This engine installation and operation manual is provided as guidance for the installation of Hyundai SeasAll engine in a boat, and to describe engine operation. Its purpose is to provide technical information to aid in performing an effective engine installation so as to achieve both maximum performance and service life.
Wait until the engine is fully cool to do inspection and maintenance. • Do not use the engine for a purpose other than what is intended by Hyundai SeasAll. Do REFUELING not modify the performance of the supplied engine without the express permission of •...
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 2. ENGINE SUSPENSION EYES 1) To lift the engine, first remove the engine cover. You will find three engine eyes (see figure). 2) To avoid engine damage, take care that engine lift chains or belts do not hit or touch surrounding parts during engine lifting.
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 3. ENGINE IDENTIFICATION Engine identification is affixed to the engine block and the ECU box (see figure). SERIAL NUMBER ON THE ENGINE BLOCK NAME PLATE ON THE ECU BOX Worldwide - 7 -...
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 7. ENGINE DIMENSIONS MerCruiser Bravo One X Diesel Front view Side view MerCruiser Bravo Two X Diesel Front view Side view - 13 -...
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INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines MerCruiser Bravo Three X Diesel Front view Side view ZF 63 A Front view Side view - 14 -...
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INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines ZF 63 C Front view Side view Waterjet adapter without ZF 45C / ZF 63C Front view Side view - 15 -...
2. ENGINE MOUNT DIMENSIONS CAUTION CAUTION USE ONLY THE ORIGINAL HYUNDAI SEASALL ENGINE MOUNTS THAT USE ONLY THE ORIGINAL HYUNDAI SEASALL ENGINE MOUNTS THAT WERE SUPPLIED WITH THE INITIAL PURCHASE. WERE SUPPLIED WITH THE INITIAL PURCHASE.
FOR INFORMATION ON INSTALLATION OF THE STERNDRIVE BRAVO MODELS, PLEASE SEE THE SEPARATE BOOKLETS INCLUDED IN THE MODELS, PLEASE SEE THE SEPARATE BOOKLETS INCLUDED IN THE ORIGINAL PACKAGING OF YOUR HYUNDAI SEASALL PURCHASE. ORIGINAL PACKAGING OF YOUR HYUNDAI SEASALL PURCHASE. - 17 -...
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 2. SEAWATER FLOW – OPEN COOLING CIRCUIT Water strainer ← Water valve ← Water pickup ↓ ① Seawater pump ↓ ② Intercooler ↓ ③ Heat exchanger ⑤ EVGT cooler ↓ ④ Oil cooler ↓...
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 4) To clean strainer filter, • Stop the engine and close the water valve • Remove the filter cap • Remove the filter element, flush it thoroughly with clean water or compressed air •...
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INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines • Apply soapy water to impeller when assembling, and reassemble twisting the impeller in the direction of rotation • Replace the O-ring on the impeller housing cover • Open the water valve •...
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 3. ENGINE COOLANT FOW – CLOSED COOLING CIRCUIT THERMOSTAT CLOSED ① Engine coolant outlet ↓ ① ① ② Exhaust manifold ↓ ③ ③ Thermostat closed (opening temp 82℃) ↓ ② ②...
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INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines If the coolant level is low, add enough specified coolant to provide protection against freezing and corrosion. Bring the level to MAX, but do not overfill. If frequent additions are required, see an authorized dealer for a cooling system inspection.
1) In order to use cabin heater, an extra coolant circulation pump is needed. 2) After connecting cabin heater lines, engine coolant must be refilled and checked. 3) Check coolant flow direction, as shown in figure. 4) If in doubt, please contact your nearest Hyundai SeasAll dealer. From heater To heater * Outer diameter of line is Ø17.3 mm...
S250 and S220 Series Engines 4. EXHAUST SYSTEM 1) Your Hyundai Seasall engine’s exhaust system consists of a coolant-cooled exhaust manifold and a seawater-cooled exhaust elbow (water injected wet exhaust system). 2) The vessel’s exhaust line should not be made too long and should have as few bends as possible.
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines CHAPTER 4 FUEL SYSTEM The fuel supply system of this engine is diesel common rail direction injection. In order to optimize engine combustion, maximum injection pressure is up to 1600 bar. Multi-injection is possible thanks to the quick response of the piezo type injector.
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 1. FUEL FLOW Fuel tank ↓ Auxiliary fuel filter ↓ ① Fuel pump (low pressure) ↓ ② Fuel filter with water detection sensor ↓ ③ Fuel pump (high pressure) ↓ ④ Common rail Fuel return ↓...
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 3. ACCELERATION SENSOR AND CONTROL LEVER 65 mm When installing control lever cable to acceleration sensor, be sure that the acceleration sensor lever is fully released at the idle position and fully pulled at the full-load position.
CAUTION CAUTION HYUNDAI SEASALL’S GUARANTEES OR WARRANTIES ARE VOID IN HYUNDAI SEASALL’S GUARANTEES OR WARRANTIES ARE VOID IN CASES WHERE DAMAGE TO FUEL INJECTON COMPONENTS (HIGH CASES WHERE DAMAGE TO FUEL INJECTON COMPONENTS (HIGH PRESSURE PUMP, INJECTORS, ETC.) CAN BE ATTRIBUTED TO THE...
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines CHAPTER 5 AIR INTAKE SYSTEM The intake air system of this engine is optimized by EVGT and a highly efficient intercooler system. The pressure of the air system is up to abs. 2.5 bar in order to optimize engine combustion.
S250 and S220 Series Engines AIR FILTER MAINTENANCE • The original Hyundai SeasAll air cleaner may be cleaned and reused. • If the air filter is very dirty, it can increase airflow resistance and reduce flow of air to the engine.
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 2. ENGINE OIL LEVEL CHECKS The engine oil level must be checked at regular intervals. Be sure the boat is level. Start the engine and allow it to reach normal operating temperature.
AND SOURCES OF IGNITION. IF YOU HAVE A USED OIL DISPOSAL PROBLEM, PLEASE HAVE THE ENGINE OIL CHANGED BY YOUR PROBLEM, PLEASE HAVE THE ENGINE OIL CHANGED BY YOUR NEAREST HYUNDAI SEASALL SERVICE DEALER. NEAREST HYUNDAI SEASALL SERVICE DEALER. - 34 -...
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines CHAPTER 7 ELECTRICAL SYSTEM 1. BATTERY CABLE CONNECTIONS Starter Motor Alternator Housing CAUTION CAUTION DO NOT TOUCH OR REMOVE ELECTRICAL PART WHEN STARTING OR DO NOT TOUCH OR REMOVE ELECTRICAL PART WHEN STARTING OR DURING OPERATION.
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 2. BATTERY CHECKS Battery inspection is very important in electronically controlled engines: You must check the battery condition regularly. LOAD TEST 1) Perform the following steps to complete the load test procedure for maintenance-free batteries.
ECU box. Always replace a blown fuse with one of the same rating. If the replacement fuse blows, this indicates an electrical problem. Avoid using the system involved and immediately consult an authorized Hyundai SeasAll dealer. Fuses in the ECU Box System Power: 30Amp...
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INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 3.2 RELAYS Relays in the ECU Box 1) Main Relay: 30 Amp 2) Oil Extraction Pump Relay: 30 Amp 3) Fuel Pump Relay : 30 Amp 4) Spare : 30 Amp 5) Start Solenoid Relay: 30 Amp 6) Fuel Heater Relay: 30 Amp Using an ohmmeter, check that there is continuity between each terminal.
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines CHAPTER 8 INSTRUMENT SYSTEM 1. INSTRUMENTS CONNECTION Gauges only available for dual EOI application ※ For information about the installation and operation of the EOI (Engine Operating Indicator) system, please refer to Chapter 9. - 39 -...
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INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 1.1 GAUGE PANEL (Option) Ø 5 RPM Gauge Coolant Temperature Gauge Battery Voltmeter Gauge Ignition Key switch NOTE: Gauge panel (show above) is not standard but available as an option 1.2 COOLANT TEMPERATURE GAUGE 1) This gauge will work when the key is in the “ON”...
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 1.3 RPM GAUGE 1) This gauge will work when the key is in the “ON” position. 2) This gauge indicates real-time engine rpm. 3) Avoid max. rpm and WOT (Wide Open Throttle) before a cold engine is fully warmed up, as it can harm the engine.
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 1.2 SWITCHES 1) Buzzer Reset Switch - This switch is used for turning off the alarm temporarily. 2) Dimmer Switch - This switch is used for controlling brightness of the other gauges connected to the EOI.
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 3. EOI PIN ASSIGNMENT CN1 (MAIN EOI CONNECTOR FROM ENGINE) 1. Ignition power 13. RPM signal 2. Main relay power 14. Spare 3. Permanent power 15. Spare 4. Not used 16. Spare 5.
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INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines CN3 (TACHOMETER) Main relay power RPM signal Ground Illumination Illumination CAN_H CAN_L Not used CN4 (COOLANT TEMP. GAUGE) Coolant temperature signal Ignition power Ground Illumination Illumination Not used CN5 (VOLTMETER) Ignition power Ground Illumination Illumination...
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines CN8 (KEY SWITCH) 1. Ignition power 2. Start power 3. Permanent power 4. NEUTRAL SWITCH AND DUAL EOI CONNECTION 1) Neutral switch wires should be connected at pin #4 and #5 of the external connector of the EOI.
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 5. TRIM WIRING CONNECTION DIAGRAM (STERNDRIVES ONLY) TRIM LIMITE TRIM SENDER TRIM PUMP REMOTE CONTROL TRANSOM PLATE TRAILER SWITCH (SIDE MOUNT TYPE ONLY) GEAR LUBE MONITOR GAUGE-TRIM GAUGE-VOLTMETER BATTERY E O I GAUGE &...
(diagnosis trouble code) will give you information about it. The DTC display is only for initial assistance and to aid communication with a Hyundai SeasAll dealer if there is an emergency. You should contact your nearest Hyundai SeasAll dealer as soon as possible if a system problem arises.
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 6.2 DTC(DIAGNOSIS TROUBLE CODE) LIST P code DESCRIPTION P0016 Crankshaft Position – Camshaft Position Correlation P0047 Turbocharger Boost Control Solenoid Circuit Low P0048 Turbocharger Boost Control Solenoid Circuit High P0069 Manifold Absolute Pressure – Barometric Pressure Correlation P0087 Fuel Rail/System Pressure - Too Low P0088...
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INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines P code DESCRIPTION P0232 Fuel Pump Secondary Circuit High P0234 Turbocharger Over boost Condition P0237 Turbocharger Boost Sensor "A" Circuit Low P0238 Turbocharger Boost Sensor "A" Circuit High P0252 Pump Pressure Regulation Valve Circuit P0253 Pump Pressure Regulation Valve Circuit Low P0254...
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INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines P code DESCRIPTION P0341 Camshaft Position Sensor A Circuit Range/Performance P0381 Glow Plug/Heater Indicator Circuit P0562 System Voltage Low P0563 System Voltage High P0601 Internal Control Module Memory Check Sum Error P0602 Control Module Programming Error P0604...
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INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines P code DESCRIPTION P1171 Minimum Rail Pressure Exceeded P1172 Maximum Rail Pressure Exceeded P1173 Set Value of PCV not in Plausibility Range P1185 Maximum Pressure Exceeded P1186 Minimum Pressure at Engine Speed Too Low P1187 Regulator Valve Stuck P1188...
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INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines P code DESCRIPTION P2138 Throttle/Pedal Position Sensor/Switch “D” / “E” Voltage Correlation P2228 Barometric Pressure Circuit Low Input P2229 Barometric Pressure Circuit High Input P2262 Turbocharger Boost Pressure Not Detected - Mechanical P2263 Turbocharger Boost System Performance P2264...
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines CHAPTER 10 ANTI CORROSION SYSTEM Intercooler Heat exchanger Sacrificial anodes A sacrificial anode must be replaced when more than 50% of it has been used. Check especially frequently when used in saltwater. It is recommended to replace the sacrificial anodes at the start of each season.
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines CHAPTER 11 ENGINE OPERATION 1. ENGINE ON/OFF 1) Before starting the engine, you should check engine oil, coolant, gearbox oil, fuel gauge, raw water pump, battery, seacocks and so on. 2) When you start the engine, check that the engine throttle lever① is in the neutral position. If not, the engine may not start or there is possibility of the boat moving inadvertently.
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 2. ENGINE BREAK-IN Initial Break-in Procedure The first 20 hours of operation is the engine break-in period. During this period, it is important that the engine is operated as outlined below. 1) DO NOT operate engine at idle rpm for extended periods of time during the first 10 hours.
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines 4. EMERGENCY STOP 1) You can stop the engine by pushing this button. After releasing the switch by twisting the button, you can start the engine again. (Normally, the button should be in the “out” position.) 2) When the button is pressed or if it doesn’t work normally, the engine doesn’t crank.
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines CHAPTER 12 ENGINE STORAGE The major consideration in preparing your engine for storage is to protect it from rust, corrosion, and damage caused by freezing of trapped water. The following storage procedures should be followed to prepare your engine for out-of-season storage or prolonged storage (two months or longer or winter storage) : CHECK LIST •...
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines CHAPTER 13 MAINTENANCE 1. PREDELIVERY INSPECTION CHECK LIST 1.1 BEFORE THE WATER TEST 1.2 ON THE WATER TEST -ENGINE CHECKS -ENGINE CHECKS Boat drain plug in place Seawater inlet valve open (Check before putting boat in water) Engine coolant level Seawater pump operation...
INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines CHAPTER 14 TROUBLESHOOTING GUIDE ■ Starter motor does not crank the engine Possible Causes •Engine stop switch “ON” position •Engine is not shifted to neutral position •Safety Stop Switch activated •Wrong neutral switch connection to EOI •Weak battery or battery connections are loose •Starter motor solenoid or slave solenoid failure or corroded...
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INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines ■ Engine rattling, noisy engine Possible Causes •Compensation of individual injector not •No engine coolant temperature sensor signal adapted •Low compression pressure •Clogged injector return line •No rail pressure sensor signal •Faulty injector •Poor injector O-ring •Carbon deposit on the injector...
CHAPTER 15 WARRANTY WHAT IS COVERED Hyundai SeasAll warrants its new products to be free of defects in material and workmanship during the period described below. DURATION OF COVERAGE This Limited Warranty provides coverage for two (2) years from the date the product is first sold to a recreational use retail purchaser or when the Product has been operated for 1000 hours, whichever occurs first.
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INSTALLATION & OPERATION MANUAL S250 and S220 Series Engines - 69 -...
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• All incidental and/or consequential damages (storage charges, telephone or rental charges of any type, inconvenience or loss of time or income) are the owner’s responsibility. • Use of other than Hyundai SeasAll genuine replacement parts when making warranty repairs. • Participating in or preparing for racing or other competitive activity.
WARRANTY REGISTRATION CARD Date of sale Check box if Warranty Transfer Month Year Please fill out the following registration card in English. ■OWNER’S INFORMATION Name/Company ZIP Code/Post Code Street/P.O. Box City State/Province Country E-Mail Telephone Mobile Phone ■ DEALER INFORMATION Dealer Name Dealer Code City...