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Steyr Marine Engine Family 2012
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1. dimus d dde 7 03 00 04 Ar System MIO 8 03 00 05 Exhaust pipe and muffler SE ENGINES 9 03 00 06 Schema Variable Geometry Turbochargers 10 03 02 Fuel Pump Unit Injector Lines 12 03 02 01 Replace fuel pump 12 03 02 02 Disassembly and assembly of unit injector 14 03 02 03 TDXCCOlIOL IO uua oce iota sees 23 03 02 04 Adjust control link injection 24 03 02 05 Release fixing of control 25 03 02 06 Adjustment of unit injector start of fuel delivery 26 03 02 07 Exchange pressure check valve at fuel outlet on block 29 03 05 Turbo charger Fehler Textmarke nicht definiert 03 05 01 Replace Variable Geometry Turbochargers VGT Fehler Textmarke nicht definiert 03 05 02 Check bearing clearance 31 03 08 Control Solenoid Injection Timing Device ITD 32 03 0
2. 57 01 05 09 Replace adjusting 58 01 06 Engine Housing Oil Pump Oil Suction Pipe 59 01 06 01 Replace engine 0 59 01 06 02 Replace rear ring 64 01 06 03 Replace rear radialshaft sealing 9 65 01 06 04 Replace oil pump front ring 66 01 06 05 Replace oil suction pipe oil return pipe 68 01 08 Intake Manifold Exhaust Manifold 69 01 08 01 Remove intake 1 0 69 01 08 02 Mount intake 75 01 08 03 Disassemble exhaust manifold complete with turbo chargers Fehler Textmarke nicht definiert 01 08 04 Mount exhaust manifold Fehler Textmarke nicht definiert 01 13 ENGING Oil COOICN Eai 81 01 13 01 Replace engine oil 81 01 13 02 Change motor oil 2 92 Z001138 1 2014 01 2 84 Items to Check Troubled Systems IC Piston Combustion Mechanical system Factors Cause of Trouble Too much oil in the oil pan oil leveltoo higa Oil leak down from
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4. 61 4 Non destructive material 61 H5 Use of adhesive and sealing 61 Solvent free sealing 61 asi 64 1 Adjustment information for service 65 11 Engine timing measured with dial indicator No 2300899 0 65 1 1 2 Tension timing belt measured with tool 515 65 1 1 3 Start of fuel delivery on the unit injectors measured with dial indicator No 2300899 0 65 1 1 4 Valve clearance measured with tool 2300712 3 65 2001138 1 2014 01 10 65 A GENERAL REMARKS A1 Model and Serial Number The primary model and serial number is located on the engine as illustrated These numbers are required for warranty claims and ordering parts zal Qo o of 2 41 11 65 2001138 1 2014 01 Preliminary Service Manual MARINE 2012 A 2 Documentation The following documentation is available in English language on our website Installation manual 2012 P N Z001139 0 operatio
5. 36 1 41 Extended Storage Preservation 41 CER RES RR Eua 43 Spare CoU MID 43 WOIKSHOD PTOlG _______________ ______ 43 INGING AC TTE 44 OY Sl CIM 46 ADOL 47 Operating material and information on disposal 48 MUT 48 Disposal of automotive waste 49 DR 50 toenerarfiotes ODsSalely 51 Guidelines for damage prevention 51 legal TUle S coli i EUM D mda ot 51 Safety in the use of operating 52 Measures in case 52 QUOS DUELO 53 Hsing of TIgntening TORQUES euni dtr s t ei m ee ute tu eu tue exta 53 General Tightening erg nt saa nette nein e e t et doas 59 2001138 1 2014 01 Preliminary Service Manual MARINE 2012 Ho
6. service Manual MARINE 2012 Map Toleranz mbar MAP mbar 2180 2240 240 2900 26900 2840 280 3000 3060 speed max MAP 2200 2350 2800 3550 3050 4000 3300 3800 3800 1 min max exhaust backpressur 150 150 150 150 150 150 150 150 150 e mbar backpressur e tolerance 0 50 0 50 0 50 0 50 0 50 0 50 0 50 0 50 0 50 mbar max engine water 81 83 83 85 86 86 86 86 87 outlet temp C exhaust gas temperature 480 415 506 510 535 510 525 oil sump temperature 95 97 10 10 10 10 10 10 10 pressure mbar min fuel supply pressure 3500 3500 3500 3500 3500 3500 3500 block inlet mbar rel 2001138 1 2014 01 16 65 engine type max engine coolant outlet temperature 105 raw water 0 37 5 286 40 5 06 38 i raw water supply pressure pf bar Tension timing belt 600 30 600 30 600 30 600 30 600 30 600 30 600 30 600 30 600 30 N unit injector opening pressure kPa UI adjustment 9 20 9 10 8 85 8 85 8 74 8 65 8 74 8 70 8 65 mm UI adjustment 0 02 0 02 0 02 0 02 0 02 0 02 0 02 0 02 0 02 tolerance UI adjustment check value 9 15 8 70 after engine braking in 8 75 UI base 8 80 3 590 26000 36000 26001 36000 26002 36000 26003 36000 26004 3
7. STEYRMOTORS INNOVATION WITH LIGHTNESS STEYR TURBO DIESEL ENGINES Steyr Marine Engine Family 2012 zl ve SERVICE MANUAL Z001 138 0 1 Edition January 2014 STEYR MOTORS GmbH www steyr motors com Im Stadtgut B1 A 4407 Steyr Gleink AUSTRIA 1 65 2001138 1 2014 01 Preliminary Service Manual MARINE 2012 THIS PAGE IS INTENTIONALLY BLANK 2001138 1 2014 01 2 65 STEYR MOTORS GmbH has developed high performance diesel engines with modulated high pressure direct injection especially for special vehicles STEYR engines are designed to be adapted to various propulsion systems This SERVICE MANUAL is published with the main intention to provide information in form of technical data and know how based on our experience in the diesel engine business which will enable you in case of possible failure to operate service and repair the engines Steyr Marine Engine Family 2012 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 following questions Which descriptions or terms understandable e Which supplements or completions do you propose Where did creep in contents related mistakes Please address your comme
8. Technical Data of alternator 14V 120 Model AAK5818 11 204 201 Minimum engine speed for Voltage generation 520 Regulated Voltage 14 6 0 15 V Load Current 2115 Amp Excitation winding resistance 2 9 0 10 Gear Ratio i 2 7 E esos a DF 0 Technical Data of alternator 14V 150Amp optional Model AAN5356 11 204 202 Minimum engine speed for Voltage generation 444 Regulated Voltage 14 1 0 15 V Load Current 2155 Amp Excitation winding resistance 2 85 0 10 Gear Ratio 2 7 2001138 1 2014 01 6 54 Electrical System 7 54 2001138 1 2014 01 Electrical System Technical Data of alternator 28V 100Amp optional Model 5357 11 204 203 Minimum engine speed for Voltage generation 444 Regulated Voltage 28 4 0 3 V Load Current 2100 Amp Excitation winding resistance 7 90 0 40 Gear Ratio 2 7 REGULATOR 2001138 1 2014 01 8 54 Electrical System 06 01 01 Adjust Poly V belt tension For Engines equipped with Raw Water Ss Pump and Hydraulic Pump k Automatic initial tension of belt tension lt gt d through spring loaded tightener gt A en POLY V BELT L 1488 6PK For Engines equipped with Raw Water SA Pump Automatic initial tension of belt tension through spring loaded tightener POLY V BELT L 1390 6PK i Pur uM For Engines without Raw Water Pump Automatic initial tension of belt tension 2 through spring
9. c5 5 598815 8 385 oo cigo s sie Se OF S 2 ol zis c 8 3 El S s5 l S 5 5245 58959 5 5155 C m MO w O gt O gt 215215 552 S Zl g 9 9 8 016 Gls g goo c 5552 5 55555 255 cc o 9 d gt Z o L 5 E 2 2 S lt AlA a iw w a e2199 3 Running out of fuel Clogging of fuel filter or water separator Clogging of the fuel oil piping before fuel E Qo Eag 5 42 L 8 5 5 e tq bus e 90 E c o E NI 5 9 gt Oj 2 gt ae Di 2 c LL Mi lt QI 2001138 1 2014 01 27 65 Preliminary Service Manual MARINE 2012 General Items to Check Troubled Systems J0joefui mn 19 000 Sugea Duu o JO fo Ajddns 1 Bussi Jepui Ao pjojiuew Buisnou 9UIGJN Jo yes WUa SAS uejooo TE Jat 3uejooo eBJeuosip JO 616 peuou Buluuns eiqejsun anoa youms JO
10. Items to Check Troubled Systems duie1 pinbi 2 Insufficient air supply volume to Compartment Air ventilation passage obstructed Raw Water amp Fresh Water Coolant System Contamination of intercooler fins Factors Cause of Trouble Z001138 1 2014 01 3 21 Cooling System 05 00 Functional Description Engine Cooling Circuit In the closed primary cooling circuit of the engine the coolant circulates by centrifugal pump circulating pump mounted at the front of engine block The pulley of the pump is driven from the back of the timing belt The pump is maintenance free The engine coolant SMO Z011785 0 in the closed circuit of the cooling system circulates as follows The circulating pump of the engine feeds this 1 1 Glycol mixture through the coolant distribution manifold into the engine block The coolant flow is split up to each cylinder in this distribution manifold The coolant circulates around the cylinders absorbing the thermal energy from the combustion passing through ports inside the cylinder blocks to the upper deck portion collecting at the front outlet manifold In the outlet manifold a cooling sensor is mounted to inform the engine management system about the operating temperatures and conditions of the engine Part of the coolant flows from the distribution manifold directly into the engine oil cooler and back
11. 28 65 2001138 1 2014 01 After first Every Every 50 hours 300 h 600 h Service and Maintenance Schedule Daily or i2 notes months months months Check For leakage ____ __ ___ Lubrication Change fe y 9 motrol e 1 4 forleakage eoo ___ o e J __ 10d o Susi Check hoses hose clamps Le e e Cooling Svstem temperature y condition Every24 months zinc anodes P X ____ Eg e intercooler or every 48 Glean months Raw Water Every 900 hours System heat exchanger or every 48 months CTC If sacrificial a material corrosion of 50 ie Clean out Raw Water raw water desposits in Cooler Oil pipelines Fuel Aux If sacrificial Lubricant change 2 anodes progress reaches a material corrosion of 5096 1 1 Change airfilerelement J Prseve Td After season forleakage 14 2 Check hoses 2 Fuel System 2 12 oo 2 Change _ 1 Preserve fuel system 111 ter season p addlevl 1 e Z4 4 J Battery Batey El electronics heck connections p
12. HOLD IN WINDING Model AZE2180 11 131 439 Nominal Tension 24V Nominal Power 2 bkW Sense of Rotation Clockwise WIRING DIAGRAM p di PULL IN WINDING HOLD IN WINDING 13 54 2001138 1 2014 01 Electrical System 06 02 02 Replace starter motor 1 Disconnect battery 2 Loosen terminal 30 battery main cable on magnetic switch by means of SW13 3 Remove start signal wiring terminal 50 from blade terminal resp M4 screw depending on model 4 Loosen M10 Allen screws SWSB of starter motor 5 Remove starter Assembly is done in reverse order NOTE Tighten Allen screws M10 with a torque of 45 Nm 2 Tighten M10 nut at starter motor solenoid for battery positive cable 30 with a torque of 10 Nm 1 Tighten M5 screw for stud signal 50 with a torque of 3 Nm 0 3 Tighten M6 screw for stud signal 50 with a torque of 4 Nm 0 4 Note After Assembly coat all electric supplies with rubber sealing Z909570 0 2001138 1 2014 01 14 54 Electrical System 06 02 03 Checking the starter motor before it is removed from engine Mechanical checking e Check starter motors fixing screw or bolts Make sure that they are tightened with proper load e Check connection bolts of terminal Make sure that they are tightened with proper load Check if starter motor is damaged from outside broken parts burned If YES remove the starter Try to crank the starter and observe un
13. S 25 65 gt 01 9 2 o mp sc aie SZlg9 c els o 2P oljclo2sS Bla gt e 51415 ol e e Biz 5 gt Oo Cle 5 214184186 06 8 521 5 061 0 de og sc gl as elo gl 9 9 2c gt 6 2o go o oS5 o o 2 64 ElL 9 O 9 9 9 Injecti Svst c 075 e9 ve b d OE Factors Cause of Trouble 1jd2jnaoalcigsS dino Fuel leakage from nozzle bod Air trapped in the fuel system at ignition ON Malfunctioning of the rack linkage or control Faulty fuel spray from the nozzle Uneven injection pressure from nozzle Malfunctioning of check valve fuel outlet Fuel system O lt Uneven injection quantity Malfunctioning of governor solenoid Faulty valve clearance Uneven compression Faulty valve seat contact Faulty Engine timing Faulty valve timing Defective tachometer of the engine Faulty idling adjustment Inas LI Base Engine System Sett Z001138 1_ 2014 01 4 47 Fuel System Items to Check Troubled Systems 5 5 9 Oo gd c 2 E 2 7 Plc gt x Sle E S9 0 2 6 o 5lo 5 9 5 5 52
14. a i aiil 183 i 5 H giis PA s 45258 ues 1 H T 4215 2001138 1 2014 01 22 54 Electrical System Wiring Diagram E Box Diagram 2181134 d 28 ha T m 15 Ar Rs 1 l 2181134 0 Alternator g STEYRMOTORS ES Starter 1 n m 2 d i gt x 8 m H 5 D i D E C EA 8 m d 7 s E m x IHH MID ee T i BE c 5 te E zu 4 3 5 mem E Jl 85 CEF DT LP EG EXT ger a METRIC m mda gepr norm A ooo a m DIMEMSIOMS ARE In BILLTIMETEHS im y a cM DEN n mls Ce siil m F 253 sis ELI dB NH i R L fep bi Hl m ge n 1 T T E F BREE a 23 54 2001138 1 2014 01 Electrical System 06 02 10 Wiring Diagram External E Box Diagram JIE F 38 30 Bree 3572 H SHRIJHITIIM HI FWY SHOIEES3HTU 3 gram pep ci pee Hem pp Sp Jno 3m 1 amp wrr3esTTQPH 40 parus 33 HOS
15. 9573 2565 _ PE signal voltage too high possible short circuit to battery X25 49811 C293 OFFLINE E FER Hybrid Control Unit HCU is offline or connection is broken if ECT gt 80 C and LPS gt 5bar observation starts 5s after IGN ON For further information refer to Service Information SI 1303 37 54 2001138 1 2014 01 Electrical System 06 04 10 Explanations of the BLimDiag Bit to limit Beta max BLDqm BLDact BLDla BLDitd BLDitderr BLDext BLDt30 64 256 1024 2048 4096 BETA_max limited on max Injection Quantity Table FN_QM limited by Air Charge Temperature BETA_max limited on insufficient boost pressure at given load amp speed TBLA TBACT Note During transient driving condition BLimDiag parameter must be ignored because this Bit indication reflects the dynamic parameter situation of momentary load amp speed condition After establishing steady state condition parameter value bit will be considered for computing BETA_max BETA_max limited due to insufficient lubricant pressure at present engine speed TBLPS BETA_max limited by engine coolant temperature TBTLIM BETA_max limited because of ITD position actual ITP BETA max limited due to ITV ITPsensor error high or low BETA max limited by Exhaust Gas Temperature measured in
16. Fill cooling system refer to 05 00 08 Z001138 1 2014 01 Assembly 74 84 01 08 02 Mount intake manifold 1 Clean sealing surfaces on motor block 111 1 Me 2 Fix 2 seals ill 1 pos 1 with grease B ei Straburax NB04 on marked surfaces of CETT mono block 3 Clean sealing surfaces on intake manifold ill 1 pos 2 4 Fix intake manifold on engine block by means of 2 Allen head screws ill 1 pos 3 Screw in remaining 10 Allen head screws SW6 and tighten with a torque of 28 2 Nm 5 Further assembly is done in reverse order of disassembly 75 84 2001138 1 2014 01 01 08 03 Disassemble exhaust manifold complete with turbo charger Preparation Drain raw water circuit Drain closed coolant circuit refer to 05 00 07 Hemove front and rear engine cover refer to XX XX XX Remove exhaust hose from exhaust elbow pipe Overview 1 Remove exhaust hose from exhaust elbow pipe For assembly Tighten hose clamps with 4Nm 0 5 2 Loosen hose clamp of upper raw water connection hose and pull off hose from heat exchanger For assembly Tighten hose clamp with 4Nm 0 5 3 Remove Plug from Speed Sensor RPM B3 4 Remove Plug from Exhaust Gas Temperature Sensor EXT B8 Z001138 1 2014 01 76 84 If required 5 Loosen hex head screw M8x120 SW13 from bracket high riser and remove distance pipe For assembly Tighten screw with 2
17. Preliminary Service Manual MARINE 2012 F Operating material and information on disposal F1 List of operating material zowoso ShelRimuleROM SWI grease Never Seeze NS 160 B 1 kg can Z909570 0 caoutchouc electric contacts 148 ml can CCONENETTIOTUTI III A NN 00020710 1 seang 5162 615 miae _ Z010014 0 1 Shell Rimula R3 long term preservation 5 litre canister Z050323 0 1 Ensis engine oil 30 long term preservation oil 5 litre canister so 1 Ceramic prtecton spray applicable on TC 00mm can soya 1 Ensis __ 2001138 1 2014 01 48 65 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 Catalogue ONORM 5 2100 refers to the required disposal in Austria 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 Respective legal local regulations are to be followed Key No Description 31 423 Oil contaminated soil or bonding agent 54 102 Waste oil 54 104 Fuels o4 202 Lubricants 54 207 Vaseline 54 917 oolid sealing material 54 927 Oil soiled cleaning rags 54 928 Used oil and air filters
18. Repair works No repair possible Exchange thermostat Test procedure Thermostat can be placed in a pot with water This water can be heated up oven While heating up the water the temperature should be measured While the temperature increases the thermostat must change its position closing resp opening the flow ports Z001138 1 2014 01 8 21 Cooling System 3 Water pump coolant circulating pump No special tools required Control works If with running engine leakage at the pump housing relief bore is noticed the slide ring seal may be worn out or damaged inside the pump To repair this damage the entire pump must be replaced Repair works Only exchange of entire pump possible 4 Cooler cap Example No special tools required Control works As a standard a cooler cap with an opening pressure of 1 5 bars 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 2 3 Repair works Not provided exchange cooler cap 9 21 Z001138 1 2014 01 Cooling System 5 Coolant loss in engine cooling system 5 1 Coolant loss Control works item 4 check cooler defective monoblock due to combustion pressure gases enter the engine cooling system 5 2 Gas air mixtures enter the cooling system 5 2 1 Defective monoblock This fault only can be stated with using special tool VR 00147 0
19. Z001138 1_ 2014 01 10 Remove fuel pump bracket and carefully turn away fuel pump Loosen 2 hex sock head cap screws M8x20 SW6 and hex head screw 8 20 SW13 For assembly Tighten screws with 23Nm 2 11 Remove oil supply pipe from intake manifold to Injection Timing Device ITD For assembly Use new sealing rings 4 Tighten hollow screws 2 M12x1 5 SW17 with 26Nm 2 12 Remove Plug from Fuel Supply Pressure Sensor FSP B10 Z001138 1 2014 01 72 84 13 Remove plug from boost pressure sensor MAP B4 14 Remove plug from air charge temperature sensor ACT B7 15 Remove plug and bracket from potentiometer accelerator B9 16 Remove plug of Ignition Timing Device Position Sensor ITP B2 17 plug of Magnetic Valve ITV Y2 73 84 Z001138 1 2014 01 18 Remove Plug of Lubricant Pressure Sensor LPS B5 19 Remove mounts of wiring harness on intake manifold and turn away wiring harness 20 Loosen hex head screws from intake manifold and remove intake manifold For assembly Clean contact surfaces on intake manifold and on engine block Use new o rings and grease with XXXX Tighten hex head screws with a torque of 23 Nm 2 6 O Ring 41x1 78 5 O Ring 25 12x1 78 1 Moulded Sealing Ring 3 M8x90 hex head screw 4 M8x140 hex head screw 7 M8x220 hex head screw Assembly 15 done in reverse order of disassembly
20. gt Q co O o 0 E O o 17 5 g L De gt 9 T 42 E 9 lt 50 95lg oq gt zu m pl 9 5 9 5 T 28 s gio 8 51 cosSs99929 55 S 91099 c t9 9 De Air Intake Fuel Supply amp Injection System 52 e gt 26 2 69 55 f Troubl gt GT Gl SO 9 G Factors Cause of Trouble 22 5 Ila EIda AlIa 5 cic gt Q 56 Oo o gt gt gt LL Water or air mixed in fuel Clogging of fuel filter fuel supply line or water separator 2 Inferior performance of feed pump A Faulty spray condition of nozzle Faulty injection timing Inferior performance of delivery valve Clogging of air filter Clogging or collapse of exhaust pipe or muffler High intake air temperature Faulty valve seat contact Wear or stiffening of valve guide Wear of piston rings cylinder liner Fuel Injection 1 1 Bl j wo LL _ _ Intake amp system System Exhaust Settings Base Engine 5 47 Z001138 1 2014 01 Fuel System 03 00 Fuel System 03 00 01 General Schematic Fuel system MARINE 2012 STEYRMOTORS KJ min ID 8 mm
21. 1 Loosen 6 Hex sock head cap screws M8x20 SW 6 and remove entire oil cooler For assembly Clean sealing surface on oil cooler and on intake manifold Install new O rings and grease O rings SMO P No 10107 4 O Ring 25 12x1 78 Tighten screws with a torque of 23 Nm 2 Use Loctite 243 Assembly is done in reverse order of disassembly Fill cooling system refer to 05 00 08 81 84 Z001138 1 2014 01 01 13 02 Change motor oil general 1 Bring engine to operating temperature and stop engine 2 Pull oil dipstick off O Ring seal Open oil filler cap but do not remove because of possible contamination 4 Loosen oil drain plug and drain oil Dispose sealing rings 5 Screw in oil drain plug and tighten with a torque of 50 Nm SW 12 Use new sealing rings NOTE Safety advice e Pay attention to hot engine oil Temperature can be well above coolant temperature to max 135 C e Dispose the oil properly according regulation of waste disposal NOTE Renew Cu washer 6 Remove oll filler cap Z001138 1 2014 01 82 84 7 Fillin STEYR turbo diesel engine oil SAE 10W 40 No 2010058 0 ill 3 or equivalent motor oil with characteristic ACEA E4 E5 E7 or B4 02 resp API code CF or higher ATTENTION Oil filling must not exceed the maximum marker Overfilling results in high operating temperatures foaming air in oil loss in efficiency
22. 16 17 18 19 23 47 Screw the sliding hammer into the insert and using force hammer the insert out lt will be necessary to clean the seating surface extremely well removing all traces of the old loctite with a strong degreasing agent on a cloth as below Clean the new insert also with a degreasing agent and fit a new o ring lt is necessary to grease the o ring to allow for a smooth fit and apply loctite 620 to the contact surface as shown below oit the new insert into the block by hand Press the insert down using the pressing tool and tighten to 18Nm Grease the flanging tool and insert it into the pressing tool ocrew the flanger all the way down through the insert This forms a flange on the end of the insert and ensures a sealed fit Screw the flanger back out of the insert and remove the pressing tool ouck out any fuel that may have entered into the with a suction bulb Refit the unit injector use new copper washer slide the rocker arm back into place and refit the half moon ring Do not forget to set the unit injector travel When all sleeves have been changed reset the rack calibration Z001138 1 2014 01 Fuel System 03 02 03 Fix control rack Preparation Remove camshaft housing Cover refer to 01 00 02 1 Unscrew setpin of control rack ill 1 pos 1 at the rear bulkhead of camshaft housing as shown 2 Position bore diameter 4 mm in control rack ill 2 pos 2 ove
23. DIN 51773 EN ISO 3675 EN ISO 12185 EN ISO 3405 EN ISO 2719 EN ISO 3104 EN ISO 20846 EN ISO 20884 EN ISO 2160 EN ISO 10370 EN ISO 6245 EN ISO 12937 EN ISO 12205 2001138 1 2014 01 Preliminary Service Manual MARINE 2012 B 2 Motor oil To obtain the best engine performance and engine life STEYR MOTORS High Performance Diesel Engine Oil SAE 5W 30 Z010059 0 is recommended Engine oils are specified by ACEA service codes and SAE viscosity numbers If STEYR MOTORS High Performance Diesel Engine Oil is not available it is required to use a reputable brand of engine oil labelled for ACEA C3 and API CF and SAE oW 30 Refer to oil identification symbol on the container 17 0 Litre Cil filling incl Initial filling quantity SE 6 Cyl Engines Litre oil filter Oil quantity between MIN and MAX on dipstick 3 5 Litre Oil change quantity 16 Litre without oil filter Oil filter Approx 1 Litre Oil specification Minimum API CF ACEA C3 STEYR MOTORS DIESEL ENGINE OIL Recommended engine oil SAE 5W 30 5 No Z010059 0 During the break in period initial 20 hours frequently check the oil level Higher oil consumption is normal until cylinder system is stabilized The oil level should be maintained between the minimum and maximum mark on the dipstick The space between the marks represents approximately 3 7 quarts 3 5 litres For oil level dipstick location
24. Electrical System 06 08 02 A Voltage regulator 24V 12V equalizer 2179789 0 loschen Fehler Textmarke nicht definiert 06 10 Actor and NR 42 06 10 01 Component configuration 42 06 10 03 Calibration of rack position 43 06 10 04 Replace senders sensors 0 0 0 0 00 45 06 10 04 01 ACT Air charge temperature sensor 45 06 10 04 02 ECT Engine Coolant temperature sensor 06 45 06 10 04 03 RPM Speed sensor 45 06 10 04 04 MAP Manifold Absolut Pressure Sensor 04 46 06 10 04 05 RPos Sensor for rack position 01 46 06 10 04 06 LPS Lubricant pressure sensor BOS 46 06 10 04 07 FSP Fuel Supply Pressure Sensor B10 46 06 10 04 08 ITP Injection Timing Position Sensor BO2 47 06 10 04 09 ITV Ignition Timing Valve 2 47 06 10 04 10 Vane Actuator 25 47 06 10 04 11 FDS Fuel density Sensor included in Kit Fuel Compensation 51205010 48 06 10 04 12 MET Manifold Exhaust Temperature Sensor X21 48 gt included in Kit Fuel Compensation 512050
25. Minimum inside diameter 16 mm Hecommended material stainless steel NOTE Min inside diameter for hosepipes or PA pipes is 16 mm Rate of flow 350 I h measurement on continuously operated fuel pump If additional filters getting installed the requirements of higher flow in the fuel gallery circuit must to be considered NOTE pipe connections pay special attention to the tightness of the suction pipe s all fittings and line located before the electric fuel pump Types of recommended pipe connections 03 00 ill 2 Back flow min 280 l h 7 47 Z001138 1 2014 01 Fuel System 03 00 03 Unit injector gear Adjusiment lever 6 Plunger E Copper seal ring Feder 1 Druckstufe Spring 2 Qu E c Qu Z001138 1 2014 01 vay Fuel System 03 00 04 Air system M16 VTI Air filter Q Turbine Q Compressor intercooler Exhaust manifold Exhaust elbow Du iLL e Exhaust outlet 7 226 gt gt ls DA www steyr motors com 22 Permissible low pressure for air filter and in air intake pipe before of turbo charger Permissible low pressure before TC intake 30 mbar low pressure with loaded air filter element 50 mbar Change Replace filter element if low pressure exceeds 50 mbar Air filter cleaning see Service and Maintenance Chart Exchange see Se
26. Preparation Put engine out off operation Disconnect battery Hemove camshaft housing cover 01 00 02 Special tool for vibration damper screws No 2300700 0 Locking pin No 2300551 2 Unscrew Allen head plug screw ill 1 5 10 4 Turn crankshaft by means of Allen socket size 10 mm until roller of rocker arm cylinder 1 runs up the ramp of injection cam ill 3 5 Insert locking pin 2300551 2 into guide hole and slightly press it against counter weight land of crank shaft 5 84 Z001138 1 2014 01 6 Continue to turn crankshaft slowly manually in direction of rotation until locking pin engages to slot at the counter weight land of crank shaft ATTENTION Never actuate starter engine as long as locking pin is inserted 00 01 ill 5 Removal of crank shaft lock pin 1 Pull out locking pin 2300551 2 NOTE Use new copper sealing ATTENTION Prior to starting make sure that Locking pin has been removed 2 Clean sealing surface of camshaft housing and camshaft housing cover Check seal for hardening and damage Exchange if necessary See 01 00 02 3 Remaining assembly is done in reserve order 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 1 is located just before the injec
27. Z001138 1 2014 01 32 84 01 01 05 Replace stud bolt for unit injector Preparation Remove camshaft housing cover 01 05 01 Remove unit injector 03 02 02 v 1 Tighten threaded pin with a torque of We S 21 1 Nm Loctite 620 40 287 0011 2011 Pus 01 01 06 Replace dowel pin for positioning of unit injector Preparation Disassemble camshaft housing 01 05 01 1 Insert new dowel pin by means of pressing tool 01 06 111 33 84 Z001138 1 2014 01 01 01 07 Replace dowel pin for positioning of camshaft housing Preparation Disassemble camshaft housing 01 05 01 Insert new dowel pin by means of pressing tool ATTENTION Do not close oil supply duct with dowel pin in front see illustration below ENGINE DAMAGE 0026 2011 Z001138 1 2014 01 34 84 01 01 08 Mount frame seal 0001 2011 1 Clean and degrease groove in cylinder block 2 Position tool no V000306 0 over cylinder block apply on metal surface of tool a film of cleaning agent Slide frame seal over tool as shown in picture NOTE For easier installation of frame seal apply alcohol on sealing profile or ultra clean agent tool V000306 0 metal surface The alcohol will in place of a lubrication agent during installation process Clean of the frame seal lip and the block slot using Acetone or a non oil based cleaner pure alcohol
28. to ground AdcCountLPS u16 0 098 V TLE RL1 FPR E MIN Fuel Pump Relay Output signal voltage too low possible short circuit to ground 1379 E MAX 2 Voltage Detection Battery voltage is too high RAMECC E FER error on ecu RAM replace ECU with new one ensor X21 1 AdcCountVBattln u16 241 24177 17 1577 629 FPR Fuel Pump Relay Output 5 voltage too high possible short circuit to battery 2 00 00 y o 1581 62D FMS_E FER Fuel Metering Solenoid rackismotcaliated yet 30or 135 1592 638 FMS_E SIG 7 FuelMeteringSolenoid nonplausiblesignalfomfms VREF1_E MIN CHEER 1603 643 VREF1 E MAX VREF1 Sensor signal voltage too high possible short circuit to battery 1000 cnts 4 888 V 1618 652 VREF2 E MIN VREF2 Sensor signal voltage too low possible short circuit to ground 20 cnts 0 098 V 1619 653 VREF2 VREF2Sensor signal voltage too high possible short circuit to battery _ 09004 2_ 016 toss 606 VREFS EMIN VREFS 2586 HCU_ERROR_E FER Hybrid Control Unit functional error on HGU O 2673 A71 E Hybrid Control Unit too high voltage on HCU 653 698 704 CLUTCH E FER Hybrid Transmission Clutch clutch is not engaged right _E A7C ail 2684 Hybrid Control Unit overtemperature on HCU 4097 1001 ITP_E
29. 3 3 7001138 1 2014 01 Cooling System 05 00 05 00 03 05 00 04 05 00 06 05 00 07 05 00 08 05 03 05 03 01 05 03 02 05 03 03 05 04 05 04 01 05 04 02 1 21 05 Cooling System Table of Contents Functional Description Engine Cooling Circuit 4 Error detection cooling system 6 Check points for problems in cooling system Component checks of engine cooling system 8 Drain the coolant from engine 11 Fill System EXample sese ua OE tr d Don aa 12 PMRENMOS Al eet 12 5 12 Excharige 13 Replace coolant supply 14 P 15 Excharge coolant PUMO 2 UI Ode PNE aC Ul 15 Iristallcoolarit 18 Z001138 1 2014 01 Cooling System Items to Check Troubled Systems Raw Water amp Fresh Water Coolant System Factors Cause of Trouble Poly V belt slip orbreakage 5 Water leaks due to defective seal packing 5 Air is picked bevor Raw Water Pump _____ Breakage of bearing at Raw Water
30. 99 910 Paint and varnish containing waste material 49 65 2001138 1 2014 01 General G Notes on safety Means risk of SERIOUS injury is present Follow instructions in the Operation Fi Maintenance amp Warranty Manual before using motor or accsessory Indicates that contents are under pressure Indicates upward movement Example White baat ia at planing speed activating trim awitch to raise the bow of the boat Indentifies the meter which indicates accumulative running of engine Identifies battery or a meter wich indicates status of battery generator charging system Identifies the meter which indicates engine coolant temperature FILTER Identifies a device which removes contaminants from fuel Identifiez the negative ground or negative voltage connection e Identifies the STOP SWITCH It may also identity STOP position of the throttle control Indicates FUEL be used FUEL is present Indicates OIL iz to be used m OIL ia present 2001138 1 2014 01 Preliminary Service Manual MARINE 2012 Safety Warning Symbols At Means place shitt control NEUTRAL before starting motor Follow instructions in Operation Maintenance amp Warranty Manual betore starting motor 4 Identifies poisonous material Position Indicator Symbols 4 1 1 2 Indicates the amount af liquid in tank eo Indic
31. Pfeil 1 Unscrew hexagon screw M6x30 SW10 of clamp of oil dipstick tube and carefully turn away oil dipstick tube For assembly Use Loctite 243 on screw thread 69 84 Z001138 1_ 2014 01 2 Loosen hose clamps of raw water connection hoses and pull off hoses from heat exchanger For assembly Tighten hose clamps with 4Nm 0 5 3 Loosen hose clamp and remove air filter from turbo charger intake For assembly Use new air filter in case of pollution Tighten hose clamp with 4Nm 0 5 4 Remove oil separator from bracket Loosen hose clamp and remove hose from oil separator Dismantle hex head screw M6x16 SW10 from oil separator bracket For assembly Tighten screw with 9 5Nm 1 5 Loosen hose clamps and remove hose connection from the turbo charger to the pressure pipe For assembly Tighten hose clamp with 4Nm 0 5 Z001138 1 2014 01 70 84 6 Remove pressure pipe from intake manifold For assembly Use new gasket Tighten hex sock head cap screws M8x30 SW6 with 23Nm 2 7 Dismantle ground cable from intake manifold For assembly Tighten hex head screw M8x90 5 13 with 23Nm 2 Ensure electrical connection from intake manifold to engine block 8 Remove fuel supply pipe from engine block inlet For assembly Use new Sealing rings 2 Tighten hollow screw 14 1 5 SW19 with 37Nm 3 9 Remove plug from fuel pump X6 71 84
32. Preparation disconnect battery close fuel feed and return line drain engine oil refer 01 13 02 Dismantle wiring harness 06 05 02 dismantle exhaust manifold remove protection plate frame seal refer 01 08 06 Z001138 1 2014 01 59 84 1 Lift engine with special tool No VR00130 0 and crane min 3500 2 Dismantle oil separator and crank case ventilation hose 3 Remove oil filter 4 Disconnect oil pipe on oil pump and on intake manifold SW 10 NOTE Tightening torque of fitting on oil pipe 9 5 Nm 1 5 Remove intake manifold refer to 01 08 01 6 Mount it on No VR00102 0 and trestle No 00101 0 by means of four hexagon screws M8x30 SW13 ATTENTION thread screwing depth 1 5xD For mounting bracket Z001138 1 2014 01 06 01 ill 3 60 84 7 Loosen hexagon screws SW10 remove timing belt covering NOTE See for arrows markings on used timing belt mark timing belt if necessary Consider change intervals see chart maintenance 8 Remove poly for poly V belt and front vibration damper 9 Remove starter motor for easy handling 10 Remove flywheel refer to 01 03 61 84 Z001138 1 2014 01 11 Unscrew frame sealing from engine housing NOTE Do not puncture frame seal 12 First loosen 16 allen head screws SW 5 then 7 hexagon screws SW15 13 Force apart housing halfs and remove Assembly 1 C
33. lt gt 2001138 1_2014 01 36 47 Fuel System 03 08 04 Remove injection timing device ITD Preparation remove intake manifold refer 01 08 01 remove camshaft housing cover refer 01 00 02 1 Disconnect battery 2 Remove c clip and pull pin out 3 Remove plug from magnetic valve Hemove connector from linear position Sensor Remove oil supply line as illustrated Hollow screw M12x1 5 SW 17 4 Loosen 4 hexagon socket head cap D screws on ITD housing and remove ITD assy Remove O rings Y HE CE tap 37 47 Z001138 1 2014 01 Fuel System 03 08 05 Install injection timing device ITD NOTE Use new O rings 1 Put new O rings onto ITD housing and lubricate rings with motor oil 2 Mount ITD on camshaft housing Re install lever of eccentric shaft 111 1 3 Mount 4 screws and tighten with a torque of 23 2 Nm 4 Connect lever with ITD install pin 2 5 1 and secure with c clip i 2 pos 2 5 Connect plug to magnetic valve and linear position sensor 6 Further re assembly is done in reverse order 08 05 ill Z001138 1 2014 01 38 47 Fuel System 03 09 Change fuel pre filter and fine filter general description Water or other fuel contaminations may form deposits which clog the fuel filter and may lead to consequently damage in the injection system Change fuel filtrer on a regular schedule is highly
34. refer to your authorized STEYR MOTORS dealer NOTE Optional there are two different oil dip sticks available according to the engine storage inclination After first 50 hours of operation change the engine oil and replace the oil filter Refer to Service and Maintenance Schedule Oil Identification Symbol Engine oils are specified by ACEA service code and SAE viscosity numbers These may be found on the label top of can or API service symbol NOTE Some engine oils have several ACEA quality ratings The recommended ACEA service letter code must be among these quality ratings STEYR MOTORS has no values regarding the oil amp fuel consumption when a not known oil is in use Refer to F1 List of operating material API Service Symbol 2001138 1 2014 01 24 65 C Maintenance and Service C1 Trouble Check Chart ATTENTION Failure to do so could result in fire 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 SYMPTOM POSSIBLE CAUSE ACTION Engine won t start Starter won t crank Engine runs erratically 25 65 16 No fuel in tank or shut off valve closed 2 Air leak in suction lines 3 Fuel line plugged or pump defective 4 Poor fuel quality 5 Water in fuel filter 6 System error or failure 7 Battery output
35. 5 M10x200 50 Nm 5 M10x250 9 5 Nm 1 M6x25 Pa PON 2001138 1 2014 01 58 65 2 General Tightening Torques Values in this table refer to industrial standard and are applicable if no specific torques are indicated For studs tightening torques are to be reduced by 50 u tot 0 125 in NM Property class Nominal 2 standard thread M4 m Metric Nominal standard thread 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 u tot total frictional value 59 65 2001138 1 2014 01 Preliminary Service Manual MARINE 2012 Re Use of Bolts Total number Bolt Location Recommendation Camshaft housing Change after exchange of camshaft housing Change at first field change Conrod Change at first field change Main Bearing Change at second field change BENE NNNM LU C 3 ___ Flywheel 22223 Change at second field change EE ___ Lo a Log WEE a i 2 2 3 3 3 3 3 3 3 3 2 Belt Tensioner Change at second field change Stud Unit Injector Change at second field change Exhaust Manifold Bolts Change at second field change Exhaust Manifold Studs 3 Change at second field change Intercooler 2 after exchange of intercooler In general all torque angle thightened bolts
36. D Hold In Winding E Solenoid Plunger F Main Contacts G Field Windings H Commwutator Brushes I Armature K Relay Winding L Relay Contact 41 Checking the starter motor before it is removed from vehicle engine 1 2 Mechanical checking YES NO VALUE 1 1 1 Are starter motors screw or bolts fixed What is the load that they are tightened with 1 1 2 Are connection bolts of terminal conected What is the load that they are tightened with Are the battery conetions clean 1 1 3 Isthe Strater Motor damaged from outside broken parts burned If Y ES remove the starter 1 1 4 Trv to crank the starter and observe untypical operations and sounds Describe the observation 1 2 Electrical checking YES NO VALUE Are conections from battery and earth cable damaged or disconeted What is the battery voltage Turn on the key What is the voltage on terminal 50 What is the volatge drop between terminal 50 and terminal 30 If all above point are checked and starter motor still does not crank the engine with perscripted performance remove the starter 2 Checking the starter motor after it is removed from vehicle engine 2 1 Visual checking YES NO VALUE 2 1 1 Is any starter motor part mechanically damaged I 2 1 2 Check the wear of pinion 2 1 3 Try to rotate the pinion 15 it rotating smoothly in one side 2 1 4 Pull out the pinion Y ou need to fill the certain force from 50 to 100N 2 1
37. GPL i Low lubricant pressure warning u16 MET T30 MR Mainrelay 0 N IDLE u32 2001138 1 2014 01 32 54 Electrical System 06 04 Electronics General 06 04 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 the following parameter limits exceeded Coolant Temperature too high low ECT warning signal Air Charge Temperature to high ACT when installed Oil Pressure drops below min limit Boost Pressure is not correct MAP Exhaust Gas Temperature is too high EXT Injection Timing Device defective ITD Manifold Exhaust Temperature too high MET Fuel Density out of range FDS Engine RPM remains on IDLE speed if potentiometer accelerator input value reading is incorrect inversion switch active option DNV Engine is stopped in case of defective Rack Position Sensor defective RPM Sensor inversion switch active option SOLAS Optical and audible warning signals depend on equipments and standards of marine manufacturer Refer to chapter general Trouble Indication Chart Please refer to marine manufacturer instruction and expla
38. Indication memorized service codes ON 0 7 y E 5 m ON 5 sec 3 Engine running after start Normal condition Note For further information see Table Error indication on Instrument Panel 2001138 1 2014 01 38 65 Engine 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 During this period vary the engine speed frequently by accelerating to approximately three fourth throttle for two to three minutes then speed remain at cruising engine operating temperature alternate engine speed while driving to assist the break in of rings and bearings 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 Illustration represent
39. Lift lever above injection timing device Then turn shaft towards exhaust system NOTE Make sure camshaft lobe is clear of shaft linkage arrangement 1 Turn crankshaft until injector cam is at base circle as well intake and exhaust valve are open in order to permit a lateral shifting of rocker arm for the following disassembly procedure 2 Before loosening flange nuts of unit injectors drain the fuel from the supply gallery by opening the fuel feed connector NOTE Close fuel supply line well from tank if existing Z001138 1 2014 01 16 47 Fuel System 3 Remove nuts on unit injector flange 2 nuts SW 13 4 Loosen left handed hexagon socket securing the control link on the control rack by using 4 mm hexagon socket wrench P N 2300908 0 Turn control link against bulk head 1 hexagon socket SW 4 LEFTHAND THREAD each unit injector 02 02 ill 8 5 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 6 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 La g E i as jp Ar 24074 02 02 1 10 17 47 Z001138 1 2014 01 Fuel S
40. Tbe 0 147 V FMS E MAX Fuel Metering Solenoid anon position is beyond the maximum SRPOS 1 nee 0 660 V 35 54 2001138 1 2014 01 Electrical System DTC List Error Code List SE Engines V50000 10 gt actual version Hex ABBREV INVOLVED DEVICE POSSIBLE CAUSE 600 258 RPOS E MAX Rack Position Sensor signal voltage too high possible short circuit to battery B1 AdcCountRPOS 146 1020 cnts 4 985 V RPOS E MIN Rack Position Sensor signal voltage too low possible short circuit to ground 0 117 V PERE Glow Plug RELAY signal voltage too low possible short circuit to ground _____ ___ 900 384 rem OFRE Glow Plug RELAY signal voltage too high possible short circuit to battery K3 BERN EXT E MIN us signal voltage too low possible short circuit to ground 0 108 V ensor Exhaust Temperature 1030 signal voltage too high possible short circuit to battery B8 1000cnts 4 888 V 12 13 LPS E MIN 1 LPS Lubricant Pressure Sensor signal voltage too high possible short circuit to battery B5 1000 cnts 4 888 V 1349 T30 E MIN signal voltage too low possible short circuit to ground 50 cnts 0 25V ensor AdcCountT30 u16 700 cnts 3 421V 1029 LIT 7 1298 TPCB_E MAX PCB temperature sensor Sensor fault for PCB temperature replace ECU AdcCountTPCB u16 hoc MW HM 5 EUDICSDE Pressure Sensor signal voltage too ONE possible short
41. 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 21 Remove locking pin from crank shaft 22 Turn crankshaft 4 turns and stop at fourth turn with a plunger guide stroke of unit injector of approx 3 65 mm dial gauge reading 23 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 13 84 A 00 03 11 21 Z001138 1 2014 01 24 on tension gauge No VR00515 0 between camshaft sprocket and tensioner as described and read measured value Timing belt tension should be 600 30 for a new timing belt NOTE If timing belt tension does not correspond to specified tension loosen tensioner and repeat adjustment according to instructions under item 22 through 25 In this case a re positioning of the camshaft sprocket may be required 25 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
42. position Ignition Key ON Start position engine nat crankinq Ignition Key turnedto ON position missing CAM Data Comrmunication Ignition Key turnedto ON position condition no Service Code storred Ignition Key turnedto position Service Code memorized Start gt engine not cranking Start running Engine idle amp charging ACT High Air Charge Temperature gt operation limit exceeded ACT Defective Air Charge Temperature Sensor gt pr sensor connection ECT High Engine CoolantTemperature gt operation limit exceeded ECT Defective Engine Coolant Temperature Sensor gt Of sensor connection EXT High Exhaust Coolant Temperature gt operation limit exceeded EXT Defective Exhaust Coolant Temperature Sensor gt sensor connection LPS Low Oil Pressure gt Lubricant pressure below limit LPS Defective Lubricant Pressure Sensor gt Of sensor connection Insuficient boost pressure atgiven load amp speed gt defective Sensor gt or sensor connection RPM Defective Engine Speed Sensor gt Of sensor connection 2001138 1 2014 01 Preliminary Service Manual MARINE 2012 Emergency cut off switch Lanyard connected open Effects noticed during operation onthe helm dash board Neutral Safety switch open normal Red Flashing Backlight Red Flashing Red Flashin Backlight no RPM indication on Tacho 34 65 ECU
43. test equipment for CO in engine cooling circuit Procedure See specification from special tool P N VR 00147 0 Conclusion CO entry combustion gas in the engine cooling circuit Control works Assembly of unit injector refer to 03 02 02 check specified tightening torque Hepeat test procedure and check according 03 14 03 to determine cylinder affecting the system resp pushing combustion gases into the coolant system Hepeat check If result remains unchanged the monoblock is defective Repair works Exchange monoblock Z001138 1_ 2014 01 10 21 Cooling System 05 00 07 Drain the coolant from engine To drain the closed cooling circuit lift or lower the engine in such a way that the engine is in horizontal position which permits an ideal drainage of engine block ATTENTION Approx 1 litre of coolant will remain in the engine block which is to be considered for refilling With hot engine the closed cooling circuit is under pressure Do not try to open the pressure cap on the expansion vessel or any drain plug or hoses of the coolant system This may lead to severe injuries by hot coolant under pressure Wait until the engine has cooled down then the pressure cap may be opened by 1 4 turn to the left to release possibly remaining system pressure Then press down the cap turn and remove 1 Loosen hose clamp on lower coolant hose at oil cooler unit Pull hose from oil cooler nipple and drain coola
44. 01 ill 6 44 84 01 05 Camshaft Housing Valve Gear 01 05 01 Replace camshaft housing Preparation Empty fuel system 03 02 02 item 2 Disconnect battery Disconnect crankshaft from TDC 01 00 01 Dismantle unit injectors 03 02 02 Remove cover timing belt 01 00 04 1 Release timing belt tensioner remove tensioner pulley entirely 2 Remove timing belt from camshaft sprocket 3 Remove plug ill 2 pos 1 for sensor of control rack 4 Remove plug ill 3 pos 1 from control solenoid 5 Remove plug from magnetic valve ill 4 pos 1 and linear sensor ill 4 pos 2 45 84 Z001138 1 2014 01 6 Disconnect speed sensor ill 7 pos 1 7 Dismantle oil supply pipe injection timing device ill 9 8 Loosen hexagon screws SW 13 7x M8x135 amp 7x M8x110 9 Remove camshaft housing upwards Remove sealing Assembly of camshaft housing 1 Clean sealing surfaces of motor block ill 11 pos 1 and camshaft housing ill 11 pos 2 2 Put on camshaft housing sealing ill 11 pos 3 ATTENTION Always use new sealing 0002 2011 Z001138 1 2014 01 46 84 3 Put on camshaft housing Take care that 5 all cam followers ill 12 pos 1 rest on valve stems ill 12 pos 2 are positioned and aligned accordingly Crankshaft must be set up to approx 40 before TDC to avoid a collision of valves with pistons Tighten screws of camshaft housing in two steps as
45. 2 Loosen plug connection ill 2 pos 1 for control rack potentiometer 3 Hemove plug from control solenoid ill 2 pos 2 4 Loosen 4 hexagon screws SST SW13 on control solenoid housing remove control solenoid assembly Fig 3 53 33 47 Z001138 1_ 2014 01 Fuel System 03 08 02 Install rack control solenoid Assembly onto camshaft housing proceed as follows NOTE Use new O ring to seal control solenoid 1 Remove camshaft housing cover 2 Put O ring into groove of control solenoid 3 Shift control rack by hand ill 1 to front position and hold 4 Insert control rack lever so that lever ill 2 pos 1 is positioned behind disc of solenoid rod ill 2 2 5 Bring up control solenoid assembly parallel to sealing surface of camshaft housing put it onto the dowel pin ill 3 pos 1 and hold it in place 6 Slowly release control rack and fasten control solenoid housing by means of 4 080212 hexagon screws 7 Install 4 hexagon screws 8 and secure with LOCTITE 243 Tighten with a torque 8 Check whether control rack can be moved up to approx 18 mm against the spring load and returns under the spring load to zero position ATTENTION Pin of control rack potentiometer is spring loaded and might easily slip off from the contact surface of control rack lever during assembly In such a case the control rack is blocked and thus preventing the rack to return to zero delivery ENGINE FAILUR
46. 32 with tool VR00228 0 counter clockwise Tighten hexagon Socket SW 8 with torque wrench to 20 2 Nm 16 Put on tension gauge No VR00515 0 ill 17 pos 1 between camshaft sprocket and tensioner Pre tension timing belt tension by further counter clockwise turning of tensioner hexagon SW 32 to read 600 30 Nm for new timing belt ATTENTION When putting on tension gauge No VR00515 0 consider the following The two stop trunnions ill 17 pos 2 00 05 ill 17 Z001138 1 2014 01 22 84 should rest on the forehead of timing belt and must not rest on the back of y y timing belt A Put measuring bow onto tooth During measuring completely push measuring bow and relax quickly n When attaining the required timing belt pe 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 A 17 crankshaft to indicated value below stroke of plunger guide and Tighten hexagon nut SW 30 of camshaft sprocket to 80 4 Nm by holding up with special tool 2300711 0 at hexagon on camshaft E ATTENTION Position camshaft to read a pre stroke of 3 65 mm movement of plunger guide unit injector During this operation camshaft sprocket and camshaft are connected A positive connection is only achieved by finally tightening the hexagon nut
47. 5 01 3 94 3 24 3 24 2 90 2 90 2 69 2 56 Ibs HP specific power 2 84 2 27 1 79 1 47 1 47 1 32 1 32 1 22 1 16 kg PS 630 630 630 630 630 630 630 630 idle speed rpm turbo Fuel Cons at idle speed 0 52 0 52 0 52 0 52 0 52 0 52 0 52 0 52 0 52 kg h air mass flow rated 490 520 710 965 808 980 860 1040 1020 power kg h Fuel cons rated power 20 1 25 4 33 7 42 5 40 9 47 3 46 1 51 52 2 kg h 2001138 1 2014 01 14 65 type exhaust mass flow rated power kg h max inlet depression at rated Power mbar spec fuel consumption at rated power g kWh min spec fuel consumption g kWh compressor outlet temperature at rated power C boost pressure adjustment value 1mm deflection mbar boost pressure adjustment value 3mm deflection mbar MAP at rated power mbar 510 1 30 50 1880 15 65 545 4 30 50 140 1680 1880 2200 743 7 30 50 240 205 145 1880 2020 2280 249 210 00 turbocharger geometrical turbocharger DOGE DEDE ENENENES 40 43 02 205 05 160 175 electronic electronic controlled controlled electronic electronic controlled 2100 controlled 2 90 2560 2840 2 40 2001138 1 2014 01 5 286 40 1091 30 50 248 210 180 2040 2240 2990 5 06 38 1072 2 30 50 243 210 180 2040 2240 3060
48. CEL shall blink with 2Hz c fuel metering solenoid cannot be governed position not reached or blocked d rack position sensor defective e at power on for approx 5 seconds when any error is active f Limitation during break in phase two hours g SOLAS Inversion Switch active h MET Manifold Exhaust Temperature is above threshold defined by SMO or sensor is defective refer to Chapter General D1 Trouble Indication i FDS Fuel Density is below threshold defined by SMO or sensor is defective refer to Chapter General D1 Trouble Indication j WIF Water In Fuel gt too much water in the water separator refer to Chapter General D1 Trouble Indication optional Equipment At ignition on the lamp shall be turned on for approx 0 7 second for checking of the bulb 2001138 1 2014 01 30 54 Electrical System 06 02 16 Battery Charge Lamp The battery charge lamp shall be turned on when the Ignition is switched on and during running condition when the alternator doesn t charge the battery For further information refer to Chapter General gt D General Information gt Trouble Indication Table 06 02 17 Warning and Parameter Limits from Engine Management System ECT Characteristic Parameter TBTLim Note Current Value Limiting starts app 105 C Values may get changed during course of development 06 03 Declaration 31 54 2001138 1 2014 01 Electrical System Signal Name GLOW PLUGS Glow Plug Relay output GND
49. Coolant pipes and hoses Hemove defective hoses by loosening the respective hose clamps and replace ATTENTION Tighten lose clamps with a torque of 3 5 Nm Ar Z001138 1_ 2014 01 12 21 Cooling System 05 03 02 Exchange thermostat Preparation Drain closed cooling circuit refer to 05 00 02 01 Loosen both hose clamps at thermostat housing and pull off both coolant hoses DISASSEMBLY 1 Loosen 3 Allen screw M6 holding the thermostat housing Remove thermostat housing including thermostat 2 Remove seal and dispose 3 Remove thermostat from housing ASSEMBLY 4 Insert thermostat into housing ventilation mark ill 4 pos 1 showing upwards ATTENTION Always use new seal 5 Install new gasket Insert 3 M6 Allen screws Tighten screws of thermostat housing with a torque of 9 5 1 Nm 6 Further re assembly is done in reverse order 7 Filling of closed cooling circuit refer to 05 00 02 01 13 21 05036284 0 Z001138 1_ 2014 01 Cooling System 05 03 03 Replace coolant supply manifold Preparation Drain closed cooling circuit refer to 05 00 02 01 Loosen both hose clamps at thermostat housing and pull off both coolant hoses Disconnect battery Disassemble control solenoid 03 08 1 Loosen 3 hex head screws SW10 at bracket 2 Loosen three allen head screws SW5 Ill 1 pos 1 remove coolant supply pipe 3 Remove gasket and dispose NOTE Use new seal for assembly R
50. EMS Beta Limitation active Boat performance velocity Engine stops running Beta Limitation Diagnostic Semice Code memorized Help as o x 2 Sensor box Service Code list EDT 2 0 Raw Water Circuit Charging system Service Code lisi Coolant Circuit Service Code lis Sensor box Raw Water Ciruit Service Code list Sensor box pressurized Lubricant System Service Code list Sensor box Combustion System Sensor box Charging System T30 Speed Sensor Trouble shooting procedure Sensor box 35 65 Optional Equipment Other Instrument Panel Factors Cause of Trouble RPOS Defective Rack Position Sensor gt of sensor connection RPOS RPOS deviation rack blocked ITD ITP deviation ITD Defective ITP Sensor gt or sensor connection SOLAS Inversion switch active MET T30 Defective Manifold ExhaustGas Temp Sensor gt or sensor connection MET T30 High Manifold Exhaust Temperature gt operation limit exceeded 205 Defective Fuel Density Sensor gt of sensor connection gt of fuel density too low 825 WIF Water in Fuel Sensor option gt gt foo much waterin the separator No charging fromthe alternator Limtitation during Break In Phase iex f Frequency Hz T time of oscillation s on
51. Exhaust Gas Temperature sensor SW 17 ATTENTION Use new sealing ring For further information refer to Extranet Troubleshooting Sensors 49 54 2001138 1 2014 01 Electrical System 06 10 05 Connectors helpful hints A contact removal tool taped or tie wrapped to the harness will make it easily available should repairs be needed Tie wraps and tape away from the rear of the connector will allow the wire to be sealed properly reduce contact force plating reduce chrimp adhesion tensile stress risers poor adhesion gt nur Solder should not be added to Deutsch terminals 2001138 1 2014 01 50 54 Electrical System 06 10 06 Connectors assembly instructions Locking fingers Contact Contact insertion Contact insertion FEES Unlocked position Contact lacked in position LEM Grasp contact Hold connector with rear Push contact straight into approximately 25 4mm grommet facing you connector grommet until a one inch behind the positive stop is felt A slight contact crimp barrel NOTE For unused wire tug will confirm that it is cavities insert sealing properly locked in place plugs for full environmental sealing Contact removal Contact removal i j Tool inserted to unlock contact Tool and contact removed With rear insert toward Slide tool along into the Pull contact wire you snap appropriate size insert cavity until it
52. Ground Power Ground Low Current Output Digital Output Relay Lamp Main Relay Output CAN Line 500 kbit Digital Ground Power Ground Analogue Input Battery 40 54 Electrical System 06 08 Potentiometer Accelerator and Voltage regulator 06 08 01 Potentiometer Accelerator 2180847 0 B09 Pin Nr Kanal 1 Kanal 2 1 2 3 4 out 5 6 5 _ Kanal 1 1 1 1 2 evi channel 2 CMD PED 1 Channel 1 rising Voltage PED 2 Channel 2 falling Voltage Summation of both voltages during the whole range hast to be 5 Volt PED 1 PED 2 5V 120mV 41 54 2001138 1 2014 01 Electrical System 06 10 Actor and Sensor 06 10 01 Component configuration engine 40 260 BS LPS _ m i 240 84 MAP Bi Rack 270 i 87 2 170 AL pie EX 250 Bet EKT 150 40 1 FMS 130 Pedal 220 BS ECT yxaiFuelbump MC _ 110 g ES Wi EE lm e c 70 METIEDS ao _ X22 Trim Gear E 100 DIAG 90 X25 VTG ISCI 230 190 X1 Panal X3 Intake mantfald Sensors iom Fuses 750 hi ALSO 10 30 X23 Solas iA Ki sER Pod Lima 2001138 1_2014 01 42 54 Electrical System 06 10 03 Calibrati
53. MIN Injection Timing Device signal voltage too low possible short circuit to ground AdcCountlTP u16 0 098 V 2001138 1 2014 01 36 54 Electrical System DTC List Error Code List SE Engines V50000 10 gt actual version Dec Hex ABBREV INVOLVED DEVICE POSSIBLE CAUSE Position Sensor EL A 4098 1002 E MAX mn Timing signal voltage too high possible short circuit to battery B2 1000 cnts 4 888 V Position Sensor 4112 1010 ITD INVCALIB E FER Injection Timing Device invalid calibration value recalibrate the ITD T ITP deviation gt 3 for min 4113 1011 ITD FP E FER Injection Timing Device ITD is possibly not moving Y2 10s 4181 1055 T30FB T30 feedback feedback current error 4182 1056 E MAX T30 Exhaust Temperature invalid signal level AdcCountT30Fb u16 GENE 8805 2265 WIF E FER Waterin e senor mre much water in the water separator Service vetat ando Manifold Air Pressure 8744 2228 MAP E MIN Sensor signal voltage too low possible short circuit to ground 150 cnts 0 733 V Boost pressure Sensor AdcCountMAP u16 Manifold Air Pressure 8 45 2229 MAP E MAX Sensor signal voltage too high possible short circuit to battery B4 980 cnts 4 790 V Boost pressure Sensor 9572 2564 VIGPOSFB E MIN tuno nager Peston signal voltage too low possible short circuit to ground X25 Feedback Turbocharger Position
54. RPM Speed sensor B03 1 Press handle and remove plug 2 Loosen hexagon screw SW10 remove sensor ATTENTION For assembly use new 0 ring Grease O ring and put it on Secure hexagon screw with LOCTITE 243 and tighten with a torque of 9 5 1 Nm 45 54 2001138 1 2014 01 Electrical System 06 10 04 04 MAP Manifold Absolut Pressure Sensor B04 1 Pull off plug by turning counterclockwise 2 Loosen sensor SW27 Remove sensor Assembly is done in reverse order off disassembly For replacing the sensor use LOCTITE 243 06 10 04 05 RPos Sensor for rack position B01 1 Remove retaining clip remove plug housing 2 Disassemble rack control solenoid refer to 03 08 01 3 Loosen 2 hex sock hd cap screws with hexagon socket SW3 remove sensor Assembly is done according to assembly of rack control solenoid refer to 03 08 06 10 04 06 LPS Lubricant pressure sensor B05 1 Remove plug housing 2 Unscrew lubricant pressure sensor SW 22 from mount ATTENTION Avoid spilling of engine oil Collect lubricant in suitable container 3 Mount sensor with new cupper seal and tighten to 28 Nm 2 Use LOCTITE 243 06 10 04 07 FSP Fuel Supply Pressure Sensor B10 1 Remove plug housing 2 Unscrew Fuel Supply Pressure sensor SW 22 3 Mount sensor by use of LOCTITE 243 2001138 1 2014 01 46 54 Electrical System 06 10 04 08 ITP Injection Timing P
55. Sensor Supply Voltage CU Ground Negative AN High CAN Low AN Connection lost Check Engine Light CEL Engine Management System 2001138 1 2014 01 Electrical System Austauschen neu machen lassen von tedoc Exhaust Temperature Sensor Engine Coolant Temperature Sensor Pedal Accelerator Lubricant Pressure Sensor Fuel Supply Pressure 20 Amp a Fuel Purnp Fuel Matering Solenoid Injection Timing Valve 25A VBATT 5 o 5 2 o INNOVATION WITH LIGHTNESS 7 X A wd UNE io DENEN Lu ul uM x Di s eo ED BS S al F 4 4 i i A d i pi 4 Bi A g Pd CER 6 m M PT SiS Wiring Harness Layout Drawing 2001138 1 2014 01 4 54 Electrical System 06 00 General Wiring For the STEYR Marine Engines wiring and plug connections have been designed according to standard DIN 72 552 In case of necessary repair of a cable connection take special care that cable quality isolation crimping strand end soldering of cable sockets as well as protective varnish isolation and or connector locks meet the respective requirements Tools for crimp connections to be found in tool catalogue P N Z001002 1 KIT 3 5 54 2001138 1 2014 01 Electrical System 06 01 Alternator f t 2 3 il 4 pes AS 22 7
56. _ connections Tighten loose Electrical Shack connections Equipment insulation Renew cables if Inversion heck PEN PEN gn driving unit cem rers 2 Turbo Charger en e Device Screws 29 65 2001138 1 2014 01 Preliminary Service Manual MARINE 2012 After first Every Every jy 50 hours 300 600 h Service and Maintenance Schedule Daily org ori2 or24 notes months months months remote control Check emergency bea rules and Safety completeness consultion of your 22222 Equipment Dealer Condition r a fei wear Poly V Belt System with standard equipment 48 e g alternator raw water ry Poly V Belt pump and hydraulic pump Change Poly V Belt System with optional equipment Every 900 hours e g 274 additional or every 48 alternator high power months hydrualic pump etc Poly V Belt 2 5 Tensioner Lubricate 1800 hours Change plugs or every 48 belt tension ti 1800 hours timing belt e idler pulley bd late Timing Belt months 9 Every 3600 hours water pump tensioner or every 48 240 900 VANGS For Commercial use only Commercial use only use onl CnC ae clearance 300 hrs Timing setlvrs A Q Evey900hous C
57. and a reduced engine life As to capacity for an oil change refer to Technical Data and engine overview chapter General As to capacity for first filling e g after engine repair refer to engine specifications Oil 02 02 8 Puton oil filler cap and lock ATTENTION 4 gt Check oil level before starting engine Hemove possible oil contaminations from oil filler cap and environment Check other fluid level before operating vehicle Check oil level after running engine 13 03 ill 3 Z001138 1 2014 01 01 13 03 Change oil filter 1 Loosen the oil filter with oil filter wrench 2300713 1 and Dispose the oil filter acc automotive waste disposal regulation 2 Clean sealing surface of oil filter head 3 Oil the seal of new oil filter and screw it onto oil filter head until the seal easily rests against Tighten the oil filter by hand app with a 3 4 turn ATTENTION Remove possible oil contaminations from filter 4 head and environment Do not forget to check engine oil level Z001138 1 2014 01 84 84 Fuel System SV SUC M a M 3 03 00 01 General 5 5 03 00 02 TuncaoDal descriplIOUluseeseei eoa iios 5 03 00 03
58. and fastened Control rack and unit injector control gear must be free to move 2 Put dial gauge rail with bracket AQ pP 2306031 6 onto camshaft housing and TSB Se fasten with M6 screws 3 Fix eccentric shaft with special tool No 2300736 1 as shown 27 47 Z001138 1 2014 01 Fuel System Connect tool VR00236 0 to valve solenoid and connect power on and to cable to release hydraulic pressure from device NOTE With the tool connected the injection timing device and eccentric shaft can be moved easily 4 Turn camshaft until bearing roller of rocker arm for unit injector being adjusted is situated on the base circle of the injector cam NOTE Unit injector spring moves to most upward position 5 Mount dial gauge No P N 2300899 0 with pointer No P N 2300641 1 into dial gauge rail 6 Put pointer onto unit injector plunger guide 7 Align dial gauge and fix gauge to approx 3 4 of its possible travel 25 mm 8 Insert unit injector extracting lever No 00126 0 ill 6 pos 1 in recess of rocker arm between rocker arm body and roller as shown and fully press down spring of unit injector Press button on dial indicator to obtain zero indication on display 00 0 Z001138 1 2014 01 O2 06 14 02 06 5 02 06 ill 6 28 47 Fuel System 9 Turn adjusting screw ill 7 pos 1 with torx screwdriver 2300873 0 and set the adjustment value as listed in table below Hold adju
59. and give time for dry this before continuing 35 84 Z001138 1 2014 01 3 Apply activator 7649 to groove in the cylinder block After waiting 2 minutes for the activator to cure apply construction adhesive LOCTITE 620 green on both sides of first profile groove in the frame seal 4 Press frame seal into cylinder block groove beginning at the cylinder block corner and then along side of the block NOTE Only press in the rubber of the frame seal by hand Do not stretch or displace Pay attention do least curing time and curing temperature Also see manufacturer s specifications 5 Secure the frame seal to the housing using new screws M6x12 Precote83 and tighten to 10 Nm ATTENTION Pay attention to safety notes rules when handling with technical liquids Z001138 1 2014 01 36 84 01 02 Crankshaft Bearing Vibration Damper 01 02 01 Replace crankshaft Preparation Disassemble flywheel housing and flywheel 01 03 01 und 01 03 02 Disassemble timing belt and vibration damper Disassemble engine housing 01 06 01 Disassemble oil suction pipe 01 06 03 Disassemble oil pump housing 01 06 02 1 Turn crankshaft in such a way that piston of first cylinder is located at TDC 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 s
60. engine load does the problem occur 2 Closed Cooling Circuit internal 2 1 At first take into consideration the following possibilities Defective or faulty coolant temperature sensor Coolant level in expansion tank less than 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 coolant circulation pump pump roller bearing defective defective seal case pump wheel Pressure cap pressure cap sealing defective loss of system pressure vacuum valve defective excess pressure valve defective opening pressure of cap according to specification 2 2 Malfunction of thermostat overheating or slow heat build up in coolant system Procedure Let the engine run until indicated temperature exceeds 80 C Feel temperature in coolant outlet pipe to radiator 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 temperature in coolant outlet pipe to radiator Z001138 1_ 2014 01 6 21 Cooling System Result Temperature on hose slowly rises simultaneously with temperature of coolant but does not reach operating temperature 80 C opening temperature of thermost
61. illustrated ill 14 from inside outwards Torque 1 Step 15 Nm 1 9 2 Step 25 Nm 2 6 Assembly unit injectors refer 03 02 02 T 8 Adjust valves refer to 01 01 02 Adjust unit injectors refer to 03 02 06 Adjust control links INJECTION QUANTITY ADJUSTMENT refer to 03 02 04 10 re adjust engine timing refer to 01 00 05 11 Calibration of rack position refer to 06 10 03 12 Assembly engine in reversed order 47 84 05 01 ill 12 Tight ning sequence exhaust side 14 10 suction side 05 01 ill 14 Z001138 1 2014 01 01 05 02 Replace gas stem gasket on engine assembly Preparation Disassemble camshaft housing 01 05 01 ATTENTION oet piston of respective cylinder on TDC 1 Mount valve spring retainer No VR001 05 1 ill 1 2 Compress valve spring ill 2 with hexagon socket SW28 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 1 4 Z001138 1_ 2014 01 48 84 6 Put special tool No V000152 0 onto valve IM ZB stem end and push new valve stem gasket a over sleeve 7 Remove sleeve and press 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 05 02 ill 5 9 Put on valve s
62. injector 00 05 11 23 NOTE If the index value of engine timing should not correspond to the specifically value follow the instructions as per item 25 22 ln case of a correct index value of engine timing remove locking pin on crankshaft and tighten the hexagon nut of the camshaft sprocket SW 30 with 240 Nm by holding up with special tool No 230071 1 0 00 05 111 24 23 ATTENTION following torques are to Z001138 1 2014 01 24 84 be checked again 1 Torque on hexagon nut of camshaft sprocket SW 30 o 240 12 Nm 2 Allen head screw SW 8 of timing belt tensioner at 45 4 Nm 3 3x TORX screws on vibration damper with 135 7 Nm 24 Remove adjustment tool from eccentric shaft Remove camshaft sprocket 25 Loosen hexagon nut of camshaft sprocket oW 30 by holding up with special tool No 2300711 0 and turn nut by approx 1 4 rotation 26 Mount extractor ill 27 pos 1 camshaft sprocket 00113 0 and screw in puller screw LEFTHAND THREAD by hand Pre stress puller screw with approx 100 5 Nm NOTE Do not remove camshaft sprocket from conical seat when screwing in the puller screw 2 Remove camshaft sprocket from conical seat by one hammer blow on puller screw NOTE To correct the setting of engine timing follow further instructions as per item 32 25 84 00 05 il 28 Z001138 1 2014 01 Readjustment of camshaft positi
63. notes on safety The general knowledge and training of the personnel and the contents of the general regulations of safety technology and machine safety regulations Machine safety regulations Maschinen Sicherheitsverordnung MSV is not subject of this chapter Inappropriate behaviour and insufficient knowledge of hazard during repair works may cause injury to persons In the description of repair works such sources of danger are marked with A ATTENTION The personnel are to be trained accordingly and requested to follow the safety 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 A 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 51 65 2001138 1 2014 01 Prelimina
64. screws with 23Nm 2 and nuts with 9 5Nm 1 Use new O rings and grease with XXX 6 O Ring 42x2 5 1 O Ring 5 23x2 62 1 O Ring 10 77x2 62 2 O Ring 23 47x2 62 4 O Ring 29 82x2 62 Assembly is done in reverse order of disassembly Fill cooling system refer to 05 00 08 79 84 Z001138 1 2014 01 01 08 06 Remove oil supply pipe of turbo charger 1 Loosen double length hollow screw on engine block 12 1 5 5 17 and remove oil pressure sensor LPS B5 For assembly Use new sealing rings Tighten double hollow screw with XXNm For assembly 2 Position of lubricant sensor LPS as illustrated 3 Loosen oil supply pipe mounting on turbo charger Mounting depends on turbo charger model e VIG Variable Turbine Geometry d Loosen locking nut and remove oil supply i E pipe assy 4 N Pfeil For assembly Tighten locking nut with XXNm X e WG turbo charger Loosen throttled hollow screw M12x1 5 SW17 and remove oil supply pipe For assembly Tighten throttled hollow screw with XXNm X Use new sealing rings Geometrical turbo charger Loosen hex head screws M8x30 SW13 For assembly Tighten screws with 23Nm 2 Use new gasket Assembly is done in reverse order Z001138 1 2014 01 80 84 01 13 Engine Oil Cooler 01 13 01 Replace engine oil cooler Preparation Drain closed cooling circuit refer to 05 00 07 Location view
65. the valve stem seal Wear of piston rings and cylinder liner raw water entry through exhaust system fuel oil streaks on water performance of engine Large fuel consumption Large lube oil consumption Exhaust smoke abnormal unstable idle running revs Low compression pressure Low drop in engine outpu Wrong position of eccentr shaft engine running away leaking o ring at unit black smoke emission white smoke emission blue smoke emission surface thermostat stuck open Check cylinder leckage rate valve amp piston ring Large blow by gas injector Inferior starting emission Knocking noise leaking oil cooler Overcooling of engine Missing or insignificant compression each cylinder Bad or inclompete fuel dispersion in piston board 3 84 Z001138 1_ 2014 01 Dismantle Engine Covers Dismantle Front Engine Cover 1 Unscrew 4 hex head screws SW10 1 M6x30 3 M6x50 For assembly Tighten screws with 9 5Nm 1 2 Remove front engine cover Assembly is done in reverse order Dismantle Rear Engine Cover 1 Unscrew 6 hex head screws M6x16 SW10 For assembly Tighten screws with 9 5Nm 1 Secure correct position of the brass inserts 2 Remove rear engine cover Assembly is done in reverse order Z001138 1 2014 01 4 84 01 00 Engine Timing Engine Mount 01 00 01Lock Crank Shaft Piston No 1 at TDC
66. washers ill 19 pos 1 02 02 ill 19 19 47 Z001138 1 2014 01 Fuel System 4 Clean conical part of copper insert with cleaning mandrel No 2300565 0 For this purpose turn cleaning mandrel several times in both directions and then clean copper insert with cleaning tissue 5 ATTENTION Insert new special copper seal washer ill 22 pos 2 from seal kit 2002031 0 with a screwdriver into copper insert Make sure the copper seal washer is level with the plane 6 Install new O rings ill 22 pos 1 from seal kit Z002031 0 and cover O rings with a thin film of clean motor oil 7 nsert unit injector into bore and align unit injector recess to dowel pin ill 23 pos 1 for positioning Avoid any contact with control link ATTENTION Hisk of damage to control rack Z001138 1 2014 01 02 0211 23 20 47 Fuel System 8 Push unit injector firmly downwards in order to position it correctly with the O rings 9 Lubricate slide cup with motor oil put it onto adjustment screw as shown and shift it together with rocker arm onto unit injector 10 Install retainer ring to secure the rocker arm 11 Screw on flange nuts hexagon nuts SW 13 and tighten evenly Absolutely tighten nuts with a torque of 18 2 Nm ATTENTION attention to horizontal installation of mounting flange 21 47 02 02 I 27 Z001138 1 2014 01 Fuel System 12 Fix control rack refer 03 02 03 13
67. without restricting flow at higher speed Since a VGT can produce boost at lower engine speed lag time is decreased Coming out of a transient driving situation with a higher exhaust manifold pressure allows this stored energy to form in a pressure to be used to drive the compressor into a higher boost level faster VGT s have the advantage that many different pressure ratios can be produced at a single engine speed due to the variable vanes changing the effective area and A R The vanes can be manipulated to create an optimal boost pressure at any speed By producing an optimal boost through a larger engine speed range the overall efficiency is increased Z001138 1 2014 01 12 47 Fuel System 03 02 Fuel Pump Unit Injector Lines 03 02 01 Replace fuel pump Example NOTE Fuel pump operation is controlled by EMS NOTE The fuel pump in a vehicle installation may vary in location Please refer to vehicle manufacturer information to locate this device in a car Preparation for disassembly RECOMMENDET TYPE OF FUELPUMP 2173396 6 Close fuel supply valve if existing in this installation ATTENTION Prior to disassembly disconnect battery cables from battery to avoid damages to the electronic system 1 Disconnect positive cable and negative cable by unscrewing hexagon nuts SW7 8 with washer from terminals of fuel pump 2 Loosen clamps and pull off fuel hoses on both sides of fuel pump 3 Open re
68. 0 Nm 4 2 step 240 Nm 12 2001138 1 2014 01 Preliminary Service Manual MARINE 2012 54 65 Screw tooth belt tensioner 45 Nm 4 Valve adjustment element 55 Nm 3 Remark Tolerable Torque Requirement for Valve lash adjustment bolt gt 20 to 35 Nm NOTE Replace entire element in case Torque Values of adjustment bolts are outside tolerable torque requirements Screw linkage lever CAUTION left hand thread 7 Nm 0 5 Stud unit injector 21 Nm 2 Loctite 620 55 65 J8 01 ill 10 2001138 1 2014 01 0024 2011 Preliminary Service Manual MARINE 2012 Collar nut for unit injector 18 Nm 2 Nut adjustment screw of unit injector 30 Nm 3 0025 2011 Plug screw for control rack in camshaft housing 50 Nm 5 Hex flange nut exhaust manifold a 23 Nm 2 gt M8x135 b 9 5 Nm 1 2001138 1 2014 01 56 65 Exhaust turbocharger A 23 Nm 2 B 50 Nm 5 C 23 Nm 2 Screws intake manifold 23 Nm 2 Glow Plugs 15 3Nm Engine oil cooler 23 Nm 2 gt M8x20 Use Loctite 243 Thermostat A 23 Nm 2 57 65 2001138 1 2014 01 Preliminary Service Manual MARINE 2012 Water pump A 23 Nm 2 B 9 5 Nm 1 gt Loctite 243 Alternator 45 Nm 5 gt M10 Engine Housing 20 Nm 10 200 20 Nm M10x250 23 Nm 2 M8x180 50 Nm
69. 00 03 ill 30 NOTE During this operation the camshaft sprocket must be released from the taper connection and should only be slightly supported by the cone Tension of timing belt remains adjusted as described before 31 RHemove locking pin from crank shaft Refer 01 00 01 32 Tighten hexagon nut SW 30 of camshaft sprocket to 80 4 Nm by holding up with special tool 2300711 0 at hexagon on camshaft 00 03 11 31 ATTENTION During this operation camshaft sprocket and camshaft are connected for measurement purpose A positive connection is only achieved by finally tightening the hexagon nut with 240 12 Nm The previously set stroke on the plunger guide must not be changed when tightening the hexagon nut 15 84 Z001138 1 2014 01 33 Turn crankshaft by 2 further turns and at the second turn fix crankshaft with locking pin in TDC position cylinder 1 in TDC see chapter 01 00 01 With locked crankshaft the plunger guide stroke of unit injector at first cylinder should show the following dial gauge value Index value of engine timing 3 59 mm 0 02 mm plunger guide stroke unit injector NOTE If the index value of engine timing should not correspond to the allowed value follow the instructions as per item 25 34 1 case of correct index value of engine timing remove locking pin on crank shaft and tighten hexagon nut of camshaft sprocket SW 30 with 240 12 Nm by holding up wi
70. 01 66 84 ATTENTION Replace radial shaft sealing ring in oil pump housing A Mount oil pump housing and insert radial shaft sealing ring with special tool No VR00119 0 NOTE Check sealing ring on oil pump housing for damage exchange oil pump if necessary Secure the 6 hexagon screws M8x35 with thread protection LOCTITE 243 Apply a small amount of LOCTITE onto thread Tighten with a torque of 28 Nm 2 5 Clean Surface of Barrel Ring Use new O ring 42x2 5 Place Barrel Ring Use Loctite 5182 67 84 Z001138 1 2014 01 01 06 05 oil suction pipe oil return pipe Preparation Exchange engine housing 01 06 01 1 Loosen 2 hex screws M6x12 SW10 on main bearing block For assembly Tighten screws with 9 5Nm 1 Use Loctite 243 on screw threads 2 Remove oil suction pipe For assembly Use new O rings and grease with XXX Assembly 15 done in reverse order of disassembly ATTENTION Make sure no forces or bracing remain in the assembled pipe system Z001138 1 2014 01 68 84 01 08 Intake Manifold 01 08 01 intake manifold Preparation Drain raw water circuit Drain closed coolant circuit refer to 05 00 07 Drain fuel system refer to XX XX XX Hemove oll filter cartridge refer to 01 13 01 Hemove front and rear engine cover refer to XX XX XX Hemove expansion tank refer to XX XX XX Overview
71. 1 4 Displace rocker arm remove slide rings remove rocker arms one by one and pull out eccentric shaft towards cylinder 6 ill 6 05 06 ill 6 For Assembly After installation eccentric shaft rotate shaft that zenith of eccentric lobe is located at the highest point 05 06 ill Z001138 1 2014 01 54 84 5 01 05 06 Replace radial shaft seal of camshaft Preparation Lock crankshaft 01 00 01 Remove timing belt Disassemble camshaft sprocket 1 Disassemble radial shaft seal 5 07 2 Mount new radial shaft seal with special tool No VR00122 0 NOTE Hadial shaft seal is waxed therefore needs not to be oiled Do not use grease on radial shaft lip seal 55 84 2001138 1 2014 01 01 05 07 Replace cam follower Preparation disassemble camshaft housing cover 1 Loosen adjusting screw ill 1 pos 1 with special tool No 00125 0 2 Lift cam follower spring ill 1 pos 2 with special tool No 000121 0 3 Compress valve spring ill 1 pos 3 with special tool No 00106 0 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 still positioned correctly ENGINE DAMAGE 4 Lift cam follower from valve stem top and turn sideward 5 Lift cam follower from ball pin 6 Lift cam follo
72. 1 of testing device 2300719 1 to block outlet 3 Connect hose of testing device 2300719 1 with return hose to fuel tank 4 Hold testing device glass bulb upwards or fix it on the vehicle Procedure Check 1 Ventilate fuel system by 6 times ignition ON Observe the sight glass as to complete ventilation of system bubble free fuel flow Result If a bubble free fuel flow cannot be achieved search for the problem at the suction side from fuel tank to fuel pump Check 1 Fuelin tank 2 Tank suction pipe and fitting 3 Water separator leaky or contaminated 4 Check all fuel lines connections and fittings in the feed line suction side up to fuel pump intake After a bubble free fuel flow can be achieved continue with check 2 Check2 Start the engine and let it run at idle speed Observe the glass bulb Result If bubble formation starts search for the problem in the unit injectors Probable contaminations on one or several nozzle elements cause a problem Due to compression combustion pressure gases enter the fuel system through the unit injector nozzle s Investigate fuel injectors and replace defective one Check Defective unit injector s is are to be detected definitely by means of manual injection test method manual injection test method refer to 03 14 01 and 03 14 02 If air bubble formation appears during load operation continue with check 3 Check 3 Start the engine bring it to operating temperatur
73. 1 0 2180831 0 2180831 0 2180831 0 2173396 6 2001138 1 2014 01 18 65 type Water Pump 2180867 1 2180867 1 ratio Heat 2180883 0 2180883 1 2180883 2 2180824 0 2180824 0 2180824 0 lubricant E 2180643 0 2180643 0 air filter 2180286 0 2180286 0 2180286 0 2180286 0 2180286 0 2180286 0 mark type electric system 12V 24 12V 24V 12V 24V 12V 24V 12V 24V 12V 24V voltage V alternator 2180569 0 2180569 0 2180569 0 2180569 0 2180569 0 2180569 0 2180569 0 204007 7 1 2040077 1 2040077 1 2040077 1 2040077 1 2040077 1 consumption 240 240 240 240 240 240 20 C ee 2180676 0 2180676 0 2180676 0 2180676 0 2180676 0 2180676 0 description flywheel torque of 0 1446 0 1446 0 1446 0 1446 0 1446 0 1446 inertia kgm 19 65 2001138 1 2014 01 2180867 1 2180643 0 2180286 0 12V 24V 2040077 1 N gt 2180676 0 0 1446 2180867 1 2180867 1 2180867 1 2180867 1 2180867 1 2180867 1 2180883 3 2180883 0 2180883 3 2180883 0 2180883 3 2180883 3 2180824 0 2180824 0 2180824 0 2180824 0 2180824 0 2180824 0 2180643 0 2180643 0 2180643 0 2180643 0 2180643 0 2180643 0 5 286 40 5 06 38 2180286 0 2180286 0 12V 24V 12V 24V 2180569 0 2180569 0 2040077 1 2040077 1 2180676 0 2180676 0 0 1446 0 1446 rr service Manual MARINE 2012 engine 2 25 SE156E26 m 2179164 0 2179164 0 2179164 0 217916
74. 10 48 06 10 04 13 WIF Water In Fuel Sensor included in Kit Fuel Prefilter 51203010 Fehler Textmarke nicht definiert 06 10 04 14 T2 Compressor Outlet Temperature Sensor Fehler Textmarke nicht definiert 06 10 04 15 EXT Exhaust Gas Temperature Sensor 49 06 10 05 Connectors helpful 00 000 50 06 10 06 Connectors assembly 51 06 12 M 53 2001138 1_2014 01 2 54 Electrical System 3 54 Items to Check Troubled Systems Electrical System Factors Cause of Trouble Overdischarge of battery Connection failure low battery Capacity Defective Key Switch Emergency Cut Off Switch Defective starter switch Defective starter solenoid Breakdown of Starter Breakdown of glow plug or air heater ECU Operation Fuel Pump Operation Governor Solenoid Rack Actuator Rack Position 10 seconds after Ignition Check Relay significant amount of white exhaust Circuit resistant 60 Ohm closed Floating Position Rack 1mm Insuficient Batterie Voltage Resistance too high Insuficient current flow Indicate Memorized Service Codes Stabilised Power Supply 5V Red Flashing Backlight Check Plug Connections Starter does not rotate Slow starter rotations Check Fuses Electrical System amp EMS CU
75. 138 1 2014 01 01 05 04 camshaft Preparation disassemble camshaft housing refer to 01 05 01 1 Loosen hexagon nut SW30 ill 1 pos 1 Retaining at hexagon camshaft 2 Disassemble camshaft sprocket with special tool No VR00113 0 ill 2 remove nut amp washer 3 Remove axial pin and retainer plate for camshaft 4 Disassemble all cam followers refer to 01 05 07 5 Push out camshaft ill 5 with radial shaft seal to the front 6 Pull out camshaft from the front of camshaft housing ATTENTION At the rear end of camshaft ill 1 pos 2 the speed sensor wheel is located E When removal or installing the camshaft take care that bearings surface of camshaft housing does not get damaged Z001138 1 2014 01 OS D4 ull 1 05 04 11 2 52 84 01 05 05 Replace eccentric shaft Preparation Disassemble camshaft housing cover 01 05 01 Loosen set screws of unit injector on rocker arm NOTE Keep sliding cups below each rocker arm set screw matched to each cylinder 1 Remove circlips on both sides of rocker arms 2 Extract retaining clip ill 2 pos 1 and pin 2 5 2 from injection timing device linkage Dismantle clamping screws from lever eccentric shaft ill 2 pos 3 3 Extract axial half moon rings ill 5 of eccentric shaft 2x same as for rocker arms 53 84 05 06 1 2 05 06 ill 5 2001138 1 2014 0
76. 3 is to be sent to the After Sales Service of STEYR MOTORS GmbH This owner identification card serves as a proof of ownership and is to be submitted in case of warranty claims 2001138 1 2014 01 4 65 TABLE OF CONTENTS MAIN ASSEMBLY GROUP ENGINE GENERAL 01 ENGINE 02 COUPLING 03 FUEL SYSTEM 04 EXHAUST SYSTEM 05 COOLING SYSTEM 06 ELECTRICAL EQUIPMENT 14 HYDRAULIC PUMP 22 ENGINE PREHEATING 5 65 2001138 1 2014 01 Preliminary Service Manual MARINE 2012 Components 01 00 01 01 01 02 Mount Bracket Crankcase Crankshaft Bearing Lifting Eye Damper Gasket Set 01 03 01 04 01 05 Flywheel Piston Camshaft Housing Rings and Pin Connection Rod 01 06 01 08 Page 1 amp 2 01 13 Oil pump Oil pipe Intake Manifold Oil cooler Filter Oilcan Exhaust Manifold 02 Coupling 02 00 02 01 Fly Wheel housing Ring Gear Carrier and Flex Plate 03 Fuel System 03 02 03 05 03 08 Unit Injector Turbocharger Contr Solenoid Fuel Pump Inj Timing Device 03 09 03 11 Fuel Filter Glow Plug 2001138 1 2014 01 6 65 04 Exhaust System 04 00 Connection to Turbo Charger 05 Cooling System 05 03 05 04 05 05 Water pipe Water pump Fan Assy Thermostat 05 06 Page 1 amp 2 Drive Belt Pulleys Tensioner Belt 1 amp 2 06 Electrical System 06 01 06 03 06 05 Alternator Bracket Starter Engine Harness 06 0
77. 31 6 dial gauge digital 2300899 0 probe pin 2300641 1 V belt tightener VR00515 0 open end wrench 230071 1 0 extractor VRO0113 0 adjust gage eccentric shaft 2300736 1 offset box wrench VR00228 0 9 84 Z001138 1_ 2014 01 6 Adjust eccentric shaft with special tool kit 2300736 1 as shown in illustration before 7 Mount dial gauge rail with brackets 2306031 6 on studs at intake side of camshaft housing 8 Insert dial gauge 2300899 0 with probe pin 2300641 1 in dial gauge rail and put probe pin onto unit injector plunger guide cylinder 1 9 Turn camshaft until the roller of rocker arm is located on base circle of injection cam Concentric part of cam 10 Press zero button an digital dial gauge Or pre set conventional type dial gauge to position 20 mm stroke small pointer at 20 inside scale big pointer at O outside scale 11 Lock Crank Shaft refer 01 00 01 to piston No 1 at TD Z001138 1 2014 01 10 84 12 Loosen Allen head screw SW 8 of belt tensioner and remove tensioner 13 Loosen 3 Torx screws M12 x 90 from vibration damper by means of special tool 2300700 0 and remove vibration damper 14 Remove timing belt ATTENTION With loose and or removed timing belt the camshaft or crankshaft must not be turned This could result in a collision of pistons and valves 15 Put new timing belt onto crankshaft sprocket and camshaft sprocket marke
78. 3Nm 2 6 Remove Plug from Engine Coolant Temperature Sensor ECT B6 7 Loosen hose clamp and remove air filter from turbo charger intake For assembly Use new air filter in case of pollution Tighten hose clamp with 4Nm 0 5 8 Remove oil return pipe Dismantle hex head screws from oil pipe flange Loosen hose clamp and remove oil return pipe For assembly ocrew size depends on turbo charger model M8x25 SW13 gt 23Nm 2 M6x16 SW10 gt 9 5Nm 1 Use new gasket 77 84 Z001138 1 2014 01 9 Remove oil supply pipe Refer to chapter Remove oil supply pipe of turbo charger 01 08 06 If required 10 Remove Plug from vane actuator on VTG turbo charger X25 11 Loosen hose clamp and remove hose from heat exchanger For assembly Tighten hose clamp with XXNm 12 Remove Coolant Pipe Loosen 3 Hex head screws M8x25 Turn away coolant pipe For assembly Tighten screws with 23Nm 2 Use new O Rings and grease with XXX Z001138 1 2014 01 78 84 13 Remove E box cover Loosen 5 M5x55 hex sock head cap screws and remove E box cover For assembly Tighten screws with 4Nm 0 5 14 L oosen two hex nut M6 and turn over e box plate carefully Pfeile auf Schrauben For assembly Tighten nuts with 9 5Nm 1 15 Loosen 12 hex head screws M8x135 SW13 and 3 hex flange nuts M6 For assembly Clean sealing surfaces on motor block Tighten
79. 4 0 2179164 0 2179164 0 2179164 0 2179164 0 2179164 0 clutch torque of inertia 0 032 0 032 0 032 0 032 0 032 0 032 0 032 0 032 0 032 kgm ave ZF ome ZF OO ZF ome ZF ZF ZF ZF omae ZF ZF ome gearbox torque of inertia idle 0 0427 0 0427 0 0427 0 0427 0 0427 0 0427 0 0427 0 0427 0 0427 position kgm propeller 3 4 17 19 3 4 17 19 Inch 17 419 Inch 17 19 Inch 17 19 Inch 17 19 Inch 17 19 Inch 17 19 Inch 8 4 17 19 inch 17 19 inch 17 19 inch 17 19 inch 17 19 inch 17 19 inch 17 19 inch 17 19 inch information Inch Ch n 2203505 0 2203505 0 2205034 5 2173969 0 2201765 0 2181154 0 2201765 0 2179202 0 2179202 0 2179798 0 0 2179798 0 2179798 0 2179798 0 2179798 0 2179798 0 2179798 0 2179798 0 Electr Control 2181056 0 2181057 0 2181058 0 2181059 0 2181060 0 2181061 0 2181062 0 2181063 0 2181007 0 Module No 2001138 1 2014 01 20 65 3 2 Overview engine M16 TCA ltem Designation Boost Pressure Sensor Zinc Anode 3 Units Intercooler Fuel Cooler Engine Oil cooler Model and Serial Number Oil Separator Raw Water Drain Plug Valve Crankshaft Housing Ventilation 10 Fuel Filter 11 Fuel Pump 12 Oil Filter 13 Raw Water Inlet Fitting 14 Raw Water Pump 15 Coolant Drain Plug 2 Units 16 Oil Suction Pipe 17 Oil Dipstick 18 Rack Position Sensor 19 Engine Lifting Eye 20
80. 46 0 and tighten by means of special tool No 2300703 0 with a torque of 15 1 Nm NOTE Grease thread of glow plug 11 00 ill 1 with high temperature grease PN Z012222 0 NOTE Exactly keep torque of 15 1Nm when fixing glow plugs Further assembly is done in reverse order of disassembly 41 47 Z001138 1 2014 01 Fuel System 03 12 Measurement of Compression Pressure Preparation remove glow plug refer to 03 1 1 1 Install special tool glow plug adaptor 2300638 2 ill 1 into cylinder to be checked ill 2 12 00 ill 1 NOTE During this compression pressure test the control rack device Y20 connector must be unplugged 2 Connect pressure hose of compression pressure meter No 2300750 0 to glow plug adaptor ill 2 3 Connect pressure hose to compression pressure meter No 2300750 0 ill 3 4 Prepare compression pressure meter refer to operation instructions of device 5 Crank engine by operating starter motor for 5 to 10 sec until indicator needle of compression pressure device does not rise any further 12 00 ill 3 Z001138 1 2014 01 42 47 Fuel System Compression pressure chart nominal value lower boundary value Refer to engine table MODEL TYPE NOM VALUE LOWER BOUNDARY VALUE M16TCA M160029 9 21 0 1 0 bar 18 0 1 0 bar M16VTI SE ENGINES 21 0 1 0 bar 18 0 1 0 bar 6 Assembly is done in reverse order Leakage rate tools f r jedes mo
81. 5 Check the terminal screws Do they move 2 1 6 Are there signes of overheating 17 54 2001138 1 2014 01 Electrical System 06 02 05 Engine harness connector B6 2poleplug Engine Coolant Temperature Sensor _ B9 6poleplg __ Pedal Accelerator 2001138 1 2014 01 18 54 Electrical System Designation Component Description connector Ta 8 pole plug Harness Intake side X6 ___ 2 ole plg _ Fuel Pump 2 pole plug Fuel Metering Solenoid 2 pole plug Injection Timing Valve 06 02 06 Connection relay socket for K1 K2 and K4 19 54 2001138 1 2014 01 Electrical System 06 02 07 Electric Box front side view bc n Panel Connector 2001138 1 2014 01 20 54 Electrical System 06 02 08 Electric Box rear side view bul ar P 7 4 F ji i Pj i A d 1 e E er X21 Option Manifold Exhaust Temp MET Fuel Density Sensor FDS 4 pole plug Option Trim Gear Option 2 pol 21 54 2001138 1 2014 01 Electrical System 06 02 09 Wiring Diagram E Box Wiring Diagram 2181123 0 2181123 9 STEYRMOTORS WI Ix Tove Onc BY ALL CASES THE ase WERE TOM OF THIS DRaH HG SHALL BE 43 PCSCHEMATIC Glow plugs BY PELAYS Cu Wiring Diagram Marine E Box 12V EE za 11 8933 Splmdler 1 8 DIMENSIONS ARE Iw MILLIMETERS
82. 6 Harness ECU 14 Hydraulic pump 14 08 Hydraulic pump 52 Air Conditioning 52 00 A C Compressor 7 65 2001138 1 2014 01 Preliminary Service Manual MARINE 2012 VERSIONS OF MANUAL Version Date Modification 1 0 01 02 2013 New edition 2001138 1 2014 01 8 65 9 65 GENERAL Table of Contents RENE SENA RENE aM eT ES VALENS 11 Model and Seral E pov p Y ovr Viv bp vba opc 11 DOCUM MATON 12 Technical Data and OVerVIGW vr eve od E ak REN RV E EVE FE 13 GOverview engdgined TO daa 21 22 UCI 15 _________ _____________ M 22 24 Maintenance and Service cccccsssccsesseccenseeseeseeeenseesenseeseenseseeasesoeseeseoaes 25 Trouble CHECK 25 Trouble Check Chart cohltllitled 26 Service and Maintenance 5 29 General INTOFMAUON 32 Electronic Engine Management System 32
83. 6000 26005 36000 26006 36000 26007 36000 26008 36000 kPa kPa kPa kPa kPa kPa kPa kPa kPa 20 8 75 adjustment value mm valve timing 9 0 02 3 59 0 02 9 0 02 9 0 02 950 02 950 02 950 02 90 02 3 59 0 02 tolerance mm 17 65 2001138 1 2014 01 9 25 8 90 8 90 8 79 8 70 8 79 9 30 8 95 8 95 8 84 8 75 8 84 3 5910 3 59 0 3 59 0 3 59 0 3 59 0 3 59 0 service Manual MARINE 2012 valve 0 25 0 25 0 25 0 25 0 25 0 25 0 25 0 25 0 25 0 25 0 25 0 25 0 25 0 25 0 25 0 25 clearancy mm TE Tee X X X X X PR INT MCD PR INT MCD PR INT MCD PR HO PR INT PR HO PR INT PR INT LL EM 0 25 0 25 exhaust e o tc 94 25 EC 2003 44 EC without integral Commercial EU 97 68 EG 2004 26 EG Cert Nr MED B 5675 Performance ller et Prope J rtrain rtrain Shaft 7 2176554 0 2176554 0 2176554 0 2176554 0 2176554 0 2176554 0 2176554 0 2176554 0 2176554 0 Engine Block 2180996 0 2180996 0 2180996 0 2180996 0 2180996 0 2180996 0 2180996 0 2180996 0 2180996 0 charge air Cooler 2180876 0 2180876 0 2180876 0 2180876 0 2180876 0 2180876 0 2180876 0 2180876 0 2180876 0 piston bowl 2179531 3 2179531 3 2179531 3 2179531 3 2179531 3 2179531 3 2179531 3 2179531 3 2179531 3 ere 2173396 6 2173396 6 2173396 6 2173396 6 2173396 6 2173396 6 2173396 6 2173396 6 fuel filter 2180831 0 2180831 0 2180831 0 2180831 0 2180831 0 218083
84. 8 01 Remove control 0 32 03 08 02 Install rack control 33 03 08 03 Replace potentiometer indication of control rack position 34 03 08 04 Remove injection timing device ITD 36 03 08 05 Install injection timing device 170 37 03 09 Change fuel pre filter and fine filter general description 38 03 11 Replace GIOW 40 03 12 Measurement of Compression Pressure 41 03 14 F el System Che 42 03 14 01 Manual injection test 42 03 14 02 Manual check of unit injector without tool No VR 00148 0 44 03 14 03 Disengagement methode 45 1 47 2001138 1 2014 01 03 Fuel System Table of Contents Fuel System 03 14 04 A Air bubble formation in fuel system Example 46 Z001138 1 2014 01 2 47 Fuel System 3 47 Z001138 1 2014 01 Fuel System Items to Check Troubled Systems c D D 9 8 Q 20 5 4 6 lt 1 09 oO c 15 o l2z INI 5 5 ol 2 gt lt 25 f 72 amp ET 51 9 gt c
85. Attach control link to control rack and adjust Refer to 03 02 04 Adjusting Control Link 14 Connect eccentric shaft linkage with injection timing device parallel pin retainer c clip 15 Adjust unit injection start of delivery Refer to 03 02 06 16 Connect fuel hose fitting and operate electric fuel pump 3 times for 10 seconds via ignition switch to vent bleed fuel system Procedure for replacing the Mono Block Copper Inserts TOOLS REQUIRED PART NUMBERS V000280 0 V00031 1 0 The above part numbers include the following tools 1 1 x Sliding Hammer with M22 thread 2 1 x Copper insert flanging tool 3 1 x Tapping guide Additional tools required 4 Unit Injector fixing bracket 5 M22 Tap Procedure 1 Turn the Crank shaft so that the piston of the cylinder to be worked on is at bottom dead centre lowest point Hemove the cam housing cover Hemove the unit injector from the cylinder to be worked on and slide the rocker arm over to one side Grease the M22 Tap wrench Insert the tapping guide onto the copper sleeve and screw down using a unit injector fixing bracket and 18Nm See Pictures below Using the tap cut a thread into the copper insert taking care that the tap is straight Cut 6 full turns of the tap to ensure that enough threads are present to pull the insert out Remove the tap the injector bracket and the tapping guide Z001138 1 2014 01 22 47 Fuel System 10 11 12 13 14 15
86. Axial play gear wheel Turbocharger Permissible Radial play of turbine shaft 0 42 mm 0 04 clearance on turbo Axial play of turbine shaft charger shaft Valve Adjustment Element 20 35Nm 12Nm Break away Torque 11 Adjustment information for service and maintenance l 1 1 Engine timing measured with dial indicator No 2300899 0 Setting instruction 3 99 0 02 mm Maintenance instruction In case the measurements are not within the specified limits of 3 57 to 3 61 mm than the settings needs to be reset to the original specified value 1 1 2 Tension timing belt measured with tool VR00515 0 Tension instruction 600 30N new belt Tension instruction 520 30 used belt Maintenance instruction In case the timing belt tension measurement is not within the specified limits of 630 N to 490 N than the settings needs to be readjusted to the specified value 1 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 1 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 mor
87. E Fig 3 50 9 Further assembly is done in reverse order Z001138 1 2014 01 34 47 Fuel System 03 08 03 Replace potentiometer indication of control rack position Preparation remove intake manifold refer 01 08 01 1 Loosen 2 Allen head screws SW 3 11 1 1 Remove potentiometer Assembly 2 Insert potentiometer in such a way that rod of potentiometer ill 2 pos 1 is positioned in front of solenoid rod il 2 pos 2 3 Secure 2 Allen head screws Allen socket 3 mm with LOCTITE 243 and tighten with a torque of 5 Nm 0 5 4 Check whether control rack can be moved up to approx 18 mm against the spring load and returns under the spring load to zero position ATTENTION Pin of control rack potentiometer is spring loaded and might easily slip off from the contact surface of control rack lever during assembly In such a case the control rack is blocked and thus preventing the rack to return to zero delivery ENGINE FAILURE 5 Further re assembly is done in reverse order 35 47 Fig 3 50 08 03 ill 2 Z001138 1 2014 01 Fuel System Schema Injection Timing Device ITD C es A v e gt 225 44 CL CL z 2 he 2 Nlded l lt 0 NId ZNidedLl lt gt SNid v lt gt voz gt 08NId ___ gt cNlIde AL
88. Measured voltage U V Required voltage value U V 14 1 28 1 Apply electrical load headlights front and rear working lights heater and measure Measured voltage U V U V should be lower for 0 4V to 0 7V If the measured output voltage is in limits then the alternator works properly If the answer is then continue with the following steps Lamp lights with full intensity all the time ves If the answer is YES then Stop the engine disconnect wire from alternator D terminal and turn on the ignition switch Does Lamp lights If the answer is YES then The cause is failure of the vehicle wiring If the answer is NO then continue with the tests bellow Are the Lamps lighting with different intensity depending of rotational speed and electrical load If the answer is YES then Is the drive belt slipping If the answer is YES then Check drive belt and pulley If the answer is then The cause is broken drive belt or faulty alternator Replace drive belt or Replace Repair alternator Remark Voltage measured on battery can be lower as on alternator terminals B B but for no more than 0 5V 2001138 1 2014 01 12 54 Electrical System 06 02 Starter motor 06 02 01 Permanent magnet reduction gear starter motor Model AZE2177 11 131 406 Nominal Tension 12V Nominal Power 2 0kW Sense of Rotation Clockwise WIRING DIAGRAM PULL IN WINDING
89. Min back flow rate 280 I h n LJ Y GN es 2 SA AY SS min ID 16 mm i aja 7 e 4 4 2 5 Anti siphon valve e Prefilter Flow rate 350 1 6 fi min ID 16 mm amp Electrical fuel pump e Fuel filter Fuel Pressure Sensor Q Fuel supply to injectors Fuel return to fuel cooler throttle hollow Screw Q Unit injectors 9 Fuel cooler AR x en S www steyr motors com 277977 0_00_111124 03 00 02 Functional description When the ignition switch is turned an electric fuel pump 3 is put into operation and the fuel flows from the fuel tank through the pre filter 2 From the fuel pump fuel is pumped to the engine fuel gallery at the rear inlet 5 and the unit injectors 6 Excess fuel not used in the engine for combustion leaves the fuel gallery by pressure check valve at the block outlet 7 The fuel flows from this point into the fuel cooler 8 and from there back to the fuel tank 1 The fuel gets pressurized by the fuel pump 3 The feed pressure to the unit injector is controlled via the pressure check valve 9 at the block outlet The operating pre pressure in the supply gallery may be in a range of app 3 5 5 5 bar Refer to engine table for specific value for your engine model For fuel requirements refer to chapter GENERAL Z001138 1 2014 01 6 47 Fuel System Specification for fuel pipes
90. Motor Oil Filler Cap 21 Potentiometer Accelerator 22 Drive Belt Raw Water Pump 23 Engine Mount 24 Drive Belt Tensioner 25 Cover T Belt Lower 26 Vibration Damper 27 Speed Sensor 28 Cover T Belt Upper 29 Cover Rear 30 Valve Cover 31 Heat Exchanger 32 Coolant Expansion Tank 33 Cooler Cap 34 Diagnostic Outlet 35 Inversion Switch 36 Connector Instrument Panel 37 Coolant Temperature Sensor 38 Thermostat Housing 39 Hydraulic Oil Tank 40 Circuit Breakers 41 Alternator 42 Hydraulic Pump 43 Oil Drain Plug 44 Starter Motor 45 Engine Management System Fuses 46 Exhaust Temperature Sensor 47 Air Filter 48 Turbo Charger 49 Exhaust Elbow 50 Starter Relais Backside E Box Ground Plate 51 Flywheel 52 Flywheel Housing 53 Oil Pressure Sensor 54 Hydraulic Oil Cooler 27 37 38 4035 361715 2 1 i CER vm mm an is y r TAT B E MB gt es uim A DH 4 diu igh FT EN o I A mamn H T 2 xd 2 LJ This sensor is magnetism sensitive All External magnets must kept away 21 65 2001138 1 2014 01 Preliminary Service Manual MARINE 2012 B Specification B1 Fuel Requirements The STEYR Marine Engines are designed for m
91. Pump Obstructed Raw Water Supply Closed Sea 5 Cock Bubbles in the Radiator Heat Exchanger ECT Gauge Indication to show cooling liquid inlet outlet temp Balance is small Damage of Raw Water Pump Engine cooling liquid temp Remains low cooling liquid Temp inlet outlet Balance is large Impeller floss of cooling liquid Low drop engine output Engine overheating Coolant discharged from L Lp Seale eccumulated in cooing system 0 Inferior thermostat performance Core fin clogged or collapsed Defective radiator cap Water leakage Clogged by scale or other substances Continuous overload operation Faulty indication of ECT gauge Clogging or collapse of exhaust pipe or muffler Faulty copper insert Leakage of Oil Cooler into Coolant Gas leakage from cylinder block Z001138 1_ 2014 01 2 21 coolant Heat Exchanger system Cooling System pinbi uogeijoosi Oeo Oc L MOUS 0 DF amp 59 lt pepesoxe wur yue uoisuedx43 005 JoDBueuox3 JOJEIPEY ui Je eduu 491eM eDeuieq si 1e no 1ejur pinbi oDJe si Ye ut
92. S 6 TFTTIBIZ eu Jg o Jberg Bul TTE MOL noe D e 8 SHOLOWHASLS 8 B E 4 Ue Zx SET EH we ie La Sa E LL 4 4 T L 1 Lt a an md z 24 54 2001138 1 2014 01 Electrical System 2181349 0 PCSCHEMATIC Alternator uum X a a Zicha DRAHIHG ortar STEYRMOTORS a p Glow plugs IH ALL CASES THE BERMAM LAMGLUAGE VERSIOM OF THIS DAMING 5HALL BE TAWEN 5 PRIORITY Wiring Diagram Marine E Box 12V 41443 _ d LLL ia DIMEMSIONMS IM MILLIMETERS mr Property af STEA iTIS Trens gr te third parties publication withaut gar Comment 38 posbibrEsd bp 25 54 2001138 1 2014 01 Electrical System 06 02 11 Wiring Diagram W iring Diagram 2181350 0 STEYRMOTORS Zeichnungs Hr DRANTHG ei1813230 0 Starter Alternator Glow plugs IH ALL CASES THE EBERMAM DAHGHAHE VEHSTOH OF THIS DRAWINGS SHALL BE A5 PRIGHITY Wiring Diagram Marine E Box 24
93. V DIMEMSIONS ARE IM BILLTMETERS Prajst mr f jt 3 a gt Praperty 35 STEYR GmbH 2001138 1 2014 01 26 54 Electrical System 06 02 12 Wiring Diagram External E Box Diagram ALIE be 22014 i M ii 5 Wa hi qua Panel ter gi Im iain ______ L 4 DN ee 1 ng g l 4 Zelchnungs Hr DRAWING MO eiBi3231 0 STEYRMOTORS 5 Glow plugs Se TM ALL CLASES THE HERMAH LAHGHAGE VERSION OF THIS DARANING SHALL 5 1 Wiring Diagram Marine external E Box Option in _ _ _ 4 1 nia DIMEMSTONS ARE IM BILLTIMETERS fr 27 54 2001138 1 2014 01 Electrical System 06 02 13 Wiring Instrument Harness Marine NOTE For power supply harness to instruments protecting circuits fuses and relays please consult marine manufacturer 06 02 14 Glow Plugs Functions e Reduce smoke emission Heat up the incoming air Reduce engine noise and vibrations Improve drivability from cold Glow Plugs 12V Technical Data Electrical test values DC 11V Current max 25Amp gt after 30 seconds gt 6 3 0 5 Temperature 850 C max 5 seconds Coil Resistance 550 670mO at 23 3 C Glow Plugs 24V Techni
94. aintenance tools tool kit II III depending on repair to be carried out a peripheral and internal work procurement and stock of required genuine spare parts proposed spare parts may be handed out upon request spare part catalogue for all STEYR ENGINES models technical literature PC diagnostics 43 65 2001138 1 2014 01 General Preliminary Service Manual MARINE 2012 E 3 Nomenclature disassemble remove unscrew de flange dismantle assemble put on place screw on flange mount disconnect connect pull of press on unscrew tighten disassemble 2 assemble 2 x loosen remove secure disassemble 3 x assemble 3 x adjust 2001138 1 2014 01 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 turn able locks Closing of turn able 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 assembl
95. assemble timing belt Disassemble oil pump 01 06 02 Disassemble oil suction pipe 01 06 03 1 Remove woodruff key ill 1 pos 1 2 Pull off gear ill 1 pos 2 with sleeve ring ill 1 pos 3 NOTE Apply surface sealing agent 5182 to contact surfaces of gear towards crankshaft and sleeve ring 3 Place oil pump drive gear with larger chamfer against crank shaft contact surface to clear machined shaft radius ill 2 pos 1 Note Proper Gear Engagement Clearance P No Z002004 0 includes already gear oil pump drive crankshaft P No 2172584 2 41 84 02 02 11 1 02 02 11 2 Z001138 1 2014 01 01 03 Flywheel 01 03 01 Replace flywheel Preparation refer to 02 00 01 Consult the manufacturer of the generator to receive instructions on how to remove respectively disassembly the generator from the engine 1 after proper removal of generator open hex head screw M24 and extract flange with special tool P No 2300962 0 Hefer to 2 00 01 2 Remove protection cover Loosen fitting nut at Oil supply line on bearing carrier plate SW14 Hemove hex head screw M6 at flange of oil pipe and remove entire pipe 3 Remove securing bolt stud at bearing carrier plate 4 Remove bearing carrier from fly wheel housing 5 Lock crank shaft refer 01 00 01 6 Loosen eight hexagon head screws M10 x 55 12 9 SW17 and remove ring gear carrier NOTE Apply thread protection LOCTITE 243 to hexa
96. at 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 Internal Cooling Circuit 1 1 hoses creaked or leaky 1 2hose clamps loose or defective 1 3thermostat thermostat defective wrong thermostat 1 4 cooler defective excess pressure valve defective vacuum valve damaged cover sealing 1 5coolant circulating pump defective housing sealing damaged roller bearing case pump wheel defective slide ring seal 1 6 coolant distribution manifold leaking connections or seals 1 701 cooler leaking connections or seals damaged hose clamps 7 21 Z001138 1 2014 01 Cooling System 05 00 06 Component checks of engine cooling system 1 Hoses and clamps drain plug etc For all models no special tool required Control works Check all external components of cooling system for leakage wear and damages Check all connections for tightness Check hoses for cracks breaks or wear Repair works Repair or exchange 2 Thermostat No special tools required Control works As a standard an 80 C thermostat is used for the vehicle engine Check thermostat for correct model and correct rated output corrosion limited mobility or broken spring
97. at oil entry to block Fehler Textmarke nicht definiert 01 01 09 bacs ai temen it eines 35 01 02 Crankshaft Bearing Vibration Damper 37 01 02 01 JREDIACE CrankSPhialtbuu uide iesu EVER a 37 01 02 02 Replace gear for oil pump 41 01 03 RETTULIT S 42 01 03 01 Replace flywheel 42 01 04 Piston and Connecting Rod eese 43 01 04 01 Dismantle piston and connecting rod 43 01 05 Camshaft Housing Valve Gear 45 01 05 01 Replace camshaft 45 01 05 02 Replace gas stem gasket on engine assembly 48 01 05 03 Replace Ol ente r2 R8 dica NR USE ERR ES 50 01 05 04 Replace CAMS all xui Ron dicunt unn 52 01 05 05 Replace CCCENINIG 53 1 84 Z001138 1 2014 01 01 Engine Table of Contents EXGEINTIRIG SEAT 55 01 05 06 Replace radial shaft seal of camshaft 55 01 05 07 Replace Cam follower 56 01 05 08 Replace retainer of cam
98. ates downward movement Example While boat at planing speed activating trim switch to lower the bow of the baat Condition Symbols Identifies the meter which indicates battery voltage or amperage v FILTER Identifies a device which removes contaminants from engine 2 07 system Identiies the EMERGENCY IGNITION CUT OFF SWITCH Emergency engine atop T identies engine drain plugs and fittings Instructional Symbols read your Operation Maintenance amp Warranty Manual before operating the product contains information instructions vital for operation of product ENGINE OIL FILL Location for introduction af oll into the engine Qu ax Functional Description Symbols Indicates that ELECTRICITY of more than 50 volts is present Indicates a potential fire hazard Indicates gear shift control positions FORWARD NEUTRAL and REVERSE Identifies the meter which indicates engine speed expressed in revolutions per minute Indenti amp ea the meter which indicates engine coolant pressure Identifies the meter which indicates the pressure of engine s lubricating system FUSE Identifies a device which protects the electrical system from overload Identifies the operating device for starting the motor 7 areas to be lubricated Indicates lubricating of used in transmissions 50 65 1 General
99. aximum fuel economy To maintain optimum performance use diesel fuel according to EN 590 or equivalent to meet this specification When temperatures are below 7 C 20 F use diesel fuels with additives for low temperature operation 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 2001138 1 2014 01 22 65 Fuel Oil Selection Chart EN 590 properties UNIT Minimum Cetane number 02 2 Gravity at 15 Kg m 820 Distillation 250 C V V 350 C V V 85 End point 360 C Flash point C 59 CFPP Cloud point C 5 s Viscosity Kinematic mm 5 2 40 C Sulphur content mg kg Cupper corrosion Rating Class 1 Carbon residue Conradson number m m 10 residue Ash m m Water content mg kg Oxidation stability g m 23 65 Maximum 845 lt 65 95 15 w 4 50 10 0 Class 1 0 30 0 01 200 25 ASTM Test procedure
100. be used as reference when remaining the common rack at the same position this forces must be felt on each of the installed injectors That way injectors who do not show a creaking point have a failure Further investigations for example air in the fuel system or mechanical defects on an injector must be undertaken this injectors with such symptoms needs to be exchanged 6 Repeat test on each unit injector 7 Assembly is done in reverse order ATTENTION Absolutely make sure to remove special tool No VR 00148 0 from camshaft housing Use new sealing ring on plug screw Z001138 1_ 2014 01 14 01 11 4 44 47 Fuel System 03 14 02 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 white in the fuel 2 Check proper flow quantity i e engine at idle flow rate after engine block 200 to 240 l h or approx 50 to 62 gal h 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 refer to picture in 03 14 01 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 pre
101. cal Data Electrical test values DC 11V Current max 25Amp gt after 30 seconds 6 3 0 5Amp Temperature 850 C max 5 seconds Coil Resistance 2 30 2 80 at 23 3 C 2001138 1 2014 01 28 54 Electrical System Exchange Glow Plugs Preparation Remove Intake Manifold refer to 01 08 1 Remove Glow Plug Cable from Glow Plugs 2 Unscrew Glow Plug by use of special tool VR00146 0 For Assembly Tighten with a Torque of 15 3Nm Use new gasket on Glow Plug Connector Grease Glow Plugs Thread with Copper paste Assembly is done in reverse order 29 54 2001138 1 2014 01 Electrical System 06 02 15 Control lamps Glow Plug Lamp Oil Pressure Lamp The GPL shall be turned on when the glow plugs are on before cranking or when the oil pressure drops below the level defined by SMO or Lubricant Pressure Sensor is defective GPL shall blink with 1Hz At ignition on the lamp shall be turned on for approx 0 7 second for checking of the bulb Glow Plug Lamp on Dash Panel Glow time depending on present condition of calculated temperature CRKT 35 4 ov 30 N 5 20 2 15 5 _ c 0 30 0 Temperature Check Engine Lamp The CEL shall be turned on when a air charge temperature is above threshold defined by SMO or sensor is defective CEL shall blink with 2Hz b Exhaust Temperature is above threshold defined by SMO or sensor is defective
102. cone on camshaft and in camshaft sprocket ATTENTION Very high for as are transmitted via this conical seat Therefore it is extremely 5 important that the two cone surfaces are assembled absolutely clean and grease free 10 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 11 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 l 00 05 il ATTENTION Pay attention to arrow marker direction of rotation on timing belt 00 05 ill 12 21 84 Z001138 1 2014 01 12 Mount vibration damper Slightly lubricate thread of 3 TORX screws Lubricant P N VR00207 0 and tighten with torque wrench to 135 7 Nm NOTE Recheck torque after first test run 13 Tightly put on timing belt from crank shaft sprocket over water pump drive wheel and camshaft sprocket and position camshaft sprocket with marked tooth towards upper sealing edge of camshaft housing 14 Clean and degrease contact surface of tensioner and camshaft housing Then mount tensioner 15 Pre tension timing belt by turning tensioner on hexagon WS
103. d the parameter limitation the system will memorize such happenings and store them permanently as misuse code Illustration of key elements for Diesel engine governing Main components engine ECU and rack control solenoid with rack position sensor engine speed sensor unit injector driven by camshaft via rocker arm 2001138 1 2014 01 34 54 Electrical System 06 04 04 Principle service code table NOTE Some codes may not apply due to different application DTC List Error Code List SE Engines V50000 10 actual version Dec ABBREV INVOLVED DEVICE 12 _ Limits 22 71 47 VTGHBRIDGE E MIN Turbocharger output control signal voltage too low possible short circuit to ground X25 72 48 VTGHBRIDGE E MAX Turbocharger output control signal voltage too high possible short circuit to battery X25 BARO FP E MIN E us xu signal voltage too low possible short circuit to ground 20 cnts 0 098 V ensor Barometric Pressure BARO Sensor signal voltage too high possible short circuit to battery 1000 cnts 4 888 V ACT_E MAX en TEMPALE signal voltage too high possible short circuit to battery B7 1007 cnts 4 922 V ensor AdcCountACT u16 ACT E MIN pe signal voltage too low possible short circuit to ground 0 244 V 279 117 ECT E MIN Engine signal voltage too low possible short circuit to ground 22 cnts 0 108 V Te
104. d tooth of camshaft sprocket points at upper edge of camshaft housing 11 84 Z001138 1 2014 01 Pay attention to arrow marker direction of rotation on timing belt I L J a 00 03 ill 15 16 Mount vibration damper Slightly lubricate thread of 3 Torx screws Lubricant P N VR00207 0 and tighten with torque wrench to 135 Nm 7 NOTE Recheck torque after first test run 17 Tightly put on timing belt from crank shaft sprocket over water pump drive pulley and camshaft sprocket and position camshaft sprocket with marked tooth towards upper sealing edge of camshaft housing 18 Clean and degrease contact surface of tensioner and camshaft housing Then mount tensioner 19 Pre tension timing belt by turning tensioner on hexagon WS 32 with tool VR00228 0 counter clockwise Tighten hexagon socket SW 8 with torque wrench to 20 Nm 2 20 Put on tension gauge No VR00515 0 ill 20 pos 1 between camshaft sprocket and tensioner Pretension timing belt tension by further counter clockwise 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 1 20 Z001138 1 2014 01 12 84 When putting on tension gauge No VR00515 0 consider the following The two stop trunnions ill 20 pos 2 should rest on the forehead
105. dell 03 14 Fuel System Check 03 14 01 Manual injection test method Preparation Remove camshaft housing cover refer to 01 00 02 1 Remove plug screw SW 24 ill 1 pos 1 with sealing ring 12 01 2 Mount special tool No VR00148 0 ill 2 pos 1 together with sealing ring 111 2 2 14 01 1 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 1 3 43 47 Z001138 1 2014 01 Fuel System 4 Put tool unit injector withdrawing lever No VR001296 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 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 Failure diagnostic via manual cracking point at low quantity setting Proceedings Rack had been lock and linking lever were readjusted to ensure proper quantity setting as specified NOTE When moving the unit injectors forces from the injector spring can be felt As soon as fuel delivery starts a slight extra force can be noticed on the lever for very short moment until the needle in the injector cracks open and this slight pressure increase disperses again This creaking point can
106. e test the vehicle under operating conditions and observe the glass bulb 47 47 Z001138 1 2014 01 Fuel System Result If it comes to air bubble formation search for the problem in the area of unit injectors Control Defective unit injector s is are to be detected definitely by means of Disengagement method of injection manual injection test method refer to 03 14 01 and 03 14 02 If there is still air bubble formation continue with check 4 Check 4 Test the engine in the operating state where bubble formation occurs by disengagement of injection per cylinder one after the other Disengagement method of injection refer to 03 14 03 Z001138 1 2014 01 48 48 Exhaust System 04 Exhaust System Disassemble assemble of Turbocharger amp Exhaust Elbow 1 Remove air intake pipe 2 Remove charge air pipe amp air filter 3 Remove exhaust elbow at turbo charger 4 Loosen M8 hex head screws SW13 1 3 Z001138 1 2014 01 Exhaust System 5 Loosen Heat Protection Turbo 6 Loosen exhaust elbow clamp and remove exhaust elbow 7 Loosen hollow screw M12x1 5 8 Loosen 2xM8x20 hex screw of oil feed line on turbocharger 9 Remove flange gasket Dispose gasket Z001138 1 2014 01 219 Exhaust System 10 Loosen hose clamp oil feed line 11 Remove Heat Protection Turbo 12 Loosen 4xMS hex flange nut heat resistant 13 Remove Turbo Charger Assembly is done in reverse order
107. e and clean skin East 10 minut lungs by aspiration agents thoroughly with A et water soap DO NOT PROVOKE Brake fluid SEE A DOCTOR VOMITING AND IMMEDIATELY SEE Battery acid DOCTOR 2001138 1 2014 01 52 65 H Tightening Torques H 1 Listing of Tightening Torques Camshaft housing screw joint to cylinder block 1 step 15 Nm 2 2 step 25 Nm 1 Tighten screws of camshaft housing in two steps in precedence of numbering on bearings from the inside outwards Plug screw for locking pin In engine housing 50Nm 5 Connecting rod screws apply oil to thread and screw head support 1 Step 10 Nm 1 2 Step 30 Nm 3 3 Step 75 4 Main bearing screws apply oil to thread and screw head support 1 Step 35 Nm 3 2 Step 45 3 3 Step 45 3 Note Use new screws 53 65 2001138 1 2014 01 General Flywheel screws apply oil to screw head support 75 Nm 5 Loctite 243 Vibration damper screws apply oil to thread and screw head support a M12x90 Allen screw 135 Nm 7 Note re assure tightness of bolts and check screw torque settings a second time copper paste b M10x25 75 Nm 5 screw quality 12 9 Note Use Loctite 243 Screw rear ring carrier use LOCTITE 243 on thread 1 step 8 Nm 1 2 step 28 Nm 3 Nut camshaft sprocket taper degreased on camshaft thread lubricated 1 step 8
108. e than 0 30 mm the settings needs to be reset to the original specified value 65 65 2001138 1 2014 01 01 00 Engine Timing Engine Mount 3 01 00 01 Lock Crank Shaft Piston No 1 at TDC 5 01 00 02 Camshaft housing cover and 5 8 01 00 03 Maintenance timing belt 9 01 00 04 Remove timing 17 01 00 05 Timing adjustment procedure for dismantled engine 19 01 00 06 Replace engine 28 01 01 Cylinder BIOCK 29 01 01 01 QUERER Onda 29 01 01 02 AdJust valve 31 01 01 03 Replace valve 31 01 01 04 Replace pressure regulating valve for oil cooling jet 32 01 01 05 Replace stud bolt for unit 33 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 O ring
109. e 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 61 65 2001138 1 2014 01 Preliminary Service Manual MARINE 2012 General guidelines of application for the of use of anaerobic sealing materials Cleanliness of components Non metallic surface protection must be removed In case of repair soiled and oily components are to be cleaned and residues of adhesive plastic material are to be removed Thread bores must be re cut with the appropriate thread bore and blown out with compressed air If solvents or degreasing agents are used for cleanin
110. eassembly in reverse order Tighten M6 bolt with a torque of 9 5 Nm 1 Z001138 1 2014 01 14 21 Cooling System 05 04 Coolant Pump 05 04 01 Exchange coolant pump Preparation Remove poly V belt remove timing belt see 01 00 02 drain closed cooling system refer to 05 00 02 1 Loosen 3 hex flangebolts M8x25 SW and remove hoses from front cover 2 Loosen 3 pcs M8 hexagon head screws one pc 8 Allen screw and one pc M6 Allen screw at coolant pump housing 3 Remove coolant pump by slight hit with plastic hammer 4 Remove gasket from engine block 15 21 Z001138 1 2014 01 Cooling System 5 Loosen 3 Hex screws M8x25 6 Remove Cooling Pipe 7 Loosen 3 Hex screws M8x30 one Nut M8 and two hex socket head cap screws M6x60 M6x30 Z001138 1 2014 01 16 21 Cooling System 8 Extract coolant water pump by hand 9 Put off the gasket 10 All parts of water pump 17 21 Z001138 1 2014 01 Cooling System 05 04 02 Install coolant pump 1 Clean and grease sealing surfaces water pump and on engine block Put on new gasket ill 2 pos 1 Align water pump on engine block Mount screws and tighten with standard torque for Its size Further assembly is done in reverse order in accordance with 01 00 02 remove timing belt Engine timing adjustment according to instructions refer to 01 00 03 engine timing tighten with a torque of 23 Nm 2 M6 tighten with a tor
111. ed only if the all the answers are YES ALTERNATOR SHOULD ONLY BE REMOVED FROM THE VEHICLE AFTER PERFORMED ALL STEPS OF THE QUESTIONNAIRE BELOW AND THE ESTABLISHED CAUSE FOR MALFUNCTION OF THE VEHICLE IS ALTERNATOR 2 FORTHE INSPECTION PROCEEDED STEP BY STEP Engine not started the ignition switch is turned on 15 the warning lamp illuminated YES If the answer is YES then Proceed with paragraph 3 2 If the answer is then Connect D terminal of the alternator to negative potential normally chassis housing of alternator and turn on the ignition switch 15 the warning lamp lighting YES No _ If the answer is YES then The cause is broken drive belt or faulty alternator Replace drive belt or Replace Repair alternator If the answer is NO then The cause is broken or disconnected wires bad or broken lamp or completely discharged Measured voltage value U V Remark If the voltage is measured on battery or on alternator terminals B B at engine stopped the value should be UJ 12V 24V for 28V systems 3 Start the engine and run it at engine nominal rotational speed the warning lamp switched off ves If the answer is the alternator should be OK but an additional check should be performed Measure the voltage on battery or on alternator terminals B B changing rotational speed idle to maximum without electrical load applied only battery
112. ed with care In 4 case of skin contact rinse thoroughly with water and consult a doctor physician 53 54 2001138 1 2014 01 Electrical System 2 The battery should always be charged as full as possible Regularly check the state of charge with the battery acid tester We recommend checking the acid density and acid level periodically every two weeks If the density is 0 04 kg dm below the value of full charge the battery is to be removed and recharged DENSITY WITH FULL CHARGE ATTENTION Never charge the battery on the marine The vapours resulting from charging could cause an explosion For a periodical check of the battery the following items are to be considered 1 2 Protect the marine against acid leakage Clean battery Check connections and cables Clean battery contacts neg pos Check holding device of battery Check housing for damages acid leakage Check acid density Disassemble battery for test In case of less than 3 4 charge charge it by means of battery charger carry out charge test 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 spec
113. el System 03 02 05 Release fixing of control rod 1 Unscrew ill 3 pos 2 from bulkhead wall Hold control rack while removing setpin Slowly release common rack towards the rear to take off applied spring load from the unit injector ill 3 pos 1 2 Reinstall setpin in rear bulkhead bore of camshaft housing ill 3 pos 1 02 05 ill 1 3 Tighten setpin snug with a torque of max 3 Nm 4 Check common rack for free travel Common rack must be able to move over its full extend of travel approx 18 mm without constraint NOTE The only restriction to feel will be the forces of the springs from the control gear ne mechanism in the unit injector The common rack should automatically return to reverse position due to spring load Z001138 1 2014 01 26 47 Fuel System 03 02 06 Adjustment of unit injector start of fuel delivery Preparation Remove camshaft housing cover refer to 01 00 02 Adjustment of unit injector start of fuel delivery is recommended to perform prior to engine timing adjustments NOTE This adjustment is necessary if unit injector was removed periodically according to maintenance chart if set value has changed see chart eer Set Values Unit Injector adjustment To obtain the proper adjustment value refer to table below and cross reference with 4 digit code on unit injector Area indicated in illustration 1 Unit injector must be installed properly
114. enerator does not generate any current the battery provides the electronic engine management system with voltage For M16 TCA Use two 12V batteries with a cold test circuit of 650 ampere each at 18 C and a capacity of 115 Ah at 27 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 marine 12V supply of all electric and electronic components on the engine including instrument panel by centre tapping Additional charge is guaranteed by charging equalization 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 with 650A After discharge for 30 sec the voltage should not drop bellow 9V Capacity With a current consumption of 1 20 of specified capacity e g with 115Ah 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 handl
115. engages assembly out of extractor tool over the wire contact and resistance is connector of contact to be removed felt NOTE Do not twist or insert tool at an angle 51 54 2001138 1 2014 01 Electrical System Contact insertion Grasp contact approximately Hold connector with rear Push contact straight into 25 4mm one inch behind grommet facing you connector grommet until a the contact crimp barrel positive stop is felt A slight tug will confirm that itis properly locked in place Once all contacts are in place insert orange wedge with arrow pointing toward exterior locking mechanism The orange wedge will snap into place Rectangular wedges are not oriented The may go in either way NOTE The receptacle is shown use the same procedure for plug Contact removal Remove orange wedge To remove the contacts Hold the rear seal in place using needle nose pliers or gently pull wire backwards as removing the contact a hook shaped wire to pull while at the same time Will displace the seal wedge straight out releasing the locking finger by moving it away from the contact with a screwdriver 2001138 1 2014 01 52 54 Electrical System 06 12 Battery Battery Acid Test when using Acid batteries The battery provides the starter engine with energy and supplies the required voltage for lighting and other electrical equipment when the engine is not running During the starting procedure and when the g
116. er MOTOT et O 13 Replace Starter molor am Posta tapis ua 14 Check starter motor principal example Fehler Textmarke nicht Cables Wiring Harness General Fehler Textmarke nicht Battery cable lengths and cross sectionsFehler Textmarke nicht Engine 18 Wiring Diagram E Box Wiring Diagram 2181123 0 22 Wiring Diagram E Box Wiring Diagram 2181134 0 23 23 Wiring Diagram External E Box Diagram 2181141 0 24 Fehler Textmarke nicht definiert Wiring Instrument Harness Marine 20 Warning and Parameter Limits from Engine Management System 31 Description to circuit diagram 31 Electronics Gel GF c Son cesso qu desee audes 33 Electronic engine management 33 Diagnostic ead etes sa ouod sues a uus 34 Principle service code 35 Explanations of the BLimDiag Bit to limit Beta 38 Configuration engine ECU M1CU3 with connector A1 39 Potentiometer Accelerator and Voltage regulator 41 Potentiometer Accelerator 218084 7 0 BOQ 41 2001138 1 2014 01
117. exhaust elbow TBEXT BETA max limited by Manifold Exhaust Temperature TBT30LIM Optional Equipment Explanations of the Engine Mode ENGMODE ENGMODE ENGMODE ENGMODE ENGMODE 2001138 1 2014 01 64 Power ON when IGN on Crank if RPM 70 Idle if engine is running SOLAS if SOLAS Inversion Switch is active 38 54 Electrical System 06 04 11 Configuration engine ECU M1CUS with connector 1 GPR 40 G R NOPWR NOPWR NOPWR NDPWR N PWR CEL 5 wm lt n W 2 a H gt gt gt gt gt gt oo Oo CAN1H gt MiCU3 11 D 2 oF 2 gt 2 2 2 24050 CAN aces 2 m 2 occ oo 5 we Caos 2 2 lt a gt gt lt lt lt gt lt 5 gt lt 5 lt ke gt O alg ow mn cul o o m A 5 no gv mo m uw eu T 0 j m N au A uo 9 9 0 Hi Side Protected Output High Current Output Rack Position Input PT200 Temperature Senor Input Analogue Input PullUp Down Analogue Input PullUp Down NTC Input NTC Input Analogue Ground Analogue Ground Analogue Ground Digital Ground Low Current Output Analog
118. fications 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 of such change 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 Every STEYR dealer is obliged to fill out the owner identification card enclosed to every sold STEYR engine or every sold vehicle with a built in STEYR engine Part 1 Owner Identification Card is to be handed over to the customer part 2 Dealer Record Card remains with the dealer and part
119. following dial gauge value Index value of engine timing 3 59 mm 0 02 mm plunger guide stroke unit injector Z001138 1 2014 01 26 84 NOTE If the index value of engine timing should not correspond to the allowed value follow the instructions as per item 25 33 In case of correct index value of engine timing remove locking pin on crankshaft and tighten hexagon nut of camshaft sprocket SW 30 with 240 12 Nm by holding up with special tool No 230071 1 0 34 ATTENTION The following torques are to be checked again 1 Torque on hexagon nut of camshaft sprocket SW 30 q 240 12 Nm 2 Fillister socket head screw SW 8 of timing belt tensioner at q 45 4 Nm 3 Allen screws on vibration damper with q 135 4 Nm 35 Remove adjustment tool 2300736 1 from eccentric shaft 36 Reassemble opened components for service purpose in reverse order 27 84 2001138 1 2014 01 01 00 06 Replace engine bracket ATTENTION Slightly lift the engine by means of suspension VH A 00130 0 at lifting shackles approx 3500 N Replace engine bracket Exhaust side Note 1 For detailed information refer to vehicle manufacturer Example 2 Loosen Hex Socket Head Cap screws SW 8 remove bracket and washers NOTE secure hexagon head screws with LOCTITE 243 Tighten 4x M10 screw with a torque of 45 Nm 3 Replace engine bracket Intake side Note For detailed
120. g take care that they are completely volatilized before application of the epoxy Storage At temperatures below 28 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 ocrews 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 jointin
121. g and spring plate and pre stress 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 Z001138 1 2014 01 30 84 01 01 02 Adjust valve clearance Preparation Remove camshaft housing cover Valve clearance is adjusted by means of special tool No VR 00125 0 and adjusting gauge 2300712 3 ill 1 pos 1 between camshaft base circle ill 1 pos 2 and cam follower ill 1 pos 3 NOTE index value outlet valve 0 25 mm index value intake valve 0 25 mm 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 1 1 31 84 Z001138 1 2014 01 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 4 seated in bore Screw in pressure regulating valve sturdily 01 04 11 1 Assembly procedure NOTE Secure ONLY thread with structural adhesive LOCTITE 243 Tighten valve assembly with 8 Nm 1 ATTENTION Only tested valves with an opening pressure of 1 6 bar 0 15 bar to be used
122. g connections and plane surfaces 2001138 1 2014 01 62 65 Hardening time Use securing Fixing sealing sm DR DF Loctite 243 Loctite 262 Loctite 620 pos Loctite 5900 Loctite 5910 Hand tightness 15 30 15 x 30 5 10 0 5 48h 30 min UN reached after min min min Functional tightness 1h 1h 1h 0 5 h 2h 2h reached after es 3h 4h 48 h 3h 3h reached after 63 65 2001138 1 2014 01 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 0 10 Connect rod bearing clear radial 0 024 0 073 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 EM dimension Gap 1 ring 0 25 0 40 0 75 Gap 2 ring 0 25 0 40 0 75 Gap 3 ring 0 20 0 40 0 75 Axial play 1 ring 0 077 0 127 0 25 Axial play 2 ring 0 07 0 102 0 25 Axial play 3 ring 0 03 0 065 0 15 Camshaft radial 0 034 0 075 0 20 Camshaft axial 0 096 0 230 0 50 indicates gauging Valve guide 7 000 7 015 0 15 depth up to 3 mm before end of valve guide Oil pressure idle run 0 6 1 5 0 50 Oil pressure rated speed 4 0 0 7 3 00 0 80 Clearance between geartooth to 0 40 housing 0 15 Backlash of teeth oil pump
123. gital 2300899 0 probe pin 2300641 1 V belt tightener VR00515 0 open end wrench 2300711 0 extractor 00113 0 adjust gage eccentric shaft 2300736 1 offset box wrench VR00228 0 19 84 Z001138 1 2014 01 1 Adjust eccentric shaft with special tool 2300736 1 as shown 2 Mount dial gauge rail with brackets 2306031 6 on studs at intake side of camshaft housing 3 Insert dial gauge 2300899 0 with probe pin 2300641 1 in dial gauge rail and put probe pin onto unit injector plunger guide cylinder 1 4 Turn camshaft until the roller of rocker arm is located on base circle of injection cam Concentric part of cam 5 press zero button on digital dial gauge Or pre set conventional dial gauge to position 20 mm stroke small pointer at 20 inside scale big pointer at 0 outside scale or press zero button on digital dial gauge 6 Slowly turn camshaft in direction of rotation until dial gauge shows a stroke of 2 mm injection stroke at unit injector 00 05 ill Z001138 1 2014 01 20 84 7 Continue to turn crankshaft in direction of rotation and position it with locking pin in crank shaft TDC piston cylinder 1 in TDC Reference TDC chapter 01 00 01 8 Continue to turn camshaft slowly in direction of rotation until a total distance of approx 3 65 mm can be read on the dial gauge plunger stroke at unit injector Assembly of camshaft sprocket 9 Clean and degrease
124. gon head screws and tighten with a torque of 75 Nm 4 Z001138 1 2014 01 01036284 0 42 84 01 04 Piston and Connecting Rod 01 04 01 Dismantle piston and connecting rod Preparation Dismantle engine housing 01 06 01 Disassemble crankshaft 01 02 01 1 Pull out piston with connecting rod 2 Remove retainer ring of piston pin by means of a fine blade screwdriver 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 pem ring pliers ATTENTION For assembly of piston rings take care of marking TOP A In case of a change of cylinder diameter take care of respective repair steps 04 01 ill 4 43 84 Z001138 1_ 2014 01 A For assembly of piston and connecting rod take care that positioning notch of connecting rod bearing 15 opposite to the clearance recess for oil injection nozzle NOTE For best result position rings with piston gap about one third of a turn a part from each others gap NOTE When inserting the piston into cylinder bore with special tool No 2300714 1 take care that arrow marking on piston top pointing to the front Z001138 1 2014 01 04 01 ill 5 y a p 0 5 1 in c Y 1 iy P 1 EN ri T A Ee euge 2 T au ee err fee 04
125. have to be renewed after 3 times off tightening 2001138 1 2014 01 60 65 H3 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 work piece 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 work piece 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 1507 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 ar
126. heck setpoint A 900 tighten torques 1 Every 900 hours For Commercial use only adjustment 300 level Hydraulic _ penam ERO cubos e Sterndrive See Change Manufacturer s Tightness of bolts 212 48 months Torsional If required Coupler Change bolts replace bolts by using loctite 243 Front Vibration Check tightening torque Damper 2001138 1 2014 01 30 65 After first Every Every jy 50 hours 300 600 h Service and Maintenance Schedule Daily org ori2 or24 notes months months months Engine leakage water Repair or consult Compartment Jeakage fuel eo J our STEYR and Bilge Jeakage exhaustgas __ e Merine Dealer Csmowhadon e amp required io be replaced by your STEYR Marine Dealer lubrication e See oil leve EM 7 Shifting adjustment Shaft Bearing Check Consult STEYR Gland _ Marine Dealer refer to manufacturer specification drain clean water from separator bowl NOTE Oil exchange interval must be adapted acc application and utilisation of vehicle respectively quality of engine lubricant in use 31 65 2001138 1 2014 01 General Preliminary Service Manual MARINE 2012 D General Information D1 Electronic Engine Management Sy
127. heck membranes of frame sealing and rubber pads for damage replace if necessary Clean and degrease all sealing surfaces Clean sealing profiles from adhesive residues Apply 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 5182 Z001138 1 2014 01 06 01 11 12 62 84 5 First put suction sides housing half onto dowel pin and then check for second housing half whether oil suction pipe and oil suction pipe horn do not collide with the housing Screw together the housing halves 6 Tighten 7 hexagon screws SW17 ill 16 pos 2 with a torque of 50 Nm 5 Nm Fasten 16 Allen head screws SW5 ill 16 pos 1 with a torque of 10 1 Nm refer to chapter General Tightening Torques 7 From engine no Screw together frame sealing with housing halves Tighten with a torque of 5 5 Nm 0 5 8 Assembly engine in reverse order 63 84 Z001138 1 2014 01 01 06 02 Replace rear ring carrier Preparation Dismantle engine housing 5 01 06 01 Loosen 7 hexagon screws SW 13 Hemove support ring Clean and degrease all sealing surfaces Clean surface on mounting bosses of block Apply LOCTITE to sealing area of block with surface sealing agent LOCTITE 5182 Mount new support ring ATTENTION Replace radial shaft sealing ri
128. ial care of correct polarity Incorrect polarity destroys electronic components 2001138 1 2014 01 54 54
129. information refer to vehicle manufacturer Example 4 Loosen hexagon screws SW 17 remove bracket and washers NOTE secure hexagon head screws with LOCTITE 243 Tighten 4x M10 screw with a torque of 45 Nm 3 Z001138 1 2014 01 28 84 Cylinder Block 01 01 01 Replace valves Preparation Disassemble engine housing 01 06 01 Disassemble crankshaft 01 02 01 Disassemble pistons 01 04 01 1 Insert special tool No VR00104 0 in cylinder bore and tighten sturdily with two hexagon screws SW19 2 Mount valve spring retainer No VR00105 1 valve spring with hexagon nut 5 28 og IA EN 7 4 Lac TM b am wr 4 01 01 1 3 p 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 1 4 29 84 Z001138 1_ 2014 01 7 Pull out valve stem gasket with special tool No 2300758 0 NOTE When inserting the valves lubricate valve stem with motor oil 8 Put special tool No V000152 0 onto valve stem end and pull on new valve stem over sleeve 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 12 Put on spring washer valve sprin
130. ing block Z001138 1 2014 01 38 84 10 Insert the two upper thrust bearing segments onto main bearing cap and mount main bearing cap Install remaining main bearing caps with bearing shells and tighten main bearing screws sturdy 11 Mount connecting rod cap with bearing shell pay attention to numbering Tightening specification for connecting rod screws thread and screw head support lubricated 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 Tightening specification for main bearing screws thread and screw head support lubricated Use new screws 1st working step all screws 35 Nm 3 2nd working step all screws 45 4 working step all screws 45 4 Special tool No 2300706 0 Tightening sequence 12 13 5 1 4 9 8 O0 O 8 O O 14 11 6 2 3 7 10 39 84 Z001138 1 2014 01 Measuring of end clearance Put on magnetic holder with dial gauge put dial gauge calliper onto crankshaft end Move crankshaft in forward direction and set dial gauge to zero Move crankshaft backwards and read measured value Clearance should be between 0 08 and 0 26 mm Z001138 1 2014 01 02 01 ill 13 40 84 01 02 02 Replace gear for oil pump drive Preparation Disassemble engine housing 01 06 01 Dis
131. ing units are used Linear km kilometre m meter mm millimetre inch Area m square meter cm square centimetre Volume cubic meter cubic centimetre dms cubic decimetre mms cubic millimetre litre Mass t metric ton kg kilogram g gram Energy N Newton KN kilo Newton daN deka Newton Electricity A ampere V volt W ohm UF microfarad Fuel consumption g kWh gram per kilowatt hour 2001138 1 2014 01 Preliminary Service Manual MARINE 2012 Pressure and Stress bar bar Pa Pascal Kpa Kilopascal N mm Newton per square millimetre Energy J Joule kW h kilowatt hour Power kW kilowatt Temperature K degrees Kelvin degrees Celsius Time h hour min minute second Velocity km h kilometre per hour m s meter per second Speed 1 min r p m 46 65 5 Abbreviations ill illustration Cu copper Massy main assembly max maximum TDC top dead center PTO POWER TAKE OFF power transmission at front of crankshaft end WS Wrench Size EMS Electronic Management System ECU Electronic Control Unit extender ECU FlexDef Electronic Management System for DPF min Minimum BDC Bottom Dead Centre DPF Diesel Particulate Filter EGR Exhaust Gas Recirulation DPFCU Diesel Particulate Filter Control Unit APS Absolut pressure sensor parametric 47 65 2001138 1 2014 01
132. insufficient 16 Battery connections loose or corroded 2 Battery is dead 3 Starter connections loose 4 Ignition switch 16 Water air and or dirt in fuel filter 2 Anti siphon valve stuck 3 Fuel pump Fill tank or open valve Bleed fuel system 6 times 10 sec ignition on and check for leaks Fuel pump may be defective Replace fuel 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 Check Engine Management System display for service code Charge or replace battery Check for loose connections and corrosions Clean connections and tighten Check level of electrolyte and charge battery Check connections and tighten If solenoid clicks when attempting to start engine check starter If inoperative replace Replace filter Inspect fuel supply line Clean and inspect or replace Tank Check operation of pump Replace fuel pump 2001138 1 2014 01 Preliminary Service Manual MARINE 2012 C1 Trouble Check Chart continued SYMPTOM POSSIBLE CAUSE ACTION Performance loss System error or failure Check Engine Management System display for service code Engine coolant temperature audible alarm 2 Fuel incorrect Fill tank with correct fuel Check fuel filter and fuel flow condition 3 Throttle not fully open Check throttle command lever for full travel 4 Overheating Check coo
133. ld also be system Low voltage characteristic evidence is low lights intensity difficult starting or High voltage lamps often blow up often needed to add water into battery faster operation of DC motors Alternator terminals designation alternator with mono function regulator Alternator of Connected terminal to designation Positive Positive terminal of pole ofthe the battery alternator terminal 30 Negative terminal of the battery terminal 31 Pre Charge excitation indicator on inspection the of operation dashboard Negative pole of the alternator ground NOTE Before commencing with the test of alternator check the following items proceed only if the all the answers are YES 11 54 2001138 1 2014 01 Electrical System 1 CHECK THE FOLLOWING ITEMS 1 Starter motor alternator battery connections OK oxidation of contacts loose or broken contacts burned contacts YES NO 2 Ground connection alternator brackets engine contact OK possible oxidation rest of painting process loose contact YES NO 3 Starter motor alternator battery connection cables without damages 4 The battery is functional and fully charged 5 Starter motor is operating correctly 6 All relevant warning light bulbs are OK 7 18 Drive belt properly tensioned and without damages NOTE Before commencing with the test of alternator check the following items proce
134. ling system 2001138 1 2014 01 26 65 Items to Check Troubled Systems Jojoeful 0 Sugea NN Jo Sugea ddns DuissiuJ JapuljAo Duisnou 399526 16 5 2 002 EBEN EN 3uejooo 10 eDJeuosip o NN __ Pueys mop youms JO EMEN B Duidee 1 UOI in osiou janj 2u159J8 peeds vod uo si 19e Joyoalul je Ajddns 4 TT TOT xXueJo nss d uoisseJduJoo ou JUU meses LL sneuxs 10 woe jou seoq BN tt JOU n MH B c N Q 9 5 Oo 5 T 5 gt o0 9 gt
135. loaded tightener POLY V BELT L 1095 6PK lt M Ll TI X 1 NS 9 54 2001138 1 2014 01 Electrical System 06 01 02 Exchange Replace Alternator Remove Alternator 1 Disconnect battery 2 Remove Poly V Belt 3 Disconnect the wiring cables For Assembly SW13 11 1 SW10 5 0 5 Nm SW 8 3 5 0 3 Nm 4 Loosen hex head screw 10 80 5 17 For Assembly Tighten with a torque of 45 5 Nm 5 Loosen hex head screw M10x100 SW17 For Assembly Tighten with a torque of 45 5 Nm Assembly is done in reverse order Note After Assembly coat all electric supplies with rubber sealing Z909570 0 2001138 1 2014 01 10 54 Electrical System 06 01 03 Alternator Performance Checklist Copy to be returned with all alternators changed under warranty 1 CUSTOMER COMPLAINT SYMPTOM BEEN M UOI 2 EQUIPMENT REQUIRED FOR QUICK CHECK OF ALTERNATOR ON THE VEHICLE Digital Voltmeter with measuring range to 50 Volts 3 ALTERNATOR INSPECTION ON THE VEHICLE Introduction When a defect in the charging system occurs the cause can be the alternator with the regulator the battery electrical connections in the system wiring harness the charge indicator or the driving belt of the alternator In majority of cases the charge indicator warning lamp indicates alternator malfunction Consequences of alternator malfunction cou
136. ly in combination with FDS Fuel Density Sensor Effects noticed during operation onthe helm dash board EGU EMS Emergency cut aff switch Lanyard connected open Neutral Safety switch opens normal closed a Sensor box Beta Limitation active Boat performance velocity Beta Limitation Diagnostic Semice Code memorized Area ta Troubleshoot Electrical System Rack Actuator Injection Timing Device lubricant system 1024 Service Code list Engine stops running o MET Sensor Be c ia e iui Fuel Density 4096 Combustion System FDS Sensor Fuel Density empty water separator Electrical system belt NO drive NO NO ON CEL ON HORN 1Hz 1 sec 4 sec 4 sec no limitation below 1000rpm limitation above 1000rpm after 180sec limitation above 2000rpm 2001138 1 2014 01 Preliminary Service Manual MARINE 2012 Diagnostic system The electronic management system monitors the following engine parameters oil pressure boost pressure coolant temperature sensor control rack potentiometer accelerator speed signal The electronic management system carries out self diagnostic and or plausibility checks for all input values and sensor connections In case of irregularities there is an optical or audible warning signal Note if prepare and installed by vehicle manufacturer Existing active failures remain stored until the problem ha
137. mperature Sensor Coolant AdcCountECT u16 280 118 9 signal voltage too high possible short circuit to battery B6 1000 cnts 4 888 V Temperature Sensor PED E NPL accelerator 1 Possibly wrong pedal used B9 PED 1 2 290 122 PED1 E MIN Potentiometer accelerator 1 signal voltage too low possible short circuit to ground 20 cnts 0 098 V AdcCo ntPED1 u16 PED1 E MAX Potentiometer accelerator 1 signal voltage too high possible short circuit to battery B9 950 cnts 4 643 V FUEL DENSITY E FER Fuel density sensor Timeout of fuel density sensor check connection and sensor 7 PF20 RANGE E FER 2005 fuel pressure is below the limit 4 2 bar for 10s PF20 E MIN signal voltage too low possible short circuit to ground 0 098 V ensor PF20 Fuel Pressure PF20 voltage too high short circuit to battery B10 1000 5 4 890 V 545 221 REM PAD E NPL Remote Pedal input signal out of valid range 546 222 PED2 Potentiometer accelerator 2 signal voltage too low possible short circuit to ground 20 cnts 0 098 V AdcCountPED2 u16 PED2 E MAX Potentiometer accelerator 2 signal voltage too high possible short circuit to battery B9 ndi i 122 74 cnts 4 MSN V FMS MALF E SIG Fuel Metering Solenoid FMS malfunction error detected FMS E MIN Fuel Metering Solenoid calibration position is below the minimum SRPOS value
138. n maintenance amp warranty manual P N Z001140 0 for MARINE 2012 general technical documentation CD ROM P N Z 001009 0 Note Further detailed service information are permanently available for the authorized SMO Service Network via log in through the established extranet access 2001138 1 2014 01 12 65 3 Technical Data and Overview Number of Cylinders _ 77 _ stroke mm 3200 3200 3200 3200 3200 3200 3200 3200 3200 displacement cm rated power kW rated speed 2500 max torque Nm max torque Ib ft co 4 140 170 170 190 190 205 215 2600 3500 4000 3600 4000 3600 4000 3800 328 347 398 391 443 420 434 2550 1800 2300 1800 2550 3300 4000 3600 4000 3600 4000 3800 404 382 406 451 454 504 489 540 E O Speed at Maximum Torque rpm 1800 1800 2050 Maximum test speed rpm Torque at maximum test speed Nm 2500 2600 3500 oO Lower tolerance of maximum power 96 Upper tolerance of maximum power 96 BB BB BB B B B B BB 13 65 2001138 1 2014 01 Preliminary Service Manual MARINE 2012 Fuel rate at rated speed 54 5 65 9 65 2 71 3 75 9 81 1 86 4 86 3 93 4 mm stroke Fuel rate at Maximum Torque 58 66 8 65 72 78 9 80 5 89 8 85 9 96 3 mm stroke mean effective Pressure 13 2 15 9 15 0 15 9 17 7 17 8 19 8 19 2 21 2 specific power 6 26
139. nations 06 04 02 Software Identification Example 5 236536 V50000 10E 23101Q smocrp 5 236536 only for this engine model useable V500000 gt Software for SE engine series 10E gt Main Software version A B C D ect 23101Q gt ongoing software number and letter higher newer 33 54 2001138 1 2014 01 Electrical System 06 04 03 Diagnostic system The electronic engine management system controls the following parameters Oil pressure boost pressure coolant temperature air charge temperature exhaust temperature The electronic engine management system has an automatic self test program checking all data of electronic sensors As soon as a fault is found there is an optical or audible signal refer to chart Service Codes Occurred faults remain stored until cancellation Stored faults may be selected analyzed and cancelled by means of PC via diagnostic connector or SCC An indicator for one or several stored service codes is the 5 second Illumination of the CHECK ENGINE LAMP and the WARNING HORN after ignition ON instead of usual 0 7 seconds refer to chart Operating Status according to marine manufacturer There are three fault categories temporary faults non essential faults and essential faults According to these categories the engine management systems may pick default values or select alternative parameters for fail save governing in order to continue engine operation If operating values are beyon
140. nction description 55 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 v Set up crankshaft to approx 40 crank angle before TDC piston cylinder 1 in in order to set all pistons in the engine to approximately the same length of stroke thus providing 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 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 adjusted Refer 03 02 02 and 03 02 06 Valve clearance set Special tool dial gauge rail 2306031 6 dial gauge di
141. nds NOTE With fixed rack rack position will be automatically stored by ECU M1CU3 otorage process will take approx 20 sec 5 urn ignition switch 6 Loosen threaded pin while retaining common rack and release under control Place threaded pin into original position rear bulkhead wall ill 1 A 7 Turn ON ignition switch for min 10 sec Note EMS memorises reference rack position and zero position of common rack During this procedure Injection Timing Zero Position value gets stored simultaneously 8 Turn OFF ignition switch 9 Remove adjustment tool 2300736 1 from eccentric shaft 10 Check if following parameters are plausible vie SMO EDT 2 0 SRPos0 5 518 NOTE If storage in ECU M1CU3 was unsuccessful an error rack code will be displayed Refer to Table Service Codes for detailed information NOTE The rack position sensor is magnetism sensitive external magnets must be kept away as the may disturb the sensor 2001138 1 2014 01 44 54 Electrical System 06 10 04 Replace actors sensors 06 10 04 01 ACT Air charge temperature sensor B07 a b 1 Unscrew temperature sensor SW19 Grease O rings before replacing sensor Preparation Drain the coolant system 1 Remove plug housing 2 Unscrew engine temperature sensor SW 17 ATTENTION Use new sealing ring 3 Fill the cooling system refer 05 00 08 06 10 04 03
142. ng recommended tool 00107 0 NOTE Secure collar screws of rear ring carrier with thread protection LOCTITE 243 Apply a small amount of LOCTITE onto thread 6 Tighten M8 collar screws of rear ring carrier with a torque of 28 Nm 3 Z001138 1 2014 01 64 84 01 06 03 Replace rear radial shaft sealing ring Preparation Remove flywheel refer 01 03 Remove radial shaft sealing ring 1 Mount special tool No VR00107 0 to press in the rear radial shaft sealing ring NOTE Specified tool enables a replacement of the radial shaft seal with assembled engine housing 2 Press radial shaft sealing into rear ring carrier by means of special tool VR00107 0 NOTE M8 collar screw must be removed during assembly of the radial shaft seal and collar screw must be tightened and sealed according recommendation in 01 06 02 p 6 Assembly engine in reverse order 65 84 Z001138 1_ 2014 01 01 06 04 Replace oil pump front ring carrier Preparation dismantle engine housing 01 06 01 remove timing belt remove vibration damper remove oil pipes 01 06 05 1 Pull of timing belt sprocket by means of special tool No 2300636 0 2 Loosen 6 hexagon screws SW13 remove oil pump housing 3 Clean surface on mounting bosses of block 4 Apply LOCTITE to sealing area of block and on Gear for Oil pump with surface sealing agent LOCTITE 5182 Z001138 1 2014
143. ngine damage if run for extended periods 10 Disconnect solenoid of engine to prevent engine from starting See ill 2 11 Fill a spray bottle with the preservation oil Shell Ensis Engine Oil 30 part number 205032310 41 65 2001138 1 2014 01 Preliminary Service Manual MARINE 2012 12 Whilst cranking the engine over spray the preservation oil into the inlet manifold until visually noticeable Shell Ensis Engine Oil has obtained visual noticeable the exhaust turbo Normally this procedure takes 3 to 4 min See ill 3 13 Replace all pipes belts and connections to original condition 14 Spray on all outside metal parts of engine SHELL ENSIS T part number 50322 and let it vent by air for 24 hours bad smell 15 Store engine again as in the condition delivered from STEYR MOTORS 16 The engine is now preserved for one more year This preservation procedure must be done every year and ensures that all of the air ways systems raw water systems oil system and the cylinders are protected against corrosion This procedure is repeatable up to a maximum of three times giving a shelf life of up to four years 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 2001138 1 2014 01 42 65 E Quality guidelines for repai
144. ngine housing by means of dipstick If necessary add oil DO NOT OVERFILL In case that the oil pressure control lamp would illuminated check for correct oil level have the engine checked by your STEYR Service 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 before starting D Deviations from normal operating conditions will be indicated by warning lights and audible alarm As to exact meanings see 06 07 02 amp 06 07 05 ATTENTION In case of non observance of break in instructions warranty will expire Engine to be filled with recommended oil quality only See chapter Engine Lubrication 2001138 1 2014 01 40 65 2 Operation after Break In The engines specified in this manual are intended to be operated at different speeds and loads but not allowing full load of the engine for more than one hour per 12 running hours Economic driving may be achieved at the following speeds MARINE 2012 2000 3200 rpm which will prolong engine life and reduce emissions and noise When starting a cold engine always allow the engine to warm up sl
145. nt into bucket NOTE There is no drain plug on the engine through which the coolant from the internal cooling circuit can be drained 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 11 21 Z001138 1 2014 01 Cooling System 05 00 08 Fill cooling system Example Closed cooling system 1 Fill cooling circuit with specified coolant SMO Z011785 0 only Coolant level should reach the lower edge of the filler neck in the expansion tank refer to vehicle manufacturer specification NOTE Cooling system purges automatically while filling ATTENTION For a new filling of the closed cooling circuit make sure that the cooling system is purged completely 2 Let the engine run check coolant level and refill coolant if necessary Due to extensioning the coolant volume a change of the cooling system characteristic appears Check the cooling system pressure The required static pressure at operating temperature 75 80 C should be 500 mBar overpressure If the coolant volume extends more than 8 litres a larger expansion tank and a pressure cap 1 5 Bar opening pressure is recommended With the set heating pump the discharge can be 18 l min depending on temperatur connecting limit 75 disconnecting limit 70 but independent on the engine speed 05 03 Pipes Thermostat 05 03 01
146. nt to vom Inland vom Ausland from home from foreign countries countries STEYR MOTORS GmbH 07252 222 52 43 07252 222 52 After Sales Service Im Stadtgut B1 07252 222 29 43 07252 222 29 4400 STEYR AUSTRIA service steyr motors com http www steyr motors com STEYRMOTORS INNOVATION WITH LIGHTNESS Feb 2012 P N 2001138 0 15 Edition 3 65 2001138 1 2014 01 Preliminary Service Manual MARINE 2012 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 components 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 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 speci
147. on 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 28 Check locking position of crankshaft or lock crank shaft if necessary piston cylinder 1 in TDC Refer 01 00 01 29 Adjust camshaft to 3 65 mm on the dial gauge by turning with special tool 230071 1 0 11 30 plunger guide at unit injector is moved down by 3 65 mm NOTE During this operation the camshaft sprocket must be released from the taper connection and should only be slightly supported by the cone Tension of timing belt remains adjusted as described before 30 Remove locking pin from crankshaft Refer 01 00 01 31 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 sprocket and camshaft are connected measurement mum purpose A positive connection is only achieved by finally tightening the hexagon nut with 240 Nm 12 The previously set stroke on the plunger guide 00 05 1 21 must be changed when tightening the hexagon nut 32 Turn crankshaft by 2 further turns and at the second turn fix crankshaft in TDC position cylinder 1 at TDC with locking pin in fly wheel bore See chapter 01 00 01 With locked crankshaft the plunger guide stroke of unit injector at first cylinder should show the
148. on 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 ITD has been disassembled or replaced Torsion Arm Assy has been replaced or loosened ITP Sensor has been replaced 10 03 11 1 10 03 ill 2 NOTE Ensure that the ignition is turned off 1 Remove threaded pin from position ill 1 2 Manually move rack ill 1 B forward until bore ill 1 C is aligned with threaded hole ill 1 D and insert threaded tapered pin The pin must be fastened hand tight and sit correctly in the rack see ill 2 above 3 Adjust eccentric shaft with special tool 2300736 1 so that the eccentric is at the highest point as shown ill 4 NOTE If it is difficult to turn the eccentric shaft proceed as following Turn Ignition ON to rotate eccentric shaft clockwise or counter clockwise for max 30 seconds By Ignition ON and if common rack is fixed in threaded hole III 1 D the solenoid of Injection Timing Device is pulsed for max 30 seconds Turn Ignition OFF when eccentric shaft is 43 54 2001138 1 2014 01 Electrical System at correct position Ill 4 4 Turn ignition switch min 20 seco
149. osition Sensor B02 1 Remove plug from sensor 2 Loosen 2 hexagon nuts remove sensor 3 Don t forget the washers 10 04 ill 8 06 10 04 09 ITV Ignition Timing Valve Y2 1 Remove intake manifold refer 01 08 01 2 Remove plug from valve 3 Loosen 2 screws remove valve and O ring FOR ASSEMBLY Use new O ring 06 10 04 010VTG Vane Actuator X25 1 Remove plug from actuator 2 Remove retaining washer 3 Loosen 3 hexagon screws and remove actuator 10 04 ill 10 47 54 2001138 1 2014 01 Electrical System 06 10 04 011 FDS Fuel density Sensor included in Kit Fuel Compensation 51205010 1 Remove plug from sensor 2 Unscrew Fuel density Sensor M14x1 5 SW30 and remove sensor NOTE Use only in combination with MET Software version min V50000 10D Tighten with a torque of 27Nm 3 Renew o ring amp copper seal ring Note Do NOT push poke or otherwise touch the Tuning Fork with any object or instrument as this may cause damage to the Sensor 06 10 04 012 MET Manifold Exhaust Temperature Sensor X21 gt included in Kit Fuel Compensation MS1205010 1 Remove plug from sensor 2 Unscrew T30 Exhaust Gas Temperature Probe M14x1 5 SW30 and remove sensor NOTE Use only in combination with FDS Software version min V50000 10D 2001138 1 2014 01 48 54 Electrical System 06 10 04 013EXT Exhaust Gas Temperature Sensor 1 Remove plug housing DE 2 Unscrew
150. owly Never run the engine at full speed until operating temperature is reached During the first 50 running hours check the oil level frequently 3 Extended Storage Preservation Procedure 1 Remove the engine from storage and place on a suitable work shop floor with access to all side of the engine Do not remove from the original packing pallet 2 Ensure fuel is supplied to the engine and let it run up to temperature 3 Stop the engine and drain the old engine oil and store for future refill and usage 4 Mount brand new oil filter on the engine 5 Fill in preservation oil Shell Ensis Engine Oil 30 part number 2050323 0 5litres to the minimum mark on the dip stick 6 Connect the fuel system to a tank or canister filled with Shell oil V1404 part number Z010014 0 5 liters See ill 1 7 Restart the engine and run for 5 minutes in idle speed or max up to 1500rpm 8 Disconnect the fuel feed line from the engine and let fuel pump run for max 10 sec emptying the fuel system Repeat until no more fuel comes from the return line 9 Either drain the preservation oil from the engine and replace with normal specified oil 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 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 e
151. pecial tool 2300746 0 remove connecting rod bearing caps with bearing shell Push down all pistons and connecting rods to TDC position NOTE Remain with crank shaft in position during work operation to avoid damage the bearings Never turn crank shaft 3 Loosen two screws of each main bearing remove main bearing shells and caps 4 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 3 84 Z001138 1 2014 01 5 Remove main bearing blocks 02 01 15 6 Pull out oil nozzles for piston cooling 7 main bearing shells from bearing EST 02 01 11 6 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 8 Check for proper installation main bearing shells and connecting rod bearing shells 02 01 ill 7 ATTENTION Main bearing base and main F bearing cap are marked with A consequential numbers on side of the bearing cast Make sure this number between base and bearing cap match 9 Insert the two upper thrust bearing segments with bearing surface towards crankshaft The side with the numbering is against at main bear
152. pring and spring washer and prestress with special tool No VR00105 1 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 49 84 Z001138 1 2014 01 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 I Disassemble unit injector of 1st cylinder 03 02 02 1 loosen 2x hex socket head cap screw M8x25 and remove Torsion Arm Assy Refer to injection timing device 03 08 04 2 Disassemble leaver to governor solenoid by loosening two hexagon screws SW8 ill 2 pos 1 Disassemble all control links ill 3 pos 1 by loosening hexagon socket SW4 ill 3 pos 2 ATTENTION LEFIHAND THREAD NOTE Connection of LEFTHAND THREAD screws and control links to be opened three times only 05 03 ill 3 Z001138 1 2014 01 50 84 4 Remove locking pin ill 4 pos 1 from last bulkhead 5 Loosen plug screw SW22 ill 5 remove sealing ring pull out control rod to the back Rear site of engine housing 6 Assembly in reverse order NOTE 7 Adjust control refer to 01 00 04 8 Calibration of rack position refer to 06 10 03 51 84 05 03 14 Z001
153. que of 9 5 Nm 1 Put sealing ring into groove Put sealing ring into groove Lubricate groove with Molykote Z001138 1 2014 01 04 02 11 2 18 21 Cooling System 9 Place gasket 10 Place coolant water pump 11 Fix coolant water pump with 3 hex head screws M8x30 one hex nut M8 and two hex socket head cap screws M6x60 M6x30 19 21 Z001138 1 2014 01 Cooling System Preparation Loosen Poly V Belt Drain Water All parts of raw water pump Change Impeller Disassemble 1 Loosen 3x hex socket head cap screws 2 Put off Water Pump Assembly 3 Loosen 6x hex head screws M4x8 SW 4 Pull out Impeller by use of pliers Assembly is done in reverse order Z001138 1 2014 01 20 21 Cooling System Change Pulley Disassemble 1 Loosen 3x hex socket head cap screws 2 Pull off pulley Assembly is done in reverse order 21 21 Z001138 1 2014 01 Electrical System 06 00 06 01 06 01 01 06 02 06 02 01 06 02 02 definiert 06 05 definiert 06 05 01 definiert 06 05 02 06 05 03 06 05 04 06 05 05 06 05 06 06 05 07 06 06 06 07 06 07 01 06 07 02 06 07 03 06 07 10 06 07 11 06 08 06 08 01 1 54 06 Electrical Systems Table of Contents SONG Kal ENERO m 5 Fehler Textmarke nicht definiert Exchange Replace 10 Start
154. r 1 Spare part specification Your STEYR engine was designed for specified operation which means operating conditions such as Long time operation at high speed load and Operation in salt or brackish water Operation in very muddy water Only use genuine STEYR spare parts in order to avoid possible loss of performance For this reason you should insist on the famous quality of genuine STEYR 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 dust free 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 STEYR MOTORS TOOL catalogue have to be used Furthermore special care is to be taken in case of purchasing and stock of required operating material spare parts and wear parts e g seals filters sealants 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 reoccurring tool kit service and m
155. r Diag Service code Action or possible reason see table trouble shooting Cooling system Sensor or connector failure see service code table See table trouble shooting Engine oil system Sensor or connector failure see service code table 32 65 Operating Parameter Insufficient boost pressure or defective sensor Engine speed sensor fault Governor position system During break in phase Effect noticed Reduction of engine speed Engine stops running Irregular engine speed or stalled engine MIL ON at high accelerator position more than 75 Panel Indication NO RPM indication in tachometer Indication light is swichted ON Additional Tool Readings Steyr Diag Power limitation Steyr Diag Service code Steyr Diag Service code Steyr Diag Break in phase Action or possible reason see table trouble shooting Air charge system see table trouble shooting Speed sensor see table trouble shooting Governing system See information break in procedure Optical and acoustical warning signals are explained on the following tables Operating Status and Error Report MIL Mal function Indication Light 33 65 2001138 1 2014 01 General Trouble Indication Chart Ignition ON gt starting Possible Indication during Operation Instrument Panel Factors Cause of Trouble Ignition Key turnedto
156. r reference bore ill 2 pos 3 in the bulkhead wall 3 Pull control rack manually to the front against spring resistance and hold Insert setpin as shown and fasten sturdily NOTE Check fixation of common rack after locking by assuring that rack does not move forward or back when trying to move manual 02 03 14 Z001138 1 2014 01 24 47 Fuel System 03 02 04 Adjust control link injection quantity Prior to adjustment unit injector must be tightened properly and control rack must be fixed in position with set pin refer 03 02 03 NOTE Readjust all control links even if only one link has been opened STARTING POSITION Slacken left handed setscrew of control link use special tool P N 2300908 0 Turn control link against bulkhead on camshaft housing 1 Carefully position end of control link on front side of unit injector quantity control gear preferably use small screwdriver 2 urn control link against unit injector quantity control gear until control gear completely pushes against upper calibrated stop and hold position with screwdriver Remain in this position and tighten left hand thread screw of control link as specified with a torque of 7 Nm 1 Hepeat steps 1 and 2 for the rest of unit injectors to obtain proper setting of the control rack 3 Calibrate rack position refer to 06 10 02 4 Release fixing of control rack refer to 03 02 05 02 04 11 4 25 47 Z001138 1 2014 01 Fu
157. recommended every 300 hours of operation and or every 2 years at least ATTENTION Close supply valve from tank if existing and tank is higher than fuel filter 1 Unscrew filter by means of filter wrench No 2300713 0 Remove filter and dispose Take care that original seal does not adhere to filter housing If so remove seal and dispose 2 Clean sealing surface on filter head 3 Slightly oil seal of new fuel filter with clean motor oil 4 Screw on new fuel filter until seal slightly rests on sealing surface of filter head Then tighten filter by hand approx 3 4 turn hand tight 5 Open fuel supply valve if this had been closed 6 Ventilate fuel system NOTE Fuel system can be ventilated via 39 47 Z001138 1 2014 01 Fuel System electric fuel pump Turn ignition ON a few times for max 10 sec ATTENTION Do not dry run fuel pump 7 Start engine and check fuel system for leakage 8 Remove possibly spilled fuel residues Dispose fuel filter according EPA regulation Z001138 1 2014 01 40 47 Fuel System 03 11 Replace Glow Plug Preparation for glow plug of first cylinder remove control solenoid refer to 03 08 01 for glow plug of second to sixth cylinder remove intake manifold refer to 01 08 01 Disconnect battery 1 Remove connector from glow plug 2 Unscrew glow plug s with special tool No VR001496 0 3 Screw in new glow plug s by means of special tool No VR001
158. rvice and Maintenance Chart 9 47 Z001138 1 2014 01 Fuel System 03 00 05 Exhaust pipe and muffler SE ENGINES ID Exhaust pipe must be properly dimensioned to meet requirements at rated speed gas flow Engine type SE ENGINES Back pressure 200 mbar Permissible tolerance 50 mbar Exhaust mass flow 840kg h 3550rpm full load NOTE Inside diameter of exhaust pipe and dimension of muffler system must be properly sized to meet requirements of above mentioned specification Z001138 1 2014 01 10 47 Fuel System 03 00 06 Schema Variable Geometry Turbochargers Function turbo charging system Engine draws in cool air Scavenged burns fuel energy drives releases hot compressor exhaust Air inlet Waste heat scavenged by turbine Turbocharger consists of two fundamental components a turbine and a compressor The function of the turbine is to scavenge waste exhaust heat and translate it into rotational motion This rotational motion is then used to drive the compressor which compresses air for the consumption of the engine The purpose behind the turbocharger is to overcome the fundamental drawback of the internal combustion engine its volumetric efficiency limit An engine drawing air in from the atmosphere can only achieve a volumetric efficiency of up to 100 meaning that the pressure inside an individual cylinder is equal to atmospheric pressure while the intake cycle is occurring Since the amount of po
159. ry Service Manual MARINE 2012 4 Safety in the use of operating material Dangerous operating materials in the sense of accident prevention are all operating materials potentially explosive fire provoking easily flammable poisonous injurious to health and corrosive Especially the following material belong to this group Spirit Mineral oils Battery acid 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 refuelling 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 First Aid Skin Swallowing Diesel fuel and Lubricams The biggest danger after an Lubricants accidental intake is the fact Remove clothes B that liquid could get into Anti freez
160. s an example which may differ from the installation in a vehicle 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 signal extinguish Next Eight Hours For the next eight hours continue to run engine at approximately three fourth throttle or less Occasionally reduce throttle to lower loads and let engine temperature cool 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 39 65 2001138 1 2014 01 Preliminary Service Manual MARINE 2012 Final Ten Hours of Break in During the final ten hours of break in the engine may run at full speed for five to ten minutes Operate engine to with specified temperature at moderate engine speed increase to cool down engine occasionally reduce the engine speed and load NOTE DURING THE BREAK IN PERIOD THE ENGINE MUST NOT BE OPERATED AT CONSTANT RPM FOR LONGER PERIODS During break in period be particularly observant of the following 16 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 Check the oil level in the e
161. s been solved Service code has been cleared from the memory to receive actual error code status To select stored service codes a PC with diagnostic program 00134 0 or diagnostic tool VR00135 1 is necessary or a SCC P No 2179497 0 must be connected Malfunction during operation is categorised in three different categories intermittent failure non essential failure and essential failure The EMS will memorize such errors and if required reduce performance of the engine while operating in a fatal range to its system Interacting components of engine management system ECU to unit injector Steyr Control Centre P No 2179497 0 front view lt TUN SS Bn e e 2001138 1 2014 01 36 65 Starting the Engine Starting procedure for the STEYR MOTORS engine is the same for both cold and warm engines The engine control unit automatically regulates the fuel supply and the preheating period for any given temperature Therefore the throttle lever should remain in neutral position 1 To start the engine move throttle lever into idle position and gear into neutral position 2 Turn ignition key into position ignition ON An audible alarm will sound and the warning lights are illuminated temporary indicating the correct function of the audible and visual warning systems Note In case of a low temperature start wait until the combined pressure glow plug pre heating indication light i
162. s turned off before you continue with the start procedure 3 Turn ignition key into position START and hold in this position until starting of engine but under no circumstances hold in this position for more than ten seconds If engine does not start release ignition key momentarily and repeat starting procedure 4 As soon as engine starts release ignition key The audible alarm will stop when normal oil pressure has been reached ATTENTION If engine fails to start within one minute and or repeated attempts contact your STEYR MOTORS Marine dealer Never turn ignition key to position START when engine is running Stopping the Engine Move throttle lever into idle position and gear in neutral position 2 Cool down the engine 9 Turn ignition key to OFF position ATTENTION Do not stop engine at speeds above idle or accelerate engine while turning off ignition This may result in engine failures 37 65 2001138 1 2014 01 Preliminary Service Manual MARINE 2012 Instrument indication during normal operation 1 Ignition ON before starting ON 0 7 sec System check see light indication Note lt At low temperature condition cold weather the combined light for glow plug preheating amp engine oil pressure will not extinguish after 0 7 sec glow plug preheating phase In this case start engine immediately after the light extinguishes 0 7 sec ON 5 sec
163. sembly in reverse order Note 1 Tighten clamp with a torque of 25 Nm 2 2 lighten 2 hex head screws and hexagon nut M8 with a torque of 23 2 Nm 3 Tighten hollow screw restricted bore of oil feed line with a torque of 25 Nm 2 Use new sealing rings Use new flange gasket and tighten 2 hex head screws to a torque of 23 Nm 2 Tighten hose clamps on drain plug with a torque of 4 Nm 0 5 a gt 31 47 Z001138 1_ 2014 01 Fuel System 03 02 08 Check bearing clearance Example 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 Measure radial clearance NOTE Determination of radial clearance is only required turbine sided 1 Put test prod of dial gauge onto centre of retainer cone of turbine wheel 2 Pull turbine wheel hub upwards by means of spring balance Measuring strength 50 N measuring strength 3 Note deflection of pointer 4 Repeat measurement by turning cursor by 90 05 02 ill Permissible radial clearance max 0 42 mm 0 04 Z001138 1_ 2014 01 32 47 Fuel System 03 08 Control Solenoid Injection Timing Device ITD 03 08 01 Remove control solenoid Preparation 1 Disconnect battery Remove intake manifold refer to 01 08 01 Fig 3 50
164. ssure build up as the duration of injection is very short 5mm 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 45 47 Z001138 1_ 2014 01 Fuel System 03 14 03 Disengagement methode of injection NOTE Disengagement method of injection is a simple and effective method to detect defective unit injectors with regard to formation of air bubbles in both the fuel system and the engine cooling system or lack of power if related to deficiencies in injection equipment NOTE In case of air in the cooling circuit system use tool VR00147 0 to detect CO2 concentration in coolant Preparation Disconnect crankshaft refer to 01 00 01 item 2 3 remove valve cover 1 Mount special tool No 00133 3 to disconnect injection 2 Start the engine let it run in idle and check if air b
165. stat housing and transmitted to the electronic management system If during operation the temperature limit exceeds 107 C the electronic management system will reduce the engine power to a perceptible extent of up to 50 ATTENTION To avoid damages on the engine occurring trouble must be analyzed and eliminated immediately Z001138 1 2014 01 4 21 Cooling System Raw Water circuit MARINE 2012 SI YRMOT ORS Raw water intake Impeller pump Fuel cooler Hydraulic oil or marine gear box oil cooler Tube stack intercooler Q Tube stack tube stack heat exchanger CU 3 Exhaust elbow AN Raw water filter www steyr motors com 2181159 0 00 111221 Coolant circuit MARINE 2012 cT EYRMOT ORS Fresh water pump Oilcooler o Water cooled exhaust manifold Turbo charger Thermostat Heat exchanger Fresh water pump supply pipe Q Expansions tank Filler www steyr motors com 2181161 1 00 111221 5 21 Z001138 1 2014 01 Cooling System 05 00 03 Error detection cooling system 1 Ask for the following information Model and serial number of engine Engine operating hours wear and corrosion How long does the problem already exist gradual or sudden occurrence Operating conditions prior to occurrence of problem What repair or service works have already been carried out thermostat etc At what engine speed does the problem occur At what
166. stem The STEYR Marine engine is equipped with an Electronic Management System EMS that performs the following e controls engine functions to ensure maximum efficiency e self diagnostic to protect the engine mechanical components against severe damage if operating parameter exceed limit s stores diagnostic data of EMS sensor circuits for maintenance and service stores abuse data Note The following general warning informations provided from Indications of faults are depending on installation done by vehicle manufacturer Engine power is reduced if Note Example based on standard Motors Instrument Panel panel maybe vehicle Operating Parameter High engine coolant temperature limit exceeded Defect engine coolant sensor Or sensor connection Oil pressure below limit Defect Oil pressure sensor or sensor connection 2001138 1 2014 01 Effect noticed Reduction of engine speed Reduction of engine speed Reduction of engine speed Reduction of engine speed oteyr Instrument different on actual Panel Indication Additional Horn ON 2x p sec Gauge reading gt 107 C Horn ON 2x p sec Gauge reading gt 120 C Horn continuous and Oil indication light continuous switched ON Oil pressure indication light switched ON 1x Sec Tool Readings Steyr Diag Power limitation Steyr Diag Service code Steyr Diag Power limitation Stey
167. sting screw in this position and tighten hexagon nut ill 7 pos 2 by means of torque wrench No 2300743 0 and tee handled socket wrench SW17 2300773 0 with a torque of 30 Nm 3 02 06 ill 7 Set values for unit injector adjustment gt refer to chapter general UNIT STROKE Note make sure to secure eccentric shaft in reference position with special tool No 2300736 1 NOTE To preclude setting properties for new assembly of unit injector copper ring we recommend a standard of pre stroke value of stroke adjustment acc to chart minus 0 05 mm 10 Recheck unit injector stroke adjustment compress unit injector spring and recheck zero on dial gauge Release spring load and reject total stroke adjustment as described in steps 8 and 9 ATTENTION In case of deviation repeat 9 setting procedure 29 47 Z001138 1 2014 01 Fuel System 03 02 07 Exchange pressure check valve at fuel outlet on block Pressure check valve is mounted at the block fuel outlet and controls fuel pre pressure in fuel gallery resp fuel supply to the individual unit injectors 1 Unscrew valve SW 19 mm ill 1 remove 2 Cu sealing rings NOTE Use new Cu sealing rings for assembly Tighten with a torque of 40 Nm 4 ATTENTION This part is of importance for the proper function of fuel system Use only genuine STEYR MOTORS spare part in case of replacement D ill Z001138 1 2014 01 30 47 Fuel System As
168. stroke of the unit injector at first cylinder should show the following value on the dial gauge Index value of engine timing 3 59 mm 0 02 mm plunger guide stroke unit injector NOTE If the index value of engine timing should not correspond to the specifically value follow the instructions as per item 27 Remove camshaft sprocket 26 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 27 extractor ill 27 pos 1 camshaft sprocket VR001 13 0 and screw in puller screw LEFTHAND THREAD by hand Pre stress puller screw with approx mam 100 Nm 5 NOTE Do not remove camshaft sprocket from conical seat when screwing in the puller screw Z001138 1 2014 01 14 84 28 Remove camshaft sprocket from conical seat by one hammer blow on puller screw NOTE correct the setting of engine timing follow further instructions as per item 30 Readjustment of camshaft position in case timing needs to be corrected NOTE This is to be carried out if the index value of the engine timing is not within the allowed adjustment tolerance 29 Check locking position of crankshaft or lock crank shaft if necessary piston cylinder 1 in TDC Refer 01 00 30 Adjust camshaft to 3 59 mm on the dial gauge by turning with special tool 230071 1 0 ill 30 plunger guide at unit injector is moved down by 3 59 mm
169. tainer bracket and remove fuel pump 13 47 Z001138 1 2014 01 Fuel System Assembly Example 1 Mount pump into bracket at correct position of rubber sleeve Tighten screws of bracket Attach fuel hoses to pump and tighten hose clamps Connect cables to negative terminal and to positive terminal Cover the two terminals with neoprene lacquer sealing No P N 2909570 0 Connect battery cables Open fuel supply valves Operate electric fuel pump by turning on ignition key 3x for 10 sec to bleed system Check fuel system for leakage Z001138 1 2014 01 14 47 Fuel System 03 02 02 Disassembly and assembly of unit injector Preparation Remove camshaft housing cover Clean sealing surface of rubber seal and check for hardening and damage Replace seal if required Example P No Unit injector 2176560 B NOTE When replacing or adjusting injectors make sure to identify the type of injector marked on the injector housing as shown The marking is part of the production number only the last 4 digits are printed 560 B Preparation for disassembly fix control rack refer 03 02 03 loosen control link refer to item 4 loosen fixing of control rack refer 03 02 05 extract retainer c clip 11 02 1 and pin 02 2 02 02 ill 2 15 47 Z001138 1 2014 01 Fuel System First turn eccentric shaft towards intake manifold until lever of eccentric shaft is free
170. th special tool No 2300711 0 ATTENTION The following torques to be checked again 34 Torque on hexagon nut of camshaft sprocket SW 30 240 12 Nm 35 Allen socket head screw SW 8 of timing belt tensioner at 45 4 Nm 36 Allen screws on vibration damper with 135 4 Nm 3 Remove adjustment tool from eccentric shaft Z001138 1 2014 01 00 03 ill 32 16 84 01 00 04 Remove timing belt Preparation put engine out of operation disconnect battery remove camshaft housing cover Special tool for vibration damper screws No 2300700 0 1 Loosen 3 Allen screws M12 x 90 Pos 18 from vibration damper by means of special tool 2300700 0 and remove vibration damper 2 Loosen hexagon screws SW10 remove timing belt covering NOTE See for arrows markings on used timing belt mark timing belt if necessary Consider change intervals see chart maintenance 17 84 Z001138 1 2014 01 3 Lock crankshaft refer 01 00 01 4 Loosen Allen head screw SW 8 of belt tensioner and remove tensioner o Hemove timing belt ATTENTION With loose and or removed timing belt the camshaft or crankshaft must not be turned This could result in a collision of pistons and valves 6 MOUNT TIMING BELT refer adjust engine timing 01 00 05 Z001138 1 2014 01 18 84 01 00 05Timing adjustment procedure for dismantled engine Fu
171. tion cam cap Z001138 1 2014 01 6 84 7 84 The marked tooth of the camshaft timing belt sprocket stays in line with the upper edge sealing surface of the camshaft housing The notch on the timing belt sprocket of crankshaft is opposite to the arrow marker on the oil pump housing 00 01 ill 9 Z001138 1 2014 01 01 00 02 Camshaft housing cover and seal Remove camshaft housing cover and instruction to exchange cover seal 1 Release 14 hexagon screw SW 10 2 Remove camshaft housing cover 3 Release camshaft housing cover sealing by means of screwdriver and remove 4 Clean sealing surface of camshaft housing and camshaft cover carefully 5 Position new seal on camshaft housing cover and press it with the thumb into the groove beginning at the half moon section ill 2 6 Put camshaft housing cover onto camshaft 00 02 1 2 housing Tighten with 14 hexagon screws SW 10 with a torque of 9 5 Nm 0 5 Z001138 1 2014 01 8 84 01 00 03Maintenance timing belt exchange Preparation put engine out of operation disconnect battery remove camshaft housing cover Special tool for vibration damper screws No 2300700 0 1 Loosen hexagon screws SW10 remove timing belt covering NOTE See for arrows markings on used timing belt mark timing belt if necessary Consider change intervals see chart maintenance Special tool dial gauge rail 23060
172. tion of armature Try to pull out the pinion You need to fill the certain force from 50N to 100N Check the terminal screws they must not move Check if there is seen the signs of overheating 06 02 04 the observe and finding describe in attached document Checking list Typical starting Circuit Operation 1 Wire B terminal 30 of starter motor must be connected to the battery positive terminal Starter motor housing must be connects to the battery negative terminal When wire from relay A is energized current flows through both pull in winding C and hold in winding D to ground Current through windings engages solenoid plunger E which closes main contacts F When main contacts close current through pull in windings stops Current continues through hold in winding keeping solenoid engaged and main contacts closed With main contacts closed current flows from battery cable B to starter motor at a very high rate Four heavy field windings carry current to commutator brushes H From field windings current flows through armature windings 1 to ground 31 making contact through commutator brushes H Strong magnetic fields are set up by current flow through field windings and armature windings Windings are arranged so that magnetic fields constantly repel each other rotating armature 2001138 1 2014 01 16 54 Electrical System A Wire from Key B Cable from Battery C Pull In Winding
173. to the outlet manifold Depending on engine operating temperature the coolant is circulated to the thermostat and at low temperature returned to the coolant pump starting its circulation through the block system again As operating temperature increases the thermostat will gradually proportionally reduce the flow through the short circuit pipe As this happen the coolant flow will decrease in the short circuit pipe and coolant will start to flow through the radiator returning to the thermostat back to the circulation pump During high load and full load operation the thermostat will completely close the short circuit pipe and the entire coolant will circulate over the radiator back to the thermostat and coolant pump The thermostat is mounted in a separate housing on the intake manifold side of the engine The thermostat operating temperatures are 80 95 the thermostat is completely open From this time the whole coolant flows through the radiator Here the hot coolant releases thermal energy via the radiator The expansion vessel serves as a continuous bleeding system for the coolant circuits and provides sufficient volume for the expending liquid The expansion vessel is equipped with a filler cap capable to maintain proper pressure in the system Operating system pressure is regulated via excess pressure valve opening pressure 1 5 bar in the pressure cap Coolant temperature is measured by means of sensor on the water pump thermo
174. typical operations and sounds Try to describe the observation Electrical checking e Check the condition of battery the battery must be fully charged Check and clean if necessary the battery contacts With multimeter measure voltage on battery and check the value in table battery of charge 12 25 12 05 12 00 e Check the mean starter motor circuit cable from battery to the starter motor and earth cable Also check all connections of mean circuit Make sure that they are In good conditions e Check the key terminal When the key is turned on the tension must be measured on terminal 50 With multimeter measure the voltage on terminal 50 and it must be higher than 8V on 12V application and higher then 16V on 24V application e Compare also voltage drop between terminal 30 and terminal 50 If the difference is more than 2V when the solenoid is energized means that circuit resistance of terminal 50 is too high If all above point are checked and starter motor still does not crank the engine with per scripted performance remove the starter 15 54 2001138 1 2014 01 Electrical System Checking the starter motor after it is removed from engine When the starter motor is removed from engine also check the condition of flywheel Visual checking Check if any starter motor part is mechanically damaged Check the wear of pinion Try to rotate the pinion In one way it must rotate smoothly in other you need to fill the rota
175. ubbles form at the fuel return line NOTE If there are no bubbles at idle speed of engine continue with item 3 Otherwise investigate fuel suction line and fittings and correct failure 3 Bring engine to operating temperature and then test the vehicle under operating conditions and watch for bubbles to form Keeping this operating condition continue with item 4 4 Loosen nut on cover see ill 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 vehicle with disengaged unit injector under operating conditions and 6 Continue to check all other injectors cylinders one by one in order to detect the defective s unit injector s NOTE Air 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 Z001138 1 2014 01 46 47 Fuel System 03 14 04 Air bubble formation in fuel system Example Preparation Change fuel filter if necessary refer to 03 09 item 1 bleed fuel system Testing device for fuel return 2300719 1 1 Disconnect hose from fuel return on block fuel cooler outlet to fuel cooler 2 Connect hose ill 1 pos
176. ue Input PullUp Down Analogue Input PullUp Down VTGPOS Analogue Input PullUp Down GEAR NTC Input NFIX1 NTC Input Analogue Ground Analogue Ground Analogue Ground Digital Ground Low Current Output Crank Sensor Input Low Side Output Rack Control High Current Output EaR HB een ola a o w ag N NIN NNN NIN N OJORA WD N Co 39 54 2001138 1 2014 01 Electrical System Designation Explication VREF3 5V Analogue Voltage Reference 5V Analogue Voltage Reference 2001138 1 2014 01 i Overside GNDPWR VBAT VREF1 PED2 OUVP CAN2H GND GNDPWR VBAT RES1 SER CEL IGN CAN1H GNDPWR GNDPWR HORN GPL MR CAN1L GND GNDPWR VBAT Analogue Input PullUp Down Analogue Input PullUp Down Analogue Input PullUp Down High Current Output Me Hi Current Output Me Hi Current Output 5V Analogue Voltage Reference 5V Analogue Voltage Reference Analogue Input PullUp Down Analogue Input PullUp Down NTC Input NTC Input Me Hi Current Output Digital Output Relay Lamp Analogue Ground Pedal Position Input Digital Input Hall Effect CAN Line 250kbit Power Ground Analogue Input Battery 5V Analogue Voltage Reference Pedal Position Input Digital Input Hall Effect CAN Line Digital Ground Power Ground Analogue Input Battery Low Current Output Digital Output Relay Lamp Digital Output Relay Lamp Ignition Switch Input CAN Line Power
177. wer by means of needle nosed pliers NOTE Adjust valves refer to 01 01 02 Z001138 1 2014 01 valve keepers ill 1 pos 4 are 05 08 111 1 56 84 01 05 08 Replace retainer of cam follower Preparation disassemble cam follower 01 05 08 1 Turn retainer spring ill 1 pos 1 sideward s and removes by means of screwdriver from valve adjusting element towards centre 05 09 ill 1 NOTE Adjust valves refer to 01 01 02 05 09 1 2 57 84 2001138 1 2014 01 01 05 09 Replace valve adjusting element Preparation Disassemble retainer spring of cam follower 01 05 09 1 Unscrew valve adjusting element with hexagon socket SW21 NOTE Apply thread protection LOCTITE 243 to valve adjusting element and tighten with a torque of 55 Nm 3 NOTE Adjust valves refer to 01 01 02 Z001138 1_ 2014 01 58 84 01 06 Engine Housing Pump Oil Suction Pipe Oil Schematic 7 2 5 702 7 wy T x 7 S o Abs 2 am gt C 0 007 1 GAAS A mM Jj 5 LS uU i Wat ni Iwas gt mme Ww i VIS 4 CH lg 26 d RA d 2 EER UB SAK sans n ADIT RSS ERT TAL 42 2 24 PO NEU DES il E 2 7 4 4 01 06 01 Replace engine housing
178. wer that can be extracted from an engine is proportional to the fuel it burns and the fuel consumption is limited by the amount of air present in a cylinder times the number of cylinders the so called displacement the volumetric efficiency limit effectively constrains the power of the engine The turbocharger provides an alternative means of extracting more power from a given displacement by increasing the volumetric efficiency to points significantly above its volumetric design The pressure in the cylinders is greater than atmospheric thanks to the compressor on the turbocharger 11 47 Z001138 1_ 2014 01 Fuel System Variable Geometry Turbocharger VGT Variable Geometry Turbochargers are turbochargers whose geometry and thus effective aspect ratio A R can be altered as needed while in use The most common design includes several adjustable vanes around a central turbine As the angle of the vanes change the angle of air flow onto the turbine blades changes which changes the effective area of the turbine and thus the aspect ratio A R changes The benefit of Variable Geometry Turbochargers lies in reducing lag time The area between the adjustable vanes works as nozzles These nozzles are thus varied in size as a function of engine operating conditions By opening the nozzles at high engine speed or closing them at low speed effectively changing the A R with engine speed or demands the turbo can produce boost from a low speed
179. with 240 12 N 18 Remove locking pin from crank shaft 00 05 ill 19 19 Turn crankshaft 4 turns and stop at fourth turn with a plunger guide stroke of unit injector of approx 3 59 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 23 84 Z001138 1_ 2014 01 20 Put on tension gauge 00515 0 between camshaft sprocket and tensioner as described under item 15 and read measured value Timing belt tension should be 600 30 Nm for a new timing belt NOTE In case of used belt adjust timing belt tension should be 520 30 Nm NOTE If timing belt tension does not correspond to desired value loosen the tensioner and repeat adjustment according to 55521155 instructions under item 15 to 20 In this case a re positioning of the camshaft sprocket may be required 21 Turn crankshaft further 2 turns and at second turn fix crankshaft in TDC position cylinder 1 in TDC with locking pin in crank shaft 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 59 mm 0 02 mm plunger guide stroke unit
180. y 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 Putting on a fixing element of a component or an assembly and tightening Taking apart assemblies into individual components Putting together components to an assembly Valve clearance start of feeding operation Elimination of a deviation by means of provided equipment or 44 65 readjust refill renew gauge replace measure check clean maintain Fasten 45 65 Devices or tools Adding and replenishing of operating agents Replacing an auxiliary material by a new one Reading in actual positions in programming memory Exchanging of a device a main assembly an assembly or a component by the same new or repaired ones Steps taken to determine the actual status by evaluating of physical entities Steps taken to compare the actual status with determined Removal of foreign and auxiliary material Steps taken to keep the respective determined planned status To secure an element with a bolt and tighten to specified torque Corrosion protection agent sealing material paint Valve lift piston diameter valve clearance close fit V belt tension Bracket fastened to engine 2001138 1 2014 01 General E4 SI System The following measur
181. ystem 7 Move the rocker arm towards timing belt side of engine and remove the slide cup NOTE Adjusting screw and slide cup match exactly and thus have to be kept matched 8 Check position of control link s against bulkhead as illustrated 9 Insert the unit injector lever SMO No VR 00126 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 NOTE For disassembly of the unit injector from cylinder No 1 the control rack is to be moved forward 10 Remove unit injector with mounting flange Z001138 1 2014 01 18 47 Fuel System 11 Remove copper seal washer from bottom side of copper insert by means of hook and lifting tool No VR 00116 0 NOTE Avoid scratches on the sealing surface of the copper insert Assembly 1 In order to secure an appropriate tight fit recheck tighten stud bolt with a torque of 20 Nm 1 2 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 18 3 Check copper insert for possibly remaining seal washers remove and dispose if necessary NOTE Always use new copper seal
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