler, refer to 05.01.08 For M16 - 246 only: Remove additional oil cooler, refer to 05.01.07...
Page 137 SERVICE MANUAL MARINE ENGINES 01 ENGINE Unscrew hollow screw of boost pressure hose (ill.5) and remove. 08.01 ill.5 Remove two supports-intercooler (ill.6/pos.1) 08.01 ill.6 Loosen hose clamps of hose connection turbocharger - intercooler (ill.7/pos.1), and remove hose. For 6. cyl. engines (item 9-10) 08.01 ill.7 Unscrew setscrews (ill.8/pos.1) for pipe support of raw water pipe.
Page 138 SERVICE MANUAL MARINE ENGINES 01 ENGINE For 4. cyl. engines Unscrew hexagon screw (SW10) (ill.9/pos.1) of raw water pipe clamp. Open hose clamp (ill.9/pos.2) on intercooler. 08.01 ill.9 Open hose clamp on heat exchanger (ill.10/pos.1) and remove raw water pipe. For 6 cyl.
Page 139 SERVICE MANUAL MARINE ENGINES 01 ENGINE Disconnect plug from control solenoid (ill.13/pos.1). Remove mounts of wiring harness on the bottom of air collector and turn away wiring harness. Only for 4 cyl. engines with hydraulic system 08.01 ill.13 Loosen 2 hexagon sockets (ill.14/pos.1), remove hydraulic tank and fix it laterally in such a way that no oil can leak.
Page 140 SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.08.02 Assembly of intercooler Preparation: check intercooler Clean sealing surfaces on motorblock (ill.1). 08.02 ill.1 For 6 cyl. engines Fix 2 seals (ill.2/pos.1) with grease Staburax NB04 on marked surfaces of monoblock. 08.02 ill.2 Clean sealing surfaces on intercooler (ill.3).
Page 141: Replace Intercooler - Element
SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.08.03 Replace intercooler - element Preparation: remove air filter, refer to 03.04.01 drain raw water circuit, refer to 05.00.07 remove intercooler, refer to 01.08.01 C 1 0 08.03 ill.1 For engines with hydraulic systems, loosen upper screw; for all other engines, loosen 3 screws (ill.1/ pos.1) from intercooler cover in front and 3 screws (ill.1/pos.2) from intercooler cover at the back from intercooler.
Page 142 SERVICE MANUAL MARINE ENGINES 01 ENGINE THIS PAGE IS INTENTIONALLY BLANK Page ENGINE - 80 Z001019/0_6_July 2008...
Page 143: Auxiliary Drive, In Front (Pto)
SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.09 AUXILIARY DRIVE, IN FRONT (PTO) Disconnect battery cables. Remove protective cover. For 4 cyl. engines (item 3-4) Loosen 3 hexagon screws (SW13) (ill.1/pos.1) and remove drive shaft. Loosen 3 hexagon screws (SW13) (ill.1/pos.2) and 09.01 ill.1 remove flange ring.
Page 144: Engine Oil Cooler
SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.13 ENGINE OIL COOLER 01.13.01 Replace engine oil cooler Preparation: Empty closed cooling circuit, 05.00.02 Remove tandem cooler 05.01.06 Loosen hose clamp (ill.1/pos.1) on oil cooler. 13.01 ill.1 Loosen fixing nut (ill.2) of oil line (SW22). 13.01 ill.2 Loosen 4 allen head screws (SW6), remove cooler.
Page 145 SERVICE MANUAL MARINE ENGINES 01 ENGINE Clean marked sealing surface (ill.4) with scraper and remove O-Ring. Assembly oil cooler 13.01 ill.4 Replace O-ring on adaptor main oil duct and slightly grease with Staburax NB U4 before assembly. When putting on the engine oil cooler, immediately fix the water intake of the oil cooler on the hose albow of the water pump .
Page 146: Repair Oil Cooler
SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.13.02 Repair oil cooler Preparation: remove oil cooler, 01.13.01 Disassembly: Unscrew two slotted round nuts (ill.1/pos.1) by means of special tool 2300709/1. Unscrew hexagon sockets (ill. 1/pos.2) (SW5), se- parate housing halfs, remove cooler element. Assembly: 13.02 ill.1 NOTE:...
Page 147: Change Motor Oil
Dispose the oil properly. Remove oil filler cap (ill.2/pos.1). Fill in STEYR turbo diesel engine oil SAE 10W-40 (No. Z010058/0) (ill.3) or equivalent motor oil with characteristics ACEA B4 - 02 or API code CF. 13.03 ill.2 ATTENTION: Oil filling must not exceed the maximum marker.
Page 148: Change Oil Filter
SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.13.04 Change oil filter For 4 cyl. engines Waiting time 30 min. after having stopped the engine. NOTE: First suck off the motor oil. This reduces the waiting time. For 6 cyl. engines 13.04 ill.1 Position (special tool No.
Page 149: Exhaust Manifold, Seals, Heat Exchanger
SERVICE MANUAL MARINE ENGINES 01 ENGINE 01.14 EXHAUST MANIFOLD, SEALS, HEAT EXCHANGER Refer to 05.01.02 Exhaust manifold, heat exchanger Z001019/0_6_July 2008 Page ENGINE - 87...
Page 150 SERVICE MANUAL MARINE ENGINES 01 ENGINE THIS PAGE IS INTENTIONALLY BLANK Page ENGINE - 88 Z001019/0_6_July 2008...
Page 151 SERVICE MANUAL MARINE ENGINES 02 COUPLING 02 COUPLING Table of Contents Page 02.01 Replace torsion coupling ..............2 02.01.01 For 6 cyl. engines ..................2 02.01.02 For 4 cyl. engines ..................4 02.01.03 Installation ....................6 Z001019/0_6_July 2008 Page COUPLING - 1...
Page 152 SERVICE MANUAL MARINE ENGINES 02 COUPLING 02.01 REPLACE TORSION COUPLING Preparatory work: disassemble flywheel housing, refer to 01.03.01. 02. 01. 01 Remove coupling for 6 cyl. engines Remove coupling for gearbox, jet drive, VOLVO stern drive apllication: Variant 1: Loosen 9 screws. Remove coupling. (Old version - replaced by variant 2) 01.01 ill.1...
Page 153 SERVICE MANUAL MARINE ENGINES 02 COUPLING Remove coupling for OMC/ VOLVO SX - stern drive apllication: Loosen 6 screws, remove washers. Remove coupling. 01.01 ill.4 Remove coupling for MERCURY - stern drive apllication: (Old version - replaced by variant 2) Variant 1: Loosen 3 screws.
Page 154 SERVICE MANUAL MARINE ENGINES 02 COUPLING 02. 01. 02 Remove coupling for 4 cyl. engines (Old version - replaced by variant 2) Remove coupling for gearbox, jet drive, VOLVO stern drive apllication: Variant 1: Loosen 9 screws. Remove coupling. Variant 2: 01.02 ill.1 Loosen 6 screws.
Page 155 SERVICE MANUAL MARINE ENGINES 02 COUPLING Remove coupling for (Old version - MERCURY - stern drive apllication: replaced by variant 2) Variant 1: Loosen 3 screws. Remove coupling. Variant 2: 01.02 ill.4 Loosen 6 screws. Remove coupling. (Current version - Loosen 9 screws.
Page 156 SERVICE MANUAL MARINE ENGINES 02 COUPLING 02.01.03 Installation Description Screw Coupling M8 x 1,25 - 8.8 Screw Coupling M8 x 1,25 - 10.9 Screw Coupling M10 x 1,5 Use locking compound LOCTITE 243 on threads. Page COUPLING - 6 Z001019/0_6_July 2008...
Page 157 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 03 FUEL SYSTEM Table of Contents Page 03.00 Fuel system / Functional description ........... 2 03.02 Fuel pump, unit injector, lines .............. 4 03.02.01 Replace fuel pump ................4 03.02.02 Disassembly and assembly of unit injector ..........7 03.02.03 Fix control rack ..................
Page 158: Fuel System / Functional Description
SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 03.00 FUEL SYSTEM Page FUEL SYSTEM - 2 Z001019/0_7_July 2012...
Page 159 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM Functional Description When the ignition switch is turned, an electric fuel pump 1 is put into operation and sucks fuel from the fuel tank 2. This fuel is led via fuel filter 3 to the fuel pump. From the fuel pump, fuel is pumped to the engine block 4 and the unit injectors 5.
Page 160: Fuel Pump, Unit Injector, Lines
SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 03.02 FUEL PUMP, UNIT INJECTOR, LINES 03.02.01 Replace fuel pump Fuel pump operation is controlled by EMS. Disassembly 02.01 ill.3 Ventilate drain fuel system.For this purpose, open fuel line between fuel filter and fuel pump (ill.4/pos.1) and let pump run for approx. 6 x 10 sec. Make sure that air is sucked into the line.
Page 161 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM For 4 cyl. engines only Unscrew two hexagon screws of filter plate. Remove filter plate and holding strap. Remove fuel pump. 02.01 ill.7 For 6 cyl. engines only (item 7-8) Remove two hexagon screws (SW10) for fixing fuel pump on filter plate (ill.8/pos.1), as well as ground wire. ATTENTION: Mark position of fuel pump on pump support. Remove pump bracket. ATTENTION: Measure height for assembly of pump 02.01 ill.8 because of fitting position of fuel lines.
Page 162 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM Assembly For 4 cyl. engines only (item 1-3) Place new fuel pump. Mount filter bracket with holding strap by means of 2 hexagon screws. Attach fuel line between filter and pump (ill.9/pos.1) as well as pump and block (ill.9/pos.2). Tighten hollow screws with a torque of 30 Nm +/-3. 02.01 ill.9 For 6.
Page 163: Disassembly And Assembly Of Unit Injector
SERVICE MANUAL MARINE ENGINES 03 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. 02.02 ill.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.
Page 164 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM Remove nuts on unit injector flange (2 hexagon nuts SW 13). 02.02 ill.5 Loosen left-handed hexagon socket securing the control link on the control rack by using a 4 mm hexagon socket wrench. Turn control link against bulk head. (1 hexagon socket SW 4 - ”LEFT-HAND THREAD”...
Page 165 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM Move the rocker arm towards timing belt side of engine and remove the tappet. NOTE: Adjusting screw and slide cup match exactly and thus have to be removed kept matched. 02.02 ill.9 Check position of control link(s) against bulkhead as illustrated.
Page 166 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 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. 02.02 ill.13 Assembly In order to secure an appropriate tight fit, recheck tighten stud bolt with a torque of 21 Nm +/- 2...
Page 167 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 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. 02.02 ill.17 ATTENTION: Insert new special copper seal washer (ill.19/pos.2), from seal kit Z002031/0, with a screwdriver into copper insert.
Page 168 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM Push unit injector firmly downwards in order to position it correctly with the O-rings. 02.02 ill.21 Lubricate slide cup with motor oil, put it onto adju- stment screw, as shown, and shift it together with rocker arm onto unit injector. 02.02 ill.22 Install retainer ring to secure the rocker arm.
Page 169 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM Fix control rack. Attach control link to control rack and adjust. Refer to 03.02.04, Adjusting Control Link. Adjust injection start. Refer to 03.02.06, Injection Start unit injector. Connect fuel pipes and operate electric fuel pump 3 times for 10 seconds to vent fuel system.
Page 170: Fix Control Rack
SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 03.02.03 Fix control rack Preparation: Remove camshaft housing cover, refer to 01.00.02 Unscrew setpin of control rack (ill.1/pos.1) at the back of camshaft housing, as shown. 02.03 ill.1 Position bore (diameter 4 mm) in control rack(ill.2/ pos.1) over reference bore (ill.2/pos.2) in the bulkhead wall.
Page 171: Adjust Control Link (Injection Quantity)
SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 03.02.04 Adjust Control Link (injection quantity) Prior to adjustment, unit injector must be tighte- ned properly, and control rack must be fixed in position with set pin. NOTE: Readjust all control links even if only one link has been opened. STARTING POSITION: 02.04 ill.1 Loosen left-handed setscrew of control link.
Page 172: Loosen Fixing Of Control Rod
SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 03.02.05 Loosen fixing of control rod Unscrew setpin (ill.3/pos.2) from bulkhead wall with removing setpin and hold control rack. Reinstall setpin in rear camshaft housing bore.(ill.3/pos.1). 02.05 ill.1 Tighten setpin with a torque of 7 Nm. 02.05 ill.2 Check axial flexibility of control rack. Control rack is to be moved easily and should automatically return to reverse position due to spring load.
Page 173: Adjust Start Of Injection
SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 03.02.06 Adjust start of injection Preparation: Remove camshaft housing cover NOTE: The adjustment of start of injection is necessary: - if unit injector was removed - periodically according to maintenance (chart) - if set value has changed (see chart Set Values Unit Injector Stroke).
Page 174 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM Insert unit injector extracting lever No. VR 00126/0 (ill.5/pos.1) in recess of rocker arm between rocker arm body and roller, as shown, and fully press down spring of unit injector. Set display to zero. NOTE: Slowly release unit injector spring. Read total indicating travel (ill.5/pos.2) on dial gauge.
Page 175 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM Engine setting values for engines with a build date from 2007 (>48227001/>68227001) Type Unit Injector Stroke Adjustment Engine Timing Valve Clerance New Copper Ring / Control Value Inlet &Outlet MO54NA33 2176553-1 8,07 ±0,02 8,12 ±0,02 3,20...
Page 176: Exchange Check Valve For Fuel Pre-Pressure To Unit Injector
Use new Cu-sealing rings for assem- bly. Tighten with a torque of 40 Nm+/-4. ATTENTION: On account of importance of this valve (proper function of fuel system), only use genuine STEYR spare part for possible exchange. 02.07 ill.1 Page FUEL SYSTEM - 20...
Page 177: Air Filter
SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 03.04 CHANGE AIR FILTER 03.04.01 Change air filter Till engine serial no. 48219069 ( 4-cyl.) and 68219174 ( 6-cyl.) Open retaining clip. 04.01 ill.1 Remove air filter and cover. Put new air filter together with cover onto filter head and fix with retaining clip. From engine serial no. 48219070 ( 4-cyl.) and 68219175 ( 6-cyl.) 04.01 ill.2 Remove hose clamp and air filter.
Page 178: Turbocharger
SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 03.05 TURbOCHARGER 03.05.01 Replace turbocharger Remove air filter, refer to 03.04.01 Remove high-riser, refer to 04.01 For 6 cyl. engines only Drain coolant from closed cooling circuit, refer to 05.00.07 05.01 ill.1 For 4 cyl. engines only (item 4-7) Loosen fastenings of heat protection.
Page 179 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM For 6 cyl. engines only Loosen 2 hexagon screws on flange of oil feed line. 05.01 ill.5 For 4 cyl. engines only Loosen hose clamps of hose connection turbochar- ger-intercooler (ill.6/pos.1) and remove hose. For 6 cyl. engines only (item 13-17) 05.01 ill.6 Loosen support screw (ill.7/pos.1) for raw-water pipe.
Page 180 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM Loosen hose clamp (ill.9/pos.1) of hose of oil sepa- rator and remove hose. 05.01 ill.9 Loosen 4 hexagon nuts (ill.10+11/pos.1) of turbochar- ger flange. Remove turbocharger and seal, dispose seal. (if seal is used) 05.01 ill.10 Assembly: ATTENTION: Check hose connection and hose between turbocharger return pipe and engine housing intake for crack and damage.
Page 181: Check Bearing Clearance
SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM For 4 cyl. engines only (item 1-2) Tighten 4 hexagon nuts of turbocharger flange with a torque of 25 Nm +/-2. Tighten 2 screws for fixing the flange of oil return pipe with a torque of 10 Nm +/-1. Tighten hollow screw with 25 Nm +/-3. For 6 cyl. engines only (item 3-6) Tighten 4 hexagon nuts of turbocharger flange by means of torque wrench No. 2300743/0 and tree- handled socket wrench No. 2300744/0 with a torque of 40 Nm +/-4. Tighten 2 screws for fixing the oil return pipe flange with a torque of 23 Nm +/-2.
Page 182: Control Solenoid
SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 03.08 CONTROL SOLENOID 03.08.01 Remove control solenoid Prepartion: for 4 cyl. engines only remove intercooler, refer to 01.08.01. Disconnect battery. For 4 cyl. engines only (item 2-3) 08.01 ill.1 Loosen plug connection (ill.2/pos.1) for control rack potentiometer.
Page 183 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM Loosen 2 hexagon nuts (SW10) (ill.5/pos.1). Remove boost pressure sensor. Loosen plug (ill.5/pos.2) for potentiometer accele- rator. Loosen 3 hexagon nuts (SW10) (ill.5/pos.3). Remove bracket with potentiometer accelerator. Remove plug (ill.5/pos.4) for sensor of control rod. 08.01 ill.5 Remove plug (ill.6/pos.1) from control solenoid.
Page 184: Install Control Solenoid
SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 03.08.02 Install control solenoid To install control solenoid assembly onto camshaft housing, proceed as follows: NOTE: Use new gasket for control solenoid if fitted. O-ring can be re-used. Remove camshaft housing cover. Move control rack by hand (ill.1) to front position and hold.
Page 185: Replace Sensor, Indication Of Control Rack Position
SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 03.08.03 Replace sensor, indication of control rack position Preparation: For 4 cyl. engines only remove shift plate, refer to 01.08.01, ill.3. For 6 cyl. engines only remove bracket of potentiometer accelerator, refer to 03.08.01, ill. 5-6 Loosen 2 Allen head screws (ill.1/pos.1) (SW3).
Page 186: Change Fuel Filter
SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 03.09 Change fuel filter Water or other fuel contaminations may form deposits which clog the fuel filter and may lead to a disturbance. Therefore, change the fuel filter every 300 operating hours and/or every 2 years at least. Ventilate fuel system. For this purpose, open fuel pipe between fuel filter and fuel supply (from fuel tank or water separator) on filter head (ill.1/pos.1), and operate the pump approx 6 times each 10 sec.
Page 187: Replace Glow Plug
SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 03.11 REPLACE GLOW PLUG For 4 cyl. engines only Preparation: for glow plug of second to fourth cylinder, remove intercooler - refer to 01.08.01 for glow plug of first cylinder, additionaly remove control solenoid - refer to 03.08.01 For 6 cyl.
Page 188: Measurement Of Compression Pressure
Start with special tool VR00145/0 only. Engine may just turn, but not feed and inject fuel. 12.00 ill.3 Compression pressure for all STEYR MARINE DIESEL ENGINES NOM. VALUE LOWER BOUNDARY VALUE 21,0 +/- 1,0 bar 18,0 +/- 1,0 bar Assembly is done in reverse order.
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Page 190: Fuel System Check
SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 03.14 FUEL SYSTEM CHECK 03.14.01 Manual injection test methode Preparation: Remove camshaft housing cover, refer to 01.00.02 Remove plug screw (ill.1/pos.1) with sealing ring. 14.01 ill.1 Mount special tool No. VR00148/0 (ill.2/pos.1) together with sealing ring (ill.2/pos.2).
Page 191 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM Put 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. As a result, unit injector is pressed down and injection process is simulated.
Page 192: Disengagement Methode Of Injection
SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 03.14.02 Disengagement methode of injection NOTE: Disengagement methode of injection is a simple and effective method to detect defective unit injectors with regard to formation of bubbles in both the fuel system and the engine cooling system or lack of power it related to deficiencies in injection equipment.
Page 193: Air Bubble Formation In Fuel System
SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 03.14.03 Air bubble formation in fuel system Preparation: Change fuel filter, if necessary refer to 03.09 (item 1, ventilate fuel system) Special tool: Testing device for fuel return 2300719/1 Disconnect hose from fuel return line on fuel cooler outlet to fuel tank.
Page 194 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM Check: Defective unit injector(s) is/are to be detected definitely by means of "manual injection test methode" (manual injection test methode, refer to 03.14.01) Manual: If during disengagement methode of injection of unit injectors a creaky noise is to be heard and a solide resistance (pressure point) can be felt, check the tightening torque of the unit injectors (03.02.02 - assembly item 11).
Page 195: Exhaust System
SERVICE MANUAL MARINE ENGINES 04 EXHAUST SYSTEM 04 EXHAUST SYSTEM Table of Contents Page 04.01 Hi-Riser ....................3 04.01.01 Replace Hi-Riser ..................3 04.01.02 Measurement of Exhaust Backpressure ........... 4 Z001019/0_6_July 2008 Page EXHAUST SYSTEM - 1...
Page 196 SERVICE MANUAL MARINE ENGINES 04 EXHAUST SYSTEM THIS PAGE IS INTENTIONALLY BLANK Page EXHAUST SYSTEM - 2 Z001019/0_6_July 2008...
Page 197 SERVICE MANUAL MARINE ENGINES 04 EXHAUST SYSTEM 04.01 HI-RISER 04.01.01 Replace hi-riser Preparation: If necessary, remove heat shield turbocharger. Disassembly: Disconnect plug (ill.2/pos.1) for exhaust temperature 01.00 ill.1 switch. If bracket is used loosen hexagon screws (ill.2/pos.2) of bracket. Loosen hose clamp (ill.3/pos.1) connecting hose; heat exchanger - hi-riser.
Page 198 SERVICE MANUAL MARINE ENGINES 04 EXHAUST SYSTEM 04.01.02 Measurement of exhaust backpressure special tool No. VR00136/0 ill.1/pos.1 pressure gauge (0-1 bar) ill.1/pos.3 intermediate sealing ring ill.1/pos.4 pressure gauge connection ill.1/pos.5 pressure hose ill.1/pos.6 double union ill.1/pos.7 sealing ring ill.1/pos.9 screw-in adaptor 01.02 ill.1 Disconnect plug for exhaust temperature switch (ill.2/ pos.5).
Page 199: Cooling System
SERVICE MANUAL MARINE ENGINES 05 COOLING SYSTEM 05 COOLING SYSTEM Table of Contents Page 05.00 Functional description cooling circuit ..........05.00.01 Raw water circuit (external cooling circuit) ..........05.00.02 Closed coolant from cooling circuit (internal engine cooling circuit) ..05.00.03 Error detection cooling system ...............
Page 200: Functional Description Cooling Circuit
SERVICE MANUAL MARINE ENGINES 05 COOLING SYSTEM 05.00. FUNCTIONAL DESCRIPTION COOLING CIRCUIT 05.00.01 Raw water circuit (external cooling circuit) Raw water is fed to the engine via a vane-type pump in the secondary circuit. The raw water pump (ill.1/2) is a self-sucking pump and is driven for 4 cyl. engines via Poly-V-belts and for 6 cyl. engines via V-belt.
Page 201 SERVICE MANUAL MARINE ENGINES 05 COOLING SYSTEM 00.01 ill.1 Raw water intake Impeller pump Fuel cooler Hydraulic oil- and transmission oil cooler Tube stake - intercooler Tube stake - heat exchanger Hi-riser Sensor exhaust gas temperature Raw water outlet Sacrificial anodes Raw water filter Splash water flap Z001019/0_6_July 2008...
Page 202: Closed Coolant From Cooling Circuit (Internal Engine Cooling Circuit)
SERVICE MANUAL MARINE ENGINES 05 COOLING SYSTEM 05.00.02 Closed coolant from cooling circuit (internal 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 motorblock. The belt pulley of the pump is driven from the back of the timing belt.
Page 203 SERVICE MANUAL MARINE ENGINES 05 COOLING SYSTEM B Circuit thermostat open 00.02 ill.2 A Circuit, thermostat closed Thermostat (open) Circulating pump Tube stake - heat exchanger Oil cooler Water-intake pipe Water jacket, block/cylinder Expansion tank Water cooled exhaust manifold Filler cap Turbocharger Coolant temperature sensor Thermostat (closed)
Page 204: Error Detection Cooling System
SERVICE MANUAL MARINE ENGINES 05 COOLING SYSTEM 05.00.03 Error Detection Cooling System Ask for the following information: How old is the device (engine number and model)? How many operating hours (wear and corrosion)? How long does the problem already exist (gradual or sudden occurence)? Operating conditions prior to occurence of problem (interior waters, salt water, muddy or sandy water?) What repair- or service works have already been carried out (exchange of impeller, etc.)?
Page 205 SERVICE MANUAL MARINE ENGINES 05 COOLING SYSTEM NOTE: When testing the device in a test tank, let the engine run in idle gear. For some test tanks the water volume possibly may not be sufficient to let the engine run in a gear without creating considerable turbulences.
Page 206 SERVICE MANUAL MARINE ENGINES 05 COOLING SYSTEM Closed Cooling Circuit (internal) At first, take into consideration the following possibilites: Defective or faulty coolant temperature sensor. Coolant level in expansion tank < as minimum. Malfunction of thermostat thermostat does not open or opens only partially thermostat blocked in partially open state thermostat blocked in completely open state damaged thermostat sealing ring...
Page 207: Check Points For Problems In Cooling System
SERVICE MANUAL MARINE ENGINES 05 COOLING SYSTEM 05.00.04 Check points for problems in cooling system Raw water circuit water intake - clogged raw water filter - clogged - strongly contaminated - filter defective hoses - fragile or leaky hose clamps - loose or defective raw water pump - impeller stronlgy worn...
Page 208: Component Check Raw Water System
SERVICE MANUAL MARINE ENGINES 05 COOLING SYSTEM 05.00.05 Component Check Raw Water System 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 tightness of all connections.
Page 209 SERVICE MANUAL MARINE ENGINES 05 COOLING SYSTEM 05.00.06 Component Checks of Engine Cooling System 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.
Page 210 SERVICE MANUAL MARINE ENGINES 05 COOLING SYSTEM Cooler cap No special tools required. Control works: As a standard, a cooler cap with an opening pressure of 1,0 bar is used. Check cooler cap for correct rated output, defective sealing (ill.2/ pos.1), defective vacuum valve (ill.2/pos.2) or broken spring (ill.2/pos.3).
Page 211: Drain The Coolant System
SERVICE MANUAL MARINE ENGINES 05 COOLING SYSTEM 05.00.07 Drain coolant system Raw water circuit Remove drain plug (ill.1/pos.1). NOTE: Drain plug (ill.1/pos.1) does not exist for all models. 00.07 ill.1 To drain the raw water ducts on the engine, remove cover rear of raw water pump (ill.2+3/pos.1).
Page 212 SERVICE MANUAL MARINE ENGINES 05 COOLING SYSTEM Closed cooling circuit To drain the closed cooling circuit, lift or lower the bow of the boat in such a way that the engine is in horizontal position, which permits an ideal drainage of motorblock and manifold.
Page 213: Fill The Cooling System
SERVICE MANUAL MARINE ENGINES 05 COOLING SYSTEM 05.00.08 Fill cooling system Closed cooling system Fill cooling circuit with specified coolant only. Coolant level should reach the lower edge of the filler neck in the expansion tank. For 4 cyl. & 6 cyl. engines with new exhaust (screwed cap) only NOTE: Cooling system deaerate automatically...
Page 214: Cooler, Heat Exchanger, Expansion Tank
SERVICE MANUAL MARINE ENGINES 05 COOLING SYSTEM 05.01 COOLER, HEAT EXCHANGER, EXPANSION TANK 05.01.01 Coolant tank The coolant tank is an integrated part of the exhaust manifold - heat exchanger housing and may not be exchanged in single parts. 01.01 ill.1 Page COOLING SYSTEM - 16 Z001019/0_6_July 2008...
Page 215: Disassembly Exhaust Manifold - Heat Exchanger
SERVICE MANUAL MARINE ENGINES 05 COOLING SYSTEM 05.01.02 Disassembly exhaust manifold - heat exchanger Preparation: tip away E-box remove air filter, refer to 03.04 NOTE: Where appropriate, remove exhaust manifold for these works, while turbo- charger and hi-riser remain. 01.02 ill.1 Drain closed cooling circuit according to instructions in 05.00.07, drain coolant Unscrew three screws (ill.1/pos.1) of upper timing...
Page 216 SERVICE MANUAL MARINE ENGINES 05 COOLING SYSTEM Cut cable tie for cable- and plug fixing of speed sensor (ill.5/pos.1) on relief hose. 01.02 ill.5 For 4 cyl. engines only (item 9-12) Loosen fixing of heat protection. Remove heat protection (ill.6/pos.1). Loosen hose clamp (ill.6/pos.2) and remove hose for air charge pressure box.
Page 217 SERVICE MANUAL MARINE ENGINES 05 COOLING SYSTEM For 6 cyl. engines only Loosen two hexagon screws on flange of oil feed line. 01.02 ill.9 For 4 cyl. engines only Loosen hose clamps of hose connection turbocharger - intercooler (ill.10/pos.1) and remove hose.
Page 218 SERVICE MANUAL MARINE ENGINES 05 COOLING SYSTEM Loosen hose clamp (ill.13/pos.1) of oil separator and remove hose. 01.02 ill.13 Unscrew 8 - 12 screws (SW13) (ill.14/pos.1) and 2 - 3 nuts (ill.14/pos.2) . CAUTION: If the exhaust manifold is not secured, it migth fall when loosening the screws.
Page 219: Checks
SERVICE MANUAL MARINE ENGINES 05 COOLING SYSTEM 05.01.03 Checks Check exhaust duct for cracks. Check raw water circuit of the heat exchanger in a pressure test with closed outlet nipple. Pressurize inlet nipple with a pressure gauge and immerse manifold into water. At a pressure of 22-25 kPa, the manifold should show no leaks.
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Page 221: Exchange Heat Exchanger Element
SERVICE MANUAL MARINE ENGINES 05 COOLING SYSTEM 05.01.04 Exchange heat exchanger element 01.04 ill.1 Dismantle heat exchanger element: Drain closed coolant circuit, refer to 05.00.07 Drain raw water circuit, refer to 05.00.07 (item 1 remove drain plug). Loosen 3 screws (ill.1/pos.1) of heat exchanger cover in front (ill.1/pos.2) and 3 screws (ill.1/pos.8) of heat exchanger cover at the back (ill.1/pos.7).
Page 222: Assembly Of Exhaust Manifold
SERVICE MANUAL MARINE ENGINES 05 COOLING SYSTEM 05.01.05 Assembly of exhaust manifold Preparation: Check heat exchanger, refer to 05.01.03 Clean sealing surfaces on motorblock. 01.05 ill.1 Clean sealing surfaces on exhaust manifold (ill.2/ pos.1). 01.05 ill.2 For 4 cyl. engines only (item 3-5) Insert O-ring on cyl.
Page 223 SERVICE MANUAL MARINE ENGINES 05 COOLING SYSTEM For 6 cyl. engines only (item 6-9) Variant with gaskets: Screw 3 assembly bolts for exhaust manifold No. P/N V000229/0 into respective left tapped hole of each seal. Put on new manifold seals. Put exhaust manifold onto 3 assembly bolts (ill.5/ pos.1) Mount manifold screws with washers and tighten sturdily.
Page 224: Exchange Tandem Cooler
SERVICE MANUAL MARINE ENGINES 05 COOLING SYSTEM 05.01.06 Exchange tandem cooler Disassembly Preparation: vent fuel system, refer to 03.09/1 Remove drain plug (ill.1/pos.1) to drain the raw water system. Loosen hose clamp (ill.1/pos.2) of hose to raw water pump, and remove hose. Loosen hose clamp of hose bend (ill.1/pos.3) to 01.06 ill.1 intercooler, and remove hose bend.
Page 225: Exchange Triple Cooler
SERVICE MANUAL MARINE ENGINES 05 COOLING SYSTEM 05.01.08 Exchange triple cooler Disassembly Preparation: vent fuel system, refer to 03.09, item 1 Remove drain plug at triple cooler to drain the raw water system.(ill.1/pos.1) Loosen union nuts of oil hoses (ill.1/pos.2) (SW 32) at the triple oil cooler.
Page 226: Exchange Thermostat
SERVICE MANUAL MARINE ENGINES 05 COOLING SYSTEM 05.03.02 Exchange thermostat Preparation: Drain closed cooling circuit refer to 05.00.07, item 7 DISASSEMBLY: 03.02 ill.1 Loosen 4 hexagon sockets fixing the covering of thermostat housing. Remove covering and seal. Dis- pose seal. 03.02 ill.2 Only for 6 cyl.
Page 227 SERVICE MANUAL MARINE ENGINES 05 COOLING SYSTEM ASSEMBLY: Clean sealing surfaces on thermostat housing and on sealing surface of cover. 03.02 ill.5 Put seal (ill.6/pos.1) onto thermostat. 03.02 ill.6 Insert thermostat into housing, ventilation mark (ill.7/ pos.1) showing upwards. ATTENTION: Put on new seal. Insert spacer.
Page 228: Exchange Sacrificial Anodes
SERVICE MANUAL MARINE ENGINES 05 COOLING SYSTEM 05.03.03 Exchange sacrificial anodes The raw water circuit of the cooling system is equipped with five sacrificial anodes. These anodes are to be removed once a year and checked for galvanic erosion. In case of a material loss of 50 %, the anode needs to be exchanged (SW23) .
Page 229: Coolant Pump
SERVICE MANUAL MARINE ENGINES 05 COOLING SYSTEM 05.04 COOLANT PUMP 05.04.01 Exchange coolant pump Preparation : remove timing belt, see 01.00.04 drain closed cooling system, refer to 05.00.07, item 7 04.01 ill.1 For 6 cyl. engines only Loosen hose clamp (ill.2/pos.1) and remove hose. 04.01 ill.2 Loosen hose clamps (SW6) and remove hose between thermostat housing and water pump (ill.3/...
Page 230: Install Coolant Pump
SERVICE MANUAL MARINE ENGINES 05 COOLING SYSTEM 05.04.02 Install coolant pump Clean all sealing surfaces on water pump and on motorblock. 04.02 ill.1 Put on new sealing (ill.2/pos.1). Align water pump on motorblock. Mount screws and nuts and tighen with standard torque for these size. Further assembly is done in reverse order, in accordance with 01.00.04 remove timing belt.
Page 231: Poly-V-Belt
SERVICE MANUAL MARINE ENGINES 05 COOLING SYSTEM 05.06 POLY-V BELT 05.06.01 Exchange Poly-V-belt For M 4 cyl. engines only Belt guide without hydraulic pump (ill.1). 04.06 ill.1 Belt guide with hydraulic pump (ill.2). NOTE*): It is recommended to spray frequently some corrosion inhibiting spray into the spring housing of the belt tensioner.
Page 232: V-Belt
SERVICE MANUAL MARINE ENGINES 05 COOLING SYSTEM 05.07 V-BELT 05.07.01 Exchange V-belts For 6 cyl. engines only Alternator: (for example - different versions possible) Loosen setscrews (ill.1+2/pos.1+2) Release V-belts by turning clamping bolt (ill.1+2/ pos.3) counterclockwise and by turning alternator 07.02 ill.1 towards engine.
Page 233 SERVICE MANUAL MARINE ENGINES 05 COOLING SYSTEM Raw water pump (current version) Preparation: Remove alternator V-belts. Loosen screw (ill.5/pos.1). Turn screw counter (ill.6/pos.1) clockwise to reduce of tension V-belt. Remove V-belt. Assembly is done in reverse order. 07.02 ill.5 Adjust V-belt tension; according 05.07.02 Tighten screw (ill.5/pos.1) with a Torque of 23 N +/-2 to secure idler pulley bracket.
Page 234: Adjust V-Belts
SERVICE MANUAL MARINE ENGINES 05 COOLING SYSTEM 05.07.02 Adjust V-belts Measuring device No. VR00515/0 for timing- and V-belt For 6 cyl. engines only With engine stopped, belts should be stretched to such an extent that they yield for 10-13 mm when pressing your finger on marked spots (07.01 ill.4/ A + B).
Page 235: Raw Water Pump
SERVICE MANUAL MARINE ENGINES 05 COOLING SYSTEM 05.10 RAW WATER PUMP 05.10.01 Exchange raw water pump Loosen 3 hexagon screws (ill.1/pos.1) of belt pulley. Remove poly-V-belt or V-belt (05.06 or 05.07) Unscrew 3 screws (ill.1/pos.1) of belt pulley and remove belt pulley (ill.1/pos.2). Loosen hose clamp (ill.1/pos.3) and remove hose.
Page 236: Checks
SERVICE MANUAL MARINE ENGINES 05 COOLING SYSTEM 05.12 CHECKS 05.12.01 Check closed engine cooling system for air This check is for determination and retrieval of an inexplicable coolant loss. Procedure: Use special tool SMO: VR00147/0 by using enclosed instruction. Conclusion: Gas entry (combustion pressure) in the cooling system.
Page 237 SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06 ELECTRICAL SYSTEM Table of Contents 06.00 General ......................3 06.00.01 Cable numbers and principal functions ............3 06.01 Alternator ..................... 4 06.01.01 Adjust poly-V-belt tension ................4 06.01.02 Replace generator..................5 06.01.03 Technical data of alternator ................
Page 238 SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06.07.13 Adjust instruments ..................68 06.07.13.01 Tachometer with running-time meter ............68 06.07.14 Replace instruments ..................70 06.07.14.01 General notes on safety ................70 06.07.14.02 Audible warner, H22 ..................72 06.07.14.03 Circuit diagram voltmeter (optional) ............. 73 06.07.14.04 Circuit diagram oil pressure gauge (optional, sensor B19-gauge P2) ..
Page 239: General
06.00 GENERAL Wiring For the STEYR Marine Engines wiring and plug connections have been defined 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 isolation and/or connector locks meet the respective requirements.
Page 240: Alternator
SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06.01 ALTERNATOR 06.01.01 Adjust poly-V-belt tension For 4 cyl. engines only Automatic initial tension of belt tension through spring-loaded tightener. (ill.1 and ill.2) 01.01 ill.1 01.01 ill.2 For 6 cyl. engines only As to tension of V-belt for alternator, refer to chapter 05.07.01 - 02 Page ELECTRICAL SYSTEM - 4 Z001019/0_6_July 2008...
Page 241 SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06.01.02 Replace alternator Preparatory work: turn off engine, disconnect battery Disconnect two cables (ill. 1/pos.1+2). Remove belt. 01.02 ill.1 Loosen screws (ill.2/pos.1+2), remove alternator. NOTE: Assembly is done in reverse order. For 4 cyl. engines only 01.02 ill.2 Connections ill.3/1...
Page 242: Technical Data Of Alternator
SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06.01.03 Technical data of alternator For 6 cyl. engines only (old version till eng. no. 68224418) Model ....................PRESTOLITE LEECE-Neville ......................8RG2043 Minimum speed for voltage generation ..........580 1/min Controlled voltage range ............... 13,9 - 14,2 V Output current ..................
Page 243 SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM For 6 cyl. engines only (old version till eng. no. 68224418) circuit diagr.: Governor 01.03 ill.3 01.03 ill.2 Check of alternator and connections: With engine stopped, measure voltage on alternator (+output and -output). Measured voltage may be lower than the battery voltage by (up to) 1 volt only.
Page 244 SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM For 6 cyl.engines / Technical data of alternator 14V / 90A (current version from eng. no. 68224419) Model ....................ISKRA-AAK5550-11.203.329 Minimum engine speed for voltage generation ........550 1/min Controlled voltage range ............... 14,1 - 14,5 V Output current ..................
Page 245 SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM For 6 cyl. engines / Technical data of alternator 28V / 80A (Option) Model ....................ISKRA-AAN5161- 11.203.220 Minimum engine speed for voltage generation ........550 1/min Controlled voltage range ............... 28,1 - 28,7 V Output current ..................
Page 246 SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM For 6 cyl. engines / Technical data of alternator 28V / 55A (Option) Model ....................ISKRA-AAK5170- 11.201.894 Minimum engine speed for voltage generation ........550 1/min Controlled voltage range ............... 28,0 - 28,4 V Output current ..................
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Page 248 SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM For 4 cyl. engines only / Technical data of alternator Model ....................BOSCH No. 6 033GB3 046 Minimum speed for voltage generation ..........550 1/min Controlled voltage range ............... 13,9 - 14,7 V Output current ..................
Page 249 SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM For 4 cyl. engines only Error Detection Check battery: All connections (terminals) Acid concentration Filling level (check, refill if necessary) Carry out load test Excessive voltage: Governor Loose connections Battery Charging voltage too low: Belt tension Output Governor...
Page 250: Check Alternator (Error Detection For Bosch Alternator, 4 Cyl. Engines)
SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06.01.04 Check alternator (error detection for BOSCH alternator, 4 cyl. engines) Trouble features Error and/or Relief Test procedure With engine stopped and ignition on, Generator control lamp (L1) burned Tester lamp connected between B+ generator control lamp (L1) not out and/or disconnection in electric and D+ on generator ;...
Page 251 SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM Check rectifier diode Measuring devices with diode test function will show the following results: 12-V-Lampe in forward direction: voltage drop from 0.4 to 0.6 volt in backward direction: reading is "OL". a) by means of control lamp 01.04 ill.1 Diode and control lamp are connected in series in both forward and backward direction in an electric...
Page 252: Replace Starter Motor
Loosen two hexagon screws (ill.2/pos.3) (SW13) of starter bracket. Loosen two screws (SW8) (ill.2/pos.4), remove starter. 03.00 ill.2 NOTE: Have starter motor repaired in an authorized STEYR workshop. After assembly, coat all electric supplies with rubber sealing Z909570/0. Page ELECTRICAL SYSTEM - 16 Z001019/0_6_July 2008...
Page 253: Check Starter
SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06.03.01 Check starter Trouble features Cause Relief When switching on the starter battery discharged and/or defective charge battery and/or replace (acutation of starter key), starter shaft not turning or only slowly; starter terminals of starter battery are loose clean terminals and tighten, treat with pinion not engaging and/or oxidized, bad ground...
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Page 255: Cables, Wiring Harness - General
SERVICE MANUAL MARINE ENGINES 06 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 256: E - Box Base Plate; To Eng.no.: 482 17 000
SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06.05.02 E - box base plate; to eng.no.: 482 17 000 05.02 ill.1 Page ELECTRICAL SYSTEM - 20 Z001019/0_6_July 2008...
Page 257: Components Of E - Box
SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06.05.02.01 Components of E - box; to eng.no.: 482 17 000 Designat. Component Description E - box control unit fuse 50 A main fuse fuse 50 A glow plugs fuse 50 A glow plugs fuse 5 A permanent current module fuse 10 A...
Page 258: Wiring Harness; To Eng.no.: 482 17 000
SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06.05.02.04 Wiring harness; to eng.no.: 482 17 000 Designation Component Description E-box control unit fuse 50 A main fuse fuse 50 A glow plugs fuse 50 A glow plugs fuse 5 A permanent current modul and K27 fuse 10 A switched current for module (K27) fuse 10 A...
Page 259 SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 05.02 ill.4 Wiring harness; to eng.no.: 482 17 000 Z001019/0_6_July 2008 Page ELECTRICAL SYSTEM - 23...
Page 260 SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM Circuit diagram; to eng.no.: 482 17 000 05.02 ill.5 Page ELECTRICAL SYSTEM - 24 Z001019/0_6_July 2008...
Page 261 SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM Line designations from - to Wiring harness; to eng. no.:48 217 000 cable No. designation from --> pin No. end point --> to pin No. 15000-01 J1 plug engine / instruments K24 relay fuel pump 15000-02 J1 plug engine / instruments K24 relay fuel pump...
Page 262 SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM Line designations from - to Wiring harness; to eng. no.:48 217 000 cable No. designation from --> pin No. end point --> to pin No. 30055-01 K24 relay fuel pump F6 fuse fuel pump 31000-01 J1 plug engine / instruments Z2 - mass point...
Page 263 SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM Line designations from - to Wiring harness; to eng. no.:48 217 000 cable No. designation from --> pin No. end point --> to pin No. 60111-01 pot. accelerator B13 X5 control unit (A5) 60112-01 X14 RACK (B14) X5 control unit (A5)
Page 264: E - Box Base Plate; From Eng.no.: 482 18 000/682 18 000 + Solas
SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06.05.03 E - box base plate; from eng. no.: 482 18 000 / 682 18 000 + SOLAS 05.03 ill.1 Page ELECTRICAL SYSTEM - 28 Z001019/0_6_July 2008...
Page 265: Components Of E - Box
SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06.05.03.01 Components of E-box; from eng. no.: 482 18 000 / 682 18 000 + SOLAS Designat. Component Description E - box control unit fuse 50 A main fuse fuse 50 A glow plugs fuse 50 A glow plugs fuse 5 A...
Page 266: Wiring Harness; From Eng.no.: 482 18 000/682 18 000 + Solas
SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06.05.03.04 Wiring harness; from eng.no.: 482 18 000 / 682 18 000 + SOLAS Designation Component Description E-Box control unit fuse 50 A main fuse fuse 50 A glow plugs fuse 50 A glow plugs fuse 5 A permanent current modul and K27...
Page 267 SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM Wiring harness; from eng.no.: 482 18 000 + SOLAS 05.03 ill.4 682 18 000 + SOLAS Z001019/0_6_July 2008 Page ELECTRICAL SYSTEM - 31...
Page 268 SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 05.03 ill.5 Page ELECTRICAL SYSTEM - 32 Z001019/0_6_July 2008...
Page 269 SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 05.03 ill.6 Z001019/0_6_July 2008 Page ELECTRICAL SYSTEM - 33...
Page 270 SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 05.03 ill.7 Page ELECTRICAL SYSTEM - 34 Z001019/0_6_July 2008...
Page 271 SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 05.03 ill.8 Z001019/0_6_July 2008 Page ELECTRICAL SYSTEM - 35...
Page 272: Electronics - General
Tools for crimp connections to be found in tool catalog P/N Z001002/0 "Level 4". 06.06.01 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.
Page 273: Diagnostic System
Effect Panel Additional possible reason noticed Indication Tool-Readings Engine speed sensor See table trouble Higher or No RPM inication Steyr Diag fault shooting: unstable idle on tachometer Service code Speed sensor speed, limited performance Engine speed remains See table trouble...
Page 274: Reading Error Codes
SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06.06.03 Reading Error Codes Entering and reading of stored faults via Check Engine Lamp and Diagnostic Outlet Plug ( X 23 ): Needed device: Tool No. VR00135/1 ( normally closed push button switch ) connected to Diagnostic Outlet Plug X23.
Page 275 SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM If more then one error code is stored in the Engine Management System the indication sequence will be continued blinking additional stored error codes. To delete a memorized error code see description Indication and Cancellation of memorized sensor and circuit faults.
Page 276: Principle Failure Code List
SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06.06.05 Principle failure code list NOTE: Some codes may not apply due to different application! REFER INVOLVED DEVICE CODE ABBREV. CIRCUIT POSSIBLE CAUSE Control code this code is designated for beginning or end of loop LoMap X12/B12 boost pressure sensor...
Page 277 SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM REFER INVOLVED DEVICE CODE ABBREV. CIRCUIT POSSIBLE CAUSE Rack0 Y14(B14) refer to setting rack pos. bad rack zero position defect in governor solenoid wire circuit (Y20, main FMSpwm X20/Y20 actuator / solenoid relay K27-no frequency sent or govenor solenoid circuit connected) HiVTGc REA unit at turbo charger...
Page 278: Replace Fuses
SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06.06.06 REPLACE FUSES Preparatory works: Engine out of operation, disconnect battery. Replace automatic circuit breaker Swing off E-box base plate. Disconnect cable from automatic circuit breaker. Loosen 2 hexagon screws (ill.1/pos.1) (SW1/4") and take off thermal circuit breaker (ill.1/pos.2).
Page 279: Connection J
SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06.06.07 Connection J1 06.07 ill.1 Cable - no. Explication 15000-01 ignition 15 15000-02 ignition 15 30012-07 terminal 30 30012-08 terminal 30 31000-01 ground connection 31000-02 ground connection 60616-01 lamp - oil pressure L3 31615-01 warning horn 60706-01...
Page 280: Connection A5 And X5
SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06.06.08 Connection A5 and X5 06.08 ill.1 Cable no. Designation Explication 30012 / 01 Vbat terminal 30 31000 / 06 terminal 31 15100 / 01 Vref + 5V free free not busy free free not busy 60616 / 01...
Page 281: Fitting Main Connector "J1" Properly
SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06.06.09 Fitting main connector "J1" properly Z001019/0_6_July 2008 Page ELECTRICAL SYSTEM - 45...
Page 282: Instrument Panel
SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06. 07. INSTRUMENT PANEL 07.00 ill.1 Instrument panel, standard tachometer blind plug - installation option for engine temperature key switch constant revolution warning light - battery charge blind plug - installation option for combined light preheating control &...
Page 283 SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06. 07. 01 Chart - Operating Status Instrument indication during normal operation 1. ignition ON (... until engine start) System check - see light indication light indication NOTE: At low temperature condition (cold weather) the combined light for glow plug preheating &...
Page 284: Chart - Error Indication On Instrument Panel
SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM 06. 07. 02 Chart - Error indication on Instrument Panel 07.02 ill.1 temperature gauge - coolant combined light preheating control & audible warner warning light engine oil pressure warning light - battery charge warning light check engine Operating condition: During normale engine operation, or indication in case of sensor defect while...
Page 285 SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM Fault Indication status Remarks 80° - 90°C check raw water high exhaust system, temperature strainer, impeller pump (off 80° C) FLASHING (2x per sec.) (2x per sec.) 07.02 ill.4 high approx 105°C after cooling down, engine coolant check engine coolant temperature to high...
Page 286 SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM Indication status Fault Remarks During start attempt Engine will not start. Failure in governing circuit. Failure in governing Positioning of rack circuit not possible. Trouble shooting of control solenoid, rack, control gear of unit injection, rack position sensor 07.02 ill.9 Page ELECTRICAL SYSTEM - 50...
Page 287 SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM THIS PAGE IS INTENTIONALLY BLANK Z001019/0_6_July 2008 Page ELECTRICAL SYSTEM - 51...
Page 288: Instrument Panel (For Solas Only)
SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 06.07.03 Instrument panel (for SOLAS only) 07.03 ill.1 tachometer with push button START (green) service hour meter temperature gauge - coolant blind plug - installation option for warning light - battery charge oil pressure gauge or combined light preheating control &...
Page 289 SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 06.07.04 Chart - Operating Status (for SOLAS only) Instrument indication during normal operation 1. ignition ON (... until engine start) System check - see light indication 07.04 ill.1 NOTE: At low temperature condition (cold weather) the combined light for glow plug preheating &...
Page 290 SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 06.07.05 Error Indication - Error indication on instrument panel (for SOLAS only) 07.05 ill.1 temperature gauge - coolant combined light preheating control & audible warning device warning light engine oil pressure warning light - battery charge warning light - check engine light Operating condition: During normal engine operation,...
Page 291 SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM Indication status Fault Remarks 80° - 90°C check raw water high exhaust system, temperature strainer, impeller pump (off 80° C) (2x per sec.) FLASHING (2x per sec.) 07.05 ill.4 high approx 105°C after cooling down, engine coolant check engine coolant temperature to high...
Page 292 SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM Indication status Fault Remarks During start attempt Engine will not start. Failure in governing circuit. Failure in governing Positioning of rack circuit not possible. Trouble shooting of control solenoid, rack, control gear of unit injection, rack position sensor 07.05 ill.9 Page ELECTRICAL SYSTEM - 56...
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Page 294: Used - Old Version
SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 06. 07. 10 6 Cyl. Wiring harness instrument panel (if alternator "PRESTOLITE" is used - old version) Designat. Component Description fuse 23-pin plug connection engine cable - instrument cable switch ignition switch fix-n (speed-selector switch optional) relay charge control (90A PRESTOLITE) lamp...
Page 295: Cyl. Wiring Harness Instrument Panel (If Alternator "Prestolite" Is Used - Old Version)
SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 6 Cyl. Wiring harness instrument panel (if alternator "PRESTOLITE" is used - old version) 07.10 ill.1 Z001019/0_6_July 2008 Page ELECTRICAL SYSTEM - 59...
Page 296 SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 6 Cyl. Wiring harness instrument panel (if alternator "PRESTOLITE" is used - old version) Designat. Component Description fuse 23-pin plug connection engine cable - instrument cable switch ignition switch fix-n (speed-selector switch optional) relay charge control (90A PRESTOLITE) lamp charge control...
Page 297 SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 6 Cyl. Wiring harness instrument panel (if alternator "PRESTOLITE" is used - old version) 07.10 ill.2 Z001019/0_6_July 2008 Page ELECTRICAL SYSTEM - 61...
Page 298: Description - Wiring Harness Instrument Panels 4/6 Cyl. Marine Engines (Current Version)
(optional) lighting tachometer gauge 1-pin plug connector illumination switch 8-pin plug connector STEYR - display splice battery + splice battery - splice ignition (+) splice key switch constant revolution 24 V interm.
Page 299 SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 58000-01 Z001019/0_6_July 2008 Page ELECTRICAL SYSTEM - 63...
Page 300 SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 58000-01 Page ELECTRICAL SYSTEM - 64 Z001019/0_6_July 2008...
Page 301 SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 58000-01 Z001019/0_6_July 2008 Page ELECTRICAL SYSTEM - 65...
Page 302 SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 58000-01 Page ELECTRICAL SYSTEM - 66 Z001019/0_6_July 2008...
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Page 304: Adjust Instruments
SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 06. 07. 13 ADJUST INSTRUMENTS 06. 07. 13. 01 Tachometer with running-time meter There are 2 possible settings Function "PULSE": - Entry of pulse rate 12,18 per revolution - inductive sender Function "ADJUST": - Using a reference rpm meter (manual rpm meter), the rpm is compared and calibrated accordingly.
Page 305 SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM Function "ADJUSt" When selecting the function "ADJUST", the rpm. display may be adjusted between 30 and 100 % of the measuring range. Using a reference rpm meter (manual rpm meter), the rpm indicator is compared. Fine adjustment requires two persons, one to operate the instrument and the other one to operate the manual rpm meter on the axis of the engine's...
Page 306: Replace Instruments
SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 06. 07. 14 REPLACE INSTRUMENTS 06. 07. 14. 01. General notes on safety Safety instructions No smoking! No open fire lights! This product has been developed, produced and tested in compliance with the basic safety requirements of EC directives and in accordance with the established state of the art.
Page 307 SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM Safety Instructions (electrical connection): To install the electric cables, use existing cable ducts and looms, but do not run the cables paralle to ignition cables or parallel to cables leading powerful consumers. Secure the cables using cable binders or adhesive tape.
Page 308: Audible Warner, H22
SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 06. 07. 14. 02 Audible warner, H22 control unit control unit 07.14 ill.1 sensor sensor sensor oil pressure exhaust gas engine coolant temperature Page ELECTRICAL SYSTEM - 72 Z001019/0_6_July 2008...
Page 309: Circuit Diagram Voltmeter (Optional)
SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 06. 07. 14. 03 Circuit diagram voltmeter (optional) 07.14 ill.2 07.14 ill.2 06. 07. 14. 04 Circuit diagram oil pressure gauge (optional, sensor B19 - gauge P2) 06. 07. 14. 04 Circuit diagram oil pressure gauge (optional, sensor B19 - gauge P2) single instruments double instruments (requires special sensor) sensor marking "G"...
Page 310: Potentiometer Accelerator, B13
SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 06.08.01 Potentiometer Accelerator, B13 Remove plug housing. Unscrew hexagon nut of accelerator lever, remove lever. Loosen 2 hexagon screws. Remove accelerator. Throttle potentiometer B13 (accelerator) (= connector X13) 08.01 ill.1 In case of defective potentiometer accelerator B13, service codes 23, 24 or 29 will flash.
Page 311: Voltage Regulator 24V-12V Equalizer
SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 06.08.02 Voltage regulator 24V-12V equalizer Powersupply to equalizer recomandet 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" positiv terminal +12V connect a red wire AWG 6 (10 mm²) at battery "B"...
Page 312: Dc-Dc Converter
SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 06.08.03 DC - DC converter DC-DC Converter IVO 8770 CIRCUIT DIAGRAM Batt "A" 24VDC Engine 12VDC Batt "B" Batt "C" Page ELECTRICAL SYSTEM - 76 Z001019/0_6_July 2008...
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Page 314: Component Configuration 4 Cyl. Engine
SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM to engine number 48226999 06.10 SENDER AND SENSOR OVERVIEW 06.10.01 Component configuration 4 cyl. engine 164/174 94/114/144 10.01 ill.1 CODE KURZNAME BESCHREIBUNG ABBREVIATION DESCRIPTION CODE KURZNAME BESCHREIBUNG Stecker Ölmanometer (Option) ABBREVIATION DESCRIPTION Connector oil pressure gauge (optional) Stecker Trimmanzeige (Option) Ladedrucksensor Connector trim (optional)
Page 315 SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM from engine number 48227000 07002 CODE BESCHREIBUNG BESCHREIBUNG CODE DESCRIPTION DESCRIPTION Ladedrucksensor Stecker Ölmanometer (Option) Boost-pressure sensor Connector oil pressure gauge (optional) Gaspedal Stecker Trimmanzeige (Option) Potentiometer accelerator Connector trim (optional) Regelstangensensor Haupt-Verbindungsstecker Rack position sensor Main connector Motordrehzahlsensor Diagnose - Stecker...
Page 316: Component Configuration 6 Cyl. Engine
SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 06.10.02 Component configuration 6 cyl. engine to engine number 68226999 2 4 6 / 2 5 6 / 1 2 6 / 1 6 6 / 10.02 ill.1 CODE KURZNAME BESCHREIBUNG ABBREVIATION DESCRIPTION CODE KURZNAME BESCHREIBUNG Stecker Ölmanometer (Option)
Page 317 SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM from engine number 68227000 07003 BESCHREIBUNG BESCHREIBUNG CODE CODE DESCRIPTION DESCRIPTION Ladedrucksensor Stecker Ölmanometer (Option) Boost-pressure sensor Connector oil pressure gauge (optional) Gaspedal Stecker Trimmanzeige (Option) Potentiometer accelerator Connector trim (optional) Regelstangensensor Haupt-Verbindungsstecker Rack position sensor Main connector Motordrehzahlsensor Diagnose - Stecker...
Page 318: Calibration Of Rack Position
SERVICE MANUAL MARINE ENGINES 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 319 SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 06.10.04 Replace Senders, Sensors 06.10.04.01 Exhaust gas temperature sensor, B17 Unlock plug (ill.1/pos.1) and remove. Unscrew temperature sensor (ill.1/pos.2) (SW19) 10.04 ill.1 06.10.04.02 Engine temperature sensor, B16 Remove plug housing (ill.2/pos.1). Unscrew engine temperature sensor. 10.04 ill.2 06.10.04.03 Speed sensor, B15 Press catch spring and remove plug.
Page 320: Potentiometer Accelerator B13
SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM Boost pressure sensor, B12 for engines 164 / 174 / 246 / 256 / 266 only Remove cable strap, lift shackle at plug and pull off plug. Loosen clamp (SW6) and pull off hose. Loosen union nut (SW17) by holding up at sensor (SW32).
Page 321: Check Sensors And Switches
SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 10.04 ill. 9 06.10.05 Check Sensors and Switches 06.10.05.01 A Check rack position feedback sensor B14 (= connector X14) In case of defective rack position feedback sensor B14, service codes (35) and (36) will flash. NOTE: First always check cables and connections.
Page 322 SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM Measure resistance between terminals B and C with inserted shaft. Resistance must be 2,4 kOhm ± 10 %. When a failure was found during one of above checks, replace rack position feedback sensor B14. 10.05 A ill.4 06.10.05.01 B Check rack position feedback sensor...
Page 323: Check Throttle Potentiometer B13 (Accelerator) (= Connector X13)
SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM Sensor retracted! Measure between terminal A (minus) and B (signal out). Measured votage must be 0,12V DC +/- 5%. When a failure was found during one of above checks, replace rack position feedback sensor B14. 10.05 B ill.4 06.10.05.02 Check throttle potentiometer B13 (accelerator) (= connector X13)
Page 324 SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 06.10.05.03 Check boost pressure sensor, B12, for engine models: 94 / 114 / 144 / 126 / 166 / 236 Athmospheric pressure 10.05 ill.7 For engine models: 164 / 174 / 246 / 256 / 266 Supply voltage 5V +/- 0,2V Connector position...
Page 325: Check Speed Sensor B15 And/Or Wiring
SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 06.10.05.04 Check speed sensor B15 and/or wiring X 15/1 15012-06 X15/2 60113-01 X15/3 31000-03 10.05 ill.9 On account of the sensor's integrated electronic system, only the supply voltage and/or the output signal and the continuity to control unit A5 can be measured. Make sure that with disconnected plug X15 and ignition "ON"...
Page 326: Check Oil Pressure Sensor B18 And/Or Wiring
SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 06.10.05.05 Check oil pressure sensor B18 and/or wiring X18/A 31100-10 X18/B 15100-07 X18/C 60117-01 10.05 ill.10 On account of the sensor's integrated electronic system,only the supply voltage and/or the output signal can be measured. Make sure that with disconnected plug X15 and ignition "ON"...
Page 327: Check Oil Pressure Sensor "Vdo-Instrument" (Option B19)
SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 06.10.05.06 Check oil pressure sensor "VDO-instrument" (option B19) NOTE: If oil pressure is questionable, - check oil level before starting the engine. - check minimum oil pressure. Minimum oil pressure Idle 1 bar 1000 2 bar 2500 and above 4 bar...
Page 328: Check Coolant Temperature Sensor, B16
SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM Check oil pressure sensor over entire pressure range: Disassemble sensor and connect it to a gauged pressure source. Connect ohmmeter and pressurize sensor. Read and record pressure and resistance at different spots over the entire pressure range. Compare pressure and resistance values with chart.
Page 329: Check Audible Warner
SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM If this check brings no information, drain the coolant and remove the sensor. Immerse sensor together with thermometer into a canister with coolant. Connect a digital ohmmeter to the sensor and heat the fluid on a heater. Monitor ohmmeter und thermometer.
Page 330: Battery
SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM 06.12. BATTERY 06.12.01 Battery Battery - Acid Test 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 331 SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM The battery should always be charged as full as possible. Regularly check the state of charge with the battery acid tester. We recommend to check the acid density and acid level periodically every two weeks.

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STEYR 4 CYLINDER Service Manual

Table of Contents

Ageneral Remarks

B Specifications

C Maintenance and Service

General Information

E Quality Gudelines for Repair

F Operating Material and Information on Disposal

Gnotes on Safety

H Thightening Torques

J Wear Limits

Table of Contents

Engine Timing, Engine Mount

Cylinder Block

Crankshaft, Bearing, Vibration Damper

Flywheel, Housing

Piston and Connecting Rod

Camshaft, Housing, Valve Gear

Engine Housing, Oil Pump, Oil Suction Pipe

Intercooler

Auxiliary Drive, in Front (PTO)

Engine Oil Cooler

Exhaust Manifold, Seals, Heat Exchanger

Table of Contents

Fuel System / Functional Description

Fuel Pump, Unit Injector, Lines

Change Air Filter

Air Filter

Turbocharger

Control Solenoid

Change Fuel Filter

Replace Glow Plug

Measurement of Compression Pressure

Fuel System Check

Cooling System

Functional Description Cooling Circuit

Cooler, Heat Exchanger, Expansion Tank

Pipes, Thermostat

Coolant Pump

Poly-V-Belt

V-Belt

Raw Water Pump

Checks

Table of Contents

Alternator

Replace Starter Motor

Cables, Wiring Harness - General

E - Box Base Plate; to Eng.no.: 482 17 000

Wiring Harness; to Eng.no.: 482 17 000

E - Box Base Plate; from Eng.no.: 482 18 000/682 18 000 + SOLAS

Wiring Harness; from Eng.no.: 482 18 000/682 18 000 + SOLAS

Electronics - General

Instrument Panel

Potentiometer Accelerator, B13

Battery

Quick Links

Chapters

Need help?

Questions and answers

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Summary of Contents for STEYR 4 CYLINDER