FRC ServiceManual PDF

STEYR MARINE ENGINES
4 CYLINDERS
+ 6 CYLINDERS
SERVICE MANUAL
P/N Z001019/0 6th Edition July 2008
www.steyr-motors.com
STEYR MOTORS GmbH
Im Stadtgut B1, A-4407 Steyr-Gleink, AUSTRIA
THIS PAGE IS INTENTIONALLY BLANK
PREFACE
STEYR MOTORS GmbH has developed high-performance diesel engines with modulated high-
pressure direct injection, especially for the marine environment. STEYR marine engines are designed to be
adapted to various propulsion systems.
This SERVICE MANUAL is published with the main intention -
to provide information in form of technical data and know-how based on our experience in the marine diesel
engine business, which will enable you in case of possible failure to operate, service and repair the engine
4 & 6 CYLINDER MARINE

ENGINES
to maintain their operating safety and reliability.
To achieve continuous improvement with regard to form and contents of the information required, we are
assigned to your aid.
We, therefore, would much appreciate your comment to the following questions -
- Which descriptions or terms are not understandable?

- Which supplements or completions do you propose ?
- Where did creep in contents-related mistakes ?
Please address your comment to:
vom Inland: vom Ausland

from home country from foreign
countries:
STEYR MOTORS GmbH
After Sales Service 07252/222/52 +43/7252/222/52
Im Stadtgut B1
4407 STEYR 07252/222/29 +43/7252/222/29
AUSTRIA
service@steyr-motors.com
http://www.steyr-motors.com
Z001019/0_6_July 2008
Repair and maintenance works on engine
The descriptions and instructions in this technical documentation should support you in use and repair of our
product. They refer to a specific equipment status of engine componets and accessories. Your individual
engine may be equipped with other or less accessory.
For any component not covered in this manual, please contact STEYR MOTORS GmbH, After Sales Ser-
vice, as to respective documentation.
This manual also contains specific references to your personal safety as user, as well as that of your
customers, their passengers and other persons being close to the engine/boat.
Product specifications, illustrations and technical data
When reference is made in this manual to a brand name, product number, product or specific tool, an
equivalent product may be used in place of the product or tool referred to, unless stated otherwise. To exclude
possible danger, the operator has to provide for adequate safety precautions.
All information, illustrations and specifications in this manual are based on the latest product data available at
the time of printing. It cannot be guaranteed that this manual is constantly updated. Revised versions edited at
a later date will replace all preceding editions.
Illustrations in this manual may not always correspond to actual implements or components and are
mainly intended as reference.
STEYR MOTORS GmbH reserves the right to make changes at any time, without notice, on technical
data or models and/or to discontinue models. The right is also reserved to change technical data or
components at any time, without incurring any obligation to retrofit new parts on models produced
prior to date of such change.
To guarantee proper function of the engine and its attached parts after a repair, correct assembly is of
utmost importance. Such works are to be carried out with greatest care, in accordance with repair
instructions.
WARRANTY: Warranty claims will expire if repair, service and operation of the engine do not
correspond to the guidelines defined by STEYR MOTORS GmbH Please
address your warranty claims, in accordance with warranty regulations, directly to
the After Sales Service of STEYR MOTORS GmbH, Steyr.
Every STEYR dealer is obliged to fill out the warranty registration card enclosed to every sold
STEYR marine engine or every sold boat with a built-in STEYR marine engine.
Part 1 (Warranty Registration Card) is to be handed over to the customer, part 2 (Dealer Record
Card) remains with the dealer and part 3 is to be sent to the After Sales Service of STEYR
MOTORS GmbH.
This warranty registration card serves as a proof of ownership and is to be submitted in case
of warranty claims.
Every STEYR dealer is also obliged to carry out the Installation and pre-delivery inspection log.
One copy (completely filled out) of this Installation and pre-delivery inspection log is to be sent
to the After Sales Service of STEYR MOTORS GmbH.
Z001019/0_6_July 2008
TABLE OF CONTENTS
(MAIN ASSEMBLY GROUP ENGINE)
GENERAL
01 ENGINE
02 COUPLING
03 FUEL SYSTEM
04 EXHAUST SYSTEM
05 COOLING SYSTEM
06 ELECTRICAL EQUIPMENT
Z001019/0_6_July 2008
Components
01
Engine
01.00 01.01 01.02
Engine timing, Cylinder block Chrankshaft
engine mount bearing,
vibration damper
01.03 01.04 01.05

Flywheel, Piston, Chamshaft,
housing connection rod housing,
valve drive
01.06 01.08 01.09

Engine housing, Intake manifold, Auxiliary drive-PTO
oil pump, intercooler
oil suction pipe
01.13 01.14
Engine oil cooler, Exhaust manifold,
seals,
heat exchanger
02
Coupling
02.01 02.02 02.03
Torsion coupling Coupler Torsion coupling
Centa
03
Fuel system 03.02 03.04 03.05
Fuel pump, Air filter Turbo charger
unit injector,
pipes
03.08 03.09 03.11

Control solenoid Fuel filter Glow plugs
04
Exhaust system
04.01
Hi-riser
Z001019/0_6_July 2008
05
Cooling system
05.01 05.03 05.04
Cooler, Pipes, Coolant pump
heat exchanger, thermostat
expansions tank
05.10 05.11
Raw water pump, Raw water pump,
side mounted front mounted
06
Electrical
06.01 06.03 06.05
system Generator, Starter motor Engine harness
alternator
06.06 06.07 06.10

EMS, E-box, Instrument panel, Sender, sensor
diagnosis system, connecting cable
fuses
06.12
Battery,
charge equalization
Z001019/0_6_July 2008
VERSIONS OF MANUAL
Version Date Modification
1.0 01. 10. 2000 new edition

2.0 01. 06. 2002 release typ 164, 246
3.0 01. 07. 2005 release typ 256
4.0 01. 07. 2007 modification
Z001019/0_6_July 2008
ToC SERVICE MANUAL MARINE ENGINES GENERAL
GENERAL
Table of Contents
A General Remarks .................................................................................. 3

A1 Model and Serial Numbers ..................................................................... 3
A2 Documentation........................................................................................ 4
A3 Model summary ...................................................................................... 5
A 3.1 Model summary 4 cylinder engines ........................................................ 5
A 3.2 Model summary 6 cylinder engines ........................................................ 8
A4 Technical Data and Overview ................................................................. 12
A 4.1 Technical Data and Overview 4 cylinder engines.................................... 12
A 4.2 Technical Data and Overview 6 cylinder engines.................................... 16
B Specifications ....................................................................................... 20
B1 Fuel Requirements ................................................................................. 20
B2 Motor oil .................................................................................................. 21
C Maintenance and Service ..................................................................... 22

C1 Trouble Check Chart ............................................................................... 22
C2 Service- and Maintenance Schedule ...................................................... 24
D General Information .............................................................................. 26

D1 Electronic Engine Management System (ECU) ...................................... 26
D2 Diagnostic System .................................................................................. 27
D3 Extended Storage Preservation Procedure ............................................. 28
D4 Engine Break-in procedure ...................................................................... 32
D5 Operation after Break-in .......................................................................... 34
E Quality Gudelines for Repair ................................................................ 36

E1 Spare parts specification ......................................................................... 36
E2 Workshop profile ..................................................................................... 36
E3 Nomenclature .......................................................................................... 37
E4 SI - System .............................................................................................. 38
E5 Abbreviations .......................................................................................... 39
F Operating material and Information on Disposal ................................ 40

F1 List of operating material ......................................................................... 40
F2 Disposal of automotive waste products .................................................... 41
G Notes on Safety ..................................................................................... 42

G1 General notes on safety ........................................................................... 42
G2 Guidelines for damage prevention ........................................................... 42
G3 Legal rules ............................................................................................... 42
G4 Safety in the use of operating material ..................................................... 43
Z001019/0_8_Octobre 2011 Page GENERAL-1
ToC SERVICE MANUAL MARINE ENGINES
GENERAL
G5 Measures in case of accidents ................................................................ 43
H Thightening Torques ............................................................................ 44

H1 Listing of Thightening Torques .................................................................. 44
H2 General Tightening torques ...................................................................... 49
H3 Testing of torque wrench .......................................................................... 50
H4 Non-destructive material testing ............................................................... 50
H5 Use of adhesive and sealing materials ..................................................... 50
H6 Solvent-free sealing materials .................................................................. 50
J Wear Limits ............................................................................................ 52

J1 Adjustment information for service and maintenance ................................ 53
Page GENERAL-2 Z001019/0_8_Octobre 2011

A GENERAL REMARKS
A1 Model and Serial Numbers
The primary model and serial number (ill.1 or ill.2) is

located on the engine as illustrated.
These numbers are required for warranty
claims and ordering parts.
FOR ALL FOR ALL

4 CYL. MARINE ENGINES 6 CYL. MARINE ENGINES
08006 08007
01.01 ill.1 01.01 ill.2
The model and serial number of the marine gearbox

is located on the marine gearbox housing as illustrated.
To obtain instructions regarding marine gearbox

operation, refer to marine gearbox owners manual.
17
06014
01.01 ill.3

GENERAL
A2 Documentation 4 and 6 cylinder
The following documentation is available in English language on our website:
http://www.steyr-motors.com/technical
technical documentation on CD - ROM P/N Z 001009/0
operation-, maintenance & warranty manual

for all marine engines P/N Z 001022/0
tool catalogue for all marine engines P/N Z 001002/1
spare parts catalogue STEYR 94 td diesel marine P/N Z 001023/0
STEYR 144 vti/td diesel marine P/N Z 001005/0
STEYR 164 td diesel marine P/N Z 001015/0
STEYR 174 vti diesel marine P/N Z 001011/0
STEYR 236 FDE P/N Z 011796/0
STEYR 236 td diesel marine P/N Z 011796/1 - Z011769/2
installation manual for marine engines P/N Z 001007/0
service manual for all marine engines P/N Z 001019/0
operator's manual marine gear ZF P/N Z 001003/0
Diagrams marine engine functions on CD P/N Z 001021/0

A3 Modell summary
A 3.1 Modell summary 4 cylinder engines
Bobtail - Version
Equipment:
with side mounted raw water
pump or,
03.01 ill.1 pump, power steering pump
Inborder i.e. ZF 45 Marinegear
Down angle
03.01 ill.2
Innenborder i.e. ZF 63 Marinegear
03.01 ill.3

GENERAL
Lifeboat Engine
Equipment
Bobtail "B"
03.01 ill.4
Direkt gearbox
03.01 ill.5
A-down angle gear box
03.01 ill.6
Parallel offset gearbox
03.01 ill.7

Jet Drive
TYPE
Alamarin
Hamilton
Castoldi
03.01 ill.8
03.01 ill.9
03.01 ill.10
Stern Drive
TYPE
Mercury Alpha Bravo I, II & III
Volvo DP 290
Volvo DP 290 Hydraulic
03.01 ill.11 SX - Stern Drive

GENERAL
A 3.2 Modell summary 6 cylinder engines
Bobtail - Version

pump or,
pump, power steering pump
and front mounted auxiliary
drive-PTO
03.02 ill.1
Inborder i.e. ZF 63 Marine gear
Down angle
03.02 ill.2
03.02 ill.3

Transmission
i = 2.5V, shaft angle 12°
i = 2.0V, shaft angle 12°
03.02 ill.4
Lifeboat Engine
Equipment
Bobtail "B"
03.02 ill.5
Direkt gearbox
03.02 ill.6
A-down angle gear box
03.02 ill.7
Parallel offset gearbox
03.02 ill.8

GENERAL
Jet drive
03.02 ill.9
Jet Drive
TYPE
Alamarin
Hamilton
03.02 ill.10
Castoldi
03.02 ill.11
Stern drive
Type
Mercury Bravo II & III
Volvo DP 290
Stern Power Drive
03.02 ill.12 Volvo DP 290 ZF

Hydraulic Pump
Volvo SX - Drive
King Cobra Drive


GENERAL
A 4.1 Technical data and overview 4 cylinder engines
MAKE STEYR M 14 TCM, TCAM
type MO84K32 MO94K33 MO114K33 MO144V38
displacement 2133 cm³
piston displacement 85,0 x 94,0 mm

rated power acc. EN ISO 8665:2006
(impeller **) KW / HP
Jet - Drive / Inboard 53 / 71 64 / 86 78 / 105 103 / 138
Z - Drive 52 / 70 63 / 84 77 / 104 101 / 136
number of cylinders 4-cylinder in-line engine (position of cyl. 1 at vibration damper side)
ignition order 1-3-4-2
sense of rotation, seen from front right
compression ratio 17,5 : 1
full-load speed range (rpm) 3000 - 3200 3050 - 3800 3200 - 3800 3600 - 3800
idle speed 650 rpm. (adjustable)
injection pump - nozzle with modelling needle control

and electronic control
fuel acc. to CEC RF-03-A-84 (DIN EN 590) Cetan >49; diesel fuel
No. 2-D, temperature above -7°C; No.1-D, temperature below -7°C
fuel filter P/No. 2203710/0
fuel filter location intake-sided
air filter P/No. 2178992/0
oil pressure above 2000 rpm. 400 - 700 kPa (60 - 100 PSI) microprocessor controlled
filling capacity motor oil approx. 8,0 l engine housing (incl. approx. 1 l oil filter contents)
specification motor oil SAE 5W-50/ACEA B4-02/API CF or 10W-40/ACEA, E4, E5, E7,
API CF / P/N0. Z010058/0
oil and oil filter change intervals*) every 150 operating hours and/or once per season
oil filter P/No. 2178582/1
oil filter location pressure-sided
electric charging system 14 V / 90 A alternator with transistorized voltage regulator
cooling system dual cooling circuit; thermostat-controlled, pressurized cooling

circuit; circulating pump with heat exchanger on engine; governor
pump, external raw water circuit to heat exchanger
coolant capacity 11,5 liters
coolant STEYR MOTORS engine coolant - 36 C°

P/No. Z011785/0
*) extended periods to be evaluated upon application and type of usage

STEYR MOTORS GmbH. reserves the right to make changes without notice or obligations.
**) Efficiency of gearbox = 97,0%, efficiency of Z-drive = 95,5%
Overview for all STEYR 4 Cyl. Marine Engines

1 2 3 4 5 6
Item Designation 19
18
1 Zinc Anode (4 Units) 1
2 Model and Serial Number 17
3 Intercooler 16 7
4 Fuel/Oil Cooler with Raw Water Drain Plug 15
5 Fuel Pump 8
14
6 Oil Seperator
7 Raw Water Drain Plug 13
8 Valve Crankshaft Housing Ventilation 12
(only SOLAS) 11
9 Oil Drain Plug 10 9 06001
10 Fuel Filter
11 Oil Filter
12 Hydraulic Pump 20 21
13 Raw Water Inlet Fitting
31 22
14 Raw Water Pump
15 Coolant Drain Plug (2 Units) 23
30
16 Engine Oilcooler 24
17 Oil Suction Pipe 29
25
18 Oil Dipstick 28
19 Hydraulic Oil Tank 26
20 Cooler Cap 27
21 Potentiometer Accelerator
22 Motor Oil Filler Cap
23 Boost Pressure Sensor
06002
24 Rack Position Sensor *)
25 Drive Belt
26 Cover T-Belt, Lower 1 32 33 34 35 36 37 38 39
27 Engine Mount 1
28 Drive Belt Tensioner
29 Vibration Damper 15
30 Cover T-Belt, Upper 40
44
31 Engine Lifting Eye
32 Speed Sensor 43 41
33 Valve Cover 42
34 Heat Exchanger
35 Coolant Expansion Tank
36 Diagnostic Outlet
37 Inversion Switch (only for SOLAS)
38 Connector Instrument Panel 06003
39 Coolant Temperature Sensor

40 Thermostat Housing
41 Alternator 45 46
42 Circuit Breakers 47
43 Engine Management System/Fuses 52
44 Exhaust Temperature Sensor
45 Air Filter
46 Turbo Charger 51 48
47 Exhaust Elbow 50 49
48 Starter Relais (Backside E-Box Ground Plate)
49 Starter Motor
50 Flywheel
51 Flywheel Housing
52 Oil Pressure Sensor 06004
*) This sensor is magnetism sensitive. All external magnets must be kept away.
GENERAL
MAKE STEYR M 14 TCAM
type MO144M38 MO164M40

Jet - Drive / Inboard 103 / 138 116 / 156
Z - Drive 101 / 136 114 / 154
ignition order 1-3-4-2
full-load speed range (rpm) 3700 - 3900 3800 - 4000

fuel filter location intake-sided
air filter P/No. 2178992/0
API CF / P/N0. Z010058/0
oil filter location pressure-sided


P/No. Z011785/0

Overview for all STEYR 4 Cyl. Marine Engines

1 2 3 4 5 6
Item Designation 19
18
1 Zinc Anode (4 Units) 1
2 Model and Serial Number 17
3 Intercooler 16 7
4 Fuel/Oil Cooler with Raw Water Drain Plug 15
5 Fuel Pump 8
14
6 Oil Seperator
8 Valve Crankshaft Housing Ventilation 12
(only SOLAS) 11
9 Oil Drain Plug 10 9 06001
10 Fuel Filter
11 Oil Filter
12 Hydraulic Pump 20 21
31 22
14 Raw Water Pump
15 Coolant Drain Plug (2 Units) 23
30
16 Engine Oilcooler 24
25
18 Oil Dipstick 28
19 Hydraulic Oil Tank 26
20 Cooler Cap 27
06002
25 Drive Belt
26 Cover T-Belt, Lower 1 32 33 34 35 36 37 38 39
27 Engine Mount 1
29 Vibration Damper 15
44
32 Speed Sensor 43 41
33 Valve Cover 42
34 Heat Exchanger
35 Coolant Expansion Tank

41 Alternator 45 46
42 Circuit Breakers 47
45 Air Filter
46 Turbo Charger 51 48
47 Exhaust Elbow 50 49
49 Starter Motor
50 Flywheel
51 Flywheel Housing
GENERAL
A 4.2 Technical data and overview 6 cylinder engines
MAKE STEYR M 16 TCM, TCAM
type MO126M28 MO166K28 MO196K35 MO236K42

Jet - Drive / Inboard 87 / 117 116 / 156 136 / 182 165 / 221
Z - Drive 86 / 115 115 / 154 134 / 179 162 / 218
ignition order 1 - 5 - 3 - 6 -2 - 4
full-load speed range (rpm) 2600 - 2800 2600 - 2800 3300 - 3500 4000 - 4300

fuel filter location suction-sided
air filter MO126 - P/No. 2178992/0; all other 6 Cyl. - P/N 2178992/1
API CF / P/N0. Z010058/0
oil filter location suction-sided


P/No. Z011785/0

Overview STEYR MO126M28, MO166K28, MO196K35, MO236K42

1 2 3 4 56 7 2
Item Designation 18

2 Zinc Anode (5 Units) 17 8
3 Intercooler 16
9
4 Fuel- / Hydr. Oil Cooler 15
5 Engine Oilcooler
6 Model and Serial Number
7 Oil Seperator 10
9 Valve Crankshaft Housing Ventilation
14 13 12 06032
(only SOLAS)
10 Fuel Filter
11 Fuel Pump
19 20 21
12 Oil Filter
14 Raw Water Pump
15 Coolant Drain Plug (2 Units)
29
16 Oil Suction Pipe
17 Oil Dipstick
19 Engine Lifting Eye 28 22
20 Motor Oil Filler Cap 23
21 Potentiometer Accelerator 27 24
22 Drive Belt, Raw Water Pump
23 Engine Mount 26 25 06033

25 Cover T-Belt, Lower
26 Vibration Damper 2 30 31 32 33 34 35 36 37
27 Drive Belt, Alternator & Hydr: Pump
2
28 Speed Sensor
30 Valve Cover 38
31 Heat Exchanger 46
39
32 Coolant Expansion Tank 45 40
33 Cooler Cap 41
35 Inversion Switch (only for SOLAS) 44
42
36 Connector Instrument Panel
37 Coolant Temperature Sensor 43 06034
39 Hydraulic Oil Tank
40 Circuit Breakers 47 48 49
41 Alternator
42 Hydraulic Pump
43 Oil Drain Plug 2
44 Starter Motor 53
52
47 Air Filter
48 Turbo Charger 51
49 Exhaust Elbow
51 Flywheel
06035
52 Flywheel Housing
53 Oil Pressure Sensor
GENERAL
MAKE STEYR M 16 TCAM
type MO256K43 MO256H45

Jet - Drive / Inboard 178 / 239 178 / 239
Z - Drive 176 / 236 176 / 236
ignition order 1 - 5 - 3 - 6 -2 - 4
full-load speed range (rpm) 4000 - 4300 4000 - 4500

fuel filter location suction-sided
air filter P/No. 2178992/0 P/No.2178992/1
API CF / P/N0. Z010058/0
oil filter location suction-sided


P/No. Z011785/0

Overview STEYR MO256K43, MO256H45

1 2 3 4 5 6 2
Item Designation 17

2 Zinc Anode (5 Units) 16 7
3 Intercooler 15
8
4 Engine Oil / Fuel / Hydr. Oil Cooler 14
5 Model and Serial Number
6 Oil Seperator
8 Valve Crankshaft Housing Ventilation (only 10
SOLAS)
13 12 11 06028
9 Fuel Filter
10 Fuel Pump
11 Oil Filter 18 19 20
13 Raw Water Pump
14 Coolant Drain Plug (2 Units)
16 Oil Dipstick
27 21
22
21 Drive Belt, Raw Water Pump 26 23
22 Engine Mount
23 Drive Belt Tensioner 25 24 06029
24 Cover T-Belt, Lower

25 Vibration Damper
26 Drive Belt, Alternator & Hydr: Pump 2 29 30 31 32 33 34 35 36
27 Speed Sensor
2
28 Cover T-Belt, Upper
29 Valve Cover 14
30 Heat Exchanger 37
45
31 Coolant Expansion Tank 38
32 Cooler Cap 44 39
33 Diagnostic Outlet 40
41
37 Thermostat Housing 42 06030
38 Hydraulic Oil Tank
39 Circuit Breakers
40 Alternator
46 47 48
41 Hydraulic Pump
42 Oil Drain Plug
43 Starter Motor 2
45 Exhaust Temperature Sensor 49
46 Air Filter
47 Turbo Charger 51
50
48 Exhaust Elbow
50 Flywheel
51 Flywheel Housing
GENERAL
B Specifications
B1 Fuel Requirements
The STEYR Marine Engines are designed for maximum fuel economy. To maintain optimum performance use
diesel fuel according to CEC RF-03-A-84 or equivalent to meet this specification. When temperatures are below
-7° C (20° F), use diesel fuels with additives for low temperature operation.
How to Select Fuel Oil

Fuel quality is an important factor in obtaining satisfactory engine performance, long engine life, and acceptable
exhaust emission levels. Direct injected diesel engines are designed to operate on most diesel fuels marketed
today. In general, fuels meeting the properties of CEC RF-03-A-84 have provided satisfactory performance.
The ASTM D 975 specification, however, does not in itself adequately define the fuel characteristics needed for
assurance of fuel quality. The properties listed in the following fuel oil selection chart have provided optimum engine
performance.
Fuel Oil Selection Chart
CEC RF-03-A-84 CEC RF-03-A-80

General Limit value and Limit value and ASTM -
Fuel classification units units Test procedure
Cetane number min. 49 - max. 53 min. 51 - max. 57 D 613 (D 976)
Gravity at 15°C (kg/l) min. 0,835 min. 0,835 D 1298

max. 0845 max. 0845
Destillation
50% min. 245°C min. 245°C D86
90% min. 320°C min. 320°C
max. 340°C max. 340°C
End point max. 370°C max. 370°C
Flash point min. 55°C min. 55°C D 93
CFPP (Cloud point) min. -- / max. -5°c max. -5°c EN 116 (CEN)
Viscosity Kinematic 40°C min. 2,5 mm²/s min. 2,5 mm²/s D 445
max. 3,5 mm²/s max. 3,5 mm²/s
Sulfur content max. 0,3 mass-% max. 0,50 mass-% D 1266/D 2622
D 2785
Cupper corrosion max. 1 max. 1 D 130
Carbon residue max. 0,2 mass-% max. 0,2 mass-% D 189

Conradson number (10% residue)
Ash max. 0,01 mass-% max. 0,01 mass-% D 482
Water content max. 0,05 mass-% max. 0,05 mass-% D 95/D 1744
Acid content (strong acid) max. 0,20 mg KOH/g max. 0,20 mg KOH/g D 974
Oxidation stability max.2,5 mg/100ml max.2,5 mg/100ml D 2274

B 2 Motor oil
To obtain the best engine performance and engine life, only motor oils of know manufacturers are to be used,
with ACEA, API service code and specified SAE viscosity. Refer to oil identification symbol on the container.
Initial filling quantity: 4 Cyl. engines 8,4 Litre (Oil filling, incl. 1l oil filter)
6 Cyl engines 10,4 Litre (Oil filling, incl. 1l oil filter)
Oil quantity between MIN. and MAX.
on dipstick 2,0 Litre
Oil change quantity: 4 Cyl. engines 7,0 Liter (without oil filter)
6 Cyl. engines 9,0 Liter (without oil filter)
Öil filter: ca. 1 Litre
Oil - specification, Minimum: API: CF or higher
ACEA: B4 - 02 or higher
Viscosity class: SYNTHETIC OIL 5W-50

SYNTHETIC OIL 10W-40
Recommended
engine oil: STEYR TURBO DIESEL ENGINE OIL - SAE 10W-40
SMO No. Z010058/0
Initial factory fill is a high quality break-in oil specified ACEA B4 - 02, SAE 5W-50. During the break
in period (20 hours), frequently check the oil level. Somewhat higher oil consumption is normal until piston rings
are seated. The oil level should be maintained between the minimum and maximum marks on the dipstick. The
space between the marks represents approximately 2 quarts (2 litres). For oil dipstick location, refer to
section Technical Data and Overview (A 4)
Refer to Service and Maintenance Chart (C 2) for

recommended oil change intervals.
FOR HEAVY DUTY
DIESEL ENGINES
Oil Identification Symbol
Motor oils are specified by ACEA, API

service code and SAE viscosity numbers.
These may be found on the label, top of can, or oil
identification symbol.
ACEA E7 or B4-02
NOTE: Some motor oils have several ACEA / API quality API CF
ratings. 02.02 ill.1
The recommended ACEA /API service letter code
must be among these quality ratings. ACEA E7 or B4 - 02
ill.1 Top of Can

SAE
5 W-50
ill.2 Oil Identification Symbol 10 W-40
API
SERVICE CODE
CF
02.02 ill.2

GENERAL
C Maintenance and Service

C1 Trouble Check Chart
ATTENTION:
After following the “Action” described in chart, and before cranking the engine, make sure
there are no loose fuel connections. Make sure engine compartment is free of fuel vapours.
Failure to do so could result in fire.
SYMPTOM POSSIBLE CAUSE ACTION
Engine won’t start 1. No fuel in tank or shut-off valve Fill tank or open valve.
closed.
2. Air leak in suction lines. Bleed fuel system and check for leaks.
3. Fuel line plugged or pump Fuel pump may be defective.

defective.
4. Poor fuel quality. Replace fuel .
5. Water in fuel filter. Replace or drain water from fuel filter.

Check fuel supply for water contamination. If water
is present, drain fuel tank and flush with fresh fuel.
6. System error or failure. Check Engine Management System

display for service code.
7. Battery output insufficient Charge or replace battery.

Only for SOLAS ==> 8. Inversion switch actuated Cancelled by ignition "OFF - ON"
Starter won’t crank 1. Battery connections loose or Check for loose connections
engine corroded and corrosions. Clean connections and
thighten.
2. Battery is dead Check level of electrolyte and charge

battery.
3. Starter connections loose Check connections and tighten.

If solenoid clicks when attempting to
start engine, check starter.
4. Ignition switch If inoperative, replace.

5. Fuse blown on panel Check and replace if defect
6. Starter auxiliary relay Check terminal connection and function of relay.
Engine runs erratically 1. Water, air and/or dirt in fuel filter Replace filter. Inspect fuel supply line.
2. Anti-siphon valve stuck Clean and inspect or replace. (Tank)
3. Fuel pump Check operation of pump.

Replace fuel pump.

Trouble Check Chart - continued
SYMPTOM POSSIBLE CAUSE ACTION
Engine vibrates Propeller condition Check for bent, broken, or damaged propeller
Check for weeds on propeller or sterndrive
gearcase. Check for bent propeller shaft.
Unit injector Check.
Engine runs but boat Fouled propeller etc. Check:

makes little or no 1. Propeller for weeds, remove
progress as required.
2. Propeller for spun hub, repair

or replace.
3. Hull for excessive marine growth, clean

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

display for service code. Engine coolant
temperature; audible alarm.
2. Boat overloaded Reduce load.
3. Boat trim Distribute boat load evenly. Adjust trim.
4. Excessive water in bilge Drain bilge.
5. Boat hull condition Cleaning
6. Improper propeller selection Select proper propeller pitch and diameter.
7. Fuel incorrect Fill tank with correct fuel.

Check fuel filter and fuel flow condition.
8. Throttle not fully open Check throttle command lever for

full travel.
9. Overheating Check cooling system. Remove debris

from water intake. Check belt tension.
Check condition of impeller.
Check for clogged heat exchanger tubing
(in raw water circuit).
10. Air intake troubles Check intake air filter.

Check ventilation of engine compartment.
Excessive free play in Steering cable loose Adjust or replace.

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

bracket shift cable
2. Remote control binding Adjust.
3. Engine / drive mechanism sticks Center.

GENERAL
after first every every

C2 Service- and Maintenance Schedule 50 hours 150 h. 300 h.
daily *) notes
or 6 or 12 or 24
months months months
ENGINE check - for leakage

LUBRICATION - oil level
change - oil filter
- motor oil
ENGINE check - for leakage

COOLING - fluid level
SYSTEM - hoses, hose clamps
- antifreeze temperature condition
change - antifreeze*) every 24 month
RAW WATER check - hoses, hose clamps

SYSTEM - zinc anodes
- raw water pump V-belt
- impeller
change - raw water pump V-belt*) if required
- impeller*) if required
- zinc anodes*) if corroded > 50%
preserve - raw water circuit*) after season
RAW WATER check - raw water passages*) clean out desposits

COOLER
(OIL-FUEL- in pipelines
AUX.LUBRICANT)
for 246 / 256 change - zinc anodes*) required if more
and 266 only than 50% material
corroded
AIR check - contamination

FILTER change - air filter element
preserve after season
FUEL check - for leakage

SYSTEM - hoses
drain - addtiional fuel filter
change - fuel filter
check - additional fuel filter
preserve - fuel system*) after season
BATTERY check - acid level

- densitiy
ELECTRONICS check - connections*) after season
ELECTRICAL check - connections tighten loose con-

EQUIPMENT - insulation nections. Renew
cables, if required.
INVERSION check - switch*) every 50 hours

SWITCH (Solas only) or every 6 months
DRIVING re-center - driving unit*) see manufacturer's

SYSTEM specifications
V-BELT check - generator & impeller pump adjust tension

- power-steering adjust tension
for all 6 cyl. change - generator*) if required

models - power-steering*) if required
POLY - V - check - belt, pulleys and tighteners

BELT for wear
change - Poly -V-belt every 1050 hours or
for all 4 cyl. every 48 months
models

after first every every

Service- and Maintenance Schedule 50 hours 150 h. 300 h.
daily *) notes
or 6 or 12 or 24
months months months
POLY - V - BELT check

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

every 48 months
TIMING check - belt tension
BELT change - timing belt*) every 1500 h. or
every 48 months
- water pump, tensioner every 3000 h. or
every 48 months
VALVES check - valve clearance*) every 750 hours
ENGINE TIMING check - set timing every 750 hours
UNIT INJECTOR - set levers*) every 750 hours

check - set point every 750 hours
- tighten torque every 750 hours
SERVO check - oil level

PUMP - for leakage
change - hydraulic oil (ATF) *) every 750 h. or
every 24 months
GEARBOX- check - oil level

STERNDRIVE - for leakage
change - gear oil (ATF) *) see manufacturer's
- oil filter specifications
FRONT VIBRA- check - torque

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

PARTMENT AND -fuel your STEYR
BILGE -exhaust gas Marine dealer
SHIFTING check - smooth action If required, to be

- adjustment replaced by your
STEYR Marine
Dealer.
STEERING check - lubrication see manufacturer´s

- oil level specification
SAFETY check - remote control local rules

EQUIPMENT - emergency cutout and consultation
- completeness of your STEYR
- condition Marine Dealer
SHAFT BEARING check - lubrication consult STEYR

GLAND - sealing Marine Dealer
ENGINE MOUNT check - torque*) every 750 hours

SCREWS
WARNING check - function

DEVICE

GENERAL
D General Information
D1 Electronic Engine Management System
The STEYR Marine engine is equipped with an Electronic Management System (EMS) that
performs the following:
* controls engine functions to ensure maximum efficiency.
* self-diagnostic to protect the engine from damage if operating parameter are exceeded.
* stores diagnostic data of EMS server circuits for maintenance and service.
* stores abuse data
Engine power is reduced if:
Operating Parameter Effect Panel Additional Action or

noticed Indication Tool-Readings possible reason
High engine coolant Reduction of Horn ON 2x p. sec. Steyr Diag See table trouble
temperature engine speed Gauge reading > Power limitation shooting:
limit exceeded 107 °C Cooling system
Defect - engine coolant Reduction of Horn ON 2x p. sec. Steyr Diag Sensor or connector
sensor or engine speed Gauge reading > Service code failure; see service
sensor connection 120 °C code table
Exhaust temperature Reduction of Horn and indication Steyr Diag See table trouble
limit exceeded engine speed light "CEL" ON 2x Power limitation shooting: Raw water
p. sec. cooling system
Defect - Exhaust Reduction of Horn and indication Steyr Diag Sensor or connector
temperature sensor or engine speed light "CEL" ON 2x Service code failure; see service
sensor connection p. sec. code table
Oil pressure below limit Reduction of Horn continuous and Steyr Diag See table trouble
engine speed Oil indication light Power limitation shooting:
continous switched Engine oil system
ON
Defect - Oil pressure Reduction of Oil pressure indication Steyr Diag Sensor or connector
sensor or sensor engine speed light switched ON 1x Service code failure; see service
connection p. sec. code table
Insufficient boost Reduction of Steyr Diag See table trouble

pressure or defective engine speed Power limitation shooting:
sensor Air charge system
Engine speed sensor Higher or No RPM indication Steyr Diag See table trouble
fault unstable idle on tachometer Service code shooting:
speed, limited Speed sensor
performance
Engine speed remains No increase of Steyr Diag See table trouble

at idle engine speed if Service code shooting:
throttle is moved Accelerator
to max. potentiometer failure
Governor position Irregular engine Steyr Diag See table trouble

system speed or stalled Service code shooting:
engine Governing system


Inverse position shut Engine shut After engine stop Reset through ignition
down (SOLAS) down beyond horn remains OFF and then ON
70° deg. angle switched ON until
ignition reset
During break in phase Cel-ON at high Indication light Steyr Diag See information break
accelerator "CEL" is switched Break-in in procedure
position (more ON phase
than 75%)
Optical and accustical warning signals are explained on the following tables.
"Operating Status and Error Report"
D2 Diagnostic system
The electronic management system monitors the following engine parameters:
oil pressure, boost pressure, coolant temperature, exhaust pipe temperature (Hi-riser), sensor control rack,
potentiometer accelerator, speed signal
The electronic management system carries out self-diagnostic and/or plausibility checks for all input values and
sensor connections. In case of irregularities, there is an optical or audible warning signal. (see page 71)
Existing active failures remain stored until the problem has been solved and the code has been cleared from the
memory.
To select stored error codes, a PC with diagnostic program (VR00134/0) or diagnostic tool (VR00135/1) is
necessary.
Malfunction during operation is ranked in three different categories intermittent failure, non essential failure and
essential failure.

GENERAL
D3 Extended Storage Preservation Procedure:
Use following kit-numbers to have the necessary equipment

for an appropriate preservation:
1st Preservation- Service Kit art.nr.Z021003-0
(valid for all 4 and 6 cylinder Marine engine models)
2nd Preservation- Service Kit art.nr. Z021004-0
(valid for all 4 and 6 cylinder Marine engine models)
1. Remove the engine from storage and place on a

suitable work shop area with access to all sides of the
engine. Engine must not be removed from pallet.
2. check fluid levels:

engine oil (min/max on oil dipstick)
engine coolant water level (min/max) ill.1
gear oil- level
hydraulic oil- level
or existing fluid levels of other system
3. Control valve clearance according SERVICE MANU-

AL MARINE ENGINES Z001019-0 (chapter 03 FUEL
SYSTEM) and investigate free movement of all valves.
4. Crank engine till oil pressure is inidicated/visible.

Do not start engine before oil pressure is approved.
NOTE: Do not crank engine over max. 30 - 40 sec.!
5. Start the engine and let it run up to temperature.

ill.2
6. Stop the engine and drain the old engine oil and store
for future refill and usage.
7. Fill in preservation oil (art.nr. Z050323-0, 5liter canister,

adequate quantity incl. in all Preservation Service
Kits) up to the minimum mark on the dip stick.
8. Connect the fuel system to a canister Z010014-0 filled

with preservation fuel (art.nr.Z010014-0, 5liter canister,
incl. in all Preservation Service Kits). See ill.1
9. Restart the engine and allow to run in idle for 5

minutes.
10. Either drain the preservation oil from the engine and ill.3
replace with normal oil (as per Service Bulletin
AS_7004) and store for future use. Alternatively leave
it in the engine for future preservation work. The
preservation oil has a shelf life of also 3 years and may
be used any number of times within this period.
NOTE: It is important to note that an engine may never
be sold on or installed with this oil in as this will
lead to severe engine damage if run for extended
periods.
11. Remove the main relay K27; this will stop fuel being
injected and therefore the engine from starting.
See ill.2
ill.4
12. Remove the air filter, plug the exhaust elbow and
remove the inlet pipe to the tandem/triple cooler,
see photo. See ill.3 and ill.4
13. Fill a spray bottle with the preservation oil

(art.nr. Z050323-0, 5 liter canister, adequate quantity
incl. in all Preservation Service Kits).
14. Whilst cranking the engine over, by turning the start

key, spray the preservation oil into the turbo inlet.
See ill.5
15. Continue this process for 20 to 30 seconds.
16. Refit the fuel feed line to the engine, ensure fuel supply ill. 5
and turn the ignition on, the fuel pump runs for 10 sec
automatically refilling the fuel system. Repeat until
fuel comes from the return line.
NOTE: For corrosion protection of fuel system leave
system filled with preservation fuel Z010014-0 till
next preservation or engine is put into operation.
17. *Only by 2nd Preservation:

After two years engine storage replace engine coolant
water (art. nr. Z011785-0, 5 liter canister, adequate
quantity incl. in 2nd Preservation Service Kit) and fill
between min/max-level in coolant expansion tank.
18. Replace all pipes and connections to original condition

and restore engine.
19. Record carried out Storage Preservation Procedure

in following documents:
1) STEYR MOTORS WARRANTY REGISTRATION
CARD
(to find under: Operation, Maintenance and Warranty
Manual Z001022/ chapter WARRANTY)
2) COMMISSIONING REPORT
(to find under: Installation Manual Z001007/0 /
chapter 19. APPENDIX)
Ensure notification in above documents for approval
of extended STEYR MOTORS BASE ENGINE
WARRANTY.
Otherwise BASE ENGINE WARRANTY will end for
PLEASURE /COMMERCIAL duty after 1 year
starting from STEYR MOTORS manufacturing date.
NOTE: For manufacturing date, see on engine carton!

See ill.6
20. Note the date of preservation on:

1) sticker for engine-carton (sticker incl. in corres-
ill. 6
ponding Preservation Service Kit) - see ill.6

GENERAL
2) sticker for Maintenance Log of Operation, MAINTENANCE LOG
Maintenance and Warranty Manual Z001022-0 (sticker Sticker of 1st preservation Sticker of 2nd preservation
(refer to Installation Manual P/N Z001007-0/
incl. in corresponding Preservation Service Kit) Chapter 18/Installation and pre-delivery
inspection report)
SERVICE MANUAL
- see ill.7 Date: Date:
STEYR MARINE ENGINES

Sticker of 3rd preservation
reser
NOTE: This preservation procedure must be done every year

and ensures that all of the air ways systems, rawwater Date: Date:
systems, oil system and the cylinders are protected Made by:
50 h Service
Made by:
150 h Service
ervice
against corrosion.
This procedure is repeatable up to a maximum of Date: Date:
300 h Service 450 h Service

two times, giving a shelf life of up to three years Made by: Ma
Made by:
(36 months).
Date: Date:
600 h Service
rvice 750 h Service
After 3 years stocking, starting from STEYR Made by: Made by:
MOTORS manufacturing date (see ill. 6), engine

Date: Date:
must be put into operation for BASE ENGINE 900 h Service 1,050 h Service
1,05
Made by: Made by:
WARRANTY approval. However preservation

procedure can be continued every year after 3 Date: Date:
years stocking without BASE ENGINE WARRANTY 68
approval from STEYR MOTORS.

ill. 7
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.


GENERAL
D4 Engine Break-In procedure
The following procedure must be used on new and rebuilt STEYR Diesel Engines. You must follow the Engine
Break-In instructions during the first 20 running hours to ensure maximum performance and longest engine life.
NOTE: NONOBSERVANCE OF BREAK-IN INSTRUCTIONS MAY CAUSE SEVERE ENGINE

FAILURE.
First Two Hours
For the first five to ten minutes of operation, run engine at a fast idle (below 1500 RPM). For the remaining first
two hours of operation, accelerate to bring boat onto plane quickly and bring throttle back to maintain a planing
attitude.
During this period, vary the engine speed frequently by accelerating to approximately three-fourth throttle for two
to three minutes, then back to minimum planing speed.
When the engine has reached operating temperature, reduce engine speed, then increase engine speed again,
to assist the break-in of rings and bearings. Maintain planing attitude to avoid excessive engine load.
NOTE: DO NOT RUN ENGINE AT A CONSTANT RPM FOR LONGER PERIODS

DURING THIS INITIAL TWO HOURS OF BREAK-IN.
ATTENTION: Warning indication engine over load during break - in via ECU
The ECU controls during the first two hours of engine operation the load on the engine and
alarms the drive by the "Check Engine Light", if much power is demanded from the new
engine.
ON
In case the operator get alert, when running the engine during break in phase, by this
"Break - In" warning indication (CEL light - ON), the throttle position must be reduced
until this signals are extinguish.
Next Eight Hours
For the next eight hours, continue to run engine at approximately three-fourth throttle or less (minimum planing
speed).
Occasionally reduce throttle to idle speed for cooling down. During this eight hours of running it is permissible to
run at full throttle for periods of less than two minutes.
NOTE: DURING BREAK-IN, DO NOT RUN ENGINE AT A CONSTANT RPM

FOR LONGER PERIODS.

Final Ten Hours of Break-in
During the final ten hours of break-in, the engine may run at full speed for five to ten minutes. After warming up
the engine to operating temperature, momentarily reduce the engine speed and then increase it again. For cooling
down the engine, occasionally reduce the engine speed.
NOTE: DURING THE BREAK-IN PERIOD, THE ENGINE MUST NOT BE OPERATED AT
CONSTANT RPM FOR LONGER PERIODS.
During break-in period, be particularly observant of the following:
A. Check motor oil level daily. Always maintain oil level in the desired range between the "MIN" and "MAX" marks
on dipstick.
When refilling motor oil, refer to information "Motor Oil" (B 2).
B. Check oil pressure control lamp. If the lamp lights up as soon as the boat changes its position (while turning,
raising the boat or planing), check the oil level in the engine housing by means of dipstick. If necessary, add
oil (DO NOT OVERFILL). In case that the oil pressure control lamp still illuminated with correct oil level, have
the engine checked by your STEYR Marine dealer as to malfunction of signal or oil pump.
NOTE: During normal operation of engine, oil pressure will rise as RPM increases and
fall as RPM decreases. In general, oil pressure will be higher with cold motor
oil and specific RPM than with hot motor oil.
C. Check engine temperature indication. Normal operation between 80° - 95°. In case of audible alarm, check
coolant level in expansion tank (only at cold engine).
D. Deviations from normal operating conditions will be indicated by warning lights and audible alarm. As to exact
meanings see 06.07.02 & 06.07.05.
ATTENTION: In case of nonobservance of break-in instructions, warranty will expire.
Engine to be filled with recommended oil quality only. See chapter "Engine Lubrication"

GENERAL
D5 Operation after Break - In
The engines specified in this manual are intended to be operated at different speeds and loads, but not allowing
full-load of the engine for more than one hour per 12 running hours. Economic driving may be achieved at the
following speeds:
M084K32 3000 rpm.
M094K33 3000 rpm.
M0114K33 3000 rpm.
M0144M38 + BUKH STEYR SOLAS 3200 rpm.
M0144V38 + BUKH STEYR SOLAS 3200 rpm
M0164M40 + BUKH STEYR SOLAS 3400 rmp
M0126M28 2200 rpm
M0166K28 2200 rpm
M0236K42 + BUKH STEYR SOLAS 3300 rpm
MO256K43 3600 rpm
MO256H45 3600 rpm
which will prolong engine life and reduce sound emissions.

When starting a cold engine, always allow the engine to warm up slowly. Never run the engine at full speed until
operating temperature is reached. During the first 50 running hours, check the oil level frequently.


GENERAL
E QUALITY GUIDELINES FOR REPAIR
E1 Spart part specification
Your STEYR marine engine was designed for marine operation which means operating
conditions such as:
* Long-time operation at high speed
* Operation in salt or brackish water
* Operation in very muddy water
Only use genuine STEYR MARINE spare parts in order to avoid possible loss of performance. For this
reason you should insist on the famous quality of genuine STEYR MARINE spare parts and under no
circumstances use spare parts of unknown quality.
E2 Workshop profile
Independently of the respective repair steps and the legal regulations the workshops have to meet the
following requirements:
- Clean, dry, and dustfree environment

- Lifting gear (crane) with a lifting capacity of 5 000 N (500 kg) minimum
- Cleaning device (wash basin) for soiled components
- Commercial tools
- Appropriate test and measuring equipment
- Receptacles for operating agents.
Depending on the repair step to be carried out, the tools indicated in the catalog TOOL KIT are to be
provided.
Furthermore special care is to be taken in case of purchasing and stock of required operating material,
spare parts and wear parts (e.g. seals, filters, anodes,...).
For appointed retailers and authorized workshops of STEYR MOTORS GmbH, the following
minimum standard is to be met:
- basic training (as soon as possible, after conclusion of contract, for trade and workshop)
- biannual training (reacurring)
- tool kit I (service and maintenance tools)
- tool kit II - III (depending on repair to be carried out)
- procurement and stock of required genuine spare parts (as per proposed spare parts)
- spare part catalogue for all STEYR MARINE ENGINES models
- technical literature
- PC diagnostics

E3 Nomenclature
Term Description Example
disassemble Removal of an assembly of a main assembly or of a component

remove of an assembly without other assemblies having been removed
unscrew before
deflange
dismantle
assemble
put on, place Putting on of an assembly on a main assembly or a component
screw on of an assembly without further assemblies being put on
flange for functional performance
mount
disconnect Separating of connections of lines, pipes and hoses, which are
separable
connect Putting together separable connections of lines, pipes and
hoses
pull off Removal of a component with press fit from another
press on Placement of a component with press fit to another
unscrew Opening of turnable locks
tighten Closing of turnable locks
disassemble Removal of an assembly from a main assembly or a component
from an assembly, if other assemblies have been removed
before
assemble Putting on an assembly to a main assembly or a component of
an assembly, if further assemblies are put on for functional
achievement
loosen Partial unlocking of fixing elements of a component or of an
assembly
remove Taking off a fixing element of a component or an assembly
secure Putting on a fixing element of a component or an assembly

and tightening
disassemble Taking apart assemblies into individual components
assemble Putting together components to an assembly
adjust Elimination of a deviation by means of provided equipment or Valve clearance,
start of feeding
readjust Devices or tools operation
refill Adding and replenishing of operating agents
renew Replacing an auxiliary material by a new one Corrosion protection
agent, sealing
material, paint
gauge Reading in actual positions in programming memory
replace Exchanging of a device, a main assembly, an assembly or a
component by the same, new or repaired ones
measure Steps taken to determine the actual status by evaluating of

physical entities
check Steps taken to compare the actual status with a determined Valve lift, piston
diameter, valve
clearance, close
fit, V-belt tension
clean Removal of foreign and auxiliary material
maintain Steps taken to keep the respective determined planned status

GENERAL
E4 SI- System
The following measuring units are used.
Linear Pressure and Stress

km = kilometer bar = bar
m = meter Pa = pascal
mm = millimeter KPa = Kilopascal
" = inch N/mm2 = newton per square millimeter
Area Energy
2
m = square meter J = Joule
cm2 = square centimeter kW/h = kilowatt hour
Volume Power
3
m = cubic meter kW = kilowatt
cm3 = cubic centimeter
dm3 = cubic decimeter
mm3 = cubic millimeter
l = litre
Mass Temperature
t = metric ton K = degrees Kelvin
kg = kilogram °C = degrees Celsius
g = gram
Energy Time
N = newton h = hour
kN = kilonewton min = minute
daN = dekanewton s = second
Electricity Velocity
A = ampere km/h = kilometer per hour
V = volt m/s = meter per second
W = ohm
µF = microfarad
Fuel consumption Speed

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

E5 Abbreviations
ill. illustration
Cu copper
MAssy main assembly
max. maximum
TDC top dead center
PTO (POWER TAKE OFF) power transmission at front crankshaft end
WS wrench size
EMS Electronic Management System
ECU Electronic Control Unit

GENERAL
F OPERATING MATERIAL AND INFORMATION ON

DISPOSAL
F1 List of operating material
Order No. Qty. Designation

VR00207/0 1 set of fuel and oil for engine service, consisting of:
Z010058/0 3 - STEYR Turbo Diesel motor oil SAE 5W-50 (4l. can.)
Z011785/0 3 - STEYR MOTORS engine coolant (5l. can.)

9000190/0 2 - hydraulic oil ATF (1l. bottle)
Z012222/0 1 - grease, Never - Seez; NS-160 B (1 kg can.)
Z909570/0 1 - caoutchouc sealing / electric contacts (148 ml can.)

9000059/1 1 - thread protection 243 (10 ml flask)
9000297/1 1 - surface sealing 509 (315 ml cartridge)
9000510/5 1 - surface sealing 5910 (50 ml cartridge)

9000019/1 1 - construction adhesive 620 (50 ml flask)
9000017/1 1 - construction adhesive 262 (50 ml flask)
Z010207/0 1 - contact grease (100 ml tube)

Z010226/0 1 - corrosion protection spray (400 ml can.)
Z010227/0 1 - corrosion protection wax (120 ml can.)
Z010084/0 1 - grease STABURAX NBU4 (1 kg can.)

Z010205/0 1 - fuel rust protection additive (5 lt can.)
9000197/0 1 - electric contact spray
Z011627/0 1 - silver varnish, RAL 9006 (1 lt can)

Z010074/0 1 - hardener varnish (0,5 lt can)
Z010075/0 1 - dilution for varnish (5 lt can)

F2 Disposal of automotive waste products
Used operating material is to be collected in special containers to enable possible subsequent treatment.
ATTENTION: All operating materials for the engine are subject to the Special Waste Act for disposal.
The "Special Waste Catalog" ÖNORM S 2100 refers to the required disposal in Austria.
Respective legal local regulations are to be followed.
The maintenance and repair personnel has to take care that operating material and other material to be
regarded as special waste product, is always deposited at collection site.
Key-No.: Description
31 423 Oil contaminated soil or oil bonding agent
54 102 Waste oil
54 104 Fuels
54 202 Lubricants
54 207 Vaseline
54 917 Solid sealing material
54 927 Oil soiled cleaning rags
54 928 Used oil and air filters
55 510 Paint and varnish containing waste material

GENERAL
G NOTES ON SAFETY
G1 General notes on safety
The general knowledge and training of the personnel and the contents of the "general regulations of safety
technology" and machine safety regulations (Maschinen-Sicherheitsverordnung - MSV) are not subject
of this chapter.
Inappropriate behaviour and insufficient knowledge of hazard during repair works may cause injury to
persons.
In the description of repair works, such sources of danger are marked with
ATTENTION
The personnel is to be trained accordingly and requested to follow the saftey rules.
G2 Guidelines for damage prevention
The general knowledge and training of the workshop personnel and the contents of the "general
regulations of safety technology" and machine safety regulations (Maschinen-Sicherheitsverordnung -
MSV) are not subject of this chapter.
Inappropriate behaviour and insufficient knowledge of hazard during repair works may cause injury to
persons.
In the description of repair works, such sources of danger are marked with
ATTENTION
While handling with operating materials, take care that these are not applied to visible surfaces.
Lubricants should form a thin film on the surface, surplus lubricants are to be wiped off.
G3 Legal rules
The following rules and guidelines are valid in Austria. For other countries, follow the local regulations.
Maschinen - Sicherheitsverordnung - MSV (machine safety regulations)

G4 Safety in the use of operating material
Dangerous operating material, in the sense of accident prevention, are all operating materials potentially
explosive, fire-provoking, easily flammable, poisonous, injurious to health and corrosive.
Especially the following material belong to this group:

- Spirit
- Mineral oils
- Battery acid
- Anti-freeze agent
- Varnishes and diluents
- Solvents
- Fluid seals and nut locks
In case of fire of operating material do not try to extinguish the fire with water. Use carbon dioxide
extinguisher or powder extinguisher. Contact fire brigade.
When operating material is spilled, e.g. in case of refueling, it is to be absorbed by sand, soil or an
appropriate bonding agent and to be disposed.
ATTENTION: In order to prevent health hazards, take care of the following:
- Avoid direct contact with dangerous operating material, as far as possible.
- Change clothes as quickly as possible, if they are soiled with dangerous operating material.
- Do not keep oily rags in work clothes.
- Clean oil soiled body parts only with products friendly to skin (never use rubbing sand or solvents).
- Never fill operating agents in beverage bottles.
G5 Measures in case of accidents
Products First Aid
Skin Eyes Swallowing
Diesel fuel DO NOT VOMIT

and mineral oils Remove clothes and Rinse thoroughly with The biggest danger after an
accidental intake is the fact that
Lubricants clean skin thoroughly water for at least liquid could get into lungs by
aspiration.
Anti-freeze agents with water and soap 10 minutes.
DO NOT PROVOKE VOMITING
Brake fluid SEE A AND IIMMEDIATELY SEE A
DOCTOR
Battery acid DOCTOR!

GENERAL
H Tightening Torques
H1 Listing of Tightening Torques
Camshaft Housing
Screw joint to cylinder block
1. step: 15 Nm +/- 2
2. step: 25 Nm +/- 1
Tighten screws of camshaft housing in two

steps in precedence of numbering on bearings
(from the inside outwards).
08.01 ill.1
Plug screw for locking pin

in engine housing
50 Nm +/- 5
08.01 ill.2
Connecting rod screws

(apply oil to thread and screwhead support)
1. step: 10 Nm +/- 1
2. step: 30 Nm +/- 3
3. step: 75° +/- 4°
08.01 ill. 3
Main bearing screws

1. step: 35 Nm +/- 3
2. step: 45° +/- 4°
3. step: 45° +/- 4°
08.01 ill.4

Flywheel screws
(use LOCTITE 243 on thread)
75 Nm +/- 4
08.01 ill.5
Vibration damper screws
135 Nm (2x) +/- 7
08.01 ill.6
Screw, rear ring carrier
1. step: 8 Nm +/- 1
2. step: 30 Nm +/- 3
08.01 ill.7
Nut, camshaft sprocket
(taper degreased on camshaft, thread
lubricated)
1. step: 80 Nm +/- 4
2. step: 240 Nm +/-12
08.01 ill.8

GENERAL
Screw tooth, belt tensioner
45 Nm +/- 4
08.01 ill.9
Valve adjustment element
55 Nm +/- 3
08.01 ill.10
Screw, linkage lever
CAUTION: left-hand thread
7 Nm +/- 0,5
08.01 ill.11
Stud, unit injector
21 Nm +/- 2
08.01 ill.12

Collar nut for unit injector
18 Nm - 2
08.01 ill.13
Nut, adjustment screw of unit injector
30 Nm +/- 3
08.01 ill.14
Plug screw for control rack
in camshaft housing
50 Nm +/- 5
08.01 ill.15
Screw, exhaust manifold
23 Nm +/- 2
08.01 ill.16

GENERAL
Studs, turbocharger
M8 - 23 Nm +/- 2
M10 - 35 Nm +/-2
Nut, turbocharger
(greased with NEVER SEEZ )
M8 - 25 Nm +/-2
M10 - 45 Nm +/-2
08.01 ill.17
Screws, intercooler
28 Nm +/- 2
08.01 ill.18
Plug screws, zinc anode
50 Nm +/- 5
08.01 ill.19
Crown nut, oil cooler
55 Nm +/- 5
NOTE:
for all clamps
3,5 Nm
08.01 ill.20

H2 General Tightening torques
Values in this table refer to industrial standard and are applicable, if no specific torques are are indicated.
For studs, tightening torques are to be reduced by 50%.
µ tot. *) 0.100 µ tot. 0.125

MA in Nm MA in NM
Property
8.8 10.9 12.9 class 8.8 10.9 12.9

Metric
Nominal Ø Nominal Ø standard thread
M4 2.4 3.3 4 M4 2.7 3.88 4.6

M5 4.9 7 8 M5 5.5 8 9.5
M6 8 12 14 M6 9.5 13 16
(M 7) 13 19 23 (M 7) 15 22 26
M8 20 28 34 M8 23 32 39
M 10 40 56 67 M 10 46 64 77
M 12 69 98 115 M 12 80 110 135

M 14 110 155 185 M 14 125 180 215
M 16 170 240 285 M 16 195 275 330
M 18 235 330 395 M 18 270 390 455

M 20 330 465 560 M 20 385 540 650
M 22 445 620 750 M 22 510 720 870
M 24 570 800 960 M 24 660 930 1100

M 27 840 1200 1400 M 27 980 1400 1650
M 30 1150 1600 1950 M 30 1350 1850 2250
Metric
Nominal Ø Nominal Ø standard thread
M 8x1 22 30 36 M 8x1 25 35 42
M 10x1.25 42 59 71 M 10x1.25 49 68 82
M 12x1.25 76 105 130 M 12x1.25 88 125 150

M 12x1.5 72 100 120 M 12x1.5 83 115 140
M 14x1.5 120 165 200 M 14x1.5 140 195 235
M 16x1.5 180 250 300 M 16x1.5 210 295 350

M 18x1.5 260 365 435 M 18x1.5 305 425 510
M 20x1.5 360 510 610 M 20x1.5 425 600 720
M 22x1.5 480 680 810 M 22x1.5 570 800 960

M 24x2 610 860 1050 M 24x2 720 1000 1200
M 27x2 900 1250 1500 M 27x2 1050 1500 1800
M 30x2 1250 1750 2100 M 30x2 1450 2050 2500
If the tightening torque of a screw connection is not reached, the tightness of the screw/nut
is too low or the ratio of friction do not correspond. In any case, the screw/nut is to be replaced.
*) µ tot. = total frictional value

GENERAL
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.
H4 Non-destructive material testing
For the detection of surface cracks, the non-destructive test according to colour penetration test
procedure is recommended.
The workpiece is sprayed or coated with a penetration agent, and after drying a developer is applied. After
a development time of appr. 10 minutes, defects on the workpiece appear as dots or lines.
H5 Use of adhesive and sealing materials
In the workshop manual adhesive and sealing materials are specified for the repair of engines and
aggregates, which are used at operating temperatures of up to 150° C and agents such as water, coolants
and hydraulic fluids, engine and gear oils as well as fuels.
Solvent-free sealing materials

The hardening takes places without loss of volume, so that a retightening of screw connections is not
necessary.
Anaerobic sealing materials

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

Due to their contents of volatile parts a loss of volume occurs during hardening. During repair, the
hardening time is taken into consideration. If such sealing materials are used, special reference is made
in the description of the workshop manual.
H6 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.

General guidelines of application for the of use of anaerobic sealing materials

Cleanliness of components
Non-metallic surface protection must be removed. In case of repair, soiled and oily components are to
be cleaned and residues of adhesive plastic material are to be removed. Thread bores are recut with the
appropriate thread bore and blown out with compressed air.
If solvents or degreasing agents are used for cleaning, take care that they are completely volatilized
before application of the epoxyl.
Storage
At temperatures below 28° C, 1 year minimum.
Guidelines of application for securing (S)
Designation: SM ....... Securing medium tight (the connection is to be loosened without problems)
Designation: SF ........Securing tight (the connection is difficult to loosen)
Application: Screw connections
Fixing procedure
In general, the application of the epoxy to the screw thread is sufficient.
If screws are screwed into socket threads, only the thread bore is wet in order to let the air escape during
screwing in.
Screws or nuts which are tightened with a specified torque, are slightly oiled on their support surface or
housing part.
Guidelines for fixing (B)
Designation: BM ....... Fixing medium tight
Designation: BF ........ Fixing tight
Application: Jointing connections, bushings, sprockets, belt pulleys, bearings etc.

Jointing procedure
In case of jointing connections both jointing parts are to be wetted. The wetting has to completely cover
the jointing surfaces. The parts are shifted into each other by turning, in case of slide fits.
No strength may be exerted to the connection until sturdiness is reached (for time, refer to Table 1).
Guidelines of application for sealing (D)

Designation: DR ....... Sealing of pipe connections
Designation: DF ........Sealing of plane surfaces
Application: Sealing of threads , screw connections, jointing connections and plane surfaces.
Hardening time
F ixing
Use S ecuring S ealing
(B )
C lass SM SF BF DR DF DF
P roduct Loctite 243 Loctite 262 Loctite 620 Loctite 509 Loctite 510 Loctite 5900
Handtightness
15 - 30 min 15 - 30 min 5 - 10 min 15 - 30 min immediately immediately
reached after
F unctional tightness
1h 1h 1h 0.5 h immediately immediately
reached after
F inal tightness
3h 3h 4h 12 - 24 h 24 h 12 - 24 h
reached after

GENERAL
J Wear Limits
Part resp. part union New part tolerance Wear Limit Remark
Main bearing clearance radial 0,032 - 0,099 0,15

Main bearing clearance axial 0,080 . 0,263 0,30
Connect.rod bearing clear. radial 0,024 - 0,073 0,10

Connect.rod bearing clear. axial 0,064 - 0,217 0,50
Cylinder bore 85,00 - 85,01 0,20
Piston travel clearance 0,071 - 0,099 0,20
Piston diameter 84,911 - 84,929 0,10 deviation from initial

dimension
Gap 1. ring 0,25 - 0,40 1,50
Gap 2. ring 0,50 - 0,75 0,25
Gap 3. ring 0,30 - 0,60 1,00
Axial play 1. ring 0,077 - 0,127 0,25

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 depth up
Valve guide 7,000 - 7,015 0,15 to 3 mm
before end of valve guide
Oil pressure idle run 0,6 - 1,5 0,50
Oil pressure rated speed 4,0 - 7,0 3,00
Backlash of teeth oil pump 0,2 - 0,3 0,80

Axial play gear wheel 0,2 0,40

J1 Adjustment information for service and maintenance
J 1.1 Engine timing (measured with dial indicator No. 2300899/0)
Setting instruction: 3,20 +/- 0,04 mm
Maintenance instruction: In case the measurements are not within the specified limits of 3,14 to
3,26 mm - than the settings needs to be reset to the original specified value.
J 1.2 Tension timing belt (measured with tool VR00515/0)
Tension instruction: 600 +/- 30 N (new belt)
Tension instruction: 520 +/- 30 N (used belt)
Maintenance instruction: In case the measurements are not within the specified limits of 630 N to
490 N - than the settings needs to be reset to the original specified value.
J 1.3 Start of fuel delivery on the unit injectors (measured with dial indicator No. 2300899/0)
Setting instruction: For original settings on your engine please see table 03. 02. 06
Maintenance instruction: In case the measurements are not within the specified limits the settings needs
to be reset to the original specified value.
J 1.4 Valve clearance (measured with tool No. 2300712/3))
Setting instruction: 0,25 mm
Maintenance instruction: In case the measurements are not within the specified limits less than 0,25
more than 0,30 mm - the settings needs to be reset to the original specified value.

GENERAL

ToC SERVICE MANUAL MARINE ENGINES 01 ENGINE
01 ENGINE
Table of Contents
01.00 Engine timing, engine mount ......................................................................... 3
01.00.01 Lock crankshaft ................................................................................................. 3
01.00.02 Exchange camshaft housing cover sealing ........................................................ 6
01.00.03 Maintenance timing-belt exchange .................................................................... 7
01.00.04 Remove timing belt........................................................................................... 15
01.00.05 Timing adjustment procedure for dismantled engine ....................................... 16
01.00.06 Replace engine mount and engine bracket ...................................................... 26
01.01 Cylinder block ................................................................................................ 28

01.01.01 Replace valves ................................................................................................ 28
01.01.02 Adjust valve clearance .................................................................................... 30
01.01.03 Replace valve guide ........................................................................................ 30
01.01.04 Replace pressure regulating valve for oil cooling jet ....................................... 31
01.01.05 Replace stud bolt for unit injector .................................................................... 32
01.01.06 Replace dowel pin for positioning of unit injector ............................................ 33
01.01.07 Replace dowel pin for positioning of camshaft housing ................................... 34
01.01.08 Replace external screw adaptor for oil cooler ................................................. 35
01.01.09 Replace coolant supply pipe ........................................................................... 35
01.01.10 Mount frame seal ............................................................................................ 36
01.02 Crankshaft, bearing, vibration damper ......................................................... 38

01.02.01 Replace crankshaft.......................................................................................... 38
01.02.02 Replace gear for oil pump drive ...................................................................... 42
01.03 Flywheel, housing ......................................................................................... 43

01.03.01 Replace flywheel housing ................................................................................ 43
01.03.02 Replace flywheel .............................................................................................. 44
01.03.03 Replace adapter ring ....................................................................................... 45
01.04 Piston and connecting rod ........................................................................... 46

01.04.01 Dismantle piston and connecting rod .............................................................. 46
01.05 Camshaft, housing, valve gear ..................................................................... 48

01.05.01 Replace camshaft housing .............................................................................. 48
01.05.02 Replace valve stem gasket (on engine assembly) .......................................... 52
01.05.03 Replace control rack ........................................................................................ 54
01.05.04 Replace camshaft ........................................................................................... 56
01.05.05 Replace rocker arm shaft ................................................................................ 58
01.05.06 Replace radial shaft seal of camshaft ............................................................. 59
01.05.07 Replace cam follower ...................................................................................... 60
01.05.08 Replace retainer of cam follower ..................................................................... 61
01.05.09 Replace valve adjusting element ..................................................................... 62
Z001019/0_6_July 2008 Page ENGINE - 1

01 ENGINE
01.06 Engine housing, oil pump, oil suction pipe ................................................ 63

01.06.01 Replace engine housing .................................................................................. 63
01.06.02 Replace support ring rear ................................................................................. 70
01.06.03 Replace rear radialshaft sealing ring ................................................................ 71
01.06.04 Replace oil pump (front ring carrier) ................................................................ 72
01.06.05 Replace oil suction pipe .................................................................................. 73
01.08 Intercooler ...................................................................................................... 74

01.08.01 Remove intercooler ......................................................................................... 74
01.08.02 Assembly of intercooler .................................................................................... 78
01.08.03 Replace intercooler - element .......................................................................... 79
01.09 Auxiliary drive, in front (PTO) ....................................................................... 81
01.13 Engine oil cooler ........................................................................................... 82

01.13.01 Replace engine oil cooler ................................................................................ 82
01.13.02 Repair oil cooler .............................................................................................. 84
01.13.03 Change motor oil .............................................................................................. 85
01.13.04 Change oil filter ................................................................................................ 86
01.14 Exhaust manifold, seals, heat exchanger ................................................... 87
Page ENGINE- 2 Z001019/0_6_July 2008

01.00 ENGINE TIMING, ENGINE MOUNT
01.00.01 Lock crankshaft
Preparation: Put engine out off operation

Disconnect battery
Remove camshaft housing cover, 01.00.02
Special tool: for vibration damper screws No. 2300767/0
Locking pin No. 2300551/2
00.01 ill.1
1 Unscrew allen head plug screw (ill.1) (SW 10).
2 Turn crankshaft by means of special tool 2300767/0

(ill.2) until roller of rocker arm cyl. 1 runs up the ramp
of injection cam (ill.3).
00.01 ill.2
00.01 ill.3
3 Insert locking pin 2300551/2 into guide hole and
slightly press it against crankshaft counter weight.
00.01 ill.4

01 ENGINE
4 Continue to turn crankshaft slowly manually in

direction of rotation until locking pin engages into slot
of crankshaft.
ATTENTION: Never actuate starter engine as long

as locking pin is inserted.
00.01 ill.5
Removal of locking pin
1 Pull out locking pin 2300551/2.
2 Screw in plug screw with hexagon socket and tighten

with 50 Nm +/- 5.
NOTE: Use new copper sealing.
ATTENTION: Prior to starting, make sure that

locking pin has been removed.
00.01 ill. 6
3 Clean sealing surface of camshaft housing and
camshaft housing cover.
Check seal for hardening and damage. Exchange, if
necessary. See 01.00.02
4 Remaining assembly is done in reserve order.
Page ENGINE - 4 Z001019/0_6_July 2008

Explanation: (for engine timing)

If the crankshaft has been locked in position as
described (piston; cylinder; in TDC), the following
positions are to be found in case of correct adjustment.
* The bearing roller of the rocker arm on cyl. 1 is

located just before the injection cam cap.
00.01 ill.8
* The marked tooth of the camshaft timing belt
sprocket stay´s in line with the upper edge (sealing
surface) of the camshaft housing.
00.01 ill.9
* The notch on the timing belt sprocket of crankshaft

is opposite to the arrow marker on the oil pump
housing.
00.01 ill.10

01 ENGINE
01.00.02 Exchange camshaft housing

cover sealing
1 Release hexagon nuts.
2 Remove camshaft housing cover.
3 For engines with plane sealing surface.

Release camshaft housing cover sealing by means
of screwdriver and remove.
4 For engines with bossed sealing surface. 00.02 ill.1

Remove seal with a scraper and dispose.
5 Clean sealing surface of camshaft housing cover and

camshaft housing.
6 For engines with plane sealing surface.

Position new seal on camshaft housing cover and
press it into the groove, beginning at the half-moon
(ill.2).
7 For engines with bossed sealing surface.

Apply LOCTITE 5900 to sealing surface of camshaft
housing cover; position the new sealing on and force
against the cover.
00.02 ill.2
8 Put camshaft housing cover onto camshaft housing.
Tighten with hexagon nuts SW 10.

01.00.03 Maintenance timing belt exchange
Preparation: put engine out of operation

disconnect battery
remove camshaft housing cover
Special tool: for vibration damper screws

No. 2300767/0
1 For 4 cyl. engines

Remove Poly-V-belt. See exchange of Poly-V-belt
(05.06)
Remove all V-belts. See exchange of V-belts (05.07) 00.03 ill.1
3 Unscrew 3 hexagon screws (SW10) of upper V-belt

covering (ill.2/pos.1) and remove V-belt covering.
4 Unscrew hexagon screws (SW 10) of lower timing

belt covering (ill.2/pos.2)) and remove timing belt
cover.
NOTE: See for arrows markings on used

timing belt; mark timing belt if
necessary.
00.03 ill. 2
Consider change intervals - see
chart "maintenance".
Special tool: 2306031/4 dial gauge rail 4 cyl.

2306031/1 dial gauge rail 6 cyl. with
bossed seal surface
plane seal surface
2300899/0 dial gauge
2300641/1 probe pin
VR00515/0 V-belt tightener
2300711/0 open end wrench
VR00113/0 remover
2300551/2 locking pin
00.03 ill. 3
5 Mount dial gauge rail with brackets 2306031/. (see
list special tool) on studs at intake side of camshaft
housing.
6 Insert dial gauge 2300899/0 with probe pin

2300641/1 in dial gauge rail and put probe pin onto
unit injector-plunger guide cylinder 1.
7 Turn camshaft until the roller of rocker arm is located

on base circle of injection cam.
00.03 ill. 4

01 ENGINE
8 Pre-set dial gauge to position 20 mm stroke (small

pointer at 20 - inside scale, big pointer at 0 - outside
scale) or press zero button an digital dial gauge. 00.
00
00.03 ill.5
9 Lock crankshaft, refer 01.00.01
00.03 ill.6
10 Loosen Allen head screw SW 8 of belt tensioner and

remove tensioner.
00.03 ill. 7
11 Loosen 3 TORX screws for vibration damper by
means of special tool 2300767/0 and remove vibration
damper.
12 Remove timing belt.
ATTENTION: With loose and/or removed timing belt,

the camshaft or crankshaft must not
be turned.
This could result in a collision of pistons
and valves.
00.03 ill. 8

13 Put new timing belt onto crankshaft sprocket and

camshaft sprocket (marked tooth of camshaft sprocket
points at upper edge of camshaft housing).
00.03 ill.9
ATTENTION: Pay attention to arrow marker
(direction of rotation) on timing belt.
00.03 ill.10
14 Mount vibriation damper. Slightly grease thread and
flange of 3 TORX screws (Grease P/N Z012222/0)
and tighten with torque wrench to 135 Nm +/-7.
NOTE: Recheck torque after first test run.
00.03 ill.11
15 Tightly put on timing belt from crank shaft sprocket

over water pump drive wheel and camshaft sprocket,
and position camshaft sprocket with marked tooth
towards upper sealing edge of camshaft housing.
00.03 ill.12

01 ENGINE
16 Clean and degrease contact surface of tensioner and

camshaft housing.
Then mount tensioner.
00.03 ill.13
17 Pre tension timing belt by turning tensioner on
hexagon WS 32 counterclockwise. Tighten
hexagon socket SW 8 with torque wrench to 20 Nm
+/- 2.
00.03 ill.14
18 Put on tension gauge No. VR00515/0 (ill.15/pos.1)
between camshaft sprocket and tensioner. Pre
tension timing belt tension by further 1
counterclockwise turning of tensioner hexagon
SW 32 to read 600 N +/- 30 Nm for new timing belt
indication on tension gauge between green and red 2
marked field.
ATTENTION: When putting on tension gauge No.

VR00515/0, consider the following:
00.03 ill.15
* The two stop trunnions (ill.15/pos.2) should rest
on the forehead of timing belt and must not rest
on the back of timing belt.
* Put measuring bow onto tooth.
* During measuring, completely push in measuring

bow and relax quickly.
When attaining the required timing belt tension, tighten

the Allen head screw SW 8 with torque wrench to 45
Nm +/-4, and hold up at the same time with wrench
SW32.
00.03 ill.16

19 Remove locking pin from crank shaft.
00.03 ill.17
20 Turn crankshaft 4 turns and stop at fourth turn with
a plunger guide stroke of unit injector of approx.
3.32 mm (dial gauge reading).
Then turn back crank shaft by a stroke measurement
of 0.5 mm on the dial gauge.
4x
NOTE: During above mentioned operation
the timing belt should run into place
and a uniform tension shall result for
measuring of timing belt tension.
21 Put on tension gauge No. VR00515/0 between

camshaft sprocket and tensioner, as described, 00.03 ill.18
and read measured value.
Timing belt tension should be 600 N +/- 30 N for a
new timing belt.
NOTE: If timing belt tension does not

correspond to specified tension, loosen
the tensioner and repeat adjustment
according to instructions under item
21 through 24.
In this case, a re-positioning of the
camshaft sprocket may be required.
00.03 ill.19
22 Turn crankshaft further 2 turns, and at second turn
fix crankshaft with locking pin in TDC position
(cylinder 1; in TDC). See chapter 01.00.01.
00.
With crank shaft in locked position, the plunger 00
guide stroke of the unit injector at first cylinder

should show the following value on the dial gauge:
Index value of engine timing

3.20 mm +/- 0,04 mm
(plunger guide stroke - unit injector)
00.03 ill.20

01 ENGINE
NOTE: If the index value of engine timing should

not correspond to the specifical value, follow
the instructions as per item 26.
Remove camshaft sprocket
23 Loosen hexagon nut of camshaft sprocket SW 30 by

holding up with special tool No. 2300711/0 and turn
nut by approx. 1/4 rotation.
00.03 ill.22
24 Mount extractor (ill.23/pos.1) camshaft sprocket

VR00113/0 and screw in puller screw "LEFTHAND
THREAD" by hand.
Prestress puller screw with approx. 100 Nm +/-5. 1
NOTE: Do not remove camshaft sprocket

from conical seat when screwing in
the puller screw.
00.03 ill.23
25 Remove camshaft sprocket from concial seat by one

hammer blow on puller screw.
NOTE: To correct the setting of engine timing,

follow further instructions as per item
26.
00.03 ill.24

Readjustment of camshaft position in case of

correction of set engine timing
NOTE: This is to be carried out, if the index

value of the engine timing is not within
the allowed adjustment tolerance.
õ
26 Check locking position of crankshaft or lock crank
shaft, if necessary. (piston; cylinder 1; in TDC).
Refer 01.00.01
00.03 ill.25
27 Adjust camshaft to 3.27 mm on the dial gauge, by
turning with special tool 2300711/0 (ill.26).(plunger 1
guide at unit injector is moved down by 3,27 mm.)
NOTE: During this operation, the camshaft

sprocket must be released from the
taper connection and should only
slightly supported by the cone. Tensi-
on of timing belt remains adjusted, as
described before.
28 Remove locking pin from crankshaft. Refer 01.00.01
00.03 ill.26
29 Tighten hexagon nut SW 30 of camshaft sprocket to

80 +/-4 Nm by holding up with special tool 2300711/
0 at hexagon on camshaft.
ATTENTION: During this operation, camshaft
sprocket and camshaft are connected
positively. A positive connection is
only achieved by tightening the
hexagon nut with 240 +/-12 Nm. The
previously set stroke on the unit
plunger guide must not be changed
when tightening the hexagon nut.
00.03 ill.27
30 Turn crankshaft by 2 further turns, and at the second

turn fix crankshaft with locking pin in TDC position
(cylinder 1; in TDC). See chapter 01.00.01. 00.
00
With locked crankshaft, the plunger guide stroke of
unit injector at first cylinder should show the following
dial gauge value:

3.20 mm +/- 0,04 mm
00.03 ill.28

01 ENGINE
NOTE: If the index value of engine timing

should not correspond to the allowed
value, follow the instructions as per
item 24.
31 In case of correct index value of engine timing,

tighten hexagon nut of camshaft sprocket SW 30
with 240 +/-12 Nm by holding up with special tool No.
2300711/0.
32 ATTENTION: The following torques are to be

checked again:
1 Torque on hexagon nut of camshaft sprocket

SW 30 240 +/-12 Nm.
2 Fillister socket head screw SW 8 of timing

belt tensioner at 45 +/-4 Nm.
3 3 TORX screws on vibration damper with

135 +/-4 Nm.
33 Remove locking pin on crankshaft.

01.00.04 Remove timing belt
Preparation: put engine out of operation

disconnect battery
remove camshaft housing cover
Special tool: for vibration damper screws

No. 2300767/0

Remove Poly-V-belt. See exchange of Poly-V-belt
(05.06)
Remove all V-belts. See exchange of V-belts (05.07) 00.04 ill.1
3 Unscrew 3 hexagon screws (SW10) of upper V-belt

covering (ill.2/pos.1) and remove V-belt covering.
4 Unscrew hexagon screws (SW 10) of lower timing

belt covering (ill.2/pos.2)) and remove timing belt
cover.
00.04 ill. 2
NOTE: See for arrows markings on used
timing belt; mark timing belt if
necessary.
Consider change intervals - see
chart "maintenance".
5 Lock crankshaft, see 01.00.01
6 Loosen Allen head screw (SW 8) of belt tensioner

and remove tensioner.
00.04 ill. 3
7 Loosen 3 TORX screws for vibration damper by
means of special tool 2300767/0 and remove vibration
damper.
8 Remove timing belt.
ATTENTION: With loose and/or removed timing belt,

the camshaft or crankshaft must not
be turned.
This could result in a collision of pistons
and valves.
MOUNT TIMING BELT - see adjust engine timing;

01.00.04
00.04 ill. 4

01 ENGINE
01.00.05 Timing adjustment procedure for

dismantled engine
Function description:
Time control of injection and valves are consistent
due to the special camshaft design (3 cams per
cylinder). During adjustment, pay attention to essen-
tial functional elements, such as unit injector, timing
belt tension and sense of rotation of engine, in order
to achieve the required setting accuracy of injection.
A change of the timing belt tension or the sense of
rotation during adjustment always causes wrong
positioning of the injection control.For this reason it is
to be ensured that the adjusting procedure follows
the conditions of real operation.
Status for job:
* Camshaft housing cover dismantled.
* Set up crankshaft to approx. 40° crank angle

before TDC (piston; cylinder 1; in TDC) in order
to set all pistons in the engine to approximately
the same length of stroke, thus providinge open
space for the valve movement (stroke). This
ensures that the camshaft may be turned to the
desired position (injection stroke - unit injector
cylinder 1) without problems. 00.05 ill.1
* Crankshaft position with dismantled vibration

damper.
* Crankshaft position with mounted damper, if

timing belt has not been removed.
NOTE: Before disassembly, mark the

vibration damper, with locked
crankshaft. A corresponding
marking must be made on the
timing belt cover.
* Unit injectors mounted and adjusted.

See 03.02.02 and 03.02.06. 00.05 ill.2
* Valve clearance set.
Special tool.: 2306031/4 dial gauge rail 4 cyl.

bossed seal surface
plane seal surface
2300641/1 probe pin
VR00515/0 V-belt tightener
2300711/0 open end wrench
VR00113/0 remover
2300551/2 locking pin 00.05 ill.3

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

list special tool) on studs at intake side of camshaft
housing.
2 Insert dial gauge 2300731/0 with probe pin

2300641/1 in dial gauge rail and put probe pin onto
unit injector-plunger guide cylinder 1.
00.05 ill.4
3 Turn camshaft until the roller of rocker arm is located
on base circle of injection cam.
00.05 ill.5
4 Pre-set dial gauge to position 20 mm stroke (small

pointer at 20 - inside scale, big pointer at 0 - outside
scale). 00.
00
00.05 ill.6
5 Slowly turn camshaft in direction of rotation until dial

gauge shows a stroke of 2 mm (injection stroke at
unit injector).

01 ENGINE
6 Continue to turn crankshaft in direction of rotation and

position it with locking pin on TDC (piston; cylinder 1;
in TDC). See chapter 01.00.01.
7 Continue to turn camshaft slowly in direction of

rotation until a total distance of 3.32 mm can be read
on the dial gauge (plunger stroke at unit injector).
Assembly of camshaft sprocket 00.05 ill.7
8 Clean and degrease cone on camshaft and in camshaft

sprocket.
ATTENTION: Very high for as are transmitted via this
conical seat. Therefore, it is extremely
important that the two cone surfaces
are assembled absolutely clean and
grease-free.
00.05 ill.8
9 Shift camshaft sprocket onto cone and slightly lubricate

thread at front end of camshaft.
Slightly turn hexagon nut and washer by hand. The
camshaft sprocket should only slightly be supported
by the cone, in this status on easily turning of the
camshaft sprocket must be possible.
00.05 ill.9
10 Put timing belt onto pre-positioned crankshaft sprocket

(Lock crank shaft - see 01.00.01) and camshaft
sprocket (marked tooth of camshaft sprocket points
•
õ
at upper edge of camshaft housing).
00.05 ill.10

ATTENTION: Pay attention to arrow marker

(direction of rotation) on timing belt.
00.05 ill.11
11 Mount vibriation damper. Slightly grease thread and
flange of 3 TORX screws (Grease P/N Z012222/0)
and tighten with torque wrench to 135 Nm +/-7.
NOTE: Recheck torque after first test run.
00.05 ill.12
12 Tightly put on timing belt from crank shaft sprocket

over water pump drive wheel and camshaft sprocket,
and position camshaft sprocket with marked tooth
towards upper sealing edge of camshaft housing.
00.05 ill.13
13 Clean and degrease contact surface of tensioner and

camshaft housing.
Then mount tensioner.
00.05 ill.14

01 ENGINE
14 Prestress timing belt by turning tensioner on hexagon

(WS 32) counterclockwise. Tighten hexagon so-
cket (SW 8) with torque wrench to 20 Nm +/- 2.
00.05 ill.15
15 Put on tension gauge No. VR00515/0 (ill.16/pos.1)
between camshaft sprocket and tensioner. Prestress
timing belt tension by further counterclockwise 1
turning of tensioner hexagon (SW 32) to 710 N +/-
30 N for new timing belt.
NOTE: 600 N +/- 30 N for used timing belt 2
ATTENTION: When putting on tension gauge No.

VR00515/0, consider the following:
* The two stop trunnions (ill.16/pos.2) should rest

00.05 ill.16
on the forehead of timing belt and must not rest
on the back of timing belt.
* Put measuring bow onto tooth.
* During measuring, completely push in measuring

bow and relax quickly.
When attaining the required timing belt tension, tighten

the Allen head screw (SW 8) with torque wrench to
45 Nm +/-4, and hold up at the same time with wrench
(SW32).
00.05 ill.17
16 Tighten hexagon nut (SW 30) of camshaft sprocket

to 80 Nm +/- 4, by holding up with special tool
2300711/0 at hexagon on camshaft.
ATTENTION: The preset stroke at the unit injector

(3.32 mm) must not be changed when
tightening the hexagon nut. During
this operation step, camshaft
measurement purpose. A positive
connection is only achieved by finally
tightening the hexagon nut with 240
Nm +/-12.
00.05 ill.18

17 Remove locking pin from crank shaft.
00.05 ill.19
18 Turn crankshaft 4 turns and stop at fourth turn with
a plunger guide stroke of unit injector of approx.
3.30 mm (dial gauge reading).
Then turn back crank shaft by a stroke measurement
of 0.5 mm on the dial gauge.
4x
NOTE: During above operation mentioned
on the timing belt shall be positioned
correctly and a uniform tension is set
up for measuring of timing belt
tension.
00.05 ill.20
19 Put on tension gauge No. VR00515/0 between

camshaft sprocket and tensioner, as described
under item 15, and read measured value.
Timing belt tension should be 600 N +/- 15 N for a
new timing belt.
NOTE: for a used timing belt 520 N +/- 30 N
NOTE: If timing belt tension does not
correspond to desired value, loosen
the tensioner and repeat adjustment
according to instructions under item
14 to 19.
In this case, a re-positioning of the
camshaft sprocket may be required.
00.05 ill.21
20 Turn crankshaft further 2 turns, and at second turn

fix crankshaft with locking pin in TDC position
00.
(cylinder 1; in TDC). See chapter 01.00.01. 00
With crank shaft in locked position, the plunger

guide stroke of the unit injector at first cylinder
should show the following value on the dial gauge:

3.20 mm +/- 0,04 mm
00.05 ill.22

01 ENGINE
NOTE: If the index value of engine timing should

not correspond to the desired value,
follow the instructions as per item 24.
21 In case of a correct index value of engine timing,

tighten the hexagon nut of the camshaft sprocket (SW
30) with 240 Nm by holding up with special tool No.
2300711/0.
00.05 ill.23

checked again.
õ

(SW 30) 240 Nm +/- 12
2 Allen head screw (SW 8) of timing belt

tensioner at 45 Nm +/- 4

135 Nm +/- 7
00.05 ill.24

Remove camshaft sprocket
24 Loosen hexagon nut of camshaft sprocket (SW 30)

by holding up with special tool No. 2300711/0 and
turn nut by approx. 1/4 rotation.
00.05 ill.25
25 Mount extractor (ill.26/pos.1) camshaft sprocket

VR00113/0 and screw in puller screw "LEFTHAND
THREAD" by hand.
1
Prestress puller screw with approx. 100 Nm +/-5.
NOTE: Do not remove camshaft sprocket

from conical seat when screwing in
the puller screw.
00.05 ill.26
26 Remove camshaft sprocket from concial seat by one

hammer blow on puller screw.
NOTE: To correct the setting of engine timing,

follow further instructions as per item
27.
00.05 ill.27

01 ENGINE
Readjustment of camshaft position in case of

correction of set engine timing
NOTE: This is to be carried out, if the index

value of the engine timing is not within
the allowed adjustment tolerance.
õ
27 Check locking position of crankshaft or lock crank
shaft, if necessary. (piston; cylinder 1; in TDC). See
01.00.01
00.05 ill.28
28 Adjust camshaft to 3.27 mm on the dial gauge, by
turning with special tool 2300711/0 (ill.29).(plunger 1
guide at unit injector is moved down by 3,27 mm.)
NOTE: During this operation, the camshaft

sprocket must be released from the
taper connection and should only
slightly supported by the cone. Tensi-
on of timing belt remains adjusted, as
described before.
29 Remove locking pin from crankshaft. See 01.00.01
00.05 ill.29
30 Tighten hexagon nut (SW 30) of camshaft sprocket

to 80 Nm +/-4 by holding up with special tool 2300711/
0 at hexagon on camshaft.
ATTENTION: During this operation, camshaft
positively. A positive connection is
only achieved by tightening the
hexagon nut with 240 Nm +/-12. The
previously set stroke on the unit
plunger guide must not be changed
when tightening the hexagon nut.
00.05 ill.30
31 Turn crankshaft by 2 further turns, and at the second

turn fix crankshaft with locking pin in TDC position
(cylinder 1; in TDC). See chapter 01.00.01. 00.
00
With locked crankshaft, the plunger guide stroke of
unit injector at first cylinder should show the following
dial gauge value:

3.20 mm +/- 0,04 mm
00.05 ill.31

NOTE: If the index value of engine timing

should not correspond to the allowed
value, follow the instructions as per
item 24.
32 In case of correct index value of engine timing,

tighten hexagon nut of camshaft sprocket (SW 30)
with 240 Nm +/-12 by holding up with special tool No.
2300711/0.

checked again:

(SW 30) 240 Nm +/-12.
2 Fillister socket head screw (SW 8) of timing

belt tensioner at 45 Nm +/-4.

135 Nm +/-4.

01 ENGINE
01.00.06 Replace engine mount and

engine bracket 1
ATTENTION: Slightly lift the engine by means of

suspension VR 00130/0 at lifting
shackles (ill.1/pos.1)
(approx. 3500 N).
Replace engine mount

00.06 ill.1
1 Loosen hexagon nut (SW24), remove washer.
2 Loosen two setscrews (SW17) of engine mount,

remove engine mount.
NOTE: After assembly of the engine mount,

center the engine to correct axis
geometry of drive unit.
Replace engine bracket 00.06 ill.2

Loosen 7 allen head screws (SW6), remove bracket
and 7 washers.
NOTE: During assembly, secure allen head

screws with LOCTITE 243
(9000059/1) and tighten with a
torque of 23 +/- 2 Nm.
00.06 ill.3
Loosen 4 allen head screws (SW8), remove bracket
and 4 washers.

(9000059/1) and tighten with a torque
of 64 +/- 5 Nm.
00.06 ill.4

Exchange bracket on flywheel housing
1 Loosen 4 allen head screws (SW10)

and remove support.

(9000059/1) and tighten with a
trorque of 75 +/- 5 Nm.
00.06 ill.5

01 ENGINE
01.01 CYLINDER BLOCK

01.01.01 Replace valves
Preparation: Disassemble engine housing,

01.06.01,
Disassemble crankshaft, 01.02.01,
Disassemble pistons, 01.04.01.
1 Insert special tool No. VR00104/00 in cylinder bore

and tighten sturdily with two hexagon screws (SW19).
01.01 ill.1
2 Mount valve spring retainer No. VR00105/1 .
01.01 ill.2
3 Prestress valve spring with hexagon nut (SW28).
01.01 ill.3
4 Remove wedges.
5 Relax valve spring again, remove valve spring, sp-

ring plate and spring washer.
6 Remove special tool from cylinder bore, remove

valves.
01.01 ill.4

7 Pull out valve stem gasket with special tool No.

2300758/0.
01.01 ill.5
NOTE: When inserting the valves, lubricate
valve stem with motor oil.
8 Put special tool No. V000152/0 onto valve stem end

and pull on new valve stem over sleeve.
9 Remove sleeve and press on valve stem gasket with

special tool No. V000166/0 until valve stem gasket is
supported on collar of valve guide.
10 Lubricate valve stem (motor oil).
11 Mount special tool No. VR00104/0 again.

01.01 ill.6
12 Put on spring washer, valve spring and spring plate

and prestress valve spring with special tool No.
VR00105/1.
NOTE: The progressively wound end of the

valve spring is located on the cylinder
block.
13 Insert wedges, relax valve spring and check correct

seat of wedges.
01.01 ill.7

01 ENGINE
01.01.02 Adjust valve clearance

1 2
Preparation: Remove camshaft housing cover
3
Valve clearance is adjusted by means of special tool

No. VR 00125/0 and adjusting gauge 2300712/3
(ill.1/pos.1) between camshaft base circle (ill.1/pos.2)
and cam follower (ill.1/pos.3).
NOTE: index value outlet valve 0.25 mm

index value intake valve 0.25 mm 01.02 ill.1
01.01.03 Replace valve guide
Preparation: Disassemble valves, 01.01.01.
1 Press out valve guide with special tool

VR00154/0.
2 Insert valve guide with special tool VR00109/0.
01.03 ill.1

01.01.04 Replace pressure regulating valve

for oil cooling jet
Preparation: Disassemble engine casing 01.06.01
Remove pressure regulating valve with open-end

wrench (WS13).
ATTENTION: Screw in pressure regulating valve until

front collar is seated in bore.
Screw in pressure regulating valve
sturdily.
01.04 ill.1
NOTE: Secure thread with structural adhesive
LOCTITE 262.
ATTENTION: Only tested valves with an opening

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

01 ENGINE
01.01.05 Replace stud bolt for

unit injector
Preparation: Remove camshaft housing cover,

01.05.01
Remove unit injector, 03.02.02
1 Tighten threaded pin with a torque of

21 +/- 1 Nm.
01.05 ill.1

01.01.06 Replace dowel pin for

positioning of unit injector
Preparation: Disassemble camshaft housing,

01.05.01.
1 Insert new dowel pin by means of setter.
01.06 ill.1

01 ENGINE
01.01.07 Replace dowel pin for

positioning of camshaft housing

01.05.01.
Insert new dowel pin by means of setter.
01.07 ill.1
ATTENTION: Do not close oil supply duct with dowel

pin in front. (see illustration below)
ENGINE DAMAGE!
Cylinder 1
Oil supply
duct
Dowel pin
01.07 ill.2
Page ENGINE - 34 Z001019/0_6_July2008

01.01.08 Replace external screw adaptor

for oil cooler
Preparation: Disassemble oil cooler,

01.06.01.
2
1. Screw in external screw part (ill.1/pos.1) with a torque 1
of 100 Nm +/-5.
2. Put on new O-ring. (ill.1/pos.2)
01.08 ill.1
01.08 ill.2
01.01.09 Replace coolant supply pipe

1
Preparation: Disassemble control solenoid,
03.08.
1 Loosen hose clamp (ill.1/pos.1), remove hose.

2
2 Loosen three allen head screws (SW5) (ill.1/pos.2),
remove coolant supply pipe.
NOTE: Use new seal for assembly.

01.09 ill.1

01 ENGINE
01.01.10 Mount frame seal
Preparation: Disassemble engine housing,

01.06.01,
Disassemble crankshaft,
01.02.01,
1 Clean and degrease groove in cylinder block.
01.10 ill.1
For engines with rubber frame seal (slot-variant)

(item 2-7)
2 Apply construction adhesive LOCTITE 262 on both
sides of first profile groove of frame seal.
01.10 ill.2
3 Apply activator 764 to groove in the cylinder block.
01.10 ill.3
4 Put frame seal from the bottom over the cylinder

block.
5 Bourrelet of frame seal profile must be placed at the

front (coolant pump) in the center of the side of
cylinder block..
Important for later assembly of engine housing.
01.10 ill.4

6 Press frame seal into cylinder block groove, beginning

at the cylinder block corner and then along side of the
block.
NOTE: Only press in the rubber of the frame
seal by hand. Do not stretch or displace.
7 Pay attention do least curing time and curing

temperature. Also see manufacturer's specifications.
ATTENTION: Pay attention to safety notes/rules.
For engines with frame seal with alu support

(screwed variant) - (item 8-9)
Special tool 4 cyl. V000307/0

6 cyl. V000306/0
Installation device
8 Slide frame seal using special tool into block-groove. 01.10 ill.5
NOTE: For easier installation of frame seal apply

alcohol on sealing profil. The alcohol will
serve as a lubrication agent during
installation process.
9 Clean of the frame seal lip and the block slot using
Acetone or a non oil based cleaner (pure alcohol) and
give time for this dry before continuing.
Place Loctite activator #7649 (see below) on the
upper edge of the frame seal lip and in the slot of the
block.
After waiting 2 minutes for Activator to work, apply
Loctite 620 (green) on the upper edge of the frame 01.10 ill.6
seal lip
10 Press frame seal into cylinder block groove, beginning

at the cylinder block corner and then along side of the
block.
NOTE: Only press in the rubber of the frame
seal by hand. Do not stretch or displace.
11 Secure the frame seal to the housing using the

screws and Loctite 243 (blue), tighten to 10 Nm.
01.10 ill.7

01 ENGINE
01.02 CRANKSHAFT, BEARING,

VIBRATION DAMPER
01.02.01 Replace crankshaft
Preparation: Disassemble flywheel housing and

flywheel, 01.03.01 und 01.03.02,
Disassemble timing belt and vibration
damper,
Dissamble engine housing, 01.06.01,
Disassemble oil suction pipe, 01.06.03.
Disassemble oil pump housing,
01.06.02,
02.01 ill.1
1 Turn crankshaft in such a way that first cylinder is
located at TDC, and secure with locking pin
No. 2300551/2.
ATTENTION: While disassembling the connecting

rod bearing caps and the main bearing
caps, the crankshaft may not be turned.
02.01 ill.2
2 Loosen the two screws of each connecting rod with
special tool 2300746/0, remove connecting rod
bearing caps with bearing shell. Push down all pistons
and connecting rods to TDC position.
NOTE: Remain with crank shaft in position

during work operation to avaid
damange the bearings.
Never turn crank shaft.
3 Remove rocking pin.
02.01 ill.3
4 Loosen two screws of each main bearing cap
with special tool No. 2300747/0, remove main bearing
shells and caps.
5 Lift out crankshaft. Remove thrust bearings from

main bearing section.
ATTENTION: When removing, take care that

released connecting rods do not hit
against cylinder liner!
02.01 ill.4

6 Remove main bearing blocks.
02.01 ill.5
7 Pull out oil nozzles for piston cooling.
02.01 ill.6
8 Remove main bearing shells from bearing blocks.
NOTE: For assembly, lubricate all bearing with

engine oil. All pistons with connecting
rods are inserted in the cylinder bore.
Mount injection oil nozzles with new O-
rings.
When inserting the crankshaft, take
care that the first connecting rod journal
pin is positioned at TDC.
9 Check, fot proper installation main bearing shells and 02.01 ill.7
connecting rod bearing shells.
ATTENTION:Main bearing base and main bearing

cap are marked with consequential
numbers on one side of the bearing
cast. Make sure this number between
base and bearing cap match.
02.01 ill.8
01 ENGINE
10 Insert the two upper thrust bearing segments onto

main bearing cap and mount main bearing cap.
Install remaining main bearing caps with bearing
shalls and tighten main bearing screws sturd.
11 Mount connecting rod cap with bearing shell. (pay

attention to numbering).
02.01 ill.9
Tightening specification for connecting rod

screws (thread and screw head support
lubricated)
1st working step: all screws 10 Nm +/-1

2nd working step: all screws 30 Nm +/-3
3rd working step: all screws 75 ° +/-4°
Special tool No. 2300706/0
ATTENTION: Use screws only twice. After tightening, 02.01 ill.10

mark with center punch.
Tightening specification for main bearing screws

(thread and screw head support lubricated):
1st working step: all screws 35 Nm +/-3

2nd working step: all screws 45 ° +/-4°
3rd working step: all screws 45 ° +/-4°
Special tool No. 2300706/0
Tightening sequence
4 cyl. engines 02.01 ill.11
10 7 1 5 4
8 9 2 3 6
6 cyl. engines
12 13 5 1 4 9 8
14 11 6 2 3 7 10 02.01 ill.12

Measuring of end clearance
Put on magnetic holder with dial gauge, put dial

gauge caliper onto crankshaft end.
Move crankshaft in forward direction and set dial
gauge to zero.
Move crankshaft backwards and read measured
value.
Clearance should be between 0.07 and 0.25 mm.
02.01 ill.13

01 ENGINE
01.02.02 Replace gear for oil pump

drive
Preparation:
Disassemble engine housing, 01.06.01,
Disassemble timing belt,
Disassemble oil pump, 01.06.02, 2
Disassemble oil suction pipe, 01.06.03.
3
1 Remove woodruff key.(ill.1/pos.1)
2 Pull off gear (ill.1/pos.2) with sleeve ring (ill.1/pos.3).

1
NOTE: Apply surface sealing agent 509 to
contact surfaces of gear towards
02.02 ill.1
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)
1
02.02 ill.2

01.03 FLYWHEEL, HOUSING

01.03.01 Replace flywheel housing
Preparation: Dismantle engine mount of flywheel

housing, 01.00.04. 1
1 Loosen 6 hexagon sockets (SW8 and 4) hexagon

sockets (SW6).
2 Remove flywheel housing from adjusting sleeve (ill.1/

pos.1).
03.01 ill.1
3 For SOLAS models only
First loosen screw (ill.2/pos.1) and fix blow-by valve

above flywheel housing.
4 Assembly is done in reverse order.
03.01 ill.2

01 ENGINE
01.03.02 Replace flywheel
Preparation: disassemble torsion coupling,

02.01
disassemble intermediate ring,
01.03.03
1 Lock crankshaft, 01.00.01
2 Loosen eight hexagon head screws (SW17) and

remove flywheel.
NOTE: Apply thread protection LOCTITE 243

to hexagon head screws and tighten
with a torque of 03.02 ill.1
75 Nm +/-4.

01.03.03 Replace adapter ring
Preparation: Dismantle flywheel housing,

01.03.01.
For 6 cyl. engines
1 Loosen 9 hexagon head screws (SW13), remove

adapter ring.
NOTE: Screw tensile strength - 10.9 03.03 ill.1

Tighten hexagon screws with a torque
of 30 Nm +/-3.

01 ENGINE
01.04 PISTON AND CONNECTING ROD

01.04.01 Dismantle piston and
connecting rod
Preparation: dismantle engine housing, 01.06.01

disassemble crankshaft, 01.02.01.
1 Pull out piston with connecting rod.
04.01 ill.1
2 Remove retainer ring of piston pin by means of
a 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 ring pliers.

Special tool: piston ring pliers 2300906/0
ATTENTION: For assembly of piston rings, take

care of marking "TOP".
In case of a change of cylinder
diameter, take care of respective
repair steps.
04.01 ill.4

ATTENTION: For assembly of piston and

connecting rod, take care that
positioning groove of connecting
rod bearing is opposite to the
clearance for injection oil nozzle.
NOTE: For best result position rings with piston

gap about one third of a turn a part
from each other gap.
04.01 ill.5
NOTE: When inserting the piston into cylinder
bore, with special tool No. 2300714/1,
take care that arrow marking on piston
bottom shows to the front.
04.01 ill.6

01 ENGINE
01.05 CAMSHAFT, HOUSING, VALVE GEAR

01.05.01 Replace camshaft housing
Preparation: Empty fuel system, 03.02.02 item 2.

Disconnect battery.
Disconnect crankshaft from TDC, 01.00.01.
Dismantle all unit injectors, 03.02.02.
1 Loosen all control links and turn to the back (ill.1/

pos.1).
ATTENTION: LEFTHAND THREAD (ill.1/pos.2) 1
05.01 ill.1
2 Release timing belt, dismantle tightener.
3 Remove timing belt from gear.
05.01 ill.2
Loosen 3 hexagon nuts (SW13) (ill.3/pos.1) and

remove.
Remove indexing plate. C1
C1
05.01 ill.3

For 6 cyl. engine (item 5-8) C3

5 Remove plug (ill.4/pos.1) for sensor of control rack.
Remove control rack.
6 Loosen plug (ill.4/pos.2) for potentiometer

accelerator. C1
7 Loosen 3 hexagon screws (SW13) (ill.4/pos.3) and
remove.
Remove bracket with potentiometer.
C2
OFF
05.01 ill.4
8 Remove plug (ill.5/pos.1) from control solenoid.
C1
05.01 ill.5
For 4 cyl. engine (item 9-12)
9 Remove plug (ill.6/pos.1) from control solenoid. C1 C3
õ
10 Remove plug (ill.6/pos.3) for sensor of control rack.
C2
11 Loosen plug (ill.6/pos.2) for potentiometer
accelerator.
05.01 ill.6
12 Dismantle supportig strap (ill.7/pos.1) between cam

shaft housing and intercooler. C1
05.01 ill.7
01 ENGINE
For 6 cyl. engines (item 13-15)
13 Loosen setscrews (ill.8/pos.1) for support of raw

water pipe.
C3 C1
14 Loosen hose clamp (ill.8/pos.2 and ill.9/pos.1) and C2
dismantle raw water pipe and bend.
15 Dismantle cover (ill.8/pos.3) to intercooler by loosening

5 hexagon screws (SW10).
05.01 ill.8
C1
05.01 ill.9
16 Disconnect speed sensor (ill.10/pos.1).
C1
05.01 ill.10
17 Loosen hexagon screws (SW13) (ill.11).
18 Remove camshaft housing upwards.

Remove sealing.
05.01 ill.11

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

and camshaft housing (ill.12/pos.2). 2
2 Put on camshaft housing sealing (ill.12/pos.3).
1
ATTENTION: Always use new sealing!
3
05.01 ill.12
3 Put on camshaft housing.
Take care that all cam followers (ill.13/pos.1) rest on
valve stems (ill.13/pos.2), are positioned and aligned
accordingly.
1
2
05.01 ill.13
4 Crankshaft must be set up to approx. 40° before TDC,
to avoid a collosion of valves with pistons.
5 Tighten screws of camshaft housing in two steps in

precedence of numbering to be read at the bearings
(from inside outwards).
Torque: 1. step 15 Nm +/- 1

2. step 25 Nm +/- 2
05.01 ill.14
6 Assembly unit injectors; refer 03.02.02
7 Adjust unit injectors, refer to 03.02.06.
8 Adjust valves, refer to 01.01.02.
9 Adjust control links (mass equalization),

refer to 03.02.04.
10 Adjust control, refer to 01.00.03.
11 Calibrate sensor for main rack position,

refer to 06.10. 03
12 Assembly engine in reversed order.

01 ENGINE
01.05.02 Replace valve stem gasket

(on engine assembly)

01.05.01.
ATTENTION: Set piston of respective cylinder on

TDC.
1 Mount valve spring retainer No. VR00105/1 (ill.1). 05.02 ill.1
2 Presstress valve spring (ill.2) with hexagon socket

(SW28).
05.02 ill.2
3 Remove wedges.
4 Relax valve spring again, remove valve spring and

spring washer.
05.02 ill.3
5 Remove valve stem gasket with special tool No.

2300758/0.
05.02 ill.4

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

and push new valve stem gasket over sleeve.
7 Remove sleeve and press on valve stem gasket with

special tool No. V000166/0 until valve stem is
supported on collar of valve guide.
8 Lubricate valve stem (motor oil).
9 Put on valve spring and spring washer and prestress 05.02 ill.5
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

01 ENGINE
01.05.03 Replace control rack
Preparation: Drain fuel system, 03.02.02

item 2.
Disassemble camshaft housing cover,
01.05.01.
Disassemble control solenoid,
03.08.01.
Disassemble unit injector of
1st cylinder, 03.02.02.
05.03 ill.1
1 Disassemble handle to control solenoid by loosening
two hexagon screws (SW8) (ill.2/pos.1).
1
05.03 ill.2
2 Disassemble all control links (ill.3/pos.1) by

loosening hexagon socket (SW4) (ill.3/pos.2).
1
ATTENTION: LEFTHAND THREAD
05.03 ill.3
3 Remove setpin (ill.4/pos.1) from last bulkhead.
05.03 ill.4

4 Loosen locking screw (SW22) (ill.5), remove sealing

ring, pull out control rod to the back.
NOTE: Connection of lefthand thread screws

and control links to be opened three
times only.
05.03 ill.5
5 Adjust control link (mass equalization),
refer to 03.02.04.
6 Adjust control, refer to 01.00.03.
7 Calibrate rack position, refer to 06.10.03

01 ENGINE
01.05.04 Replace camshaft
Preparation: disassemble camshaft housing,

refer to 01.05.01.
1 Loosen hexagon nut (SW30). (ill.1/pos.1) 2 1
05.04 ill.1
2 Disassemble camshaft wheel with special tool No.

VR00113/0 (ill.2), remove washer.
05.04 ill.2
3 Remove axial holder of camshaft and rocker arm

shaft. (ill.3)
05.04 ill.3
4 Disassemble all cam followers, refer to 01.05.07.
05.04 ill.4

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

front.
6 Pull out camshaft from the front of camshaft housing.
ATTENTION: On all 4 cyl. and 6 cyl. engines before:

68224400
At the rear end of camshaft (ill.1/pos.2)
the speed sensor wheel is located.
When pulling out and pushing in the
camshaft, take care that bearings of
camshaft are not damaged.
05.04 ill.5

01 ENGINE
01.05.05 Replace rocker arm shaft
Preparation: Disassemble camshaft housing

cover, 01.05.01.
Loosen setscrews of unit
injector on rocker arm.
1
1 Remove half-moon rings (ill.1/pos.1) on both sides
of rocker arms. 05.05 ill.1
2 Variant 1:
Extract axial holder (ill.2) of camshaft and rocker
arm shaft.
05.05 ill.2
3 Variant 2:
Extract axial half-moon rings (ill.3) of rocker arm
shaft (2x)
(same as for rocker arms)
05.05 ill.3
4 Displace rocker arm, remove slide rings, remove

rocker arms one by one and pull out rocker arm
shaft towards cyl. 4 or 6. (ill.4).
05.05 ill.4

01.05.06 Replace radial shaft seal of

camshaft
Preparation: Lock crankshaft, 01.00.01.

Remove timing belt.
Disassemble camshaft wheel.
1 Disassemble radial shaft seal.
2 Mount new radial shaft seal with special tool No.

VR00122/0.
05.06 ill.1
NOTE: Radial shaft seal is waxed; therefore
needs not to be oiled.
Do not use grease on radial shaft lip
seal.

01 ENGINE
01.05.07 Replace cam follower

1
Preparation: disassemble camshaft housing cover. 4
1 Loosen adjusting screw (ill.1/pos.1) with special 2

tool No. VR00125/0.
3
05.07 ill.1
2 Chuck cam follower spring (ill.1/pos.2) with special
tool No. V000121/0.
3 Compress valve spring (ill.1/pos.3) with special tool 05.07 ill.2

No. VR00106/0.
NOTE: Crankshaft is first to be turned in a

position which prevents collision
between valve - piston bottom.
ATTENTION: Before r elaxing the valve spring,

check whether the valve wedges
(ill.1/pos.4) are still positioned
correctly.
ENGINE DAMAGE!
05.07 ill.3
4 Lift cam follower from valve stem end and turn

sidewards.
5 Lift cam follower from ball pin.
6 Lift cam follower by means of pointed pliers.
NOTE: Adjust valves, refer to 01.01.02.
05.07 ill.4

01.05.08 Replace retainer of cam follower
Preparation: disassemble cam follower,

01.05.07
1
1 Turn retainer spring (ill.1/pos.1) sidewards and
remove by means of screwdriver from valve adjusting
element towards center.
05.08 ill.1
05.08 ill.2

01 ENGINE
01.05.09 Replace valve adjusting element
Preparation: Disassemble retainer spring of

cam follower spring, 01.05.08
1 Unscrew valve adjusting element with hexagon

socket (SW21).
NOTE: Apply thread protection LOCTITE 243

to valve adjusting element and tighten
with a torque of 55 Nm +/-3.
05.09 ill.1
05.09 ill.2

01.06 ENGINE HOUSING, OIL PUMP,

OIL SUCTION PIPE
01.06.01 Replace engine housing
Preparation: disconnect battery

close fuel feed- and return line,
empty closed cooling circuit,
refer to 05.00.02.01.
suck off motor oil
dismantle wiring harness, 06.05.02.
dismantle E-box
dismantle exhaust manifold - heat
exchanger, refer to 05.01.02. 06.01 ill.1
1 Lock lifting chain special tool No. VR00103/0 onto the

two lifting shackles (ill.2/1).
1
06.01 ill.2
2 Lift engine with special tool No. VR00130/0 and
crane (min. 3500 N) and mount it on No.VR00102/0
and trestle No. VR00101/0 by means of four hexagon
screws M8x30 (SW13).
ATTENTION: thread screwing depth 1,5xD.
06.01 ill.3
3 Dismantle oil dipstick tube (ill.4/pos.1) and ventilation

hose (ill.4/pos.2).
4 Dismantle tandem cooler, refer to 05.01.03.
2
06.01 ill.4

01 ENGINE
5 Dismantle oil hose on engine cooler (ill.5/pos.1).
06.01 ill.5
6 Disconnect oil hose on oil pump (ill.6/pos.1).
06.01 ill.6
7 Unscrew hollow screw (SW19) (ill.7/pos.1) to fuel

feed pipe.
06.01 ill.7
For 4 cyl. engines
8 Remove oil filter bracket.
06.01 ill.8

For 6 cyl. engines
9 Loosen two hexagon nuts and two hexagon screws

(SW13).
Remove filter plate.
10 Remove V-belt.
For 4 cyl. engines
11 Remove Poly-V-belt.
12 Dismantle raw water pump laterally, refer to 05.10

06.01 ill.9
13 Loosen 11 hexagon screws (SW10), remove lower

timing belt covering.
For 6 cyl. engines
14 Loosen 6 hexagon screws.

Remove lower timing belt covering.
06.01 ill.10
15 Dismantle flywheel housing, refer to 01.03.
Dismantle torsion coupling, refer to 02.
Remove flywheel, refer to 01.03.
16 Dismantle engine cooler, refer to 01.13.
06.01 ill.11
For engines with screwed frame seal (alu support)
17 Unscrew frame sealing from housing halfs.
06.01 ill.12

01 ENGINE
For engines with rubber frame seal (slot variant)
18 Force out frame sealing from engine housing slot by

means of broad screwdriver.
NOTE:
Do not puncture frame seal.
06.01 ill.13
19 Loosen one hexagon screw (SW10) (ill.14/pos.1).
Remove protective sheet.
06.01 ill.14
For 4 cyl. engines
20 First loosen 11 Allen head screws (SW5) (ill.15/

pos.1), then 7 hexagon screws (SW17) (ill.15/pos.2).
1
2 2
For 6 cyl. engines 06.01 ill.15
21 First loosen 13 Allen head screws (SW5) (ill.17/

pos.1), then 3 hexagon screws (SW13) (ill.17/pos.2),
and at last 4 hexagon screws (SW17) (ill.17/pos.3).
1
3 3
2
06.01 ill.17

22 Force apart housing halfs and remove.
06.01 ill.18
Assembly
1 Check membrans of frame sealing for damage,

replace if necessary.
2 Clean and degrease all sealing surfaces.
For 4 cyl. engines
3 Wet front and rear ring carrier with construction

adhesive LOCTITE 620, in the area of the parting
plane from the engine housing.
Wet sealing surfaces of screws with surface sealing
agent LOCTITE 509.
06.01 ill.20
For 6 cyl. engines (item 4 - 6)
4 Clean sealing profiles from adhesive residues.
5 Only for engines with rubber frame seal (slot

variant)
Wet sealing profile of frame sealing on both sides
with construction adhesive LOCTITE 262.
6 Wet sealing ring on front ring carrier with surface

sealing agent LOCTITE 5910.
Wet rear ring carrier in the area of the parting plane

from the engine housing with construction adhesive
LOCTITE 620.
01 ENGINE
7 First put suction-sides housing half onto dowel pin,

then check for second housing half wether oil suction
pipe and oil suction pipe horn do not collide with the
housing.
8 Screw together the housing halfs.
06.01 ill.21
ATTENTION: Tighten 7 hexagon screws (SW17)

(ill.22/pos.2) with a torque of 1
50 Nm +/-5.
Fasten 11 Allen head screws (SW5)
(ill.22/pos.1) with a torque of 10 Nm 2 2
+/-1.
06.01 ill.22
ATTENTION: Tighten 4 hexagon screws (SW17)

(ill.23/pos.3) with a torque of
50 Nm +/-5.
Then fasten 3 hexagon screws with a
torque of 23 Nm +/-2 (SW13) (ill. 23/
1
pos.2) and at last 13 Allen head screws 3 3
with a torque of 10 Nm +/-1(SW5)
(ill.23/pos.1). 2
06.01 ill.23
11 For engines with screwed frame seal (alu support)
Screw together frame sealing with housing halfs.

Tighten with a torque of 5,5 Nm +/-0,5.
06.01 ill.24

12 For engines with rubber frame seal (slot variant)
Press frame sealing by hand into housing halfs.
NOTE:
To avoid an extension of the rubber, only push frame
seal profil straight into groove of engine housing.
06.01 ill.25
13 Further assembly is done in reverse order of
disassembly.

01 ENGINE
01.06.02 Replace support ring rear
Preparation: Replace engine housing,

01.06.01
1 Loosen 7 hexagon screws.

Remove support ring.
2 Clean and degrease all sealing surfaces.
3 Wet sealing area of support ring with surface sealing

agent LOCTITE 509.
06.02 ill.1
4 Mount new support ring
ATTENTION: Replace radial shaft sealing ring.

(VR00107/0)
5 Tighten flange screws of rear ring carrier with a

torque of 28 Nm +/-3.
NOTE: Secure flange screws of rear ring

carrier with thread protection
LOCTITE 243.

01.06.03 Replace rear radialshaft sealing ring
Preparation: Remove flywheel, refer 01.03

Remove radial shaft sealing ring
1 Mount special tool No. VR00107/0 to press in the rear

radial shaft sealing ring.
06.03 ill.1
2 Press radial shaft sealing into rear built-in ring carrier

by means of special tool No. VR00107/0.
Assembly engine in reverse order.
06.03 ill.2

01 ENGINE
01.06.04 Replace oil pump

(front ring carrier)
Preparation: dismantle engine housing, 01.06.01.

remove timing belt
remove vibration damper
1 Pull of timing belt sprocket by means of special tool

No. 2300636/0 (ill.1).
06.04 ill.1
2 Loosen 6 hexagon screws (SW13) (ill.2), remove oil

pump housing.
õ
06.04 ill.2
ATTENTION: Replace radial shaft sealing ring (ill.3/

pos.1) in oil pump housing. Mount oil 2
pump housing, and insert radial shaft
sealing ring with special tool No.
VR00118/0.
NOTE: Check sealing ring (ill.3/pos.2) on oil 1

pump housing for damage; exchange
if necessary. (wet new sealing ring
with surface sealing agent LOCTITE
5910)
Apply LOCTITE 509 to flange surface

to front main bearing block and oil 06.04 ill.3
pump (front ring carrier)
Secure the 6 hexagon screws (ill.2)

with thread protection LOCTITE 243
and tighten with a torque of
23 Nm +/-2.

01.06.05 Replace oil suction pipe
Preparation: Exchange engine housing,

01.06.01.
06.05 ill.1
1 Unscrew 2 screws (ill.2/pos.1) on main bearing block.
Remove plate (only possible at 4 cyl. engines) - (ill.2/
pos.2).
2
2 Pull of oil suction pipe. Check O-ring (ill.2/pos.3),

replace if necessary.
1
3
ATTENTION: During assembly of oil suction pipe,
take care that no bracings occur.
06.05 ill.2
Assembly is done in reverse order.
3 Grease O - ring during assembly.
4 Secure the screws with thread protection LOCTITE

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

01 ENGINE
01.08 INTERCOOLER
01.08.01 Remove intercooler
Preparation: remove air filter, 03.04.01
C1
08.01 ill.1
1 Unscrew hexagon screw (ill.2/pos.1) (SW10) of
clamp of oil dipstick tube, carefully turn away oil
dipstick tube.
2 Remove tandem cooler, refer to 05.01.06

or
remove triple cooler, refer to 05.01.08 C1
or
For M16 - 246 only: Remove additional
oil cooler, refer to 05.01.07
For 4. cyl. engines (item 3-8) 08.01 ill.2
3 Unscrew 3 hexagon nuts (ill.3/pos.1) of shift plate

and remove.
C1
C1
08.01 ill.3
4 Loosen plug connections of boost pressure sensor

(ill.4/pos.1), loosen accelerator potentiometer (ill.4/
pos.2).
1
5 Loosen hose clamp (ill.4/pos.3). Take off hose and 2
A
remove shift plate.
08.01 ill.4

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

and remove.
08.01 ill.5
7 Remove two supports-intercooler (ill.6/pos.1)
08.01 ill.6
8 Loosen hose clamps of hose connection
turbocharger - intercooler (ill.7/pos.1), and remove
hose.
1
A
For 6. cyl. engines (item 9-10)

08.01 ill.7
9 Unscrew setscrews (ill.8/pos.1) for pipe support of
raw water pipe.
10 Remove cover (ill.8/pos.2) to intercooler by loosening

5 hexaong screws (SW10).
C2
1
08.01 ill.8

01 ENGINE
11 For 4. cyl. engines

Unscrew hexagon screw (SW10) (ill.9/pos.1) of raw 1
A
water pipe clamp.
2
A
12 Open hose clamp (ill.9/pos.2) on intercooler.
08.01 ill.9
13 Open hose clamp on heat exchanger (ill.10/pos.1)
and remove raw water pipe.
C1
For 6 cyl. engines (item 14-19) 08.01 ill.10
14 Loosen hose clamp (ill.11/pos.1). Loosen 2 hexagon

screws (SW13) (ill.11/pos.2) and remove connecting
bend. C2 C1
08.01 ill.11
15 Pull of plug (ill.12/pos.1) for sensor of control rack. C3

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

remove.
Remove bracket with potentiometer. C1
C4
18 Loosen hollow screw of boost pressure hose (ill.12/
pos.4) on air collector and remove. C2
08.01 ill.12

19 Disconnect plug from control solenoid (ill.13/pos.1).
20 Remove mounts of wiring harness on the bottom of C1

air collector and turn away wiring harness.
21 Only for 4 cyl. engines with hydraulic system

08.01 ill.13
Loosen 2 hexagon sockets (ill.14/pos.1), remove
hydraulic tank and fix it laterally in such a way that no
oil can leak. 1
A
08.01 ill.14
22 Unscrew hexagon sockets (SW6) from intercooler
and remove.
08.01 ill.15

01 ENGINE
01.08.02 Assembly of intercooler
Preparation: check intercooler
1 Clean sealing surfaces on motorblock (ill.1).
08.02 ill.1
Fix 2 seals (ill.2/pos.1) with grease Staburax NB04
on marked surfaces of monoblock.
C1
08.02 ill.2
3 Clean sealing surfaces on intercooler (ill.3).

Apply a slight film of LOCTITE 5900 to the sealing
surfaces (ill.3) of intercooler.
08.02 ill.3
5 Fix intercooler on engine block by means of 2 hexagon
sockets. For 4 cyl. engines, screw in remaining 6
hexagon sockets (SW8), and for 6 cyl. engines
remaining 10 hexagon sockets, and tighten with a
6 Further assembly is done in reverse order of

disassembly.
08.02 ill.4

01.08.03 Replace intercooler - element
Preparation: remove air filter, refer to 03.04.01

drain raw water circuit, refer to 05.00.07
remove intercooler, refer to 01.08.01
C7
C8
C9
C4
C1
C2
C3
C6
C
10
08.03 ill.1
C5
1 For engines with hydraulic systems, loosen upper screw; for all other engines, loosen 3 screws (ill.1/
pos.1) from intercooler cover in front and 3 screws (ill.1/pos.2) from intercooler cover at the back from
intercooler. Remove intercooler cover in front (ill.1/pos.4) and at the back (ill.1/pos.3).
2 Loosen the intercooler element by slightly knocking with a plastic hammer on the front end of the
element, and remove it. Dispose the O-ring of the element as well as the O-rings in the intercooler
covers.
3 Clean all sealing surfaces on intercooler, intercooler-element and intermediate flange.
4 Grease O-ring (ill.1/pos.5) with Molykote BR 2 PLUS and shift it up to the flange of the intercooler
element (ill.1/pos.10). Insert intercooler element into intercooler. Grease O-ring (ill.1/pos.6) with
Molykote BR 2 PLUS, insert it into intercooler cover (ill.1/pos.3), fix on intercooler and loosely mount
on intercooler with 3 screws (ill.1/pos.2).
5 Push O-ring greased with Molykote BR 2 PLUS (ill.1/pos.7), intermediate flange (ill.1/pos.8) and O-
ring greased with Molykote BR 2 PLUS (ill.1/pos.9) onto exposed end of intercooler element. Mount
intercooler cover in front (ill.1/pos.4) with upper screw (for all engines with hydraulic system) and all
other engines onto intercooler with 3 screws (ill.1/pos.1)
6 Tighten screws (ill.1/pos.2) with standard torque of 23 Nm +/-2.

NOTE: For engines with hydraulic system, tighten the screw (ill.1/pos.1) together with the two
screws for fixation of the hydraulic tank, with a torque of 23 Nm +/-2.
7 Remaining assembly is done in reverse order.

01 ENGINE

01.09 AUXILIARY DRIVE, IN FRONT (PTO)

2
1 Disconnect battery cables.
2 Remove protective cover.

remove drive shaft.
1
remove flange ring. 09.01 ill.1

remove elastic shaft with adapter plate. 1
6 Loosen 3 hexagon screws (SW13) and 3 hexagon
nuts (SW13) (ill.2/pos.2).
Remove adapter plate from elastic shaft.

2
09.01 ill.2

01 ENGINE
01.13 ENGINE OIL COOLER

01.13.01 Replace engine oil cooler
Preparation: Empty closed cooling circuit,

05.00.02
Remove tandem cooler
05.01.06
1 Loosen hose clamp (ill.1/pos.1) on oil cooler.
C1
13.01 ill.1
6 Loosen fixing nut (ill.2) of oil line (SW22).
13.01 ill.2
7 Loosen 4 allen head screws (SW6), remove cooler.
13.01 ill.3

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

remove O-Ring.
Assembly oil cooler

13.01 ill.4
Replace O-ring on adaptor main oil duct and slightly
grease with Staburax NB U4 before assembly. When
putting on the engine oil cooler, immediately fix the
water intake of the oil cooler on the hose albow of the
water pump . Take care that the engine oil cooler is
led parallel to the assembly surface (O-ring may be
damaged in main oil duct ill.6/pos.1). Replace O-
rings of oil hoses and grease with Staburax NB04.
Filling refer to 05.00.08

Filling - closed cooling system.
1
NOTE: Cover the three contact surfaces with

surface sealing agent LOCTITE 5900 13.01 ill.5
Tighten 4 allen head screws with a
torque of 23 Nm +/- 2.
Secure union nuts of oil hoses with
LOCTITE 243 and tighten with a torque
of 20 Nm +/-2.
Further assembly is done in reverse order of

disassembly.

01 ENGINE
01.13.02 Repair oil cooler

1
Preparation: remove oil cooler, 01.13.01
3
2
Disassembly:
1 Unscrew two slotted round nuts (ill.1/pos.1) by

means of special tool 2300709/1.
2 Unscrew hexagon sockets (ill. 1/pos.2) (SW5), se-

parate housing halfs, remove cooler element. 3
Assembly:
13.02 ill.1
NOTE: Prior to assembly, clean all sealing
surfaces. Slightly grease the O-rings
with Staburax NB04.
1 Cover sealing surfaces of the two housing halfs with

surface sealing agent LOCTITE 5900, special tool
No. 2300717/0.
2 Put together cooler insert and housing halfs with

three new O-rings (ill.1/pos.3).
3 Loosely screw in hexagon sockets. (SW5)

(ill.1/pos.2).
4 Screw in the two slotted round nuts with thread

protection LOCTITE 243 and tighten with a torque of
55 Nm +/-3.
5 Tighten hexagon sockets with a torque of

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

01.13.03 Change motor oil
1 Bring engine to operating temperature and stop

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

because of possible contamination.
4 Suck off motor oil on oil dipstick tube by means of 13.03 ill.1
suction pump No. 0172473/0 (ill.2/pos.2), and pump
it into a suitable receptacle. 1
NOTE: Pay attention to heat- (approx. 120°C)

and oil resistance of receptacle for the
used motor oil.
Dispose the oil properly. 2
5 Remove oil filler cap (ill.2/pos.1).
6 Fill in STEYR turbo diesel engine oil SAE 10W-40

(No. Z010058/0) (ill.3) or equivalent motor oil with
characteristics ACEA B4 - 02 or API code CF. 13.03 ill.2
ATTENTION: Oil filling must not exceed the
maximum marker. Overfilling results
in high operating temperatures,
foaming (air in oil), loss in efficiency
and a reduced engine life.
As the quantity for an oil change, refer to

Specifications Motor Oil GENERAL B 2
As the quantity for first filling (e.g. after engine

repair), refer to Specifications Motor Oil GENERAL
B2
7 Put on oil filler cap and lock.
ATTENTION: Remove possible oil contaminations 13.03 ill.3

from oil filler cap and environment.
ATTENTION: Do not forget oil check after test run.

01 ENGINE
01.13.04 Change oil filter

Waiting time 30 min. after having stopped the engine.
NOTE: First suck off the motor oil. This

reduces the waiting time.

Position (special tool No. VR 00132/0) oil collecting 13.04 ill.1
pan below oil filter (ill.2).
3 Loosen the oil filter with oil filter wrench

No. 2300713/1 and unscrew by hand. Dispose the oil
filter acc. EPA-regulation.
4 Clean sealing surface of oil filter head.
5 Oil the seal of new oil filter and screw it onto oil filter
head until the seal easily rests against. Tighten the oil
filter with a 3/4 turn.
13.04 ill.2
ATTENTION: Remove possible oil contaminations
from filter head and environment.
Do not forget to check engine oil level!
13.04 ill.3

01.14 EXHAUST MANIFOLD, SEALS, HEAT EXCHANGER
Refer to 05.01.02 Exhaust manifold, heat exchanger

01 ENGINE

ToC SERVICE MANUAL MARINE ENGINES 02 COUPLING
02 COUPLING
Table of Contents
Page
02.01 Replace torsion coupling ...................................................................... 2

02.01.01 For 6 cyl. engines ...................................................................................... 2
02.01.02 For 4 cyl. engines ...................................................................................... 4
02.01.03 Installation ................................................................................................. 6
Z001019/0_6_July 2008 Page COUPLING - 1

02 COUPLING
02.01 REPLACE TORSION COUPLING
Preparatory work: disassemble flywheel housing,

refer to 01.03.01.
02. 01. 01 Remove coupling for 6 cyl. engines
Remove coupling for gearbox, jet drive, VOLVO

stern drive apllication:
Variant 1:
Loosen 9 screws. Remove coupling. (Old version -
replaced by variant 2)
01.01 ill.1
Variant 2:
Loosen 6 screws. Remove coupling. (Current version -
replaced variant 1)
01.01 ill.2
Variant 3:
Loosen 9 hexagon screws. Remove flywheel adaptor
and coupling.
01.01 ill.3
Page COUPLING - 2 Z001019/0_6_July 2008

Remove coupling for

OMC/ VOLVO SX - stern drive apllication:
Loosen 6 screws, remove washers. Remove coupling.
01.01 ill.4
Remove coupling for
MERCURY - stern drive apllication:
(Old version -
Variant 1:
Loosen 3 screws. Remove coupling.
Loosen 9 screws. Remove flywheel adaptor,

if necessary.
01.01 ill.5
Variant 2:
Loosen 6 screws. Remove coupling. (Current version -
replaced variant 1)
if necessary.
Variant 3: 01.01 ill.6


if necessary.
01.01 ill.7

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

(Old version -
Remove coupling for gearbox, jet drive, VOLVO
stern drive apllication:
Variant 1:

(Current version -
replaced variant 1)
Loosen 9 hexagon screws. Remove coupling.
Remove coupling for

OMC/ VOLVO SX - stern drive apllication:
01.02 ill.2
Loosen 6 screws, remove washers. Remove coupling.
01.02 ill.3

Remove coupling for (Old version -

MERCURY - stern drive apllication: replaced by variant 2)
Variant 1:

(Current version -
Loosen 9 screws. Remove flywheel adaptor, replaced variant 1)
if necessary.
01.02 ill.5

02 COUPLING
02.01.03 Installation
Description Nm
Screw Coupling M8 x 1,25 - 8.8 23
Screw Coupling M8 x 1,25 - 10.9 32
Screw Coupling M10 x 1,5 45
Use locking compound LOCTITE 243 on threads.

SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM
03 FUEL SYSTEM
Table of Contents
Page
03.00 Fuel system / Functional description .................................................... 2
03.02 Fuel pump, unit injector, lines ............................................................... 4

03.02.01 Replace fuel pump ................................................................................. 4
03.02.02 Disassembly and assembly of unit injector ............................................... 7
03.02.03 Fix control rack......................................................................................... 14
03.02.04 Adjust control link (injection quantity)....................................................... 15
03.02.05 Loosen fixing of control rod ..................................................................... 16
03.02.06 Adjust start of injection............................................................................. 17
03.02.07 Exchange check valve for fuel pre-pressure to unit injector ................... 20
03.04 Air filter .................................................................................................. 21

03.04.01 Change air filter ....................................................................................... 21
03.05 Turbocharger ......................................................................................... 22

03.05.01 Replace turbocharger ............................................................................. 22
03.05.02 Check bearing clearance......................................................................... 25
03.08 Control solenoid.................................................................................... 26

03.08.01 Remove control solenoid......................................................................... 26
03.08.02 Install control solenoid.............................................................................. 28
03.08.03 Replace sensor, indication of control rack position.................................. 29
03.09 Change fuel filter .................................................................................. 30
03.11 Replace glow plug ................................................................................ 31
03.12 Measurement of Compression Pressure.............................................. 32
03.14 Fuel system check.................................................................................. 34

03.14.01 Manual injection test methode.................................................................. 34
03.14.02 Disengagement methode of injection........................................................ 36
03.14.03 Air bubble formation in fuel system........................................................... 37
Z001019/0_7_July 2012 Page FUEL SYSTEM - 1

03 FUEL SYSTEM
14
Page FUEL SYSTEM - 2

03.00 fuel system
6
13 5
8 3
12 2
Saugventil 9 4
1 Anti-siphon valve
Absperrhahn 1 Kipphebel
2 Fuel stop cock Rocker arm 9
10 15
11
Kraftstoff Filter Anlenkhebel
3 Fuel filter Adjustment lever 10
Kraftstoffpumpe 7 Regelstange
4 Fuel pump Common rack 11
Rückschlagventil Aktuator
5 Check valve Control solenoid 12
Kraftstoffzufuhr PD Druckhalteventil
6 Fuel supply UI Fuel check valve 13
Pumpedüse Kraftstoffkühler
7 Unit Injector Fuel cooler 14
Regelstangensensor Kraftstoffrücklauf
8 Rack position sensor Fuel return line 15
SERVICE MANUAL MARINE ENGINES
Z001019/0_7_July 2012
Functional Description
When the ignition switch is turned, an electric fuel pump 1 is put into operation and sucks fuel from
the fuel tank 2. This fuel is led via fuel filter 3 to the fuel pump. From the fuel pump, fuel is pumped
to the engine block 4 and the unit injectors 5. Excess fuel not injected by the unit injectors is led via
fuel cooler 6 back to the fuel tank.
The operating pressure is controlled by pressure valve 7 (1,8 - 2,5 bar at idle).
8 anti-siphon valve; 9 baffles (depending on tank size)
For fuel requirements, refer to chapter GENERAL

03.00 ill. 1
Specification for fuel pipes
Minimum inside diameter: 8 mm

Recommended material: stainless steel or copper
NOTE: Min. inside diameter for hosepipes or PA-pipes is 10 mm.
Rate of flow: > 240l/h +/-7 (in case of continuously operating pump)
If additional filters are installed, the requirements of
higher flow rates must to be considered. (filter dimension)
NOTE: In case of pipe connections, pay special attention to the

tightness of the suction pipe (all fittings and line before fuel pump)!
Types of pipe connections
03.00 ill. 2
03 FUEL SYSTEM SERVICE MANUAL MARINE ENGINES
03.02 FUEL PUMP, UNIT INJECTOR,

LINES
03.02.01 Replace fuel pump
Fuel pump operation is controlled by EMS.

Disassembly
02.01 ill.3
1 Ventilate drain fuel system.For this purpose, open
fuel line between fuel filter and fuel pump (ill.4/pos.1)
and let pump run for approx. 6 x 10 sec. Make sure
1
that air is sucked into the line.
ATTENTION: Close fuel cock on tank, if tank is higher.
2 ATTENTION: Prior to disassembly, disconnect

battery cables from battery, to avoid
damages to the electronic system.
02.01 ill.4
3 Disconnect positive cable and negative cable (ill.6)

by unscrewing hexagon nuts (SW7/8) with washer
from terminals of fuel pump.
2
4 Unscrew hollow screw (ill.6/pos.1) of fuel feed line.
Dispose Cu-sealing rings. + -
5 Unscrew hollow screw (ill.6/pos.2) of fuel line. Dispose
Cu-sealing rings.
ATTENTION: Hold up with second wrench on he-

xagon of pump housing, to avoid a a
damage to the E-pump.
1
02.01 ill.6
Page FUEL SYSTEM - 4 Z001019/0_7_July 2012

6 For 4 cyl. engines only
Unscrew two hexagon screws of filter plate.

Remove filter plate and holding strap.
Remove fuel pump.
02.01 ill.7
For 6 cyl. engines only (item 7-8)
7 Remove two hexagon screws (SW10) for fixing fuel

pump on filter plate (ill.8/pos.1), as well as ground
wire. 1
ATTENTION: Mark position of fuel pump on pump

support.
8 Remove pump bracket.
ATTENTION: Measure height for assembly of pump 02.01 ill.8

because of fitting position of fuel lines.

Assembly 2
For 4 cyl. engines only (item 1-3) + -
1 Place new fuel pump.
2 Mount filter bracket with holding strap by means of

2 hexagon screws.
3 Attach fuel line between filter and pump (ill.9/pos.1)

as well as pump and block (ill.9/pos.2). Tighten hollow
screws with a torque of 30 Nm +/-3. 1
02.01 ill.9
For 6. cyl. engines only (item 4-7)
4 Mount bracket in correct position onto new fuel pump.

Tighten screws of bracket.
5 Mount pump and ground wire on filter plate and fix with
two hexagon screws (ill.10/pos.1). Tighten screws
with a standard torque of 10 Nm +/-1 .
Torque wrench No. 2300704/0.
Fix ground cable together with bracket.
6 Mount adaptor with Cu-sealing rings at top face of

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

pump and block. Tighten hollow screws with a torque
of 30 Nm +/-3.
1
ATTENTION: Hold up with second wrench on he-
xagon of pump housing, to avoid a
damage to the E-pump.
Always use new Cu-sealing rings.
8 Connect two cables to negative terminal (-) and to

positive terminal (+). Cover the two terminals with
neoprene lacquer sealing No. P/N Z909570/0.
02.01 ill.10
9 Connect battery cables.
10 Connect fuel lines and operate electric fuel pump

3 times for 10 sec., to bleed fuel system.
11 Check fuel system for leakage.ò

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

03.02.02 Disassembly and assembly of

unit injector
Preparation: Remove camshaft housing cover.

Clean sealing surface of rubber seal
and check for hardening and damage.
Replace seal, if required.
02.02 ill.1
1 Turn crankshaft until injector cam is at base circle as

well intake and exhaust valve are open, in order to
permit a lateral shifting of rocker arm.
02.02 ill.2
02.02 ill.3
2 Before loosening flange nuts of unit injectors, ven- 1

tilate fuel system. For this purpose, open screw of
banjo fitting just enaugh to let air through seal rings
between fuel filter and fuel pump (ill.4/pos.1), and let
pump run approx. 6 times for 10 sec.
Make sure that air is sucked.
ATTENTION: Close fuel cock on tank, if tank is higher

than fuel supply on filter head.
02.02 ill.4

3 Remove nuts on unit injector flange (2 hexagon nuts

SW 13).
02.02 ill.5
4 Loosen left-handed hexagon socket securing the
control link on the control rack by using a 4 mm
hexagon socket wrench. Turn control link against
bulk head. (1 hexagon socket SW 4 - ”LEFT-HAND
THREAD” per unit injector).
02.02 ill.6
5 Loosen adjusting nut with 17 mm socket wrench
(hexagon nut SW 17 and screwdriver). Turn adjusting
screw to such an extent that the slide cup is loosely
attached to the spring plate. Do not remove.
02.02 ill.7
6 Insert screwdriver with small blade into recess of

retainer ring (half-moon ring) for rocker arm lock,
push retainer ring upwards and remove.
For disassembly of unit injector, always remove rocker

arm retaining ring at timing belt side.
02.02 ill.8


7 Move the rocker arm towards timing belt side of engine
and remove the tappet.
NOTE: Adjusting screw and slide cup match

exactly and thus have to be removed
kept matched.
02.02 ill.9
8 Check position of control link(s) against bulkhead
as illustrated.
02.02 ill.10
9 Insert the unit injector lever SMO No. VR00126/0
below the camshaft and push upwards against the
body of unit injector. The unit injector is thus lifted out
from the engine block and may be removed manually.
NOTE: For disassembly of the unit injector

from cylinder No. 1, the control rack
is to be moved forward.
02.02 ill.11
10 Remove unit injector with mounting flange.
02.02 ill.12

11 Remove copper seal washer from bottom side of

copper insert by means of hook- and lifting tool (No.
VR 00116/0).
NOTE: Avoid scratches on the sealing surface

of the copper insert.
02.02 ill.13
Assembly
1 In order to secure an appropriate tight fit, recheck

tighten stud bolt with a torque of 21 Nm +/- 2
02.02 ill.14
2 Drain possible fuel residues by means of suction de-

vice 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 cham-

ber may cause severe damage to the
engine.
02.02 ill.15
3 Check copper insert for possibly remaining seal

washers; remove and dispose, if necessary.
NOTE: Always use new copper seal washers!

(ill.16/pos.1 )

02.02 ill.16

4 Clean conical part of copper insert with cleaning

mandrel No. 2300565/0. For this purpose,, turn
cleaning mandrel several times in both directions
and then clean copper insert with cleaning tissue.
02.02 ill.17
5 ATTENTION: Insert new special copper seal washer
(ill.19/pos.2), from seal kit Z002031/0,
with a screwdriver into copper insert.
Make sure the copper seal washer is
plane.

02.02 ill.18
6 Install new O-rings (ill. 19/pos.1), from seal kit
Z002031/0, and cover O-rings with a thin coat of
clean motor oil.
02.02 ill.19
7 Insert unit injector into bore and align unit injector
recess to dowel pin (ill. 20/pos.1) for positioning.
Avoid any contact with control link.

ATTENTION:
Risk of damage to control rack.
02.02 ill.20

8 Push unit injector firmly downwards in order to position

it correctly with the O-rings.
02.02 ill.21
9 Lubricate slide cup with motor oil, put it onto adju-
stment screw, as shown, and shift it together with
rocker arm onto unit injector.
02.02 ill.22
10 Install retainer ring to secure the rocker arm.
02.02 ill.23
11 Screw on flange nuts (hexagon nuts SW 13) and

tighten evenly. Absolutely tighten nuts with a torque
of 18 /-2 Nm.
ATTENTION: Pay attention to horizontal installation

of mounting flange.
02.02 ill.24

12 Fix control rack.
13 Attach control link to control rack and adjust.

Refer to 03.02.04, Adjusting Control Link.
14 Adjust injection start. Refer to 03.02.06, Injection

Start unit injector.
15 Connect fuel pipes and operate electric fuel pump 3

times for 10 seconds to vent fuel system.

03.02.03 Fix control rack

refer to 01.00.02

1

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

of camshaft housing, as shown.
02.03 ill.1
2 Position bore (diameter 4 mm) in control rack(ill.2/

pos.1) over reference bore (ill.2/pos.2) in the bulkhead
wall.
2
02.03 ill.2
3 Pull control rack manually to the front, against spring

resistance, and hold. Insert setpin, as shown, and
fasten sturdily.
02.03 ill.3
3 2 1
02.03 ill.4

03.02.04 Adjust Control Link

(injection quantity)
Prior to adjustment, unit injector must be tighte-

ned properly, and control rack must be fixed in
position with set pin.
NOTE: Readjust all control links even if only

one link has been opened.
STARTING POSITION: 02.04 ill.1
Loosen left-handed setscrew of control link. Turn

control link against bulkhead on camshaft housing.
02.04 ill.2
1 Carefully position end of control link on front side of
unit injector control rack (possibly use screwdriver).
2
Turn control link against unit injector control gear until
control gear completely pushes against upper gauged
stop and hold position with screwdriver. Hold in this
position and tighten left-handed setscrew of control
link with a torque of 7 Nm +/-0,5. Repeat steps 1 and
2 for the rest of unit injector control racks.

02.04 ill.3
3 Calibrate rack position, refer to 06.10.03
4 Loosen fixing of control rack, refer to 03.02.05
02.04 ill.4

03.02.05 Loosen fixing of control rod
1 Unscrew setpin (ill.3/pos.2) from bulkhead wall with

removing setpin and hold control rack. Reinstall setpin
in rear camshaft housing bore.(ill.3/pos.1).
02.05 ill.1
2 Tighten setpin with a torque of 7 Nm.
02.05 ill.2
3 Check axial flexibility of control rack. Control rack is

to be moved easily and should automatically return
to reverse position due to spring load.
2 1
02.05 ill.3

03.02.06 Adjust start of injection

NOTE: The adjustment of start of injection is
necessary:
- if unit injector was removed
- periodically according to
maintenance (chart)
- if set value has changed (see chart
Set Values Unit Injector Stroke).
02.06 ill.1
Adjustment of injection start is to be
done prior to adjustment of engine
control.
Special tool.: 2306031/4 dial gauge rail 4 cyl.

bossed seal surface
plane seal surface
2300641/1 probe pin
1 Unit injector must be installed properly and fastened.

Control rack and unit injector control gear must
be free to move. 02.06 ill.2

2 Put dial gauge rail with bracket, No. 2306031/. (see
list special tool), onto stud bolt at intercooler side of
camshaft housing and fasten with nuts.
3 Turn camshaft until bearing rollers of rocker arm for

unit injector being adjusted is on the base circle of the
cam. Unit injector spring should be in most relaxed
position.
02.06 ill.3
4 Mount dial gauge No. 2300899/0 with pointer
No. 2300641/1 into dial gauge rail.
00.
00
5 Put pointer onto unit injector plunger guide.

02.06 ill.4

7 Insert unit injector extracting lever No. VR 00126/0 1

(ill.5/pos.1) in recess of rocker arm between rocker
arm body and roller, as shown, and fully press down
spring of unit injector. Set display to zero.
NOTE: Slowly release unit injector spring.

Read total indicating travel (ill.5/pos.2) 2
on dial gauge.
02.06 ill.5
8 Turn adjusting screw (ill.6/pos.1) with screwdriver
and set to the value as listed in below table. Hold
1
adjusting screw in this position and tighten hexagon
nut (ill.6/pos.2) by means of torque wrench No.
2300743/0 and tee-handled socket wrench (SW17)
02.06 ill.6
Engine setting values for engines with a build date before 2007 (<48226999/<68226999)
TYPE Unit Injector Stroke Adjustment Engine Timing Valve Clerance
New Copper Ring / Control Value Inlet &Outlet
M094K32 2176555/5 8,27 ±0,02

8,32 ±0,02 3,20 ±0,05
0,25/0,25
M0114K33 2176555/5 8,27 ±0,02

8,32 ±0,02 3,20 ±0,05
0,25/0,25
M0144M38 2176555/5 8,27 ±0,02

8,32 ±0,02 3,20 ±0,05
0,25/0,25
M0144V38 2176555/5 8,27 ±0,02

8,32 ±0,02 3,20 ±0,05
0,25/0,25
M0164M40 2176557/0 8,27 ±0,02

8,32 ±0,02 3,20 ±0,05
0,25/0,25
MO174V40 2176557/0 8,07 ±0,02

8,12 ±0,02 3,20 ±0,05
0,25/0,25
MO126K28 2176555/5 8,27 ±0,02

8,32 ±0,02 3,20 ±0,05
0,25/0,25
MO166K28 2176555/5 8,27 ±0,02

8,32 ±0,02 3,20 ±0,05
0,25/0,25
MO236K43 2176555/5 8,27 ±0,02

8,32 ±0,02 3,20 ±0,05
0,25/0,25
MO246M41 2176557/0 8,27 ±0,02

8,32 ±0,02 3,20 ±0,05
0,25/0,25
MO256H45 2176557/0 8,27 ±0,02

8,32 ±0,02 3,20 ±0,05
0,25/0,25
MO256K43 2176557/0 8,27 ±0,02

8,32 ±0,02 3,20 ±0,05
0,25/0,25
±0,05
MO266K43 2176557/0 8,07 ±0,02 8,12 ±0,02 3,20 0,25/0,25

Engine setting values for engines with a build date from 2007 (>48227001/>68227001)
Type Unit Injector S

troke Adjustment Engine Timing Valve Clerance
New Copper Ring / Control Value Inlet &Outlet
±0,02 ±0,02 ±0,02

MO54NA33 2176553-1 8,07 8,12 3,20 0,25 / 0,25
±0,02 ±0,02 ±0,02
MO84K32 2176555-5 8,47 8,52 3,20 0,25 / 0,25
±0,02 ±0,02 ±0,02
MO94K33 2176555-5 8,47 8,52 3,20 0,25 / 0,25
±0,02 ±0,02 ±0,02
MO114K33 2176557-0 8,47 8,52 3,20 0,25 / 0,25
±0,02 ±0,02 ±0,02
MO144V38 2176557-0 8,27 8,32 3,20 0,25 / 0,25
±0,02 ±0,02 ±0,02
MO144M38 2176557-0 8,47 8,52 3,20 0,25 / 0,25
±0,02 ±0,02 ±0,02
MO164M40 2176557-0 8,37 8,42 3,20 0,25 / 0,25
±0,02 ±0,02 ±0,02
MO174V40 2176552-1 8,77 8,82 3,20 0,25 / 0,25
±0,02 ±0,02 ±0,02
MO126K25 2176552-1 9,29 9,34 3,20 0,25 / 0,25
±0,02 ±0,02 ±0,02
MO156K25 2176552-1 9,15 9,20 3,20 0,25 / 0,25
±0,02 ±0,02 ±0,02
MO196K35 2176555-5 8,47 8,52 3,20 0,25 / 0,25
±0,02 ±0,02 ±0,02
MO236K42 2176557-0 8,37 8,42 3,20 0,25 / 0,25
±0,02 ±0,02 ±0,02
MO256K43 2176557-0 8,27 8,32 3,20 0,25 / 0,25
±0,02 ±0,02 ±0,02
MO256H45 2176557-0 8,27 8,32 3,20 0,25 / 0,25
±0,02 ±0,02 ±0,02
MO286H43 2176552-1 8,70 8,75 3,20 0,25 / 0,25
±0,02 ±0,02 ±0,02
MO306H43WJ 2176552-1 8,55 8,60 3,20 0,25 / 0,25
9 Recheck stroke adjustment, recheck zero value and

total stroke adjustment as described in steps 7 and
8.

ATTENTION: In case of deviation, repeat setting
process.

03.02.07 Exchange check valve for fuel pre- pressure to unit injector
1. Unscrew valve SW 19 mm (ill.1/pos.1), remove 2

Cu-sealing rings.
NOTE: Use new Cu-sealing rings for assem-

bly. Tighten with a torque of 40 Nm+/-4.
1
ATTENTION: On account of importance of this
valve (proper function of fuel system),
only use genuine STEYR spare part
for possible exchange.
02.07 ill.1

03.04 CHANGE AIR FILTER
03.04.01 Change air filter
Till engine serial no. 48219069 ( 4-cyl.)

and 68219174 ( 6-cyl.)
1 Open retaining clip.
04.01 ill.1
2 Remove air filter and cover.
3 Put new air filter together with cover onto filter head
and fix with retaining clip.
From engine serial no. 48219070 ( 4-cyl.)

and 68219175 ( 6-cyl.)
04.01 ill.2
1 Remove hose clamp and air filter.
2 Mount new air filter together with hose clamp and

tighten clamp solid.
04.01 ill.3

03.05 TurboCHARGER
03.05.01 Replace turbocharger
1 Remove air filter, refer to 03.04.01
2 Remove high-riser, refer to 04.01

Drain coolant from closed cooling circuit,
refer to 05.00.07
05.01 ill.1
4 Loosen fastenings of heat protection. Remove heat

1 2
protection (ill.2/pos.1). 3
5 Loosen hose clamp (ill.2/pos.2) and remove hose for
air charge pressure box.
6 Loosen screw (ill.2/pos.3) for raw-water pipe support

(SW10).
05.01 ill.2
7 Loosen hollow screw (ill.3/pos.1) of oil feed line on
turbocharger. 1
8 Remove plug of oil pressure switch (ill.3/pos.2).

motorblock. Dispose Cu-sealing rings.
2
05.01 ill.3
10 Loosen two hexagon screws (ill.4) of oil return line.
Dispose seal.
05.01 ill.4
Loosen 2 hexagon screws on flange of oil feed line.
05.01 ill.5

Loosen hose clamps of hose connection turbochar-
ger-intercooler (ill.6/pos.1) and remove hose.

05.01 ill.6
13 Loosen support screw (ill.7/pos.1) for raw-water pipe.
14 Remove covering (ill.7/pos.3) to intercooler by loo-

sening 5 hexagon screws (SW10) (ill.7/pos.2).
2 3
1
05.01 ill.7
15 Loosen hose clamp (ill.8/pos.1) connection compres-

sion housing.
C2 C1
16 Loosen 2 hexagon screws (ill.8/pos.2) and remove 3
connecting bend.
17 Loosen hollow screw (ill.8/pos.3) of cooling system

- vent pipe (SW14) . Remove pipe.
05.01 ill.8
18 Loosen hose clamp (ill.9/pos.1) of hose of oil sepa-

rator and remove hose.
19 Loosen 4 hexagon nuts (ill.10+11/pos.1) of turbochar- 05.01 ill.9

ger flange. Remove turbocharger and seal, dispose
seal. (if seal is used)
05.01 ill.10
Assembly:
ATTENTION: Check hose connection and hose

between turbocharger return pipe
and engine housing intake for crack
1
and damage. Replace, if necessary.
05.01 ill.11
For 4 cyl. engines only Clean sealing surface of flange turbo charger and exhaust manifold
and lubricate with grease Z012222/0.
For 6 cyl. engines only: Clean sealing surfaces of flange turbo charger and exhaust
manifold. Replace flange seal.
Further assembly is done in reverse order.
ATTENTION: Tigthen the two spring-clamps of hose turbocharger - intercooler with a torque of
3,5 Nm. Don´t strip!

1 Tighten 4 hexagon nuts of turbocharger flange with a torque of 25 Nm +/-2.
2 Tighten 2 screws for fixing the flange of oil return pipe with a torque of 10 Nm +/-1.
Tighten hollow screw with 25 Nm +/-3.
3 Tighten 4 hexagon nuts of turbocharger flange by means of torque wrench No. 2300743/0 and tree-
handled socket wrench No. 2300744/0 with a torque of 40 Nm +/-4.
4 Tighten 2 screws for fixing the oil return pipe flange with a torque of 23 Nm +/-2.
Tighten hollow screw with 40 Nm +/-4.
5 Tighten hollow screw of vent pipe (cooling circuit) with a torque of 20 Nm +/-2 . Maintain horizontal
position of banjo fitting while tightning hollow screw.
6 Fill closed cooling circuit, refer to 05.00.08
03.05.02 Check bearing clearance

measuring point
Measure end clearance:
1 Put test prod of dial gauge onto face of turbine wheel

hub.
2 Push cursor downwards and set dial gauge to "0".
3 Push cursor against dial gauge and note deflection

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

05.02 ill.1
Measure radial clearance:
location point
NOTE: Determination of radial clearance is
of dial gauge
only required turbine-sided.
prod
1 Put test prod of dial gauge onto center of retainer
cone of turbine wheel.
2 Pull turbine wheel hub upwards by means of spring

balance. Measuring strength 50 N.
3 Note deflection of pointer. measuring

strength
4 Repeat measurement, by turning cursor by 90°.
Permissible radial clearance: max. 0.42 mm +/-0,04

05.02 ill.2

03.08 CONTROL SOLENOID

03.08.01 Remove control solenoid
Prepartion: for 4 cyl. engines only

remove intercooler,
refer to 01.08.01.
1 Disconnect battery.

08.01 ill.1
2 Loosen plug connection (ill.2/pos.1) for control rack
potentiometer.
3 Remove plug from control solenoid (ill.2/pos.2). 1

2
For 6 cyl. engines only (item 4-11) 08.01 ill.2
4 Unscrew 3 hexagon screws (SW10) (ill.3/pos.1) of

upper timing belt covering.
08.01 ill.3
5 Unscrew 2 hexagon screws (SW10) (ill.4/pos.1) of
front control solenoid covering.
08.01 ill.4
6 Loosen 2 hexagon nuts (SW10) (ill.5/pos.1). Remove C3

boost pressure sensor.
7 Loosen plug (ill.5/pos.2) for potentiometer accele-

rator. C1
8 Loosen 3 hexagon nuts (SW10) (ill.5/pos.3). Remove
bracket with potentiometer accelerator.
C4
9 Remove plug (ill.5/pos.4) for sensor of control rod.
C2
10 Remove plug (ill.6/pos.1) from control solenoid. 08.01 ill.5
11 Loosen 4 hexagon screws (SW13) (ill.6/pos.2) on 1

control solenoid housing; Remove control solenoid
assembly. Remove seal and dispose.
For 4 cyl. engines only

08.01 ill.6
12 Loosen 4 hexagon screws (SW13) (ill.7) on control
solenoid housing, remove control solenoid assembly.
Remove seal and dispose.
08.01 ill.7

03.08.02 Install control solenoid
To install control solenoid assembly onto camshaft

housing, proceed as follows:
NOTE: Use new gasket for control solenoid if fitted.

O-ring can be re-used.
1 Remove camshaft housing cover.
2 Move control rack by hand (ill.1) to front position and

hold.
08.02 ill.1
3 Insert control rack lever in to the solenoid as shown.
(ill.2/pos.1)
4 Bring up control solenoid assembly parallel to sealing

surface of camshaft housing, put it onto the dowel 2
pin(s) (ill.3/pos.1) and hold.
5 Slowly release control rack and fasten control so- 1

lenoid housing by means of 4 screws.

Secure the 4 screws with LOCTITE 243 and tighten
08.02 ill.2

7 Cover the two lower screws with LOCTITE 243 and 1
slightly tighen.
8 Cover the two upper screws with LOCTITE 243. Bring

into position bracket with potentiometer accelerator
and fix with upper screws. Tighten the 4 screws with
a torque of 23 Nm+/-2.
9 Check whether the control rack can be moved over

a distance of approx. 18 mm.
08.02 ill.3
ATTENTION: Pin of control rack position sensor is
spring-loaded and might easily slip
off from the face of control rack lever,
during assembly. In such a case, the
control rack is blocked and thus pre-
vents resetting to zero delivery
===> ENGINE FAILURE.
NOTE: The rack position sensor is magnetism

sensitive. All external magnets must
be kept away as the may disturb the
sensor.

03.08.03 Replace sensor, indication of control rack position
Preparation:
remove shift plate, refer to 01.08.01, ill.3.

remove bracket of potentiometer
accelerator, refer to 03.08.01, ill. 5-6
1 Loosen 2 Allen head screws (ill.1/pos.1) (SW3).

Remove rack position sensor.
08.03 ill.1
Assembly
1 Insert new sensor in such a way that rod of poten- 1 2

tiometer (ill.2/pos.1) is positioned in front of solenoid
rod (ill.2/pos.2).
2 Secure 2 Allen head screws 3 mm with Loctite 243

and tighten with a torque of 5 Nm +/-0,5.
3 Check whether control rack can be moved over a

distance of approx. 18 mm.
08.03 ill.2
ATTENTION: Rod of rack rack position sensor
is spring-loaded and might easily
slip off from the face of solenoid
rod (ill.2/pos.2), during assembly.
In such a case the control rack is
blocked, and thus prevents resetting
to zero delivery
===> ENGINE FAILURE.
4 Remaining assembly is done in reverse oder.

sensor.

03.09 Change fuel filter

1
Water or other fuel contaminations may form
deposits which clog the fuel filter and may lead
to a disturbance. Therefore, change the fuel filter
every 300 operating hours and/or every 2 years
at least.
1 Ventilate fuel system. For this purpose, open fuel

pipe between fuel filter and fuel supply (from fuel
tank or water separator) on filter head (ill.1/pos.1),
and operate the pump approx 6 times each 10 sec.
= 6 times 10 sec. ignition ON. Make sure that air is 09.00 ill.1
sucked.
ATTENION: Close fuel cock on tank, if tank is higher

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

2300713/1. Remove filter and dispose. Take care
that original seal does not adhere to filter housing. If
so, remove seal and dispose.
3 Clean sealing surface on filter head (ill.3). 09.00 ill.2
4 Slightly oil seal of new fuel filter with clean motor oil
(ill.4).
5 Screw on new fuel filter until seal slightly rests on

sealing surface of filter head. Then tighten filter by
hand with 3/4 turn.
6 Connect fuel pipe between fuel filter and fuel supply

or water separator on filter head (ill.1/pos.1) again.
7 Ventilate fuel system.

09.00 ill.3
NOTE: Fuel system is ventilated via E-fuel
pump.
Turn ignition ON 6 times each 10 sec.
8 Remove possibly spilled fuel residues. Start engine

and check fuel system for leakage.
09.00 ill.4

03.11 Replace GlOW Plug
Preparation: For 4 cyl. engines only

for glow plug of second to fourth cylinder, remove intercooler -
refer to 01.08.01
for glow plug of first cylinder, additionaly remove control solenoid - refer to
03.08.01

for glow plug of first cylinder, remove control solenoid - refer to 03.08.01
for glow plug of second to sixth cylinder, remove intercooler -
refer to 01.08.01
1 Remove glow plug.
2 Unscrew glow plug(s) with special tool

No.VR00146/0.
3 Screw in new glow plug(s) by means of special tool

No. VR00146/0 and tighten by means of special tool
No. 2300703/0 with a torque of 15 Nm +/-1.
11.00 ill.1
NOTE: Exactly keep torque of 15 Nm +/-1

when fixing glow plugs!
11.00 ill.2

03.12 MEASUREMENT OF COMPRESSION

PRESSURE
Preparation: remove glow plug, refer to 03.11
1 Screw special tool glow plug adaptor 230 0638/2

(ill.1) into cylinder to be checked (ill.2).
12.00 ill.1
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 Remove plug J1.

Connect special tool No. VR00145/0 instead of plug
J1.
5 Put into operation compression pressure meter ac-

cording to operating instructions.
6 Start engine by pressing the button for 5 to 10 sec. 12.00 ill.2

of special tool No. VR00145/0 until compression
pressure rises no more.
ATTENTION:
Start with special tool VR00145/0
only. Engine may just turn, but not
feed and inject fuel.
12.00 ill.3
Compression pressure
for all STEYR MARINE DIESEL ENGINES
NOM. VALUE LOWER BOUNDARY VALUE
21,0 +/- 1,0 bar 18,0 +/- 1,0 bar


03.14 FUEL SYSTEM CHECK

03.14.01 Manual injection test methode

refer to 01.00.02
1
1 Remove plug screw (ill.1/pos.1) with sealing ring.
14.01 ill.1
2 Mount special tool No. VR00148/0 (ill.2/pos.1) together

with sealing ring (ill.2/pos.2).
14.01 ill.2
3 Move control rack by means of special tool No.

VR00148/0 into idle injection position
(approx.5-6 mm) (ill.3) and remain in this position.
14.01 ill.3

4 Put unit injector withdrawing lever No. VR00126/0

onto rocker arm of individual unit injectors (ill. 4) and
move upper end of lever in direction of air intake
manifold. As a result, unit injector is pressed down
and injection process is simulated.
NOTE: When moving the unit injectors, a

creaky noise is to be heard during
the injection process and/or a solide
resistance is to be felt due to pro-
duced injection pressure (pressure
point) .
If no difference is detectable in the individual unit

injectors, continue with item 5.
5 Adjust control rack by means of special tool No.

VR00148/0 to partial load (approx. 10-12 mm in di-
rection full delivery) (ill.3) and remain in this position.
6 Repeat item 4.
14.01 ill.4
NOTE: Defective unit injectors which fail to produce a creaky noise in one or none of the two
checks and/or where no resistance (pressure point) can be felt are to be exchanged.
(Exchange unit injector, refer to 03.02.02).
ATTENTION: Absolutely remove special tool

No. VR 00148/0.
Use new sealing ring.
Manual check of unit injector without tool No. VR 00148/0
Fuel System Check:

1. Investigate condition of return fuel. There should be neither air bubbles nor discoloration (gray) in the fuel.
2. Check proper flow quantity (i.e. engine at idle - flow rate after engine block 180 to 240 l/hr; 47 to 63 gal.)
Injector Check:
To feel the injection activities, move the control rack (quantity delivery) in between its acceptable travel (5 to
14mm) while depressing the „plunger“ with the rocker arm. For safe and easier handling, use our special tool lever.
While moving the rocker arm (and/or the plunger up and down), try to get the control rack into idle delivery
position (approx. 4-5 mm). In this spot you will feel only a very slight/short pressure build up as the duration
of injection is very short (~ 5mm³/stroke).
Keep this position on the control rack (freeze there) and then move over with tool VR 00126/0 to the next unit
injector/rocker arm to repeat the plunge movement and feel the resistance during injection.
The test should give an equal pressure load/peak on each injector, while maintaining the same position on
the control rack.
If one injector fails to show any pressure or this pressure peak is found in a much higher position of the con-
trol rack, this is an indication for a possible deficiency on this injector.
ATTENTION: Before removing this unit injector from the engine, check for proper adjustment of the linking
lever and for correct fit/tightness and/or torque of the unit injector mounting nuts.

03.14.02 Disengagement methode of injection
NOTE: Disengagement methode of injection

2
is a simple and effective method to detect defective
1
unit injectors with regard to formation of bubbles in
both the fuel system and the engine cooling system
or lack of power it related to deficiencies in injection
equipment.

refer 01.00.02
Special tool: 4 cyl. engines VR00133/1

14.02 ill.1
6 cyl. engines with bossed seal surface
VR00133/0
6 cyl. engines with plane seal surface
VR00133/2
1 Mount special tool No. VR00133/.(see list special

tool) to disconnect injection.
2 Start the engine, let it run in idle and check if bubbles

form.
NOTE: If there are no bubbles at idle speed

of engine, continue with item 3.
3 Bring engine to operating temperature and then test

the boat under operating conditions and watch for
bubbles to form.
Keeping this operating condition, continue with item 4.
4 Loosen nut on cover (ill .1/pos.1), screw in, with

fast turns, screw (ill.1/pos.2) until knocking noise
disappears. Tighten nut (ill.1/pos.1) again. As a re-
sult, unit injector is pressed down to such an extent
that injector cam can no more touch the rocker arm,
thus preventing the injection of fuel. (respectively
eliminating combustion)
5 Test the boat with disengaged unit injector under

operating conditions and observe the returning fuel
if bubbles still appear.
6 Continue to check all other injectors (cylinders) in

order to detect the defective(s) unit injector(s).
NOTE: Bubble formation will change and/or

stop as soon as injection of defective
unit injector(s) is disengaged.
7 Replace defective unit injector(s).

(Replace unit injector, refer to 03.02.02)

03.14.03 Air bubble formation in fuel system 1 2

Preparation: Change fuel filter, if necessary
refer to 03.09
(item 1, ventilate fuel system)
Special tool:
Testing device for fuel return 2300719/1
1 Disconnect hose from fuel return line on fuel cooler

outlet to fuel tank. (ill.2/pos.1).
2 Connect hose (ill.1/pos.1) of testing device

2300719/1 to tandem cooler outlet. (ill.2/pos.1). 14.03 ill.1
3 Connect hose (ill.2/pos.2) of testing device

2300719/1 with return hose to fuel tank. (ill.2/pos.2). 3
4 Hold testing device, glass bulb upwards (ill.2/pos.3),
or fix it on the boat.
Procedure: 14.03 ill.2
Check 1: Ventilate fuel system by 6 times ignition ON. Observe the sight glass as to complete
ventilation of system (bubblefree fuel flow).
Result: If a bubblefree fuel flow cannot be achieved, search for the problem at the suction
side (from fuel tank to fuel pump).
Check: 1. Fuel in tank.

2. Tank suction pipe and fitting
3. ANTI-SIPHON VALVE (if installed) leckage.
4. Water separator leaky or contaminated.
5. Check all fuel lines connections and fittings in the feed line
(suction side) up to fuel pump intake.
After a bubblefree fuel flow can be achieved, continue with check 2.
Check2: 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
contamination , on one or several nozzle elements cause a problem.
Due to compression/combustion pressure, gases into the are forced fuel system
throug the unit nozzle(s).

Check: Defective unit injector(s) is/are to be detected definitely by means of "manual injection
test methode"
(manual injection test methode, refer to 03.14.01)
Manual: If during disengagement methode of injection of unit injectors a creaky noise is to

be heard and a solide resistance (pressure point) can be felt, check the tightening
torque of the unit injectors (03.02.02 - assembly item 11).
Then repeat check 3.
If a bubble formation appears during load operation, continue with check 3.
Check 3: Start the engine, bring it to operating temperature, test the boat under operating
conditions and observe the glass bulb.
Result: If it comes to bubble formation, search for the problem in the area of unit injectors.
Control: Defective unit injector(s) is/are to be detected definitely by means of "Disengagement

methode of injection"
(manual injection test methode, refer to 03.14.01)
If there is still bubble formation, continue with check 4.
Check 4: Test the engine in the operating state where bubble formation occurs, by disengage-
ment of injection per cylinder one after the other.
(Disengagement methode of injection, refer to 03.14.02).



ToC SERVICE MANUAL MARINE ENGINES 04 EXHAUST SYSTEM
04 EXHAUST SYSTEM
Table of Contents
Page
04.01 Hi-Riser ................................................................................................... 3

04.01.01 Replace Hi-Riser ....................................................................................... 3
04.01.02 Measurement of Exhaust Backpressure ................................................... 4
Z001019/0_6_July 2008 Page EXHAUST SYSTEM - 1

04 EXHAUST SYSTEM
Page EXHAUST SYSTEM - 2 Z001019/0_6_July 2008

ToC SERVICE MANUAL MARINE ENGINES 04 EXHAUST SYSTEM
04.01 HI-RISER
04.01.01 Replace hi-riser
Preparation: If necessary,
remove heat shield turbocharger.
Disassembly:
1 Disconnect plug (ill.2/pos.1) for exhaust temperature

01.00 ill.1
switch.
2 If bracket is used loosen hexagon screws (ill.2/pos.2)

of bracket. 3
3 Loosen hose clamp (ill.3/pos.1) connecting hose;
2
heat exchanger - hi-riser.
4 Loosen 2 hose clamp (ill.4/pos.2) from exhaust pipe

elbow.
1
5 Variant 1
Loosen hexagon screws (ill.2/pos.3) of hi-riser.
Remove hi-riser.
01.00 ill.2
6 Variant 2
Loosen profiled clamp (ill.4/pos.1) of
hi-riser.
Remove hi-riser.
Assembly:
01.00 ill.3
1 Prior to assembly, clean sealing surfaces of
turbocharger - high-riser and lubricate with
high-temperature grease.(SMO Z012222/0)
2 Replace seal (if used). Tighten screws (M8) with a

torque of 23 Nm. (Lubricate threads with high 1
temperature grease Z012222/0)
Tighten profile clamp hand-screwed.

2
01.00 ill.4
Z001019/0_6_July 2008 Page EXHAUST SYSTEM - 3
04 EXHAUST SYSTEM
04.01.02 Measurement of exhaust

backpressure 9 10 1 2
8
special tool No. VR00136/0 3
7 4
ill.1/pos.1 pressure gauge (0-1 bar) 6
ill.1/pos.3 intermediate sealing ring
5
ill.1/pos.4 pressure gauge connection
ill.1/pos.5 pressure hose
ill.1/pos.6 double union
ill.1/pos.7 sealing ring
ill.1/pos.9 screw-in adaptor
01.02 ill.1
1 Disconnect plug for exhaust temperature switch (ill.2/
pos.5).
2 Dismantle high-riser temperature sensor, connect

plug to sensor again, and fix it temporary on the 1
engine.
9 7 6
3 Mount double union (ill.1/pos.6) with sealing ring
(ill.1/pos.7) instead of hi-riser temperature sensor.
3 4
4 For 6 cyl. engines only (with FORD ECU)

5
Screw in double union (ill.1/6) with sealing ring (ill.1/
7) into screw-in adaptor (ill.1/9) and mount screw-in
adaptor instead of hi-riser temperature sensor. 01.02 ill.2
5 Mount seal ring (ill.1/pos.3) with pressure gauge

connection (ill.1/pos.4) onto pressure gauge (ill.1/
pos.1) Connect pressure gauge to one end of pressure
hose (ill.1/pos.5).
6 Connect the other end of pressure hose (ill.1/pos.5)

to double union (ill.1/pos.6).
MEASUREMENT: Drive the boat under operating conditions (rated output at rated speed) and read off pressure
on pressure gauge.
RESULT: With an exhaust pressure below 100 mbar at rated output of engine, the exhaust system
is dimentional correctly and represents the ideal status. (up to max. 200 mbar acceptable)
With an exhaust pressure exceeding 200 mbar at rated output of engine, tuning of exhaust
system is no more ideal. To avoid losses in efficiency, changes in the exhaust system should
be made (pipe diameter, pipe lengths, muffler etc.)
An exhaust pressure of 300 mbar at rated output of engine is no more acceptable.
ATTENTION: Changes in the exhaust system (pipe diameter, pipe lengths, muffler etc.) absolutely required.
Considerable influence on output, fuel consumption and life of engine.
7 Assembly is done in reverse order:
Page EXHAUST SYSTEM - 4 Z001019/0_6_July 2008

ToC SERVICE MANUAL MARINE ENGINES 05 COOLING SYSTEM
05 COOLING SYSTEM
Table of Contents
Page
05.00 Functional description cooling circuit ............................................... 2

05.00.01 Raw water circuit (external cooling circuit) ............................................. 2
05.00.02 Closed coolant from cooling circuit (internal engine cooling circuit) ....... 4
05.00.03 Error detection cooling system ............................................................... 6
05.00.04 Check points for problems in cooling system ......................................... 9
05.00.05 Component check raw water system ................................................... 10
05.00.06 Component check engine cooling system ................................................ 11
05.00.07 Drain the coolant system........................................................................ 13
05.00.08 Fill the cooling system ............................................................................. 15
05.01 Cooler, heat exchanger, expansion tank ............................................ 16

05.01.01 Coolant tank ........................................................................................... 16
05.01.02 Disassembly exhaust manifold - heat exchanger .................................. 17
05.01.03 Checks ................................................................................................... 21
05.01.04 Exchange heat exchanger element ........................................................ 23
05.01.05 Assembly of exhaust manifold ............................................................... 24
05.01.06 Exchange tandem cooler ........................................................................ 26
05.01.07 Exchange additional oil cooler (only type 246) ........................................ 26
05.01.08 Exchange triple cooler............................................................................. 27
05.03 Pipes, thermostat ................................................................................. 27

05.03.01 Coolant pipes and hoses ....................................................................... 27
05.03.02 Exchange thermostat ............................................................................. 28
05.03.03 Exchange sacrificial anodes ................................................................... 30
05.04 Coolant pump ........................................................................................ 31

05.04.01 Exchange coolant pump ........................................................................ 31
05.04.02 Install coolant pump ................................................................................ 32
05.06 Poly-V-Belt ............................................................................................. 33

05.06.01 Exchange Poly-V-belt .............................................................................. 33
05.07 V-belt ...................................................................................................... 34

05.07.01 Exchange V-belts .................................................................................... 34
05.07.02 Adjust V-belts .......................................................................................... 36
05.10 Raw water pump ................................................................................... 37

05.10.01 Exchange raw water pump ...................................................................... 37
05.12 Checks .................................................................................................. 38

05.12.01 Check closed engine cooling system for air ............................................ 38
Z001019/0_6_July 2008 Page COOLING SYSTEM - 1

ToC 05 COOLING SYSTEM SERVICE MANUAL MARINE ENGINES
05.00. FUNCTIONAL DESCRIPTION COOLING CIRCUIT
05.00.01 Raw water circuit (external cooling circuit)
Raw water is fed to the engine via a vane-type pump in the secondary circuit. The raw water pump
(ill.1/2) is a self-sucking pump and is driven for 4 cyl. engines via Poly-V-belts and for 6 cyl. engines
via V-belt. The impeller is arranged eccentrically.
At higher speeds, it acts as combinded centrifugal- and displacement pump. At slow speeds, the
impeller acts as displacement pump. This causes a pump effect of the impeller wings during operation
of the engine. At high engine speed, the resistance of water on its way through the pump is sufficient
to avoid a contact of the impeller wing with the inner side of housing. The wings are only bent inside
in direction of impeller center, thus acting as combined centrifugal- and displacement pump.
Raw water is fed to the raw water pump via raw water pick-up (ill.1/1) and/or via drive unit (Z-drive, jet-
drive) and/or raw water filter (ill.1/11) arranged between. From the raw water pump, water flows into
the combined fuel- (ill.1/3) and steering- and/or transmission oil cooler (ill.1/4) where the raw water
absorbs thermal energy from the fuel- and steering- and/or transmission oil system.
Then water flows through the tube stake of intercooler (ill. 1/5) where the raw water absorbs thermal
energy from air charge.
Through the connecting line above the rear part of the camshaft case the raw water enters the tube
stake of heat exchanger (ill.1/6) where the raw water still absorbs thermical energy from engine
coolant.
Then raw water flows through the high-riser (ill.1/7) where the raw water still absorbs thermal energy
from exhaust gas, and finally leaves, mixed with exhaust gas, the raw water circuit via exhaust pipe
(raw water outlet) (ill. 1/9) either through the drive or a muffler, and is blown in below water surface.
The splash water flap (ill.1/12) avoids a possible raw water entry with stopped engine.
The raw water circuit is equipped with 5 sacrificial anodes (ill.1/10) (for salt water made of zinc; for sea
water magnesium anodes are recommended).
Temperature of raw water, mixed with exhaust gas, is controlled by means of sensor (ill.1/8) on high-
riser and transmitted to the electronic management system. If during operation the limit of 60°C is
exceeded, the electronic management system will reduce the engine power to a perceptible extent of
up to 50%.
This disturbance will be indicated on the instrument panel by means of signal lamp for engine check
which blinks 2 times/sec. and an audible warner (2times/sec).
ATTENTION: To exclude consecutive damages, occured trouble should be analyzed and eliminated
as soon as possible.
Page COOLING SYSTEM - 2 Z001019/0_6_July 2008

SERVICE MANUAL MARINE ENGINES 05 COOLING SYSTEM
00.01 ill.1
1 Raw water intake

2 Impeller pump
3 Fuel cooler
4 Hydraulic oil- and transmission oil cooler
5 Tube stake - intercooler
6 Tube stake - heat exchanger
7 Hi-riser
8 Sensor exhaust gas temperature
9 Raw water outlet
10 Sacrificial anodes
11 Raw water filter
12 Splash water flap

05.00.02 Closed coolant from cooling circuit (internal engine cooling circuit)
In the closed (primary) cooling circuit of the engine, the coolant circulates by centrifugal pump
(circulating pump) mounted at the front of motorblock.
The belt pulley of the pump is driven from the back of the timing belt. The pump is maintenance-free.
The engine coolant in the closed circuit of the cooling system circulates as follows:
The circulating pump (ill.2/1) of the engine feeds the coolant through the oil cooler (ill.2/2) where
thermal energy is absorbed from motor oil.
Then the coolant flows through the water jacket (ill.2/3) into the motorblock. Coolant circulates around
the cylinders. Here, thermal energy of combustion is absorbed.
Then coolant reaches the exhaust manifold (ill.2/4), flows through the exhaust manifold in a separate
channel and absorbs thermal energy from exhaust gas.
For most of 6 cyl. marine engines (excluded 256H), coolant additionally flows through the exhaust
turbocharger (ill.2/5). Here, thermal energy is also absorbed from exhaust gas.
Then the coolant reaches the thermostat housing. By means of thermostat, depending on the engine's
operating temperature, the coolant is fed to the heat exchanger or directly to the engine coolant pump.
If the engine has not yet achieved the operating temperature of 80°C, the thermostat remains closed
and the coolant is fed via contact-channel directly to the intake side of coolant pump.
This circulating circuit (ill.2/A) is continued until the coolant in the thermostat housing (ill.2/6a) has
achieved the temperature (80°C).
As soon as the temperature of 80°C in the thermostat housing is achieved, the thermostat opens and
the coolant is partially (thermostat opens according to operating temperature) transmitted to the heat
exchanger (ill.2/B). Via the contact-channel the coolant partially arrives directly at the intake-side of
the coolant pump (ill.2/A).
Only after the coolant in the thermostat housing has achieved a temperature of 90-93°C, the thermostat
(ill.2/6b) is completely open. From this time, the whole coolant flows through the tube stake of heat
exchanger (ill.2/7) in the exhaust manifold housing. Here, the warmed up coolant releases thermal
energy to the raw water circuit, and the coolant is fed via engine water pipe to the centrifugal pump
again.
The heat exchanger is an integrated component of the aluminium exhaust manifold. This component
also includes the expansion tank (ill.2/9) with coolant reservoir, required for the pressure system.
Operating pressure is regulated via excess-pressure valve (opening pressure 0,9 bar) in the cooler
cap (ill.2/10).
Coolant temperature is measured by means of sensor (ill.2/11) on exhaust manifold next to drain cock
(ill.2/12) of coolant, and transmitted to the electronic management system. If during operation the limit
(107°C) is exceeded, the electronic management system will reduce the engine power to a perceptible
extent of up to 50%.
This disturbance is indicated on the instrument panel by an audible warner (2 times/sec.).
ATTENTION: To avoid consecutive damages, occured trouble should be analyzed and eliminated
as soon as possible.

B Circuit
thermostat open
00.02 ill.2
A Circuit, thermostat
closed
6b Thermostat (open)
1 Circulating pump 7 Tube stake - heat exchanger
2 Oil cooler 8 Water-intake pipe
3 Water jacket, block/cylinder 9 Expansion tank
4 Water cooled exhaust manifold 10 Filler cap
5 Turbocharger 11 Coolant temperature sensor
6a Thermostat (closed) 12 Drain plug

05.00.03 Error Detection Cooling System
1 Ask for the following information:

- How old is the device (engine number and model)?
- How many operating hours (wear and corrosion)?
- How long does the problem already exist (gradual or sudden occurence)?
- Operating conditions prior to occurence of problem (interior waters, salt water, muddy
or sandy water?)
- What repair- or service works have already been carried out (exchange of impeller, etc.)?
- At what engine speed does the problem occur?
- At what engine load does the problem occur?
2 Raw water circuit (external)
2.1 At first, take into consideration the following possibilities:
- Defective or faulty cooling water temperature sensor (high-riser)
- Sufficient rate of flow for raw water

- raw water pick-up damaged or clogged
- wrongly mounted raw water pick-up
- raw water filter clogged
- stop valve (bottom valve) defective (only opens partially)
- Raw water pump

- impeller defective (broken or strong wear)
- suction pipe from raw water filter to raw water pump clogged or deformed
- shaft bearing defective
- Sealing
- O-ring of impeller housing defective
- impeller plate seal
- Tandem cooler contaminated (e.g. through a part of broken impeller)

- Tube stake - intercooler contaminatd
- Heat exchanger exhaust
- contaminated
- seal in heat exchanger cover defective.
- Ventilation
- Alga vegetation on quill
- Deformations on hull, etc.
2.2 - Problems of raw water supply due to troubles in the drive unit
- defective seals or water pipes in lower gear box
- damaged rubber seal on water pipe
- damaged seal on box inlet
- leaky impeller plate seal
- leaky O-ring on impeller housing
- defective hose connection between pivot housing and Cardan housing
- observe notes and instructions of manufacturer.
2.3 - Inspection wether air reaches raw water.

Procedure: Replace water hose between raw water pump and tandem cooler (fuel/hydraulic
cooler) by transparent plastic hose. Let the device run in a test tank or with the boat
in water, at rotation speeds which cause an overheating, in order to detect a possible
bubble formation in the transparent plastic hose.

NOTE: When testing the device in a test tank, let the engine run in idle gear. For some test tanks
the water volume possibly may not be sufficient to let the engine run in a gear without
creating considerable turbulences. These could take effect onto water suction and be
interpreted by mistake as a cooling problem.
2.4 Check rate of flow of raw water.

9 10 1 2
Special tool No. VR00136/0 (ill.1)
8
ill.1/pos.2pressure gauge (0-4bar)
3
ill.1/pos.3intermediate sealing ring
7 4
ill.1/pos.4pressure gauge connection 6
ill.1/pos.5pressure hose 5
ill.1/pos.10 pipe stub, measurement of pressure
raw water
Measurement of pump feed pressure at the outlet of

raw water pump (ill.2)
1 Disconnect hose from pressure side of raw water 00.03 ill.1

pump, connect pipe stub (ill.2/pos.10) and connect
raw water hose to pipe stub again.
2
2 Mount intermediate sealing ring (ill.2/pos.3) with
pressure gauge connection (ill.2/pos.4) onto pressure
3
gauge (ill.2/pos.2) and connect it at one end of 4
pressure hose (ill.2/pos.5). 10
3 Connect the other end of pressure hose (ill.2/pos.5)
5
to pipe stub (ill.2/pos.10).
4 Start the engine and check for leakages.

00.03 ill.2
5 Put boat into operation and approach speed points according to diagram. Compare measured pressure
with table below.
Conclusion: - If the pump pressure is lower than the min. quantity in the table, the problem is
at suction side of raw water system.
- If the pump pressure is higher than the max. quantity in the diagram, the problem
is at pressure side of raw water system.
Raw water pump delivered pressure (standard impeller)
RPM Bar
600 0,20
1300 0,60
1800 1,00
2300 1,50
2800 1.85
3300 1,80
3800 1,60
4300 1,45

3 Closed Cooling Circuit (internal)
3.1 At first, take into consideration the following possibilites:
- Defective or faulty coolant temperature sensor.

- Coolant level in expansion tank < as minimum.
- Malfunction of thermostat
- thermostat does not open or opens only partially
- thermostat blocked in partially open state
- thermostat blocked in completely open state
- damaged thermostat sealing ring
- Malfunction of water circulating pump of engine

- pump bearing defective
- defective impeller seal
- excessive wear of impeller wings
- Cooler cap (pressure loss)

- Cooler cap sealing defective
- vacuum valve defective
- excess-pressure valve defective.
3.2 Malfunction of thermostat - overheating or slow heating of coolant:
- Procedure: Let the engine run until indicated temperature exceeds 80° C. Feel on hose of front
engine water pipe between heat exchanger and water-intake pipe.
- Result: Hose cold.
- Conclusion: Thermostat got stuck in closed state.
- Result: Hose warm or hot.
- Conclusion: Thermostat opens partially or completely.
- Procedure: Let the engine run; temperature of coolant will rise very slowly (feel on hose of front
engine water pipe between heat exchanger and water-intake pipe).
- Result: Themperature on hose slowly rises simultaneously with temperature of coolant, but
does not reach operating temperature (80°C opening temperature of thermostat).
- Conclusion: - Thermostat blocked in partially open or completely open state.

- Sealing ring of thermostat defective.
- Control: - Thermostat got stuck in open or closed position.

- Defective thermostat sealing.
- Wrong thermostat for this type of engine.

05.00.04 Check points for problems in cooling system
1 Raw water circuit
1.1 water intake - clogged
1.2 raw water filter - clogged

- strongly contaminated
- filter defective
1.3 hoses - fragile or leaky
1.4 hose clamps - loose or defective
1.5 raw water pump - impeller stronlgy worn

- impeller broken
- cover loose
- shaft bearing defective
1.6 tandem cooler - clogged

- leaky
- broken
1.7 intercooler - pipes clogged

- internal leakage
1.8 exhaust manifold - heat exchanger clogged

- internal leakage
1.9 cooling water temperature sensor - defective
1.10 manifold, elbows, seals, hoses - wrongly mounted seals

- sand or dross in manifold
- burned out hoses
1.11 hull - state of hull

- marine vegetation
- equipment attached to hull
NOTE: Mountings protruding over the hull may produce cavitations during fast ride which cause air
bubbles. These are possibly taken at the lower gear box by the drive and mixed with the
inflowing cooling water. Due to bad refrigerating capacity of the external cooling system, an
overheating in the internal cooling system (engine) may occur.
2 Internal Cooling Circuit
2.1 hoses - craked or leaky
2.2 hose clamps - loose or defective
2.3 thermostat - thermostat defective

- wrong thermostat
2.4 cooler cap - defective excess-pressure valve

- defective vacuum valve
- damaged cover sealing
2.5 coolant circulating pump - defective casing sealing

- damaged bearing
- worn impeller
- defective slide ring sealing
2.6 coolant guide on cylinder block - leaky connectors

05.00.05 Component Check Raw Water System
1 Hoses and clamps, drain plug etc.

For all models: no special tool required.
Control works:
Check all external components of cooling system for leakage, wear and damages. Check tightness
of all connections. Check hoses for cracks, breaks or wear. Water-supply hoses must be in
accordance with SAE 20R3 specifications, class D-2.
Repair works:
Repair or exchange, as required.
2 Manifold, heat exchanger and intercooler:

No special tools required.
Control works:
Check components for leakage, in a pressure test. Disassembly and check for corrosion and
material residues.
Repair works:
Remove residues of foreign material from pipes. If there are signs of spongy spots between water
ducts and exhaust channel, the component is to be exchanged. Also check exchangeable
elements for damages. For assembly, use new sealings and sealing rings.
3 Raw water pump

Control works:
With running engine, check rotation of pump belt pulley. If belt pulley runs out of true, this may
cause excessive wear of the pulley and damages on the pump itself.
If with running engine leakages on the pump are stated, the shaft sealing ring at the front of the pump
is leaky or the spacer is defective.
Repair works:
Not provided; exchange pump.
4 Fuel- and oil cooler

Control works:
Check components for internal leakage, in a pressure test. If possible, dismantle and check for
corrosion and residues of foreign material.
Repair works:
Remove residues of foreign material. If possible, exchange inserts or replace components.
5 Water pump in stern-drive

Control works:
Check water sucking filter at lower gear box for clogging. Check for sufficient water supply - as per
section Cooling System - Error Detection.
Repair works:
Dismantle water pump and repair or exchange defective components. For assembly, take care of
respective sealing of water pump. See notes and instructions of manufacturer.

05.00.06 Component Checks of Engine Cooling System
1 Hoses and clamps, drain plug etc.
For all models: no special tool required.
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
Water-supply hoses must be in accordance with SAE 20R3 specifications, class D-2.
2 Thermostat
Control works:
As a standard, an 80° C thermostat is used for the
marine engine. Check thermostat for correct
model and correct rated output, corrosion, limited
mobility or broken spring.
Repair works:
No repair possible. Exchange thermostat.
Test procedure: 00.06 ill.1
Dip the thermostat together with a thermometer into a water tank and heat up the water.
At a temperature of 80-81° C the thermostat should begin to open, and should open for 3,8-4,0 mm
at a temperature of 85-88° C (ill.1/A). At 90-93°C the thermostat should be open for 7 mm in order
to lock the little cooling circuit (contact-channel), thus permitting a complete flow through the heat
exchanger. Off 95 °C, the complete thermostat stroke of 8.0-8,2 mm is achieved.
3 Water pump (coolant circulating pump)

Control works:
If with running engine leakage on the pump is stated, the slide-ring sealing at the front of the pump
is leaky.
Repair works:
Not provided; exchange pump.

4 Cooler cap
Control works:
As a standard, a cooler cap with an opening
pressure of 1,0 bar is used. Check cooler cap
for correct rated output, defective sealing (ill.2/ 3
pos.1), defective vacuum valve (ill.2/pos.2) or
broken spring (ill.2/pos.3). 1
Repair works: 2
Not provided; exchange cooler cap.
00.06 ill.2
5 Coolant loss in closed engine cooling system
5.1 Coolant loss:
Control works:
- (item 4) check cooler cap
- defective exhaust manifold (exhaust gases reach the engine cooling circuit)
- defective monoblock (due to combustion pressure, gases reach the engine cooling system).
5.2 Gas-air mixtures reach the cooling system.
5.2.1- Defective exhaust manifold
Control works:
05.01.03 Check exhaust manifold heat exchanger.
5.2.2 - Defective (leaky) monoblock
Control works:
Use special tool SMO: VR00147/0 by using enclosed instruction.
Conclusion: Gas entry (combustion pressure) in the engine cooling circuit.
Control works:
Assembly of unit injector, refer to 03.02.02 "ASSEMBLY" item 11; check specified
tightening torque.
Repeat check. If result remains unchanged, the monoblock is defective.
Repair works:
Not provided; exchange monoblock.

05.00.07 Drain coolant system
Raw water circuit
1 Remove drain plug (ill.1/pos.1). 1

NOTE: Drain plug (ill.1/pos.1) does not exist
for all models.
2 To drain the raw water ducts on the engine, remove 00.07 ill.1
cover rear of raw water pump (ill.2+3/pos.1).
NOTE: For complete removal of water residues

from pump housing and water ducts
of raw water circuit, proceed as follows:
3 Lock exhaust pipe with special tool No. VR00144/0

(ill.4/pos.1) 1
4 Remove plug J 1.
Connect special tool No. VR00145/0 instead of plug
J1.
00.07 ill.2
5 Start the engine by pressing the button, until raw

water system is completly emptied.
ATTENTION: Only start with special tool No.

VR00145/0. Engine only be cranked
by starter motor, but not start.
6 After complete drainage, assembly is done in reverse 1

order.
ATTENTION: If the water is not drained in time before

the winter season, this could result in 00.07 ill.3
frost damage on the engine as well as
the drive.
00.07 ill.4

Closed cooling circuit

1
To drain the closed cooling circuit, lift or lower the
bow of the boat in such a way that the engine is in
horizontal position, which permits an ideal drainage
of motorblock and manifold.
ATTENTION: Approx. 1 liter of coolant will remain in

the motorblock which is to be
considered for refilling.
With hot engine, the closed cooling

circuit is under pressure. Do not try to 00.07 ill.5
open the coolant tank cap or the drain
plug when the engine is hot. This could
lead to severe injuries by hot coolant 1
under pressure. As soon as the engine
has cooled down, the cap may be
opened by 1/4 turn to the left, to release
possibly remaining pressure. Then
press down the cap, turn and remove.
7 There are two drain plugs on the engine through

which the coolant from the internal cooling circuit can
be drained.
00.07 ill.6
(Refer to ill.5/pos.1 and ill.6/pos.1)
8 Loosen the two drain plugs (ill.5/pos.1 and 6/pos.1),

possibly stick a hose onto the drain plugs and collect
the coolant in a bucket.
ATTENTION: The closed cooling circuit must always

be filled with coolant. If the circuit
remains for a long time without coolant,
corrosion damages may occur.

05.00.08 Fill cooling system
Closed cooling system
1 Fill cooling circuit with specified coolant only. Coolant

level should reach the lower edge of the filler neck in
the expansion tank.
2 For 4 cyl. & 6 cyl. engines with new exhaust

(screwed cap) only
NOTE: Cooling system deaerate automatically

while filling.
For 6 cyl. engines (old version) only (item 3-4)
Remove venting screw (ill.2/pos.1) (SW6) at the

front of heat exchanger. Fill cooling circuit with
specified coolant only. Coolant level should reach the
lower edge of the filler neck in the expansion tank.
00.08 ill.1
4 Mount venting screw again and tighten.
ATTENTION: For a new filling of the closed cooling

circuit, make sure that the cooling
1
system is deaerated completely.
5 Let the engine run, check coolant level and refill

coolant if necessary.
00.08 ill.2
Raw water circuit
After engine start, filling is done automatically via raw

water pump.
ATTENTION: Raw water intake valve must be open.

05.01 COOLER, HEAT EXCHANGER, EXPANSION TANK
05.01.01 Coolant tank
The coolant tank is an integrated part of the exhaust

manifold - heat exchanger housing and may not be
exchanged in single parts.
01.01 ill.1

05.01.02 Disassembly exhaust manifold -

heat exchanger
Preparation: tip away E-box

1
remove air filter, refer to 03.04
NOTE: Where appropriate, remove exhaust

manifold for these works, while turbo-
charger and hi-riser remain.
01.02 ill.1
1 Drain closed cooling circuit according to instructions
in 05.00.07, drain coolant
2 Unscrew three screws (ill.1/pos.1) of upper timing 1

belt covering. Remove covering.
3 Disconnect water hose (ill.2/pos.2) to thermostat

housing.
4 Loosen hose clamp (ill.2/pos.1) and remove coolant

pipe. 2
01.02 ill.2
5 Loosen hose clamp (ill.3/pos.1) and remove coolant

pipe.
1
6 Loosen hose clamp (ill.3/pos.2) and remove hose.
2
01.02 ill.3
7 Disconnect coolant temperature sensor (ill.4/pos.1).
01.02 ill.4

8 Cut cable tie for cable- and plug fixing of speed

sensor (ill.5/pos.1) on relief hose.
01.02 ill.5
9 Loosen fixing of heat protection. Remove heat 1 2

protection (ill.6/pos.1).
3
10 Loosen hose clamp (ill.6/pos.2) and remove hose
for air charge pressure box.
11 Loosen screw (SW10) (ill.6/pos.3) for raw-water-

pipe support.
01.02 ill.6
12 Loosen hollow screw (SW14) (ill.7/pos.1) of oil feed

line on turbocharger. 1
13 Remove plug of oil pressure switch (ill.7/pos.2).

motorblock. Dispose Cu-sealing rings.
2
01.02 ill.7
15 Loosen 2 hexagon screws (ill.8/1) of oil return line.

Dispose seal.
01.02 ill.8


Loosen two hexagon screws on flange of oil feed
line.
01.02 ill.9
Loosen hose clamps of hose connection
turbocharger - intercooler (ill.10/pos.1) and remove
hose.
õõ
1
01.02 ill.10
18 Loosen setscrew (ill.11/pos.1) for support of sea

water pipe.
19 Remove covering (ill.11/pos.3) to intercooler by

loosening 5 hexagon screws (SW10) (ill.11/pos.2). 2 3
1
20 Loosen hose clamp (ill.12/pos.1) compressor 01.02 ill.11

housing connection.

remove connecting manifold. C2 C1
01.02 ill.12

22 Loosen hose clamp (ill.13/pos.1) of oil separator and

remove hose.
23 Unscrew 8 - 12 screws (SW13) (ill.14/pos.1) and 01.02 ill.13

2 - 3 nuts (ill.14/pos.2) .
1
CAUTION: If the exhaust manifold is not secured,
it migth fall when loosening the screws.
24 Remove exhaust manifold with turbocharger and 2

high-riser.
CAUTION: Heavy unit (approx. 40 kg).

Disassembly ONLY with suitable lifting 01.02 ill.14
device or second person.
25 Remove O-rings or gaskets from exhaust manifold or

cyl. block, and dispose.
01.02 ill.15

05.01.03 Checks
Check exhaust duct for cracks. Check raw water

circuit of the heat exchanger in a pressure test with
closed outlet nipple. Pressurize inlet nipple with a
pressure gauge and immerse manifold into water. At
a pressure of 22-25 kPa, the manifold should show
no leaks.
ATTENTION: Mostly, structural cracks are highly

dependent on thermal influence. In
order to achieve a more reliable result
of the pressure test, the component
should be heated up to approx. 80°C.


05.01.04 Exchange heat exchanger element
7
9
8
6
5 4
3
2
01.04 ill.1
1
Dismantle heat exchanger element:
1 Drain closed coolant circuit, refer to 05.00.07
2 Drain raw water circuit, refer to 05.00.07 (item 1 remove drain plug).
3 Loosen 3 screws (ill.1/pos.1) of heat exchanger cover in front (ill.1/pos.2) and 3 screws (ill.1/pos.8)
of heat exchanger cover at the back (ill.1/pos.7). Remove heat exchanger cover in front and at the back.
Loosen the element by slightly knocking with a plastic hammer on the rear end of the element, and
remove it. Dispose O-ring and rear cover of heat exchanger element as well as seal of heat exchanger
cover.
4 Clean all sealing surfaces.
Assembly:
5 Grease O-Ring (ill.1/pos.5) with Molykote BR 2 PLUS and push it onto flange of heat exchanger
element (ill.1/pos.4). Then insert heat exchanger element from front into exhaust manifold.
Grease O-ring (ill.1/pos.6) with Molykote BR 2 PLUS and push it onto exposed rear end of heat
exchanger element.
6 Grease seal (ill.1/pos.9) with Molykote BR 2 PLUS and insert it into heat exchanger cover at the back
(ill.1/pos.7). Fix cover on exhaust manifold and loosely mount it with 3 screws (ill 1/pos.8) on exhaust
manifold.
7 Fix seal (ill.1/pos.3) together with heat exchanger cover in front on exhaust manifold and loosely mount
it with 3 screws (ill.1/pos.1).
8 First tighten 3 screws (ill.1/pos.1) of heat exchanger cover in front, with a torque of 23 Nm +/-2, then
3 screws (ill.1/pos.8) of heat exchanger cover at the back, with a torque of 23 Nm +/-2.

05.01.05 Assembly of exhaust manifold
Preparation: Check heat exchanger,

refer to 05.01.03
1 Clean sealing surfaces on motorblock.
01.05 ill.1
2 Clean sealing surfaces on exhaust manifold (ill.2/

pos.1).
01.05 ill.2
3 Insert O-ring on cyl. bloc (ill.3/pos.1) by means of

Molykote.
01.05 ill.3
4 Insert two O-rings (ill.4/pos.1) into exhaust manifold
by means of Molykote.
ATTENTION: different sizes

1
5 Thinly cover sealing surfaces (ill.4/pos.2) of exhaust

manifold with surface sealing agent LOCTITE 5900.
2
01.05 ill.4

Variant with gaskets:

1
6 Screw 3 assembly bolts for exhaust manifold No.

P/N V000229/0 into respective left tapped hole of
each seal. Put on new manifold seals.
7 Put exhaust manifold onto 3 assembly bolts (ill.5/

pos.1) Mount manifold screws with washers and
tighten sturdily. Remove assembly bolts and screw in
remaining 3 screws and 3 nuts with washers, and
tighten with a torque of 23 Nm +/-2.
01.05 ill.5
Variant with O-rings:
8 Insert all O-rings into exhaust manifold by means of

Molykote.
9 Put exhaust manifold onto 3 assembly bolts (ill.5/

pos.1). Mount manifold screws and tighten sturdily.
Remove assembly bolts and screw in remaining 3
screw and 3 nuts. Tighten screws with a torque of
23 NM +/-2, nuts with 10 Nm.
1
01.05 ill.6
10 Put exhaust manifold onto the two threaded bolts
(ill.6/pos.1).
1
11 Tighten 8 hexagon screws (SW13) (ill.7/pos.1) with
a torque of 23 Nm +/-2. Tighten 2 hexagon nuts
10 Nm (SW 10) (ill.7/pos.2).
12 Further assembly is done in reverse order of 2

disassembly.
ATTENTION: Plug and cable of speed sensor to 01.05 ill.7

be tied up again with 2 cable ties on
venting hose.
13 Mount E-box properly.
14 Fill heat exchanger and motorblock with coolant,

according to instructions in this paragraph.
õ

05.01.06 Exchange tandem cooler
Disassembly
5 3
Preparation: vent fuel system,
refer to 03.09/1
1. Remove drain plug (ill.1/pos.1) to drain the raw 1

water system.
2 4 6
2. Loosen hose clamp (ill.1/pos.2) of hose to raw water
pump, and remove hose.
3. Loosen hose clamp of hose bend (ill.1/pos.3) to

01.06 ill.1
intercooler, and remove hose bend.
4 Loosen fuel return line (ill.1/pos.4) (SW19) mm and

hydraulic lines.
5. Unscrew two Allen head screws (SW6) (ill.1/pos.5)

of clamps, and remove tandem cooler (ill.1/pos.6).
Assembly
ATTENTION: Use new sealing rings.
05.01.07 Exchange additional oil cooler

(used only at type 246)
5
3
Disassembly
Preparation: loosen clamp oil dipstick (SW10)
6
1. Remove drain plug at tandem cooler to drain the raw
water system.
1
1
2. Loosen union nuts of oil hoses (ill.1/pos.1) (SW 21) 2
at the additional oil cooler.
3. Loosen hose clamp (ill.1/pos.2) of hose to raw water

pump. 01.07 ill.1
4. Loosen hose clamp of hose (ill.1/pos.3) to tandem

cooler.
5. Unscrew two Allen head screws (SW6) (ill.1/pos.5)

of clamps, and remove additional cooler (ill.1/pos.6).
Assembly
ATTENTION: Use new sealing rings for oil hoses.

LOCTITE 243 and tighten with a
torque of 20 NM +/-2

05.01.08 Exchange triple cooler

5
3 3
Disassembly
Preparation: vent fuel system, refer to 03.09,
item 1
1. Remove drain plug at triple cooler to drain the raw

1 4 6
water system.(ill.1/pos.1) 2
2. Loosen union nuts of oil hoses (ill.1/pos.2) (SW 32)
at the triple oil cooler.
3. Loosen hose clamps (ill.1/pos.3) of hose to raw 01.08 ill.1

water hoses.
4. Loosen fuel lines (ill.1/pos.4) (SW 19) and hydraulik

lines (SW 22)
5. Unscrew three Allen head screws (SW6) (ill.1/pos.5)

of clamps, and remove triple cooler (ill.1/pos.6).
Assembly
ATTENTION: Use new sealing rings for oil hoses.

LOCTITE 243 and tighten with a
torque of 45 NM +/-2
05.03 PIPES, THERMOSTAT
05.03.01 Coolant pipes and hoses
Remove defective hoses by loosening the respective hose clamps and replace.
ATTENTION: Tightning toose clamps with a torque of 3,5 Nm.

05.03.02 Exchange thermostat
Preparation: Drain closed cooling circuit

refer to 05.00.07, item 7
DISASSEMBLY:
03.02 ill.1
1 Loosen 4 hexagon sockets fixing the covering of

thermostat housing. Remove covering and seal. Dis-
pose seal.
03.02 ill.2
Only for 6 cyl. engines with hydraulic system
(item 2-3)
2 Loosen hexagon screw (SW10) fixing the oil tank of

hydraulic system (ill.3/pos.1). Remove oil tank from
mount and fix it laterally to avoid any leaking of
hydraulic oil.
3 Loosen the two lower hexagon sockets (SW5) (ill.3/ 2

pos.2) fixing the covering of thermostat housing. 1
Remove covering of thermostat housing and seal
together with mount for hydraulic tank. Dispose seal.
03.02 ill.3
4 Remove spacer (ill.4/pos.1) and thermostat (ill.4/

pos.2) with seal.
1 2
03.02 ill.4

ASSEMBLY:
1 Clean sealing surfaces on thermostat housing and

on sealing surface of cover.
.
03.02 ill.5
2 Put seal (ill.6/pos.1) onto thermostat.
03.02 ill.6
4 Insert thermostat into housing, ventilation mark (ill.7/

pos.1) showing upwards.
ATTENTION: Put on new seal. 1
5 Insert spacer.
03.02 ill.7
6 Remaing assembly is done in reverse order.
7 Tighten screws of thermostat housing cover with a

8 Filling of closed cooling circuit,

refer to 05.00.08
03.02 ill.8

05.03.03 Exchange sacrificial anodes
The raw water circuit of the cooling system is equipped

with five sacrificial anodes. These anodes are to be
removed once a year and checked for galvanic
erosion. In case of a material loss of 50 %, the anode
needs to be exchanged (SW23) .
1 Anodes 1 and 2 (ill.2/pos.1-2) are on the intercooler.
2 Anodes 3 is in the high riser (elbow).

03.03 ill.1
3 Anodes 4 and 5 (ill.2/pos.4-5) are on the heat
exchanger.
4 Illustration 1 shows a new anode.
NOTE: For operation with fresh water,

magnesium anode sticks are
recommended.
03.03 ill.2

05.04 COOLANT PUMP

05.04.01 Exchange coolant pump
Preparation : remove timing belt, see 01.00.04
drain closed cooling system,

refer to 05.00.07, item 7
04.01 ill.1
Loosen hose clamp (ill.2/pos.1) and remove hose.
1
04.01 ill.2
2 Loosen hose clamps (SW6) and remove hose
between thermostat housing and water pump (ill.3/
pos.1)
3 Loosen hose clamp of hose elbow (ill.3/pos.2) at oil 1

cooler side.
2
04.01 ill.3
4 Loosen all screws (ill.4) and hexagon nut of water
pump (ill.4/pos.3).
2 1
5 Loosen water pump by slight knocking with plastic
hammer and remove hose elbow.
1
3
04.01 ill.4

05.04.02 Install coolant pump
1 Clean all sealing surfaces on water pump and on

motorblock.
04.02 ill.1
2 Put on new sealing (ill.2/pos.1).
3 Align water pump on motorblock. Mount screws and

nuts and tighen with standard torque for these size.
4 Further assembly is done in reverse order, in 1

accordance with 01.00.04 remove timing belt.
5 Adjust control according to instructions in paragraph

01.00.05 engine timing adjustment procedure.
04.02 ill.2

05.06 POLY-V BELT

05.06.01 Exchange Poly-V-belt
For M 4 cyl. engines only
Belt guide without hydraulic pump (ill.1).
*)
04.06 ill.1
Belt guide with hydraulic pump (ill.2).
NOTE*): It is recommended to spray

frequently some corrosion inhibiting
spray into the spring housing of the
belt tensioner.
*)
04.06 ill.2
1 Release belt tension by pulling tensioner from V-belt
of torque wrench No. 2300704/0 (ill.3/pos.1). Remove
Poly-V belt.
2 Pull the belt tightener counterclockwise by means of

torque wrench No. 2300704/0 into position as show
(ill.3/pos.1). Apply the Poly-V belt acc. to ill.1 for
engine with hydraulic pump or ill.2 for engine without
hydraulic pump. Tighten the belt by releasing the belt
tightener.
1
04.06 ill.3

05.07 V-BELT
3 1
05.07.01 Exchange V-belts
2
Alternator: (for example - different versions
possible)
1 Loosen setscrews (ill.1+2/pos.1+2)
2 Release V-belts by turning clamping bolt (ill.1+2/

pos.3) counterclockwise and by turning alternator
towards engine. 07.02 ill.1
Remove pair of V-belts.
1
(According 05.07.02)
4 Adjust belt tension to 350 +/- 50 N. 3

5 Check tension of alternator V-belt on spot (ill.4/A) in
the middle between crankshaft (ill.4/pos.1) and
alternator (ill.4/pos.2). 2
NOTE: Always change V-belts in pairs only.
07.02 ill.2
Servopump
NOTE: The servopump is driven together with the

alternator. Tension of V-belt is done via
alternator. 4
Raw water pump: (old version)

1
Preparation: Remove alternator V-belts. 2
1 Loosen setscrews (ill.3/pos.1).
3
2 Loosen hexagon nut of clamping bolt (ill.3/pos.2).
Release V-belt by turning the clamping bolt (ill.3/
07.02 ill.3
pos.3) counterclockwise and turning the pump
towards engine.
Remove V-belt (ill.3/pos.4).
4 Check tension of raw water pump V-belt on spot (ill.4/

2 3
B) in the middle between crankshaft (ill.4/pos.1) and A B
raw water pump (ill.4/pos.3).
5 Adjust belt tension to 350 +/- 50 N.

(According 05.07.02)
1
07.02 ill.4

Raw water pump: (current version)
Preparation: Remove alternator V-belts.

1
1 Loosen screw (ill.5/pos.1).
Turn screw counter (ill.6/pos.1) clockwise to reduce
of tension V-belt.
2 Remove V-belt.
4 Adjust V-belt tension; according 05.07.02 07.02 ill.5
5 Tighten screw (ill.5/pos.1) with a

Torque of 23 N +/-2 to secure idler pulley bracket. 1
07.02 ill.6

05.07.02 Adjust V-belts

Measuring device No. VR00515/0 for timing- and V-belt
With engine stopped, belts should be stretched to

such an extent that they yield for 10-13 mm when
pressing your finger on marked spots (07.01 ill.4/ A +
B). This corresponds to a belt tension of
350 Nm +/- 50.
If the belt is too loose, it may slip through which
results in higher wear and bad efficiency of alternator
or servo pump.
Belt tension is to be checked after first 10 operating
hours and than every 50 operating hours.
07.02 ill.1
07.02 ill.2

05.10 RAW WATER PUMP

05.10.01 Exchange raw water pump
1 Loosen 3 hexagon screws (ill.1/pos.1) of belt pulley. 3

2 Remove poly-V-belt or V-belt (05.06 or 05.07) 5
4
3 Unscrew 3 screws (ill.1/pos.1) of belt pulley and
remove belt pulley (ill.1/pos.2).
2
4 Loosen hose clamp (ill.1/pos.3) and remove hose.
1
5 Loosen 4 screws (ill.1/pos.4), remove raw water
pump (ill.1/pos.5).
10.01 ill.1
7 Torque screws M6 (pos.4) with 9,5 Nm; screws M8

(pos.1) with 23 Nm.
Secure all threads with LOCTITE 243.
For 6 cyl. engines only (old version)
1 Loosen two setscrews (SW17) (ill.2/pos.1)

4 5
2 Loosen hexagon nut of clamp bolt (ill.2/pos.2),
relieve V-belt by turning clamp bolt (ill.2/pos.3)
counterclockwise.
3 Remove V-belt (ill.2/pos.4).

1
2
4 Loosen hose clamps (ill.2/pos.5) and remove hoses.
5 Unscrew two setscrews (SW17) (ill.2/pos.1+2).

3
Remove raw water pump with tightener.
10.01 ill.2
5 Loosen 4 hexagon screws (SW13), remove raw

water pump.

05.12 CHECKS
05.12.01 Check closed engine cooling system
for air
This check is for determination and retrieval of an inexplicable

coolant loss.
Procedure: Use special tool SMO: VR00147/0 by using

enclosed instruction.
Conclusion: Gas entry (combustion pressure) in the cooling

system.
Control works: Check tightening torque of unit injectors

(03.02.02 "ASSEMBLY", item 11) and repeat
check.
NOTE: If there is no gas entry, coolant loss is

eliminated.
If there is still gas entry, refer to 03.14.02, to

"disengagement methode of injection" this methode
can help to detect a possible transfer of combustion
gases into the water jacket.
NOTE: If the defective cylinder is detected through

the disconnection method and bubble formation and/
or coolant loss stops, the monoblock is to be replaced.

ToC SERVICE MANUAL MARINE ENGINES 06 ELECTRICAL SYSTEM
06 ELECTRICAL SYSTEM
Table of Contents
06.00 General ......................................................................................................... 3

06.00.01 Cable numbers and principal functions .......................................................... 3
06.01 Alternator ..................................................................................................... 4

06.01.01 Adjust poly-V-belt tension ............................................................................. 4
06.01.02 Replace generator......................................................................................... 5
06.01.03 Technical data of alternator .......................................................................... 6
06.01.04 Check alternator (error detection for BOSCH alternator, 4 cyl. engines) .... 14
06.03 Replace starter motor ............................................................................... 16

06.03.01 Check starter ................................................................................................ 17
06.05 Cables, wiring harness - general ............................................................. 19

06.05.01 Battery cable lengths and cross-sections .................................................... 19
06.05.02 E - box base plate; to eng.no.: 482 17 000 ................................................. 20
06.05.02.01 Components of E - box ................................................................................ 21
06.05.02.02 Connection start assist relay K28 ................................................................. 21
06.05.02.03 Connection relay socket for K24, K26-1, K26-2, and K27 ............................ 21
06.05.02.04 Wiring harness; to eng.no.: 482 17 000 ...................................................... 22
06.05.03 E - box base plate; from eng.no.: 482 18 000/682 18 000 + SOLAS ......... 28
06.05.03.01 Components of E - box ................................................................................ 29
06.05.03.02 Connection start assist relay K28 and K26-2 ............................................... 29
06.05.03.03 Connection relay socket for K24, K26-1, and K27 ....................................... 29
06.05.03.04 Wiring harness; from eng.no.: 482 18 000/682 18 000 + SOLAS .............. 30
06.06 Electronics - general .................................................................................. 36

06.06.01 Electronic Engine Management System ..................................................... 36
06.06.02 Diagnostic system ....................................................................................... 37
06.06.03 Reading error codes .................................................................................... 38
06.06.04 Idication & cancellation of memorized sensor and circuit faults .................. 39
06.06.05 Principle failure code list ............................................................................. 40
06.06.06 Replace fuses ............................................................................................. 42
06.06.07 Connection J 1 ............................................................................................. 43

06.06.08 Connection A 5 and X5 ................................................................................ 44
06.06.09 Fitting main connector "J1" properly ............................................................ 45
06.07 Instrument panel ....................................................................................... 46

06.07.01 Chart - operating status normal operation ................................................... 47
06.07.02 Chart - error indication on instrument panel ................................................ 48
06.07.03 Instrument panel (for SOLAS only) ............................................................. 52
06.07.04 Chart - operating status normal operation (for SOLAS only) ...................... 53
06.07.05 Chart - error indication on instrument panel (for SOLAS only) .................... 54
06.07.10 6 Cyl. Wiring harness instrument panel (if alternator "PRESTOLITE" is

used - old version) ........................................................................................ 58
06.07.11 Description - Wiring harness instrument panels 4/6 cyl. marine engines
(current version) ........................................................................................... 62
Z001019/0_6_July 2008 Page ELECTRICAL SYSTEM - 1

06.07.13 Adjust instruments ....................................................................................... 68

06.07.13.01 Tachometer with running-time meter ........................................................... 68
06.07.14 Replace instruments .................................................................................... 70

06.07.14.01 General notes on safety ............................................................................... 70
06.07.14.02 Audible warner, H22 ..................................................................................... 72
06.07.14.03 Circuit diagram voltmeter (optional) ............................................................. 73
06.07.14.04 Circuit diagram oil pressure gauge (optional, sensor B19-gauge P2) .......... 73
06.08.01 Potentiometer accelerator, B13 ................................................................ 74

06.08.02 Voltage regulator 24V - 12V equalizer ......................................................... 75
06.08.03 DC - DC converter ........................................................................................ 76
06.10 Sender, sensor .......................................................................................... 78

06.10.01 Component configuration 4 cyl. engine ........................................................ 78
06.10.02 Component configuration 6 cyl. engine ........................................................ 80
06.10.03 Calibration of rack position ........................................................................... 82
06.10.04 Replace sender, sensor ............................................................................... 83

06.10.04.01 Sensor exhaust gas temperature B17 .......................................................... 83
06.10.04.02 Sensor engine temperature B16 .................................................................. 83
06.10.04.03 Sensor engine speed B15 ............................................................................ 83
06.10.04.04 Sensor boost pressure B12 .......................................................................... 83
06.10.04.05 Sensor rack position feedback B14.............................................................. 84
06.10.04.06 Sensor oil pressure B18 ............................................................................... 84
06.10.04.07 Potentiometer accelerator B13 ..................................................................... 84
06.10.05 Check sensors and switches ........................................................................ 85
06.10.05.01 Check rack position feedback sensor B14 (= connector X14) ..................... 85
06.10.05.02 Check throttle potentiometer B13 (accelerator) (= connector X13) .............. 87
06.10.05.03 Check boost pressure sensor, B12 .............................................................. 88
06.10.05.04 Check speed sensor B15 and/or wiring ....................................................... 89
06.10.05.05 Check oil pressure sensor B18 and/or wiring ............................................... 90
06.10.05.06 Check oil pressure sensor "VDO-instrument" (option B19) .......................... 91
06.10.05.07 Check coolant temperature sensor, B16 ...................................................... 92
06.10.05.08 Check audible warner .................................................................................. 93
06.12 Battery ........................................................................................................ 94

06.12.01 Battery ......................................................................................................... 94
Page ELECTRICAL SYSTEM - 2 Z001019/0_6_July 2008

06.00 GENERAL
Wiring
For the STEYR Marine Engines wiring and plug connections have been defined according
to standard DIN 72 552.
In case of necessary repair of a cable connection, take special care that cable quality, isolation,
crimping, strand end soldering of cable sockets as well as protective varnish isolation and/or
connector locks meet the respective requirements.
Tools for crimp connections to be found in tool catalog P/N Z001002/0 "Level 4".
06.00.01 Cable numbers / principal functions:
15000-xx ignition - positive 31100-xx Do not connect earth for sensors

(from ignition switch) with battery-negative!
15012-xx +12 volt via main relay 601xx-01 Sensor signal to control unit
and control unit A5 A5 and/or instruments.
15100-xx +5 volt supply voltage for sensors 606xx-01 Output from control unit A5
to display system (tachometer,
30000-xx battery-positive (not secured) temperature display, ...)
30012-xx battery-positive (secured)
31000-xx battery-negative (GND)

06.01 ALTERNATOR
06.01.01 Adjust poly-V-belt tension
Automatic initial tension of belt tension

through spring-loaded tightener. (ill.1 and ill.2)
1
01.01 ill.1
1
01.01 ill.2
As to tension of V-belt for alternator,

refer to chapter 05.07.01 - 02

06.01.02 Replace alternator
Preparatory work: turn off engine, disconnect battery
1 Disconnect two cables (ill. 1/pos.1+2).
2
1
2 Remove belt.
01.02 ill.1
3 Loosen screws (ill.2/pos.1+2), remove alternator.
NOTE: Assembly is done in reverse order.
For 4 cyl. engines only 01.02 ill.2
Connections ill.3/1 B+ battery

acc. illustration 3:
ill.3/2 D+ charging control (L1)
ill.3/3 DF D-field (rotor winding)
ill.3/4 D+ on governor
3
4 2
1
For 4 cyl engines only
01.02 ill.3
Governor ill.4/1 B-
acc. illustration 4:
ill.4/2 DF 1 2 3
ill.4/3 D+
ill.4/4 D+
01.02 ill.4

06.01.03 Technical data of alternator

For 6 cyl. engines only (old version till eng. no. 68224418)
Model .................................................................................................... PRESTOLITE LEECE-Neville

.............................................................................................................. 8RG2043
Minimum speed for voltage generation ................................................. 580 1/min
Controlled voltage range ....................................................................... 13,9 - 14,2 V
Output current ....................................................................................... 90 A
Governor ............................................................................................... integrated base governor
Charge capacity
at 750 r.p.m. .......................................................................................... approx. 34 A
at 2500 r.p.m ......................................................................................... maximum charge capacity
Condensor capacity .............................................................................. 2,2 µF
01.03 ill.1
Charging circuit - scheme
1 ...... battery
2 ..... Z2, ground connection on engine
3 ..... red
4 ..... fuse 50 A
5 ..... starter engine
6 ..... red
7 ..... plug (engine electrics/instrument cable)
8 ..... fuse 10 A
9 ..... starter key lock
10 ..... 15000-xx
11 ..... red 16 mm²
12 ..... generator
13 ..... charging controll (L1)
14 ..... 61000-02 (18-pole connecting cable No.: 11)
15 ..... relay K10
16 ..... blocking diode (1N4007)
For 6 cyl. engines only (old version till eng. no. 68224418)
circuit diagr.:
Governor
01.03 ill.2 01.03 ill.3
Check of alternator and connections:

With engine stopped, measure voltage on alternator (+output and -output).
Measured voltage may be lower than the battery voltage by (up to) 1 volt only.
Where appropriate, test wiring of cables and connections.
Check of control voltage and/or alternator voltage:
NOTE: For these works, the battery's state of charge should be 95% at least.
Check tension of belt on alternator drive and make sure that cables are perfectly connected.
1. Disconnect all electrical consuming devices and adjust engine to a speed of approx. 1000 rpm.
2. Connect voltmeter to alternator output "B +".
3. Remove plastic screw on governor and apply screw driver with fine blade on adjusting screw.
ATTENTION: The adjusting screw has a min./max. stop. There is danger to damage the governor
when turning by force the adjusting screw so far that it overtravels the specified
control range.
4. Turn screwdriver clockwise to increase the operating voltage and/or anticlockwise to lower the
operating voltage. Adjust voltage range between 14,0 and 14,2 volt (28,0 to 28,4 volt for 24-volt plants).
ATTENTION: Do not turn adjusting screw so far that it overtravels the stop, to prevent
damages to the governor.
5. After adjustment, remove screwdriver and voltmeter and lock the governor by means of removed plastic
screw.
If voltage cannot be set to specified value, replace governor and/or alternator.
Check of slip pistons:

Disconnect battery and/or main switch.
Unscrew governor. Clean slip ring and wipers; where appropriate, replace wipers.

For 6 cyl.engines / Technical data of alternator 14V / 90A (current version from eng. no. 68224419)
Model .................................................................................................... ISKRA-AAK5550-11.203.329

Minimum engine speed for voltage generation ..................................... 550 1/min
Output current ....................................................................................... 90 A
Governor ............................................................................................... integratedl base governor
Excitation winding resistance ................................................................ 2,7 / +0,27
01.03 ill.4
Error Detection
Check battery: Charging voltage too low:

- All connections (terminals) - Belt tension
- Acid concentration - Output
- Filling level (check, refill if necessary) - Governor
- Carry out load test - Slip ring
Excessive voltage: - Internal components of alternator
- Governor
No charging voltage:
- Loose connections
- Belt tension
- Battery
- Charging control lamp defective (12V/2W)
- Output
- Cables and connections
- Governor
- Slip ring
- Internal components of alternator

For 6 cyl. engines / Technical data of alternator 28V / 80A (Option)
Model .................................................................................................... ISKRA-AAN5161- 11.203.220

Output current ....................................................................................... 80 A
01.03 ill.5
Error Detection

- Governor
- Loose connections
- Belt tension
- Battery
- Output
- Governor
- Slip ring

For 6 cyl. engines / Technical data of alternator 28V / 55A (Option)
Model .................................................................................................... ISKRA-AAK5170- 11.201.894

Output current ....................................................................................... 55 A
01.03 ill.6
Error Detection

- Governor
- Loose connections
- Belt tension
- Battery
- Output
- Governor
- Slip ring


For 4 cyl. engines only / Technical data of alternator
Model .................................................................................................... BOSCH No. 6 033GB3 046

Minimum speed for voltage generation ................................................. 550 1/min
Output current ....................................................................................... 90 A
Charge capacity
at 750 r.p.m. .......................................................................................... ca. 34 A
at 3000 r.p.m. ........................................................................................ maximum charge capacity
Condensor capacity .............................................................................. 2,2 µF
01.03 ill.7
Charging circuit - scheme
1 ...... battery
2 ..... Z2, ground connection on engine
3 ..... red
4 ..... fuse 50 A
5 ..... starter engine
6 ..... red
7 ..... plug (engine electrics/instrument cable)
8 ..... fuse 10 A
9 ..... starter key lock
10 ..... 15000-xx
11 ..... red 16 mm²
12 ..... generator
13 ..... charging control (L1)
14 ..... 61000-02 (18-pole connecting cable Nr.: 11)
15 ..... blocking diode (1N4007)

Error Detection
Check battery:
- All connections (terminals)
- Acid concentration
- Filling level (check, refill if necessary)
- Carry out load test
Excessive voltage:
- Governor
- Loose connections
- Battery
Charging voltage too low:

- Belt tension
- Output
- Governor
- Slip ring
- Belt tension
- Output
- Governor
- Slip ring
Alternator - scheme
Governor
01.03 ill.8

06.01.04 Check alternator (error detection for BOSCH alternator, 4 cyl. engines)
Trouble features Test procedure Error and/or Relief
With engine stopped and ignition on, Tester lamp connected between B+ Generator control lamp (L1) burned
generator control lamp (L1) not and D+ on generator ; shining brightly. out and/or disconnection in electric
shining or only slightly. circuit of generator control lamp (L1)
between term. 15 (No. 15000-xx) and
term. D+ (No. 61000-02) on
generator.
Tester lamp connected between B+ Short circuit of a positive diode.

and D+ on generator ; not shining, but Immediately disconnect starter
shining brightly when connected battery from generator, otherwise
between D+ and ground. Generator battery may be discharged on state -
control lamp (L1) does not shine in > replace generator.
both cases.
Tester lamp connected between D+ Error, wipers of governor worn out,

and ground; tester lamp and oxid film on slip rings, disconnection
generator control lamp (L1) glowing. of rotor winding -> replace governor
and/or generator.
With both engine stopped and With engine stopped, disassemble

running, generator lamp (L1) attached governor.
constantly shines brightly.
Generator control lamp (L1) still Earth short circuit in lead betweeen
shining brightly. generator control lamp and terminal
D+ on generator.
Generator control lamp (L1)

extinguishes. Install governor again.
Connect ammeter between B+ and
D+ (on generator). Exciting current
is lower than specified (4 amp Governor is defective -> replace
+/- 0,4). governor.
Exciting current is higher than Earth short circuit in the field of

specified (4 amp +/- 0,4). governor and connection DF (see
ill.) of generator, earth short circuit in
rotor winding -> replace generator.
With engine stopped, generator Connect tester lamp between B+ and

control lamp (L1) shines brightly, D+ of generator.
with engine running only shines
slightly. With engine running, tester lamp Contact resistance in charging circuit
extinguishes. or in conductor to generator control
lamp (L1)
With engine running, tester lamp Governor or generator defective.
glows.
With engine stopped, install new

governor and start engine again.
Tester lamp between B+ und D+ Disassembled governor was
Tester lamp extinguishes defective.
Tester lamp still glows Generator is defective -> replace.

Check rectifier diode
Measuring devices with diode test function will show

the following results:
12-V-Lampe
- in forward direction: voltage drop from 0.4 to 0.6
volt
- in backward direction: reading is "OL". + 12V -
a) by means of control lamp

01.04 ill.1
Diode and control lamp are connected in series in
both forward and backward direction in an electric
circuit. Diodes permitting passage in both directions
were mostly exposed to excessive voltages. On the
other hand, diodes with an interruption in forward
direction were mostly destroyed by excessive current
or excessive heating.
ill. 04.1 Lamp burning: diode functional.

Lamp not burning: diode interrupted.
ill. 04.2 Lamp not burning: diode functional, 12-V-Lampe

Lamp burning: diode had short circuit.
+ 12V -
01.04 ill.2
b) by means of ohmmeter
For diode testing, only a simple, battery-powered

ohmmeter may be used.
Measuring bridges are unsuitable, as they indicate
wrong values. Under no circumstances, hand
generators may be used. Their high voltage would
destroy the diodes. A perfect diode shows a resistance
of only a few ohms (0,5 ...10 Ohm) in forward direction,
but several kiloohms (almost) in backward direction.

06.03 REPLACE STARTER MOTOR
1 Disconnect battery.
2 Remove cover of E-box. Remove E-box.
3 Loosen terminal +30 (ill.2/pos.1) on magnetic switch

by means of (SW13).
4 Loosen start signal wiring (terminal 50) (ill.2/pos.2)

by means of (SW10).
03.00 ill.1
5 Loosen two hexagon screws (ill.2/pos.3) (SW13) of

starter bracket.
6 Loosen two screws (SW8) (ill.2/pos.4), remove starter. 1
4 3
03.00 ill.2
NOTE: Have starter motor repaired in an

authorized STEYR workshop.
After assembly, coat all electric

supplies with rubber sealing
Z909570/0.

06.03.01 Check starter
Trouble features Cause Relief
When switching on the starter battery discharged and/or defective charge battery and/or replace
(acutation of starter key), starter shaft
not turning or only slowly; starter terminals of starter battery are loose clean terminals and tighten, treat with
pinion not engaging and/or oxidized, bad ground pole grease, provide ground
connection connection
earth short circuit of terminals of eliminate earth short circuit

starter or carbon brushes
carbon brushes not resting on depending on failure, make work

collector (sticking in guide, are carbon brushes, clean or replace -->
broken, oily or worn out) in case of very strong wear, replace
various parts and/or starter
starter key or starter relay K28 and/or replace starter key or relay
actuating relay on starter defective
voltage drop in lines too large, lines check starter line, eventually replace,
damaged, line connections loose, clean links and tighten
links oxidized
starter keeps on running after starter starter does not interrupt; starter key, immediately turn off ignition,
key was released starter relay (K28), actuating relay immediately disconnect battery;
(on starter) defective check key and/or relay, evenutally
short-circuit in wiring (cable No.: replace; check wiring
50000-xx connected to +12V) in case of longer running time -->
replace starter


06.05 CABLES, WIRING HARNESS - GENERAL
Cable / wiring
In case of necessary repair of a cable connection, take special care that cable quality,
isolation, crimping, strand end soldering of cable sockets as well as protective varnish isolation
and/or connector locks meet the respective requirements.
Tools for crimp connections to be found in tool catalog P/N Z001002/0 "KIT 3".
06. 05. 01. Battery cable lengths and cross-sections
Determine the lenght of the positive cable from the positive pole (+) of the battery to connection No.
30 at the starter.
Total lenght is the sum of cable length of positive cable (+) and earth cable (-).
For example:
positive cable = 3,0 m

ground cable = 2,0 m
-----------------------------
Total length = 5,0 m ===> cable cross section = 70 mm²
For ground connection, determine corresponding cross-sections as per chart.
starter engine: 2 kW - 12 volt

battery size: 92 AH
length cable cross-section AWG

in m in mm²
0,0 - 4,0 50 0
4,1 - 5,0 70 00
5,1 - 6,0 95 0000
starter engine: 3 kW - 12 Volt

battery size: 110 AH
length cable cross-section AWG

in m in mm²
0,0 - 3,0 50 0
3,1 - 4,5 70 00
4,6 - 5,5 95 0000
In general, take care that battery cable lengths are kept as short as possible.

06.05.02 E - box base plate; to eng.no.: 482 17 000
05.02 ill.1

06.05.02.01 Components of E - box; to eng.no.: 482 17 000
Designat. Component Description
A5 E - box control unit

F1 fuse 50 A main fuse
F2 fuse 50 A glow plugs
F4 fuse 5 A permanent current module
F5 fuse 10 A switched current for module (K27)
F6 fuse 10 A fuel pump (K24)
J1 plug 23-pole connection engine cable - instrument cable
K24 relay fuel pump
K26-1 relay preheating
K26-2 realy preheating
K27 relay main circuit
K28 relay start assist relay
X5 plug 35-pole module
06.05.02.02 Connection start assist relay K28
05.02 ill.2
06.05.02.03 Connection relay socket for K24, K26-1, K26-2 and K27
05.02 ill.3

06.05.02.04 Wiring harness; to eng.no.: 482 17 000
Designation Component Description
A5 E-box control unit

F4 fuse 5 A permanent current modul and K27
G1 alternator
G2 battery to be provided by customer
J1 23-pole plug connection engine cable - instrument cable
K24 relay fuel pump
K26-1 relay preheating - load circuit
K28 relay start
M1 starter
M2 fuel pump
R10 glow pins
X2 (S2) 2-pole plug gear switch
X5 (A5) 35-pole plug module

X12 (B12) 3-pole plug boost-pressure sensor
X13 (B13) 5-pole plug pot. accelerator
X14 (B14) 3-pole plug pot. rack position
X15(B15) 3-pole plug engine speed sensor
X16 B(16) 2-pole plug engine temperature sensor
X17 (B17) 2-pole plug exhaust gas temperature sensor
X18 (B18) 3-pole plug oil pressure sensor
X19 (B19) 1-pole plug oil pressure gauge (optional)
X20 (Y20) 2-pole plug control solenoid
X22 (B22) without stop trim sensor (optional)
X23 6-pole plug diagnosis
Z1 splice spot earth connection sensor

Z2 splice spot earth connection (31) on engine
Z3 splice spot sensor supply +5V
Z4 splice spot earth connection (31) on E-box plate
Cable numbers / principal functions:

15000-xx ignition - positive 31100-xx Do not connect earth for sensors
(from ignition switch) with battery-negative!
15012-xx +12 volt via main relay 601xx-01 Sensor signal to control unit
and control unit A5 A5 and/or instruments.
15100-xx +5 volt supply voltage for sensors 606xx-01 Output from control unit A5
30000-xx battery-positive (not secured) to display system (tachometer,
30012-xx battery-positive (secured) temperature display, ...)
31000-xx battery-negative (GND)

05.02 ill.4 Wiring harness; to eng.no.: 482 17 000

Circuit diagram; to eng.no.: 482 17 000 05.02 ill.5

Line designations from - to

Wiring harness; to eng. no.:48 217 000
cable No. designation from --> pin No. end point --> to pin No.
15000-01 J1 plug engine / instruments A K24 relay fuel pump 86
15000-02 J1 plug engine / instruments B K24 relay fuel pump 86
15000-03 X5 control unit (A5) 19 K24 relay fuel pump 86
15012-01 X20 control solenoid(Y20) 1 X5 control unit (A5) 17
15012-02 X5 control unit (A5) 18 K27 main circuit relay 87
15012-03 K27 main circuit relay 87 K26/1 relay preheating 86
15012-04 K26/1 relay preheating 86 K26/2 relay preheating 86
15012-06 X15 speed sensor (B15) C K26/2 relay preheating 86
15100-01 X5 control unit (A5) 3 Z3 link (splice)
15100-02 X13 pot. accelerator (B13) 5 Z3 link (splice)
15100-05 X12 boost press. sensor(B12) 3 Z3 link (splice)
15100-06 X14 pot. rack position (B14) C Z3 link (splice)
15100-07 X18 oil pressure sensor (B18) B Z3 link (splice)
17415-01 F2 50A fuse glow plugs IN K26/1 relay preheating 87
17415-02 F3 50A fuse glow plugs IN K26/2 relay preheating 87
30000-03 K26/1 relay preheating 30 K28 starter relay 30
30000-04 K26/2 relay preheating 30 K28 starter relay 30
30000-05 F1 50A main fuse IN starter solenoid 30
30012-01 X5 control unit (A5) 1 F4 fuse control unit 2
30012-02 K27 main circuit relay 86 F4 fuse control unit 2
30012-03 X23 diag 6 K27 main circuit relay 86
30012-04 K27 main circuit relay 30 F5 fuse control unit 2
30012-05 F1 50A main fuse OUT F5 fuse control unit 1
30012-06 F1 50A main fuse OUT F6 fuse fuel pump 1
30012-07 F1 50A main fuse OUT J1 plug engine / instruments C
30012-08 F1 50A main fuse OUT J1 plug engine / instruments D
30012-09 F5 fuse control unit 1 F4 fuse control unit 1


30055-01 K24 relay fuel pump 30 F6 fuse fuel pump 2
31000-01 J1 plug engine / instruments E Z2 - mass point
31000-02 J1 plug engine / insruments F Z2 - mass point 32
31000-03 Z4 earth connection in box X15 speed sensor (B15) 3
31000-04 fuel pump (M2) (M5)negat. Z2 link (splice)
31000-05 X23 diag 1 Z2 link (splice)
31000-06 S4 earth connection in box X5 control unit (A5) 2
31000-07 X2 gear switch(S2) 2 S2 link (splice)
31000-08 S4 earth connection in box Z2 earth connection engine
31100-01 X5 control unit (A5) 20 Z1 link (splice)
31100-07 X16 ECT (B16) 2 Z1 link (splice)
31100-08 X12 MAP (B12) 2 Z1 link (splice)
31100-09 X14 RACK (B14) A Z1 link (splice)
31100-10 X18 oil pressure sensor (B18) A Z1 link (splice)
31100-11 X17 sensor exh.gas temp.(B17) 2 Z1 link (splice)
31409-01 X20 control solenoid (Y20) 2 X5 control unit (A5) 35
31554-01 K24 relay fuel pump 85 X5 control unit (A5) 22
31555-01 K26/1 relay preheating 85 X5 control unit (A5) 7
31555-02 K26/1 relay preheating 85 K26/2 relay preheating 86
31558-01 K27 main circuit relay 85 X5 control unit (A5) 24
31615-01 J1 plug engine / instruments H X5 control unit (A5) 6
50000-01 K28 starter relay 87 X5 control unit (A5) 13
50000-02 K28 starter relay 86 J1 plug engine / instruments S
50000-03 K28 starter relay Kl.86 J1 plug engine / instruments T
60110-01 X12 MAP (B12) 1 X5 control unit (A5) 28


60111-01 pot. accelerator B13 2 X5 control unit (A5) 12
60112-01 X14 RACK (B14) B X5 control unit (A5) 11
60113-01 X15 speed sensor (B15) 2 X5 control unit (A5) 33
60114-01 X16 ECT (B16) 1 X5 control unit (A5) 9
60116-01 X13 pot. accelerator (B13) 1 X5 control unit (A5) 30
60117-01 X18 oil pressure sensor (B18) C X5 control unit (A5) 10
60118-01 X17 sensor exh.gas temp.(B17) 1 X5 control unit (A5) 27
60121-01 J1 plug engine / instruments P oil pressure gauge optional
60122-01 X2 gear switch(S2) 1 X5 control unit (A5) 14
60412-01 M2 fuel pump (M4)posit. K24 relay fuel pump 87
60613-01 J1 plug engine / instruments N X5 control unit (A5) 8
60614-01 J1 plug engine / instruments K X5 control unit (A5) 26
60616-01 J1 plug engine / instruments G X5 control unit (A5) 25
60706-01 J1 plug engine / instruments J X5 fixed rotation speed (A5) 29
60808-01 Z 5 60808 X5 control unit (A5) 32
60808-02 Z 5 60808 J1 plug engine / instruments M
60808-03 Z 5 60808 X23 diag 2
60810-01 J1 plug engine / instruments R X5 control unit (A5) 23
60900-01 X23 diag 5 X5 control unit (A5) 15
60901-01 X23 diag 4 X5 control unit (A5) 16
61000-02 alternator D+ D+ J1 plug engine / instruments L
network shield B15 S4 earth connection E-box
Z5 was only built up for wiring harnesses up to engine No. 48217020 (no function),
J1 / M on panel wiring harness „ free „.

06.05.03 E - box base plate; from eng. no.: 482 18 000 / 682 18 000 + SOLAS
05.03 ill.1

06.05.03.01 Components of E-box; from eng. no.: 482 18 000 / 682 18 000 + SOLAS
A5 E - box control unit

F4 fuse 5 A permanent current module
F6 fuse 10 A fuel pump
J1 plug 23-pole connection engine cable - instrument cable
K24 relay fuel pump
K26-1 relay preheating
K26-2 realy preheating
K28 relay start
X3 plug 2-pole inversion switch (for SOLAS only)
S3 inversion switch (for SOLAS only)
X5 plug 35-pole module
06.05.03.02 Connection relay K28 and K26/2
05.03 ill.2
06.05.03.03 Connection relay socket for K24, K26-1 and K27
05.03 ill.3

06.05.03.04 Wiring harness; from eng.no.: 482 18 000 / 682 18 000 + SOLAS
Designation Component Description
A5 E-Box control unit

F4 fuse 5 A permanent current modul and K27
F7 fuse 10 A preheating - control circuit
G1 alternator
G2 battery to be provided by customer
J1 plug 23--pole connection engine cable - instrument cable
K24 relay fuel pump
K26-1 relay preheating - control circuit
K28 relay start
M1 starter
M2 fuel pump
R10 glow pins
X2 (S2) plug 2-pole gears switch
X3 (S3) plug 2-pole inversion switch ( only SOLAS)
X5 (A5) plug 35-pole module
X12 (B12) plug 3-pole boost-pressure sensor
X13 (B13) plug 5-pole potentiometer accelerator
X14 (B14) plug 3-pole pot. rack position
X15(B15) plug 3-pole engine speed sensor
X16 B(16) plug 2-pole engine temperature sensor
X17 (B17) plug 2-pole exhaust gas temperature sensor
X18 (B18) plug 3-pole oil pressure sensor
X19 (B19) plug 1-pole oil pressure gauge (optional)
X20 (Y20) plug 2-pole control solenoid
X22 (B22) without stop trim sensor (optional)
X23 plug 6-pole diagnosis
X26 (Y26) plug 2-pole disconnection blow-by (only SOLAS)
Z1 splice spot earth connection sensor
Z2 splice spot earth connection (31) on engine
Z3 splice spot sensor supply +5V
Z4 splice spot earth connection (31) on E-box plate
Z6 splice spot shield speed sensor line
Cable numbers / principal functions:

15000-xx ignition - positive 31100-xx Do not connect mass for sensors
(from ignition switch) with battery negative!
15012-xx +12 volt via main relay 601xx-01 Sensor signal to modulator unit
and modulator unit A5 A5 and/or instruments.
15100-xx +5 volt supply voltage for sensors 606xx-01 Exit from modulator unit A5
30000-xx battery-positive (not secured) to display system (tachometer,
30012-xx battery-positive (secured) temperature display, ...)
31000-xx battery negative (GND)
Wiring harness;
from eng.no.:
482 18 000 + SOLAS
682 18 000 + SOLAS 05.03 ill.4

ToC
WIRING DIAGRAM / MARINE BASE - 4/6 CYLINDER - 12V
Batt +
Batt -
Ign 15
Supplied by Relais
Sens ECU K X
L
W
J1 M
B J
Page ELECTRICAL SYSTEM - 32

Control ECU H V
N C
A
DIAG G U
O D
E F T
Start P
Q R S
Charge D+
Sens 5V
Sens - 61001-02
B+ 24V
CAN
STARTER
60901-03
J1 / U
60900-03
J1 / V
R10/5
6 CYL.
R10/1
R10/2 4 CYL.
R10/3
R10/4 4 CYL.
R10/6
CONNECTOR "A5" (ENGINE-CONTROL-UNIT) 60808-01 ISO 6 CYL.
Z5
60 60900-01 CAN-H
123
-01 X23
60901-01 CAN-L 60900-02 6
WS 5
1
4
5 CAN "H" 2
Z6 60901-02 3
4 CAN "L" 6
5 1
4 2
3
X3
Wiring LPS / All engines before 2007
60123-01 X3/S3 Invers
EXT
31000-11 X3/S3 Solas
A
15100-07
Optional
31100-10
24V DC
60117-01
Wiring MAP / All engines before 2007 D+ B+

ALL ENGINE EXCEPTIONS:
TYPES WITH ONLY FOR TYP:
FOLLOWING MO 164M40
EXCEPTIONS MO 174V40
MO 246K41
A
MO 256H45
MO 256K43
15100-05
15100-05
31100-08
31100-08
05.03 ill.5
MO 266K43
60110-01 60110-01
www.steyr-motors.com 2179349/0-02-070118_tedoc
Z001019/0_6_July 2008
WIRING DIAGRAM / MARINE - 6 CYLINDER - 24V (OPTION)
Batt +
Batt -
Ign 15
Supplied by Relais
Z001019/0_6_July 2008
Sens ECU
Control ECU L
K X
W
J1 M
DIAG B J
N C H V
A
Start G U
O D
E F T
Charge D+ P
Q R S
Sens 5V 60120-01
Preheating Preheating Start
Sens - Fuel Pump Main Control Relay Load Relay Relay
B+ 24V Relay Relay Trim-Sensor
Control K28 61001-02
K24 K27 K26/1 K26/2 (Option)
Solenoid
B22
Y20
M2
STARTER
Fuel 60901-03
Pump J1 / U
60900-03
J1 / V
F8 - 5 A
R10
60120-01
G2
CONNECTOR "A5" (ELECTRONIC-CONTROL-UNIT) 60808-01 ISO
Z5
60 60900-01 CAN-H
123
-01 X23
60901-01 CAN-L 60900-02 6
AUX LPS ECT EXT WS 5
1
4
5 CAN "H" 2
3
Z6 60901-02
4 CAN "L" 6
5 1
4 2
3
S3
Wiring LPS / All engines before 2007 Sensor Oil
LPS Map Pressure 60123-01 X3/1 Invers
B18 B12 RPM Gear Gauge
ECT EXT PED RPOS Switch (Option)
B15
31000-11 X3/2 Solas
B16 B17 B13 B14 S2 B19
A
F8
15100-07
61001-01
31100-10
60117-01
Wiring MAP / All engines before 2007

Batt + / 24V
D+ B+
B-
FOLLOWING MO 164M40 Batt - / 24 V G1
MO 246K41
A
MO 256H45
MO 256K43
15100-05
15100-05
31100-08
31100-08
MO 266K43
05.03 ill.6
60110-01 60110-01

ToC
WIRING DIAGRAM / MARINE - 4/6 CYLINDER - 2-POLE - 12V (OPTION)
Batt +
Batt -
Ign 15
Supplied by Relais
Sens ECU
Control ECU
DIAG

Start
Charge D+
Sens 5V
Sens -
B+ 24V
CAN
R10/5
6 CYL.
R10/1
R10/2 4 CYL.
R10/3
R10/4 4 CYL.
R10/6
60808-01 ISO 6 CYL.
Z5
60 60900-01 CAN-H
123
-01
60901-01 CAN-L 60900-02
WS
Z6 60901-02
15100-07
31100-10
60117-01

FOLLOWING MO 164M40
MO 246K41
05.03 ill.7
A
MO 256H45
MO 256K43
15100-05
15100-05
31100-08
31100-08
MO 266K43
60110-01 60110-01 www.steyr-motors.com 2179350/0-02-070118_tedoc
Z001019/0_6_July 2008
Batt +
Batt -
Ign 15
Supplied by Relais
Z001019/0_6_July 2008
Sens ECU
Control ECU
DIAG
Start
Charge D+
Sens 5V
Sens -
B+ 24V
CAN
R10/5
R10/1
R10/2
R10/3
R10/4
R10/6
60808-01 ISO
Z5
60 60900-01 CAN-H
123
-01
60901-01 CAN-L 60900-02
WS
Z6 60901-02
15100-07
31100-10
60117-01

FOLLOWING MO 164M40
MO 246K41
A
MO 256H45
MO 256K43
15100-05
15100-05
31100-08
31100-08
MO 266K43
05.03 ill.8
60110-01 60110-01

06.06 ELECTRONICS - GENERAL
Wiring
In case of necessary repair of a cable connection, take special care that cable quality,
isolation, crimping, strand end soldering of cable sockets as well as protective varnish isolation
and/or connector locks meet the respective requirements.
Tools for crimp connections to be found in tool catalog P/N Z001002/0 "Level 4".
06.06.01 Electronic Engine Management System

The STEYR Marine engine is equipped with an Electronic Management System (EMS) that
performs the following:
* controls engine functions to ensure maximum efficiency.
* self-diagnostic to protect the engine from damage if operating parameter are exceeded.
* stores diagnostic data of EMS server circuits for maintenance and service.
Engine power is reduced if:

High engine coolant Reduction of Horn ON 2x p. sec. Steyr Diag See table trouble
temperature engine speed Gauge reading > Power limitation shooting:
limit exceeded 107 °C Cooling system
Defect - engine coolant Reduction of Horn ON 2x p. sec. Steyr Diag Sensor or connector
sensor or engine speed Gauge reading > Service code failure; see service
sensor connection 120 °C code table
Exhaust temperature Reduction of Horn and indication Steyr Diag See table trouble
limit exceeded engine speed light "CEL" ON 2x Power limitation shooting: Raw water
p. sec. cooling system
Defect - Exhaust Reduction of Horn and indication Steyr Diag Sensor or connector
temperature sensor or engine speed light "CEL" ON 2x Service code failure; see service
sensor connection p. sec. code table
Oil pressure below limit Reduction of Horn continuos and Steyr Diag See table trouble
engine speed Oil indication light Power limitation shooting:
continuos switched Engine oil system
ON
Defect - Oil pressure Reduction of Oil pressure indication Steyr Diag Sensor or connector
sensor or sensor engine speed light switched ON 1x Service code failure; see service
connection p. sec. code table
Insufficient boost Reduction of Steyr Diag See table trouble

pressure or defictive engine speed Power limitation shooting:
sensor Air charge system


Engine speed sensor Higher or No RPM inication Steyr Diag See table trouble
fault unstable idle on tachometer Service code shooting:
speed, limited Speed sensor
performance
Engine speed remains No increase of Steyr Diag See table trouble

at idle engine speed if Service code shooting:
throttle is moved Accelerator
to max. potentiometer failure
Governor position Irregular engine Steyr Diag See table trouble

system speed or stalled Service code shooting:
engine Governing system
Inverse position shut Engine shut After engine stop Reset through ignition
down (SOLAS) down beyond horn remains OFF and then ON
70° deg. angle switched ON until
ignition reset
During break in phase Cel-ON at high Indication light Steyr Diag See information break
accelerator "CEL" is switched Break-in in procedure
position (more ON phase
than 75%)
Optical and audible warning signals as shown on the dash board, are illustrated in chapter "Operating Status
and Error Report"
06.06.02 Diagnostic system

The electronic engine management system controls the following parameters:
Oil pressure, boost pressure, coolant temperature, hi-riser (bend) temperature.
The electronic engine management system has an automatic self-test program checking all data
of electronic sensors. As soon as a fault is found, there is an optical or audible signal (refer to chart
"Error Codes").
Occurred faults remain stored until cancellation. Stored faults may be selected, analyzed and
cancelled by means of PC via diagnostic outlet.
A reference to one or several stored faults is the 5 second "TESTING" of the "CHECK-ENGINE
LAMP" and the "WARNING HORN" after ignition ON, instead of usual 0,7 seconds. (refer to chart
"Operating Status")
On the CHECK-ENGINE lamp (E) stored faults may be indicated by flashing codes. (With a
special procedure, (06.06.04) individual cancellation is possible.) Error codes are regarded both as
flashing codes as will as display by diagnostic instrument.
There are three fault categories: temporary faults, non essential faults and essential faults.

06.06.03 Reading Error Codes
Entering and reading of stored faults via Check Engine Lamp and Diagnostic Outlet Plug ( X 23 ):
Needed device:
Tool No. VR00135/1
( normally closed push button switch )
connected to Diagnostic Outlet Plug X23.
In case this tool is not available:

Connect temporarily Pin - Pos. 1 with Pin - Pos. 2
of Diagnostic Plug X 23
( before ignition is turned on at key switch )
Code indication and indication sequence:

06.03 ill.1
After entering the error code indication modus the Engine
Management System will display a blink code at the Check Engine Light on the dash panel.
The blinking sequence will always begin and end with control code indication # 12. Each ERROR CODE will be
repeated 3 times to reassure your correct reading – see below bar code illustration.
Example sequence check engine light (ill.2/pos.1):

Error code # 14
06.03 ill.2
06.03 ill.3
Stroke = Check Engine Light illuminated for 0,3 sec. (Light Off - period within blink sequence 0,4 sec.)
Dashed Line = interruption within code indication 1,5 sec.

Solid Line = interval interruption between error code 3,0 sec.

If more then one error code is stored in the Engine Management System the indication sequence will be
continued blinking additional stored error codes. To delete a memorized error code see description Indication
and Cancellation of memorized sensor and circuit faults.
For a description of the possible error codes refer to enclosed Table – Error Codes
ATTENTION: To exit from Error code indication. Tool VR00135/1 must be removed
( connection between Pin 1 to Pin 2 opened ) before ignition is turned ON again.
06.06.04 Indication and Cancellation of memorized sensor and circuit faults
Selection and clearing of stored error codes:
Procedure:
* Ignition — OFF
* Connect Tool VR00135/1 to Diagnostic Outlet Plug ( X 23 ) – see 06.03 ill.1
* Ignition — ON
Note: The program changes automatically to indication of error codes.
If no error code is stored, only repeating control code reading “ CODE # 12 “ will be displayed.
Possible memorized codes are indicated as shown in the previous illustrated example ( blinking 3x
CODE # 12 i. e. 3x ERROR CODE # 14 etc. ) The sequence will be prolonged with additional codes if more
then one ERROR CODE is stored.
See Table – ERROR CODES for description
* To delete a determined ERROR CODE from the Engine Management System concentrate for the 3rd times
flashing the desired ERROR CODE. While this ERROR CODE is displayed the third time the button ( Tool
VR00135/1 ) must be pushed and kept in this position ( contact open ).
* The indication on the Check Engine Light changes to a fast blinking of the lamp ( app. 4 times per
sec. ). During this rapid flashing light the push button must be released ( close contact after app. 2
sec.) to delete this ERROR CODE.
Note: Any other ERROR CODE have to be selected and cleared individually following the above
mentioned procedure to delete a determined ERROR CODE.
Note: An ERROR CODE can only be deleted if no defect exists in this circuit. In case of a present active
failure, the ERROR CODE keeps reappearing until the problem has been repaired and the circuit is
properly working again.
* Disconnect Tool VR00135/1 from Diagnostic Outlet Plug ( X 23 ) to exit from error code display.
Note: Watch indication of the Check Engine Light and the Warning Horn after ignition contact. If all
ERROR CODES are deleted from the Engine Management System the indication resumes to 0.7 sec.
function test of Check Engine Light and the Warning Horn.
For more details see Chart – Operating Conditions - Instrument panel.

06.06.05 Principle failure code list

NOTE: Some codes may not apply due to different application!
REFER
TO
CODE ABBREV. CIRCUIT INVOLVED DEVICE POSSIBLE CAUSE
12 Control code this code is designated for beginning or end of loop
13 LoMap X12/B12 boost pressure sensor signal level too low (short circuit or missing contact)
14 HiMap X12/B12 boost pressure sensor signal level too high (missing connection)
17 LoEXH X17/B17 air charge temp. sensor signal level too low (short circuit or missing contact)
18 HiEXH X17/B17 air charge temp. sensor signal level too high (missing connection)
21 LoECT X16/B16 water temp. sensor signal level too low (short circuit or missing contact)
22 HiECT X16/B16 water temp. sensor signal level too high (missing connection)
23 LoPed1 X13/B13 potentiometer accelerator signal level entry too low
24 HiPed1 X13/B13 potentiometer accelerator signal level entry too high
25 LoVPWR F5/K27 main relay low voltage supply to ECU, F5, K27
26 HiVPWR F5/K27 main relay too high voltage on VPROT input
27 LoVREF X5/Z3 module, connector too low voltage on sensor supply, possible short circuit
28 HiVREF X5/Z1 module, connector too high voltage on sensor supply
29 PedS X13/B13 accelerator potentiometer defect on pedal safety switch, pin 1-2
31 LoLPS X18/B18 lubricant pressure sensor signal level too low (short circuit or missing contact)
32 HiLPS X18/B18 lubricant pressure sensor signal level too high (missing connection)
33 LoPed2 X13/B13 potentiometer accelerator signal level too low
34 HiPed2 X13/B13 potentiometer accelerator signal level too high (missing connection)
35 LoRPos X14/B14 rack position sensor signal level too low (short circuit or missing contact)
36 HiRPos X14/B14 rack position sensor signal level too high (missing connection)
37 LoLOP X18/B18 lubricant pressure sensor signal level too low (short circuit)
38 HiLOP X18/B18 lubricant pressure sensor signal level too high (missing connection)
53 N_RFI X15/B15 RPM-sensor radio interference / sensor input
54 BadSta M1-Pin50 K28 start assist relay no start signal from assist solenoid
55 NoPuls X15/B15 RPM-sensor no speed signal during crank
56 Srpos Y14(B14) refer to setting rack pos. rack calibration bad/rack position outside tolerance field

REFER
TO
CODE ABBREV. CIRCUIT INVOLVED DEVICE POSSIBLE CAUSE
57 Rack0 Y14(B14) refer to setting rack pos. bad rack zero position
defect in governor solenoid wire circuit (Y20, main
99 FMSpwm X20/Y20 actuator / solenoid relay K27-no frequency sent or govenor solenoid
circuit connected)
161 HiVTGc Y28 REA unit at turbo charger defect in circuit of actuator turbo charger (short circuit)
162 LoVTGc Y28 REA unit at turbo charger defect in circuit of actuator turbo charger (missing connection)
164 CELs L2 check engine lamp Current limit exceeded (short circuit)
165 CELo L2 check engine lamp missing connection or bulb blown
167 FPR_s K24 fuel pump relay Current limit exceeded in relay circuit (short circuit)
168 FPR_o K24 fuel pump relay no current detected in relay circuit (disconnection)
177 MR_s K27 main relay no current detected in main relay circuit (short circuit)
178 MR_o K27 main relay no current detected in main relay circuit (disconnection)
181 WarnLs L3 oil pressure lamp Current limit exceeded (short circuit)
182 WarnLo L3 oil pressure lamp no current in circuit of oil pressure lamp
186 BadPos Y20 governor solenoid Nominal-actual value difference (rack pos. error, rack jammed)
187 HiFMSC X20/X20 governor solenoid defect in governor wire circuit (resistance too high)
(bulb blown or missing connection)
188 LoFMSc X20 governor solenoid defect in governor wire circuit (resistance too low)
193 VTG_Bad Y28 REA unit at turbo charger defect in output circuit (short circuit or missing connection)
194 GPR_s K26 glow assist relay current limit exceeded in glow plug relay circuit (short circuit)
195 GPR_o K26 glow assist relay no current detected in glow plug relay circuit (disconnection)
201 HiTEMP -- operation limit exceeded - engine was operated with too high coolant temperature
engine overheated
202 Lop -- operation limit exceeded - engine was operated with too low lubricant pressure
lubricant pressure too low
203 Manop -- operation limit exceeded - engine operated with manual movement of rack
rack position too high
251 ITSL_Bad B30 position sensor - ITD signal level too low (short circuit) on injection timing sensor
252 ITV_LoCur Y29 proportional valve - ITD defect in circuit of valve (no current flow)
253 ITV_HiCur Y29 proportional valve - ITD defect in circuit of valve (current value too high)
254 SpvP_Bad B30 position sensor or ITD commanded timing position can not be achieved
(sensor or injection timing device defect, eccenter
shaft jammed)
255 Spv_INI B30 reference-position timing position calibration bad (position out of tolercance)
sensor ITD

06.06.06 REPLACE FUSES
Preparatory works: Engine out of operation,

disconnect battery.
Replace automatic circuit breaker
1 Swing off E-box base plate.
2 Disconnect cable from automatic circuit breaker.
3 Loosen 2 hexagon screws (ill.1/pos.1) (SW1/4") and

take off thermal circuit breaker (ill.1/pos.2).
3
2
1
NOTE: For assembly, seal cable screw
connections with rubber varnish. 06.06 ill.1
Replace fuses
1 Remove E-box cover.
2 Remove fuse protection cap.

Pull out fuses (ill.1/pos.3)
Replace defect fuse.

06.06.07 Connection J1
06.07 ill.1
Pin Cable - no. Explication
A 15000-01 ignition 15
B 15000-02 ignition 15
C 30012-07 terminal 30
D 30012-08 terminal 30
E 31000-01 ground connection
F 31000-02 ground connection
G 60616-01 lamp - oil pressure L3
H 31615-01 warning horn
J 60706-01 const. speed switch
K 60614-01 temperature display
L 61000-02 alternator D+
M blind plug
N 60613-01 tachometer (speed)
O 60121-01 oil pressure gauge (optional)
P 60810-01 check engine lamp
Q 50000-02 ignition lock start
R 50000-03 ignition lock start
S 60120-01 trim (optional)
T 61001-02 alternator B+ 24V DC (ifused)
U 60901-03 CAN-low
V 60900-03 CAN-high
W blind plug
X blind plug

06.06.08 Connection A5 and X5
06.08 ill.1
Pin Cable no. Designation Explication
1 30012 / 01 Vbat terminal 30

2 31000 / 06 GND terminal 31
3 15100 / 01 Vref + 5V
4 free free not busy
6 60616 / 01 GPL oil pressure lamp L3
7 31555 / 01 GPR preheating relay
8 60613 / 01 Tacho speed instrument
9 60114 / 01 ECT engine coolant temperature sensor
10 60117 / 01 LPS oil pressure sensor
11 60112 / 01 RPOS pot. rack position
12 60111 / 01 PED1 pedal 1
13 50000 / 01 CRI start signal identification
14 60122 / 01 CLS gear switch
15 60900 / 01 CANH canbus high
16 60901 / 01 CANL canbus low
17 15012 / 01 VPROT2 direct supply line to control solenoid
18 15012 / 02 VPROT protected 12V (after K27 and protective
wiring in governor)
19 15000 / 03 IGN ignition terminal 15
20 31100 / 01 Gnd Vref sensor ground connection
22 31554 / 01 FPR fuel pump relay
23 60810 / 01 CEL check engine lamp
24 31558 / 01 MR main relay (K27)
25 31615 / 01 WOUT warning horn
26 60614 / 01 TEMP temperature display
27 60118 / 01 EXT exhaust gas water temperature
28 60110 / 01 MAP boost pressure sensor
29 60706 / 01 AUX fixed speed
30 60116 / 01 PED2 pedal 2
31 60123 / 01 WS warning switch / Solas inversion switch
32 60808 / 01 ISO ISO 9141 (diag. cable)
33 60113 / 01 RPM engine speed sensor
35 31409 / 01 FMS approach line for control solenoid

06.06.09 Fitting main connector "J1" properly
" J1" Fitting Main Connector - M1 / 01

06. 07. INSTRUMENT PANEL
B A H
I 07.00 ill.1
G F
Instrument panel, standard

A tachometer G blind plug - installation option for
B engine temperature key switch constant revolution
C warning light - battery charge H blind plug - installation option for
D combined light preheating control & oil pressure gauge or
warning light engine oil pressure voltmeter 12V
E warning light check engine I audible warner
F ignition key lock (installed to rear side of paneel)

06. 07. 01 Chart - Operating Status
Instrument indication during normal operation
1. ignition ON (... until engine start)

light indication
System check - see light indication
ON NOTE:
At low temperature condition (cold weather)
ON (0,7 sec.) the combined light for glow plug preheating &
warning light engine oil pressure will not
extinguish after 0,7 sec. (glow plug preheating
ON (0,7 sec.)
phase)
In this case start engine immediately after the
light extinguishes.
07.01 ill.1
ON (0,7 sec.)

light indication Indication active error
ON
ON (0,7 sec.)
ON (5 sec.)
07.01 ill.2
ON (5 sec.)
3. engine running after start

Normal condition
OFF
OFF
OFF
07.01 ill.3 OFF
NOTE:
Further information see:
"Table - Error indication on Instrument
Panel"

06. 07. 02 Chart - Error indication on Instrument Panel
B 07.02 ill.1
A temperature gauge - coolant D combined light preheating control &

B audible warner warning light engine oil pressure
C warning light - battery charge E warning light check engine
Operating condition: During normale engine operation, or indication in case of sensor defect while
ignition is switched ON.
Event: Speed resp. performance limitation during engine operation
Indication status Fault Remarks
80° - 90°C
OFF oil pressure below min. check oil level

limit
ON
ON
OFF
07.02 ill.2
80° - 90°C
OFF fault oil pressure check oil pressure sensor

sensor or (B18) and connection
sensor connection
FLASHING
OFF
(1x per sec.)
OFF
07.02 ill.3
NOTE: (see cap. general, D3)
ON engine overload during reduce throttle position
ON break-in period until light goes OFF
(indication during first 2
hours of operation)

ToC SERVICE MANUAL MARINE ENGINES ELECTRICAL SYSTEM
80° - 90°C
OFF high exhaust check raw water

temperature system,
(off 80° C) strainer, impeller pump
OFF
ON
FLASHING
(2x per sec.)
(2x per sec.)
07.02 ill.4
high approx 105°C
OFF engine coolant after cooling down,

temperature to high check engine coolant
level
OFF
ON
OFF
(2x per sec.)
07.02 ill.5
120°C
OFF defect engine coolant after cooling down,

sensor or check engine coolant
sensor connection level, sensor (B16)
OFF and connection
ON
OFF
(2x per sec.)
07.02 ill.6
80° - 90°C
instable idle speed, defect speed sensor (B15)
OFF no indication on or
tachometer sensor connection
OFF
OFF
OFF
07.02 ill.7
80° - 90°C
OFF Trouble in governing loop, Failure in governing loop:

involved components: time limit exceed for rack
control solenoid, rack, positioning. Restriction
OFF control gear of or high friction in control
ON
unit injector, devices.Stored failure code
rack position sensor must be cleared memory.
ON
Tool: PC-service program
07.02 ill.8

ELECTRICAL SYSTEM
During start attempt
ON Engine will not start. Failure in governing circuit.

Failure in governing Positioning of rack
circuit not possible.
OFF Trouble shooting of control
ON
solenoid, rack, control gear
of unit injection,
ON
rack position sensor
07.02 ill.9


ELECTRICAL SYSTEM
06.07.03 Instrument panel (for SOLAS only)
A B
J C D E H
07.03 ill.1
A tachometer with G push button START (green)

service hour meter
B temperature gauge - coolant H blind plug - installation option for
C warning light - battery charge oil pressure gauge or
D combined light preheating control & voltmeter 12V
warning light engine oil pressure
E warning light - check engine light I emergency cut off switch
F push button - ignition ON/OFF (red) J audible warning device

(installed to rear side of panel)
NOTE: Instrument gauges are automatically illuminated if ignition is turned ON.
NOTE: In case an inversion occured, the engine gets shut down automatically to re-establish regular
running and operation the push button Ignition (F) must be switched OFF and then ON again and
engine must be restarted with push button START (G).

06.07.04 Chart - Operating Status (for SOLAS only)
Instrument indication during normal operation

07.04 ill.1 System check - see light indication
NOTE:
At low temperature condition (cold weather)
the combined light for glow plug preheating &
warning light engine oil pressure will not
extinguish after 0,7 sec. (glow plug preheating
phase)
In this case start engine immediately after the
light extinguishes.
ON
ON (0,7 sec.)
ON (0,7 sec.)
ON (0,7 sec.)

07.04 ill.2
Indication active error
ON
ON (0,7 sec.)
ON (5 sec.)
ON (5 sec.)
3. engine running after start

07.04 ill.3
Normal condition
NOTE:
Further information see:
"Table - Error indication on
Instrument Panel"
OFF

ELECTRICAL SYSTEM
06.07.05 Error Indication - Error indication on instrument panel

A
(for SOLAS only)
B C D E 07.05 ill.1
A temperature gauge - coolant D combined light preheating control &

B audible warning device warning light engine oil pressure
C warning light - battery charge E warning light - check engine light
Operating condition: During normal engine operation,
or indication in case of sensor defect while ignition is switched ON.
Event: Speed resp. performance limitation during engine operation
ON 80° - 90°C
oil pressure below min. check oil level
limit
OFF ON
OFF
07.05 ill.2
OFF 80° - 90°C
fault oil pressure check oil pressure sensor

sensor or (B18) and connection
sensor connection
OFF FLASHING OFF

07.05 ill.3 (1x per sec.)
NOTE: (see cap. general, D3)
engine overload during reduce throttle position until light
ON ON break-in period goes OFF (indication during first 2
hours of operation)
ON 80° - 90°C
high exhaust check raw water
temperature system,
(off 80° C) strainer, impeller pump
(2x per sec.)
OFF OFF FLASHING

07.05 ill.4 (2x per sec.)
ON high approx 105°C

engine coolant after cooling down,
temperature to high check engine coolant
level
(2x per sec.)
OFF OFF OFF

07.05 ill.5
ON 120°C
defect engine coolant after cooling down,
sensor or check engine coolant
(2x per sec.) sensor connection level, sensor (B16)
and connection
OFF OFF OFF

07.05 ill.6
OFF 80° - 90°C

instable idle speed, defect speed sensor (B15)
no indication on or
tachometer sensor connection
OFF OFF OFF

07.05 ill.7
ON 80° - 90°C
Trouble in governing loop, Failure in governing loop:
involved components: time limit exceed for rack
control solenoid, rack, positioning. Restriction
control gear of or high friction in control
unit injector, devices.Stored failure code
rack position sensor must be cleared memory.
Tools: PC-service program
OFF OFF ON
07.05 ill.8
ELECTRICAL SYSTEM
During start attempt

ON
Engine will not start. Failure in governing circuit.
Failure in governing Positioning of rack
circuit not possible.
Trouble shooting of control
solenoid, rack, control gear
of unit injection,
rack position sensor
ON OFF ON
07.05 ill.9


ELECTRICAL SYSTEM
06. 07. 10 6 Cyl. Wiring harness instrument panel (if alternator "PRESTOLITE" is
used - old version)
F9 fuse
J1 23-pin plug connection engine cable - instrument cable
S1 switch ignition
S7 switch fix-n (speed-selector switch optional)
K10 relay charge control (90A PRESTOLITE)
L1 lamp charge control
L2 lamp cel - check engine lamp
L3 lamp oil pressure / pre-heating control
P1 gauge coolant
P2 gauge oil pressure (optional)
P3 gauge tachometer with running-time meter
P4 gauge trim (optional)
H22 warning horn
XS8 1-pin plug to lighting switch - instrument panel
XS9 2-pin plug charging control/relay charging control (wiring harness side)
XS10 2-pin plug charging control/relay charging control (instrument side)
X1/S1 4-pin plug ignition
X2/L1 10-pin plug charge control lamp
X3/L2 10-pin plug cel - check engine lamp
X4/L3 10-pin plug oil pressure warning lamp
X5/E10 2-pin plug lighting coolant display
X6/P1 3-pin plug coolant temperature gauge
X7/E11 2-pin plug lighting oil pressure
X8/P2 3-pin plug oil pressure gauge
X9/S7 10-pin plug speed-selector switch (optional)
X11/P3/E12 8-pin plug speed instrument / lighting speed instrument
X12/E13 2-pin plug lighting trim (optional)
X22/P4 3-pin plug trim (optional)

6 Cyl. Wiring harness instrument panel (if alternator "PRESTOLITE" is

used - old version)
07.10 ill.1

ELECTRICAL SYSTEM

used - old version)
F9 fuse
S1 switch ignition
S7 switch fix-n (speed-selector switch optional)
K10 relay charge control (90A PRESTOLITE)
L3 lamp oil pressure / pre-heating control
P1 gauge coolant
P4 gauge trim (optional)
H22 warning horn
XS8 1-pin plug to lighting switch - instrument panel
XS9 2-pin plug charging control/relay charging control (wiring harness side)
XS10 2-pin plug charging control/relay charging control (instrument side)
X1/S1 4-pin plug ignition
X2/L1 10-pin plug charge control lamp
X3/L2 10-pin plug cel - check engine lamp
X4/L3 10-pin plug oil pressure warning lamp
X5/E10 2-pin plug lighting coolant display
X6/P1 3-pin plug coolant temperature gauge
X7/E11 2-pin plug lighting oil pressure
X8/P2 3-pin plug oil pressure gauge
X9/S7 10-pin plug speed-selector switch (optional)
X11/P3/E12 8-pin plug speed instrument / lighting speed instrument
X12/E13 2-pin plug lighting trim (optional)
X22/P4 3-pin plug trim (optional)


used - old version)
07.10 ill.2

ELECTRICAL SYSTEM
06. 07. 11 Description - Wiring harness instrument panels 4/6 cyl. marine engines
(current version)
F9 fuse 10 A
S1 switch ignition (red)
S2 switch start (green)
S3 switch emergency cut off (orange)
S7 switch key switch constant revolution (optional)
L3 lamp oil pressure / preheating conrol
P1 gauge engine coolant temperature
H22 warning horn
E10 lighting engine coolant temperature gauge
E11 lighting oil pressure gauge (optional)
E12 lighting tachometer gauge
X8 1-pin plug connector illumination switch
X24 8-pin plug connector STEYR - display
Z1 splice battery +
Z2 splice battery -
Z3 splice ignition (+)
Z4 splice key switch constant revolution
24 V interm. cable charge indicator

WIRING DIAGRAM / INSTRUMENT PANEL - 4/6 CYLINDER - 12 V
°C
80
40
105 175 10
0
°F 210 20
12
250
0
SCC
10 30
K X 0 40 STEYR-CONTROL-CENTER
L 49.16.45N
48.08.56N 102.41.11W 117 14:05
014.27.47W 57,4 22:57
W
M SPEED/KN RPM MAIN
J1 B J
OIL- Engine 34
10.0 2 3 1500
2650
rpm x 1000
1 4
H V Charge Check Preheating Coolant Lighting Opt. Key Opt. Gauge Lighting Lighting 0 5
Z001019/0_6_July 2008
N C
SWITCH
A 3 4 4 3 85 4
22 bar 65 2 °C 5
G U Ignition Control Engine control Temperature ECT- Switch-Constant Oil- Opt. Gauge RPM- RPM- Warning 0
1 8
6 50
1 120
6
2,8
6.3 73
77.8
OIL TEMP
O D OIL/BAR TEMP/°C
E F T Switch Lamp Lamp Lamp Gauge Gauge Revolution Pressure Oil-Pressure Gauge Gauge Horn
P
Q R S S1 L1 L2 L3 P1 E10 S7 P2 E11 P3 E12 H22
Fuse 1 2 1 2 _ 1 2 14 22 13 21 + G _ 1 2 2 4 3 1 5
_ X 24
1 5 6 7 1 2 + G +
No./colours of shielded wire correspond to 1 2 3 4
10A
individual cable No. (15000-01)
F9
Z3
Z1
15000-01
J1 / A 1
58000-01
15000-02
J1 / B 2 Connector
30012-07 Illumination
J1 / C 3 X8 switch
30012-08
J1 / D 4
31000-01
J1 / E 5
Z2
3100-02
J1 / F 6
60616-01
J1 / G 7
31615-01
J1 / H 8
60706-01
J1 / J 9
Z4
60614-01
J1 / K 10
61000-02
J1 / L 11
31000-16 Ground shield
J1 / M
60613-01
J1 / N 13
60121-01
J1 / O 14
60810-01
J1 / P 15
50000-02
J1 / Q 16
50000-03 - Start
J1 / R 17 Batt + Start
60120-01
J1 / S 18 Trim (Option) Batt - Charge
61001-01 B+ / 24V
J1 / T 12 Sens ECU Illumination
60901-03
J1 / U 21 Control ECU Option
60900-03
J1 / V 22 61 +24V 15
J1 / W 19 (no connection) 60 CAN
J1 / X 20 (no connection)
ELECTRICAL SYSTEM

www.steyr-motors.com 2179338/D-02-070627_tedoc
ToC
WIRING DIAGRAM / INSTRUMENT PANEL - 4/6 CYLINDER - 24V (OPTION)

SCC
°C
80
40
105 175 10 STEYR-CONTROL-CENTER
0
°F 210 20
12
250
0 49.16.45N
48.08.56N 102.41.11W 117 14:05
014.27.47W 57,4 22:57
K X 10 30
SPEED/KN RPM MAIN

L
34
10.0 2 3 1500
2650
rpm x 1000
W 0 40 1 4
M
0 5
J1 B J
SWITCH
H V 3 4 4 3 85 4
22 65 2 5
N C OIL- Engine bar °C
0
1 8
6 50
1 120
6
A 2,8
6.3 73
77.8
OIL
OIL/BAR TEMP
TEMP/°C
G U Charge Intermediate Check Preheating Coolant Lighting Opt. Key Opt. Gauge Lighting Lighting
O D
E F T Ignition Control Cable Charge Engine control Temperature ECT- Switch-Constant Oil- Opt. Gauge RPM- RPM- Warning
P
Q R S Switch Lamp Indicator Lamp Lamp Gauge Gauge Revolution Pressure Oil-Pressure Gauge Gauge Horn
24 V L2 S7 P2 E11 E12
ELECTRICAL SYSTEM
S1 L1 L3 P1 E10 P3 H22
X 24
1 2 3 4
_ _

No./colours of shielded wire correspond to Fuse 1 5 6 7 1 2 85 86 87a 87 30 1 2 1 2 + G 1 2 14 22 13 21 + G 1 2 2 4 3 1 5
_
+
individual cable No. (15000-01) 10A
F9
Z3
Z1
15000-01
J1 / A 1
58000-01
15000-02
J1 / B 2 Connector
J1 / C 3 X8
switch
30012-08
J1 / D 4
31000-01
J1 / E 5 Z2
3100-02
J1 / F 6
60616-01
J1 / G 7
31615-01
J1 / H 8
60706-01
J1 / J 9
60614-01
Z4
J1 / K 10
61000-02
J1 / L 11
J1 / M
60613-01
J1 / N 13
60121-01
J1 / O 14
60810-01
J1 / P 15
50000-02
J1 / Q 16
50000-03 - Start
60120-01
Trim (Option)
J1 / S 18 Batt - Charge
61001-01 B+ / 24V
60901-03
60900-03
J1 / V 22 61 +24V 15
Z001019/0_6_July 2008
WIRING DIAGRAM / INSTR. PANEL - 4/6 CYL. - Solas - 12V (OPTION)
°C
80
40
105 175 10
0
SCC
°F 210 20
12
250
0
10 30
STEYR-CONTROL-CENTER
49.16.45N
48.08.56N 102.41.11W 117 14:05
014.27.47W 57,4 22:57
0 40
SPEED/KN RPM MAIN
34
10.0 2 3 1500
2650
rpm x 1000
OIL- Engine 1 4
K X 0 5
SWITCH
L
3 4 4 3 85 4
22 bar 65 2 °C 5
W Emergency Charge Check Preheating Coolant Lighting Opt. Key Opt. Gauge Lighting Lighting 0
1 8
6 50
1 120
6
M 2,8
6.3 73
77.8
OIL
OIL/BAR TEMP
TEMP/°C
J1 B J IGN (red) START CUT OFF Control Engine control Temperature ECT- Switch-Constant Oil- Opt. Gauge RPM- RPM- Warning
Z001019/0_6_July 2008
N C H V
A ON/OFF (green) Switch Lamp Lamp Lamp Gauge Gauge Revolution Pressure Oil-Pressure Gauge Gauge Horn
G U
O D
E F T S1 S2 S3 L1 L2 L3 P1 E10 S7 P2 E11 P3 E12 H22
P
Q R S
X 24
Fuse 1 2 1 2 1 2 + G _ 1 2 14 22 13 21 + G _ 1 2 2 4 3 1 5
_ 1 2 3 4
3 4 3 4 M M +
10A
F9
No./colours of shielded wire correspond to
individual cable No. (15000-01)
Z3
Z1
15000-01
J1 / A 1
15000-02
J1 / B 2 Connector
58000-01
J1 / C 3 X8 switch
30012-08
J1 / D 4
31000-01 Z2
J1 / E 5
3100-02
J1 / F 6
60616-01
J1 / G 7
31615-01
J1 / H 8
60706-01
J1 / J 9 Z4
60614-01
J1 / K 10
61000-02
J1 / L 11
J1 / M
60613-01
J1 / N 13
60121-01
J1 / O 14
60810-01
J1 / P 15
50000-02
J1 / Q 16
50000-03 - Start
60120-01
61001-01 B+ / 24V
J1 / T 12 Optional 24 V Sens ECU Illumination
60901-03 Control ECU Option
J1 / U 21
60900-03 61 +24V 15
J1 / V 22
J1 / W 19 ohne Anschlag (no connection) 60 CAN
J1 / X 20 ohne Anschlag (no connection)
ELECTRICAL SYSTEM

ToC
WIRING DIAGRAM / INSTR. PANEL - 4/6 CYL. - Solas - 24V (OPTION)

SCC
STEYR-CONTROL-CENTER
°C
80
40 49.16.45N
48.08.56N 102.41.11W 117 14:05
014.27.47W 57,4 22:57
105 175 10
0
°F 210 20
12 SPEED/KN RPM MAIN
250
0
10 30 34
10.0 2 3 1500
2650
rpm x 1000
1 4
K X
L 0 5
W 0 40 SWITCH
J1 M 3 4 4 3 85 4
22 bar 65 2 °C 5
B J 0
1 8
6 50
1 120
6
2,8
6.3 73
77.8
OIL
OIL/BAR TEMP
TEMP/°C
N C H V OIL- Engine
A
G U Emergency Charge Intermediate Check Preheating Coolant Lighting Opt. Key Opt. Gauge Lighting Lighting
O D
P
E F T IGN (red) START CUT OFF Control Cable Charge Engine control Temperature ECT- Switch-Constant Oil- Opt. Gauge RPM- RPM- Warning
Q R S ON/OFF (green) Switch Lamp Indicator Lamp Lamp Gauge Gauge Revolution Pressure Oil-Pressure Gauge Gauge Horn
ELECTRICAL SYSTEM
S1 S2 S3 L1 24 V L2 L3 P1 E10 S7 P2 E11 P3 E12 H22 X 24

1 2 3 4

Fuse 1 2 85 86 87a 87 30 1 2 1 2 + G _ 1 2 14 22 13 21 + G _ 1 2 2 4 3 1 5
_
3 4 3 4 M M +
No./colours of shielded wire correspond to 10A
individual cable No. (15000-01) F9
Z3
Z1
15000-01
J1 / A 1
58000-01
15000-02
J1 / B 2
Connector
J1 / C 3
X8 switch
30012-08
J1 / D 4
31000-01 Z2
J1 / E 5
3100-02
J1 / F 6
60616-01
J1 / G 7
31615-01
J1 / H 8
60706-01
J1 / J 9 Z4
60614-01
J1 / K 10
61000-02
J1 / L 11
J1 / M
60613-01
J1 / N 13
60121-01
J1 / O 14
60810-01
J1 / P 15
50000-02
J1 / Q 16
50000-03 - Start
60120-01
61001-01 B+ / 24V
60901-03
60900-03
J1 / V 22 61 +24V 15
Z001019/0_6_July 2008
www.steyr-motors.com 2179341/D-03-070627-tedoc

ELECTRICAL SYSTEM
06. 07. 13 ADJUST INSTRUMENTS

06. 07. 13. 01 Tachometer with running-time meter
There are 2 possible settings
Function "PULSE": - Entry of pulse rate

12,18 per revolution
- inductive sender
Function "ADJUST": - Using a reference rpm

meter (manual rpm meter),
the rpm is compared and
calibrated accordingly.
07.13 ill.1
Selection of function
Operating voltage off.
Press and hold down key on back of housing.
Operating voltage (ignition) on.
The display shows "PULSE" and "ADJUST"
every 2 seconds in alternation.
To select shown function, release the
key for respective indication.
Function "PULSE"
When the function PULSE is selected, "P12.18" 07.13 ill.2

(12.18 pulses per revolution) appears for example
on the display after approx. 3 seconds, with a flashing
last digit. Immediately start entry of known pulse rate
by repeated pressing of key.
The flashing digit may be adjusted by activating the

key (possible pulse settings: 0.50 to 399.99).
After having adjusted the flashing digit, wait for approx.
3 sec. Then the next digit begins to flash. At completion
of pulse rate setting, activate the key no more.
The display then changes over to counting of running-
time. Thus the setting procedure is completed.
By repeated selection of function PULSE the selected

pulse rate may be checked. The pulse rate appears
on the display and the individual digits begin to flash
in sequence, starting with the last digit.
07.13 ill.3
P-12,18

Function "ADJUSt"
When selecting the function "ADJUST", the rpm.

display may be adjusted between 30 and 100 % of
the measuring range.
Using a reference rpm meter (manual rpm meter),
the rpm indicator is compared.
Fine adjustment requires two persons, one to operate

the instrument and the other one to operate the
manual rpm meter on the axis of the engine's
crankshaft. Extreme caution is required! Do not wear
loose clothing!
When the function ADJUSt is selected, UP or dn (UP

or DOWN) appears in alternation on the display after
approx. 3 seconds.
If, for example, the key is pressed and held down 07.13 ill.4
when UP is displayed, the pointer deflection changes
upwards (for "dn" analogously downwards).
If you release the key for 2 seconds and then press
it again, the pointer deflection changes downwards.
At the beginning, the pointer deflection changes very
slowly which permits a very precise fine adjustment.
With a short release of the key, the procedure is
repeated. With a longer pressing of the key, the
pointer deflection will change faster. Release the key
as soon as the fine adjustment corresponds to the
reference rpm. The display then changes to counting
of running-time. Fine adjustment is completed.
Fine Adjustment:
During normal operation of the indicator, a fine

adjustment is possible by using the key. The
adjustment range is +/- 20 % of the actual reading.
Press the key, with voltage supply on.
On the display appears A 0.0
By pressing and holding the key, the adjustment

factor increases in steps of 0,5%.
If you release the key for 2 seconds and then press
it again, the adjustment factor decreases in steps of
0,5%.
If the key is not pressed for more than 5 seconds, the

adjustment factor will be stored and the indicator
switches back to the normal running-time display. 07.13 ill.5

ELECTRICAL SYSTEM
06. 07. 14 REPLACE INSTRUMENTS

06. 07. 14. 01. General notes on safety
Safety instructions
No smoking!
No open fire lights!
This product has been developed, produced and tested in compliance with the basic safety
requirements of EC directives and in accordance with the established state of the art.
Use our product for the intended purpose only.
The consequences of use of the product for other than the intended purpose may be personal injury
and damage to property as well as environmental damage.
The unit is designed for use in sports boats.
Record data of other instruments with transient electronic memories.
Please note during installation:

The product should be installed by your boatyard or by a person specialised in the installation of
such devices.
If you wish to carry out installation yourself, wear suitable working clothing. Do not wear loose-
fitting clothing. This may be caught by moving parts. If you have long hair, wear a hair net.
When working on electric equipment, do not wear any metallic or conductive jewellery such as
chains, bracelets, rings etc.
Before beginning work, disconnect the negative pole of the battery, since otherwise there is a risk
of a short ciruit. Short circuits can cause cable fires, battery explosions and damage to other
electronic storage systems. Please note that when the battery is disconnected, all transient
electronic memories lose the values entered and have to be reprogrammed.
With petrol engines, allow the engine compartment fan to run before beginning work in the engine
compartment.
At the installation site, make sure there is sufficient space behind drilled holes or the installation
aperture.
First drill small holes at the installation apertures, and enlarge if necessary using tapered drills,
compass saws, fretsaws of files. Deburr edges.The safety instructions of the hand tool manufacturer
must be observed.
If work has to be carried out without interruptions in voltage, only insulated tools may be used.
The electrical outputs of the display unit and the connected cables must be protected from direct
contact and damage. To this end, the cables used must have adequate insulation and/or dielectric
strenght, and the contacts must be shockproof.
The electrical conductive parts of the connected consumers must also be protected from direct
contact by suitable means. The installation of bare metal cables and contacts is forbidden.
After installation, please note:

Clamp the earthing cable firmly to the negative pole of the battery.
Enter/program the values of the transient electronic memories again.
Test all functions.

Safety Instructions
(electrical connection):
To install the electric cables, use existing cable ducts and looms, but do not run the cables paralle
to ignition cables or parallel to cables leading powerful consumers. Secure the cables using cable
binders or adhesive tape.
Do not run the cables over moving parts.
Ensure that the cables are not exposed to any tensile, compressive or shear forces.
If the cables have to be run through drilled holes, protect the cables using grommets or rubber
bushings etc.
Use only a cable stripper to strip the cables. Adjust the cable stripper so that the individual strands
are not damaged or cut off.
New connections should only be made using soft solder, or with commercial crimp connectors.
Crimped connections should only be made using cable crimping pliers. The safety instructions of
the hand tool manufacturer must be observed. Insulate exposed leads in such a way that short
circuits cannot occur.
Caution: Risk of short circuit through faulty junctions or damaged cables.
Short circuits in the electrical system can cause cable fires, battery explosions and damage to
other electronic systems. For this reason, all connections in the voltage supply system must be
either soldered or fitted with weldable connectors and adequately insulated.
Pay particular attention to correct earth connections.
Incorrect connections can lead to short circuits. The cables must only be connected in accordance
with the electrical terminal connection diagram.

ELECTRICAL SYSTEM
06. 07. 14. 02 Audible warner, H22
control unit
07.14 ill.1
sensor sensor sensor

exhaust gas engine coolant oil pressure
temperature

06. 07. 14. 03 Circuit diagram voltmeter (optional)
07.14 ill.2
06. 07. 14. 04 Circuit diagram oil pressure gauge (optional, sensor B19 - gauge P2)
single instruments double instruments (requires special sensor)
sensor marking "G"

07.14 ill.3 one sensor for two
two displays
displays

ELECTRICAL SYSTEM
06.08.01 Potentiometer Accelerator, B13
1 Remove plug housing.
2 Unscrew hexagon nut of accelerator lever, remove

lever.
3 Loosen 2 hexagon screws. Remove accelerator.
Throttle potentiometer B13 (accelerator)

(= connector X13)
In case of defective potentiometer accelerator B13, 08.01 ill.1
service codes 23, 24 or 29 will flash.
NOTE: First check cables and

connections.
R1 Resistance between terminals 3 and 1;

approximately 1,2 kOhm resistance value switch to 1 2 3 4 5
infinetely after moving throttle lever from idle position.
Switch contact should open within the first 10% of
throttle lever (pedal) movement.
R2 Resistance between terminals 5 and 4; 1,2 kOhm

08.01 ill.2
R3 Resistance between terminals 5 and 2; 2,2 kOhm
for normal position of potentiometer accelerator ;
1,4 kOhm at "full speed " max. throttle position.
Wiring Circuit - Potentiometer P/N 2176860/0
~ 1k
1
R1
~9
3
+ ~ 1k R3
~ 1k 2
R2
- 4
08.01 ill.3

06.08.02 Voltage regulator 24V-12V equalizer
Powersupply to equalizer recomandet wire gauge size.
Starter must be connecting by customer use a wire min. AWG 0 (50 mm²)
connect a red wire AWG 8 (6 mm²) at battery "A" positiv terminal +12V
connect a red wire AWG 6 (10 mm²) at battery "B" positiv terminal +24V
connect a black wire AWG 6 (10 mm²) directly at battery "A" negativ terminal.
Battery equalizer
GND +24V
BLACK AWG 6 RED AWG 6
20A
25A
30A
12V Protected
OUT 12V 24V LOAD
Output
(STARTER , ALTERNATOR,
RED AWG 8 power supply glow , .....)
(*)
“A” “B”
08.02 ill.1
* Note:......Mainswitsches are mechanically interlinked.
X21 ARMATUREN PLUG 6-POLE: --> USE ONLY 12 VOLT INSTRUMENTS
pin1 60810--> check engine lampe (12V/2W)

pin2 60616--> glow lamp (12V/2W)
pin3 60614--> temperature instruments (12V)
pin4 60613--> engine speed instruments (12V)
pin5 50000--> starter terminal 50 (detection of start)
pin6 15000--> ignition connect it to the ignition-switch of the vehicle (protect with 5 Amp fuse)
Note: The glow lamp has 2 functions --> at first it works as glow lamp after start it works as oil
pressure lamp.
ALTERNATOR
B+ must be connection by customer --> use a wire AWG 6 (10 mm²) charging control --> must be connecting
by customer.
ATTENTION:
Please observer and follow Original inclosed 08.02 ill.2
manufactures recommentation!

ELECTRICAL SYSTEM
06.08.03 DC - DC converter
DC-DC Converter
IVO 8770
CIRCUIT DIAGRAM
IE
Batt "A" 16A IA 25A
24VDC
U1 U2 Engine G
12VDC
Batt "B"
Batt "C"


ELECTRICAL SYSTEM
06.10 SENDER AND SENSOR OVERVIEW to engine number 48226999

06.10.01 Component configuration 4 cyl. engine
164/174
94/114/144
10.01 ill.1
CODE KURZNAME BESCHREIBUNG
ABBREVIATION DESCRIPTION

ABBREVIATION DESCRIPTION Stecker Ölmanometer (Option)
Connector oil pressure gauge (optional)
MAP Ladedrucksensor Stecker Trimmanzeige (Option)

Boost-pressure sensor Connector trim (optional)
PED Gaspedal J1 Verbindungsstecker Motor - EMS

Potentiometer accelerator Connector engine cable - EMS
RPOS Regelstangensensor DIAG Diagnose - Stecker

Rack position sensor Diagnosis - plug
RPM Motordrehzahlsensor FMS Steuermagnet

Sensor engine speed Control solenoid
ECT Kühlflüssigkeitstemperatursensor Stecker Getriebeschalter (Option)

ECT
Sensor engine coolant temperature Connector gear switch (optional)
EXT Abgastemperatursensor Inversionsschalter (Nur bei SOLAS)

Sensor exhaust gas temperature Inversion switch (only for SOLAS)
LPS Öldrucksensor Abschaltventil (Nur bei SOLAS)

Lubricant pressure sensor Blow - by (only for SOLAS)

from engine number 48227000
07002
CODE BESCHREIBUNG CODE BESCHREIBUNG

DESCRIPTION DESCRIPTION
B12 Ladedrucksensor Stecker Ölmanometer (Option)

Boost-pressure sensor X19 Connector oil pressure gauge (optional)
B13 Gaspedal Stecker Trimmanzeige (Option)

X22
Potentiometer accelerator Connector trim (optional)
B14 Regelstangensensor Haupt-Verbindungsstecker

J1
Rack position sensor Main connector
B15 Motordrehzahlsensor Diagnose - Stecker

X23
Sensor engine speed Diagnosis - plug
B16 Kühlflüssigkeittemperatursensor
Y20 Steuermagnet
Sensor engine coolant temperature Control solenoid
B17 Abgastemperatursensor Stecker Getriebeschalter (Option)

X2
Sensor exhaust gas temperature Connector gear switch (optional)
B18 Öldrucksensor Inversionsschalter (nur bei SOLAS)

S3
Lubricant pressure sensor Inversion switch (only for SOLAS)

ELECTRICAL SYSTEM
06.10.02 Component configuration 6 cyl. engine to engine number 68226999
246/256/
266
126/166/
236
10.02 ill.1

ABBREVIATION DESCRIPTION

ABBREVIATION DESCRIPTION Stecker Ölmanometer (Option)
Connector oil pressure gauge (optional)
MAP Ladedrucksensor Stecker Trimmanzeige (Option)

Boost-pressure sensor Connector trim (optional)
PED Gaspedal J1 Verbindungsstecker Motor - EMS

Potentiometer accelerator Connector engine cable - EMS
RPOS Regelstangensensor DIAG Diagnose - Stecker

Rack position sensor Diagnosis - plug
RPM Motordrehzahlsensor FMS Steuermagnet

Sensor engine speed Control solenoid
ECT
ECT Kühlflüssigkeitstemperatursensor Stecker Getriebeschalter (Option)
Sensor engine coolant temperature Connector gear switch (optional)
EXT Abgastemperatursensor Inversionsschalter (Nur bei SOLAS)

Sensor exhaust gas temperature Inversion switch (only for SOLAS)
LPS Öldrucksensor Abschaltventil (Nur bei SOLAS)

Lubricant pressure sensor Blow - by (only for SOLAS)

from engine number 68227000
07003
CODE BESCHREIBUNG CODE BESCHREIBUNG

DESCRIPTION DESCRIPTION
B12 Ladedrucksensor Stecker Ölmanometer (Option)

Boost-pressure sensor X19 Connector oil pressure gauge (optional)
B13 Gaspedal Stecker Trimmanzeige (Option)

Potentiometer accelerator
X22
Connector trim (optional)
B14 Regelstangensensor Haupt-Verbindungsstecker

J1
Rack position sensor Main connector
B15 Motordrehzahlsensor Diagnose - Stecker

Sensor engine speed
X23 Diagnosis - plug
B16 Kühlflüssigkeittemperatursensor
Y20
Steuermagnet
Sensor engine coolant temperature Control solenoid
B17 Abgastemperatursensor Stecker Getriebeschalter (Option)

X2
Sensor exhaust gas temperature Connector gear switch (optional)
B18 Öldrucksensor Inversionsschalter (nur bei SOLAS)

S3
Lubricant pressure sensor Inversion switch (only for SOLAS)

ELECTRICAL SYSTEM
06.10.03 Calibration of rack position
This procedure must be carried out if any of the following has been done:
- Control solenoid has been disassembled or replaced, refer to 03. 08. 01.
- Rack position sensor has been disassembled or replaced, refer to 03. 08. 03.
- Engine control unit has been replaced.
- Rack or linkage lever have been replaced or loosened.
D C B A
1
F
10.03 ill.1 10.03 ill.2
NOTE: Ensure that the ignition is turned off.
1 Remove threaded pin from position A (ill. 1).
2 Manually move rack (ill.1/B) forward until borehole (ill.1/C) is over tapped hole (ill.1/D) and fix
with threaded pin. The pin must be fastened hand tight and sit correctly in the rack, see ill. 2.
above.
3 Turn on ignition,rack position will be automatically stored in the ECU A5.

Storage process will take approx. 20 sec.
4 Turn off ignition.
5 Loosen threaded pin and screw it into rear bulkhead wall (ill.1/A).
NOTE: If storage in ECU A5 was unsuccessful, error code 56 will be detected.

Refer to Error Codes.

sensor.

06.10.04 Replace Senders, Sensors
06.10.04.01 Exhaust gas temperature sensor, B17
1 Unlock plug (ill.1/pos.1) and remove.
2 Unscrew temperature sensor (ill.1/pos.2) (SW19)
2 1
10.04 ill.1
06.10.04.02 Engine temperature sensor, B16
1 Remove plug housing (ill.2/pos.1).
2 Unscrew engine temperature sensor. 1
10.04 ill.2
06.10.04.03 Speed sensor, B15
1 Press catch spring and remove plug.
2 Loosen hexagon screw (SW10), pull out sensor.
ATTENTION: For assembly, use new 0-ring.

Grease O-ring and put it on.
06.10.04.04 Boost pressure sensor, B12

for engines 94 / 114 / 144 / 126 / 166 / 236 only 10.04 ill.3
1 Remove hose from exhaust manifold.

2 2
ATTENTION: Do not remove hose from boost
pressure sensor.
2 Press retaining clip against plug housing (ill.4/pos.1),

remove plug.
1
3 Loosen two hexagon screws (SW10), remove boost
pressure sensor (ill.4/pos.2).
NOTE: For assembly, take care of the 2

sealing cushions of plug housing.
10.04 ill.4

ELECTRICAL SYSTEM
Boost pressure sensor, B12

for engines 164 / 174 / 246 / 256 / 266 only
1 Remove cable strap, lift shackle at plug and pull off

plug.
2 Loosen clamp (SW6) and pull off hose.
3 Loosen union nut (SW17) by holding up at sensor

(SW32). Remove sensor
Assembly is done in reverse order off disassembly.
NOTE: Wetten the thread from the new sensor
with LOCTITE 243. Thigthen union
nut solid.
10.04 ill.5
06.10.04.05 Rack position feedback sensor, B14
1
1 Remove retaining clip, remove plug housing
(ill.6/pos.1).
2 Disassemble control solenoid, refer to 03.08.01
3 Loosen 2 cylinder screws with hexagon socket (SW 2

3), remove sensor (ill.6/pos.2).
Assembly is done according to assembly

of control solenoid, refer to 03.08.
10.04 ill.6
06.10.04.06 Oil pressure sensor, B18
1
1 Remove plug housing.
2 Unscrew oil pressure sensor (ill.7/pos.1) from mount

(ill.7/pos.2).
ATTENTION: Collect running out motor oil in a

suitable vessel. 2
10.04 ill.7
06.10.04.07 Potentiometer Accelerator, B13
3
1 Disassemble indexing plate (ill.8+9/pos.1).
2 Remove plug housing (ill.8+9/pos.2).

1
3 Unscrew hexagon nut of accelerator lever (ill.8+9/
pos.3), remove lever.
4 Loosen 2 hexagon screws. Remove accelerator 4

(ill.8+9/pos.4).
2
10.04 ill.8

4
2
10.04 ill. 9
06.10.05 Check Sensors and Switches
06.10.05.01 A Check rack position feedback sensor

B14 (= connector X14)
In case of defective rack position feedback sensor
B14, service codes (35) and (36) will flash.
NOTE: First always check cables and connections.
10.05 A ill.1
Final check:
C
Disassemble rack position feedback sensor
from control solenoid.
A
1 Check resistance between terminals A and C with a
digital ohmmeter. Resistance must be between
2,2 kOhm ± 10 %.
10.05 A ill.2
2 Measure resistance between terminals B and C with
extended shaft. Resistance must be
0,5 kOhm ± 10 %. C
10.05 A ill.3
ELECTRICAL SYSTEM
3 Measure resistance between

terminals B and C with inserted shaft.
Resistance must be C
2,4 kOhm ± 10 %.
When a failure was found during one

of above checks, replace rack position
feedback sensor B14.
10.05 A ill.4
06.10.05.01 B Check rack position feedback sensor
B14 (= connector X14)
In case of defective rack position feedback sensor
B14, service codes 35 and 36 or 186 will flash.
NOTE: First always check cables and connections.
10.05 B ill.1
Final check:
Disassemble rack position feedback sensor

C
from control solenoid.
A
1 Supply terminals A ("-"; minus) and C ("+"; plus) with
5,0V DC +/- 1%.
-
5V DC
+
10.05 B ill.2
2 Sensor extended!
Measure between terminal A (minus) and B (signal
out). Measured voltage must be 4,8V DC +/- 5%.
B A
10.05 B ill.3
3 Sensor retracted!
Measure between terminal A (minus) and B (signal
out). Measured votage must be 0,12V DC +/- 5%.
B A
When a failure was found during one of above

checks, replace rack position feedback sensor B14.
10.05 B ill.4
06.10.05.02 Check throttle potentiometer B13 (accelerator)

(= connector X13)
In case of defective potentiometer accelerator B13,
service codes 23, 24 or 29 will flash.
NOTE: First check cables and

connections.
10.05 ill.5
* Resistance between terminals 5 and 4; 1,2 kOhm

for normal position of potentiometer accelerator ;
1,4 kOhm at "full speed " max. impact.

With approx. 10% of max. first route, resistance 1 2 3 4 5
value must increase infinetely high ==>
(disconnection).
10.05 ill.6

ELECTRICAL SYSTEM SERVICE MANUAL MARINE ENGINES
06.10.05.03 Check boost pressure sensor, B12, for engine models: 94 / 114 / 144 / 126 / 166 / 236
100 microbar (absolute)
Athmospheric pressure
PSI
10.05 ill.7
For engine models: 164 / 174 / 246 / 256 / 266
5,0
4,5
4,0 Supply voltage

5V +/- 0,2V
Output - voltage (Volt)
3,5
3,0 Connector position

A = +5V
2,5 B = GND
2,0 C = Signal
1,5 Max. pressure with

1,0
3 bar (3,5 absolut)
0,5
0,0
0,0 0,5 1,0 1,5 2,0 2,5 3,0 3,5 4,0
10.05 ill.8 Absolut - air pressure (bar)
NOTE: Before checking the boost pressure sensor, check air filter, sensor hose and connector.
Pressure test:
For a pressure test of the sensor, disconnect the sensor hose and connect a pressure gauge with a
short piece of hose to the sensor.
Carefully pressurize the sensor. Read and record the values on the gauge (input pressure) and on the
display (output pressure) for 5 spots between 0 and 1.5 bar. Compare recorded input and output values
with the chart.
- If values are not within tolerance limits, replace the boost pressure sensor.
- If values are within tolerance limits, the boost pressure sensor is functional and the turbocharger
must be checked.

06.10.05.04 Check speed sensor B15 and/or wiring
X15 1
2
3
X 15/1 15012-06
X15/2 60113-01
X15/3 31000-03
10.05 ill.9
On account of the sensor's integrated electronic system, only the supply voltage and/or the output
signal and the continuity to control unit A5 can be measured.
Make sure that with disconnected plug X15 and ignition "ON" an error code can be stored
--> At completion of checking, cancel the error code; refer to 06.06.04
Use a standard voltmeter / multimeter to measure the supply voltage and/or the resistance.
Supply voltage Ubat (12V +/- 2V)

ignition ON main relay K27 active
measurement point GND on X15/3 against +supply voltage on X15/1
Continuity from X15/2 to control unit X5/33

max. resistance 2 ohms
If supply voltage and transition from X15/2 to X5/33 are connect, replace the speed sensor.
In case an error was detected during preceding measurements, check wiring according to circuit
diagram and wiring harness diagram.

ELECTRICAL SYSTEM
06.10.05.05 Check oil pressure sensor B18 and/or wiring
X18
X18/A 31100-10
X18/B 15100-07
X18/C 60117-01
10.05 ill.10
On account of the sensor's integrated electronic system,only the supply voltage and/or the output
signal can be measured.
Make sure that with disconnected plug X15 and ignition "ON" the error code 32 HiLPS is stored
--> At completion of check, cancel the error code; refer to 06.06.04
Use a standard voltmeter / multimeter to mesure the supply voltage and/or the resistance.
Supply voltage + 5V +/- 0,4V

ignition ON main relay K27 active
measuring point GND on X18/A against + 5V on X18/B
Continuity from X18/C to control unit X5/10

max. resistance 2 ohms
Output signal depending on pressure; see diagram

Remove B18 and admit pressure when X18 is connected; max. 5 bars
measuring point X18/C --> X18/B
voltage via pressure
voltage
voltage (V)
pressure (bar)
10.05 ill.11

06.10.05.06 Check oil pressure sensor "VDO-instrument"

(option B19)
NOTE: If oil pressure is questionable,
- check oil level before starting the engine.
- check minimum oil pressure.
Minimum oil pressure
Idle 1 bar
1000 2 bar
2500 and above 4 bar
Check minimum oil pressure:

Start engine and let engine run at idle speed, 1000
and 2500 r.p.m. Check tachometer and and oil
pressure gauge. Record oil pressure value for idle
speed, 1000 and 2500 r.p.m. If values are not
appropriate, check the oil pressure gauge before
checking the oil pressure sensor. To check the oil
pressure gauge, disconnect cable from sensor, turn
on ignition key and shortly put the sensor cable to
ground connection. If gauge functions properly, the
pointer will shortly deflect to high values. If there is no
malfunction of the gauge, replace the oil pressure
sensor.
Check of oil pressure sensor:
1. To check the oil pressure sensor, disconnect the
sensor cable and connect an ohmmeter to sensor
terminal and sensor.
2. Check resistance at zero pressure; resistance should
be 240 Ohm ± 10 %.
- If resistance is out of tolerance limits, replace the
oil pressure sensor.
- If resistance is within the tolerance range but
function of oil pressure sensor is still questionable,
measure the resistance over the entire field.
PRESSURE
RESISTANCE (OHM)
10.05 ill.12
ELECTRICAL SYSTEM
Check oil pressure sensor over entire pressure range:

1. Disassemble sensor and connect it to a gauged
pressure source.
2. Connect ohmmeter and pressurize sensor. Read
and record pressure and resistance at different spots
over the entire pressure range.
3. Compare pressure and resistance values with chart.
If values are not within tolerance range at one spot,
replace sensor.
06.10.05.07 Check coolant temperature sensor, B16
To check the coolant temperature sensor, make the

following test with connected ohmmeter. In case of
failure, replace the sender.
1. Compare resistance value and ambient temperature
to curve of diagram. Range of tolerance is ± 10 %.
kOhm
120
100
80
60
40
20
0
0 10 20 30 40 50 60 70 80 90 100
TEMP °C
10.05 ill.13

2. If this check brings no information, drain the coolant

and remove the sensor. Immerse sensor together
with thermometer into a canister with coolant.
Connect a digital ohmmeter to the sensor and heat
the fluid on a heater. Monitor ohmmeter und
thermometer. The ohmmeter should show values
corresponding to the values of the resistance curve
with a tolerance range of ± 10%.
06.10.05.08 Check audible warner
0,7 sec. with ignition "ON" ==> function check and

message "no error stored"

ELECTRICAL SYSTEM
06.12. BATTERY
06.12.01 Battery
Battery - Acid Test

The battery provides the starter engine with energy and supplies the required voltage for lighting and
other electrical equipment when the engine is not running. During the starting procedure and when the
generator does not generate any current, the battery provides the electronic engine management
system with voltage.

Use a 12 V battery with a cold test circuit of 450 ampere at -18°C and a capacity of 92 Ah at 27°C, to
guarantee the supply of the electric and electronic components for all operating conditions.
For 24 V - installation only

Use two 12V batteries with a cold test circuit of 650 ampere each at -18°C and a capacity of 115 Ah
at 27°C, to guarantee the supply of the electric and electronic components for all operating conditions.
The batteries are connected in series and provide a capacity of 115 Ah / 24 V for the external supply
of all electric components on the boat.
12V supply of all electric and electronic components on the engine (including instrument panel) by
center tapping. Additional charge is guaranteed by charging equalization.

Use a 12 V battery with a cold test circuit of 650 ampere at -18°C and a capacity of 115 Ah at 27°C,
to guarantee the supply of the electric and electronic components.
Explanation:
Cold current test: The cold current test is a specified load test of a battery.The
charge of battery with specified current (e.g. 450A).
After discharge for 30 sec., the voltage should not drop bellow ³9V.
Capacity: With a current consumption of 1/20 of specified capacity (e.g. 92Ah) the battery
voltage must not fall below 10 V after 20 hours, to guarantee the engine's
starting ability.
Maintenance
To guarantee long battery life, the following tests should be carried out periodically.
1 The level of battery acid must always be above plates and separators. The acid level should reach the
marking on the battery. Acid may only be refilled by an expert when it was definitely stated that some
of it has been spilled.
ATTENTION: Battery fluid is an aggressive acid and must be handled with care. In case of skin
contact rinse thoroughly with water and consult a doctor - physician.

2 The battery should always be charged as full as

possible. Regularly check the state of charge with
the battery acid tester. We recommend to check the
acid density and acid level periodically every two
weeks. If the density is 0.04 kg/dm³ below the value
of full charge, the battery is to be removed and re-
charged.
DENSITY WITH FULL CHARGE: 1.260 kg/dm3 (at

27°C).
ATTENTION: Never charge the battery on the

boat. The vapors resulting from
charging could cause an explosion! 12.01 ill.1
For a periodical check of the battery, the following items are to be considered:
1 Protect the boat against acid leakage.
2 Clean battery.
3 Check connections and cables.
4 Clean battery contacts. (neg./pos.)
5 Check holding device of battery.
6 Check housing for damages (acid leakage).

7 Check acid density.
8 Disassemble battery for test. In case of less than 3/4 charge, charge it by means of battery charger,
carry out charge test.
9 Check acid level.

In case of a bad state of charge or excessive loss of water, check charge circuit.
Clean battery, contacts and terminals with a solution of soda and water. This neutralizes the battery
acid. After cleaning with the solution, rinse the surface with water by taking care that the solution does
not penetrate into the battery
ATTENTION: When connecting the battery cables, take special care of correct polarity. Incorrect
polarity destroys electronic components.

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STEYR MARINE ENGINES

This SERVICE MANUAL is published with the main intention -

4 & 6 CYLINDER MARINE

- Which descriptions or terms are not understandable?

Please address your comment to:

vom Inland: vom Ausland

Product specifications, illustrations and technical data

(MAIN ASSEMBLY GROUP ENGINE)

01.03 01.04 01.05

01.06 01.08 01.09

03.08 03.09 03.11

06.06 06.07 06.10

Version Date Modification

1.0 01. 10. 2000 new edition

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

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

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

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

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

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

G5 Measures in case of accidents ................................................................ 43

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

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

Page GENERAL-2 Z001019/0_8_Octobre 2011

A1 Model and Serial Numbers

The primary model and serial number (ill.1 or ill.2) is

FOR ALL FOR ALL

01.01 ill.1 01.01 ill.2

The model and serial number of the marine gearbox

To obtain instructions regarding marine gearbox

Z001019/0_8_Octobre 2011 Page GENERAL-3

A2 Documentation 4 and 6 cylinder

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

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

operation-, maintenance & warranty manual

tool catalogue for all marine engines P/N Z 001002/1

spare parts catalogue STEYR 94 td diesel marine P/N Z 001023/0

STEYR 144 vti/td diesel marine P/N Z 001005/0

STEYR 164 td diesel marine P/N Z 001015/0

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

STEYR 166 td diesel marine P/N Z 011796/1

STEYR 236 FDE P/N Z 011796/0

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

STEYR 246 td diesel marine P/N Z 011800/0

STEYR 256 td diesel marine P/N Z 011810/0

STEYR 266 td diesel marine P/N Z 011805/0

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

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

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

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

Page GENERAL-4 Z001019/0_8_Octobre 2011

A 3.1 Modell summary 4 cylinder engines

Inborder i.e. ZF 45 Marinegear

Innenborder i.e. ZF 63 Marinegear

Z001019/0_8_Octobre 2011 Page GENERAL-5

A-down angle gear box

Parallel offset gearbox

Page GENERAL-6 Z001019/0_8_Octobre 2011

Mercury Alpha Bravo I, II & III

Volvo DP 290 Hydraulic

03.01 ill.11 SX - Stern Drive

Z001019/0_8_Octobre 2011 Page GENERAL-7

A 3.2 Modell summary 6 cylinder engines