Weber Automotive MPE 750 Turbo Marine Service Manual
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Summary of Contents for Weber Automotive MPE 750 Turbo Marine
- Page 1 Service Manual MPE 750 Turbo Marine Open Loop MPE 750 Turbo Marine - Open Loop This service manual is valid for the following engine variants: • 103875_I2 749 MAR TC-110 DS V1 2007 3.1 103875_SHB_Rev1.1_080611...
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Page 2: Table Of Contents
Service Manual MPE 750 Turbo Marine Open Loop Table of contents About this document 1.1 Meaning of the symbols in the text Safety 2.1 Basic principle 2.2 Meaning of the safety symbols 2.3 General safety instructions Description 3.1 Technical specifications 3.2 Serial number 3.3 Operating materials 3.4 Running in the engine 3.5 Operating the engine without sea water Maintenance 4.1 Maintenance work by the user of the vehicle 4.2 Maintenance intervals 4.3 Decommissioning at the end of the season 4.4 Motor oil and oil filter 4.5... -
Page 3: About This Document
Service Manual MPE 750 Turbo Marine Open Loop About this document This chapter will familiarize you with the structure of this document so that you can find the information it contains quickly and easily. This document uses symbols and signs that allow you to find information quickly. Please read the explanations of the symbols and signs in this chapter. Be sure to read all safety instructions in this service manually especially carefully. Always keep this documentation handy and make sure it is always in the vehicle. Be sure to inform other users of all safety provisions. Meaning of the symbols in the text Symbol / Explanation Sign Need Required tools for carrying out the activities in this section. Need Required spare parts for the activities in this section. -
Page 4: Safety
Service Manual MPE 750 Turbo Marine Open Loop Safety Basic principle This engine is state-of-the-art and built according to recognized safety-technical regulations. Nevertheless, people can be injured or the engine damaged if the safety instructions in this manual are disregarded. Only put the engine into operation if it is technically perfect. Faults that compromise the safety of people or of the engine must be eliminated immediately by trained service personnel. -
Page 5: General Safety Instructions
Service Manual MPE 750 Turbo Marine Open Loop General safety instructions The engine may only be operated at idle speed for a maximum of 30 seconds without sea water. Engine damage due to overheating. ATTENTION See Chapter Operating the engine without sea water. Lift a submerged engine out of the water as quickly as possible and take it to a professional shop for maintenance within 24 hours. Belated... -
Page 6: Description
Service Manual MPE 750 Turbo Marine Open Loop Description The MPE 750 Turbo Marine - Open Loop is a 2-cylinder in-line engine. It is intended for recreational watercraft. It is not designed for constant loads at high speeds as can occur during races, for example. Technical specifications Type 2-cylinder parallel twin with vibration compensation shaft Displacement 749 cm³ Engine power 81 kW (110 PS) [109 HP] SAE 1228 8000 U/min [RPM] Max. speed 8400 U/min [RPM] Charging Turbocharger Combustion system Intake-manifold fuel injection Injection regulation electronic Lubrication system Dry sump Cooling system Water-cooled with open sea water cooling circuit Serial number The 8-digit serial number (1) serves to identify the engine. It is engraved in the... -
Page 7: Operating Materials
Service Manual MPE 750 Turbo Marine Open Loop Operating materials The use of other operating materials causes damage to the engine and the voiding of the warranty. ATTENTION Fuel Fuel quality Unleaded gasoline according to DIN 51607 („super unleaded“), with an octane rating of at least 95 ROZ [RON] or 85 MOZ [MON]. In case of emergency, unleaded fuel with 91 ROZ [RON] or 82.5 MOZ [MON] may be used for a short time. Lower-quality fuels should only be used in case of emergency. If used regularly, they cause... -
Page 8: Running In The Engine
Service Manual MPE 750 Turbo Marine Open Loop Running in the engine Weber Automotive GmbH recommends that during the first five hours of operation, you should not operate the engine over 6,000 U/min [RPM]. This protective running-in has a positive effect on the engine‘s lifespan. Operating the engine without sea water If it is necessary to operate the engine longer than 30 seconds without sea water, the vehicle‘s rinsing equipment must be used. See chapter Flush sea water cooling circuit after driving. -
Page 9: Maintenance
During the warranty period, maintenance and repair work may only be carried out in Weber Motor service stations or in associated shops. If necessary, contact your vehicle dealer. Weber Automotive GmbH reserves the right to demand that proof of warranty be provided in writing for warranty service. See Proof of maintenance for work carried out. The vehicle owner or user is responsible for adhering to the maintenance intervals. Weber Automotive GmbH assumes no liability for damage ATTENTION that arises due to maintenance not carried out. 103875_SHB_Rev1.1_080611 Page 7... -
Page 10: Maintenance Work By The User Of The Vehicle
Service Manual MPE 750 Turbo Marine Open Loop Maintenance work by the user of the vehicle Regular checks before driving Always check the oil level before driving. See Chapter Oil level check. Underrunning and exceeding the motor oil fill level specified in this manual can cause damage to the engine. ATTENTION Flush sea water cooling circuit after driving In order to protect the sea water cooling circuit against soiling, calcium deposits and such, the sea water cooling circuit must be flushed after each use. Soiling in the sea water cooling circuit can cause severe damage to the exhaust manifold. ATTENTION The flushing is done with a flush kit in the vehicle. See the vehicle manufacturer‘s service... -
Page 11: Maintenance Intervals
Service Manual MPE 750 Turbo Marine Open Loop Maintenance intervals Activities on the engine must be carried out by trained service personnel. mainte- nance Maintenance interval after 10 - 12 every 25 every 100 Motor oil and oil Change ■ ■ ■ filter Check / ■ clean Spark plugs Change ■ Check / Valve play ■ ■ h = hours of operation or at least once a year if the hours of operation specified above are not reached before that. -
Page 12: Decommissioning At The End Of The Season
Service Manual MPE 750 Turbo Marine Open Loop Decommissioning at the end of the season The decommissioning of the vehicle is necessary ..at the end of the season if the vehicle will be decommissioned during the winter months..if the vehicle will not be used for more than 30 days. In addition to the maintenance work described in the maintenance interval table under end of the season, various other service work is also required. -
Page 13: Motor Oil And Oil Filter
Service Manual MPE 750 Turbo Marine Open Loop Motor oil and oil filter Oil level check - Use a clean, lint-free cloth The oil level must be measured with oil warm from operation (approx. 80 °C [176 °F]) and with the motor at a standstill. Measurements with cold oil are not meaningful. The desired motor temperature is achieved after a driving time of approx. 10 minutes at 4000 - 4500 U/min [RPM]. Measurement with a motor warm from operation is necessary, because the oil volume changes depending on the temperature. To avoid mistaken measurements, the vehicle must be level. - Page 14 Service Manual MPE 750 Turbo Marine Open Loop Oil level check (continuation) Unscrew the oil dipstick (1) from the oil tank and wipe it clean with a cloth. Replace the oil dipstick in the oil tank. Do not screw it in. Then remove it again and read the oil level. With a motor warm from operation, the oil level must be just below the MAX marking.
- Page 15 Service Manual MPE 750 Turbo Marine Open Loop Changing the motor oil and oil filter Oil extraction pump Catch basin for old oil, fill volume at least 4 liters [4.3 qt (US)] Flathead screwdriver or wrench to open the screw clamps Torque wrench to close the screw clamps Torque wrench SW27 [1 1/16 “] for oil filter cover Possible hose extension for oil feed hose with screw clamps Funnel tube for motor oil Motor oil, see chapter Operating materials Oil filter, see spare parts catalogue Draining the motor oil With a motor warm from operation, the greatest oil volume is sucked out of the motor. Unscrew the oil dipstick from the oil tank. See Chapter Oil level check. Insert the suction hose of the oil...
- Page 16 Service Manual MPE 750 Turbo Marine Open Loop Draining the motor oil (continuation) The motor oil in the dry sump tank is pumped out with the help of the engine dry sump pump. Remove the cable harness from the spark plugs and the injection valves. See Chapter Removing the spark plugs. Remove the oil feed hose (2) on one side of the oil tank. If necessary, extend the oil feed hose. Tightening torque: 3 Nm ± 10 % [2.2 ft. lb.]...
- Page 17 Service Manual MPE 750 Turbo Marine Open Loop Changing the oil filter Unplug the plug from switch 70/65°C (3). 10) Unscrew the oil filter cover (4). Tightening torque: 24 Nm ± 10 % [17.7 ft. lb.] 11) Replace the oil filter (5) and O-ring (6). 12) Coat the O-ring (6) lightly with motor oil. During reassembly, make sure that the oil filter snaps in. Assembly occurs in reverse order. Please note instructions after this ...
- Page 18 Service Manual MPE 750 Turbo Marine Open Loop Refilling the motor oil 13) Fill oil tank with 2.5 liters of motor oil. 14) Close the oil tank with the oil dipstick. 15) Warm up the motor in a body of water for approx. 10 minutes at 4000 - 4500 U/min. 16) Fill up the oil level with a motor warm from operation until just below the MAX marking.
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Page 19: Spark Plugs
Service Manual MPE 750 Turbo Marine Open Loop Spark plugs Checking the spark plugs Socket wrench SW16 [5/8 “] Feeler gauge, measurement range 0.69 mm - 0.84 mm [0.0272 - 0.0331 in.] Torque wrench 2x spark plugs, see spare parts catalogue Removing the spark plugs Remove cable harness on the ignition coils (1). Loosen the cable harness on the cable holders (2). Remove the cable harness on the injection valves (3). Before disassembling, make sure that the plugs of the ignition coils and the injection valves are not switched during assembly. - Page 20 Service Manual MPE 750 Turbo Marine Open Loop Removing the spark plugs (continuation) Remove the screws and washers (4). Remove the ignition coils (5) Install the spark plugs only in a cold engine. Grease the threads of the spark plugs with commercial graphite grease. Tightening torque: 10 Nm ± 10 % [7.4 ft. lb.] Unscrew the spark plugs (6). Tightening torque: 27 Nm ± 20 % [19.9 ft. lb.] Assembly occurs in reverse order. Please note instructions after this ...
- Page 21 Service Manual MPE 750 Turbo Marine Open Loop Checking the spark plugs Check the electrode distance of the spark plugs with the help of the feeler gauge. 0,69 - 0,84 mm [0.0272 - 0.0331 in.] 103875_SHB_Rev1.1_080611 Page 1...
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Page 22: Valve Play
Service Manual MPE 750 Turbo Marine Open Loop Valve play Checking and setting the valve play Hex wrench SW5 [3/16 “] Feeler gauge, measurement range 0.08 mm - 0.25 mm [0.0031 - 0.0098 in.] Valve adjustment tool, see spare parts catalogue Combination wrench 24mm [15/16 “] Bar magnet Measurement tool for adjustment plate, reading 0.01mm [0.0003 in.] Adjustment plates from 2.5 - 3.7 mm [0.0984 - 0.1457 in.], see spare parts catalogue Valve cover seals, see spare parts catalogue 2x O-rings, see spare parts catalogue To get correct measurement valves, check and adjust valve play with a cold engine. Removing the valve cover Remove the cable harness on the cam shaft sensor (1). Remove the spark plugs. See Chapter Removing the spark plugs. 103875_SHB_Rev1.1_080611 Page 0... - Page 23 Service Manual MPE 750 Turbo Marine Open Loop Removing the valve cover (continuation) Unscrew the valve cover (2) along with bracket and valve (3). Tightening torque: 10 Nm ± 10 % [7.4 ft. lb.] The sequence of the connection occurs according figure. Replace the valve cover seals (4). Clean seal areas of the valve cover and cylinder head. Assembly occurs in reverse order. Please note instructions after this ...
- Page 24 Service Manual MPE 750 Turbo Marine Open Loop Desmontar la tapa de válvula Checking the valve play of the first cylinder Start the vehicle’s starter and let Exhaust side the engine crank until both cams of the second cylinder are pointing upwards. The rocker of the first cylinder demonstrates a little play. 2nd cylinder 1st cylinder Drive side Intake side...
- Page 25 Service Manual MPE 750 Turbo Marine Open Loop Adjusting the valve play To adjust the valve play on the intake side, it is necessary to remove the fuel distributor rail. Remove the cable harness on the coolant sensor (7). Loosen the screws and washers (8) and remove the fuel distributor rail (9). Tightening torque: 10 Nm ± 10 % [7.4 ft. lb.] 103875_SHB_Rev1.1_080611...
- Page 26 Service Manual MPE 750 Turbo Marine Open Loop Adjusting the valve play (continuation) Replace the O-rings (9) on the injector valves. Coat the O-rings lightly with motor oil. Mount the valve adjustment tool (11) with two screws. Tightening torque: 10 Nm ± 10 % [7.4 ft. lb.] The engine may not be turned over until all valve plays of the first cylinder are adjusted. ATTENTION 103875_SHB_Rev1.1_080611 Page ...
- Page 27 Service Manual MPE 750 Turbo Marine Open Loop Adjusting the valve play (continuation) Press the rocker downwards with a 24 combination wrench (12). 10) Clamp both valves by pressing in the sliding piece (13). 11) Remove the adjustment plate with the bar magnet. 12) Measure the strength of the adjustment plate and replace with an adjustment plate with which the permissible tolerance is adhered 13) Replace the adjustment plate in the spring seat.
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Page 28: Malfunctions
Service Manual MPE 750 Turbo Marine Open Loop Malfunctions If you cannot correct a malfunction yourself using the table below, contact your vehicle dealer‘s customer service. In case of improperly-made repairs, the warranty is voided and Weber Automotive GmbH is not liable for any resulting subsequent damage. Engine does not crank Possible cause Remedy Main power switch not plugged in. Plug in main power switch. Battery voltage too low. Remove soiling and corrosion on the battery poles and connect battery connections - Open-circuit voltage < 12 volts. correctly. - During activation of the starter With non maintenance-free batteries, check < 10.5 volts. - Page 29 Service Manual MPE 750 Turbo Marine Open Loop Engine cranks but does not start Possible cause Remedy Lanyard not plugged in. Plug in lanyard. Defective fuse. Check the fuses in the cable harness. Too little or no fuel in the tank. Fill up fuel. Check the engine for signs of leaky fuel lines and, if necessary, have it checked by a professional shop. Cable harness plug connections not Check plug connections. plugged in or not plugged in correctly. Spark plugs defective. Check the spark plugs and, if necessary, replace them. See Chapter Spark plugs.
- Page 30 Service Manual MPE 750 Turbo Marine Open Loop Engine stalls and cannot be started again Possible cause Remedy Lanyard not plugged in. Plug in lanyard. Defective fuse. Check the fuses in the cable harness. Too little or no fuel in the tank. Fill up fuel. Check the engine for signs of leaky fuel lines and, if necessary, have it checked by a professional shop. Cable harness plug connections not Check plug connections. plugged in or not plugged in correctly. Spark plugs defective. Check the spark plugs and, if necessary, replace them. See Chapter Spark plugs.
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Page 31: Terminology
Service Manual MPE 750 Turbo Marine Open Loop Terminology Adjusting the valve play 23 Changing the oil filter 15 Checking the spark plugs 19 Checking the valve play 22 Decommissioning at the end of the season 10 Draining the motor oil 13 Fuel quality 5 Maintenance intervals 9 Maintenance work by the user of the watercraft 8 Malfunctions 26 Oil level check 11 Oil specification 5 Operating materials 5 Operating the engine without sea water Refilling the motor oil 16 Regular checks before driving 8 Removing the spark plugs 17 Removing the valve cover 20 Rinse sea water cooling circuit after driving 8 Running in the engine 6 Serial number 4 Submerged engine 3 Technical specifications 4 103875_SHB_Rev1.1_080611 Page ... -
Page 32: Appendix
Service Manual MPE 750 Turbo Marine Open Loop Appendix Manufacturer Weber Automotive GmbH Address Otto-Lilienthal-Str.5 88677 Markdorf Germany Internet www.weber-automotive.com Engine MPE 750 SO Engine family WEBM.750TG (EU family designation) 8WEBM.7508TG (USA family designation, adjusted to the model year annually) Directives Weber Automotive GmbH thus confirms that the construction of the engine corresponds to the following pertinent conditions: – EU directive about sport boats 94/25/EG with addendum 2003/44/EG – USA EPA Federal Register 40 CFR Part 91 – USA CARB 13 California Code of Regulation Article 4.7 Spark Ignition Marine Engines 103875_SHB_Rev1.1_080611 Page 30... -
Page 33: Exhaust Type Authorizations
Service Manual MPE 750 Turbo Marine Open Loop Exhaust type authorizations Type test center Europe Germanischer Lloyd Type test center USA CARB (California Air Resources Board) EPA (United States Environmental Protection Agency) All originals are present and can be viewed at any time. They can be called up on the Internet at www.weber-automotive.com. Appendices to this service manual: „Declaration of Conformity for Recreational Craft Propulsion Engines“ „California Emission Control Warranty Statement“ 103875_SHB_Rev1.1_080611 Page 31... -
Page 34: Proof Of Maintenance For Work Carried Out
Service Manual MPE 750 Turbo Marine Open Loop Proof of maintenance for work carried out _ _ _ _ _ _ _ _ _ _ _________________ Motor - serial number (8-digit) Date of initial registration Work carried out: Work carried out: Motor oil change Motor oil change Date: Date: Oil filter change Oil filter change Spark plug change... - Page 35 Service Manual MPE 750 Turbo Marine Open Loop Work carried out: Work carried out: Motor oil change Motor oil change Date: Date: Oil filter change Oil filter change Spark plug change Spark plug change Valve play checked Valve play checked Status Status Valve play adjusted Valve play adjusted Hours of operation: Hours of operation: Coolant change Coolant change ............................................................................
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