ServiceManual

STEYR MARINE ENGINES 

4 CYLINDERS 

+ 6 CYLINDERS 

SERVICE MANUAL 

P/N Z001019/0 6 th Edition July 2008 

www.steyr-motors.com 

STEYR MOTORS GmbH 

Im Stadtgut B1, A-4407 Steyr-Gleink, AUSTRIA

THIS PAGE IS INTENTIONALLY BLANK

PREFACE 

STEYR MOTORS GmbH has developed high-performance diesel engines with modulated highpressure 

direct injection, especially for the marine environment. STEYR marine engines are designed to be 

adapted to various propulsion systems. 

This SERVICE MANUAL is published with the main intention - 

to provide information in form of technical data and know-how based on our experience in the marine diesel 

engine business, which will enable you in case of possible failure to operate, service and repair the engine 

4 & 6 CYLINDER MARINE 

ENGINES 

to maintain their operating safety and reliability. 

To achieve continuous improvement with regard to form and contents of the information required, we are 

assigned to your aid. 

We, therefore, would much appreciate your comment to the following questions - 

- Which descriptions or terms are not understandable? 

- Which supplements or completions do you propose ? 

- Where did creep in contents-related mistakes ? 

Please address your comment to: 

STEYR MOTORS GmbH 

After Sales Service 

Im Stadtgut B1 

4407 STEYR 

AUSTRIA 

vom Inland: 

from home country 

07252/222/52 

07252/222/29 

vom Ausland 

from foreign 

countries: 

+43/7252/222/52 

+43/7252/222/29 

service@steyr-motors.com 

http://www.steyr-motors.com 

Z001019/0_6_July 2008

Repair and maintenance works on engine 

The descriptions and instructions in this technical documentation should support you in use and repair of our 

product. They refer to a specific equipment status of engine componets and accessories. Your individual 

engine may be equipped with other or less accessory. 

For any component not covered in this manual, please contact STEYR MOTORS GmbH, After Sales Service, 

as to respective documentation. 

This manual also contains specific references to your personal safety as user, as well as that of your 

customers, their passengers and other persons being close to the engine/boat. 

Product specifications, illustrations and technical data 

When reference is made in this manual to a brand name, product number, product or specific tool, an 

equivalent product may be used in place of the product or tool referred to, unless stated otherwise. To exclude 

possible danger, the operator has to provide for adequate safety precautions. 

All information, illustrations and specifications in this manual are based on the latest product data available at 

the time of printing. It cannot be guaranteed that this manual is constantly updated. Revised versions edited at 

a later date will replace all preceding editions. 

Illustrations in this manual may not always correspond to actual implements or components and are 

mainly intended as reference. 

STEYR MOTORS GmbH reserves the right to make changes at any time, without notice, on technical 

data or models and/or to discontinue models. The right is also reserved to change technical data or 

components at any time, without incurring any obligation to retrofit new parts on models produced 

prior to date of such change. 

To guarantee proper function of the engine and its attached parts after a repair, correct assembly is of 

utmost importance. Such works are to be carried out with greatest care, in accordance with repair 

instructions. 

WARRANTY: 

Warranty claims will expire if repair, service and operation of the engine do not 

correspond to the guidelines defined by STEYR MOTORS GmbH Please 

address your warranty claims, in accordance with warranty regulations, directly to 

the After Sales Service of STEYR MOTORS GmbH, Steyr. 

Every STEYR dealer is obliged to fill out the warranty registration card enclosed to every sold 

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. 

This warranty registration card serves as a proof of ownership and is to be submitted in case 

of warranty claims. 

Every STEYR dealer is also obliged to carry out the Installation and pre-delivery inspection log. 

One copy (completely filled out) of this Installation and pre-delivery inspection log is to be sent 

to the After Sales Service of STEYR MOTORS GmbH. 

Z001019/0_6_July 2008

TABLE OF CONTENTS 

(MAIN ASSEMBLY GROUP ENGINE) 

GENERAL 

01 ENGINE 

02 COUPLING 

03 FUEL SYSTEM 

04 EXHAUST SYSTEM 

05 COOLING SYSTEM 

06 ELECTRICAL EQUIPMENT 

Z001019/0_6_July 2008

Components 

01 

Engine 

01.00 

Engine timing, 

engine mount 

01.01 

Cylinder block 

01.02 

Chrankshaft 

bearing, 

vibration damper 

01.03 

Flywheel, 

housing 

01.04 

Piston, 

connection rod 

01.05 

Chamshaft, 

housing, 

valve drive 

01.06 

Engine housing, 

oil pump, 

oil suction pipe 

01.08 

Intake manifold, 

intercooler 

01.09 

Auxiliary drive-PTO 

01.13 

Engine oil cooler, 

01.14 

Exhaust manifold, 

seals, 

heat exchanger 

02 

Coupling 

02.01 

Torsion coupling 

02.02 

Coupler 

02.03 

Torsion coupling 

Centa 

03 

Fuel system 

03.02 

Fuel pump, 

unit injector, 

pipes 

03.04 

Air filter 

03.05 

Turbo charger 

03.08 

Control solenoid 

03.09 

Fuel filter 

03.11 

Glow plugs 

04 

Exhaust system 

04.01 

Hi-riser 

Z001019/0_6_July 2008

05 

Cooling system 

05.01 

Cooler, 

heat exchanger, 

expansions tank 

05.03 

Pipes, 

thermostat 

05.04 

Coolant pump 

05.10 

Raw water pump, 

side mounted 

05.11 

Raw water pump, 

front mounted 

06 

Electrical 

system 

06.01 

Generator, 

alternator 

06.03 

Starter motor 

06.05 

Engine harness 

06.06 

EMS, E-box, 

diagnosis system, 

fuses 

06.07 

Instrument panel, 

connecting cable 

06.10 

Sender, sensor 

06.12 

Battery, 

charge equalization 

Z001019/0_6_July 2008

VERSIONS OF MANUAL 

Version Date Modification 

1.0 01. 10. 2000 new edition 

2.0 01. 06. 2002 release typ 164, 246 

3.0 01. 07. 2005 release typ 256 

4.0 01. 07. 2007 modification 



Z001019/0_6_July 2008

ToC 

SERVICE MANUAL MARINE ENGINES 

GENERAL 

Table of Contents 

GENERAL 

A General Remarks .................................................................................. 3 

A 1 Model and Serial Numbers ..................................................................... 3 

A 2 Documentation........................................................................................ 4 

A 3 Model summary ...................................................................................... 5 

A 3.1 Model summary 4 cylinder engines ........................................................ 5 

A 3.2 Model summary 6 cylinder engines ........................................................ 8 

A 4 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 

B Specifications ....................................................................................... 20 

B 1 Fuel Requirements ................................................................................. 20 

B 2 Motor oil .................................................................................................. 21 

C Maintenance and Service ..................................................................... 22 

C 1 Trouble Check Chart ............................................................................... 22 

C 2 Service- and Maintenance Schedule ...................................................... 24 

D General Information .............................................................................. 26 

D 1 Electronic Engine Management System (ECU) ...................................... 26 

D 2 Diagnostic System .................................................................................. 27 

D 3 Extended Storage Preservation Procedure............................................. 28 

D 4 Engine Break-in procedure ...................................................................... 32 

D 5 Operation after Break-in .......................................................................... 34 

E Quality Gudelines for Repair ................................................................ 36 

E 1 Spare parts specification ......................................................................... 36 

E 2 Workshop profile ..................................................................................... 36 

E 3 Nomenclature .......................................................................................... 37 

E 4 SI - System .............................................................................................. 38 

E 5 Abbreviations .......................................................................................... 39 

F Operating material and Information on Disposal................................ 40 

F 1 List of operating material ......................................................................... 40 

F 2 Disposal of automotive waste products .................................................... 41 

G Notes on Safety..................................................................................... 42 

G 1 General notes on safety ........................................................................... 42 

G 2 Guidelines for damage prevention ........................................................... 42 

G 3 Legal rules ............................................................................................... 42 

G 4 Safety in the use of operating material ..................................................... 43 

Z001019/0_8_Octobre 2011 

Page GENERAL-1

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GENERAL 


G 5 Measures in case of accidents ................................................................ 43 

H Thightening Torques ............................................................................ 44 

H 1 Listing of Thightening Torques.................................................................. 44 

H 2 General Tightening torques ...................................................................... 49 

H 3 Testing of torque wrench .......................................................................... 50 

H 4 Non-destructive material testing ............................................................... 50 

H 5 Use of adhesive and sealing materials..................................................... 50 

H 6 Solvent-free sealing materials .................................................................. 50 

J Wear Limits ............................................................................................ 52 

J 1 Adjustment information for service and maintenance ................................ 53 

Page GENERAL-2 Z001019/0_8_Octobre 2011

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GENERAL 

A 

A 1 

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 

4 CYL. MARINE ENGINES 

FOR ALL 

6 CYL. MARINE ENGINES 

1 

1 

01.01 ill.1 

08006 

01.01 ill.2 

08007 

The model and serial number of the marine gearbox 

is located on the marine gearbox housing as illustrated. 

To obtain instructions regarding marine gearbox 

operation, refer to marine gearbox owners manual. 

17 

01.01 ill.3 

06014 

Z001019/0_8_Octobre 2011 

Page GENERAL-3

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GENERAL 

A 2 Documentation 4 and 6 cylinder 


The following documentation is available in English language on our website: 

http://www.steyr-motors.com/technical 

technical documentation on CD - ROM P/N Z 001009/0 

operation-, maintenance & warranty manual 

for all marine engines 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 P/N Z 001015/0 

STEYR 174 vti diesel marine P/N Z 001011/0 


STEYR 236 FDE P/N Z 011796/0 

STEYR 236 td diesel marine P/N Z 011796/1 - Z011769/2 




installation manual for marine engines P/N Z 001007/0 

service manual for all marine engines P/N Z 001019/0 

operator's manual marine gear ZF P/N Z 001003/0 

Diagrams marine engine functions on CD P/N Z 001021/0 


ToC 


A 3 Modell summary 

GENERAL 

A 3.1 Modell summary 4 cylinder engines 

Bobtail - Version 

03.01 ill.1 

Equipment: 

with side mounted raw water 

pump or, 


pump, power steering pump 

Inborder i.e. ZF 45 Marinegear 

Down angle 

03.01 ill.2 

Innenborder i.e. ZF 63 Marinegear 

03.01 ill.3 

Z001019/0_8_Octobre 2011 

Page GENERAL-5

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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 


ToC 


GENERAL 

Jet Drive 

TYPE 

Alamarin 

Hamilton 

03.01 ill.8 

Castoldi 

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

ToC 

GENERAL 

A 3.2 Modell summary 6 cylinder engines 

Bobtail - Version 



pump or, 


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 


ToC 


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

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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 


ToC 


GENERAL 

THIS PAGE IS INTENTIONALLY BLANK 

Z001019/0_8_Octobre 2011 

Page GENERAL-11

ToC 

GENERAL 

A 4.1 

MAKE 

Technical data and overview 4 cylinder engines 

STEYR M 14 TCM, TCAM 


type MO84K32 MO94K33 MO114K33 MO144V38 

displacement 

piston displacement 

rated power acc. EN ISO 8665:2006 

(impeller **) KW / HP 

Jet - Drive / Inboard 

Z - Drive 

number of cylinders 

2133 cm³ 

85,0 x 94,0 mm 

53 / 71 

52 / 70 

64 / 86 

63 / 84 

78 / 105 

77 / 104 

103 / 138 

101 / 136 

4-cylinder in-line engine (position of cyl. 1 at vibration damper side) 

ignition order 1 - 3 - 4 - 2 

sense of rotation, seen from front 

right 

compression ratio 17,5 : 1 

full-load speed range (rpm) 3000 - 3200 3050 - 3800 3200 - 3800 3600 - 3800 

idle speed 

injection 

fuel 

650 rpm. (adjustable) 

pump - nozzle with modelling needle control 

and electronic control 

acc. to CEC RF-03-A-84 (DIN EN 590) Cetan >49; diesel fuel 

No. 2-D, temperature above -7°C; No.1-D, temperature below -7°C 

fuel filter P/No. 2203710/0 

fuel filter location 

intake-sided 

air filter P/No. 2178992/0 

oil pressure above 2000 rpm. 

filling capacity motor oil 

400 - 700 kPa (60 - 100 PSI) microprocessor controlled 

approx. 8,0 l engine housing (incl. approx. 1 l oil filter contents) 

specification motor oil SAE 5W-50/ACEA B4-02/API CF or 10W-40/ACEA, E4, E5, E7, 

API CF / P/N0. Z010058/0 

oil and oil filter change intervals*) 

every 150 operating hours and/or once per season 

oil filter P/No. 2178582/1 

oil filter location 

electric charging system 

cooling system 

coolant capacity 

pressure-sided 

14 V / 90 A alternator with transistorized voltage regulator 

dual cooling circuit; thermostat-controlled, pressurized cooling 

circuit; circulating pump with heat exchanger on engine; governor 

pump, external raw water circuit to heat exchanger 

11,5 liters 

coolant 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% 


ToC 


GENERAL 

Overview for all STEYR 4 Cyl. Marine Engines 

Item 

Designation 

1 Zinc Anode (4 Units) 

2 Model and Serial Number 

3 Intercooler 

4 Fuel/Oil Cooler with Raw Water Drain Plug 

5 Fuel Pump 

6 Oil Seperator 

7 Raw Water Drain Plug 

8 Valve Crankshaft Housing Ventilation 

(only SOLAS) 

9 Oil Drain Plug 

10 Fuel Filter 

11 Oil Filter 

12 Hydraulic Pump 

13 Raw Water Inlet Fitting 

14 Raw Water Pump 

15 Coolant Drain Plug (2 Units) 

16 Engine Oilcooler 

17 Oil Suction Pipe 

18 Oil Dipstick 

19 Hydraulic Oil Tank 

20 Cooler Cap 

21 Potentiometer Accelerator 

22 Motor Oil Filler Cap 

23 Boost Pressure Sensor 

24 Rack Position Sensor *) 

25 Drive Belt 

26 Cover T-Belt, Lower 

27 Engine Mount 

28 Drive Belt Tensioner 

29 Vibration Damper 

30 Cover T-Belt, Upper 

31 Engine Lifting Eye 

32 Speed Sensor 

33 Valve Cover 

34 Heat Exchanger 

35 Coolant Expansion Tank 

36 Diagnostic Outlet 

37 Inversion Switch (only for SOLAS) 

38 Connector Instrument Panel 

39 Coolant Temperature Sensor 

40 Thermostat Housing 

41 Alternator 

42 Circuit Breakers 

43 Engine Management System/Fuses 

44 Exhaust Temperature Sensor 

45 Air Filter 

46 Turbo Charger 

47 Exhaust Elbow 

48 Starter Relais (Backside E-Box Ground Plate) 

49 Starter Motor 

50 Flywheel 

51 Flywheel Housing 

52 Oil Pressure Sensor 

19 

18 

17 

16 

15 

14 

13 

12 

11 

20 

31 

30 

29 

28 

44 

43 

45 

52 

51 

50 

1 2 3 4 5 6 

10 9 

1 32 33 34 35 36 37 

38 

39 

1 

7 

8 

06001 

21 

22 

23 

24 

25 

26 

27 

06002 

1 

15 

40 

41 

42 

06003 

46 

47 

48 

49 

06004 

*) This sensor is magnetism sensitive. All external magnets must be kept away. 

Z001019/0_8_Octobre 2011 

Page GENERAL-13

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GENERAL 


MAKE 

STEYR M 14 TCAM 

type MO144M38 MO164M40 

displacement 





Z - Drive 


2133 cm³ 

85,0 x 94,0 mm 

103 / 138 

101 / 136 

116 / 156 

114 / 154 


ignition order 1 - 3 - 4 - 2 


right 


full-load speed range (rpm) 3700 - 3900 3800 - 4000 

idle speed 

injection 

fuel 








intake-sided 

air filter P/No. 2178992/0 






API CF / P/N0. Z010058/0 








pressure-sided 





11,5 liters 


P/No. Z011785/0 





ToC 


GENERAL 

Overview for all STEYR 4 Cyl. Marine Engines 

Item 

Designation 



3 Intercooler 

4 Fuel/Oil Cooler with Raw Water Drain Plug 

5 Fuel Pump 




(only SOLAS) 



11 Oil Filter 









20 Cooler Cap 





25 Drive Belt 
















41 Alternator 




45 Air Filter 





50 Flywheel 



19 

18 

17 

16 

15 

14 

13 

12 

11 

20 

31 

30 

29 

28 

44 

43 

45 

52 

51 

50 

1 2 3 4 5 6 

10 9 

1 32 33 34 35 36 37 

38 

39 

1 

7 

8 

06001 

21 

22 

23 

24 

25 

26 

27 

06002 

1 

15 

40 

41 

42 

06003 

46 

47 

48 

49 

06004 


Z001019/0_8_Octobre 2011 

Page GENERAL-15

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GENERAL 

A 4.2 

Technical data and overview 6 cylinder engines 


MAKE 

STEYR M 16 TCM, TCAM 

type MO126M28 MO166K28 MO196K35 MO236K42 

displacement 





Z - Drive 


3200 cm³ 

85,0 x 94,0 mm 

87 / 117 

86 / 115 

116 / 156 

115 / 154 

136 / 182 

134 / 179 

165 / 221 

162 / 218 


ignition order 1 - 5 - 3 - 6 -2 - 4 


right 


full-load speed range (rpm) 2600 - 2800 2600 - 2800 3300 - 3500 4000 - 4300 

idle speed 

injection 

fuel 








suction-sided 

air filter MO126 - P/No. 2178992/0; all other 6 Cyl. - P/N 2178992/1 






API CF / P/N0. Z010058/0 








suction-sided 





13,2 liters 


P/No. Z011785/0 





ToC 


GENERAL 

Overview STEYR MO126M28, MO166K28, MO196K35, MO236K42 

Item 

Designation 

18 

1 2 3 4 5 6 7 2 



3 Intercooler 

4 Fuel- / Hydr. Oil Cooler 






(only SOLAS) 


11 Fuel Pump 

12 Oil Filter 










22 Drive Belt, Raw Water Pump 





27 Drive Belt, Alternator & Hydr: Pump 






33 Cooler Cap 








41 Alternator 






47 Air Filter 




51 Flywheel 




17 

16 

15 

46 

45 

44 

29 

28 

27 

14 

13 

12 

19 20 21 

26 

25 

22 

23 

24 

8 

9 

10 

11 

06032 

06033 

2 30 31 32 33 34 35 36 37 

43 

47 48 49 

53 

52 

2 

50 

51 

2 

15 

38 

39 

40 

41 

42 

06034 

06035 

Z001019/0_8_Octobre 2011 

Page GENERAL-17

ToC 

GENERAL 


MAKE 

STEYR M 16 TCAM 

type MO256K43 MO256H45 

displacement 





Z - Drive 


3200 cm³ 

85,0 x 94,0 mm 

178 / 239 

176 / 236 

178 / 239 

176 / 236 


ignition order 1 - 5 - 3 - 6 -2 - 4 


right 


full-load speed range (rpm) 4000 - 4300 4000 - 4500 

idle speed 

injection 

fuel 








suction-sided 

air filter P/No. 2178992/0 P/No.2178992/1 






API CF / P/N0. Z010058/0 








suction-sided 





13,2 liters 


P/No. Z011785/0 





ToC 


Overview STEYR MO256K43, MO256H45 

GENERAL 

Item 

Designation 

17 

1 2 3 4 5 6 2 



3 Intercooler 

4 Engine Oil / Fuel / Hydr. Oil Cooler 




8 Valve Crankshaft Housing Ventilation (only 

SOLAS) 

9 Fuel Filter 

10 Fuel Pump 

11 Oil Filter 










21 Drive Belt, Raw Water Pump 





26 Drive Belt, Alternator & Hydr: Pump 






32 Cooler Cap 








40 Alternator 






46 Air Filter 




50 Flywheel 



16 

15 

14 

45 

44 

43 

28 

27 

26 

13 

12 

11 

18 19 20 

25 

24 

21 

22 

23 

7 

8 

9 

10 

06028 

06029 

2 29 30 31 32 33 34 35 36 

42 

46 47 48 

52 

51 

2 

49 

50 

2 

14 

37 

38 

39 

40 

41 

06030 

06031 


Z001019/0_8_Octobre 2011 

Page GENERAL-19

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GENERAL 


B 

Specifications 

B 1 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. 

How to Select Fuel Oil 

Fuel quality is an important factor in obtaining satisfactory engine performance, long engine life, and acceptable 

exhaust emission levels. Direct injected diesel engines are designed to operate on most diesel fuels marketed 

today. In general, fuels meeting the properties of CEC RF-03-A-84 have provided satisfactory performance. 

The ASTM D 975 specification, however, does not in itself adequately define the fuel characteristics needed for 

assurance of fuel quality. The properties listed in the following fuel oil selection chart have provided optimum engine 

performance. 

Fuel Oil Selection Chart 

General 

Fuel classification 

CEC RF-03-A-84 

Limit value and 

units 

CEC RF-03-A-80 

Limit value and 

units 

ASTM - 

Test procedure 

Cetane number 

min. 49 - max. 53 

min. 51 - max. 57 

D 613 (D 976) 

Gravity at 15°C (kg/l) 

min. 0,835 

max. 0845 

min. 0,835 

max. 0845 

D 1298 

Destillation 

50% 

90% 

min. 245°C 

min. 320°C 

max. 340°C 

min. 245°C 

min. 320°C 

max. 340°C 

D86 

End point 

max. 370°C 

max. 370°C 

Flash point 

min. 55°C 

min. 55°C 

D 93 

CFPP (Cloud point) 

min. -- / max. -5°c 

max. -5°c 

EN 116 (CEN) 

Viscosity Kinematic 40°C 

min. 2,5 mm²/s 

max. 3,5 mm²/s 

min. 2,5 mm²/s 

max. 3,5 mm²/s 

D 445 

Sulfur content 

max. 0,3 mass-% 


D 1266/D 2622 

D 2785 

Cupper corrosion 

max. 1 

max. 1 

D 130 

Carbon residue 

Conradson number (10% residue) 



D 189 

Ash 



D 482 

Water content 



D 95/D 1744 

Acid content (strong acid) 

max. 0,20 mg KOH/g 

max. 0,20 mg KOH/g 

D 974 

Oxidation stability 

max.2,5 mg/100ml 

max.2,5 mg/100ml 

D 2274 


ToC 


GENERAL 

B 2 

Motor oil 

To obtain the best engine performance and engine life, only motor oils of know manufacturers are to be used, 

with ACEA, API service code and specified SAE viscosity. Refer to oil identification symbol on the container. 

Initial filling quantity: 4 Cyl. engines 8,4 Litre (Oil filling, incl. 1l oil filter) 

6 Cyl engines 10,4 Litre (Oil filling, incl. 1l oil filter) 

Oil quantity between MIN. and MAX. 

on dipstick 

2,0 Litre 

Oil change quantity: 4 Cyl. engines 7,0 Liter (without oil filter) 

6 Cyl. engines 9,0 Liter (without oil filter) 

Öil filter: 

ca. 1 Litre 

Oil - specification, Minimum: API: CF or higher 

ACEA: 

B4 - 02 or higher 

Viscosity class: SYNTHETIC OIL 5W-50 

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. The oil level should be maintained between the minimum and maximum marks on the dipstick. The 

space between the marks represents approximately 2 quarts (2 litres). For oil dipstick location, refer to 

section Technical Data and Overview (A 4) 

Refer to Service and Maintenance Chart (C 2) for 

recommended oil change intervals. 

FOR HEAVY DUTY 

DIESEL ENGINES 

Oil Identification Symbol 

Motor oils are specified by ACEA, API 

service code and SAE viscosity numbers. 

These may be found on the label, top of can, or oil 

identification symbol. 

NOTE: 

Some motor oils have several ACEA / API quality 

ratings. 

The recommended ACEA /API service letter code 

must be among these quality ratings. 

02.02 ill.1 

ACEA E7 or B4 - 02 

ACEA E7 or B4-02 

API CF 

ill.1 Top of Can 

ill.2 Oil Identification Symbol 

SAE 

5 W-50 

10 W-40 

02.02 ill.2 

API 

SERVICE CODE 

CF 

Z001019/0_8_Octobre 2011 

Page GENERAL-21

ToC 

GENERAL 


C 

C 1 

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. 

SYMPTOM POSSIBLE CAUSE ACTION 

Engine won’t start 1. No fuel in tank or shut-off valve Fill tank or open valve. 

closed. 

2. Air leak in suction lines. Bleed fuel system and check for leaks. 

3. Fuel line plugged or pump Fuel pump may be defective. 

defective. 

4. Poor fuel quality. Replace fuel . 

5. Water in fuel filter. Replace or drain water from fuel filter. 

Check fuel supply for water contamination. If water 

is present, drain fuel tank and flush with fresh fuel. 

6. System error or failure. Check Engine Management System 

display for service code. 

7. Battery output insufficient Charge or replace battery. 

Only for SOLAS ==> 8. Inversion switch actuated Cancelled by ignition "OFF - ON" 

Starter won’t crank 1. Battery connections loose or Check for loose connections 

engine corroded and corrosions. Clean connections and 

thighten. 

2. Battery is dead Check level of electrolyte and charge 

battery. 

3. Starter connections loose Check connections and tighten. 

If solenoid clicks when attempting to 

start engine, check starter. 

4. Ignition switch If inoperative, replace. 

5. Fuse blown on panel Check and replace if defect 

6. Starter auxiliary relay Check terminal connection and function of relay. 

Engine runs erratically 1. Water, air and/or dirt in fuel filter Replace filter. Inspect fuel supply line. 

2. Anti-siphon valve stuck Clean and inspect or replace. (Tank) 

3. Fuel pump Check operation of pump. 

Replace fuel pump. 


ToC 


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. 

Engine runs but boat Fouled propeller etc. Check: 

makes little or no 

1. Propeller for weeds, remove 

progress 

as required. 

2. Propeller for spun hub, repair 

or replace. 

3. Hull for excessive marine growth, clean 

as required. 

Performance loss 1. System error or failure. Check Engine Management System 

display for service code. Engine coolant 

temperature; audible alarm. 

2. Boat overloaded Reduce load. 

3. Boat trim Distribute boat load evenly. Adjust trim. 

4. Excessive water in bilge Drain bilge. 

5. Boat hull condition Cleaning 

6. Improper propeller selection Select proper propeller pitch and diameter. 

7. Fuel incorrect Fill tank with correct fuel. 

Check fuel filter and fuel flow condition. 

8. Throttle not fully open Check throttle command lever for 

full travel. 

9. Overheating Check cooling system. Remove debris 

from water intake. Check belt tension. 

Check condition of impeller. 

Check for clogged heat exchanger tubing 

(in raw water circuit). 

10. Air intake troubles Check intake air filter. 

Check ventilation of engine compartment. 

Excessive free play in Steering cable loose Adjust or replace. 

steering wheel 

High shift effort 1. Remote control or transom Replace and adjust. 

bracket shift cable 

2. Remote control binding Adjust. 

3. Engine / drive mechanism sticks Center. 

Z001019/0_8_Octobre 2011 

Page GENERAL-23

ToC 

GENERAL 


C2 Service- and Maintenance Schedule 

daily 

after first 

50 hours 

or 6 

months 

every 

150 h. 

or 12 

months 

every 

300 h. 

or 24 

months 

*) notes 

ENGINE check - for leakage 

LUBRICATION 

- oil level 

change - oil filter 

- motor oil 

ENGINE check - for leakage 

COOLING 

- fluid level 

SYSTEM 

- hoses, hose clamps 

- antifreeze temperature condition 

change - antifreeze*) every 24 month 

RAW WATER check - hoses, hose clamps 

SYSTEM 

- zinc anodes 

- raw water pump V-belt 

- impeller 

change - raw water pump V-belt*) if required 

- impeller*) if required 

- zinc anodes*) if corroded > 50% 

preserve - raw water circuit*) after season 

RAW WATER check - raw water passages*) clean out desposits 

COOLER 

(OIL-FUEL- 

in pipelines 

AUX.LUBRICANT) 

for 246 / 256 change - zinc anodes*) required if more 

and 266 only 

than 50% material 

corroded 

AIR check - contamination 

FILTER change - air filter element 

preserve 

after season 

FUEL check - for leakage 

SYSTEM 

- hoses 

drain - addtiional fuel filter 

change - fuel filter 

check - additional fuel filter 

preserve - fuel system*) after season 

BATTERY check - acid level 

- densitiy 

ELECTRONICS check - connections*) after season 

ELECTRICAL check - connections tighten loose con- 

EQUIPMENT - insulation nections. Renew 

cables, if required. 

INVERSION check - switch*) every 50 hours 

SWITCH (Solas only) or every 6 months 

DRIVING re-center - driving unit*) see manufacturer's 

SYSTEM 

specifications 

V-BELT check - generator & impeller pump adjust tension 

- power-steering adjust tension 

for all 6 cyl. change - generator*) if required 

models - power-steering*) if required 

POLY - V - check - belt, pulleys and tighteners 

BELT for wear 

change - Poly -V-belt every 1050 hours or 

for all 4 cyl. 

every 48 months 

models 


ToC 


GENERAL 

Service- and Maintenance Schedule 

daily 

after first 

50 hours 

or 6 

months 

every 

150 h. 

or 12 

months 

every 

300 h. 

or 24 

months 

*) notes 

POLY - V - BELT 

TENSION 

check 

lubricate 

GLOW PLUGS change - plugs*) every 1500 h. or 


TIMING check - belt tension 

BELT change - timing belt*) every 1500 h. or 


- water pump, tensioner every 3000 h. or 


VALVES check - valve clearance*) every 750 hours 

ENGINE TIMING check - set timing every 750 hours 

UNIT INJECTOR - set levers*) every 750 hours 

check - set point every 750 hours 

- tighten torque every 750 hours 

SERVO check - oil level 

PUMP 

- for leakage 

change - hydraulic oil (ATF) *) every 750 h. or 


GEARBOX- check - oil level 

STERNDRIVE 

- for leakage 

change - gear oil (ATF) *) see manufacturer's 

- oil filter specifications 

FRONT VIBRA- check - torque 

TION DAMPER 

ENGINE COM- check for - leakage -water repair or consult 

PARTMENT AND -fuel your STEYR 

BILGE -exhaust gas Marine dealer 

SHIFTING check - smooth action If required, to be 

- adjustment replaced by your 

STEYR Marine 

Dealer. 

STEERING check - lubrication see manufacturer´s 

- 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 check - torque*) every 750 hours 

SCREWS 

WARNING check - function 

DEVICE 

Z001019/0_8_Octobre 2011 

Page GENERAL-25

ToC 

GENERAL 


D 

General Information 

D 1 Electronic Engine Management System 

The STEYR Marine engine is equipped with an Electronic Management System (EMS) that 

performs the following: 

* controls engine functions to ensure maximum efficiency. 

* self-diagnostic to protect the engine from damage if operating parameter are exceeded. 

* stores diagnostic data of EMS server circuits for maintenance and service. 

* stores abuse data 

Engine power is reduced if: 

Operating Parameter 

Effect 

noticed 

Panel 

Indication 

Additional 

Tool-Readings 

Action or 

possible reason 

High engine coolant 

temperature 

limit exceeded 

Reduction of 

engine speed 

Horn ON 2x p. sec. 

Gauge reading > 

107 °C 

Steyr Diag 

Power limitation 

See table trouble 

shooting: 


Defect - engine coolant 

sensor or 

sensor connection 

Reduction of 

engine speed 



120 °C 

Steyr Diag 

Service code 

Sensor or connector 

failure; see service 

code table 

Exhaust temperature 


Reduction of 

engine speed 

Horn and indication 

light "CEL" ON 2x 

p. sec. 

Steyr Diag 



shooting: Raw water 


Defect - Exhaust 

temperature sensor or 


Reduction of 

engine speed 



p. sec. 

Steyr Diag 

Service code 



code table 

Oil pressure below limit 

Reduction of 

engine speed 

Horn continuous and 

Oil indication light 

continous switched 

ON 

Steyr Diag 



shooting: 

Engine oil system 

Defect - Oil pressure 

sensor or sensor 

connection 

Reduction of 

engine speed 

Oil pressure indication 

light switched ON 1x 

p. sec. 

Steyr Diag 

Service code 



code table 

Insufficient boost 

pressure or defective 

sensor 

Reduction of 

engine speed 

Steyr Diag 



shooting: 

Air charge system 

Engine speed sensor 

fault 

Higher or 

unstable idle 

speed, limited 

performance 

No RPM indication 

on tachometer 

Steyr Diag 

Service code 


shooting: 

Speed sensor 

Engine speed remains 

at idle 

No increase of 

engine speed if 

throttle is moved 

to max. 

Steyr Diag 

Service code 


shooting: 

Accelerator 

potentiometer failure 

Governor position 

system 

Irregular engine 

speed or stalled 

engine 

Steyr Diag 

Service code 


shooting: 

Governing system 


ToC 


GENERAL 


Effect 

noticed 

Panel 

Indication 

Additional 

Tool-Readings 

Action or 


Inverse position shut 

down (SOLAS) 

Engine shut 

down beyond 

70° deg. angle 

After engine stop 

horn remains 

switched ON until 

ignition reset 

Reset through ignition 

OFF and then ON 

During break in phase 

Cel-ON at high 

accelerator 

position (more 

than 75%) 

Indication light 

"CEL" is switched 

ON 

Steyr Diag 

Break-in 

phase 

See information break 

in procedure 

Optical and accustical warning signals are explained on the following tables. 

"Operating Status and Error Report" 

D 2 

Diagnostic system 

The electronic management system monitors the following engine parameters: 

oil pressure, boost pressure, coolant temperature, exhaust pipe temperature (Hi-riser), sensor control rack, 

potentiometer accelerator, speed signal 

The electronic management system carries out self-diagnostic and/or plausibility checks for all input values and 

sensor connections. In case of irregularities, there is an optical or audible warning signal. (see page 71) 

Existing active failures remain stored until the problem has been solved and the code has been cleared from the 

memory. 

To select stored error codes, a PC with diagnostic program (VR00134/0) or diagnostic tool (VR00135/1) is 

necessary. 

Malfunction during operation is ranked in three different categories intermittent failure, non essential failure and 

essential failure. 

Z001019/0_8_Octobre 2011 

Page GENERAL-27

ToC 

GENERAL 


D 3 

Extended Storage Preservation Procedure: 

Use following kit-numbers to have the necessary equipment 

for an appropriate preservation: 

1 st Preservation- Service Kit art.nr.Z021003-0 

(valid for all 4 and 6 cylinder Marine engine models) 

2 nd Preservation- Service Kit art.nr. Z021004-0 

(valid for all 4 and 6 cylinder Marine engine models) 

1. Remove the engine from storage and place on a 

suitable work shop area with access to all sides of the 

engine. Engine must not be removed from pallet. 

2. check fluid levels: 

engine oil (min/max on oil dipstick) 

engine coolant water level (min/max) 

gear oil- level 

hydraulic oil- level 

or existing fluid levels of other system 

ill.1 

3. Control valve clearance according SERVICE MANU- 

AL MARINE ENGINES Z001019-0 (chapter 03 FUEL 

SYSTEM) and investigate free movement of all valves. 

4. Crank engine till oil pressure is inidicated/visible. 

Do not start engine before oil pressure is approved. 

NOTE: Do not crank engine over max. 30 - 40 sec.! 

5. Start the engine and let it run up to temperature. 

6. Stop the engine and drain the old engine oil and store 

for future refill and usage. 

ill.2 

7. Fill in preservation oil (art.nr. Z050323-0, 5liter canister, 

adequate quantity incl. in all Preservation Service 

Kits) up to the minimum mark on the dip stick. 

8. Connect the fuel system to a canister Z010014-0 filled 

with preservation fuel (art.nr.Z010014-0, 5liter canister, 

incl. in all Preservation Service Kits). See ill.1 

9. Restart the engine and allow to run in idle for 5 

minutes. 

10. Either drain the preservation oil from the engine and 

replace with normal oil (as per Service Bulletin 

AS_7004) and store for future use. Alternatively leave 

it in the engine for future preservation work. The 

preservation oil has a shelf life of also 3 years and may 

be used any number of times within this period. 

NOTE: It is important to note that an engine may never 

be sold on or installed with this oil in as this will 

lead to severe engine damage if run for extended 

periods. 

11. Remove the main relay K27; this will stop fuel being 

injected and therefore the engine from starting. 

See ill.2 

ill.3 

ill.4 


ToC 


GENERAL 

12. Remove the air filter, plug the exhaust elbow and 

remove the inlet pipe to the tandem/triple cooler, 

see photo. See ill.3 and ill.4 

13. Fill a spray bottle with the preservation oil 

(art.nr. Z050323-0, 5 liter canister, adequate quantity 

incl. in all Preservation Service Kits). 

14. Whilst cranking the engine over, by turning the start 

key, spray the preservation oil into the turbo inlet. 

See ill.5 

15. Continue this process for 20 to 30 seconds. 

16. Refit the fuel feed line to the engine, ensure fuel supply 

and turn the ignition on, the fuel pump runs for 10 sec 

automatically refilling the fuel system. Repeat until 

fuel comes from the return line. 

NOTE: For corrosion protection of fuel system leave 

system filled with preservation fuel Z010014-0 till 

next preservation or engine is put into operation. 

ill. 5 

17. *Only by 2 nd Preservation: 

After two years engine storage replace engine coolant 

water (art. nr. Z011785-0, 5 liter canister, adequate 

quantity incl. in 2 nd Preservation Service Kit) and fill 

between min/max-level in coolant expansion tank. 

18. Replace all pipes and connections to original condition 

and restore engine. 

19. Record carried out Storage Preservation Procedure 

in following documents: 

1) STEYR MOTORS WARRANTY REGISTRATION 

CARD 

(to find under: Operation, Maintenance and Warranty 

Manual Z001022/ chapter WARRANTY) 

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. 

NOTE: 

For manufacturing date, see on engine carton! 

See ill.6 

20. Note the date of preservation on: 

1) sticker for engine-carton (sticker incl. in corresponding 

Preservation Service Kit) - see ill.6 

ill. 6 

Z001019/0_8_Octobre 2011 

Page GENERAL-29

ToC 

GENERAL 


2) sticker for Maintenance Log of Operation, 

Maintenance and Warranty Manual Z001022-0 (sticker 

incl. in corresponding Preservation Service Kit) 

- see ill.7 

MAINTENANCE LOG 

Sticker of 1 st preservation 

(refer to Installation Manual P/N Z001007-0/ 

Chapter 18/Installation and pre-delivery 

i nspection report) 

Sticker of 2 nd preservation 

NOTE: 

This preservation procedure must be done every year 

and ensures that all of the air ways systems, rawwater 

systems, oil system and the cylinders are protected 

against corrosion. 

This procedure is repeatable up to a maximum of 

two times, giving a shelf life of up to three years 

(36 months). 

After 3 years stocking, starting from STEYR 

MOTORS manufacturing date (see ill. 6), engine 

must be put into operation for BASE ENGINE 

WARRANTY approval. However preservation 

procedure can be continued every year after 3 

years stocking without BASE ENGINE WARRANTY 

approval from STEYR MOTORS. 

STEYR MARINE ENGINES 

SERVICE MANUAL 

Date: 

Date: 

Made by: 

Date: 

Made by: 

Date: 

Made by: 

Date: 

Made by: 

Date: 

ill. 7 

Sticker of 3 rd preservation 

50 h Service 

300 h Service 

600 h Service 

900 h Service 

68 

Date: 

Date: 

Made by: 

Date: 

Made by: 

Date: 

Made by: 

Date: 

Made by: 

Date: 

150 h Service 

450 h Service 

750 h Service 

1,050 h Service 

NOTE: 

When commissioning or running an engine that has 

been preserved as stated above the engine will run 

roughly and smoke for the first few minutes. Do not be 

alarmed as this is normal until the deposits of the 

preservation materials have cleared. 


ToC 


GENERAL 


Z001019/0_8_Octobre 2011 

Page GENERAL-31

ToC 

GENERAL 


D 4 

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. 

First Two Hours 

For the first five to ten minutes of operation, run engine at a fast idle (below 1500 RPM). For the remaining first 

two hours of operation, accelerate to bring boat onto plane quickly and bring throttle back to maintain a planing 

attitude. 

During this period, vary the engine speed frequently by accelerating to approximately three-fourth throttle for two 

to three minutes, then back to minimum planing speed. 

When the engine has reached operating temperature, reduce engine speed, then increase engine speed again, 

to assist the break-in of rings and bearings. Maintain planing attitude to avoid excessive engine load. 

NOTE: 

DO NOT RUN ENGINE AT A CONSTANT RPM FOR LONGER PERIODS 

DURING THIS INITIAL TWO HOURS OF BREAK-IN. 

ATTENTION: Warning indication engine over load during break - in via ECU 

The ECU controls during the first two hours of engine operation the load on the engine and 

alarms the drive by the "Check Engine Light", if much power is demanded from the new 

engine. 

ON 

In case the operator get alert, when running the engine during break in phase, by this 

"Break - In" warning indication (CEL light - ON), the throttle position must be reduced 

until this signals are extinguish. 

Next Eight Hours 

For the next eight hours, continue to run engine at approximately three-fourth throttle or less (minimum planing 

speed). 

Occasionally reduce throttle to idle speed for cooling down. During this eight hours of running it is permissible to 

run at full throttle for periods of less than two minutes. 

NOTE: 

DURING BREAK-IN, DO NOT RUN ENGINE AT A CONSTANT RPM 

FOR LONGER PERIODS. 


ToC 


GENERAL 

Final Ten Hours of Break-in 

During the final ten hours of break-in, the engine may run at full speed for five to ten minutes. After warming up 

the engine to operating temperature, momentarily reduce the engine speed and then increase it again. For cooling 

down the engine, occasionally reduce the engine speed. 

NOTE: 

DURING THE BREAK-IN PERIOD, THE ENGINE MUST NOT BE OPERATED AT 

CONSTANT RPM FOR LONGER PERIODS. 

During break-in period, be particularly observant of the following: 

A. Check motor oil level daily. Always maintain oil level in the desired range between the "MIN" and "MAX" marks 

on dipstick. 

When refilling motor oil, refer to information "Motor Oil" (B 2). 

B. Check oil pressure control lamp. If the lamp lights up as soon as the boat changes its position (while turning, 

raising the boat or planing), check the oil level in the engine housing by means of dipstick. 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. In general, oil pressure will be higher with cold motor 

oil and specific RPM than with hot motor oil. 

C. Check engine temperature indication. Normal operation between 80° - 95°. In case of audible alarm, check 

coolant level in expansion tank (only at cold engine). 

D. Deviations from normal operating conditions will be indicated by warning lights and audible alarm. As to exact 

meanings see 06.07.02 & 06.07.05. 

ATTENTION: In case of nonobservance of break-in instructions, warranty will expire. 

Engine to be filled with recommended oil quality only. See chapter "Engine Lubrication" 

Z001019/0_8_Octobre 2011 

Page GENERAL-33

ToC 

GENERAL 


D 5 

Operation after Break - In 

The engines specified in this manual are intended to be operated at different speeds and loads, but not allowing 

full-load of the engine for more than one hour per 12 running hours. Economic driving may be achieved at the 

following speeds: 

M084K32 

M094K33 

M0114K33 

M0144M38 + BUKH STEYR SOLAS 

M0144V38 + BUKH STEYR SOLAS 

M0164M40 + BUKH STEYR SOLAS 

3000 rpm. 

3000 rpm. 

3000 rpm. 

3200 rpm. 

3200 rpm 

3400 rmp 

M0126M28 

M0166K28 

M0236K42 + BUKH STEYR SOLAS 

MO256K43 

MO256H45 

2200 rpm 

2200 rpm 

3300 rpm 

3600 rpm 

3600 rpm 

which will prolong engine life and reduce sound emissions. 

When starting a cold engine, always allow the engine to warm up slowly. Never run the engine at full speed until 

operating temperature is reached. During the first 50 running hours, check the oil level frequently. 


ToC 


GENERAL 


Z001019/0_8_Octobre 2011 

Page GENERAL-35

ToC 

GENERAL 


E 

E 1 

QUALITY GUIDELINES FOR REPAIR 

Spart part specification 

Your STEYR marine engine was designed for marine operation which means operating 

conditions such as: 

* Long-time operation at high speed 

* Operation in salt or brackish water 

* 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. 

E 2 

Workshop profile 

Independently of the respective repair steps and the legal regulations the workshops have to meet the 

following requirements: 

- Clean, dry, and dustfree environment 

- Lifting gear (crane) with a lifting capacity of 5 000 N (500 kg) minimum 

- Cleaning device (wash basin) for soiled components 

- Commercial tools 

- Appropriate test and measuring equipment 

- Receptacles for operating agents. 

Depending on the repair step to be carried out, the tools indicated in the catalog TOOL KIT are to be 

provided. 

Furthermore special care is to be taken in case of purchasing and stock of required operating material, 

spare parts and wear parts (e.g. seals, filters, anodes,...). 

For appointed retailers and authorized workshops of STEYR MOTORS GmbH, the following 

minimum standard is to be met: 

- basic training (as soon as possible, after conclusion of contract, for trade and workshop) 

- biannual training (reacurring) 

- tool kit I (service and maintenance tools) 

- tool kit II - III (depending on repair to be carried out) 

- procurement and stock of required genuine spare parts (as per proposed spare parts) 

- spare part catalogue for all STEYR MARINE ENGINES models 

- technical literature 

- PC diagnostics 


ToC 


GENERAL 

E 3 

Nomenclature 

Term Description Example 

disassemble 

remove 

unscrew 

deflange 

dismantle 

assemble 

put on, place 

screw on 

flange 

mount 

disconnect 

connect 

pull off 

press on 

unscrew 

tighten 

disassemble 

assemble 

loosen 

remove 

Removal of an assembly of a main assembly or of a component 

of an assembly without other assemblies having been removed 

before 

Putting on of an assembly on a main assembly or a component 

of an assembly without further assemblies being put on 

for functional performance 

Separating of connections of lines, pipes and hoses, which are 

separable 

Putting together separable connections of lines, pipes and 

hoses 

Removal of a component with press fit from another 

Placement of a component with press fit to another 

Opening of turnable locks 

Closing of turnable locks 

Removal of an assembly from a main assembly or a component 

from an assembly, if other assemblies have been removed 

before 

Putting on an assembly to a main assembly or a component of 

an assembly, if further assemblies are put on for functional 

achievement 

Partial unlocking of fixing elements of a component or of an 

assembly 

Taking off a fixing element of a component or an assembly 

secure 

Putting on a fixing element of a component or an assembly 

and tightening 

disassemble Taking apart assemblies into individual components 

assemble 

Putting together components to an assembly 

adjust Elimination of a deviation by means of provided equipment or Valve clearance, 

start of feeding 

readjust Devices or tools operation 

refill 

Adding and replenishing of operating agents 

renew Replacing an auxiliary material by a new one Corrosion protection 

agent, sealing 

material, paint 

gauge 

Reading in actual positions in programming memory 

replace 

Exchanging of a device, a main assembly, an assembly or a 

component by the same, new or repaired ones 

measure 

Steps taken to determine the actual status by evaluating of 

physical entities 

check Steps taken to compare the actual status with a determined Valve lift, piston 

diameter, valve 

clearance, close 

fit, V-belt tension 

clean 

Removal of foreign and auxiliary material 

maintain 

Steps taken to keep the respective determined planned status 

Z001019/0_8_Octobre 2011 

Page GENERAL-37

ToC 

GENERAL 


E 4 

SI- System 

The following measuring units are used. 

Linear 

Pressure and Stress 

km = kilometer bar = bar 

m = meter Pa = pascal 

mm = millimeter KPa = Kilopascal 

" = inch N/mm 2 = newton per square millimeter 

Area 

Energy 

m 2 = square meter J = Joule 

cm 2 = square centimeter kW/h = kilowatt hour 

Volume 

Power 

m 3 = cubic meter kW = kilowatt 

cm 3 = cubic centimeter 

dm 3 = cubic decimeter 

mm 3 = cubic millimeter 

l = litre 

Mass 

Temperature 

t = metric ton K = degrees Kelvin 

kg = kilogram ° C = degrees Celsius 

g = gram 

Energy 

Time 

N = newton h = hour 

kN = kilonewton min = minute 

daN = dekanewton s = second 

Electricity 

Velocity 

A = ampere km/h = kilometer per hour 

V = volt m/s = meter per second 

W = ohm 

µF = microfarad 

Fuel consumption 

Speed 

g/kWh = gram per kilowatt hour 1/min = r.p.m. 


ToC 


GENERAL 

E 5 

Abbreviations 

ill. 

Cu 

MAssy 

max. 

TDC 

PTO 

WS 

EMS 

ECU 

illustration 

copper 

main assembly 

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

ToC 

GENERAL 


F 

F 1 

OPERATING MATERIAL AND INFORMATION ON 

DISPOSAL 

List of operating material 

Order No. 

VR00207/0 

Z010058/0 

Z011785/0 

9000190/0 

Z012222/0 

Z909570/0 

9000059/1 

9000297/1 

9000510/5 

9000019/1 

9000017/1 

Z010207/0 

Z010226/0 

Z010227/0 

Z010084/0 

Z010205/0 

9000197/0 

Z011627/0 

Z010074/0 

Z010075/0 

Qty. 

1 

3 

3 

2 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

Designation 

set of fuel and oil for engine service, consisting of: 

- STEYR Turbo Diesel motor oil SAE 5W-50 (4l. can.) 

- STEYR MOTORS engine coolant (5l. can.) 

- hydraulic oil ATF (1l. bottle) 

- grease, Never - Seez; NS-160 B (1 kg can.) 

- caoutchouc sealing / electric contacts (148 ml can.) 

- thread protection 243 (10 ml flask) 

- surface sealing 509 (315 ml cartridge) 

- surface sealing 5910 (50 ml cartridge) 

- construction adhesive 620 (50 ml flask) 

- construction adhesive 262 (50 ml flask) 

- contact grease (100 ml tube) 

- corrosion protection spray (400 ml can.) 

- corrosion protection wax (120 ml can.) 

- grease STABURAX NBU4 (1 kg can.) 

- fuel rust protection additive (5 lt can.) 

- electric contact spray 

- silver varnish, RAL 9006 (1 lt can) 

- hardener varnish (0,5 lt can) 

- dilution for varnish (5 lt can) 


ToC 


GENERAL 

F 2 

Disposal of automotive waste products 

Used operating material is to be collected in special containers to enable possible subsequent treatment. 

ATTENTION: All operating materials for the engine are subject to the Special Waste Act for disposal. 

The "Special Waste Catalog" ÖNORM S 2100 refers to the required disposal in Austria. 

Respective legal local regulations are to be followed. 

The maintenance and repair personnel has to take care that operating material and other material to be 

regarded as special waste product, is always deposited at collection site. 

Key-No.: 

Description 

31 423 Oil contaminated soil or oil bonding agent 

54 102 Waste oil 

54 104 Fuels 

54 202 Lubricants 

54 207 Vaseline 

54 917 Solid sealing material 

54 927 Oil soiled cleaning rags 

54 928 Used oil and air filters 

55 510 Paint and varnish containing waste material 

Z001019/0_8_Octobre 2011 

Page GENERAL-41

ToC 

GENERAL 


G 

G 1 

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. 

Inappropriate behaviour and insufficient knowledge of hazard during repair works may cause injury to 

persons. 

In the description of repair works, such sources of danger are marked with 

ATTENTION 

The personnel is to be trained accordingly and requested to follow the saftey rules. 

G 2 

Guidelines for damage prevention 

The general knowledge and training of the workshop personnel and the contents of the "general 

regulations of safety technology" and machine safety regulations (Maschinen-Sicherheitsverordnung - 

MSV) are not subject of this chapter. 

Inappropriate behaviour and insufficient knowledge of hazard during repair works may cause injury to 

persons. 

In the description of repair works, such sources of danger are marked with 

ATTENTION 

While handling with operating materials, take care that these are not applied to visible surfaces. 

Lubricants should form a thin film on the surface, surplus lubricants are to be wiped off. 

G 3 

Legal rules 

The following rules and guidelines are valid in Austria. For other countries, follow the local regulations. 

Maschinen - Sicherheitsverordnung - MSV (machine safety regulations) 


ToC 


GENERAL 

G 4 

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 

- Anti-freeze agent 

- Varnishes and diluents 

- Solvents 

- Fluid seals and nut locks 

In case of fire of operating material do not try to extinguish the fire with water. Use carbon dioxide 

extinguisher or powder extinguisher. Contact fire brigade. 

When operating material is spilled, e.g. in case of refueling, it is to be absorbed by sand, soil or an 

appropriate bonding agent and to be disposed. 

ATTENTION: In order to prevent health hazards, take care of the following: 

- Avoid direct contact with dangerous operating material, as far as possible. 

- Change clothes as quickly as possible, if they are soiled with dangerous operating material. 

- Do not keep oily rags in work clothes. 

- Clean oil soiled body parts only with products friendly to skin (never use rubbing sand or solvents). 

- Never fill operating agents in beverage bottles. 

G 5 

Measures in case of accidents 

Products First Aid 

Skin Eyes Swallowing 

Diesel fuel 

DO NOT VOMIT 

and mineral oils Remove clothes and Rinse thoroughly with The biggest danger after an 

accidental intake is the fact that 

Lubricants clean skin thoroughly water for at least liquid could get into lungs by 

aspiration. 

Anti-freeze agents with water and soap 10 minutes. 

DO NOT PROVOKE VOMITING 

Brake fluid SEE A AND IIMMEDIATELY SEE A 

DOCTOR 

Battery acid 

DOCTOR! 

Z001019/0_8_Octobre 2011 

Page GENERAL-43

ToC 

GENERAL 


H 

H 1 

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). 

08.01 ill.1 

Plug screw for locking pin 

in engine housing 

50 Nm +/- 5 

08.01 ill.2 

Connecting rod screws 

(apply oil to thread and screwhead support) 

1. step: 10 Nm +/- 1 

2. step: 30 Nm +/- 3 

3. step: 75° +/- 4° 

08.01 ill. 3 

Main bearing screws 


1. step: 35 Nm +/- 3 

2. step: 45° +/- 4° 

3. step: 45° +/- 4° 

08.01 ill.4 


ToC 


GENERAL 

Flywheel screws 

(use LOCTITE 243 on thread) 

75 Nm +/- 4 

Vibration damper screws 


08.01 ill.5 

135 Nm (2x) +/- 7 

Screw, rear ring carrier 


08.01 ill.6 

1. step: 8 Nm +/- 1 

2. step: 30 Nm +/- 3 

Nut, camshaft sprocket 

(taper degreased on camshaft, thread 

lubricated) 

08.01 ill.7 

1. step: 80 Nm +/- 4 

2. step: 240 Nm +/-12 

08.01 ill.8 

Z001019/0_8_Octobre 2011 

Page GENERAL-45

ToC 

GENERAL 


Screw tooth, belt tensioner 

45 Nm +/- 4 

Valve adjustment element 

08.01 ill.9 

55 Nm +/- 3 

Screw, linkage lever 

CAUTION: left-hand thread 

7 Nm +/- 0,5 

08.01 ill.10 

Stud, unit injector 

08.01 ill.11 

21 Nm +/- 2 

08.01 ill.12 


ToC 


GENERAL 

Collar nut for unit injector 

18 Nm - 2 

Nut, adjustment screw of unit injector 

08.01 ill.13 

30 Nm +/- 3 

Plug screw for control rack 

in camshaft housing 

08.01 ill.14 

50 Nm +/- 5 

Screw, exhaust manifold 

08.01 ill.15 

23 Nm +/- 2 

08.01 ill.16 

Z001019/0_8_Octobre 2011 

Page GENERAL-47

ToC 

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 

Screws, intercooler 

08.01 ill.17 

28 Nm +/- 2 

Plug screws, zinc anode 

08.01 ill.18 

50 Nm +/- 5 

Crown nut, oil cooler 


08.01 ill.19 

55 Nm +/- 5 

NOTE: 

for all clamps 

3,5 Nm 

08.01 ill.20 


ToC 


GENERAL 

H 2 

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 tot. 0.125 

MA in Nm MA in NM 

Property 

Nominal Ø 

8.8 10.9 12.9 class 

8.8 10.9 12.9 

Metric 

Nominal Ø standard thread 

M 4 2.4 3.3 4 M 4 2.7 3.88 4.6 

M 5 4.9 7 8 M 5 5.5 8 9.5 

M 6 8 12 14 M 6 9.5 13 16 

(M 7) 13 19 23 (M 7) 15 22 26 

M 8 20 28 34 M 8 23 32 39 

M 10 40 56 67 M 10 46 64 77 

M 12 69 98 115 M 12 80 110 135 

M 14 110 155 185 M 14 125 180 215 

M 16 170 240 285 M 16 195 275 330 

M 18 235 330 395 M 18 270 390 455 

M 20 330 465 560 M 20 385 540 650 

M 22 445 620 750 M 22 510 720 870 

M 24 570 800 960 M 24 660 930 1100 

M 27 840 1200 1400 M 27 980 1400 1650 

M 30 1150 1600 1950 M 30 1350 1850 2250 

Nominal Ø 

Nominal Ø 

Metric 

standard thread 

M 8x1 22 30 36 M 8x1 25 35 42 

M 10x1.25 42 59 71 M 10x1.25 49 68 82 

M 12x1.25 76 105 130 M 12x1.25 88 125 150 

M 12x1.5 72 100 120 M 12x1.5 83 115 140 

M 14x1.5 120 165 200 M 14x1.5 140 195 235 

M 16x1.5 180 250 300 M 16x1.5 210 295 350 

M 18x1.5 260 365 435 M 18x1.5 305 425 510 

M 20x1.5 360 510 610 M 20x1.5 425 600 720 

M 22x1.5 480 680 810 M 22x1.5 570 800 960 

M 24x2 610 860 1050 M 24x2 720 1000 1200 

M 27x2 900 1250 1500 M 27x2 1050 1500 1800 

M 30x2 1250 1750 2100 M 30x2 1450 2050 2500 

If the tightening torque of a screw connection is not reached, the tightness of the screw/nut 

is too low or the ratio of friction do not correspond. In any case, the screw/nut is to be replaced. 

*) µ tot. = total frictional value 

Z001019/0_8_Octobre 2011 

Page GENERAL-49

ToC 

GENERAL 


H 3 

Testing of torque wrenches 

The torque wrenches are subject to regular tests of the set values. By doing so, the tripping value of 

signalling torque wrenches and the scale accuracy of measuring torque wrenches are tested. 

H 4 

Non-destructive material testing 

For the detection of surface cracks, the non-destructive test according to colour penetration test 

procedure is recommended. 

The workpiece is sprayed or coated with a penetration agent, and after drying a developer is applied. After 

a development time of appr. 10 minutes, defects on the workpiece appear as dots or lines. 

H 5 

Use of adhesive and sealing materials 

In the workshop manual adhesive and sealing materials are specified for the repair of engines and 

aggregates, which are used at operating temperatures of up to 150° C and agents such as water, coolants 

and hydraulic fluids, engine and gear oils as well as fuels. 

Solvent-free sealing materials 

The hardening takes places without loss of volume, so that a retightening of screw connections is not 

necessary. 

Anaerobic sealing materials 

These are used for securing, fixing and sealing, and only harden under exclusion of air. 

Solvent containing sealing materials 

Due to their contents of volatile parts a loss of volume occurs during hardening. During repair, the 

hardening time is taken into consideration. If such sealing materials are used, special reference is made 

in the description of the workshop manual. 

H 6 

Solvent-free sealing materials 

Silicon sealing materials 

They consist of silicon and filling materials and are free of solvents. 

The product is applied to the cleaned sealing surface from the tube or cartridge in form of a string. Sealing 

material residues are removed with cleaning agent. 

Silicon sealing material is to be stored below 30° C. 

Anaerobic sealing materials 

They consist of a single component epoxy in liquid form. The product is applied as a liquid to the 

components and remains liquid, as long as it is in contact with ambient air (oxygen). Only when the 

parts are assembled, chemical reaction starts due to exclusion of air (oxygen) and metal contact, i.e. 

transformation of liquid state into an epoxy built up by molecular chains. 

Any residues remaining after assembly and/or are pressed out of the connection remain liquid and may 

be removed easily. 


ToC 


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. 

If solvents or degreasing agents are used for cleaning, take care that they are completely volatilized 

before application of the epoxyl. 

Storage 

At temperatures below 28° C, 1 year minimum. 

Guidelines of application for securing (S) 

Designation: SM ....... Securing medium tight (the connection is to be loosened without problems) 

Designation: SF ........Securing tight (the connection is difficult to loosen) 

Application: Screw connections 

Fixing procedure 

In general, the application of the epoxy to the screw thread is sufficient. 

If screws are screwed into socket threads, only the thread bore is wet in order to let the air escape during 

screwing in. 

Screws or nuts which are tightened with a specified torque, are slightly oiled on their support surface or 

housing part. 

Guidelines for fixing (B) 

Designation: BM ....... Fixing medium tight 

Designation: BF ........ Fixing tight 

Application: Jointing connections, bushings, sprockets, belt pulleys, bearings etc. 

Jointing procedure 

In case of jointing connections both jointing parts are to be wetted. The wetting has to completely cover 

the jointing surfaces. The parts are shifted into each other by turning, in case of slide fits. 

No strength may be exerted to the connection until sturdiness is reached (for time, refer to Table 1). 

Guidelines of application for sealing (D) 

Designation: DR ....... Sealing of pipe connections 

Designation: DF ........Sealing of plane surfaces 

Application: Sealing of threads , screw connections, jointing connections and plane surfaces. 

Hardening time 

Use 

S ecuring 

Fixing 

(B) 

Sealing 

Class SM SF BF DR DF DF 

Product Loctite 243 Loctite 262 Loctite 620 Loctite 509 Loctite 510 Loctite 5900 

Handtightnes s 

reached after 

Functional tightness 

reached after 

F inal tightnes s 

reached after 

Z001019/0_8_Octobre 2011 

15 - 30 min 15 - 30 min 5 - 10 min 15 - 30 min immediately immediately 

1 h 1 h 1 h 0.5 h immediately immediately 

3 h 3 h 4 h 12 - 24 h 24 h 12 - 24 h 

Page GENERAL-51

ToC 

GENERAL 


J 

Wear Limits 

Part resp. part union 

New part tolerance 

Wear Limit 

Remark 

Main bearing clearance radial 

0,032 - 0,099 

0,15 

Main bearing clearance axial 

0,080 . 0,263 

0,30 

Connect.rod bearing clear. radial 

0,024 - 0,073 

0,10 

Connect.rod bearing clear. axial 

0,064 - 0,217 

0,50 

Cylinder bore 

85,00 - 85,01 

0,20 

Piston travel clearance 

0,071 - 0,099 

0,20 

Piston diameter 

84,911 - 84,929 

0,10 

deviation from initial 

dimension 

Gap 1. ring 

0,25 - 0,40 

1,50 

Gap 2. ring 

0,50 - 0,75 

0,25 

Gap 3. ring 

0,30 - 0,60 

1,00 

Axial play 1. ring 

0,077 - 0,127 

0,25 


0,07 - 0,102 

0,25 


0,03 - 0,065 

0,15 

Camshaft radial 

0,034 - 0,075 

0,20 

Camshaft axial 

0,096 - 0,230 

0,50 

indicates gauging depth up 

Valve guide 

7,000 - 7,015 

0,15 

to 3 mm 

before end of valve guide 

Oil pressure idle run 

0,6 - 1,5 

0,50 

Oil pressure rated speed 

4,0 - 7,0 

3,00 

Backlash of teeth oil pump 

0,2 - 0,3 

0,80 

Axial play gear wheel 

0,2 

0,40 


ToC 


GENERAL 

J 1 

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. 

J 1.2 

Tension timing belt (measured with tool VR00515/0) 

Tension instruction: 

Tension instruction: 

600 +/- 30 N (new belt) 

520 +/- 30 N (used belt) 

Maintenance instruction: In case the measurements are not within the specified limits of 630 N to 

490 N - than the settings needs to be reset to the original specified value. 

J 1.3 Start of fuel delivery on the unit injectors (measured with dial indicator No. 2300899/0) 

Setting instruction: For original settings on your engine please see table 03. 02. 06 

Maintenance instruction: In case the measurements are not within the specified limits the settings needs 

to be reset to the original specified value. 

J 1.4 Valve clearance (measured with tool No. 2300712/3)) 

Setting instruction: 

0,25 mm 

Maintenance instruction: In case the measurements are not within the specified limits less than 0,25 

more than 0,30 mm - the settings needs to be reset to the original specified value. 

Z001019/0_8_Octobre 2011 

Page GENERAL-53

ToC 

GENERAL 




ToC SERVICE MANUAL MARINE ENGINES 

01 ENGINE 

01 ENGINE 


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....................................... 16 

01.00.06 Replace engine mount and engine bracket ...................................................... 26 

01.01 Cylinder block................................................................................................ 28 

01.01.01 Replace valves ................................................................................................ 28 

01.01.02 Adjust valve clearance .................................................................................... 30 

01.01.03 Replace valve guide ........................................................................................ 30 

01.01.04 Replace pressure regulating valve for oil cooling jet ....................................... 31 

01.01.05 Replace stud bolt for unit injector .................................................................... 32 

01.01.06 Replace dowel pin for positioning of unit injector ............................................ 33 

01.01.07 Replace dowel pin for positioning of camshaft housing................................... 34 

01.01.08 Replace external screw adaptor for oil cooler ................................................. 35 

01.01.09 Replace coolant supply pipe ........................................................................... 35 

01.01.10 Mount frame seal ............................................................................................ 36 

01.02 Crankshaft, bearing, vibration damper ......................................................... 38 

01.02.01 Replace crankshaft.......................................................................................... 38 

01.02.02 Replace gear for oil pump drive ...................................................................... 42 

01.03 Flywheel, housing ......................................................................................... 43 

01.03.01 Replace flywheel housing................................................................................ 43 

01.03.02 Replace flywheel .............................................................................................. 44 

01.03.03 Replace adapter ring ....................................................................................... 45 

01.04 Piston and connecting rod ........................................................................... 46 

01.04.01 Dismantle piston and connecting rod .............................................................. 46 

01.05 Camshaft, housing, valve gear ..................................................................... 48 

01.05.01 Replace camshaft housing .............................................................................. 48 

01.05.02 Replace valve stem gasket (on engine assembly) .......................................... 52 

01.05.03 Replace control rack........................................................................................ 54 

01.05.04 Replace camshaft ........................................................................................... 56 

01.05.05 Replace rocker arm shaft ................................................................................ 58 

01.05.06 Replace radial shaft seal of camshaft ............................................................. 59 

01.05.07 Replace cam follower ...................................................................................... 60 

01.05.08 Replace retainer of cam follower ..................................................................... 61 

01.05.09 Replace valve adjusting element ..................................................................... 62 

Z001019/0_6_July 2008 Page ENGINE - 1

ToC 

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 .................................................................................. 73 

01.08 Intercooler ...................................................................................................... 74 

01.08.01 Remove intercooler ......................................................................................... 74 

01.08.02 Assembly of intercooler .................................................................................... 78 

01.08.03 Replace intercooler - element .......................................................................... 79 

01.09 Auxiliary drive, in front (PTO) ....................................................................... 81 

01.13 Engine oil cooler ........................................................................................... 82 

01.13.01 Replace engine oil cooler ................................................................................ 82 

01.13.02 Repair oil cooler .............................................................................................. 84 

01.13.03 Change motor oil .............................................................................................. 85 

01.13.04 Change oil filter ................................................................................................ 86 

01.14 Exhaust manifold, seals, heat exchanger ................................................... 87 

Page ENGINE- 2 Z001019/0_6_July 2008


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 

1 Unscrew allen head plug screw (ill.1) (SW 10). 

00.01 ill.1 

2 Turn crankshaft by means of special tool 2300767/0 

(ill.2) until roller of rocker arm cyl. 1 runs up the ramp 

of injection cam (ill.3). 

00.01 ill.2 

3 Insert locking pin 2300551/2 into guide hole and 

slightly press it against crankshaft counter weight. 

00.01 ill.3 

00.01 ill.4 


ToC 

01 ENGINE SERVICE MANUAL MARINE ENGINES 

4 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. 

Removal of locking pin 

1 Pull out locking pin 2300551/2. 

2 Screw in plug screw with hexagon socket and tighten 

with 50 Nm +/- 5. 

00.01 ill.5 

NOTE: 

Use new copper sealing. 

ATTENTION: Prior to starting, make sure that 

locking pin has been removed. 

3 Clean sealing surface of camshaft housing and 

camshaft housing cover. 

Check seal for hardening and damage. Exchange, if 

necessary. See 01.00.02 

00.01 ill. 6 

4 Remaining assembly is done in reserve order. 

Page ENGINE - 4 Z001019/0_6_July 2008


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. 

* The marked tooth of the camshaft timing belt 

sprocket stay´s in line with the upper edge (sealing 

surface) of the camshaft housing. 

00.01 ill.8 

00.01 ill.9 

* The notch on the timing belt sprocket of crankshaft 

is opposite to the arrow marker on the oil pump 

housing. 

00.01 ill.10 


ToC 


01.00.02 Exchange camshaft housing 

cover sealing 

1 Release hexagon nuts. 

2 Remove camshaft housing cover. 

3 For engines with plane sealing surface. 

Release camshaft housing cover sealing by means 

of screwdriver and remove. 

4 For engines with bossed sealing surface. 

Remove seal with a scraper and dispose. 

00.02 ill.1 

5 Clean sealing surface of camshaft housing cover and 

camshaft housing. 

6 For engines with plane sealing surface. 

Position new seal on camshaft housing cover and 

press it into the groove, beginning at the half-moon 

(ill.2). 

7 For engines with bossed sealing surface. 

Apply LOCTITE 5900 to sealing surface of camshaft 

housing cover; position the new sealing on and force 

against the cover. 

8 Put camshaft housing cover onto camshaft housing. 

Tighten with hexagon nuts SW 10. 

00.02 ill.2 



01 ENGINE 

01.00.03 Maintenance timing belt exchange 

Preparation: 

Special tool: 

put engine out of operation 

disconnect battery 

remove camshaft housing cover 

for vibration damper screws 

No. 2300767/0 

1 For 4 cyl. engines 

Remove Poly-V-belt. See exchange of Poly-V-belt 

(05.06) 


Remove all V-belts. See exchange of V-belts (05.07) 

00.03 ill.1 

3 Unscrew 3 hexagon screws (SW10) of upper V-belt 

covering (ill.2/pos.1) and remove V-belt covering. 

4 Unscrew hexagon screws (SW 10) of lower timing 

belt covering (ill.2/pos.2)) and remove timing belt 

cover. 

NOTE: 

See for arrows markings on used 

timing belt; mark timing belt if 

necessary. 

Consider change intervals - see 

chart "maintenance". 

00.03 ill. 2 

Special tool: 

2306031/4 dial gauge rail 4 cyl. 

2306031/1 dial gauge rail 6 cyl. with 

bossed seal surface 


plane seal surface 

2300899/0 dial gauge 

2300641/1 probe pin 

VR00515/0 V-belt tightener 

2300711/0 open end wrench 

VR00113/0 remover 

2300551/2 locking pin 

5 Mount dial gauge rail with brackets 2306031/. (see 

list special tool) on studs at intake side of camshaft 

housing. 

00.03 ill. 3 

6 Insert dial gauge 2300899/0 with probe pin 

2300641/1 in dial gauge rail and put probe pin onto 

unit injector-plunger guide cylinder 1. 

7 Turn camshaft until the roller of rocker arm is located 

on base circle of injection cam. 

00.03 ill. 4 


ToC 


8 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. 

00.00 

9 Lock crankshaft, refer 01.00.01 

00.03 ill.5 

00.03 ill.6 

10 Loosen Allen head screw SW 8 of belt tensioner and 

remove tensioner. 

11 Loosen 3 TORX screws for vibration damper by 

means of special tool 2300767/0 and remove vibration 

damper. 

00.03 ill. 7 

12 Remove timing belt. 

ATTENTION: With loose and/or removed timing belt, 

the camshaft or crankshaft must not 

be turned. 

This could result in a collision of pistons 

and valves. 

00.03 ill. 8 



01 ENGINE 

13 Put new timing belt onto crankshaft sprocket and 

camshaft sprocket (marked tooth of camshaft sprocket 

points at upper edge of camshaft housing). 

ATTENTION: Pay attention to arrow marker 

(direction of rotation) on timing belt. 

00.03 ill.9 

14 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. 

00.03 ill.10 

NOTE: 

Recheck torque after first test run. 

00.03 ill.11 

15 Tightly put on timing belt from crank shaft sprocket 

over water pump drive wheel and camshaft sprocket, 

and position camshaft sprocket with marked tooth 

towards upper sealing edge of camshaft housing. 

00.03 ill.12 


ToC 


16 Clean and degrease contact surface of tensioner and 


Then mount tensioner. 

17 Pre tension timing belt by turning tensioner on 

hexagon WS 32 counterclockwise. Tighten 

hexagon socket SW 8 with torque wrench to 20 Nm 

+/- 2. 

00.03 ill.13 

18 Put on tension gauge No. VR00515/0 (ill.15/pos.1) 

between camshaft sprocket and tensioner. Pre 

tension timing belt tension by further 

counterclockwise turning of tensioner hexagon 

SW 32 to read 600 N +/- 30 Nm for new timing belt 

indication on tension gauge between green and red 

marked field. 

00.03 ill.14 

2 

1 

ATTENTION: When putting on tension gauge No. 

VR00515/0, consider the following: 

* The two stop trunnions (ill.15/pos.2) should rest 

on the forehead of timing belt and must not rest 

on the back of timing belt. 

* Put measuring bow onto tooth. 

* During measuring, completely push in measuring 

bow and relax quickly. 

When attaining the required timing belt tension, tighten 

the Allen head screw SW 8 with torque wrench to 45 

Nm +/-4, and hold up at the same time with wrench 

SW32. 

00.03 ill.15 

00.03 ill.16 



01 ENGINE 

19 Remove locking pin from crank shaft. 

20 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. 

NOTE: 

During above mentioned operation 

the timing belt should run into place 

and a uniform tension shall result for 

measuring of timing belt tension. 

00.03 ill.17 

4x 

21 Put on tension gauge No. VR00515/0 between 

camshaft sprocket and tensioner, as described, 

and read measured value. 

Timing belt tension should be 600 N +/- 30 N for a 

new timing belt. 

00.03 ill.18 

NOTE: 

If timing belt tension does not 

correspond to specified tension, loosen 

the tensioner and repeat adjustment 

according to instructions under item 

21 through 24. 

In this case, a re-positioning of the 

camshaft sprocket may be required. 

22 Turn crankshaft further 2 turns, and at second turn 

fix crankshaft with locking pin in TDC position 

(cylinder 1; in TDC). See chapter 01.00.01. 

With crank shaft in locked position, the plunger 

guide stroke of the unit injector at first cylinder 

should show the following value on the dial gauge: 

Index value of engine timing 

3.20 mm +/- 0,04 mm 

(plunger guide stroke - unit injector) 

00.03 ill.19 

00.00 

00.03 ill.20 


ToC 


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 

23 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. 

00.03 ill.22 

24 Mount extractor (ill.23/pos.1) camshaft sprocket 

VR00113/0 and screw in puller screw "LEFTHAND 

THREAD" by hand. 

Prestress puller screw with approx. 100 Nm +/-5. 

1 

NOTE: 

Do not remove camshaft sprocket 

from conical seat when screwing in 

the puller screw. 

00.03 ill.23 

25 Remove camshaft sprocket from concial seat by one 

hammer blow on puller screw. 

NOTE: 

To correct the setting of engine timing, 

follow further instructions as per item 

26. 

00.03 ill.24 



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. 

26 Check locking position of crankshaft or lock crank 

shaft, if necessary. (piston; cylinder 1; in TDC). 

Refer 01.00.01 

õ 

27 Adjust camshaft to 3.27 mm on the dial gauge, by 

turning with special tool 2300711/0 (ill.26).(plunger 

guide at unit injector is moved down by 3,27 mm.) 

00.03 ill.25 

1 

NOTE: 

During this operation, the camshaft 

sprocket must be released from the 

taper connection and should only 

slightly supported by the cone. Tension 

of timing belt remains adjusted, as 

described before. 

28 Remove locking pin from crankshaft. Refer 01.00.01 

00.03 ill.26 

29 Tighten hexagon nut SW 30 of camshaft sprocket to 

80 +/-4 Nm by holding up with special tool 2300711/ 

0 at hexagon on camshaft. 

ATTENTION: During this operation, camshaft 

sprocket and camshaft are connected 

positively. A positive connection is 

only achieved by tightening the 

hexagon nut with 240 +/-12 Nm. The 

previously set stroke on the unit 

plunger guide must not be changed 

when tightening the hexagon nut. 

00.03 ill.27 

30 Turn crankshaft by 2 further turns, and at the second 

turn fix crankshaft with locking pin in TDC position 


With locked crankshaft, the plunger guide stroke of 

unit injector at first cylinder should show the following 

dial gauge value: 

00.00 


3.20 mm +/- 0,04 mm 


00.03 ill.28 


ToC 


NOTE: 

If the index value of engine timing 

should not correspond to the allowed 

value, follow the instructions as per 

item 24. 

31 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. 

2300711/0. 

32 ATTENTION: The following torques are to be 

checked again: 

1 Torque on hexagon nut of camshaft sprocket 

SW 30 240 +/-12 Nm. 

2 Fillister socket head screw SW 8 of timing 

belt tensioner at 45 +/-4 Nm. 

3 3 TORX screws on vibration damper with 

135 +/-4 Nm. 

33 Remove locking pin on crankshaft. 



01 ENGINE 

01.00.04 Remove timing belt 

Preparation: 

Special tool: 

put engine out of operation 


remove camshaft housing cover 

for vibration damper screws 

No. 2300767/0 


Remove Poly-V-belt. See exchange of Poly-V-belt 

(05.06) 


Remove all V-belts. See exchange of V-belts (05.07) 

00.04 ill.1 

3 Unscrew 3 hexagon screws (SW10) of upper V-belt 

covering (ill.2/pos.1) and remove V-belt covering. 

4 Unscrew hexagon screws (SW 10) of lower timing 

belt covering (ill.2/pos.2)) and remove timing belt 

cover. 

NOTE: 

See for arrows markings on used 

timing belt; mark timing belt if 

necessary. 

Consider change intervals - see 

chart "maintenance". 

00.04 ill. 2 

5 Lock crankshaft, see 01.00.01 

6 Loosen Allen head screw (SW 8) of belt tensioner 

and remove tensioner. 

7 Loosen 3 TORX screws for vibration damper by 

means of special tool 2300767/0 and remove vibration 

damper. 

00.04 ill. 3 

8 Remove timing belt. 

ATTENTION: With loose and/or removed timing belt, 

the camshaft or crankshaft must not 

be turned. 

This could result in a collision of pistons 

and valves. 

MOUNT TIMING BELT - see adjust engine timing; 

01.00.04 

00.04 ill. 4 


ToC 


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 essential 

functional elements, such as unit injector, timing 

belt tension and sense of rotation of engine, in order 

to achieve the required setting accuracy of injection. 

A change of the timing belt tension or the sense of 

rotation during adjustment always causes wrong 

positioning of the injection control.For this reason it is 

to be ensured that the adjusting procedure follows 

the conditions of real operation. 

Status for job: 

* Camshaft housing cover dismantled. 

* Set up crankshaft to approx. 40° crank angle 

before TDC (piston; cylinder 1; in TDC) in order 

to set all pistons in the engine to approximately 

the same length of stroke, thus providinge open 

space for the valve movement (stroke). This 

ensures that the camshaft may be turned to the 

desired position (injection stroke - unit injector 

cylinder 1) without problems. 

00.05 ill.1 

* Crankshaft position with dismantled vibration 

damper. 

* Crankshaft position with mounted damper, if 

timing belt has not been removed. 

NOTE: 

Before disassembly, mark the 

vibration damper, with locked 

crankshaft. A corresponding 

marking must be made on the 

timing belt cover. 

* Unit injectors mounted and adjusted. 

See 03.02.02 and 03.02.06. 

00.05 ill.2 

* Valve clearance set. 

Special tool.: 








VR00515/0 V-belt tightener 

2300711/0 open end wrench 

VR00113/0 remover 

2300551/2 locking pin 

00.05 ill.3 



01 ENGINE 

1 Mount dial gauge rail with brackets 2306031/. (see 

list special tool) on studs at intake side of camshaft 

housing. 

2 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. 

3 Turn camshaft until the roller of rocker arm is located 

on base circle of injection cam. 

00.05 ill.4 

00.05 ill.5 

4 Pre-set dial gauge to position 20 mm stroke (small 

pointer at 20 - inside scale, big pointer at 0 - outside 

scale). 

00.00 

00.05 ill.6 

5 Slowly turn camshaft in direction of rotation until dial 

gauge shows a stroke of 2 mm (injection stroke at 

unit injector). 


ToC 


6 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. 

7 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). 

Assembly of camshaft sprocket 

00.05 ill.7 

8 Clean and degrease cone on camshaft and in camshaft 

sprocket. 

ATTENTION: Very high for as are transmitted via this 

conical seat. Therefore, it is extremely 

important that the two cone surfaces 

are assembled absolutely clean and 

grease-free. 

00.05 ill.8 

9 Shift camshaft sprocket onto cone and slightly lubricate 

thread at front end of camshaft. 

Slightly turn hexagon nut and washer by hand. The 

camshaft sprocket should only slightly be supported 

by the cone, in this status on easily turning of the 

camshaft sprocket must be possible. 

00.05 ill.9 

10 Put timing belt onto pre-positioned crankshaft sprocket 

(Lock crank shaft - see 01.00.01) and camshaft 

sprocket (marked tooth of camshaft sprocket points 

at upper edge of camshaft housing). 

õ 

• 

00.05 ill.10 



01 ENGINE 

ATTENTION: Pay attention to arrow marker 

(direction of rotation) on timing belt. 

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. 

00.05 ill.11 

NOTE: 

Recheck torque after first test run. 

00.05 ill.12 

12 Tightly put on timing belt from crank shaft sprocket 

over water pump drive wheel and camshaft sprocket, 

and position camshaft sprocket with marked tooth 

towards upper sealing edge of camshaft housing. 

00.05 ill.13 

13 Clean and degrease contact surface of tensioner and 


Then mount tensioner. 

00.05 ill.14 


ToC 


14 Prestress timing belt by turning tensioner on hexagon 

(WS 32) counterclockwise. Tighten hexagon socket 

(SW 8) with torque wrench to 20 Nm +/- 2. 

15 Put on tension gauge No. VR00515/0 (ill.16/pos.1) 

between camshaft sprocket and tensioner. Prestress 

timing belt tension by further counterclockwise 

turning of tensioner hexagon (SW 32) to 710 N +/- 

30 N for new timing belt. 

NOTE: 600 N +/- 30 N for used timing belt 

00.05 ill.15 

2 

1 

ATTENTION: When putting on tension gauge No. 

VR00515/0, consider the following: 

* The two stop trunnions (ill.16/pos.2) should rest 

on the forehead of timing belt and must not rest 

on the back of timing belt. 

* Put measuring bow onto tooth. 

* During measuring, completely push in measuring 

bow and relax quickly. 

When attaining the required timing belt tension, tighten 

the Allen head screw (SW 8) with torque wrench to 

45 Nm +/-4, and hold up at the same time with wrench 

(SW32). 

00.05 ill.16 

16 Tighten hexagon nut (SW 30) of camshaft sprocket 

to 80 Nm +/- 4, by holding up with special tool 

2300711/0 at hexagon on camshaft. 

00.05 ill.17 

ATTENTION: The preset stroke at the unit injector 

(3.32 mm) must not be changed when 

tightening the hexagon nut. During 

this operation step, camshaft 


measurement purpose. A positive 

connection is only achieved by finally 

tightening the hexagon nut with 240 

Nm +/-12. 

00.05 ill.18 



01 ENGINE 

17 Remove locking pin from crank shaft. 

18 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. 

NOTE: 

During above operation mentioned 

on the timing belt shall be positioned 

correctly and a uniform tension is set 

up for measuring of timing belt 

tension. 

00.05 ill.19 

4x 

00.05 ill.20 

19 Put on tension gauge No. VR00515/0 between 

camshaft sprocket and tensioner, as described 

under item 15, and read measured value. 

Timing belt tension should be 600 N +/- 15 N for a 

new timing belt. 

NOTE: for a used timing belt 520 N +/- 30 N 

NOTE: 

If timing belt tension does not 

correspond to desired value, loosen 

the tensioner and repeat adjustment 

according to instructions under item 

14 to 19. 

In this case, a re-positioning of the 

camshaft sprocket may be required. 

20 Turn crankshaft further 2 turns, and at second turn 

fix crankshaft with locking pin in TDC position 


With crank shaft in locked position, the plunger 

guide stroke of the unit injector at first cylinder 

should show the following value on the dial gauge: 


3.20 mm +/- 0,04 mm 


00.05 ill.21 

00.00 

00.05 ill.22 


ToC 


NOTE: If the index value of engine timing should 

not 

correspond to the desired value, 

follow the instructions as per item 24. 

21 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. 

2300711/0. 

00.05 ill.23 


checked again. 

õ 


(SW 30) 240 Nm +/- 12 

2 Allen head screw (SW 8) of timing belt 

tensioner at 45 Nm +/- 4 


135 Nm +/- 7 


00.05 ill.24 



01 ENGINE 

Remove camshaft sprocket 

24 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 

25 Mount extractor (ill.26/pos.1) camshaft sprocket 

VR00113/0 and screw in puller screw "LEFTHAND 

THREAD" by hand. 

Prestress puller screw with approx. 100 Nm +/-5. 

1 

NOTE: 

Do not remove camshaft sprocket 

from conical seat when screwing in 

the puller screw. 

00.05 ill.26 

26 Remove camshaft sprocket from concial seat by one 

hammer blow on puller screw. 

NOTE: 

To correct the setting of engine timing, 

follow further instructions as per item 

27. 

00.05 ill.27 


ToC 


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. 

27 Check locking position of crankshaft or lock crank 

shaft, if necessary. (piston; cylinder 1; in TDC). See 

01.00.01 

õ 

28 Adjust camshaft to 3.27 mm on the dial gauge, by 

turning with special tool 2300711/0 (ill.29).(plunger 

guide at unit injector is moved down by 3,27 mm.) 

00.05 ill.28 

1 

NOTE: 

During this operation, the camshaft 

sprocket must be released from the 

taper connection and should only 

slightly supported by the cone. Tension 

of timing belt remains adjusted, as 

described before. 

29 Remove locking pin from crankshaft. See 01.00.01 

00.05 ill.29 

30 Tighten hexagon nut (SW 30) of camshaft sprocket 

to 80 Nm +/-4 by holding up with special tool 2300711/ 

0 at hexagon on camshaft. 

ATTENTION: During this operation, camshaft 


positively. A positive connection is 

only achieved by tightening the 

hexagon nut with 240 Nm +/-12. The 

previously set stroke on the unit 

plunger guide must not be changed 

when tightening the hexagon nut. 

00.05 ill.30 

31 Turn crankshaft by 2 further turns, and at the second 

turn fix crankshaft with locking pin in TDC position 


With locked crankshaft, the plunger guide stroke of 

unit injector at first cylinder should show the following 

dial gauge value: 

00.00 


3.20 mm +/- 0,04 mm 


00.05 ill.31 



01 ENGINE 

NOTE: 

If the index value of engine timing 

should not correspond to the allowed 

value, follow the instructions as per 

item 24. 

32 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. 

2300711/0. 


checked again: 


(SW 30) 240 Nm +/-12. 

2 Fillister socket head screw (SW 8) of timing 

belt tensioner at 45 Nm +/-4. 


135 Nm +/-4. 



ToC 


01.00.06 Replace engine mount and 

engine bracket 

1 

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 

1 Loosen hexagon nut (SW24), remove washer. 

00.06 ill.1 

2 Loosen two setscrews (SW17) of engine mount, 

remove engine mount. 

NOTE: 

After assembly of the engine mount, 

center the engine to correct axis 

geometry of drive unit. 

Replace engine bracket 

00.06 ill.2 


Loosen 7 allen head screws (SW6), remove bracket 

and 7 washers. 

NOTE: 

During assembly, secure allen head 

screws with LOCTITE 243 

(9000059/1) and tighten with a 

torque of 23 +/- 2 Nm. 


Loosen 4 allen head screws (SW8), remove bracket 

and 4 washers. 

00.06 ill.3 

NOTE: 



(9000059/1) and tighten with a torque 

of 64 +/- 5 Nm. 

00.06 ill.4 



01 ENGINE 

Exchange bracket on flywheel housing 

1 Loosen 4 allen head screws (SW10) 

and remove support. 

NOTE: 



(9000059/1) and tighten with a 

trorque of 75 +/- 5 Nm. 

00.06 ill.5 


ToC 

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. 

1 Insert special tool No. VR00104/00 in cylinder bore 

and tighten sturdily with two hexagon screws (SW19). 

01.01 ill.1 

2 Mount valve spring retainer No. VR00105/1 . 

01.01 ill.2 

3 Prestress valve spring with hexagon nut (SW28). 

01.01 ill.3 

4 Remove wedges. 

5 Relax valve spring again, remove valve spring, spring 

plate and spring washer. 

6 Remove special tool from cylinder bore, remove 

valves. 

01.01 ill.4 



01 ENGINE 

7 Pull out valve stem gasket with special tool No. 

2300758/0. 

NOTE: 

When inserting the valves, lubricate 

valve stem with motor oil. 

01.01 ill.5 

8 Put special tool No. V000152/0 onto valve stem end 

and pull on new valve stem over sleeve. 

9 Remove sleeve and press on valve stem gasket with 

special tool No. V000166/0 until valve stem gasket is 

supported on collar of valve guide. 

10 Lubricate valve stem (motor oil). 

11 Mount special tool No. VR00104/0 again. 

01.01 ill.6 

12 Put on spring washer, valve spring and spring plate 

and prestress valve spring with special tool No. 

VR00105/1. 

NOTE: 

The progressively wound end of the 

valve spring is located on the cylinder 

block. 

13 Insert wedges, relax valve spring and check correct 

seat of wedges. 

01.01 ill.7 


ToC 

01 ENGINE 


01.01.02 Adjust valve clearance 

Preparation: Remove camshaft housing cover 

3 

1 

2 

Valve clearance is adjusted by means of special tool 

No. VR 00125/0 and adjusting gauge 2300712/3 

(ill.1/pos.1) between camshaft base circle (ill.1/pos.2) 

and cam follower (ill.1/pos.3). 

NOTE: index value outlet valve 0.25 mm 

index value intake valve 0.25 mm 

01.02 ill.1 

01.01.03 Replace valve guide 

Preparation: Disassemble valves, 01.01.01. 

1 Press out valve guide with special tool 

VR00154/0. 

2 Insert valve guide with special tool VR00109/0. 

01.03 ill.1 



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. 

NOTE: 

Secure thread with structural adhesive 

LOCTITE 262. 

01.04 ill.1 

ATTENTION: Only tested valves with an opening 

pressure of 1.6 bar (+/- 0,15 bar) to be 

used. 


ToC 

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 

1 Tighten threaded pin with a torque of 

21 +/- 1 Nm. 

01.05 ill.1 



01 ENGINE 

01.01.06 Replace dowel pin for 

positioning of unit injector 

Preparation: 

Disassemble camshaft housing, 

01.05.01. 

1 Insert new dowel pin by means of setter. 

01.06 ill.1 


ToC 

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 

duct 

Dowel pin 

01.07 ill.2 



01 ENGINE 

01.01.08 Replace external screw adaptor 

for oil cooler 

Preparation: Disassemble oil cooler, 

01.06.01. 

1. Screw in external screw part (ill.1/pos.1) with a torque 

of 100 Nm +/-5. 

2. Put on new O-ring. (ill.1/pos.2) 

1 

2 

01.08 ill.1 

01.08 ill.2 

01.01.09 Replace coolant supply pipe 

1 

Preparation: Disassemble control solenoid, 

03.08. 

1 Loosen hose clamp (ill.1/pos.1), remove hose. 

2 Loosen three allen head screws (SW5) (ill.1/pos.2), 

remove coolant supply pipe. 

2 

NOTE: 

Use new seal for assembly. 

01.09 ill.1 


ToC 

01 ENGINE 


01.01.10 Mount frame seal 

Preparation: 

Disassemble engine housing, 

01.06.01, 

Disassemble crankshaft, 

01.02.01, 

1 Clean and degrease groove in cylinder block. 

01.10 ill.1 

For engines with rubber frame seal (slot-variant) 

(item 2-7) 

2 Apply construction adhesive LOCTITE 262 on both 

sides of first profile groove of frame seal. 

01.10 ill.2 

3 Apply activator 764 to groove in the cylinder block. 

01.10 ill.3 

4 Put frame seal from the bottom over the cylinder 

block. 

5 Bourrelet of frame seal profile must be placed at the 

front (coolant pump) in the center of the side of 

cylinder block.. 

Important for later assembly of engine housing. 

01.10 ill.4 



01 ENGINE 

6 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. 

7 Pay attention do least curing time and curing 

temperature. Also see manufacturer's specifications. 

ATTENTION: Pay attention to safety notes/rules. 

For engines with frame seal with alu support 

(screwed variant) - (item 8-9) 

Special tool 4 cyl. V000307/0 

6 cyl. V000306/0 

Installation device 

8 Slide frame seal using special tool into block-groove. 

01.10 ill.5 

NOTE: 

For easier installation of frame seal apply 

alcohol on sealing profil. The alcohol will 

serve as a lubrication agent during 

installation process. 

9 Clean of the frame seal lip and the block slot using 

Acetone or a non oil based cleaner (pure alcohol) and 

give time for this dry before continuing. 

Place Loctite activator #7649 (see below) on the 

upper edge of the frame seal lip and in the slot of the 

block. 

After waiting 2 minutes for Activator to work, apply 

Loctite 620 (green) on the upper edge of the frame 

seal lip 

01.10 ill.6 

10 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. 

11 Secure the frame seal to the housing using the 

screws and Loctite 243 (blue), tighten to 10 Nm. 

01.10 ill.7 


ToC 

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, 

1 Turn crankshaft in such a way that first cylinder is 

located at TDC, and secure with locking pin 

No. 2300551/2. 

02.01 ill.1 

ATTENTION: While disassembling the connecting 

rod bearing caps and the main bearing 

caps, the crankshaft may not be turned. 

2 Loosen the two screws of each connecting rod with 

special tool 2300746/0, remove connecting rod 

bearing caps with bearing shell. Push down all pistons 

and connecting rods to TDC position. 

02.01 ill.2 

NOTE: 

Remain with crank shaft in position 

during work operation to avaid 

damange the bearings. 

Never turn crank shaft. 

3 Remove rocking pin. 

4 Loosen two screws of each main bearing cap 

with special tool No. 2300747/0, remove main bearing 

shells and caps. 

02.01 ill.3 

5 Lift out crankshaft. Remove thrust bearings from 

main bearing section. 

ATTENTION: When removing, take care that 

released connecting rods do not hit 

against cylinder liner! 

02.01 ill.4 



01 ENGINE 

6 Remove main bearing blocks. 

7 Pull out oil nozzles for piston cooling. 

02.01 ill.5 

02.01 ill.6 

8 Remove main bearing shells from bearing blocks. 

NOTE: 

For assembly, lubricate all bearing with 

engine oil. All pistons with connecting 

rods are inserted in the cylinder bore. 

Mount injection oil nozzles with new O- 

rings. 

When inserting the crankshaft, take 

care that the first connecting rod journal 

pin is positioned at TDC. 

9 Check, fot proper installation main bearing shells and 

connecting rod bearing shells. 

02.01 ill.7 

ATTENTION:Main bearing base and main bearing 

cap are marked with consequential 

numbers on one side of the bearing 

cast. Make sure this number between 

base and bearing cap match. 

02.01 ill.8 


ToC 

01 ENGINE 


10 Insert the two upper thrust bearing segments onto 

main bearing cap and mount main bearing cap. 

Install remaining main bearing caps with bearing 

shalls and tighten main bearing screws sturd. 

11 Mount connecting rod cap with bearing shell. (pay 

attention to numbering). 

02.01 ill.9 

Tightening specification for connecting rod 

screws (thread and screw head support 

lubricated) 

1st working step: all screws 10 Nm +/-1 

2nd working step: all screws 30 Nm +/-3 

3rd working step: all screws 75 ° +/-4° 

Special tool No. 2300706/0 

ATTENTION: Use screws only twice. After tightening, 

mark with center punch. 

02.01 ill.10 

Tightening specification for main bearing screws 

(thread and screw head support lubricated): 

1st working step: all screws 35 Nm +/-3 

2nd working step: all screws 45 ° +/-4° 

3rd working step: all screws 45 ° +/-4° 

Special tool No. 2300706/0 

Tightening sequence 

4 cyl. engines 

02.01 ill.11 

10 7 1 5 4 

8 

9 

2 

3 

6 

6 cyl. engines 

12 

13 

5 

1 

4 

9 

8 

14 

11 

6 

2 

3 

7 

10 

02.01 ill.12 



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. 

Clearance should be between 0.07 and 0.25 mm. 

02.01 ill.13 


ToC 

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. 

1 Remove woodruff key.(ill.1/pos.1) 

2 

3 

2 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 

crankshaft and sleeve ring. 

02.02 ill.1 

1 

3 Place oil pump drive gear with larger chamfer against 

crank shaft contact surface to clear machined shaft 

radius. (ill.2/pos.1) 

1 

02.02 ill.2 



01 ENGINE 

01.03 FLYWHEEL, HOUSING 

01.03.01 Replace flywheel housing 

Preparation: Dismantle engine mount of flywheel 

housing, 01.00.04. 

1 

1 Loosen 6 hexagon sockets (SW8 and 4) hexagon 

sockets (SW6). 

2 Remove flywheel housing from adjusting sleeve (ill.1/ 

pos.1). 

3 For SOLAS models only 

03.01 ill.1 

First loosen screw (ill.2/pos.1) and fix blow-by valve 

above flywheel housing. 

4 Assembly is done in reverse order. 

1 

03.01 ill.2 


ToC 

01 ENGINE 


01.03.02 Replace flywheel 

Preparation: disassemble torsion coupling, 

02.01 

disassemble intermediate ring, 

01.03.03 

1 Lock crankshaft, 01.00.01 

2 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 

75 Nm +/-4. 

03.02 ill.1 



01 ENGINE 

01.03.03 Replace adapter ring 

Preparation: Dismantle flywheel housing, 

01.03.01. 

For 6 cyl. engines 

1 Loosen 9 hexagon head screws (SW13), remove 

adapter ring. 

NOTE: Screw tensile strength - 10.9 

Tighten hexagon screws with a torque 

of 30 Nm +/-3. 

03.03 ill.1 


ToC 

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. 

1 Pull out piston with connecting rod. 

2 Remove retainer ring of piston pin by means of 

a screwdriver. 

04.01 ill.1 

04.01 ill.2 

3 Push out piston pin, remove piston from connecting 

rod. 

04.01 ill.3 

4 Remove piston rings by means of piston ring pliers. 

Special tool: piston ring pliers 2300906/0 

ATTENTION: 

For assembly of piston rings, take 

care of marking "TOP". 

In case of a change of cylinder 

diameter, take care of respective 

repair steps. 

04.01 ill.4 



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. 

NOTE: 

When inserting the piston into cylinder 

bore, with special tool No. 2300714/1, 

take care that arrow marking on piston 

bottom shows to the front. 

04.01 ill.5 

04.01 ill.6 


ToC 

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. 

1 Loosen all control links and turn to the back (ill.1/ 

pos.1). 

ATTENTION: LEFTHAND THREAD (ill.1/pos.2) 

1 

2 

05.01 ill.1 

2 Release timing belt, dismantle tightener. 

3 Remove timing belt from gear. 

05.01 ill.2 


Loosen 3 hexagon nuts (SW13) (ill.3/pos.1) and 

remove. 

Remove indexing plate. 

C1 

C1 

05.01 ill.3 



01 ENGINE 

For 6 cyl. engine (item 5-8) 

C3 

5 Remove plug (ill.4/pos.1) for sensor of control rack. 

Remove control rack. 

6 Loosen plug (ill.4/pos.2) for potentiometer 

accelerator. 

7 Loosen 3 hexagon screws (SW13) (ill.4/pos.3) and 

remove. 

Remove bracket with potentiometer. 

C1 

C2 

05.01 ill.4 

OFF 

8 Remove plug (ill.5/pos.1) from control solenoid. 

C1 

05.01 ill.5 

For 4 cyl. engine (item 9-12) 


C1 

C3 

10 Remove plug (ill.6/pos.3) for sensor of control rack. 

11 Loosen plug (ill.6/pos.2) for potentiometer 

accelerator. 

C2 

õ 

05.01 ill.6 

12 Dismantle supportig strap (ill.7/pos.1) between cam 

shaft housing and intercooler. 

C1 

05.01 ill.7 


ToC 

01 ENGINE 


For 6 cyl. engines (item 13-15) 

13 Loosen setscrews (ill.8/pos.1) for support of raw 

water pipe. 

14 Loosen hose clamp (ill.8/pos.2 and ill.9/pos.1) and 

dismantle raw water pipe and bend. 

C2 

C3 

C1 

15 Dismantle cover (ill.8/pos.3) to intercooler by loosening 

5 hexagon screws (SW10). 

05.01 ill.8 

C1 

05.01 ill.9 

16 Disconnect speed sensor (ill.10/pos.1). 

C1 

17 Loosen hexagon screws (SW13) (ill.11). 

05.01 ill.10 

18 Remove camshaft housing upwards. 

Remove sealing. 

05.01 ill.11 



01 ENGINE 

Assembly of camshaft housing 

1 Clean sealing surfaces of motorblock (ill.12/pos.1) 

and camshaft housing (ill.12/pos.2). 

2 

2 Put on camshaft housing sealing (ill.12/pos.3). 

ATTENTION: Always use new sealing! 

1 

3 

3 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. 

05.01 ill.12 

1 

2 

4 Crankshaft must be set up to approx. 40° before TDC, 

to avoid a collosion of valves with pistons. 

05.01 ill.13 

5 Tighten screws of camshaft housing in two steps in 

precedence of numbering to be read at the bearings 

(from inside outwards). 

Torque: 1. step 15 Nm +/- 1 

2. step 25 Nm +/- 2 

6 Assembly unit injectors; refer 03.02.02 

7 Adjust unit injectors, refer to 03.02.06. 

8 Adjust valves, refer to 01.01.02. 

9 Adjust control links (mass equalization), 

refer to 03.02.04. 

10 Adjust control, refer to 01.00.03. 

11 Calibrate sensor for main rack position, 

refer to 06.10. 03 

12 Assembly engine in reversed order. 

05.01 ill.14 


ToC 

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. 

1 Mount valve spring retainer No. VR00105/1 (ill.1). 

05.02 ill.1 

2 Presstress valve spring (ill.2) with hexagon socket 

(SW28). 

05.02 ill.2 

3 Remove wedges. 

4 Relax valve spring again, remove valve spring and 

spring washer. 

05.02 ill.3 

5 Remove valve stem gasket with special tool No. 

2300758/0. 

05.02 ill.4 



01 ENGINE 

6 Put special tool No. V000152/0 onto valve stem end 

and push new valve stem gasket over sleeve. 

7 Remove sleeve and press on valve stem gasket with 

special tool No. V000166/0 until valve stem is 

supported on collar of valve guide. 

8 Lubricate valve stem (motor oil). 

9 Put on valve spring and spring washer and prestress 

with special tool No. VR00105/1. 

05.02 ill.5 

NOTE: 

Progressively wound end of valve 

spring is located at cylinder block. 

10 Put in wedges, relax valve spring, check correct seat 

of wedges. 

NOTE: 

In case of replacing other valve stem 

gaskets, take care that respective 

piston is set to TDC. 

05.02 ill.6 


ToC 

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 

1 st cylinder, 03.02.02. 

05.03 ill.1 

1 Disassemble handle to control solenoid by loosening 

two hexagon screws (SW8) (ill.2/pos.1). 

1 

05.03 ill.2 

2 Disassemble all control links (ill.3/pos.1) by 

loosening hexagon socket (SW4) (ill.3/pos.2). 

ATTENTION: 

LEFTHAND THREAD 

1 

2 

3 Remove setpin (ill.4/pos.1) from last bulkhead. 

05.03 ill.3 

1 

05.03 ill.4 



01 ENGINE 

4 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 

5 Adjust control link (mass equalization), 

refer to 03.02.04. 

6 Adjust control, refer to 01.00.03. 

7 Calibrate rack position, refer to 06.10.03 


ToC 

01 ENGINE 


01.05.04 Replace camshaft 

Preparation: disassemble camshaft housing, 

refer to 01.05.01. 

1 Loosen hexagon nut (SW30). (ill.1/pos.1) 

2 

1 

05.04 ill.1 

2 Disassemble camshaft wheel with special tool No. 

VR00113/0 (ill.2), remove washer. 

05.04 ill.2 

3 Remove axial holder of camshaft and rocker arm 

shaft. (ill.3) 

4 Disassemble all cam followers, refer to 01.05.07. 

05.04 ill.3 

05.04 ill.4 



01 ENGINE 

5 Push out camshaft (ill.5) with radial shaft seal to the 

front. 

6 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. 

When pulling out and pushing in the 

camshaft, take care that bearings of 

camshaft are not damaged. 

05.04 ill.5 


ToC 

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. 

1 Remove half-moon rings (ill.1/pos.1) on both sides 

of rocker arms. 

05.05 ill.1 

1 

2 Variant 1: 

Extract axial holder (ill.2) of camshaft and rocker 

arm shaft. 

3 Variant 2: 

Extract axial half-moon rings (ill.3) of rocker arm 

shaft (2x) 

(same as for rocker arms) 

05.05 ill.2 

4 Displace rocker arm, remove slide rings, remove 

rocker arms one by one and pull out rocker arm 

shaft towards cyl. 4 or 6. (ill.4). 

05.05 ill.3 

05.05 ill.4 



01 ENGINE 

01.05.06 Replace radial shaft seal of 

camshaft 

Preparation: Lock crankshaft, 01.00.01. 

Remove timing belt. 

Disassemble camshaft wheel. 

1 Disassemble radial shaft seal. 

2 Mount new radial shaft seal with special tool No. 

VR00122/0. 

NOTE: 

Radial shaft seal is waxed; therefore 

needs not to be oiled. 

Do not use grease on radial shaft lip 

seal. 

05.06 ill.1 


ToC 

01 ENGINE 


01.05.07 Replace cam follower 

Preparation: disassemble camshaft housing cover. 

1 

4 

1 Loosen adjusting screw (ill.1/pos.1) with special 

tool No. VR00125/0. 

2 

3 

2 Chuck cam follower spring (ill.1/pos.2) with special 

tool No. V000121/0. 

05.07 ill.1 

3 Compress valve spring (ill.1/pos.3) with special tool 

No. VR00106/0. 

05.07 ill.2 

NOTE: 

Crankshaft is first to be turned in a 

position which prevents collision 

between valve - piston bottom. 

ATTENTION: Before relaxing the valve spring, 

check whether the valve wedges 

(ill.1/pos.4) are still positioned 

correctly. 

ENGINE DAMAGE! 

05.07 ill.3 

4 Lift cam follower from valve stem end and turn 

sidewards. 

5 Lift cam follower from ball pin. 

6 Lift cam follower by means of pointed pliers. 

NOTE: Adjust valves, refer to 01.01.02. 

05.07 ill.4 



01 ENGINE 

01.05.08 Replace retainer of cam follower 

Preparation: disassemble cam follower, 

01.05.07 

1 Turn retainer spring (ill.1/pos.1) sidewards and 

remove by means of screwdriver from valve adjusting 

element towards center. 

1 

05.08 ill.1 


05.08 ill.2 


ToC 

01 ENGINE 


01.05.09 Replace valve adjusting element 

Preparation: 

Disassemble retainer spring of 

cam follower spring, 01.05.08 

1 Unscrew valve adjusting element with hexagon 

socket (SW21). 

NOTE: Apply thread protection LOCTITE 243 

to valve adjusting element and tighten 

with a torque of 55 Nm +/-3. 

05.09 ill.1 


05.09 ill.2 



01 ENGINE 

01.06 ENGINE HOUSING, OIL PUMP, 

OIL SUCTION PIPE 

01.06.01 Replace engine housing 

Preparation: 


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 

exchanger, refer to 05.01.02. 

06.01 ill.1 

1 Lock lifting chain special tool No. VR00103/0 onto the 

two lifting shackles (ill.2/1). 

1 

2 Lift engine with special tool No. VR00130/0 and 

crane (min. 3500 N) and mount it on No.VR00102/0 

and trestle No. VR00101/0 by means of four hexagon 

screws M8x30 (SW13). 

06.01 ill.2 

ATTENTION: thread screwing depth 1,5xD. 

06.01 ill.3 

3 Dismantle oil dipstick tube (ill.4/pos.1) and ventilation 

hose (ill.4/pos.2). 

4 Dismantle tandem cooler, refer to 05.01.03. 

1 

06.01 ill.4 

2 


ToC 

01 ENGINE 


5 Dismantle oil hose on engine cooler (ill.5/pos.1). 

1 

6 Disconnect oil hose on oil pump (ill.6/pos.1). 

06.01 ill.5 

1 

06.01 ill.6 

7 Unscrew hollow screw (SW19) (ill.7/pos.1) to fuel 

feed pipe. 

1 

06.01 ill.7 


8 Remove oil filter bracket. 

06.01 ill.8 



01 ENGINE 


9 Loosen two hexagon nuts and two hexagon screws 

(SW13). 

Remove filter plate. 

10 Remove V-belt. 


11 Remove Poly-V-belt. 

12 Dismantle raw water pump laterally, refer to 05.10 

06.01 ill.9 

13 Loosen 11 hexagon screws (SW10), remove lower 

timing belt covering. 


14 Loosen 6 hexagon screws. 

Remove lower timing belt covering. 

15 Dismantle flywheel housing, refer to 01.03. 

Dismantle torsion coupling, refer to 02. 

Remove flywheel, refer to 01.03. 

06.01 ill.10 

16 Dismantle engine cooler, refer to 01.13. 

06.01 ill.11 

For engines with screwed frame seal (alu support) 

17 Unscrew frame sealing from housing halfs. 

06.01 ill.12 


ToC 

01 ENGINE 


For engines with rubber frame seal (slot variant) 

18 Force out frame sealing from engine housing slot by 

means of broad screwdriver. 

NOTE: 

Do not puncture frame seal. 

19 Loosen one hexagon screw (SW10) (ill.14/pos.1). 

Remove protective sheet. 

06.01 ill.13 

1 


06.01 ill.14 

20 First loosen 11 Allen head screws (SW5) (ill.15/ 

pos.1), then 7 hexagon screws (SW17) (ill.15/pos.2). 

1 

2 2 


06.01 ill.15 

21 First loosen 13 Allen head screws (SW5) (ill.17/ 

pos.1), then 3 hexagon screws (SW13) (ill.17/pos.2), 

and at last 4 hexagon screws (SW17) (ill.17/pos.3). 

3 

1 

2 

3 

06.01 ill.17 



01 ENGINE 

22 Force apart housing halfs and remove. 

06.01 ill.18 

Assembly 

1 Check membrans of frame sealing for damage, 

replace if necessary. 

2 Clean and degrease all sealing surfaces. 


3 Wet front and rear ring carrier with construction 

adhesive LOCTITE 620, in the area of the parting 

plane from the engine housing. 

Wet sealing surfaces of screws with surface sealing 

agent LOCTITE 509. 

For 6 cyl. engines (item 4 - 6) 

06.01 ill.20 

4 Clean sealing profiles from adhesive residues. 

5 Only for engines with rubber frame seal (slot 

variant) 

Wet sealing profile of frame sealing on both sides 

with construction adhesive LOCTITE 262. 

6 Wet sealing ring on front ring carrier with surface 

sealing agent LOCTITE 5910. 

Wet rear ring carrier in the area of the parting plane 

from the engine housing with construction adhesive 

LOCTITE 620. 


ToC 

01 ENGINE 


7 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. 

8 Screw together the housing halfs. 


ATTENTION: Tighten 7 hexagon screws (SW17) 

(ill.22/pos.2) with a torque of 

50 Nm +/-5. 

Fasten 11 Allen head screws (SW5) 

(ill.22/pos.1) with a torque of 10 Nm 

+/-1. 

06.01 ill.21 

1 

2 2 


06.01 ill.22 

ATTENTION: Tighten 4 hexagon screws (SW17) 

(ill.23/pos.3) with a torque of 

50 Nm +/-5. 

Then fasten 3 hexagon screws with a 

torque of 23 Nm +/-2 (SW13) (ill. 23/ 

pos.2) and at last 13 Allen head screws 

with a torque of 10 Nm +/-1(SW5) 

(ill.23/pos.1). 

3 

1 

2 

3 

06.01 ill.23 

11 For engines with screwed frame seal (alu support) 

Screw together frame sealing with housing halfs. 

Tighten with a torque of 5,5 Nm +/-0,5. 

06.01 ill.24 



01 ENGINE 

12 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. 

13 Further assembly is done in reverse order of 

disassembly. 

06.01 ill.25 


ToC 

01 ENGINE 


01.06.02 Replace support ring rear 

Preparation: 

Replace engine housing, 

01.06.01 

1 Loosen 7 hexagon screws. 

Remove support ring. 

2 Clean and degrease all sealing surfaces. 

3 Wet sealing area of support ring with surface sealing 

agent LOCTITE 509. 

4 Mount new support ring 

06.02 ill.1 

ATTENTION: Replace radial shaft sealing ring. 

(VR00107/0) 

5 Tighten flange screws of rear ring carrier with a 

torque of 28 Nm +/-3. 

NOTE: 

Secure flange screws of rear ring 

carrier with thread protection 

LOCTITE 243. 



01 ENGINE 

01.06.03 Replace rear radialshaft sealing ring 

Preparation: Remove flywheel, refer 01.03 

Remove radial shaft sealing ring 

1 Mount special tool No. VR00107/0 to press in the rear 

radial shaft sealing ring. 

06.03 ill.1 

2 Press radial shaft sealing into rear built-in ring carrier 

by means of special tool No. VR00107/0. 

Assembly engine in reverse order. 

06.03 ill.2 


ToC 

01 ENGINE 


01.06.04 Replace oil pump 

(front ring carrier) 

Preparation: dismantle engine housing, 01.06.01. 

remove timing belt 

remove vibration damper 

1 Pull of timing belt sprocket by means of special tool 

No. 2300636/0 (ill.1). 

06.04 ill.1 

2 Loosen 6 hexagon screws (SW13) (ill.2), remove oil 

pump housing. 

õ 

06.04 ill.2 

ATTENTION: Replace radial shaft sealing ring (ill.3/ 

pos.1) in oil pump housing. Mount oil 

pump housing, and insert radial shaft 

sealing ring with special tool No. 

VR00118/0. 

2 

NOTE: 

Check sealing ring (ill.3/pos.2) on oil 

pump housing for damage; exchange 

if necessary. (wet new sealing ring 

with surface sealing agent LOCTITE 

5910) 

1 

Apply LOCTITE 509 to flange surface 

to front main bearing block and oil 

pump (front ring carrier) 

06.04 ill.3 

Secure the 6 hexagon screws (ill.2) 

with thread protection LOCTITE 243 

and tighten with a torque of 

23 Nm +/-2. 



01 ENGINE 

01.06.05 Replace oil suction pipe 

Preparation: 

Exchange engine housing, 

01.06.01. 

1 Unscrew 2 screws (ill.2/pos.1) on main bearing block. 

Remove plate (only possible at 4 cyl. engines) - (ill.2/ 

pos.2). 

06.05 ill.1 

2 

2 Pull of oil suction pipe. Check O-ring (ill.2/pos.3), 

replace if necessary. 

ATTENTION: During assembly of oil suction pipe, 

take care that no bracings occur. 

Assembly is done in reverse order. 

3 Grease O - ring during assembly. 

4 Secure the screws with thread protection LOCTITE 

243 and tighten with a torque of 10 Nm +/- 1. 

1 

06.05 ill.2 

3 


ToC 

01 ENGINE 


01.08 INTERCOOLER 

01.08.01 Remove intercooler 

Preparation: remove air filter, 03.04.01 

C1 

1 Unscrew hexagon screw (ill.2/pos.1) (SW10) of 

clamp of oil dipstick tube, carefully turn away oil 

dipstick tube. 

08.01 ill.1 

2 Remove tandem cooler, refer to 05.01.06 

or 

remove triple cooler, refer to 05.01.08 

or 

For M16 - 246 only: Remove additional 

oil cooler, refer to 05.01.07 

C1 

For 4. cyl. engines (item 3-8) 

08.01 ill.2 

3 Unscrew 3 hexagon nuts (ill.3/pos.1) of shift plate 

and remove. 

C1 

C1 

08.01 ill.3 

4 Loosen plug connections of boost pressure sensor 

(ill.4/pos.1), loosen accelerator potentiometer (ill.4/ 

pos.2). 

5 Loosen hose clamp (ill.4/pos.3). Take off hose and 

remove shift plate. 

1 

A2 

3 

08.01 ill.4 



01 ENGINE 

6 Unscrew hollow screw of boost pressure hose (ill.5) 

and remove. 

7 Remove two supports-intercooler (ill.6/pos.1) 

08.01 ill.5 

1 

8 Loosen hose clamps of hose connection 

turbocharger - intercooler (ill.7/pos.1), and remove 

hose. 

08.01 ill.6 

A1 

For 6. cyl. engines (item 9-10) 

9 Unscrew setscrews (ill.8/pos.1) for pipe support of 

raw water pipe. 

10 Remove cover (ill.8/pos.2) to intercooler by loosening 

5 hexaong screws (SW10). 

08.01 ill.7 

C2 

1 

08.01 ill.8 


ToC 

01 ENGINE 


11 For 4. cyl. engines 

Unscrew hexagon screw (SW10) (ill.9/pos.1) of raw 

water pipe clamp. 

12 Open hose clamp (ill.9/pos.2) on intercooler. 

A2 

A1 

13 Open hose clamp on heat exchanger (ill.10/pos.1) 

and remove raw water pipe. 

08.01 ill.9 

C1 


14 Loosen hose clamp (ill.11/pos.1). Loosen 2 hexagon 

screws (SW13) (ill.11/pos.2) and remove connecting 

bend. 

08.01 ill.10 

C2 

C1 

08.01 ill.11 

15 Pull of plug (ill.12/pos.1) for sensor of control rack. 

C3 

16 Loosen plug (ill.12/pos.2) for accelerator 

potentiometer. 


remove. 

Remove bracket with potentiometer. 

18 Loosen hollow screw of boost pressure hose (ill.12/ 

pos.4) on air collector and remove. 

C1 

C2 

C4 

08.01 ill.12 



01 ENGINE 

19 Disconnect plug from control solenoid (ill.13/pos.1). 

20 Remove mounts of wiring harness on the bottom of 

air collector and turn away wiring harness. 

C1 

21 Only for 4 cyl. engines with hydraulic system 

Loosen 2 hexagon sockets (ill.14/pos.1), remove 

hydraulic tank and fix it laterally in such a way that no 

oil can leak. 

08.01 ill.13 

A1 

22 Unscrew hexagon sockets (SW6) from intercooler 

and remove. 

08.01 ill.14 

08.01 ill.15 


ToC 

01 ENGINE 


01.08.02 Assembly of intercooler 

Preparation: check intercooler 

1 Clean sealing surfaces on motorblock (ill.1). 


Fix 2 seals (ill.2/pos.1) with grease Staburax NB04 

on marked surfaces of monoblock. 

08.02 ill.1 

C1 

3 Clean sealing surfaces on intercooler (ill.3). 

08.02 ill.2 


Apply a slight film of LOCTITE 5900 to the sealing 

surfaces (ill.3) of intercooler. 

5 Fix intercooler on engine block by means of 2 hexagon 

sockets. For 4 cyl. engines, screw in remaining 6 

hexagon sockets (SW8), and for 6 cyl. engines 

remaining 10 hexagon sockets, and tighten with a 


08.02 ill.3 


disassembly. 

08.02 ill.4 



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 

C7 

C8 

C9 

C4 

C1 

C2 

C3 

C6 

08.03 ill.1 

C10 

C5 

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. Remove intercooler cover in front (ill.1/pos.4) and at the back (ill.1/pos.3). 

2 Loosen the intercooler element by slightly knocking with a plastic hammer on the front end of the 

element, and remove it. Dispose the O-ring of the element as well as the O-rings in the intercooler 

covers. 

3 Clean all sealing surfaces on intercooler, intercooler-element and intermediate flange. 

4 Grease O-ring (ill.1/pos.5) with Molykote BR 2 PLUS and shift it up to the flange of the intercooler 

element (ill.1/pos.10). Insert intercooler element into intercooler. Grease O-ring (ill.1/pos.6) with 

Molykote BR 2 PLUS, insert it into intercooler cover (ill.1/pos.3), fix on intercooler and loosely mount 

on intercooler with 3 screws (ill.1/pos.2). 

5 Push O-ring greased with Molykote BR 2 PLUS (ill.1/pos.7), intermediate flange (ill.1/pos.8) and O- 

ring greased with Molykote BR 2 PLUS (ill.1/pos.9) onto exposed end of intercooler element. Mount 

intercooler cover in front (ill.1/pos.4) with upper screw (for all engines with hydraulic system) and all 

other engines onto intercooler with 3 screws (ill.1/pos.1) 

6 Tighten screws (ill.1/pos.2) with standard torque of 23 Nm +/-2. 

NOTE: For engines with hydraulic system, tighten the screw (ill.1/pos.1) together with the two 

screws for fixation of the hydraulic tank, with a torque of 23 Nm +/-2. 

7 Remaining assembly is done in reverse order. 


ToC 

01 ENGINE 





01 ENGINE 

01.09 AUXILIARY DRIVE, IN FRONT (PTO) 

1 Disconnect battery cables. 

2 

2 Remove protective cover. 



remove drive shaft. 


remove flange ring. 


09.01 ill.1 

1 


remove elastic shaft with adapter plate. 

1 

6 Loosen 3 hexagon screws (SW13) and 3 hexagon 

nuts (SW13) (ill.2/pos.2). 

Remove adapter plate from elastic shaft. 


2 

09.01 ill.2 


ToC 

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 

1 Loosen hose clamp (ill.1/pos.1) on oil cooler. 

C1 

13.01 ill.1 

6 Loosen fixing nut (ill.2) of oil line (SW22). 

13.01 ill.2 

7 Loosen 4 allen head screws (SW6), remove cooler. 

13.01 ill.3 



01 ENGINE 

4 Clean marked sealing surface (ill.4) with scraper and 

remove O-Ring. 

Assembly oil cooler 

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 . Take care that the engine oil cooler is 

led parallel to the assembly surface (O-ring may be 

damaged in main oil duct ill.6/pos.1). Replace O- 

rings of oil hoses and grease with Staburax NB04. 

13.01 ill.4 

Filling refer to 05.00.08 

Filling - closed cooling system. 

1 

NOTE: 

Cover the three contact surfaces with 

surface sealing agent LOCTITE 5900 

Tighten 4 allen head screws with a 

torque of 23 Nm +/- 2. 

Secure union nuts of oil hoses with 

LOCTITE 243 and tighten with a torque 

of 20 Nm +/-2. 

13.01 ill.5 

Further assembly is done in reverse order of 

disassembly. 


ToC 

01 ENGINE 


01.13.02 Repair oil cooler 

Preparation: remove oil cooler, 01.13.01 

Disassembly: 

3 

2 

1 

1 Unscrew two slotted round nuts (ill.1/pos.1) by 

means of special tool 2300709/1. 

2 Unscrew hexagon sockets (ill. 1/pos.2) (SW5), separate 

housing halfs, remove cooler element. 

3 

Assembly: 

NOTE: 

Prior to assembly, clean all sealing 

surfaces. Slightly grease the O-rings 

with Staburax NB04. 

13.02 ill.1 

1 Cover sealing surfaces of the two housing halfs with 

surface sealing agent LOCTITE 5900, special tool 

No. 2300717/0. 

2 Put together cooler insert and housing halfs with 

three new O-rings (ill.1/pos.3). 

3 Loosely screw in hexagon sockets. (SW5) 

(ill.1/pos.2). 

4 Screw in the two slotted round nuts with thread 

protection LOCTITE 243 and tighten with a torque of 

55 Nm +/-3. 

5 Tighten hexagon sockets with a torque of 

10 Nm +/-1 (ill.1/pos.2). 



01 ENGINE 

01.13.03 Change motor oil 

1 Bring engine to operating temperature and stop 

engine. 

2 Remove oil dipstick (ill.1/pos.1). 

1 

3 Open oil filler cap (ill.2/pos.1), but do not remove 

because of possible contamination. 

4 Suck off motor oil on oil dipstick tube by means of 

suction pump No. 0172473/0 (ill.2/pos.2), and pump 

it into a suitable receptacle. 

13.03 ill.1 

1 

NOTE: 

Pay attention to heat- (approx. 120°C) 

and oil resistance of receptacle for the 

used motor oil. 

Dispose the oil properly. 

2 

5 Remove oil filler cap (ill.2/pos.1). 

6 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. Overfilling results 

in high operating temperatures, 

foaming (air in oil), loss in efficiency 

and a reduced engine life. 

As the quantity for an oil change, refer to 

Specifications Motor Oil GENERAL B 2 

As the quantity for first filling (e.g. after engine 

repair), refer to Specifications Motor Oil GENERAL 

B 2 

7 Put on oil filler cap and lock. 

ATTENTION: Remove possible oil contaminations 

from oil filler cap and environment. 

13.03 ill.3 

ATTENTION: Do not forget oil check after test run. 


ToC 

01 ENGINE 


01.13.04 Change oil filter 


Waiting time 30 min. after having stopped the engine. 

NOTE: 

First suck off the motor oil. This 

reduces the waiting time. 


Position (special tool No. VR 00132/0) oil collecting 

pan below oil filter (ill.2). 

13.04 ill.1 

3 Loosen the oil filter with oil filter wrench 

No. 2300713/1 and unscrew by hand. Dispose the oil 

filter acc. EPA-regulation. 

4 Clean sealing surface of oil filter head. 

5 Oil the seal of new oil filter and screw it onto oil filter 

head until the seal easily rests against. Tighten the oil 

filter with a 3/4 turn. 

ATTENTION: Remove possible oil contaminations 

from filter head and environment. 

Do not forget to check engine oil level! 

13.04 ill.2 

13.04 ill.3 



01 ENGINE 

01.14 EXHAUST MANIFOLD, SEALS, HEAT EXCHANGER 

Refer to 05.01.02 Exhaust manifold, heat exchanger 


ToC 

01 ENGINE 





02 COUPLING 

02 COUPLING 


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

ToC 

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) 

Variant 2: 


01.01 ill.1 

(Current version - 

replaced variant 1) 

Variant 3: 

Loosen 9 hexagon screws. Remove flywheel adaptor 

and coupling. 

01.01 ill.2 

01.01 ill.3 

Page COUPLING - 2 Z001019/0_6_July 2008


02 COUPLING 

Remove coupling for 

OMC/ VOLVO SX - stern drive apllication: 

Loosen 6 screws, remove washers. Remove coupling. 


MERCURY - stern drive apllication: 

Variant 1: 


Loosen 9 screws. Remove flywheel adaptor, 

if necessary. 

01.01 ill.4 



Variant 2: 



if necessary. 

01.01 ill.5 



Variant 3: 



if necessary. 

01.01 ill.6 

01.01 ill.7 


ToC 

02 COUPLING 

02. 01. 02 Remove coupling for 4 cyl. engines 

Remove coupling for gearbox, jet drive, VOLVO 

stern drive apllication: 




Variant 1: 


Variant 2: 


01.02 ill.1 



Loosen 9 hexagon screws. Remove coupling. 


OMC/ VOLVO SX - stern drive apllication: 

01.02 ill.2 

Loosen 6 screws, remove washers. Remove coupling. 

01.02 ill.3 




MERCURY - stern drive apllication: 

02 COUPLING 



Variant 1: 


Variant 2: 



if necessary. 

01.02 ill.4 



01.02 ill.5 


ToC 

02 COUPLING 


02.01.03 Installation 

Description 

Nm 

Screw Coupling M8 x 1,25 - 8.8 23 

Screw Coupling M8 x 1,25 - 10.9 32 

Screw Coupling M10 x 1,5 45 

Use locking compound LOCTITE 243 on threads. 






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......................................................................................... 14 

03.02.04 Adjust control link (injection quantity)....................................................... 15 

03.02.05 Loosen fixing of control rod ..................................................................... 16 

03.02.06 Adjust start of injection............................................................................. 17 

03.02.07 Exchange check valve for fuel pre-pressure to unit injector ................... 20 

03.04 Air filter .................................................................................................. 21 

03.04.01 Change air filter ....................................................................................... 21 

03.05 Turbocharger ......................................................................................... 22 

03.05.01 Replace turbocharger ............................................................................. 22 

03.05.02 Check bearing clearance......................................................................... 25 

03.08 Control solenoid.................................................................................... 26 

03.08.01 Remove control solenoid......................................................................... 26 

03.08.02 Install control solenoid.............................................................................. 28 

03.08.03 Replace sensor, indication of control rack position.................................. 29 

03.09 Change fuel filter .................................................................................. 30 

03.11 Replace glow plug ................................................................................ 31 

03.12 Measurement of Compression Pressure.............................................. 32 

03.14 Fuel system check.................................................................................. 34 

03.14.01 Manual injection test methode.................................................................. 34 

03.14.02 Disengagement methode of injection........................................................ 36 

03.14.03 Air bubble formation in fuel system........................................................... 37 

Z001019/0_7_July 2012 Page FUEL SYSTEM - 1

03 FUEL SYSTEM SERVICE MANUAL MARINE ENGINES 

03.00 fuel system 

1 

2 

3 

4 

5 

6 

7 

8 

Saugventil 

Anti-siphon valve 

Absperrhahn 

Fuel stop cock 

Kraftstoff Filter 

Fuel filter 

Kraftstoffpumpe 

Fuel pump 

Rückschlagventil 

Check valve 

Kraftstoffzufuhr PD 

Fuel supply UI 

Pumpedüse 

Unit Injector 

Regelstangensensor 

Rack position sensor 

9 

10 

7 

Kipphebel 

Rocker arm 

Anlenkhebel 

Adjustment lever 

Regelstange 

Common rack 

Druckhalteventil 

Fuel check valve 

Kraftstoffrücklauf 

Fuel return line 

9 

10 

11 

12 

13 

14 

15 

6 

13 

3 

1 

2 

Aktuator 


Kraftstoffkühler 

Fuel cooler 

15 

5 

4 

14 

12 

8 

11 

Page FUEL SYSTEM - 2 Z001019/0_7_July 2012



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. Excess fuel not injected by the unit injectors is led via 

fuel cooler 6 back to the fuel tank. 

The operating pressure is controlled by pressure valve 7 (1,8 - 2,5 bar at idle). 

8 anti-siphon valve; 9 baffles (depending on tank size) 

For fuel requirements, refer to chapter GENERAL 

Specification for fuel pipes 

03.00 ill. 1 

Minimum inside diameter: 

Recommended material: 

NOTE: 

8 mm 

stainless steel or copper 

Min. inside diameter for hosepipes or PA-pipes is 10 mm. 

Rate of flow: > 240l/h +/-7 (in case of continuously operating pump) 

If additional filters are installed, the requirements of 

higher flow rates must to be considered. (filter dimension) 

NOTE: 

In case of pipe connections, pay special attention to the 

tightness of the suction pipe (all fittings and line before fuel pump)! 

Types of pipe connections 

03.00 ill. 2 



03.02 FUEL PUMP, UNIT INJECTOR, 

LINES 

03.02.01 Replace fuel pump 

Fuel pump operation is controlled by EMS. 

Disassembly 

1 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. 

02.01 ill.3 

1 

ATTENTION: Close fuel cock on tank, if tank is higher. 

2 ATTENTION: Prior to disassembly, disconnect 

battery cables from battery, to avoid 

damages to the electronic system. 

02.01 ill.4 

3 Disconnect positive cable and negative cable (ill.6) 

by unscrewing hexagon nuts (SW7/8) with washer 

from terminals of fuel pump. 

4 Unscrew hollow screw (ill.6/pos.1) of fuel feed line. 

Dispose Cu-sealing rings. 

2 

+ - 

5 Unscrew hollow screw (ill.6/pos.2) of fuel line. Dispose 

Cu-sealing rings. 

ATTENTION: Hold up with second wrench on hexagon 

of pump housing, to avoid a a 

damage to the E-pump. 

02.01 ill.6 

1 




6 For 4 cyl. engines only 

Unscrew two hexagon screws of filter plate. 

Remove filter plate and holding strap. 

Remove fuel pump. 

For 6 cyl. engines only (item 7-8) 

02.01 ill.7 

7 Remove two hexagon screws (SW10) for fixing fuel 

pump on filter plate (ill.8/pos.1), as well as ground 

wire. 

1 

ATTENTION: Mark position of fuel pump on pump 

support. 

8 Remove pump bracket. 

ATTENTION: Measure height for assembly of pump 

because of fitting position of fuel lines. 

02.01 ill.8 



Assembly 


2 

+ - 

1 Place new fuel pump. 

2 Mount filter bracket with holding strap by means of 

2 hexagon screws. 

3 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. 

For 6. cyl. engines only (item 4-7) 

4 Mount bracket in correct position onto new fuel pump. 

Tighten screws of bracket. 

5 Mount pump and ground wire on filter plate and fix with 

two hexagon screws (ill.10/pos.1). Tighten screws 

with a standard torque of 10 Nm +/-1 . 

Torque wrench No. 2300704/0. 

Fix ground cable together with bracket. 

6 Mount adaptor with Cu-sealing rings at top face of 

fuel pump. 

7 Attach fuel lines between filter and pump, as well as 

pump and block. Tighten hollow screws with a torque 

of 30 Nm +/-3. 

02.01 ill.9 

1 

ATTENTION: Hold up with second wrench on hexagon 

of pump housing, to avoid a 

damage to the E-pump. 

Always use new Cu-sealing rings. 

1 

8 Connect two cables to negative terminal (-) and to 

positive terminal (+). Cover the two terminals with 

neoprene lacquer sealing No. P/N Z909570/0. 

9 Connect battery cables. 

02.01 ill.10 

10 Connect fuel lines and operate electric fuel pump 

3 times for 10 sec., to bleed fuel system. 

11 Check fuel system for leakage.ò 

(No. 2300719/1, mount fuel return line) 




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 

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. 

02.02 ill.2 

02.02 ill.3 

2 Before loosening flange nuts of unit injectors, ventilate 

fuel system. For this purpose, open screw of 

banjo fitting just enaugh to let air through seal rings 

between fuel filter and fuel pump (ill.4/pos.1), and let 

pump run approx. 6 times for 10 sec. 

Make sure that air is sucked. 

1 

ATTENTION: Close fuel cock on tank, if tank is higher 

than fuel supply on filter head. 

02.02 ill.4 



3 Remove nuts on unit injector flange (2 hexagon nuts 

SW 13). 

4 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” per unit injector). 

02.02 ill.5 

5 Loosen adjusting nut with 17 mm socket wrench 

(hexagon nut SW 17 and screwdriver). Turn adjusting 

screw to such an extent that the slide cup is loosely 

attached to the spring plate. Do not remove. 

02.02 ill.6 

02.02 ill.7 

6 Insert screwdriver with small blade into recess of 

retainer ring (half-moon ring) for rocker arm lock, 

push retainer ring upwards and remove. 

For disassembly of unit injector, always remove rocker 

arm retaining ring at timing belt side. 

02.02 ill.8 




7 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. 

8 Check position of control link(s) against bulkhead 

as illustrated. 

02.02 ill.9 

9 Insert the unit injector lever SMO No. VR00126/0 

below the camshaft and push upwards against the 

body of unit injector. The unit injector is thus lifted out 

from the engine block and may be removed manually. 

02.02 ill.10 

NOTE: 

For disassembly of the unit injector 

from cylinder No. 1, the control rack 

is to be moved forward. 

02.02 ill.11 

10 Remove unit injector with mounting flange. 

02.02 ill.12 



11 Remove copper seal washer from bottom side of 

copper insert by means of hook- and lifting tool (No. 

VR 00116/0). 

NOTE: 

Avoid scratches on the sealing surface 

of the copper insert. 

Assembly 

02.02 ill.13 

1 In order to secure an appropriate tight fit, recheck 

tighten stud bolt with a torque of 21 Nm +/- 2 

02.02 ill.14 

2 Drain possible fuel residues by means of suction device 

No. VR 00121/0 from the combustion chamber. 

Suction device must be equipped with a suction hose 

of at least 250 mm of length in order that possible 

fuel residues can be sucked from piston recess. 

NOTE: 

Fuel residues in the combustion chamber 

may cause severe damage to the 

engine. 

02.02 ill.15 

3 Check copper insert for possibly remaining seal 

washers; remove and dispose, if necessary. 

NOTE: 

Always use new copper seal washers! 

(ill.16/pos.1 ) 

1 

02.02 ill.16 




4 Clean conical part of copper insert with cleaning 

mandrel No. 2300565/0. For this purpose,, turn 

cleaning mandrel several times in both directions 

and then clean copper insert with cleaning tissue. 

5 ATTENTION: Insert new special copper seal washer 

(ill.19/pos.2), from seal kit Z002031/0, 

with a screwdriver into copper insert. 

Make sure the copper seal washer is 

plane. 

02.02 ill.17 

02.02 ill.18 

6 Install new O-rings (ill. 19/pos.1), from seal kit 

Z002031/0, and cover O-rings with a thin coat of 

clean motor oil. 

1 

2 

7 Insert unit injector into bore and align unit injector 

recess to dowel pin (ill. 20/pos.1) for positioning. 

Avoid any contact with control link. 

02.02 ill.19 

ATTENTION: Risk of damage to control rack. 

1 

02.02 ill.20 



8 Push unit injector firmly downwards in order to position 

it correctly with the O-rings. 

9 Lubricate slide cup with motor oil, put it onto adjustment 

screw, as shown, and shift it together with 

rocker arm onto unit injector. 

02.02 ill.21 

02.02 ill.22 

10 Install retainer ring to secure the rocker arm. 

02.02 ill.23 

11 Screw on flange nuts (hexagon nuts SW 13) and 

tighten evenly. Absolutely tighten nuts with a torque 

of 18 /-2 Nm. 

ATTENTION: Pay attention to horizontal installation 

of mounting flange. 

02.02 ill.24 




12 Fix control rack. 

13 Attach control link to control rack and adjust. 

Refer to 03.02.04, Adjusting Control Link. 

14 Adjust injection start. Refer to 03.02.06, Injection 

Start unit injector. 

15 Connect fuel pipes and operate electric fuel pump 3 

times for 10 seconds to vent fuel system. 



03.02.03 Fix control rack 

Preparation: 

Remove camshaft housing cover, 

refer to 01.00.02 

1 

1 Unscrew setpin of control rack (ill.1/pos.1) at the back 

of camshaft housing, as shown. 

02.03 ill.1 

2 Position bore (diameter 4 mm) in control rack(ill.2/ 

pos.1) over reference bore (ill.2/pos.2) in the bulkhead 

wall. 

2 

1 

02.03 ill.2 

3 Pull control rack manually to the front, against spring 

resistance, and hold. Insert setpin, as shown, and 

fasten sturdily. 

02.03 ill.3 

3 

2 

02.03 ill.4 

1 




03.02.04 Adjust Control Link 

(injection quantity) 

Prior to adjustment, unit injector must be tightened 

properly, and control rack must be fixed in 

position with set pin. 

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. Turn 

control link against bulkhead on camshaft housing. 

02.04 ill.2 

1 Carefully position end of control link on front side of 

unit injector control rack (possibly use screwdriver). 

2 Turn control link against unit injector control gear until 

control gear completely pushes against upper gauged 

stop and hold position with screwdriver. Hold in this 

position and tighten left-handed setscrew of control 

link with a torque of 7 Nm +/-0,5. Repeat steps 1 and 

2 for the rest of unit injector control racks. 

02.04 ill.3 

3 Calibrate rack position, refer to 06.10.03 

4 Loosen fixing of control rack, refer to 03.02.05 

02.04 ill.4 



03.02.05 Loosen fixing of control rod 

1 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). 

2 Tighten setpin with a torque of 7 Nm. 

02.05 ill.1 

02.05 ill.2 

3 Check axial flexibility of control rack. Control rack is 

to be moved easily and should automatically return 

to reverse position due to spring load. 

2 

1 

02.05 ill.3 




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). 

Adjustment of injection start is to be 

done prior to adjustment of engine 

control. 

02.06 ill.1 

Special tool.: 








1 Unit injector must be installed properly and fastened. 

Control rack and unit injector control gear must 

be free to move. 

02.06 ill.2 

2 Put dial gauge rail with bracket, No. 2306031/. (see 

list special tool), onto stud bolt at intercooler side of 

camshaft housing and fasten with nuts. 

3 Turn camshaft until bearing rollers of rocker arm for 

unit injector being adjusted is on the base circle of the 

cam. Unit injector spring should be in most relaxed 

position. 

4 Mount dial gauge No. 2300899/0 with pointer 

No. 2300641/1 into dial gauge rail. 

02.06 ill.3 

5 Put pointer onto unit injector plunger guide. 

00.00 

. 

02.06 ill.4 



7 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. 

1 

NOTE: 

Slowly release unit injector spring. 

Read total indicating travel (ill.5/pos.2) 

on dial gauge. 

2 

02.06 ill.5 

8 Turn adjusting screw (ill.6/pos.1) with screwdriver 

and set to the value as listed in below table. Hold 

adjusting screw in this position and tighten hexagon 

nut (ill.6/pos.2) by means of torque wrench No. 

2300743/0 and tee-handled socket wrench (SW17) 


1 

2 

02.06 ill.6 

Engine setting values for engines with a build date before 2007 (



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 ±0,02 0,25 / 0,25 

MO84K32 2176555-5 8,47 ±0,02 8,52 ±0,02 3,20 ±0,02 0,25 / 0,25 

MO94K33 2176555-5 8,47 ±0,02 8,52 ±0,02 3,20 ±0,02 0,25 / 0,25 

MO114K33 2176557-0 8,47 ±0,02 8,52 ±0,02 3,20 ±0,02 0,25 / 0,25 

MO144V38 2176557-0 8,27 ±0,02 8,32 ±0,02 3,20 ±0,02 0,25 / 0,25 

MO144M38 2176557-0 8,47 ±0,02 8,52 ±0,02 3,20 ±0,02 0,25 / 0,25 

MO164M40 2176557-0 8,37 ±0,02 8,42 ±0,02 3,20 ±0,02 0,25 / 0,25 

MO174V40 2176552-1 8,77 ±0,02 8,82 ±0,02 3,20 ±0,02 0,25 / 0,25 

MO126K25 2176552-1 9,29 ±0,02 9,34 ±0,02 3,20 ±0,02 0,25 / 0,25 

MO156K25 2176552-1 9,15 ±0,02 9,20 ±0,02 3,20 ±0,02 0,25 / 0,25 

MO196K35 2176555-5 8,47 ±0,02 8,52 ±0,02 3,20 ±0,02 0,25 / 0,25 

MO236K42 2176557-0 8,37 ±0,02 8,42 ±0,02 3,20 ±0,02 0,25 / 0,25 

MO256K43 2176557-0 8,27 ±0,02 8,32 ±0,02 3,20 ±0,02 0,25 / 0,25 

MO256H45 2176557-0 8,27 ±0,02 8,32 ±0,02 3,20 ±0,02 0,25 / 0,25 

MO286H43 2176552-1 8,70 ±0,02 8,75 ±0,02 3,20 ±0,02 0,25 / 0,25 

MO306H43WJ 2176552-1 8,55 ±0,02 8,60 ±0,02 3,20 ±0,02 0,25 / 0,25 

9 Recheck stroke adjustment, recheck zero value and 

total stroke adjustment as described in steps 7 and 

8. 

ATTENTION: In case of deviation, repeat setting 

process. 



03.02.07 Exchange check valve for fuel pre- pressure to unit injector 

1. Unscrew valve SW 19 mm (ill.1/pos.1), remove 2 

Cu-sealing rings. 

NOTE: 

Use new Cu-sealing rings for assembly. 

Tighten with a torque of 40 Nm+/-4. 

1 

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 




03.04 CHANGE AIR FILTER 

03.04.01 Change air filter 

Till engine serial no. 48219069 ( 4-cyl.) 

and 68219174 ( 6-cyl.) 

1 Open retaining clip. 

04.01 ill.1 

2 Remove air filter and cover. 

3 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.) 

1 Remove hose clamp and air filter. 

04.01 ill.2 

2 Mount new air filter together with hose clamp and 

tighten clamp solid. 

04.01 ill.3 



03.05 TurboCHARGER 

03.05.01 Replace turbocharger 

1 Remove air filter, refer to 03.04.01 

2 Remove high-riser, refer to 04.01 


Drain coolant from closed cooling circuit, 

refer to 05.00.07 

05.01 ill.1 


4 Loosen fastenings of heat protection. Remove heat 

protection (ill.2/pos.1). 

1 

3 

2 

5 Loosen hose clamp (ill.2/pos.2) and remove hose for 

air charge pressure box. 

6 Loosen screw (ill.2/pos.3) for raw-water pipe support 

(SW10). 

7 Loosen hollow screw (ill.3/pos.1) of oil feed line on 

turbocharger. 

8 Remove plug of oil pressure switch (ill.3/pos.2). 

05.01 ill.2 

1 


motorblock. Dispose Cu-sealing rings. 

2 

3 

10 Loosen two hexagon screws (ill.4) of oil return line. 

Dispose seal. 

05.01 ill.3 

05.01 ill.4 





Loosen 2 hexagon screws on flange of oil feed line. 


05.01 ill.5 

Loosen hose clamps of hose connection turbocharger-intercooler 

(ill.6/pos.1) and remove hose. 

1 


13 Loosen support screw (ill.7/pos.1) for raw-water pipe. 

05.01 ill.6 

14 Remove covering (ill.7/pos.3) to intercooler by loosening 

5 hexagon screws (SW10) (ill.7/pos.2). 

2 3 

1 

05.01 ill.7 

15 Loosen hose clamp (ill.8/pos.1) connection compression 

housing. 

16 Loosen 2 hexagon screws (ill.8/pos.2) and remove 

connecting bend. 

C2 

C1 

3 

17 Loosen hollow screw (ill.8/pos.3) of cooling system 

- vent pipe (SW14) . Remove pipe. 

05.01 ill.8 



18 Loosen hose clamp (ill.9/pos.1) of hose of oil separator 

and remove hose. 

1 

19 Loosen 4 hexagon nuts (ill.10+11/pos.1) of turbocharger 

flange. Remove turbocharger and seal, dispose 

seal. (if seal is used) 

05.01 ill.9 

1 

1 

05.01 ill.10 

Assembly: 

ATTENTION: Check hose connection and hose 

between turbocharger return pipe 

and engine housing intake for crack 

and damage. Replace, if necessary. 

1 

For 4 cyl. engines only 

For 6 cyl. engines only: 

05.01 ill.11 

Clean sealing surface of flange turbo charger and exhaust manifold 

and lubricate with grease Z012222/0. 

Clean sealing surfaces of flange turbo charger and exhaust 

manifold. Replace flange seal. 

Further assembly is done in reverse order. 

ATTENTION: Tigthen the two spring-clamps of hose turbocharger - intercooler with a torque of 

3,5 Nm. Don´t strip! 





1 Tighten 4 hexagon nuts of turbocharger flange with a torque of 25 Nm +/-2. 

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. 


3 Tighten 4 hexagon nuts of turbocharger flange by means of torque wrench No. 2300743/0 and treehandled 

socket wrench No. 2300744/0 with a torque of 40 Nm +/-4. 

4 Tighten 2 screws for fixing the oil return pipe flange with a torque of 23 Nm +/-2. 

Tighten hollow screw with 40 Nm +/-4. 

5 Tighten hollow screw of vent pipe (cooling circuit) with a torque of 20 Nm +/-2 . Maintain horizontal 

position of banjo fitting while tightning hollow screw. 

6 Fill closed cooling circuit, refer to 05.00.08 

03.05.02 Check bearing clearance 

Measure end clearance: 

measuring point 

1 Put test prod of dial gauge onto face of turbine wheel 

hub. 

2 Push cursor downwards and set dial gauge to "0". 

3 Push cursor against dial gauge and note deflection 

of pointer. 

permissible end clearance: max. 0.16 mm +/-0,01 

05.02 ill.1 

Measure radial clearance: 

NOTE: 

Determination of radial clearance is 

only required turbine-sided. 

1 Put test prod of dial gauge onto center of retainer 

cone of turbine wheel. 

location point 

of dial gauge 

prod 

2 Pull turbine wheel hub upwards by means of spring 

balance. Measuring strength 50 N. 

3 Note deflection of pointer. 

4 Repeat measurement, by turning cursor by 90°. 

measuring 

strength 

Permissible radial clearance: max. 0.42 mm +/-0,04 

05.02 ill.2 



03.08 CONTROL SOLENOID 

03.08.01 Remove control solenoid 

Prepartion: 

for 4 cyl. engines only 

remove intercooler, 

refer to 01.08.01. 

1 Disconnect battery. 


2 Loosen plug connection (ill.2/pos.1) for control rack 

potentiometer. 

08.01 ill.1 

3 Remove plug from control solenoid (ill.2/pos.2). 

2 

1 


08.01 ill.2 

4 Unscrew 3 hexagon screws (SW10) (ill.3/pos.1) of 

upper timing belt covering. 

1 

08.01 ill.3 

5 Unscrew 2 hexagon screws (SW10) (ill.4/pos.1) of 

front control solenoid covering. 

1 

08.01 ill.4 




6 Loosen 2 hexagon nuts (SW10) (ill.5/pos.1). Remove 

boost pressure sensor. 

7 Loosen plug (ill.5/pos.2) for potentiometer accelerator. 

8 Loosen 3 hexagon nuts (SW10) (ill.5/pos.3). Remove 

bracket with potentiometer accelerator. 

9 Remove plug (ill.5/pos.4) for sensor of control rod. 

C3 

C1 

C4 

C2 


11 Loosen 4 hexagon screws (SW13) (ill.6/pos.2) on 

control solenoid housing; Remove control solenoid 

assembly. Remove seal and dispose. 

08.01 ill.5 

1 

2 


12 Loosen 4 hexagon screws (SW13) (ill.7) on control 

solenoid housing, remove control solenoid assembly. 

Remove seal and dispose. 

08.01 ill.6 

08.01 ill.7 



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. 

1 Remove camshaft housing cover. 

2 Move control rack by hand (ill.1) to front position and 

hold. 

3 Insert control rack lever in to the solenoid as shown. 

(ill.2/pos.1) 

08.02 ill.1 

4 Bring up control solenoid assembly parallel to sealing 

surface of camshaft housing, put it onto the dowel 

pin(s) (ill.3/pos.1) and hold. 

2 

5 Slowly release control rack and fasten control solenoid 

housing by means of 4 screws. 

1 


Secure the 4 screws with LOCTITE 243 and tighten 


08.02 ill.2 


7 Cover the two lower screws with LOCTITE 243 and 

slightly tighen. 

1 

8 Cover the two upper screws with LOCTITE 243. Bring 

into position bracket with potentiometer accelerator 

and fix with upper screws. Tighten the 4 screws with 

a torque of 23 Nm+/-2. 

9 Check whether the control rack can be moved over 

a distance of approx. 18 mm. 

ATTENTION: Pin of control rack position sensor is 

spring-loaded and might easily slip 

off from the face of control rack lever, 

during assembly. In such a case, the 

control rack is blocked and thus prevents 

resetting to zero delivery 

===> ENGINE FAILURE. 

08.02 ill.3 


NOTE: 

The rack position sensor is magnetism 

sensitive. All external magnets must 

be kept away as the may disturb the 

sensor. 




03.08.03 Replace sensor, indication of control rack position 

Preparation: 


remove shift plate, refer to 01.08.01, ill.3. 


remove bracket of potentiometer 

accelerator, refer to 03.08.01, ill. 5-6 

1 Loosen 2 Allen head screws (ill.1/pos.1) (SW3). 

Remove rack position sensor. 

08.03 ill.1 

Assembly 

1 Insert new sensor in such a way that rod of potentiometer 

(ill.2/pos.1) is positioned in front of solenoid 

rod (ill.2/pos.2). 

2 Secure 2 Allen head screws 3 mm with Loctite 243 

and tighten with a torque of 5 Nm +/-0,5. 

3 Check whether control rack can be moved over a 

distance of approx. 18 mm. 

1 

2 

ATTENTION: Rod of rack rack position sensor 

is spring-loaded and might easily 

slip off from the face of solenoid 

rod (ill.2/pos.2), during assembly. 

In such a case the control rack is 

blocked, and thus prevents resetting 

to zero delivery 

===> ENGINE FAILURE. 

08.03 ill.2 

4 Remaining assembly is done in reverse oder. 

NOTE: 




sensor. 



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. 

1 

1 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. 

= 6 times 10 sec. ignition ON. Make sure that air is 

sucked. 

09.00 ill.1 

ATTENION: 

Close fuel cock on tank, if tank is higher 

than fuel filer. 

2 Unscrew filter (ill.2) by means of filter wrench No. 

2300713/1. Remove filter and dispose. Take care 

that original seal does not adhere to filter housing. If 

so, remove seal and dispose. 

3 Clean sealing surface on filter head (ill.3). 

09.00 ill.2 

4 Slightly oil seal of new fuel filter with clean motor oil 

(ill.4). 

5 Screw on new fuel filter until seal slightly rests on 

sealing surface of filter head. Then tighten filter by 

hand with 3/4 turn. 

6 Connect fuel pipe between fuel filter and fuel supply 

or water separator on filter head (ill.1/pos.1) again. 

7 Ventilate fuel system. 

NOTE: 

Fuel system is ventilated via E-fuel 

pump. 

Turn ignition ON 6 times each 10 sec. 

09.00 ill.3 

8 Remove possibly spilled fuel residues. Start engine 

and check fuel system for leakage. 

09.00 ill.4 




03.11 Replace GlOW Plug 

Preparation: 

03.08.01 


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 


for glow plug of first cylinder, remove control solenoid - refer to 03.08.01 

for glow plug of second to sixth cylinder, remove intercooler - 

refer to 01.08.01 

1 Remove glow plug. 

2 Unscrew glow plug(s) with special tool 

No.VR00146/0. 

3 Screw in new glow plug(s) by means of special tool 

No. VR00146/0 and tighten by means of special tool 

No. 2300703/0 with a torque of 15 Nm +/-1. 

11.00 ill.1 

NOTE: Exactly keep torque of 15 Nm +/-1 

when fixing glow plugs! 

11.00 ill.2 



03.12 MEASUREMENT OF COMPRESSION 

PRESSURE 

Preparation: remove glow plug, refer to 03.11 

1 Screw special tool glow plug adaptor 230 0638/2 

(ill.1) into cylinder to be checked (ill.2). 

2 Connect pressure hose of compression pressure 

meter No. 2300750/0 to glow plug adaptor (ill.2). 

12.00 ill.1 

3 Connect pressure hose to compression pressure 

meter No. 2300750/0 (ill.3). 

4 Remove plug J1. 

Connect special tool No. VR00145/0 instead of plug 

J1. 

5 Put into operation compression pressure meter according 

to operating instructions. 

6 Start engine by pressing the button for 5 to 10 sec. 

of special tool No. VR00145/0 until compression 

pressure rises no more. 

12.00 ill.2 

ATTENTION: 

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 








03.14 FUEL SYSTEM CHECK 

03.14.01 Manual injection test methode 

Preparation: 

Remove camshaft housing cover, 

refer to 01.00.02 

1 

1 Remove plug screw (ill.1/pos.1) with sealing ring. 

14.01 ill.1 

2 Mount special tool No. VR00148/0 (ill.2/pos.1) together 

with sealing ring (ill.2/pos.2). 

2 

1 

14.01 ill.2 

3 Move control rack by means of special tool No. 

VR00148/0 into idle injection position 

(approx.5-6 mm) (ill.3) and remain in this position. 

14.01 ill.3 




4 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. 

NOTE: 

When moving the unit injectors, a 

creaky noise is to be heard during 

the injection process and/or a solide 

resistance is to be felt due to produced 

injection pressure (pressure 

point) . 

If no difference is detectable in the individual unit 

injectors, continue with item 5. 

5 Adjust control rack by means of special tool No. 

VR00148/0 to partial load (approx. 10-12 mm in direction 

full delivery) (ill.3) and remain in this position. 

6 Repeat item 4. 

NOTE: 

14.01 ill.4 

Defective unit injectors which fail to produce a creaky noise in one or none of the two 

checks and/or where no resistance (pressure point) can be felt are to be exchanged. 

(Exchange unit injector, refer to 03.02.02). 


ATTENTION: Absolutely remove special tool 

No. VR 00148/0. 

Use new sealing ring. 

Manual check of unit injector without tool No. VR 00148/0 

Fuel System Check: 

1. Investigate condition of return fuel. There should be neither air bubbles nor discoloration (gray) in the fuel. 

2. Check proper flow quantity (i.e. engine at idle - flow rate after engine block 180 to 240 l/hr; 47 to 63 gal.) 

Injector Check: 

To feel the injection activities, move the control rack (quantity delivery) in between its acceptable travel (5 to 

14mm) while depressing the „plunger“ with the rocker arm. For safe and easier handling, use our special tool lever. 

While moving the rocker arm (and/or the plunger up and down), try to get the control rack into idle delivery 

position (approx. 4-5 mm). In this spot you will feel only a very slight/short pressure build up as the duration 

of injection is very short (~ 5mm³/stroke). 

Keep this position on the control rack (freeze there) and then move over with tool VR 00126/0 to the next unit 

injector/rocker arm to repeat the plunge movement and feel the resistance during injection. 

The test should give an equal pressure load/peak on each injector, while maintaining the same position on 

the control rack. 

If one injector fails to show any pressure or this pressure peak is found in a much higher position of the control 

rack, this is an indication for a possible deficiency on this injector. 

ATTENTION: 

before removing this unit injector from the engine, check for proper adjustment of the linking 

lever and for correct fit/tightness and/or torque of the unit injector mounting nuts. 



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. 

1 

2 

Preparation: 

Special tool: 

Remove camshaft housing cover 

refer 01.00.02 

4 cyl. engines VR00133/1 

6 cyl. engines with bossed seal surface 

VR00133/0 

6 cyl. engines with plane seal surface 

VR00133/2 

14.02 ill.1 

1 Mount special tool No. VR00133/.(see list special 

tool) to disconnect injection. 

2 Start the engine, let it run in idle and check if bubbles 

form. 

NOTE: 

If there are no bubbles at idle speed 

of engine, continue with item 3. 

3 Bring engine to operating temperature and then test 

the boat under operating conditions and watch for 

bubbles to form. 

Keeping this operating condition, continue with item 4. 

4 Loosen nut on cover (ill .1/pos.1), screw in, with 

fast turns, screw (ill.1/pos.2) until knocking noise 

disappears. Tighten nut (ill.1/pos.1) again. As a result, 

unit injector is pressed down to such an extent 

that injector cam can no more touch the rocker arm, 

thus preventing the injection of fuel. (respectively 

eliminating combustion) 

5 Test the boat with disengaged unit injector under 

operating conditions and observe the returning fuel 

if bubbles still appear. 

6 Continue to check all other injectors (cylinders) in 

order to detect the defective(s) unit injector(s). 

NOTE: 

bubble formation will change and/or 

stop as soon as injection of defective 

unit injector(s) is disengaged. 

7 Replace defective unit injector(s). 

(Replace unit injector, refer to 03.02.02) 



03.14.03 Air bubble formation in fuel system 

1 2 


Preparation: 

Change fuel filter, if necessary 

refer to 03.09 

(item 1, ventilate fuel system) 

Special tool: 

Testing device for fuel return 2300719/1 

1 Disconnect hose from fuel return line on fuel cooler 

outlet to fuel tank. (ill.2/pos.1). 

2 Connect hose (ill.1/pos.1) of testing device 

2300719/1 to tandem cooler outlet. (ill.2/pos.1). 

14.03 ill.1 

3 Connect hose (ill.2/pos.2) of testing device 

2300719/1 with return hose to fuel tank. (ill.2/pos.2). 

3 

4 Hold testing device, glass bulb upwards (ill.2/pos.3), 

or fix it on the boat. 

1 

2 

Procedure: 

Check 1: 

Result: 

14.03 ill.2 

Ventilate fuel system by 6 times ignition ON. Observe the sight glass as to complete 

ventilation of system (bubblefree fuel flow). 

If a bubblefree fuel flow cannot be achieved, search for the problem at the suction 

side (from fuel tank to fuel pump). 

Check: 

1. Fuel in tank. 

2. Tank suction pipe and fitting 

3. ANTI-SIPHON VALVE (if installed) leckage. 

4. Water separator leaky or contaminated. 

5. Check all fuel lines connections and fittings in the feed line 

(suction side) up to fuel pump intake. 

After a bubblefree fuel flow can be achieved, continue with check 2. 

Check2: 

Result: 

Start the engine and let it run at idle speed. Observe the glass bulb. 

If bubble formation starts, search for the problem in the unit injectors. Probable 

contamination , on one or several nozzle elements cause a problem. 

Due to compression/combustion pressure, gases into the are forced fuel system 

throug the unit nozzle(s). 



Check: 

Manual: 

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) 

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). 

Then repeat check 3. 

If a bubble formation appears during load operation, continue with check 3. 

Check 3: 

Result: 

Start the engine, bring it to operating temperature, test the boat under operating 

conditions and observe the glass bulb. 

If it comes to bubble formation, search for the problem in the area of unit injectors. 

Control: 

Defective unit injector(s) is/are to be detected definitely by means of "Disengagement 

methode of injection" 

(manual injection test methode, refer to 03.14.01) 

If there is still bubble formation, continue with check 4. 

Check 4: 

Test the engine in the operating state where bubble formation occurs, by disengagement 

of injection per cylinder one after the other. 

(Disengagement methode of injection, refer to 03.14.02). 







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

ToC 




Page EXHAUST SYSTEM - 2 Z001019/0_6_July 2008



04.01 HI-RISER 

04.01.01 Replace hi-riser 

Preparation: 

If necessary, 

remove heat shield turbocharger. 

Disassembly: 

1 Disconnect plug (ill.2/pos.1) for exhaust temperature 

switch. 

2 If bracket is used loosen hexagon screws (ill.2/pos.2) 

of bracket. 

3 Loosen hose clamp (ill.3/pos.1) connecting hose; 

heat exchanger - hi-riser. 

01.00 ill.1 

3 

2 

4 Loosen 2 hose clamp (ill.4/pos.2) from exhaust pipe 

elbow. 

5 Variant 1 

Loosen hexagon screws (ill.2/pos.3) of hi-riser. 

Remove hi-riser. 

6 Variant 2 

Loosen profiled clamp (ill.4/pos.1) of 

hi-riser. 

Remove hi-riser. 

01.00 ill.2 

1 

1 

Assembly: 

1 Prior to assembly, clean sealing surfaces of 

turbocharger - high-riser and lubricate with 

high-temperature grease.(SMO Z012222/0) 

01.00 ill.3 

2 Replace seal (if used). Tighten screws (M8) with a 

torque of 23 Nm. (Lubricate threads with high 

temperature grease Z012222/0) 

Tighten profile clamp hand-screwed. 


1 

2 

01.00 ill.4 

Z001019/0_6_July 2008 Page EXHAUST SYSTEM - 3

ToC 



04.01.02 Measurement of exhaust 

backpressure 

special tool No. VR00136/0 

ill.1/pos.1 

ill.1/pos.3 

ill.1/pos.4 

ill.1/pos.5 

ill.1/pos.6 

ill.1/pos.7 

ill.1/pos.9 

pressure gauge (0-1 bar) 

intermediate sealing ring 

pressure gauge connection 

pressure hose 

double union 

sealing ring 

screw-in adaptor 

9 

8 

7 

6 

10 

1 2 

3 

4 

5 

1 Disconnect plug for exhaust temperature switch (ill.2/ 

pos.5). 

01.02 ill.1 

2 Dismantle high-riser temperature sensor, connect 

plug to sensor again, and fix it temporary on the 

engine. 

3 Mount double union (ill.1/pos.6) with sealing ring 

(ill.1/pos.7) instead of hi-riser temperature sensor. 

9 

7 

6 

1 

3 4 

4 For 6 cyl. engines only (with FORD ECU) 

Screw in double union (ill.1/6) with sealing ring (ill.1/ 

7) into screw-in adaptor (ill.1/9) and mount screw-in 

adaptor instead of hi-riser temperature sensor. 

5 Mount seal ring (ill.1/pos.3) with pressure gauge 

connection (ill.1/pos.4) onto pressure gauge (ill.1/ 

pos.1) Connect pressure gauge to one end of pressure 

hose (ill.1/pos.5). 

6 Connect the other end of pressure hose (ill.1/pos.5) 

to double union (ill.1/pos.6). 

01.02 ill.2 

5 

MEASUREMENT: Drive the boat under operating conditions (rated output at rated speed) and read off pressure 

on pressure gauge. 

RESULT: 

With an exhaust pressure below 100 mbar at rated output of engine, the exhaust system 

is dimentional correctly and represents the ideal status. (up to max. 200 mbar acceptable) 

With an exhaust pressure exceeding 200 mbar at rated output of engine, tuning of exhaust 

system is no more ideal. To avoid losses in efficiency, changes in the exhaust system should 

be made (pipe diameter, pipe lengths, muffler etc.) 

An exhaust pressure of 300 mbar at rated output of engine is no more acceptable. 

ATTENTION: 

Changes in the exhaust system (pipe diameter, pipe lengths, muffler etc.) absolutely required. 

Considerable influence on output, fuel consumption and life of engine. 

7 Assembly is done in reverse order: 

Page EXHAUST SYSTEM - 4 Z001019/0_6_July 2008





Page 

05.00 Functional description cooling circuit ............................................... 2 

05.00.01 Raw water circuit (external cooling circuit) ............................................. 2 

05.00.02 Closed coolant from cooling circuit (internal engine cooling circuit) ....... 4 

05.00.03 Error detection cooling system ............................................................... 6 

05.00.04 Check points for problems in cooling system ......................................... 9 

05.00.05 Component check raw water system ................................................... 10 

05.00.06 Component check engine cooling system................................................ 11 

05.00.07 Drain the coolant system........................................................................ 13 

05.00.08 Fill the cooling system ............................................................................. 15 

05.01 Cooler, heat exchanger, expansion tank ............................................ 16 

05.01.01 Coolant tank ........................................................................................... 16 

05.01.02 Disassembly exhaust manifold - heat exchanger .................................. 17 

05.01.03 Checks ................................................................................................... 21 

05.01.04 Exchange heat exchanger element........................................................ 23 

05.01.05 Assembly of exhaust manifold ............................................................... 24 

05.01.06 Exchange tandem cooler ........................................................................ 26 

05.01.07 Exchange additional oil cooler (only type 246) ........................................ 26 

05.01.08 Exchange triple cooler............................................................................. 27 

05.03 Pipes, thermostat ................................................................................. 27 

05.03.01 Coolant pipes and hoses ....................................................................... 27 

05.03.02 Exchange thermostat ............................................................................. 28 

05.03.03 Exchange sacrificial anodes................................................................... 30 

05.04 Coolant pump ........................................................................................ 31 

05.04.01 Exchange coolant pump ........................................................................ 31 

05.04.02 Install coolant pump ................................................................................ 32 

05.06 Poly-V-Belt ............................................................................................. 33 

05.06.01 Exchange Poly-V-belt .............................................................................. 33 

05.07 V-belt ...................................................................................................... 34 

05.07.01 Exchange V-belts .................................................................................... 34 

05.07.02 Adjust V-belts .......................................................................................... 36 

05.10 Raw water pump ................................................................................... 37 

05.10.01 Exchange raw water pump...................................................................... 37 

05.12 Checks .................................................................................................. 38 

05.12.01 Check closed engine cooling system for air ............................................ 38 

Z001019/0_6_July 2008 Page COOLING SYSTEM - 1

ToC 



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. The impeller is arranged eccentrically. 

At higher speeds, it acts as combinded centrifugal- and displacement pump. At slow speeds, the 

impeller acts as displacement pump. This causes a pump effect of the impeller wings during operation 

of the engine. At high engine speed, the resistance of water on its way through the pump is sufficient 

to avoid a contact of the impeller wing with the inner side of housing. The wings are only bent inside 

in direction of impeller center, thus acting as combined centrifugal- and displacement pump. 

Raw water is fed to the raw water pump via raw water pick-up (ill.1/1) and/or via drive unit (Z-drive, jetdrive) 

and/or raw water filter (ill.1/11) arranged between. From the raw water pump, water flows into 

the combined fuel- (ill.1/3) and steering- and/or transmission oil cooler (ill.1/4) where the raw water 

absorbs thermal energy from the fuel- and steering- and/or transmission oil system. 

Then water flows through the tube stake of intercooler (ill. 1/5) where the raw water absorbs thermal 

energy from air charge. 

Through the connecting line above the rear part of the camshaft case the raw water enters the tube 

stake of heat exchanger (ill.1/6) where the raw water still absorbs thermical energy from engine 

coolant. 

Then raw water flows through the high-riser (ill.1/7) where the raw water still absorbs thermal energy 

from exhaust gas, and finally leaves, mixed with exhaust gas, the raw water circuit via exhaust pipe 

(raw water outlet) (ill. 1/9) either through the drive or a muffler, and is blown in below water surface. 

The splash water flap (ill.1/12) avoids a possible raw water entry with stopped engine. 

The raw water circuit is equipped with 5 sacrificial anodes (ill.1/10) (for salt water made of zinc; for sea 

water magnesium anodes are recommended). 

Temperature of raw water, mixed with exhaust gas, is controlled by means of sensor (ill.1/8) on highriser 

and transmitted to the electronic management system. If during operation the limit of 60°C is 

exceeded, the electronic management system will reduce the engine power to a perceptible extent of 

up to 50%. 

This disturbance will be indicated on the instrument panel by means of signal lamp for engine check 

which blinks 2 times/sec. and an audible warner (2times/sec). 

ATTENTION: 

To exclude consecutive damages, occured trouble should be analyzed and eliminated 

as soon as possible. 

Page COOLING SYSTEM - 2 Z001019/0_6_July 2008



00.01 ill.1 

1 Raw water intake 

2 Impeller pump 

3 Fuel cooler 

4 Hydraulic oil- and transmission oil cooler 

5 Tube stake - intercooler 

6 Tube stake - heat exchanger 

7 Hi-riser 

8 Sensor exhaust gas temperature 

9 Raw water outlet 

10 Sacrificial anodes 

11 Raw water filter 

12 Splash water flap 


ToC 



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. The pump is maintenance-free. 

The engine coolant in the closed circuit of the cooling system circulates as follows: 

The circulating pump (ill.2/1) of the engine feeds the coolant through the oil cooler (ill.2/2) where 

thermal energy is absorbed from motor oil. 

Then the coolant flows through the water jacket (ill.2/3) into the motorblock. Coolant circulates around 

the cylinders. Here, thermal energy of combustion is absorbed. 

Then coolant reaches the exhaust manifold (ill.2/4), flows through the exhaust manifold in a separate 

channel and absorbs thermal energy from exhaust gas. 

For most of 6 cyl. marine engines (excluded 256H), coolant additionally flows through the exhaust 

turbocharger (ill.2/5). Here, thermal energy is also absorbed from exhaust gas. 

Then the coolant reaches the thermostat housing. By means of thermostat, depending on the engine's 

operating temperature, the coolant is fed to the heat exchanger or directly to the engine coolant pump. 

If the engine has not yet achieved the operating temperature of 80°C, the thermostat remains closed 

and the coolant is fed via contact-channel directly to the intake side of coolant pump. 

This circulating circuit (ill.2/A) is continued until the coolant in the thermostat housing (ill.2/6a) has 

achieved the temperature (80°C). 

As soon as the temperature of 80°C in the thermostat housing is achieved, the thermostat opens and 

the coolant is partially (thermostat opens according to operating temperature) transmitted to the heat 

exchanger (ill.2/B). Via the contact-channel the coolant partially arrives directly at the intake-side of 

the coolant pump (ill.2/A). 

Only after the coolant in the thermostat housing has achieved a temperature of 90-93°C, the thermostat 

(ill.2/6b) is completely open. From this time, the whole coolant flows through the tube stake of heat 

exchanger (ill.2/7) in the exhaust manifold housing. Here, the warmed up coolant releases thermal 

energy to the raw water circuit, and the coolant is fed via engine water pipe to the centrifugal pump 

again. 

The heat exchanger is an integrated component of the aluminium exhaust manifold. This component 

also includes the expansion tank (ill.2/9) with coolant reservoir, required for the pressure system. 

Operating pressure is regulated via excess-pressure valve (opening pressure 0,9 bar) in the cooler 

cap (ill.2/10). 

Coolant temperature is measured by means of sensor (ill.2/11) on exhaust manifold next to drain cock 

(ill.2/12) of coolant, and transmitted to the electronic management system. If during operation the limit 

(107°C) is exceeded, the electronic management system will reduce the engine power to a perceptible 

extent of up to 50%. 

This disturbance is indicated on the instrument panel by an audible warner (2 times/sec.). 

ATTENTION: 

To avoid consecutive damages, occured trouble should be analyzed and eliminated 

as soon as possible. 




B Circuit 

thermostat open 

00.02 ill.2 

1 Circulating pump 

2 Oil cooler 

3 Water jacket, block/cylinder 

4 Water cooled exhaust manifold 

5 Turbocharger 

6a Thermostat (closed) 

A Circuit, thermostat 

closed 

6b Thermostat (open) 

7 Tube stake - heat exchanger 

8 Water-intake pipe 

9 Expansion tank 

10 Filler cap 

11 Coolant temperature sensor 

12 Drain plug 


ToC 


05.00.03 Error Detection Cooling System 


1 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.)? 

- At what engine speed does the problem occur? 

- At what engine load does the problem occur? 

2 Raw water circuit (external) 

2.1 At first, take into consideration the following possibilities: 

- Defective or faulty cooling water temperature sensor (high-riser) 

- Sufficient rate of flow for raw water 

- raw water pick-up damaged or clogged 

- wrongly mounted raw water pick-up 

- raw water filter clogged 

- stop valve (bottom valve) defective (only opens partially) 

- Raw water pump 

- impeller defective (broken or strong wear) 

- suction pipe from raw water filter to raw water pump clogged or deformed 

- shaft bearing defective 

- Sealing 

- O-ring of impeller housing defective 

- impeller plate seal 

- Tandem cooler contaminated (e.g. through a part of broken impeller) 

- Tube stake - intercooler contaminatd 

- Heat exchanger exhaust 

- contaminated 

- seal in heat exchanger cover defective. 

- Ventilation 

- Alga vegetation on quill 

- Deformations on hull, etc. 

2.2 - Problems of raw water supply due to troubles in the drive unit 

- defective seals or water pipes in lower gear box 

- damaged rubber seal on water pipe 

- damaged seal on box inlet 

- leaky impeller plate seal 

- leaky O-ring on impeller housing 

- defective hose connection between pivot housing and Cardan housing 

- observe notes and instructions of manufacturer. 

2.3 - Inspection wether air reaches raw water. 

Procedure: Replace water hose between raw water pump and tandem cooler (fuel/hydraulic 

cooler) by transparent plastic hose. Let the device run in a test tank or with the boat 

in water, at rotation speeds which cause an overheating, in order to detect a possible 

bubble formation in the transparent plastic hose. 




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. These could take effect onto water suction and be 

interpreted by mistake as a cooling problem. 

2.4 Check rate of flow of raw water. 

Special tool No. VR00136/0 (ill.1) 

ill.1/pos.2pressure gauge (0-4bar) 

ill.1/pos.3intermediate sealing ring 

ill.1/pos.4pressure gauge connection 

ill.1/pos.5pressure hose 

ill.1/pos.10 pipe stub, measurement of pressure 

raw water 

9 

8 

7 

6 

10 

1 2 

3 

4 

5 

Measurement of pump feed pressure at the outlet of 

raw water pump (ill.2) 

1 Disconnect hose from pressure side of raw water 

pump, connect pipe stub (ill.2/pos.10) and connect 

raw water hose to pipe stub again. 

00.03 ill.1 

2 

2 Mount intermediate sealing ring (ill.2/pos.3) with 

pressure gauge connection (ill.2/pos.4) onto pressure 

gauge (ill.2/pos.2) and connect it at one end of 

pressure hose (ill.2/pos.5). 

3 Connect the other end of pressure hose (ill.2/pos.5) 

to pipe stub (ill.2/pos.10). 

10 

3 

4 

5 

4 Start the engine and check for leakages. 

00.03 ill.2 

5 Put boat into operation and approach speed points according to diagram. Compare measured pressure 

with table below. 

Conclusion: 

- If the pump pressure is lower than the min. quantity in the table, the problem is 

at suction side of raw water system. 

- If the pump pressure is higher than the max. quantity in the diagram, the problem 

is at pressure side of raw water system. 

Raw water pump delivered pressure (standard impeller) 

RPM 

600 

1300 

1800 

2300 

2800 

3300 

3800 

4300 

Bar 

0,20 

0,60 

1,00 

1,50 

1.85 

1,80 

1,60 

1,45 


ToC 



3 Closed Cooling Circuit (internal) 

3.1 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 

- Malfunction of water circulating pump of engine 

- pump bearing defective 

- defective impeller seal 

- excessive wear of impeller wings 

- Cooler cap (pressure loss) 

- Cooler cap sealing defective 

- vacuum valve defective 

- excess-pressure valve defective. 

3.2 Malfunction of thermostat - overheating or slow heating of coolant: 

- Procedure: Let the engine run until indicated temperature exceeds 80° C. Feel on hose of front 

engine water pipe between heat exchanger and water-intake pipe. 

- Result: Hose cold. 

- Conclusion: Thermostat got stuck in closed state. 

- Result: Hose warm or hot. 

- Conclusion: Thermostat opens partially or completely. 

- Procedure: Let the engine run; temperature of coolant will rise very slowly (feel on hose of front 

engine water pipe between heat exchanger and water-intake pipe). 

- Result: Themperature on hose slowly rises simultaneously with temperature of coolant, but 

does not reach operating temperature (80°C opening temperature of thermostat). 

- Conclusion: - Thermostat blocked in partially open or completely open state. 

- Sealing ring of thermostat defective. 

- Control: - Thermostat got stuck in open or closed position. 

- Defective thermostat sealing. 

- Wrong thermostat for this type of engine. 




05.00.04 Check points for problems in cooling system 

1 Raw water circuit 

1.1 water intake - clogged 

1.2 raw water filter - clogged 

- strongly contaminated 

- filter defective 

1.3 hoses - fragile or leaky 

1.4 hose clamps - loose or defective 

1.5 raw water pump - impeller stronlgy worn 

- impeller broken 

- cover loose 

- shaft bearing defective 

1.6 tandem cooler - clogged 

- leaky 

- broken 

1.7 intercooler - pipes clogged 

- internal leakage 

1.8 exhaust manifold - heat exchanger clogged 

- internal leakage 

1.9 cooling water temperature sensor - defective 

1.10 manifold, elbows, seals, hoses - wrongly mounted seals 

- sand or dross in manifold 

- burned out hoses 

1.11 hull - state of hull 

- marine vegetation 

- equipment attached to hull 

NOTE: 

Mountings protruding over the hull may produce cavitations during fast ride which cause air 

bubbles. These are possibly taken at the lower gear box by the drive and mixed with the 

inflowing cooling water. Due to bad refrigerating capacity of the external cooling system, an 

overheating in the internal cooling system (engine) may occur. 

2 Internal Cooling Circuit 

2.1 hoses - craked or leaky 

2.2 hose clamps - loose or defective 

2.3 thermostat - thermostat defective 

- wrong thermostat 

2.4 cooler cap - defective excess-pressure valve 

- defective vacuum valve 

- damaged cover sealing 

2.5 coolant circulating pump - defective casing sealing 

- damaged bearing 

- worn impeller 

- defective slide ring sealing 

2.6 coolant guide on cylinder block - leaky connectors 


ToC 



05.00.05 Component Check Raw Water System 

1 Hoses and clamps, drain plug etc. 

For all models: no special tool required. 

Control works: 

Check all external components of cooling system for leakage, wear and damages. Check tightness 

of all connections. Check hoses for cracks, breaks or wear. Water-supply hoses must be in 

accordance with SAE 20R3 specifications, class D-2. 

Repair works: 

Repair or exchange, as required. 

2 Manifold, heat exchanger and intercooler: 

No special tools required. 


Check components for leakage, in a pressure test. Disassembly and check for corrosion and 

material residues. 

Repair works: 

Remove residues of foreign material from pipes. If there are signs of spongy spots between water 

ducts and exhaust channel, the component is to be exchanged. Also check exchangeable 

elements for damages. For assembly, use new sealings and sealing rings. 

3 Raw water pump 



With running engine, check rotation of pump belt pulley. If belt pulley runs out of true, this may 

cause excessive wear of the pulley and damages on the pump itself. 

If with running engine leakages on the pump are stated, the shaft sealing ring at the front of the pump 

is leaky or the spacer is defective. 

Repair works: 

Not provided; exchange pump. 

4 Fuel- and oil cooler 



Check components for internal leakage, in a pressure test. If possible, dismantle and check for 

corrosion and residues of foreign material. 

Repair works: 

Remove residues of foreign material. If possible, exchange inserts or replace components. 

5 Water pump in stern-drive 



Check water sucking filter at lower gear box for clogging. Check for sufficient water supply - as per 

section Cooling System - Error Detection. 

Repair works: 

Dismantle water pump and repair or exchange defective components. For assembly, take care of 

respective sealing of water pump. See notes and instructions of manufacturer. 




05.00.06 Component Checks of Engine Cooling System 

1 Hoses and clamps, drain plug etc. 

For all models: no special tool required. 


Check all external components of cooling system for leakage, wear and damages. Check all 

connections for tightness. Check hoses for cracks, breaks or wear. 

Repair works: 

Repair or exchange 

Water-supply hoses must be in accordance with SAE 20R3 specifications, class D-2. 

2 Thermostat 



As a standard, an 80° C thermostat is used for the 

marine engine. Check thermostat for correct 

model and correct rated output, corrosion, limited 

mobility or broken spring. 

Repair works: 

No repair possible. Exchange thermostat. 

Test procedure: 

00.06 ill.1 

Dip the thermostat together with a thermometer into a water tank and heat up the water. 

At a temperature of 80-81° C the thermostat should begin to open, and should open for 3,8-4,0 mm 

at a temperature of 85-88° C (ill.1/A). At 90-93°C the thermostat should be open for 7 mm in order 

to lock the little cooling circuit (contact-channel), thus permitting a complete flow through the heat 

exchanger. Off 95 °C, the complete thermostat stroke of 8.0-8,2 mm is achieved. 

3 Water pump (coolant circulating pump) 



If with running engine leakage on the pump is stated, the slide-ring sealing at the front of the pump 

is leaky. 

Repair works: 

Not provided; exchange pump. 


ToC 



4 Cooler cap 



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). 

Repair works: 

Not provided; exchange cooler cap. 

2 

3 

1 

5 Coolant loss in closed engine cooling system 

00.06 ill.2 

5.1 Coolant loss: 


- (item 4) check cooler cap 

- defective exhaust manifold (exhaust gases reach the engine cooling circuit) 

- defective monoblock (due to combustion pressure, gases reach the engine cooling system). 

5.2 Gas-air mixtures reach the cooling system. 

5.2.1- Defective exhaust manifold 


05.01.03 Check exhaust manifold heat exchanger. 

5.2.2 - Defective (leaky) monoblock 


Use special tool SMO: VR00147/0 by using enclosed instruction. 

Conclusion: Gas entry (combustion pressure) in the engine cooling circuit. 


Assembly of unit injector, refer to 03.02.02 "ASSEMBLY" item 11; check specified 

tightening torque. 

Repeat check. If result remains unchanged, the monoblock is defective. 

Repair works: 

Not provided; exchange monoblock. 




05.00.07 Drain coolant system 

Raw water circuit 

1 Remove drain plug (ill.1/pos.1). 

1 

NOTE: 

Drain plug (ill.1/pos.1) does not exist 

for all models. 

2 To drain the raw water ducts on the engine, remove 

cover rear of raw water pump (ill.2+3/pos.1). 

00.07 ill.1 

NOTE: 

For complete removal of water residues 

from pump housing and water ducts 

of raw water circuit, proceed as follows: 

3 Lock exhaust pipe with special tool No. VR00144/0 

(ill.4/pos.1) 

1 

4 Remove plug J 1. 

Connect special tool No. VR00145/0 instead of plug 

J1. 

00.07 ill.2 

5 Start the engine by pressing the button, until raw 

water system is completly emptied. 

ATTENTION: Only start with special tool No. 

VR00145/0. Engine only be cranked 

by starter motor, but not start. 

6 After complete drainage, assembly is done in reverse 

order. 

1 

ATTENTION: If the water is not drained in time before 

the winter season, this could result in 

frost damage on the engine as well as 

the drive. 

00.07 ill.3 

1 

00.07 ill.4 


ToC 


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. 


1 

ATTENTION: Approx. 1 liter of coolant will remain in 

the motorblock which is to be 

considered for refilling. 

With hot engine, the closed cooling 

circuit is under pressure. Do not try to 

open the coolant tank cap or the drain 

plug when the engine is hot. This could 

lead to severe injuries by hot coolant 

under pressure. As soon as the engine 

has cooled down, the cap may be 

opened by 1/4 turn to the left, to release 

possibly remaining pressure. Then 

press down the cap, turn and remove. 

00.07 ill.5 

1 

7 There are two drain plugs on the engine through 

which the coolant from the internal cooling circuit can 

be drained. 

(Refer to ill.5/pos.1 and ill.6/pos.1) 

8 Loosen the two drain plugs (ill.5/pos.1 and 6/pos.1), 

possibly stick a hose onto the drain plugs and collect 

the coolant in a bucket. 

00.07 ill.6 

ATTENTION: The closed cooling circuit must always 

be filled with coolant. If the circuit 

remains for a long time without coolant, 

corrosion damages may occur. 




05.00.08 Fill cooling system 

Closed cooling system 

1 Fill cooling circuit with specified coolant only. Coolant 

level should reach the lower edge of the filler neck in 

the expansion tank. 

2 For 4 cyl. & 6 cyl. engines with new exhaust 

(screwed cap) only 

NOTE: 

Cooling system deaerate automatically 

while filling. 

For 6 cyl. engines (old version) only (item 3-4) 

Remove venting screw (ill.2/pos.1) (SW6) at the 

front of heat exchanger. Fill cooling circuit with 

specified coolant only. Coolant level should reach the 

lower edge of the filler neck in the expansion tank. 

4 Mount venting screw again and tighten. 

00.08 ill.1 

ATTENTION: For a new filling of the closed cooling 

circuit, make sure that the cooling 

system is deaerated completely. 

1 

5 Let the engine run, check coolant level and refill 

coolant if necessary. 

00.08 ill.2 

Raw water circuit 

After engine start, filling is done automatically via raw 

water pump. 

ATTENTION: Raw water intake valve must be open. 


ToC 



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 



05.01.02 Disassembly exhaust manifold - 

heat exchanger 

Preparation: 

tip away E-box 

remove air filter, refer to 03.04 


1 

NOTE: 

Where appropriate, remove exhaust 

manifold for these works, while turbocharger 

and hi-riser remain. 

1 Drain closed cooling circuit according to instructions 

in 05.00.07, drain coolant 

01.02 ill.1 

2 Unscrew three screws (ill.1/pos.1) of upper timing 

belt covering. Remove covering. 

1 

3 Disconnect water hose (ill.2/pos.2) to thermostat 

housing. 

4 Loosen hose clamp (ill.2/pos.1) and remove coolant 

pipe. 

2 


5 Loosen hose clamp (ill.3/pos.1) and remove coolant 

pipe. 

6 Loosen hose clamp (ill.3/pos.2) and remove hose. 

01.02 ill.2 

1 

2 

01.02 ill.3 

7 Disconnect coolant temperature sensor (ill.4/pos.1). 

1 

01.02 ill.4 


ToC 



8 Cut cable tie for cable- and plug fixing of speed 

sensor (ill.5/pos.1) on relief hose. 

1 


01.02 ill.5 

9 Loosen fixing of heat protection. Remove heat 

protection (ill.6/pos.1). 

10 Loosen hose clamp (ill.6/pos.2) and remove hose 

for air charge pressure box. 

1 2 

3 

11 Loosen screw (SW10) (ill.6/pos.3) for raw-waterpipe 

support. 

01.02 ill.6 

12 Loosen hollow screw (SW14) (ill.7/pos.1) of oil feed 

line on turbocharger. 

1 

13 Remove plug of oil pressure switch (ill.7/pos.2). 


motorblock. Dispose Cu-sealing rings. 

2 

3 

01.02 ill.7 

15 Loosen 2 hexagon screws (ill.8/1) of oil return line. 

Dispose seal. 

1 

01.02 ill.8 





Loosen two hexagon screws on flange of oil feed 

line. 


Loosen hose clamps of hose connection 

turbocharger - intercooler (ill.10/pos.1) and remove 

hose. 

01.02 ill.9 

õ õ 

1 


01.02 ill.10 

18 Loosen setscrew (ill.11/pos.1) for support of sea 

water pipe. 

19 Remove covering (ill.11/pos.3) to intercooler by 

loosening 5 hexagon screws (SW10) (ill.11/pos.2). 

2 3 

1 

20 Loosen hose clamp (ill.12/pos.1) compressor 

housing connection. 

01.02 ill.11 


remove connecting manifold. 

C2 

C1 

01.02 ill.12 


ToC 



22 Loosen hose clamp (ill.13/pos.1) of oil separator and 

remove hose. 

1 

23 Unscrew 8 - 12 screws (SW13) (ill.14/pos.1) and 

2 - 3 nuts (ill.14/pos.2) . 

01.02 ill.13 

CAUTION: 

If the exhaust manifold is not secured, 

it migth fall when loosening the screws. 

1 

24 Remove exhaust manifold with turbocharger and 

high-riser. 

2 

CAUTION: 

Heavy unit (approx. 40 kg). 

Disassembly ONLY with suitable lifting 

device or second person. 

01.02 ill.14 

25 Remove O-rings or gaskets from exhaust manifold or 

cyl. block, and dispose. 

1 

01.02 ill.15 




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. 

ATTENTION: Mostly, structural cracks are highly 

dependent on thermal influence. In 

order to achieve a more reliable result 

of the pressure test, the component 

should be heated up to approx. 80°C. 


ToC 







05.01.04 Exchange heat exchanger element 

7 

9 

8 

6 

5 

4 

01.04 ill.1 

3 

2 

1 

Dismantle heat exchanger element: 

1 Drain closed coolant circuit, refer to 05.00.07 

2 Drain raw water circuit, refer to 05.00.07 (item 1 remove drain plug). 

3 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). Remove heat exchanger cover in front and at the back. 

Loosen the element by slightly knocking with a plastic hammer on the rear end of the element, and 

remove it. Dispose O-ring and rear cover of heat exchanger element as well as seal of heat exchanger 

cover. 

4 Clean all sealing surfaces. 

Assembly: 

5 Grease O-Ring (ill.1/pos.5) with Molykote BR 2 PLUS and push it onto flange of heat exchanger 

element (ill.1/pos.4). Then insert heat exchanger element from front into exhaust manifold. 

Grease O-ring (ill.1/pos.6) with Molykote BR 2 PLUS and push it onto exposed rear end of heat 

exchanger element. 

6 Grease seal (ill.1/pos.9) with Molykote BR 2 PLUS and insert it into heat exchanger cover at the back 

(ill.1/pos.7). Fix cover on exhaust manifold and loosely mount it with 3 screws (ill 1/pos.8) on exhaust 

manifold. 

7 Fix seal (ill.1/pos.3) together with heat exchanger cover in front on exhaust manifold and loosely mount 

it with 3 screws (ill.1/pos.1). 

8 First tighten 3 screws (ill.1/pos.1) of heat exchanger cover in front, with a torque of 23 Nm +/-2, then 

3 screws (ill.1/pos.8) of heat exchanger cover at the back, with a torque of 23 Nm +/-2. 



ToC 



05.01.05 Assembly of exhaust manifold 

Preparation: 

Check heat exchanger, 

refer to 05.01.03 

1 Clean sealing surfaces on motorblock. 

01.05 ill.1 

2 Clean sealing surfaces on exhaust manifold (ill.2/ 

pos.1). 

1 


01.05 ill.2 

3 Insert O-ring on cyl. bloc (ill.3/pos.1) by means of 

Molykote. 

1 

4 Insert two O-rings (ill.4/pos.1) into exhaust manifold 

by means of Molykote. 

01.05 ill.3 

ATTENTION: different sizes 

1 

5 Thinly cover sealing surfaces (ill.4/pos.2) of exhaust 

manifold with surface sealing agent LOCTITE 5900. 

2 

01.05 ill.4 





Variant with gaskets: 

1 

6 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. 

7 Put exhaust manifold onto 3 assembly bolts (ill.5/ 

pos.1) Mount manifold screws with washers and 

tighten sturdily. Remove assembly bolts and screw in 

remaining 3 screws and 3 nuts with washers, and 

tighten with a torque of 23 Nm +/-2. 

Variant with O-rings: 

01.05 ill.5 

8 Insert all O-rings into exhaust manifold by means of 

Molykote. 

9 Put exhaust manifold onto 3 assembly bolts (ill.5/ 

pos.1). Mount manifold screws and tighten sturdily. 

Remove assembly bolts and screw in remaining 3 

screw and 3 nuts. Tighten screws with a torque of 

23 NM +/-2, nuts with 10 Nm. 


10 Put exhaust manifold onto the two threaded bolts 


11 Tighten 8 hexagon screws (SW13) (ill.7/pos.1) with 

a torque of 23 Nm +/-2. Tighten 2 hexagon nuts 

10 Nm (SW 10) (ill.7/pos.2). 

01.05 ill.6 

1 

1 


disassembly. 

2 

ATTENTION: 

Plug and cable of speed sensor to 

be tied up again with 2 cable ties on 

venting hose. 

01.05 ill.7 

13 Mount E-box properly. 

14 Fill heat exchanger and motorblock with coolant, 

according to instructions in this paragraph. 

õ 


ToC 



05.01.06 Exchange tandem cooler 

Disassembly 

Preparation: 

vent fuel system, 

refer to 03.09/1 

1. Remove drain plug (ill.1/pos.1) to drain the raw 

water system. 

2. Loosen hose clamp (ill.1/pos.2) of hose to raw water 

pump, and remove hose. 

3. Loosen hose clamp of hose bend (ill.1/pos.3) to 

intercooler, and remove hose bend. 

4 Loosen fuel return line (ill.1/pos.4) (SW19) mm and 

hydraulic lines. 

5. Unscrew two Allen head screws (SW6) (ill.1/pos.5) 

of clamps, and remove tandem cooler (ill.1/pos.6). 

Assembly 


ATTENTION: Use new sealing rings. 

5 

2 4 6 

01.06 ill.1 

3 

1 

05.01.07 Exchange additional oil cooler 

(used only at type 246) 

5 

3 

Disassembly 

Preparation: loosen clamp oil dipstick (SW10) 

1. Remove drain plug at tandem cooler to drain the raw 

water system. 

2. Loosen union nuts of oil hoses (ill.1/pos.1) (SW 21) 

at the additional oil cooler. 

2 

1 

6 

1 

3. Loosen hose clamp (ill.1/pos.2) of hose to raw water 

pump. 

01.07 ill.1 

4. Loosen hose clamp of hose (ill.1/pos.3) to tandem 

cooler. 

5. Unscrew two Allen head screws (SW6) (ill.1/pos.5) 

of clamps, and remove additional cooler (ill.1/pos.6). 

Assembly 


ATTENTION: 

Use new sealing rings for oil hoses. 


LOCTITE 243 and tighten with a 

torque of 20 NM +/-2 




05.01.08 Exchange triple cooler 

Disassembly 

Preparation: vent fuel system, refer to 03.09, 

item 1 

3 

5 

3 

1. Remove drain plug at triple cooler to drain the raw 

water system.(ill.1/pos.1) 

1 

2 

4 

6 

2. Loosen union nuts of oil hoses (ill.1/pos.2) (SW 32) 

at the triple oil cooler. 

3. Loosen hose clamps (ill.1/pos.3) of hose to raw 

water hoses. 

01.08 ill.1 

4. Loosen fuel lines (ill.1/pos.4) (SW 19) and hydraulik 

lines (SW 22) 

5. Unscrew three Allen head screws (SW6) (ill.1/pos.5) 

of clamps, and remove triple cooler (ill.1/pos.6). 

Assembly 


ATTENTION: 

Use new sealing rings for oil hoses. 


LOCTITE 243 and tighten with a 

torque of 45 NM +/-2 

05.03 PIPES, THERMOSTAT 

05.03.01 Coolant pipes and hoses 

Remove defective hoses by loosening the respective hose clamps and replace. 

ATTENTION: Tightning toose clamps with a torque of 3,5 Nm. 


ToC 



05.03.02 Exchange thermostat 

Preparation: Drain closed cooling circuit 

refer to 05.00.07, item 7 

DISASSEMBLY: 

03.02 ill.1 

1 Loosen 4 hexagon sockets fixing the covering of 

thermostat housing. Remove covering and seal. Dispose 

seal. 

Only for 6 cyl. engines with hydraulic system 

(item 2-3) 

2 Loosen hexagon screw (SW10) fixing the oil tank of 

hydraulic system (ill.3/pos.1). Remove oil tank from 

mount and fix it laterally to avoid any leaking of 

hydraulic oil. 

3 Loosen the two lower hexagon sockets (SW5) (ill.3/ 

pos.2) fixing the covering of thermostat housing. 

Remove covering of thermostat housing and seal 

together with mount for hydraulic tank. Dispose seal. 

03.02 ill.2 

1 

2 

03.02 ill.3 

4 Remove spacer (ill.4/pos.1) and thermostat (ill.4/ 

pos.2) with seal. 

03.02 ill.4 

1 2 




ASSEMBLY: 

1 Clean sealing surfaces on thermostat housing and 

on sealing surface of cover. 

. 

03.02 ill.5 

2 Put seal (ill.6/pos.1) onto thermostat. 

1 

03.02 ill.6 

4 Insert thermostat into housing, ventilation mark (ill.7/ 

pos.1) showing upwards. 

ATTENTION: Put on new seal. 

1 

5 Insert spacer. 

6 Remaing assembly is done in reverse order. 

03.02 ill.7 

7 Tighten screws of thermostat housing cover with a 


8 Filling of closed cooling circuit, 

refer to 05.00.08 

03.02 ill.8 


ToC 



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) . 

1 Anodes 1 and 2 (ill.2/pos.1-2) are on the intercooler. 

2 Anodes 3 is in the high riser (elbow). 

3 Anodes 4 and 5 (ill.2/pos.4-5) are on the heat 

exchanger. 

03.03 ill.1 

4 Illustration 1 shows a new anode. 

NOTE: 

For operation with fresh water, 

magnesium anode sticks are 

recommended. 

03.03 ill.2 




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 

Loosen hose clamp (ill.2/pos.1) and remove hose. 

2 Loosen hose clamps (SW6) and remove hose 

between thermostat housing and water pump (ill.3/ 

pos.1) 

04.01 ill.2 

1 

3 Loosen hose clamp of hose elbow (ill.3/pos.2) at oil 

cooler side. 

1 

4 Loosen all screws (ill.4) and hexagon nut of water 

pump (ill.4/pos.3). 

04.01 ill.3 

2 

5 Loosen water pump by slight knocking with plastic 

hammer and remove hose elbow. 

2 

1 

1 

3 

04.01 ill.4 


ToC 



05.04.02 Install coolant pump 

1 Clean all sealing surfaces on water pump and on 

motorblock. 

04.02 ill.1 

2 Put on new sealing (ill.2/pos.1). 

3 Align water pump on motorblock. Mount screws and 

nuts and tighen with standard torque for these size. 

4 Further assembly is done in reverse order, in 

accordance with 01.00.04 remove timing belt. 

1 

5 Adjust control according to instructions in paragraph 

01.00.05 engine timing adjustment procedure. 

04.02 ill.2 




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. 

*) 

1 Release belt tension by pulling tensioner from V-belt 

of torque wrench No. 2300704/0 (ill.3/pos.1). Remove 

Poly-V belt. 

04.06 ill.2 

2 Pull the belt tightener counterclockwise by means of 

torque wrench No. 2300704/0 into position as show 

(ill.3/pos.1). Apply the Poly-V belt acc. to ill.1 for 

engine with hydraulic pump or ill.2 for engine without 

hydraulic pump. Tighten the belt by releasing the belt 

tightener. 

1 

04.06 ill.3 


ToC 


05.07 V-BELT 

05.07.01 Exchange V-belts 


Alternator: (for example - different versions 

possible) 


3 

1 

2 

1 Loosen setscrews (ill.1+2/pos.1+2) 

2 Release V-belts by turning clamping bolt (ill.1+2/ 

pos.3) counterclockwise and by turning alternator 

towards engine. 

Remove pair of V-belts. 


(According 05.07.02) 

4 Adjust belt tension to 350 +/- 50 N. 

07.02 ill.1 

3 

1 

5 Check tension of alternator V-belt on spot (ill.4/A) in 

the middle between crankshaft (ill.4/pos.1) and 

alternator (ill.4/pos.2). 

2 

NOTE: Always change V-belts in pairs only. 

Servopump 

07.02 ill.2 

NOTE: 

The servopump is driven together with the 

alternator. Tension of V-belt is done via 

alternator. 

4 

Raw water pump: (old version) 

Preparation: Remove alternator V-belts. 

2 

1 

1 Loosen setscrews (ill.3/pos.1). 

2 Loosen hexagon nut of clamping bolt (ill.3/pos.2). 

Release V-belt by turning the clamping bolt (ill.3/ 

pos.3) counterclockwise and turning the pump 

towards engine. 

Remove V-belt (ill.3/pos.4). 

07.02 ill.3 

3 


4 Check tension of raw water pump V-belt on spot (ill.4/ 

B) in the middle between crankshaft (ill.4/pos.1) and 

raw water pump (ill.4/pos.3). 

2 

A 

B 

3 

5 Adjust belt tension to 350 +/- 50 N. 

(According 05.07.02) 

1 

07.02 ill.4 




Raw water pump: (current version) 

Preparation: Remove alternator V-belts. 

1 

1 Loosen screw (ill.5/pos.1). 

Turn screw counter (ill.6/pos.1) clockwise to reduce 

of tension V-belt. 

2 Remove V-belt. 


4 Adjust V-belt tension; according 05.07.02 

07.02 ill.5 

5 Tighten screw (ill.5/pos.1) with a 

Torque of 23 N +/-2 to secure idler pulley bracket. 

1 

07.02 ill.6 


ToC 



05.07.02 Adjust V-belts 

Measuring device No. VR00515/0 for timing- and V-belt 


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). This corresponds to a belt tension of 

350 Nm +/- 50. 

If the belt is too loose, it may slip through which 

results in higher wear and bad efficiency of alternator 

or servo pump. 

Belt tension is to be checked after first 10 operating 

hours and than every 50 operating hours. 

07.02 ill.1 

07.02 ill.2 




05.10 RAW WATER PUMP 

05.10.01 Exchange raw water pump 

1 Loosen 3 hexagon screws (ill.1/pos.1) of belt pulley. 

3 

2 Remove poly-V-belt or V-belt (05.06 or 05.07) 

3 Unscrew 3 screws (ill.1/pos.1) of belt pulley and 

remove belt pulley (ill.1/pos.2). 

5 

4 

2 

4 Loosen hose clamp (ill.1/pos.3) and remove hose. 

5 Loosen 4 screws (ill.1/pos.4), remove raw water 

pump (ill.1/pos.5). 


10.01 ill.1 

1 

7 Torque screws M6 (pos.4) with 9,5 Nm; screws M8 

(pos.1) with 23 Nm. 

Secure all threads with LOCTITE 243. 

For 6 cyl. engines only (old version) 

1 Loosen two setscrews (SW17) (ill.2/pos.1) 

2 Loosen hexagon nut of clamp bolt (ill.2/pos.2), 

relieve V-belt by turning clamp bolt (ill.2/pos.3) 

counterclockwise. 

3 Remove V-belt (ill.2/pos.4). 

4 Loosen hose clamps (ill.2/pos.5) and remove hoses. 

5 Unscrew two setscrews (SW17) (ill.2/pos.1+2). 

Remove raw water pump with tightener. 

4 

10.01 ill.2 

3 

2 

5 

1 

5 Loosen 4 hexagon screws (SW13), remove raw 

water pump. 



ToC 



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. 

Control works: Check tightening torque of unit injectors 

(03.02.02 "ASSEMBLY", item 11) and repeat 

check. 

NOTE: 

If there is no gas entry, coolant loss is 

eliminated. 

If there is still gas entry, refer to 03.14.02, to 

"disengagement methode of injection" this methode 

can help to detect a possible transfer of combustion 

gases into the water jacket. 

NOTE: If the defective cylinder is detected through 

the disconnection method and bubble formation and/ 

or coolant loss stops, the monoblock is to be replaced. 



06 ELECTRICAL SYSTEM 



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 .......................................................................... 6 

06.01.04 Check alternator (error detection for BOSCH alternator, 4 cyl. engines) .... 14 

06.03 Replace starter motor ............................................................................... 16 

06.03.01 Check starter ................................................................................................ 17 

06.05 Cables, wiring harness - general ............................................................. 19 

06.05.01 Battery cable lengths and cross-sections.................................................... 19 

06.05.02 E - box base plate; to eng.no.: 482 17 000 ................................................. 20 

06.05.02.01 Components of E - box ................................................................................ 21 

06.05.02.02 Connection start assist relay K28................................................................. 21 

06.05.02.03 Connection relay socket for K24, K26-1, K26-2, and K27............................ 21 

06.05.02.04 Wiring harness; to eng.no.: 482 17 000 ...................................................... 22 

06.05.03 E - box base plate; from eng.no.: 482 18 000/682 18 000 + SOLAS ......... 28 

06.05.03.01 Components of E - box ................................................................................ 29 

06.05.03.02 Connection start assist relay K28 and K26-2 ............................................... 29 

06.05.03.03 Connection relay socket for K24, K26-1, and K27 ....................................... 29 

06.05.03.04 Wiring harness; from eng.no.: 482 18 000/682 18 000 + SOLAS .............. 30 

06.06 Electronics - general .................................................................................. 36 

06.06.01 Electronic Engine Management System ..................................................... 36 

06.06.02 Diagnostic system ....................................................................................... 37 

06.06.03 Reading error codes.................................................................................... 38 

06.06.04 Idication & cancellation of memorized sensor and circuit faults .................. 39 

06.06.05 Principle failure code list ............................................................................. 40 

06.06.06 Replace fuses ............................................................................................. 42 

06.06.07 Connection J 1 ............................................................................................. 43 

06.06.08 Connection A 5 and X5 ................................................................................ 44 

06.06.09 Fitting main connector "J1" properly ............................................................ 45 

06.07 Instrument panel ....................................................................................... 46 

06.07.01 Chart - operating status normal operation................................................... 47 

06.07.02 Chart - error indication on instrument panel ................................................ 48 

06.07.03 Instrument panel (for SOLAS only) ............................................................. 52 

06.07.04 Chart - operating status normal operation (for SOLAS only) ...................... 53 

06.07.05 Chart - error indication on instrument panel (for SOLAS only) .................... 54 

06.07.10 6 Cyl. Wiring harness instrument panel (if alternator "PRESTOLITE" is 

used - old version)........................................................................................ 58 

06.07.11 Description - Wiring harness instrument panels 4/6 cyl. marine engines 

(current version) ........................................................................................... 62 

Z001019/0_6_July 2008 Page ELECTRICAL SYSTEM - 1

ToC 



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) .......... 73 

06.08.01 Potentiometer accelerator, B13 ................................................................ 74 

06.08.02 Voltage regulator 24V - 12V equalizer ......................................................... 75 

06.08.03 DC - DC converter........................................................................................ 76 

06.10 Sender, sensor .......................................................................................... 78 

06.10.01 Component configuration 4 cyl. engine ........................................................ 78 

06.10.02 Component configuration 6 cyl. engine ........................................................ 80 

06.10.03 Calibration of rack position ........................................................................... 82 

06.10.04 Replace sender, sensor ............................................................................... 83 

06.10.04.01 Sensor exhaust gas temperature B17.......................................................... 83 

06.10.04.02 Sensor engine temperature B16 .................................................................. 83 

06.10.04.03 Sensor engine speed B15 ............................................................................ 83 

06.10.04.04 Sensor boost pressure B12.......................................................................... 83 

06.10.04.05 Sensor rack position feedback B14.............................................................. 84 

06.10.04.06 Sensor oil pressure B18 ............................................................................... 84 

06.10.04.07 Potentiometer accelerator B13..................................................................... 84 

06.10.05 Check sensors and switches........................................................................ 85 

06.10.05.01 Check rack position feedback sensor B14 (= connector X14) ..................... 85 

06.10.05.02 Check throttle potentiometer B13 (accelerator) (= connector X13) .............. 87 

06.10.05.03 Check boost pressure sensor, B12 .............................................................. 88 

06.10.05.04 Check speed sensor B15 and/or wiring ....................................................... 89 

06.10.05.05 Check oil pressure sensor B18 and/or wiring ............................................... 90 

06.10.05.06 Check oil pressure sensor "VDO-instrument" (option B19) .......................... 91 

06.10.05.07 Check coolant temperature sensor, B16 ...................................................... 92 

06.10.05.08 Check audible warner .................................................................................. 93 

06.12 Battery ........................................................................................................ 94 

06.12.01 Battery ......................................................................................................... 94 

Page ELECTRICAL SYSTEM - 2 Z001019/0_6_July 2008



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. 

Tools for crimp connections to be found in tool catalog P/N Z001002/0 "Level 4". 

06.00.01 Cable numbers / principal functions: 

15000-xx 

ignition - positive 

(from ignition switch) 

31100-xx 

Do not connect earth for sensors 

with battery-negative! 

15012-xx 

+12 volt via main relay 

and control unit A5 

601xx-01 

Sensor signal to control unit 

A5 and/or instruments. 

15100-xx 

30000-xx 

+5 volt supply voltage for sensors 

battery-positive (not secured) 

606xx-01 

Output from control unit A5 

to display system (tachometer, 

temperature display, ...) 

30012-xx 

battery-positive (secured) 

31000-xx 

battery-negative (GND) 


ToC 



06.01 ALTERNATOR 

06.01.01 Adjust poly-V-belt tension 


Automatic initial tension of belt tension 

through spring-loaded tightener. (ill.1 and ill.2) 

1 

01.01 ill.1 

1 

01.01 ill.2 


As to tension of V-belt for alternator, 

refer to chapter 05.07.01 - 02 




06.01.02 Replace alternator 

Preparatory work: turn off engine, disconnect battery 

1 Disconnect two cables (ill. 1/pos.1+2). 

2 Remove belt. 

1 

2 

3 Loosen screws (ill.2/pos.1+2), remove alternator. 

01.02 ill.1 

NOTE: 


1 

2 


01.02 ill.2 

Connections ill.3/1 B+ battery 

acc. illustration 3: 

ill.3/2 D+ charging control (L1) 

ill.3/3 DF D-field (rotor winding) 

ill.3/4 D+ on governor 

3 

4 

1 

2 

For 4 cyl engines only 

Governor ill.4/1 B- 

acc. illustration 4: 

ill.4/2 DF 

ill.4/3 D+ 

ill.4/4 D+ 

01.02 ill.3 

1 

2 3 

4 

01.02 ill.4 


ToC 



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 ....................................................................................... 90 A 

Governor ............................................................................................... integrated base governor 

Charge capacity 

at 750 r.p.m. .......................................................................................... approx. 34 A 

at 2500 r.p.m ......................................................................................... maximum charge capacity 

Condensor capacity .............................................................................. 2,2 µF 

01.03 ill.1 

Charging circuit - scheme 

1 ...... battery 

2 ..... Z2, ground connection on engine 

3 ..... red 

4 ..... fuse 50 A 

5 ..... starter engine 

6 ..... red 

7 ..... plug (engine electrics/instrument cable) 

8 ..... fuse 10 A 

9 ..... starter key lock 

10 ..... 15000-xx 

11 ..... red 16 mm² 

12 ..... generator 

13 ..... charging controll (L1) 

14 ..... 61000-02 (18-pole connecting cable No.: 11) 

15 ..... relay K10 

16 ..... blocking diode (1N4007) 




For 6 cyl. engines only (old version till eng. no. 68224418) 

circuit diagr.: 

Governor 

01.03 ill.2 

01.03 ill.3 

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. 

Where appropriate, test wiring of cables and connections. 

Check of control voltage and/or alternator voltage: 

NOTE: 

For these works, the battery's state of charge should be 95% at least. 

Check tension of belt on alternator drive and make sure that cables are perfectly connected. 

1. Disconnect all electrical consuming devices and adjust engine to a speed of approx. 1000 rpm. 

2. Connect voltmeter to alternator output "B +". 

3. Remove plastic screw on governor and apply screw driver with fine blade on adjusting screw. 

ATTENTION: 

The adjusting screw has a min./max. stop. There is danger to damage the governor 

when turning by force the adjusting screw so far that it overtravels the specified 

control range. 

4. Turn screwdriver clockwise to increase the operating voltage and/or anticlockwise to lower the 

operating voltage. Adjust voltage range between 14,0 and 14,2 volt (28,0 to 28,4 volt for 24-volt plants). 

ATTENTION: 

Do not turn adjusting screw so far that it overtravels the stop, to prevent 

damages to the governor. 

5. After adjustment, remove screwdriver and voltmeter and lock the governor by means of removed plastic 

screw. 

If voltage cannot be set to specified value, replace governor and/or alternator. 

Check of slip pistons: 

Disconnect battery and/or main switch. 

Unscrew governor. Clean slip ring and wipers; where appropriate, replace wipers. 


ToC 



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 



Governor ............................................................................................... integratedl base governor 

Excitation winding resistance ................................................................ 2,7 / +0,27 

01.03 ill.4 

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 

- Slip ring 

- Internal components of alternator 

No charging voltage: 


- Charging control lamp defective (12V/2W) 

- Output 

- Cables and connections 

- Governor 

- Slip ring 





For 6 cyl. engines / Technical data of alternator 28V / 80A (Option) 

Model ....................................................................................................ISKRA-AAN5161- 11.203.220 






01.03 ill.5 








- Governor 


- Battery 



- Output 

- Governor 

- Slip ring 





- Output 


- Governor 

- Slip ring 



ToC 



For 6 cyl. engines / Technical data of alternator 28V / 55A (Option) 

Model ....................................................................................................ISKRA-AAK5170- 11.201.894 






01.03 ill.6 








- Governor 


- Battery 



- Output 

- Governor 

- Slip ring 





- Output 


- Governor 

- Slip ring 







ToC 



For 4 cyl. engines only / Technical data of alternator 

Model .................................................................................................... BOSCH No. 6 033GB3 046 

Minimum speed for voltage generation ................................................. 550 1/min 




Charge capacity 

at 750 r.p.m. .......................................................................................... ca. 34 A 

at 3000 r.p.m. ........................................................................................ maximum charge capacity 

Condensor capacity .............................................................................. 2,2 µF 

01.03 ill.7 

Charging circuit - scheme 

1 ...... battery 

2 ..... Z2, ground connection on engine 

3 ..... red 

4 ..... fuse 50 A 

5 ..... starter engine 

6 ..... red 

7 ..... plug (engine electrics/instrument cable) 

8 ..... fuse 10 A 

9 ..... starter key lock 

10 ..... 15000-xx 

11 ..... red 16 mm² 

12 ..... generator 

13 ..... charging control (L1) 

14 ..... 61000-02 (18-pole connecting cable Nr.: 11) 

15 ..... blocking diode (1N4007) 












- Governor 


- Battery 



- Output 

- Governor 

- Slip ring 





- Output 


- Governor 

- Slip ring 


Alternator - scheme 

Governor 

01.03 ill.8 


ToC 



06.01.04 Check alternator (error detection for BOSCH alternator, 4 cyl. engines) 

Trouble features 

With engine stopped and ignition on, 

generator control lamp (L1) not 

shining or only slightly. 

Test procedure 

Tester lamp connected between B+ 

and D+ on generator ; shining brightly. 

Tester lamp connected between B+ 

and D+ on generator ; not shining, but 

shining brightly when connected 

between D+ and ground. Generator 

control lamp (L1) does not shine in 

both cases. 

Error and/or Relief 

Generator control lamp (L1) burned 

out and/or disconnection in electric 

circuit of generator control lamp (L1) 

between term. 15 (No. 15000-xx) and 

term. D+ (No. 61000-02) on 

generator. 

Short circuit of a positive diode. 

Immediately disconnect starter 

battery from generator, otherwise 

battery may be discharged on state - 

> replace generator. 

With both engine stopped and 

running, generator lamp (L1) 

constantly shines brightly. 

Tester lamp connected between D+ 

and ground; tester lamp and 

generator control lamp (L1) glowing. 

With engine stopped, disassemble 

attached governor. 

Generator control lamp (L1) still 

shining brightly. 

Generator control lamp (L1) 

extinguishes. Install governor again. 

Connect ammeter between B+ and 

D+ (on generator). Exciting current 

is lower than specified (4 amp 

+/- 0,4). 

Exciting current is higher than 

specified (4 amp +/- 0,4). 

Error, wipers of governor worn out, 

oxid film on slip rings, disconnection 

of rotor winding -> replace governor 

and/or generator. 

Earth short circuit in lead betweeen 

generator control lamp and terminal 

D+ on generator. 

Governor is defective -> replace 

governor. 

Earth short circuit in the field of 

governor and connection DF (see 

ill.) of generator, earth short circuit in 

rotor winding -> replace generator. 

With engine stopped, generator 

control lamp (L1) shines brightly, 

with engine running only shines 

slightly. 

Connect tester lamp between B+ and 

D+ of generator. 

With engine running, tester lamp 

extinguishes. 

With engine running, tester lamp 

glows. 

With engine stopped, install new 

governor and start engine again. 

Tester lamp between B+ und D+ 

Tester lamp extinguishes 

Tester lamp still glows 

Contact resistance in charging circuit 

or in conductor to generator control 

lamp (L1) 

Governor or generator defective. 

Disassembled governor was 

defective. 

Generator is defective -> replace. 




Check rectifier diode 

Measuring devices with diode test function will show 

the following results: 

- in forward direction: voltage drop from 0.4 to 0.6 

volt 

- in backward direction: reading is "OL". 

12-V-Lampe 

+ 12V - 

a) by means of control lamp 

Diode and control lamp are connected in series in 

both forward and backward direction in an electric 

circuit. Diodes permitting passage in both directions 

were mostly exposed to excessive voltages. On the 

other hand, diodes with an interruption in forward 

direction were mostly destroyed by excessive current 

or excessive heating. 

01.04 ill.1 

ill. 04.1 

ill. 04.2 

Lamp burning: diode functional. 

Lamp not burning: diode interrupted. 

Lamp not burning: diode functional, 

Lamp burning: diode had short circuit. 

12-V-Lampe 

+ 12V - 

01.04 ill.2 

b) by means of ohmmeter 

For diode testing, only a simple, battery-powered 

ohmmeter may be used. 

Measuring bridges are unsuitable, as they indicate 

wrong values. Under no circumstances, hand 

generators may be used. Their high voltage would 

destroy the diodes. A perfect diode shows a resistance 

of only a few ohms (0,5 ...10 Ohm) in forward direction, 

but several kiloohms (almost) in backward direction. 


ToC 



06.03 REPLACE STARTER MOTOR 

1 Disconnect battery. 

2 Remove cover of E-box. Remove E-box. 

3 Loosen terminal +30 (ill.2/pos.1) on magnetic switch 

by means of (SW13). 

4 Loosen start signal wiring (terminal 50) (ill.2/pos.2) 

by means of (SW10). 

03.00 ill.1 

5 Loosen two hexagon screws (ill.2/pos.3) (SW13) of 

starter bracket. 

2 

6 Loosen two screws (SW8) (ill.2/pos.4), remove starter. 

1 

03.00 ill.2 

4 

3 

NOTE: 

Have starter motor repaired in an 

authorized STEYR workshop. 

After assembly, coat all electric 

supplies with rubber sealing 

Z909570/0. 




06.03.01 Check starter 

Trouble features 

When switching on the starter 

(acutation of starter key), starter shaft 

not turning or only slowly; starter 

pinion not engaging 

Cause 

battery discharged and/or defective 

terminals of starter battery are loose 

and/or oxidized, bad ground 

connection 

earth short circuit of terminals of 

starter or carbon brushes 

carbon brushes not resting on 

collector (sticking in guide, are 

broken, oily or worn out) 

starter key or starter relay K28 and/or 

actuating relay on starter defective 

Relief 

charge battery and/or replace 

clean terminals and tighten, treat with 

pole grease, provide ground 

connection 

eliminate earth short circuit 

depending on failure, make work 

carbon brushes, clean or replace --> 

in case of very strong wear, replace 

various parts and/or starter 

replace starter key or relay 

voltage drop in lines too large, lines 

damaged, line connections loose, 

links oxidized 

check starter line, eventually replace, 

clean links and tighten 

starter keeps on running after starter 

key was released 

starter does not interrupt; starter key, 

starter relay (K28), actuating relay 

(on starter) defective 

short-circuit in wiring (cable No.: 

50000-xx connected to +12V) 

immediately turn off ignition, 

immediately disconnect battery; 

check key and/or relay, evenutally 

replace; check wiring 

in case of longer running time --> 

replace starter 


ToC 







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. 

Tools for crimp connections to be found in tool catalog P/N Z001002/0 "KIT 3". 

06. 05. 01. Battery cable lengths and cross-sections 

Determine the lenght of the positive cable from the positive pole (+) of the battery to connection No. 

30 at the starter. 

Total lenght is the sum of cable length of positive cable (+) and earth cable (-). 

For example: 

positive cable = 3,0 m 

ground cable = 2,0 m 

----------------------------- 

Total length = 5,0 m ===> cable cross section = 70 mm² 

For ground connection, determine corresponding cross-sections as per chart. 


starter engine: 2 kW - 12 volt 

battery size: 92 AH 

length 

in m 

0,0 - 4,0 

4,1 - 5,0 

5,1 - 6,0 

cable cross-section 

in mm² 

50 

70 

95 

AWG 

0 

00 

0000 


starter engine: 3 kW - 12 Volt 

battery size: 110 AH 

length 

in m 

0,0 - 3,0 

3,1 - 4,5 

4,6 - 5,5 

cable cross-section 

in mm² 

50 

70 

95 

AWG 

0 

00 

0000 

In general, take care that battery cable lengths are kept as short as possible. 


ToC 



06.05.02 E - box base plate; to eng.no.: 482 17 000 

05.02 ill.1 




06.05.02.01 Components of E - box; to eng.no.: 482 17 000 

Designat. Component Description 

A5 E - box control unit 

F1 fuse 50 A main fuse 

F2 fuse 50 A glow plugs 


F4 fuse 5 A permanent current module 

F5 fuse 10 A switched current for module (K27) 

F6 fuse 10 A fuel pump (K24) 

J1 plug 23-pole connection engine cable - instrument cable 

K24 relay fuel pump 

K26-1 relay preheating 

K26-2 realy preheating 

K27 relay main circuit 

K28 relay start assist relay 

X5 plug 35-pole module 

06.05.02.02 Connection start assist relay K28 

05.02 ill.2 

06.05.02.03 Connection relay socket for K24, K26-1, K26-2 and K27 

05.02 ill.3 


ToC 



06.05.02.04 Wiring harness; to eng.no.: 482 17 000 

Designation Component Description 

A5 E-box control unit 




F4 fuse 5 A permanent current modul and K27 



G1 

alternator 

G2 battery to be provided by customer 

J1 23-pole plug connection engine cable - instrument cable 


K26-1 relay preheating - load circuit 



K28 relay start 

M1 

starter 

M2 

fuel pump 

R10 

glow pins 

X2 (S2) 2-pole plug gear switch 

X5 (A5) 35-pole plug module 

X12 (B12) 3-pole plug boost-pressure sensor 

X13 (B13) 5-pole plug pot. accelerator 

X14 (B14) 3-pole plug pot. rack position 

X15(B15) 3-pole plug engine speed sensor 

X16 B(16) 2-pole plug engine temperature sensor 

X17 (B17) 2-pole plug exhaust gas temperature sensor 

X18 (B18) 3-pole plug oil pressure sensor 

X19 (B19) 1-pole plug oil pressure gauge (optional) 

X20 (Y20) 2-pole plug control solenoid 

X22 (B22) without stop trim sensor (optional) 

X23 6-pole plug diagnosis 

Z1 splice spot earth connection sensor 

Z2 splice spot earth connection (31) on engine 

Z3 splice spot sensor supply +5V 

Z4 splice spot earth connection (31) on E-box plate 

Cable numbers / principal functions: 

15000-xx ignition - positive 


15012-xx +12 volt via main relay 

and control unit A5 

15100-xx +5 volt supply voltage for sensors 

30000-xx battery-positive (not secured) 

30012-xx battery-positive (secured) 

31000-xx battery-negative (GND) 

31100-xx 

601xx-01 

606xx-01 

Do not connect earth for sensors 

with battery-negative! 

Sensor signal to control unit 


Output from control unit A5 






05.02 ill.4 Wiring harness; to eng.no.: 482 17 000 


ToC 



Circuit diagram; to eng.no.: 482 17 000 

05.02 ill.5 




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 A K24 relay fuel pump 86 

15000-02 J1 plug engine / instruments B K24 relay fuel pump 86 

15000-03 X5 control unit (A5) 19 K24 relay fuel pump 86 

15012-01 X20 control solenoid(Y20) 1 X5 control unit (A5) 17 

15012-02 X5 control unit (A5) 18 K27 main circuit relay 87 

15012-03 K27 main circuit relay 87 K26/1 relay preheating 86 

15012-04 K26/1 relay preheating 86 K26/2 relay preheating 86 

15012-06 X15 speed sensor (B15) C K26/2 relay preheating 86 

15100-01 X5 control unit (A5) 3 Z3 link (splice) 

15100-02 X13 pot. accelerator (B13) 5 Z3 link (splice) 

15100-05 X12 boost press. sensor(B12) 3 Z3 link (splice) 

15100-06 X14 pot. rack position (B14) C Z3 link (splice) 

15100-07 X18 oil pressure sensor (B18) B Z3 link (splice) 

17415-01 F2 50A fuse glow plugs IN K26/1 relay preheating 87 

17415-02 F3 50A fuse glow plugs IN K26/2 relay preheating 87 

30000-03 K26/1 relay preheating 30 K28 starter relay 30 

30000-04 K26/2 relay preheating 30 K28 starter relay 30 

30000-05 F1 50A main fuse IN starter solenoid 30 

30012-01 X5 control unit (A5) 1 F4 fuse control unit 2 

30012-02 K27 main circuit relay 86 F4 fuse control unit 2 

30012-03 X23 diag 6 K27 main circuit relay 86 

30012-04 K27 main circuit relay 30 F5 fuse control unit 2 

30012-05 F1 50A main fuse OUT F5 fuse control unit 1 

30012-06 F1 50A main fuse OUT F6 fuse fuel pump 1 

30012-07 F1 50A main fuse OUT J1 plug engine / instruments C 

30012-08 F1 50A main fuse OUT J1 plug engine / instruments D 

30012-09 F5 fuse control unit 1 F4 fuse control unit 1 


ToC 






30055-01 K24 relay fuel pump 30 F6 fuse fuel pump 2 

31000-01 J1 plug engine / instruments E Z2 - mass point 

31000-02 J1 plug engine / insruments F Z2 - mass point 32 

31000-03 Z4 earth connection in box X15 speed sensor (B15) 3 

31000-04 fuel pump (M2) (M5)negat. Z2 link (splice) 

31000-05 X23 diag 1 Z2 link (splice) 

31000-06 S4 earth connection in box X5 control unit (A5) 2 

31000-07 X2 gear switch(S2) 2 S2 link (splice) 

31000-08 S4 earth connection in box Z2 earth connection engine 

31100-01 X5 control unit (A5) 20 Z1 link (splice) 



31100-07 X16 ECT (B16) 2 Z1 link (splice) 

31100-08 X12 MAP (B12) 2 Z1 link (splice) 

31100-09 X14 RACK (B14) A Z1 link (splice) 

31100-10 X18 oil pressure sensor (B18) A Z1 link (splice) 

31100-11 X17 sensor exh.gas temp.(B17) 2 Z1 link (splice) 

31409-01 X20 control solenoid (Y20) 2 X5 control unit (A5) 35 

31554-01 K24 relay fuel pump 85 X5 control unit (A5) 22 

31555-01 K26/1 relay preheating 85 X5 control unit (A5) 7 

31555-02 K26/1 relay preheating 85 K26/2 relay preheating 86 

31558-01 K27 main circuit relay 85 X5 control unit (A5) 24 

31615-01 J1 plug engine / instruments H X5 control unit (A5) 6 

50000-01 K28 starter relay 87 X5 control unit (A5) 13 

50000-02 K28 starter relay 86 J1 plug engine / instruments S 

50000-03 K28 starter relay Kl.86 J1 plug engine / instruments T 

60110-01 X12 MAP (B12) 1 X5 control unit (A5) 28 







60111-01 pot. accelerator B13 2 X5 control unit (A5) 12 

60112-01 X14 RACK (B14) B X5 control unit (A5) 11 

60113-01 X15 speed sensor (B15) 2 X5 control unit (A5) 33 

60114-01 X16 ECT (B16) 1 X5 control unit (A5) 9 

60116-01 X13 pot. accelerator (B13) 1 X5 control unit (A5) 30 

60117-01 X18 oil pressure sensor (B18) C X5 control unit (A5) 10 

60118-01 X17 sensor exh.gas temp.(B17) 1 X5 control unit (A5) 27 

60121-01 J1 plug engine / instruments P oil pressure gauge optional 

60122-01 X2 gear switch(S2) 1 X5 control unit (A5) 14 

60412-01 M2 fuel pump (M4)posit. K24 relay fuel pump 87 

60613-01 J1 plug engine / instruments N X5 control unit (A5) 8 

60614-01 J1 plug engine / instruments K X5 control unit (A5) 26 

60616-01 J1 plug engine / instruments G X5 control unit (A5) 25 

60706-01 J1 plug engine / instruments J X5 fixed rotation speed (A5) 29 

60808-01 Z 5 60808 X5 control unit (A5) 32 

60808-02 Z 5 60808 J1 plug engine / instruments M 

60808-03 Z 5 60808 X23 diag 2 

60810-01 J1 plug engine / instruments R X5 control unit (A5) 23 

60900-01 X23 diag 5 X5 control unit (A5) 15 

60901-01 X23 diag 4 X5 control unit (A5) 16 

61000-02 alternator D+ D+ J1 plug engine / instruments L 

network shield B15 S4 earth connection E-box 

Z 5 

was only built up for wiring harnesses up to engine No. 48217020 (no function), 

J1 / M on panel wiring harness „ free „. 


ToC 



06.05.03 E - box base plate; from eng. no.: 482 18 000 / 682 18 000 + SOLAS 

05.03 ill.1 




06.05.03.01 Components of E-box; from eng. no.: 482 18 000 / 682 18 000 + SOLAS 


A5 E - box control unit 




F4 fuse 5 A permanent current module 


F6 fuse 10 A fuel pump 

J1 plug 23-pole connection engine cable - instrument cable 


K26-1 relay preheating 

K26-2 realy preheating 



X3 plug 2-pole inversion switch (for SOLAS only) 

S3 inversion switch (for SOLAS only) 

X5 plug 35-pole module 

06.05.03.02 Connection relay K28 and K26/2 

05.03 ill.2 

06.05.03.03 Connection relay socket for K24, K26-1 and K27 

05.03 ill.3 


ToC 



06.05.03.04 Wiring harness; from eng.no.: 482 18 000 / 682 18 000 + SOLAS 

Designation Component Description 

A5 E-Box control unit 




F4 fuse 5 A permanent current modul and K27 



F7 fuse 10 A preheating - control circuit 

G1 

alternator 

G2 battery to be provided by customer 

J1 plug 23--pole connection engine cable - instrument cable 


K26-1 relay preheating - control circuit 




M1 

starter 

M2 

fuel pump 

R10 

glow pins 

X2 (S2) plug 2-pole gears switch 

X3 (S3) plug 2-pole inversion switch ( only SOLAS) 

X5 (A5) plug 35-pole module 

X12 (B12) plug 3-pole boost-pressure sensor 

X13 (B13) plug 5-pole potentiometer accelerator 

X14 (B14) plug 3-pole pot. rack position 

X15(B15) plug 3-pole engine speed sensor 

X16 B(16) plug 2-pole engine temperature sensor 

X17 (B17) plug 2-pole exhaust gas temperature sensor 

X18 (B18) plug 3-pole oil pressure sensor 

X19 (B19) plug 1-pole oil pressure gauge (optional) 

X20 (Y20) plug 2-pole control solenoid 

X22 (B22) without stop trim sensor (optional) 

X23 plug 6-pole diagnosis 

X26 (Y26) plug 2-pole disconnection blow-by (only SOLAS) 

Z1 splice spot earth connection sensor 

Z2 splice spot earth connection (31) on engine 

Z3 splice spot sensor supply +5V 

Z4 splice spot earth connection (31) on E-box plate 

Z6 splice spot shield speed sensor line 

Cable numbers / principal functions: 

15000-xx ignition - positive 


15012-xx +12 volt via main relay 

and modulator unit A5 

15100-xx +5 volt supply voltage for sensors 

30000-xx battery-positive (not secured) 

30012-xx battery-positive (secured) 

31000-xx battery negative (GND) 

31100-xx 

601xx-01 

606xx-01 

Do not connect mass for sensors 

with battery negative! 

Sensor signal to modulator unit 


Exit from modulator unit A5 






Wiring harness; 

from eng.no.: 

482 18 000 + SOLAS 

682 18 000 + SOLAS 

05.03 ill.4 


L 

J 

T 

6 

5 

4 

2 

3 

1 

23 

A 

ToC 



X 

K W 

V 

H 

B 

U 

M 

C 

A G 

N D E F 

S 

O 

P R 

Q 

STARTER 

J1 

X23 

6 

54 

1 

WIRING DIAGRAM / MARINE BASE - 4/6 CYLINDER - 12V 

Batt + 

Batt - 

Ign 15 

Supplied by Relais 

Sens ECU 

Control ECU 

DIAG 

Start 

Charge D+ 

Sens 5V 

Sens - 

B+ 24V 

CAN 

CONNECTOR "A5" (ENGINE-CONTROL-UNIT) 

Wiring LPS / All engines before 2007 

EXT 

Wiring MAP / All engines before 2007 

EXCEPTIONS: 

ONLY FOR TYP: 

MO 164M40 

MO 174V40 

MO 246K41 

MO 256H45 

MO 256K43 

MO 266K43 

61001-02 

60901-03 

60900-03 

Z5 

60900-02 

Z6 60901-02 

60123-01 

31000-11 

Optional 

24V DC 

D+ B+ 

J1 / U 

A 

J1 / V 

5 CAN "H" 

4 CAN "L" 

X3/S3 Invers 

X3/S3 Solas 

X3 

31100-08 

15100-05 

60110-01 

60110-01 


60 

123 

-01 

WS 

60808-01 ISO 

60900-01 CAN-H 

60901-01 CAN-L 

R10/5 

R10/1 

6 CYL. 

R10/2 

4 CYL. 

R10/3 

R10/4 

4 CYL. 

R10/6 

6 CYL. 

2179349/0-02-070118_tedoc 

31100-10 

15100-07 

60117-01 

ALL ENGINE 

TYPES WITH 

FOLLOWING 

EXCEPTIONS 

31100-08 

15100-05 

05.03 ill.5 


L 

J 

6 

5 

4 

2 

3 

1 

23 



X 

K W 

V 

H 

B 

U 

M 

C 

A G 

N D E F T 

S 

O 

P R 

Q 

STARTER 

Z5 

60900-02 

Z6 60901-02 

J1 

X23 

6 

54 

1 

WIRING DIAGRAM / MARINE - 6 CYLINDER - 24V (OPTION) 

Batt + 

Batt - 

Ign 15 


Sens ECU 

Control ECU 

DIAG 

Start 

Charge D+ 

Sens 5V 

Sens - 

B+ 24V 

Fuel Pump 

Relay 

K24 

Main 

Relay 

K27 

Preheating 

Control Relay 

K26/1 

Preheating 

Load Relay 

A 

K26/2 

Control 

Solenoid 

Y20 

Start 

Relay 

K28 

Trim-Sensor 

(Option) 

B22 

M2 

F8 - 5 A 

Fuel 

Pump 

G2 

CONNECTOR "A5" (ELECTRONIC-CONTROL-UNIT) 

AUX 

LPS ECT 

EXT 

A 


LPS 

Map 

B18 

B12 

ECT EXT 

PED 

RPOS 

RPM 

B15 

B16 B17 

B13 

B14 


60 

123 

-01 

WS 

Gear 

Switch 

S2 

60808-01 ISO 

60900-01 CAN-H 

60901-01 CAN-L 

Sensor Oil 

Pressure 

Gauge 

(Option) 

B19 

60120-01 

61001-02 

60901-03 

60900-03 

J1 / U 

J1 / V 

60120-01 

5 CAN "H" 

4 CAN "L" 

60123-01 

31000-11 

X3/1 Invers 

X3/2 Solas 

F8 

61001-01 

Batt + / 24V 

D+ B+ 

B- 

Batt - / 24 V 

R10 

S3 

G1 

2179345/0-02-070118_tedoc 

31100-10 

15100-07 

60117-01 


ALL ENGINE 

TYPES WITH 

FOLLOWING 

EXCEPTIONS 

EXCEPTIONS: 

ONLY FOR TYP: 

MO 164M40 

MO 174V40 

MO 246K41 

MO 256H45 

MO 256K43 

MO 266K43 

31100-08 

15100-05 

31100-08 

15100-05 

60110-01 

60110-01 

05.03 ill.6 


ToC 



WIRING DIAGRAM / MARINE - 4/6 CYLINDER - 2-POLE - 12V (OPTION) 

Batt + 

Batt - 

Ign 15 


Sens ECU 

Control ECU 

DIAG 

Start 

Charge D+ 

Sens 5V 

Sens - 

B+ 24V 

CAN 

60808-01 ISO 

60 

123 

-01 

WS 

60900-01 CAN-H 

60901-01 CAN-L 



Z6 

Z5 

60900-02 

60901-02 

R10/5 

R10/1 

R10/2 

R10/3 

R10/4 

R10/6 

6 CYL. 

4 CYL. 

4 CYL. 

A 

6 CYL. 

A 

2179350/0-02-070118_tedoc 

31100-10 

15100-07 

60117-01 


ALL ENGINE 

TYPES WITH 

FOLLOWING 

EXCEPTIONS 

EXCEPTIONS: 

ONLY FOR TYP: 

MO 164M40 

MO 174V40 

MO 246K41 

MO 256H45 

MO 256K43 

MO 266K43 

31100-08 

15100-05 

31100-08 

15100-05 

60110-01 

60110-01 

05.03 ill.7 




Batt + 

Batt - 

Ign 15 


Sens ECU 

Control ECU 

DIAG 

Start 

Charge D+ 

Sens 5V 

Sens - 

B+ 24V 

CAN 



60 

123 

-01 

WS 

60808-01 ISO 

60900-01 CAN-H 

60901-01 CAN-L 

Z6 

Z5 

60900-02 

60901-02 

R10/5 

R10/1 

R10/2 

A 

R10/3 

R10/4 

R10/6 

A 

2179351/0-02-070118_tedoc 

31100-10 

15100-07 

31100-08 

15100-05 

60117-01 


ALL ENGINE 

TYPES WITH 

FOLLOWING 

EXCEPTIONS 

EXCEPTIONS: 

ONLY FOR TYP: 

MO 164M40 

MO 174V40 

MO 246K41 

MO 256H45 

MO 256K43 

MO 266K43 

60110-01 

31100-08 

15100-05 

60110-01 

05.03 ill.8 


ToC 



06.06 ELECTRONICS - GENERAL 

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. 

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. 

* self-diagnostic to protect the engine from damage if operating parameter are exceeded. 

* stores diagnostic data of EMS server circuits for maintenance and service. 

Engine power is reduced if: 


Effect 

noticed 

Panel 

Indication 

Additional 

Tool-Readings 

Action or 


High engine coolant 

temperature 


Reduction of 

engine speed 



107 °C 

Steyr Diag 



shooting: 


Defect - engine coolant 

sensor or 


Reduction of 

engine speed 



120 °C 

Steyr Diag 

Service code 



code table 

Exhaust temperature 


Reduction of 

engine speed 



p. sec. 

Steyr Diag 



shooting: Raw water 


Defect - Exhaust 

temperature sensor or 


Reduction of 

engine speed 



p. sec. 

Steyr Diag 

Service code 



code table 

Oil pressure below limit 

Reduction of 

engine speed 

Horn continuos and 

Oil indication light 

continuos switched 

ON 

Steyr Diag 



shooting: 

Engine oil system 

Defect - Oil pressure 

sensor or sensor 

connection 

Reduction of 

engine speed 

Oil pressure indication 

light switched ON 1x 

p. sec. 

Steyr Diag 

Service code 



code table 

Insufficient boost 

pressure or defictive 

sensor 

Reduction of 

engine speed 

Steyr Diag 



shooting: 

Air charge system 





Effect 

noticed 

Panel 

Indication 

Additional 

Tool-Readings 

Action or 


Engine speed sensor 

fault 

Higher or 

unstable idle 

speed, limited 

performance 

No RPM inication 

on tachometer 

Steyr Diag 

Service code 


shooting: 

Speed sensor 

Engine speed remains 

at idle 

No increase of 

engine speed if 

throttle is moved 

to max. 

Steyr Diag 

Service code 


shooting: 

Accelerator 

potentiometer failure 

Governor position 

system 

Irregular engine 

speed or stalled 

engine 

Steyr Diag 

Service code 


shooting: 

Governing system 

Inverse position shut 

down (SOLAS) 

Engine shut 

down beyond 

70° deg. angle 

After engine stop 

horn remains 

switched ON until 

ignition reset 

Reset through ignition 

OFF and then ON 

During break in phase 

Cel-ON at high 

accelerator 

position (more 

than 75%) 

Indication light 

"CEL" is switched 

ON 

Steyr Diag 

Break-in 

phase 

See information break 

in procedure 

Optical and audible warning signals as shown on the dash board, are illustrated in chapter "Operating Status 

and Error Report" 

06.06.02 Diagnostic system 

The electronic engine management system controls the following parameters: 

Oil pressure, boost pressure, coolant temperature, hi-riser (bend) temperature. 

The electronic engine management system has an automatic self-test program checking all data 

of electronic sensors. As soon as a fault is found, there is an optical or audible signal (refer to chart 

"Error Codes"). 

Occurred faults remain stored until cancellation. Stored faults may be selected, analyzed and 

cancelled by means of PC via diagnostic outlet. 

A reference to one or several stored faults is the 5 second "TESTING" of the "CHECK-ENGINE 

LAMP" and the "WARNING HORN" after ignition ON, instead of usual 0,7 seconds. (refer to chart 

"Operating Status") 

On the CHECK-ENGINE lamp (E) stored faults may be indicated by flashing codes. (With a 

special procedure, (06.06.04) individual cancellation is possible.) Error codes are regarded both as 

flashing codes as will as display by diagnostic instrument. 

There are three fault categories: temporary faults, non essential faults and essential faults. 


ToC 



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. 

In case this tool is not available: 

Connect temporarily Pin - Pos. 1 with Pin - Pos. 2 

of Diagnostic Plug X 23 

( before ignition is turned on at key switch ) 

Code indication and indication sequence: 

06.03 ill.1 

After entering the error code indication modus the Engine 

Management System will display a blink code at the Check Engine Light on the dash panel. 

The blinking sequence will always begin and end with control code indication # 12. Each ERROR CODE will be 

repeated 3 times to reassure your correct reading – see below bar code illustration. 

Example sequence check engine light (ill.2/pos.1): 

Error code # 14 

1 

06.03 ill.2 

06.03 ill.3 

Stroke = Check Engine Light illuminated for 0,3 sec. (Light Off - period within blink sequence 0,4 sec.) 

Dashed Line = interruption within code indication 1,5 sec. 

Solid Line = interval interruption between error code 3,0 sec. 




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. 

For a description of the possible error codes refer to enclosed Table – Error Codes 

ATTENTION: To exit from Error code indication. Tool VR00135/1 must be removed 

( connection between Pin 1 to Pin 2 opened ) before ignition is turned ON again. 

06.06.04 Indication and Cancellation of memorized sensor and circuit faults 

Selection and clearing of stored error codes: 

Procedure: 

* Ignition — OFF 

* Connect Tool VR00135/1 to Diagnostic Outlet Plug ( X 23 ) – see 06.03 ill.1 

* Ignition — ON 

Note: The program changes automatically to indication of error codes. 

If no error code is stored, only repeating control code reading “ CODE # 12 “ will be displayed. 

Possible memorized codes are indicated as shown in the previous illustrated example ( blinking 3x 

CODE # 12 i. e. 3x ERROR CODE # 14 etc. ) The sequence will be prolonged with additional codes if more 

then one ERROR CODE is stored. 

See Table – ERROR CODES for description 

* To delete a determined ERROR CODE from the Engine Management System concentrate for the 3 rd times 

flashing the desired ERROR CODE. While this ERROR CODE is displayed the third time the button ( Tool 

VR00135/1 ) must be pushed and kept in this position ( contact open ). 

* The indication on the Check Engine Light changes to a fast blinking of the lamp ( app. 4 times per 

sec. ). During this rapid flashing light the push button must be released ( close contact after app. 2 

sec.) to delete this ERROR CODE. 

Note: Any other ERROR CODE have to be selected and cleared individually following the above 

mentioned procedure to delete a determined ERROR CODE. 

Note: An ERROR CODE can only be deleted if no defect exists in this circuit. In case of a present active 

failure, the ERROR CODE keeps reappearing until the problem has been repaired and the circuit is 

properly working again. 

* Disconnect Tool VR00135/1 from Diagnostic Outlet Plug ( X 23 ) to exit from error code display. 

Note: Watch indication of the Check Engine Light and the Warning Horn after ignition contact. If all 

ERROR CODES are deleted from the Engine Management System the indication resumes to 0.7 sec. 

function test of Check Engine Light and the Warning Horn. 

For more details see Chart – Operating Conditions - Instrument panel. 


ToC 



06.06.05 Principle failure code list 

NOTE: Some codes may not apply due to different application! 

REFER 

TO 

CODE ABBREV. CIRCUIT INVOLVED DEVICE POSSIBLE CAUSE 

12 

Control code 

this code is designated for beginning or end of loop 

13 

LoMap 

X12/B12 

boost pressure sensor 

signal level too low (short circuit or missing contact) 

14 

HiMap 

X12/B12 

boost pressure sensor 

signal level too high (missing connection) 

17 

LoEXH 

X17/B17 

air charge temp. sensor 


18 

HiEXH 

X17/B17 

air charge temp. sensor 


21 

LoECT 

X16/B16 

water temp. sensor 


22 

HiECT 

X16/B16 

water temp. sensor 


23 

LoPed1 

X13/B13 

potentiometer accelerator 

signal level entry too low 

24 

HiPed1 

X13/B13 


signal level entry too high 

25 

LoVPWR 

F5/K27 

main relay 

low voltage supply to ECU, F5, K27 

26 

HiVPWR 

F5/K27 

main relay 

too high voltage on VPROT input 

27 

LoVREF 

X5/Z3 

module, connector 

too low voltage on sensor supply, possible short circuit 

28 

HiVREF 

X5/Z1 

module, connector 

too high voltage on sensor supply 

29 

PedS 

X13/B13 

accelerator potentiometer 

defect on pedal safety switch, pin 1-2 

31 

LoLPS 

X18/B18 

lubricant pressure sensor 


32 

HiLPS 

X18/B18 



33 

LoPed2 

X13/B13 


signal level too low 

34 

HiPed2 

X13/B13 



35 

LoRPos 

X14/B14 

rack position sensor 


36 

HiRPos 

X14/B14 



37 

LoLOP 

X18/B18 


signal level too low (short circuit) 

38 

HiLOP 

X18/B18 



53 

N_RFI 

X15/B15 

RPM-sensor 

radio interference / sensor input 

54 

BadSta 

M1-Pin50 

K28 start assist relay 

no start signal from assist solenoid 

55 

NoPuls 

X15/B15 

RPM-sensor 

no speed signal during crank 

56 

Srpos 

Y14(B14) 

refer to setting rack pos. 

rack calibration bad/rack position outside tolerance field 




CODE 

ABBREV. 

REFER 

TO 

CIRCUIT INVOLVED DEVICE POSSIBLE CAUSE 

57 

Rack0 

Y14(B14) 

refer to setting rack pos. 

bad rack zero position 

99 

161 

FMSpwm 

HiVTGc 

X20/Y20 

Y28 

actuator / solenoid 

REA unit at turbo charger 

defect in governor solenoid wire circuit (Y20, main 

relay K27-no frequency sent or govenor solenoid 

circuit connected) 

defect in circuit of actuator turbo charger (short circuit) 

162 

LoVTGc 

Y28 


defect in circuit of actuator turbo charger (missing connection) 

164 

CELs 

L2 

check engine lamp 

Current limit exceeded (short circuit) 

165 

CELo 

L2 

check engine lamp 

missing connection or bulb blown 

167 

FPR_s 

K24 

fuel pump relay 

Current limit exceeded in relay circuit (short circuit) 

168 

FPR_o 

K24 

fuel pump relay 

no current detected in relay circuit (disconnection) 

177 

MR_s 

K27 

main relay 

no current detected in main relay circuit (short circuit) 

178 

MR_o 

K27 

main relay 

no current detected in main relay circuit (disconnection) 

181 

WarnLs 

L3 

oil pressure lamp 

Current limit exceeded (short circuit) 

182 

WarnLo 

L3 

oil pressure lamp 

no current in circuit of oil pressure lamp 

186 

BadPos 

Y20 

governor solenoid 

Nominal-actual value difference (rack pos. error, rack jammed) 

187 

HiFMSC 

X20/X20 


defect in governor wire circuit (resistance too high) 

(bulb blown or missing connection) 

188 

LoFMSc 

X20 


defect in governor wire circuit (resistance too low) 

193 

VTG_Bad 

Y28 


defect in output circuit (short circuit or missing connection) 

194 

GPR_s 

K26 

glow assist relay 

current limit exceeded in glow plug relay circuit (short circuit) 

195 

GPR_o 

K26 

glow assist relay 

no current detected in glow plug relay circuit (disconnection) 

201 

HiTEMP 

-- 

operation limit exceeded - 

engine overheated 

engine was operated with too high coolant temperature 

202 

Lop 

-- 


lubricant pressure too low 

engine was operated with too low lubricant pressure 

203 

Manop 

-- 


rack position too high 

engine operated with manual movement of rack 

251 

ITSL_Bad 

B30 

position sensor - ITD 

signal level too low (short circuit) on injection timing sensor 

252 

ITV_LoCur 

Y29 

proportional valve - ITD 

defect in circuit of valve (no current flow) 

253 

ITV_HiCur 

Y29 

proportional valve - ITD 

defect in circuit of valve (current value too high) 

254 

SpvP_Bad 

B30 

position sensor or ITD 

commanded timing position can not be achieved 

(sensor or injection timing device defect, eccenter 

shaft jammed) 

255 

Spv_INI 

B30 

reference-position 

sensor ITD 

timing position calibration bad (position out of tolercance) 


ToC 



06.06.06 REPLACE FUSES 

Preparatory works: 

Engine out of operation, 

disconnect battery. 

Replace automatic circuit breaker 

1 Swing off E-box base plate. 

2 Disconnect cable from automatic circuit breaker. 

3 Loosen 2 hexagon screws (ill.1/pos.1) (SW1/4") and 

take off thermal circuit breaker (ill.1/pos.2). 

3 

2 

NOTE: 

For assembly, seal cable screw 

connections with rubber varnish. 

06.06 ill.1 

1 

Replace fuses 

1 Remove E-box cover. 

2 Remove fuse protection cap. 

Pull out fuses (ill.1/pos.3) 

Replace defect fuse. 




06.06.07 Connection J1 

06.07 ill.1 

Pin Cable - no. Explication 

A 15000-01 ignition 15 

B 15000-02 ignition 15 

C 30012-07 terminal 30 

D 30012-08 terminal 30 

E 31000-01 ground connection 

F 31000-02 ground connection 

G 60616-01 lamp - oil pressure L3 

H 31615-01 warning horn 

J 60706-01 const. speed switch 

K 60614-01 temperature display 

L 61000-02 alternator D+ 

M 

blind plug 

N 60613-01 tachometer (speed) 

O 60121-01 oil pressure gauge (optional) 

P 60810-01 check engine lamp 

Q 50000-02 ignition lock start 

R 50000-03 ignition lock start 

S 60120-01 trim (optional) 

T 61001-02 alternator B+ 24V DC (ifused) 

U 60901-03 CAN-low 

V 60900-03 CAN-high 

W 

blind plug 

X 

blind plug 


ToC 



06.06.08 Connection A5 and X5 

06.08 ill.1 

Pin Cable no. Designation Explication 

1 30012 / 01 Vbat terminal 30 

2 31000 / 06 GND terminal 31 

3 15100 / 01 Vref + 5V 

4 free free not busy 


6 60616 / 01 GPL oil pressure lamp L3 

7 31555 / 01 GPR preheating relay 

8 60613 / 01 Tacho speed instrument 

9 60114 / 01 ECT engine coolant temperature sensor 

10 60117 / 01 LPS oil pressure sensor 

11 60112 / 01 RPOS pot. rack position 

12 60111 / 01 PED1 pedal 1 

13 50000 / 01 CRI start signal identification 

14 60122 / 01 CLS gear switch 

15 60900 / 01 CANH canbus high 

16 60901 / 01 CANL canbus low 

17 15012 / 01 VPROT2 direct supply line to control solenoid 

18 15012 / 02 VPROT protected 12V (after K27 and protective 

wiring in governor) 

19 15000 / 03 IGN ignition terminal 15 

20 31100 / 01 Gnd Vref sensor ground connection 


22 31554 / 01 FPR fuel pump relay 

23 60810 / 01 CEL check engine lamp 

24 31558 / 01 MR main relay (K27) 

25 31615 / 01 WOUT warning horn 

26 60614 / 01 TEMP temperature display 

27 60118 / 01 EXT exhaust gas water temperature 

28 60110 / 01 MAP boost pressure sensor 

29 60706 / 01 AUX fixed speed 

30 60116 / 01 PED2 pedal 2 

31 60123 / 01 WS warning switch / Solas inversion switch 

32 60808 / 01 ISO ISO 9141 (diag. cable) 

33 60113 / 01 RPM engine speed sensor 


35 31409 / 01 FMS approach line for control solenoid 




06.06.09 Fitting main connector "J1" properly 

" J1" Fitting Main Connector - M1 / 01 


ToC 



06. 07. INSTRUMENT PANEL 

B A H 

C 

D 

E 

G 

I 

F 

07.00 ill.1 

Instrument panel, standard 

A tachometer G blind plug - installation option for 

B engine temperature key switch constant revolution 

C warning light - battery charge H blind plug - installation option for 

D combined light preheating control & oil pressure gauge or 

warning light engine oil pressure 

voltmeter 12V 

E warning light check engine I audible warner 

F ignition key lock (installed to rear side of paneel) 




06. 07. 01 Chart - Operating Status 

Instrument indication during normal operation 

1. ignition ON (... until engine start) 

07.01 ill.1 

light indication 

ON 

ON (0,7 sec.) 

ON (0,7 sec.) 

ON (0,7 sec.) 

System check - see light indication 

NOTE: 

At low temperature condition (cold weather) 

the combined light for glow plug preheating & 

warning light engine oil pressure will not 

extinguish after 0,7 sec. (glow plug preheating 

phase) 

In this case start engine immediately after the 

light extinguishes. 


light indication 

ON 

Indication active error 

ON (0,7 sec.) 

ON (5 sec.) 

07.01 ill.2 

ON (5 sec.) 

3. engine running after start 

OFF 

Normal condition 

OFF 

OFF 

07.01 ill.3 

OFF 

NOTE: 

Further information see: 

"Table - Error indication on Instrument 

Panel" 


ToC 



06. 07. 02 Chart - Error indication on Instrument Panel 

A 

C 

D 

E 

B 

07.02 ill.1 

A temperature gauge - coolant D combined light preheating control & 

B audible warner warning light engine oil pressure 

C warning light - battery charge E warning light check engine 

Operating condition: During normale engine operation, or indication in case of sensor defect while 

ignition is switched ON. 

Event: Speed resp. performance limitation during engine operation 

Indication status 

80° - 90°C 

Fault 

Remarks 

OFF 

oil pressure below min. 

limit 

check oil level 

ON 

ON 

07.02 ill.2 

OFF 

80° - 90°C 

OFF 

OFF 

FLASHING 

(1x per sec.) 

fault oil pressure 

sensor or 


check oil pressure sensor 

(B18) and connection 

OFF 

07.02 ill.3 

NOTE: (see cap. general, D3) 

ON 

ON 

engine overload during 

break-in period 

reduce throttle position 

until light goes OFF 

(indication during first 2 

hours of operation) 




Fault 

ELECTRICAL SYSTEM 

Remarks 

80° - 90°C 

ON 

OFF 

OFF 

high exhaust 

temperature 

(off 80° C) 

check raw water 

system, 

strainer, impeller pump 

(2x per sec.) 

FLASHING 

(2x per sec.) 

07.02 ill.4 

high approx 105°C 

ON 

OFF 

OFF 

engine coolant 

temperature to high 

after cooling down, 

check engine coolant 

level 

OFF 

(2x per sec.) 

07.02 ill.5 

120°C 

ON 

OFF 

OFF 

defect engine coolant 

sensor or 




level, sensor (B16) 

and connection 

OFF 

(2x per sec.) 

07.02 ill.6 

80° - 90°C 

OFF 

instable idle speed, 

no indication on 

tachometer 

defect speed sensor (B15) 

or 


OFF 

OFF 

OFF 

07.02 ill.7 

80° - 90°C 

ON 

OFF 

OFF 

ON 

Trouble in governing loop, 

involved components: 

control solenoid, rack, 

control gear of 



Failure in governing loop: 

time limit exceed for rack 

positioning. Restriction 

or high friction in control 

devices.Stored failure code 

must be cleared memory. 

Tool: PC-service program 

07.02 ill.8 


ToC 




Fault 

Remarks 

During start attempt 

ON 

ON 

OFF 

ON 

Engine will not start. 

Failure in governing 

circuit 

Failure in governing circuit. 

Positioning of rack 

not possible. 

Trouble shooting of control 

solenoid, rack, control gear 

of unit injection, 


07.02 ill.9 






ToC 



06.07.03 Instrument panel (for SOLAS only) 

A 

B 

F 

G 

I 

J 

C 

D 

E 

H 

07.03 ill.1 

A tachometer with G push button START (green) 

service hour meter 

B temperature gauge - coolant H blind plug - installation option for 

C warning light - battery charge oil pressure gauge or 

D combined light preheating control & voltmeter 12V 

warning light engine oil pressure 

E warning light - check engine light I emergency cut off switch 

F push button - ignition ON/OFF (red) J audible warning device 

(installed to rear side of panel) 

NOTE: 

Instrument gauges are automatically illuminated if ignition is turned ON. 

NOTE: 

In case an inversion occured, the engine gets shut down automatically to re-establish regular 

running and operation the push button Ignition (F) must be switched OFF and then ON again and 

engine must be restarted with push button START (G). 




06.07.04 Chart - Operating Status (for SOLAS only) 

Instrument indication during normal operation 


07.04 ill.1 

System check - see light indication 

NOTE: 

At low temperature condition (cold weather) 

the combined light for glow plug preheating & 

warning light engine oil pressure will not 

extinguish after 0,7 sec. (glow plug preheating 

phase) 

In this case start engine immediately after the 

light extinguishes. 

ON 

ON (0,7 sec.) 

ON (0,7 sec.) 

ON (0,7 sec.) 


07.04 ill.2 

Indication active error 

ON 

ON (0,7 sec.) 

ON (5 sec.) 

ON (5 sec.) 

3. engine running after start 

07.04 ill.3 

Normal condition 

OFF 

NOTE: 

Further information see: 

"Table - Error indication on 

Instrument Panel" 


ToC 



06.07.05 Error Indication - Error indication on instrument panel 

(for SOLAS only) 

A 

B 

C 

D 

E 

07.05 ill.1 

A temperature gauge - coolant D combined light preheating control & 

B audible warning device warning light engine oil pressure 

C warning light - battery charge E warning light - check engine light 

Operating condition: During normal engine operation, 

or indication in case of sensor defect while ignition is switched ON. 

Event: 

Speed resp. performance limitation during engine operation 


Fault 

Remarks 

ON 

80° - 90°C 

oil pressure below min. 

limit 

check oil level 

OFF 

07.05 ill.2 

OFF 

ON 

OFF 

80° - 90°C 

fault oil pressure 

sensor or 


check oil pressure sensor 

(B18) and connection 

OFF 

07.05 ill.3 

FLASHING 

(1x per sec.) 

NOTE: (see cap. general, D3) 

ON 

ON 

OFF 

engine overload during 

break-in period 

reduce throttle position until light 

goes OFF (indication during first 2 

hours of operation) 




Fault 


Remarks 

ON 

(2x per sec.) 

80° - 90°C 

high exhaust 

temperature 

(off 80° C) 

check raw water 

system, 

strainer, impeller pump 

OFF 

07.05 ill.4 

OFF FLASHING 

(2x per sec.) 

ON high approx 105°C 

(2x per sec.) 


temperature to high 



level 

OFF OFF OFF 

07.05 ill.5 

ON 

120°C 

(2x per sec.) 

defect engine coolant 

sensor or 




level, sensor (B16) 

and connection 

OFF OFF OFF 

07.05 ill.6 

OFF 

80° - 90°C 

instable idle speed, 

no indication on 

tachometer 

defect speed sensor (B15) 

or 


OFF OFF OFF 

07.05 ill.7 

ON 

80° - 90°C 

OFF OFF ON 

07.05 ill.8 

Trouble in governing loop, 

involved components: 

control solenoid, rack, 

control gear of 



Failure in governing loop: 

time limit exceed for rack 

positioning. Restriction 

or high friction in control 

devices.Stored failure code 

must be cleared memory. 

Tools: PC-service program 


ToC 



During start attempt 

ON 

ON OFF ON 

07.05 ill.9 

Fault 

Engine will not start. 

Failure in governing 

circuit 


Remarks 

Failure in governing circuit. 

Positioning of rack 

not possible. 

Trouble shooting of control 

solenoid, rack, control gear 

of unit injection, 







ToC 



06. 07. 10 6 Cyl. Wiring harness instrument panel (if alternator "PRESTOLITE" is 

used - old version) 


F9 

fuse 

J1 23-pin plug connection engine cable - instrument cable 

S1 switch ignition 

S7 switch fix-n (speed-selector switch optional) 

K10 relay charge control (90A PRESTOLITE) 

L1 lamp charge control 

L2 lamp cel - check engine lamp 

L3 lamp oil pressure / pre-heating control 

P1 gauge coolant 

P2 gauge oil pressure (optional) 

P3 gauge tachometer with running-time meter 

P4 gauge trim (optional) 

H22 

warning horn 

XS8 1-pin plug to lighting switch - instrument panel 

XS9 2-pin plug charging control/relay charging control (wiring harness side) 

XS10 2-pin plug charging control/relay charging control (instrument side) 

X1/S1 4-pin plug ignition 

X2/L1 10-pin plug charge control lamp 

X3/L2 10-pin plug cel - check engine lamp 

X4/L3 10-pin plug oil pressure warning lamp 

X5/E10 2-pin plug lighting coolant display 

X6/P1 3-pin plug coolant temperature gauge 

X7/E11 2-pin plug lighting oil pressure 

X8/P2 3-pin plug oil pressure gauge 

X9/S7 10-pin plug speed-selector switch (optional) 

X11/P3/E12 8-pin plug speed instrument / lighting speed instrument 

X12/E13 2-pin plug lighting trim (optional) 

X22/P4 3-pin plug trim (optional) 




6 Cyl. Wiring harness instrument panel (if alternator "PRESTOLITE" is 


07.10 ill.1 


ToC 






F9 

fuse 


S1 switch ignition 

S7 switch fix-n (speed-selector switch optional) 

K10 relay charge control (90A PRESTOLITE) 



L3 lamp oil pressure / pre-heating control 

P1 gauge coolant 



P4 gauge trim (optional) 

H22 

warning horn 

XS8 1-pin plug to lighting switch - instrument panel 

XS9 2-pin plug charging control/relay charging control (wiring harness side) 

XS10 2-pin plug charging control/relay charging control (instrument side) 

X1/S1 4-pin plug ignition 

X2/L1 10-pin plug charge control lamp 

X3/L2 10-pin plug cel - check engine lamp 

X4/L3 10-pin plug oil pressure warning lamp 

X5/E10 2-pin plug lighting coolant display 

X6/P1 3-pin plug coolant temperature gauge 

X7/E11 2-pin plug lighting oil pressure 

X8/P2 3-pin plug oil pressure gauge 

X9/S7 10-pin plug speed-selector switch (optional) 

X11/P3/E12 8-pin plug speed instrument / lighting speed instrument 

X12/E13 2-pin plug lighting trim (optional) 

X22/P4 3-pin plug trim (optional) 






07.10 ill.2 


ToC 



06. 07. 11 Description - Wiring harness instrument panels 4/6 cyl. marine engines 

(current version) 


F9 

fuse 10 A 


S1 switch ignition (red) 

S2 switch start (green) 

S3 switch emergency cut off (orange) 

S7 switch key switch constant revolution (optional) 



L3 lamp oil pressure / preheating conrol 

P1 gauge engine coolant temperature 



H22 

warning horn 

E10 lighting engine coolant temperature gauge 

E11 lighting oil pressure gauge (optional) 

E12 lighting tachometer gauge 

X8 1-pin plug connector illumination switch 

X24 8-pin plug connector STEYR - display 

Z1 splice battery + 

Z2 splice battery - 

Z3 splice ignition (+) 

Z4 splice key switch constant revolution 

24 V interm. cable charge indicator 


°C 

°F 

250 

80 

40 

100 

120 

0 

L 

MAIN 

RPM 

34 

J 

4 

1 

5 

0 

3 85 4 

3 4 4 

5 

2 

6 

5 

2 

120 6 

1 0 

6.3 

_ 

_ 



Opt. Gauge 

Oil- 

Pressure 

P2 

Lighting 

Opt. Gauge 

Oil-Pressure 

E11 

+ G 

1 2 

Batt + 

Batt - 

Sens ECU 

Control ECU 

61 +24V 

Lighting 

RPM- 

Gauge 

E12 

1 5 

SCC 

Warning 

Horn 

H22 

_ 

+ 

X 24 

1 2 3 4 

Start 

Charge 

Illumination 

Option 

15 

60 CAN 

2179338/D-02-070627_tedoc 

20 30 

10 40 

RPM- 

Gauge 

P3 

2 4 3 

STEYR-CONTROL-CENTER 

49.16.45N 48.08.56N 102.41.11W 014.27.47W 57,4 117 14:05 22:57 

SPEED/KN 

10.0 

2 3 

rpm x 1000 

2650 1500 

bar °C 

6 8 1 50 

2,8 77.8 73 

OIL/BAR 

TEMP/°C 

SWITCH 

WIRING DIAGRAM / INSTRUMENT PANEL - 4/6 CYLINDER - 12 V 

40 

105 

175 210 

Engine 

Coolant 

Temperature 

Gauge 

P1 

OIL- 

Preheating 

control 

Lamp 

L3 

X 

K W 

V 

H 

B 

U 

M 

C 

A G 

N D E F T 

S 

O 

P R 

Q 

J1 

Opt. Key 

Switch-Constant 

Revolution 

S7 

Lighting 

ECT- 

Gauge 

E10 

Check 

Engine 

Lamp 

L2 

Charge 

Control 

Lamp 

L1 

Ignition 

Switch 

S1 

14 22 13 21 

1 2 

+ G 

1 2 

1 2 

1 2 

1 5 6 7 

Fuse 

10A 

No./colours of shielded wire correspond to 

individual cable No. (15000-01) 

F9 

Z3 

Z1 

58000-01 

15000-01 

15000-02 

Connector 

Illumination 

switch 

30012-07 

X8 

30012-08 

J1 / A 1 

J1 / B 2 

J1 / C 3 

J1 / D 4 

31000-01 

Z2 

3100-02 

J1 / E 5 

J1 / F 6 

60616-01 

J1 / G 7 

31615-01 

J1 / H 8 

60706-01 

Z4 

60614-01 

J1 / J 9 

J1 / K 10 

61000-02 

J1 / L 11 

31000-16 Ground shield 

J1 / M 

60613-01 

J1 / N 13 

60121-01 

J1 / O 14 

60810-01 

J1 / P 15 

- Start 

50000-02 

50000-03 

J1 / Q 16 

J1 / R 17 

Trim (Option) 

60120-01 

J1 / S 18 

61001-01 B+ / 24V 

J1 / T 12 

60901-03 

J1 / U 21 

60900-03 

J1 / V 22 

(no connection) 

J1 / W 19 


J1 / X 20 



°C 

°F 

250 

80 

40 

100 

120 

MAIN 

L 

RPM 

34 

4 

1 

0 

J 

5 

0 

3 85 4 

3 4 4 

5 

2 

6 

5 

2 

120 6 

1 0 

6.3 

_ 

_ 

ToC 



Lighting 

RPM- 

Gauge 

E12 

1 5 

Warning 

Horn 

H22 

+ 

_ 

Start 

Charge 

Illumination 

Option 

15 

60 CAN 

2179339/D-02-070627_tedoc 

20 30 

10 40 

RPM- 

Gauge 

P3 

2 4 3 

WIRING DIAGRAM / INSTRUMENT PANEL - 4/6 CYLINDER - 24V (OPTION) 

SCC 


49.16.45N 48.08.56N 102.41.11W 014.27.47W 57,4 117 14:05 22:57 

SPEED/KN 

10.0 

2 3 

rpm x 1000 

2650 1500 

SWITCH 

bar °C 

6 8 1 50 

2,8 77.8 73 

OIL/BAR 

TEMP/°C 

X 24 

1 2 3 4 

40 

105 

175 210 

X 

K W 

V 

H 

B 

U 

M 

C 

A G 

N D E F T 

S 

O 

P R 

Q 

J1 

Lighting 

Opt. Gauge 

Oil-Pressure 

E11 

Opt. Gauge 

Oil- 

Pressure 

P2 

Opt. Key 


Revolution 

S7 

Lighting 

ECT- 

Gauge 

E10 

Engine 

Coolant 

Temperature 

Gauge 

P1 

OIL- 

Preheating 

control 

Lamp 

L3 

Check 

Engine 

Lamp 

L2 

Intermediate 

Cable Charge 

Indicator 

24 V 

Charge 

Control 

Lamp 

L1 

Ignition 

Switch 

S1 

1 2 

+ G 

14 22 13 21 

1 2 

+ G 

1 2 

1 2 

85 86 87a 87 30 

1 2 

1 5 6 7 

Fuse 

10A 



F9 

Z3 

58000-01 

Z1 

15000-01 

15000-02 

Connector 

Illumination 

switch 

30012-07 

X8 

30012-08 

31000-01 

Z2 

3100-02 

60616-01 

31615-01 

60706-01 

Z4 

60614-01 

61000-02 


Batt + 

Batt - 

Sens ECU 

Control ECU 

61 +24V 

60120-01 

Trim (Option) 

61001-01 B+ / 24V 

J1 / A 1 

J1 / B 2 

J1 / C 3 

J1 / D 4 

J1 / E 5 

J1 / F 6 

J1 / G 7 

J1 / H 8 

J1 / J 9 

J1 / K 10 

J1 / L 11 

J1 / M 

J1 / N 13 

J1 / O 14 

J1 / P 15 

J1 / Q 16 

J1 / R 17 

J1 / S 18 

J1 / T 12 

J1 / U 21 

J1 / V 22 

J1 / W 19 

60613-01 

60121-01 

60810-01 

- Start 

50000-02 

50000-03 

60901-03 

60900-03 



J1 / X 20 



°C 

°F 

250 

80 

40 

100 

120 

0 

MAIN 

RPM 

34 

4 

1 

5 

0 

L 

3 85 4 

3 4 4 

5 

2 

6 

5 

2 

120 6 

1 0 

6.3 

J 

_ 

_ 



WIRING DIAGRAM / INSTR. PANEL - 4/6 CYL. - Solas - 12V (OPTION) 

Warning 

Horn 

H22 

_ 

+ 

Start 

Charge 

Illumination 

Option 

15 

60 CAN 

2179340/D-02-070627_tedoc 

40 

105 

175 210 

Lighting 

Opt. Gauge 

Oil-Pressure 

E11 

Opt. Gauge 

Oil- 

Pressure 

P2 

Opt. Key 


Revolution 

S7 

Lighting 

ECT- 

Gauge 

E10 

Lighting 

RPM- 

Gauge 

E12 

Engine 

Coolant 

Temperature 

Gauge 

P1 

1 5 

20 30 

10 40 

RPM- 

Gauge 

P3 

2 4 3 

SCC 


49.16.45N 48.08.56N 102.41.11W 014.27.47W 57,4 117 14:05 22:57 

SPEED/KN 

10.0 

2 3 

rpm x 1000 

2650 1500 

SWITCH 

bar °C 

6 8 1 50 

2,8 77.8 73 

OIL/BAR 

TEMP/°C 

X 24 

1 2 3 4 

OIL- 

Preheating 

control 

Lamp 

L3 

Check 

Engine 

Lamp 

L2 

Charge 

Control 

Lamp 

L1 

Emergency 

CUT OFF 

Switch 

S3 

START 

(green) 

S2 

IGN (red) 

ON/OFF 

S1 

X 

K W 

V 

H 

B 

U 

M 

C 

A G 

N D E F T 

S 

O 

P R 

Q 

J1 

1 2 

+ G 

14 22 13 21 

1 2 

+ G 

1 2 

1 2 

1 2 

M M 

3 4 

3 4 

Fuse 

10A 

F9 



Z3 

Z1 

15000-01 

58000-01 

15000-02 

Connector 

Illumination 

switch 

30012-07 

X8 

30012-08 

Z2 

31000-01 

3100-02 

J1 / A 1 

J1 / B 2 

J1 / C 3 

J1 / D 4 

J1 / E 5 

J1 / F 6 

J1 / G 7 

J1 / H 8 

J1 / J 9 

J1 / K 10 

J1 / L 11 

60616-01 

31615-01 

60706-01 

Z4 

60614-01 

61000-02 


60613-01 

60121-01 

60810-01 

Batt + 

Batt - 

Sens ECU 

Control ECU 

61 +24V 

- Start 

50000-02 

50000-03 

60120-01 

Trim (Option) 

61001-01 B+ / 24V 

Optional 24 V 

60901-03 

60900-03 

J1 / M 

J1 / N 13 

J1 / O 14 

J1 / P 15 

J1 / Q 16 

J1 / R 17 

J1 / S 18 

J1 / T 12 

J1 / U 21 

J1 / V 22 

ohne Anschlag (no connection) 

J1 / W 19 

ohne Anschlag (no connection) 

J1 / X 20 



°C 

°F 

80 

40 

100 

MAIN 

RPM 

120 

34 

250 

4 

1 

L 

5 

0 

0 

3 85 4 

3 4 4 

J 

5 

2 

6 

5 

2 

120 6 

1 0 

6.3 

4 

_ 

_ 

ToC 



SCC 


49.16.45N 48.08.56N 102.41.11W 014.27.47W 57,4 117 14:05 22:57 

SPEED/KN 

10.0 

2 3 

rpm x 1000 

2650 1500 

SWITCH 

bar °C 

6 8 1 50 

2,8 77.8 73 

OIL/BAR 

TEMP/°C 

Warning 

Horn 

H22 

X 24 

1 2 3 4 

+ 

WIRING DIAGRAM / INSTR. PANEL - 4/6 CYL. - Solas - 24V (OPTION) 

_ 

Start 

Charge 

Illumination 

Option 

15 

60 CAN 

2179341/D-03-070627-tedoc 

40 

105 

175 210 

20 30 

10 40 

X 

K W 

V 

H 

B 

U 

M 

C 

A G 

N D E F T 

S 

O 

P R 

Q 

J1 

Lighting 

RPM- 

Gauge 

E12 

RPM- 

Gauge 

P3 

Lighting 

Opt. Gauge 

Oil-Pressure 

E11 

Opt. Gauge 

Oil- 

Pressure 

P2 

Opt. Key 


Revolution 

S7 

Lighting 

ECT- 

Gauge 

E10 

Engine 

Coolant 

Temperature 

Gauge 

P1 

OIL- 

Preheating 

control 

Lamp 

L3 

Check 

Engine 

Lamp 

L2 

Intermediate 

Cable Charge 

Indicator 

24 V 

Charge 

Control 

Lamp 

L1 

Emergency 

CUT OFF 

Switch 

S3 

START 

(green) 

S2 

IGN (red) 

ON/OFF 

S1 

1 2 14 22 + G 

1 2 2 3 13 21 1 5 

1 2 85 86 87a 87 30 1 2 1 2 + G 

3 4 3 4 M M 

Fuse 

10A 

F9 



Z3 

58000-01 

Z1 

15000-01 

15000-02 

Connector 

Illumination 

switch 

30012-07 

X8 

30012-08 

Z2 

31000-01 

J1 / A 1 

J1 / B 2 

J1 / C 3 

J1 / D 4 

J1 / E 5 

3100-02 

J1 / F 6 

60616-01 

J1 / G 7 

31615-01 

J1 / H 8 

60706-01 

Z4 

60614-01 

61000-02 

J1 / J 9 

J1 / K 10 

J1 / L 11 


60613-01 

60121-01 

60810-01 

- Start 

50000-02 

Batt + 

Batt - 

Sens ECU 

Control ECU 

61 +24V 

50000-03 

60120-01 

Trim (Option) 

61001-01 B+ / 24V 

J1 / M 

J1 / N 13 

J1 / O 14 

J1 / P 15 

J1 / Q 16 

J1 / R 17 

J1 / S 18 

J1 / T 12 

J1 / U 21 

J1 / V 22 

J1 / W 19 

60901-03 

60900-03 



J1 / X 20 







ToC 



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. 

07.13 ill.1 

Selection of function 

Operating voltage off. 

Press and hold down key on back of housing. 

Operating voltage (ignition) on. 

The display shows "PULSE" and "ADJUST" 

every 2 seconds in alternation. 

To select shown function, release the 

key for respective indication. 

Function "PULSE" 

When the function PULSE is selected, "P12.18" 

(12.18 pulses per revolution) appears for example 

on the display after approx. 3 seconds, with a flashing 

last digit. Immediately start entry of known pulse rate 

by repeated pressing of key. 

07.13 ill.2 

The flashing digit may be adjusted by activating the 

key (possible pulse settings: 0.50 to 399.99). 

After having adjusted the flashing digit, wait for approx. 

3 sec. Then the next digit begins to flash. At completion 

of pulse rate setting, activate the key no more. 

The display then changes over to counting of runningtime. 

Thus the setting procedure is completed. 

By repeated selection of function PULSE the selected 

pulse rate may be checked. The pulse rate appears 

on the display and the individual digits begin to flash 

in sequence, starting with the last digit. 

P-12,18 

07.13 ill.3 




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 

crankshaft. Extreme caution is required! Do not wear 

loose clothing! 

When the function ADJUSt is selected, UP or dn (UP 

or DOWN) appears in alternation on the display after 

approx. 3 seconds. 

If, for example, the key is pressed and held down 

when UP is displayed, the pointer deflection changes 

upwards (for "dn" analogously downwards). 

If you release the key for 2 seconds and then press 

it again, the pointer deflection changes downwards. 

At the beginning, the pointer deflection changes very 

slowly which permits a very precise fine adjustment. 

With a short release of the key, the procedure is 

repeated. With a longer pressing of the key, the 

pointer deflection will change faster. Release the key 

as soon as the fine adjustment corresponds to the 

reference rpm. The display then changes to counting 

of running-time. Fine adjustment is completed. 

07.13 ill.4 

Fine Adjustment: 

During normal operation of the indicator, a fine 

adjustment is possible by using the key. The 

adjustment range is +/- 20 % of the actual reading. 

Press the key, with voltage supply on. 

On the display appears A 0.0 

By pressing and holding the key, the adjustment 

factor increases in steps of 0,5%. 

If you release the key for 2 seconds and then press 

it again, the adjustment factor decreases in steps of 

0,5%. 

If the key is not pressed for more than 5 seconds, the 

adjustment factor will be stored and the indicator 

switches back to the normal running-time display. 

07.13 ill.5 


ToC 



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. 

Use our product for the intended purpose only. 

The consequences of use of the product for other than the intended purpose may be personal injury 

and damage to property as well as environmental damage. 

The unit is designed for use in sports boats. 

Record data of other instruments with transient electronic memories. 

Please note during installation: 

The product should be installed by your boatyard or by a person specialised in the installation of 

such devices. 

If you wish to carry out installation yourself, wear suitable working clothing. Do not wear loosefitting 

clothing. This may be caught by moving parts. If you have long hair, wear a hair net. 

When working on electric equipment, do not wear any metallic or conductive jewellery such as 

chains, bracelets, rings etc. 

Before beginning work, disconnect the negative pole of the battery, since otherwise there is a risk 

of a short ciruit. Short circuits can cause cable fires, battery explosions and damage to other 

electronic storage systems. Please note that when the battery is disconnected, all transient 

electronic memories lose the values entered and have to be reprogrammed. 

With petrol engines, allow the engine compartment fan to run before beginning work in the engine 

compartment. 

At the installation site, make sure there is sufficient space behind drilled holes or the installation 

aperture. 

First drill small holes at the installation apertures, and enlarge if necessary using tapered drills, 

compass saws, fretsaws of files. Deburr edges.The safety instructions of the hand tool manufacturer 

must be observed. 

If work has to be carried out without interruptions in voltage, only insulated tools may be used. 

The electrical outputs of the display unit and the connected cables must be protected from direct 

contact and damage. To this end, the cables used must have adequate insulation and/or dielectric 

strenght, and the contacts must be shockproof. 

The electrical conductive parts of the connected consumers must also be protected from direct 

contact by suitable means. The installation of bare metal cables and contacts is forbidden. 

After installation, please note: 

Clamp the earthing cable firmly to the negative pole of the battery. 

Enter/program the values of the transient electronic memories again. 

Test all functions. 




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. 

Do not run the cables over moving parts. 

Ensure that the cables are not exposed to any tensile, compressive or shear forces. 

If the cables have to be run through drilled holes, protect the cables using grommets or rubber 

bushings etc. 

Use only a cable stripper to strip the cables. Adjust the cable stripper so that the individual strands 

are not damaged or cut off. 

New connections should only be made using soft solder, or with commercial crimp connectors. 

Crimped connections should only be made using cable crimping pliers. The safety instructions of 

the hand tool manufacturer must be observed. Insulate exposed leads in such a way that short 

circuits cannot occur. 

Caution: Risk of short circuit through faulty junctions or damaged cables. 

Short circuits in the electrical system can cause cable fires, battery explosions and damage to 

other electronic systems. For this reason, all connections in the voltage supply system must be 

either soldered or fitted with weldable connectors and adequately insulated. 

Pay particular attention to correct earth connections. 

Incorrect connections can lead to short circuits. The cables must only be connected in accordance 

with the electrical terminal connection diagram. 


ToC 



06. 07. 14. 02 Audible warner, H22 

control unit control unit 

07.14 ill.1 

sensor 

exhaust gas 

temperature 

sensor 


sensor 

oil pressure 




06. 07. 14. 03 Circuit diagram voltmeter (optional) 

07.14 ill.2 

06. 07. 14. 04 Circuit diagram oil pressure gauge (optional, sensor B19 - gauge P2) 

single instruments 

double instruments (requires special sensor) 

07.14 ill.3 

sensor marking "G" 

one sensor for two displays 


ToC 



06.08.01 Potentiometer Accelerator, B13 

1 Remove plug housing. 

2 Unscrew hexagon nut of accelerator lever, remove 

lever. 

3 Loosen 2 hexagon screws. Remove accelerator. 

Throttle potentiometer B13 (accelerator) 

(= connector X13) 

In case of defective potentiometer accelerator B13, 

service codes 23, 24 or 29 will flash. 

08.01 ill.1 

NOTE: 

First check cables and 

connections. 

R1 Resistance between terminals 3 and 1; 

approximately 1,2 kOhm resistance value switch to 

infinetely after moving throttle lever from idle position. 

Switch contact should open within the first 10% of 

throttle lever (pedal) movement. 

1 2 3 4 5 

R2 

R3 

Resistance between terminals 5 and 4; 1,2 kOhm 

Resistance between terminals 5 and 2; 2,2 kOhm 

for normal position of potentiometer accelerator ; 

1,4 kOhm at "full speed " max. throttle position. 

08.01 ill.2 

Wiring Circuit - Potentiometer P/N 2176860/0 

~1k 

1 

~9 

3 

R1 

5 

+ 

~1k 

- 

~1k 

2 

4 

R3 

R2 

08.01 ill.3 




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" positiv terminal +24V 

connect a black wire AWG 6 (10 mm²) directly at battery "A" negativ terminal. 

Battery equalizer 

GND 

+24V 

BLACK AWG 6 RED AWG 6 

25A 

20A 

(*) 

30A 

12V Protected 

Output 

RED AWG 8 

OUT 12V 

24V LOAD 

(STARTER , ALTERNATOR, 

power supply glow , .....) 

“A” 

* Note:......Mainswitsches are mechanically interlinked. 

“B” 

08.02 ill.1 

X21 ARMATUREN PLUG 6-POLE: --> USE ONLY 12 VOLT INSTRUMENTS 

pin1 

pin2 

pin3 

pin4 

pin5 

pin6 

Note: 

60810--> check engine lampe (12V/2W) 

60616--> glow lamp (12V/2W) 

60614--> temperature instruments (12V) 

60613--> engine speed instruments (12V) 

50000--> starter terminal 50 (detection of start) 

15000--> ignition connect it to the ignition-switch of the vehicle (protect with 5 Amp fuse) 

The glow lamp has 2 functions --> at first it works as glow lamp after start it works as oil 

pressure lamp. 

ALTERNATOR 

B+ must be connection by customer --> use a wire AWG 6 (10 mm²) charging control --> must be connecting 

by customer. 

ATTENTION: 

Please observer and follow Original inclosed 

manufactures recommentation! 

08.02 ill.2 


ToC 



06.08.03 DC - DC converter 

DC-DC Converter 

IVO 8770 

CIRCUIT DIAGRAM 

IE 

Batt "A" 

Batt "B" 

U1 

16A 

24VDC 

12VDC 

U2 

IA 

25A 

Engine 

G 

Batt "C" 






ToC 


06.10 SENDER AND SENSOR OVERVIEW 

06.10.01 Component configuration 4 cyl. engine 


to engine number 48226999 

164/174 

94/114/144 

10.01 ill.1 

CODE 

KURZNAME 

ABBREVIATION 

BESCHREIBUNG 

DESCRIPTION 

CODE 

KURZNAME 

ABBREVIATION 

BESCHREIBUNG 

DESCRIPTION 

Stecker Ölmanometer (Option) 

Connector oil pressure gauge (optional) 

MAP 

Ladedrucksensor 

Boost-pressure sensor 

Stecker Trimmanzeige (Option) 

Connector trim (optional) 

PED 

Gaspedal 

Potentiometer accelerator 

J1 

Verbindungsstecker Motor - EMS 

Connector engine cable - EMS 

RPOS 



DIAG 

Diagnose - Stecker 

Diagnosis - plug 

RPM 

Motordrehzahlsensor 

Sensor engine speed 

FMS 

Steuermagnet 


ECT 

Kühlflüssigkeitstemperatursensor 

Sensor engine coolant temperature 

Stecker Getriebeschalter (Option) 

Connector gear switch (optional) 

EXT 

Abgastemperatursensor 

Sensor exhaust gas temperature 

Inversionsschalter (Nur bei SOLAS) 

Inversion switch (only for SOLAS) 

LPS 

Öldrucksensor 

Lubricant pressure sensor 

Abschaltventil (Nur bei SOLAS) 

Blow - by (only for SOLAS) 




from engine number 48227000 

07002 

CODE 

BESCHREIBUNG 

DESCRIPTION 

CODE 

BESCHREIBUNG 

DESCRIPTION 

B12 



X19 



B13 

Gaspedal 


X22 



B14 



J1 

Haupt-Verbindungsstecker 

Main connector 

B15 



X23 



B16 

Kühlflüssigkeittemperatursensor 


Y20 

Steuermagnet 


B17 



X2 



B18 



S3 

Inversionsschalter (nur bei SOLAS) 



ToC 


06.10.02 Component configuration 6 cyl. engine 


to engine number 68226999 

246/256/ 

266 

126/166/ 

236 

10.02 ill.1 

CODE 

KURZNAME 

ABBREVIATION 

BESCHREIBUNG 

DESCRIPTION 

CODE 

KURZNAME 

ABBREVIATION 

BESCHREIBUNG 

DESCRIPTION 



MAP 





PED 

Gaspedal 


J1 

Verbindungsstecker Motor - EMS 

Connector engine cable - EMS 

RPOS 



DIAG 



RPM 



FMS 

Steuermagnet 


ECT 

Kühlflüssigkeitstemperatursensor 




EXT 



Inversionsschalter (Nur bei SOLAS) 


LPS 



Abschaltventil (Nur bei SOLAS) 

Blow - by (only for SOLAS) 




from engine number 68227000 

07003 

CODE 

BESCHREIBUNG 

DESCRIPTION 

CODE 

BESCHREIBUNG 

DESCRIPTION 

B12 



X19 



B13 

Gaspedal 


X22 



B14 



J1 

Haupt-Verbindungsstecker 

Main connector 

B15 



X23 



B16 

Kühlflüssigkeittemperatursensor 


Y20 

Steuermagnet 


B17 



X2 



B18 



S3 

Inversionsschalter (nur bei SOLAS) 



ToC 



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. 

- Rack or linkage lever have been replaced or loosened. 

E 

1 

10.03 ill.1 

F 

D 

C 

B 

A 

10.03 ill.2 

NOTE: 

Ensure that the ignition is turned off. 

1 Remove threaded pin from position A (ill. 1). 

2 Manually move rack (ill.1/B) forward until borehole (ill.1/C) is over tapped hole (ill.1/D) and fix 

with threaded pin. The pin must be fastened hand tight and sit correctly in the rack, see ill. 2. 

above. 

3 Turn on ignition,rack position will be automatically stored in the ECU A5. 

Storage process will take approx. 20 sec. 

4 Turn off ignition. 

5 Loosen threaded pin and screw it into rear bulkhead wall (ill.1/A). 

NOTE: 

If storage in ECU A5 was unsuccessful, error code 56 will be detected. 

Refer to Error Codes. 

NOTE: 




sensor. 




06.10.04 Replace Senders, Sensors 

06.10.04.01 Exhaust gas temperature sensor, B17 

1 Unlock plug (ill.1/pos.1) and remove. 

2 Unscrew temperature sensor (ill.1/pos.2) (SW19) 

2 

1 

10.04 ill.1 

06.10.04.02 Engine temperature sensor, B16 

1 Remove plug housing (ill.2/pos.1). 

2 Unscrew engine temperature sensor. 

1 

06.10.04.03 Speed sensor, B15 

10.04 ill.2 

1 Press catch spring and remove plug. 

2 Loosen hexagon screw (SW10), pull out sensor. 

ATTENTION: For assembly, use new 0-ring. 

Grease O-ring and put it on. 

06.10.04.04 Boost pressure sensor, B12 

for engines 94 / 114 / 144 / 126 / 166 / 236 only 

1 Remove hose from exhaust manifold. 

ATTENTION: Do not remove hose from boost 

pressure sensor. 

2 Press retaining clip against plug housing (ill.4/pos.1), 

remove plug. 

10.04 ill.3 

2 

2 

3 Loosen two hexagon screws (SW10), remove boost 

pressure sensor (ill.4/pos.2). 

1 

NOTE: For assembly, take care of the 2 

sealing cushions of plug housing. 

10.04 ill.4 


ToC 



Boost pressure sensor, B12 

for engines 164 / 174 / 246 / 256 / 266 only 

1 Remove cable strap, lift shackle at plug and pull off 

plug. 

2 Loosen clamp (SW6) and pull off hose. 

3 Loosen union nut (SW17) by holding up at sensor 

(SW32). Remove sensor 

Assembly is done in reverse order off disassembly. 

NOTE: Wetten the thread from the new sensor 

with LOCTITE 243. Thigthen union 

nut solid. 

06.10.04.05 Rack position feedback sensor, B14 

1 Remove retaining clip, remove plug housing 


10.04 ill.5 

1 

2 Disassemble control solenoid, refer to 03.08.01 

3 Loosen 2 cylinder screws with hexagon socket (SW 

3), remove sensor (ill.6/pos.2). 

2 

Assembly is done according to assembly 

of control solenoid, refer to 03.08. 

06.10.04.06 Oil pressure sensor, B18 

1 Remove plug housing. 

2 Unscrew oil pressure sensor (ill.7/pos.1) from mount 


ATTENTION: Collect running out motor oil in a 

suitable vessel. 

10.04 ill.6 

2 

1 

06.10.04.07 Potentiometer Accelerator, B13 

1 Disassemble indexing plate (ill.8+9/pos.1). 

2 Remove plug housing (ill.8+9/pos.2). 

3 Unscrew hexagon nut of accelerator lever (ill.8+9/ 

pos.3), remove lever. 

10.04 ill.7 

1 

3 

4 Loosen 2 hexagon screws. Remove accelerator 

(ill.8+9/pos.4). 

4 

2 

10.04 ill.8 




3 

1 

4 

2 

06.10.05 Check Sensors and Switches 

10.04 ill. 9 

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. 

10.05 A ill.1 

Final check: 

Disassemble rack position feedback sensor 

from control solenoid. 

1 Check resistance between terminals A and C with a 

digital ohmmeter. Resistance must be between 

2,2 kOhm ± 10 %. 

C 

A 

10.05 A ill.2 

2 Measure resistance between terminals B and C with 

extended shaft. Resistance must be 

0,5 kOhm ± 10 %. C 

B 

10.05 A ill.3 


ToC 



3 Measure resistance between 

terminals B and C with inserted shaft. 

Resistance must be 

2,4 kOhm ± 10 %. 

B 

C 

When a failure was found during one 

of above checks, replace rack position 

feedback sensor B14. 

06.10.05.01 B Check rack position feedback sensor 

B14 (= connector X14) 

In case of defective rack position feedback sensor 

B14, service codes 35 and 36 or 186 will flash. 

10.05 A ill.4 

NOTE: 

First always check cables and connections. 

10.05 B ill.1 

Final check: 

Disassemble rack position feedback sensor 

from control solenoid. 

1 Supply terminals A ("-"; minus) and C ("+"; plus) with 

5,0V DC +/- 1%. 

C 

A 

10.05 B ill.2 

- 

+ 

5V DC 

2 Sensor extended! 

Measure between terminal A (minus) and B (signal 

out). Measured voltage must be 4,8V DC +/- 5%. 

B 

A 

10.05 B ill.3 




3 Sensor retracted! 

Measure between terminal A (minus) and B (signal 

out). Measured votage must be 0,12V DC +/- 5%. 

B 

A 

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) 

In case of defective potentiometer accelerator B13, 

service codes 23, 24 or 29 will flash. 

NOTE: 

First check cables and 

connections. 

10.05 ill.5 

* Resistance between terminals 5 and 4; 1,2 kOhm 


for normal position of potentiometer accelerator ; 

1,4 kOhm at "full speed " max. impact. 


With approx. 10% of max. first route, resistance 

value must increase infinetely high ==> 

(disconnection). 

1 2 3 4 5 

10.05 ill.6 




06.10.05.03 Check boost pressure sensor, B12, for engine models: 94 / 114 / 144 / 126 / 166 / 236 

100 microbar (absolute) 

Athmospheric pressure 

PSI 

10.05 ill.7 

For engine models: 164 / 174 / 246 / 256 / 266 

5,0 

4,5 

Output - voltage (Volt) 

4,0 

3,5 

3,0 

2,5 

2,0 

1,5 

1,0 

0,5 

0,0 

0,0 0,5 1,0 1,5 2,0 2,5 3,0 3,5 4,0 

10.05 ill.8 Absolut - air pressure (bar) 

Supply voltage 

5V +/- 0,2V 

Connector position 

A = +5V 

B = GND 

C = Signal 

Max. pressure with 

3 bar (3,5 absolut) 

NOTE: 

Before checking the boost pressure sensor, check air filter, sensor hose and connector. 

Pressure test: 

For a pressure test of the sensor, disconnect the sensor hose and connect a pressure gauge with a 

short piece of hose to the sensor. 

Carefully pressurize the sensor. Read and record the values on the gauge (input pressure) and on the 

display (output pressure) for 5 spots between 0 and 1.5 bar. Compare recorded input and output values 

with the chart. 

- If values are not within tolerance limits, replace the boost pressure sensor. 

- If values are within tolerance limits, the boost pressure sensor is functional and the turbocharger 

must be checked. 




06.10.05.04 Check speed sensor B15 and/or wiring 

X15 

1 23 

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" an error code can be stored 

--> At completion of checking, cancel the error code; refer to 06.06.04 

Use a standard voltmeter / multimeter to measure the supply voltage and/or the resistance. 

Supply voltage Ubat (12V +/- 2V) 

ignition ON main relay K27 active 

measurement point GND on X15/3 against +supply voltage on X15/1 

Continuity from X15/2 to control unit X5/33 

max. resistance 2 ohms 

If supply voltage and transition from X15/2 to X5/33 are connect, replace the speed sensor. 

In case an error was detected during preceding measurements, check wiring according to circuit 

diagram and wiring harness diagram. 


ToC 



06.10.05.05 Check oil pressure sensor B18 and/or wiring 

X18 

X18/A 31100-10 

X18/B 15100-07 

X18/C 60117-01 

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" the error code 32 HiLPS is stored 

--> At completion of check, cancel the error code; refer to 06.06.04 

Use a standard voltmeter / multimeter to mesure the supply voltage and/or the resistance. 

Supply voltage + 5V +/- 0,4V 

ignition ON main relay K27 active 

measuring point GND on X18/A against + 5V on X18/B 

Continuity from X18/C to control unit X5/10 

max. resistance 2 ohms 

Output signal depending on pressure; see diagram 

Remove B18 and admit pressure when X18 is connected; max. 5 bars 

measuring point X18/C --> X18/B 

10.05 ill.10 

voltage via pressure 

voltage (V) 

voltage 

pressure (bar) 

10.05 ill.11 




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 

Check minimum oil pressure: 

Start engine and let engine run at idle speed, 1000 

and 2500 r.p.m. Check tachometer and and oil 

pressure gauge. Record oil pressure value for idle 

speed, 1000 and 2500 r.p.m. If values are not 

appropriate, check the oil pressure gauge before 

checking the oil pressure sensor. To check the oil 

pressure gauge, disconnect cable from sensor, turn 

on ignition key and shortly put the sensor cable to 

ground connection. If gauge functions properly, the 

pointer will shortly deflect to high values. If there is no 

malfunction of the gauge, replace the oil pressure 

sensor. 

Check of oil pressure sensor: 

1. To check the oil pressure sensor, disconnect the 

sensor cable and connect an ohmmeter to sensor 

terminal and sensor. 

2. Check resistance at zero pressure; resistance should 

be 240 Ohm ± 10 %. 

- If resistance is out of tolerance limits, replace the 

oil pressure sensor. 

- If resistance is within the tolerance range but 

function of oil pressure sensor is still questionable, 

measure the resistance over the entire field. 

PRESSURE 

10.05 ill.12 

RESISTANCE (OHM) 


ToC 



Check oil pressure sensor over entire pressure range: 

1. Disassemble sensor and connect it to a gauged 

pressure source. 

2. Connect ohmmeter and pressurize sensor. Read 

and record pressure and resistance at different spots 

over the entire pressure range. 

3. Compare pressure and resistance values with chart. 

If values are not within tolerance range at one spot, 

replace sensor. 

06.10.05.07 Check coolant temperature sensor, B16 

To check the coolant temperature sensor, make the 

following test with connected ohmmeter. In case of 

failure, replace the sender. 

1. Compare resistance value and ambient temperature 

to curve of diagram. Range of tolerance is ± 10 %. 

kOhm 

120 

100 

80 

60 

40 

20 

0 

10.05 ill.13 

0 10 20 30 40 50 60 70 80 90 100 

TEMP °C 




2. 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. The ohmmeter should show values 

corresponding to the values of the resistance curve 

with a tolerance range of ± 10%. 

06.10.05.08 Check audible warner 

0,7 sec. with ignition "ON" ==> function check and 

message "no error stored" 


ToC 



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. 


Use a 12 V battery with a cold test circuit of 450 ampere at -18°C and a capacity of 92 Ah at 27°C, to 

guarantee the supply of the electric and electronic components for all operating conditions. 

For 24 V - installation only 

Use two 12V batteries with a cold test circuit of 650 ampere each at -18°C and a capacity of 115 Ah 

at 27°C, to guarantee the supply of the electric and electronic components for all operating conditions. 

The batteries are connected in series and provide a capacity of 115 Ah / 24 V for the external supply 

of all electric components on the boat. 

12V supply of all electric and electronic components on the engine (including instrument panel) by 

center tapping. Additional charge is guaranteed by charging equalization. 


Use a 12 V battery with a cold test circuit of 650 ampere at -18°C and a capacity of 115 Ah at 27°C, 

to guarantee the supply of the electric and electronic components. 

Explanation: 

Cold current test: 

The cold current test is a specified load test of a battery.The 

charge of battery with specified current (e.g. 450A). 

After discharge for 30 sec., the voltage should not drop bellow ³9V. 

Capacity: 

With a current consumption of 1 / 20 

of specified capacity (e.g. 92Ah) the battery 

voltage must not fall below 10 V after 20 hours, to guarantee the engine's 

starting ability. 

Maintenance 

To guarantee long battery life, the following tests should be carried out periodically. 

1 The level of battery acid must always be above plates and separators. The acid level should reach the 

marking on the battery. Acid may only be refilled by an expert when it was definitely stated that some 

of it has been spilled. 

ATTENTION: 

Battery fluid is an aggressive acid and must be handled with care. In case of skin 

contact rinse thoroughly with water and consult a doctor - physician. 




2 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. If the density is 0.04 kg/dm³ below the value 

of full charge, the battery is to be removed and recharged. 

DENSITY WITH FULL CHARGE: 1.260 kg/dm 3 (at 

27°C). 

ATTENTION: 

Never charge the battery on the 

boat. The vapors resulting from 

charging could cause an explosion! 

12.01 ill.1 

For a periodical check of the battery, the following items are to be considered: 

1 Protect the boat against acid leakage. 

2 Clean battery. 

3 Check connections and cables. 

4 Clean battery contacts. (neg./pos.) 

5 Check holding device of battery. 

6 Check housing for damages (acid leakage). 

7 Check acid density. 

8 Disassemble battery for test. In case of less than 3/4 charge, charge it by means of battery charger, 

carry out charge test. 

9 Check acid level. 

In case of a bad state of charge or excessive loss of water, check charge circuit. 

Clean battery, contacts and terminals with a solution of soda and water. This neutralizes the battery 

acid. After cleaning with the solution, rinse the surface with water by taking care that the solution does 

not penetrate into the battery 

ATTENTION: 

When connecting the battery cables, take special care of correct polarity. Incorrect 

polarity destroys electronic components.

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