1 SERVICE MANUAL
Contents
1. 2001019 0 6 July 2008 Page FUEL SYSTEM 33 03 FUEL SYSTEM SERVICE MANUAL MARINE ENGINES 03 14 FUEL SYSTEM CHECK 03 14 01 Manual injection test methode Preparation Remove camshaft housing cover refer to 01 00 02 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 ee 14 01 ill 2 3 Move control rack by means of special tool No VR001 48 0 into idle injection position approx 5 6 mm 111 3 and remain in this position 14 01 ill 3 Page FUEL SYSTEM 34 Z001019 0_6 July 2008 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 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 soli de resistance is to be felt due to produced injection pressure pressure point If no difference is detectable in the individual unit injectors continue with item 5 5 Adjust control rack by means of special tool No VR00148 0 to partial load approx 10 12 mm direction full delivery ill 3 and remain inthis position 6 Repeat item 4 14 01 ill 4 NOTE Defective unit injectors which fail to pr2. 2 Z001019 0 6 July 2008 R SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM Functional Description When the ignition switch is turned an electric fuel pump 1 is putinto 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 g VE z e 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 gt 240 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 ap gps 03 00 ill 2 Z001019 0 6 July 2008 Page FUEL SYSTEM 3 03 FUEL SYSTEM SERVICE MANUAL MARINE ENGINES 03 02 FUEL PUMP UNIT INJECTOR LINES 03 02 01 Replace fuel pump Fuel pump operat
3. A and engine housing intake for crack and damage Replace if necessary 05 01 11 44 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 Page FUEL SYSTEM 24 Z001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM For 4 cyl engines only item 1 2 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 For6cyl engines only item 3 6 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 en
4. ENGINES 7 Insert unit injector extracting lever No VR 00126 0 ill 5 pos 1 in recess of rocker arm between rocker arm body and roller as shown and fully press down spring of unit injector Set display to zero NOTE Slowly release unit injector spring Readtotal indicating travel ill 5 pos 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 adjusting screw in this position and tighten hexagon nut ill 6 pos 2 by means of torque wrench 2300743 0 and tee handled socket wrench SW17 with a torque of 30 Nm 3 02 06 ill 6 Engine setting values for engines with a build date before 2007 lt 48226999 lt 68226999 TYPE Unit Injector Stroke Adjustment Engine Timing Valve Clerance New Copper Ring Control Value Inlet amp Outlet M094K32 2176555 5 8 27 8 32 3 20 0 25 0 25 M0O114K33 2176555 5 8 27 8 32 3 20 0 25 0 25 M0144M38 2176555 5 8 27 8 32 3 20 0 25 0 25 M0144V38 2176555 5 8 27 8 32 3 20 0 25 0 25 MO164M4O 2176557 0 8 27 8 32 3 20 0 25 0 25 MO174V40 2176557 0 8 07 8 12 3 20 0 25 0 25 MO126K28 2176555 5 8 27 8 32 3 20 0 25 0 25 MO166K28 2176555 5 8 27 8 32 3 20 0 25 0 25 MO236K43 2176555 5 8 27 8 32 3 20 0 25 0 25 MO246M41 2176557 0 8 27 8 32 3 20 0 25 0 25 MO256H45 2176557 0 8 27 8 32 3 20 0 25 0 25 MO256K43 2176557 0 8 27 8 32 3 20 0 25 0 25 MO266K43 2176557 0 8 07 8 12 3 20 0 25 0 25 Tolerance 0 02 0 02 0 05 Page
5. NOTE Use new Cu sealing rings for assembly Tighten with a torque of 40 Nm 4 ATTENTION On account of importance of this valve proper function of fuel System only use genuine STEYR spare part for possible 02 07 ill 1 exchange Page FUEL SYSTEM 20 Z001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 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 2 Remove air filter and cover 3 Put new air filter together with cover onto filter head and fix with retaining clip From engine serial no 48219070 4 cyl and 68219175 6 cyl 1 Remove hose clamp and air filter 2 Mount new air filter together with hose clamp and tighten clamp solid 04 01 ill 3 Z001019 0 6 July 2008 Page FUEL SYSTEM 21 03 FUEL SYSTEM SERVICE MANUAL MARINE ENGINES 03 05 TURBOCHARGER 03 05 01 Replace turbocharger 1 2 Remove air filter refer to 03 04 01 Remove high riser refer to 04 01 For 6 cyl engines only Drain coolant from closed cooling circuit refer to 05 00 07 For 4 cyl engines only item 4 7 Loosen fastenings of heat protection Remove heat protection ill 2 pos 1 Loosen hose clamp ill 2 pos 2 and remove hose for air charge pressure box Loosen screw ill 2 pos 3 for raw water pipe support SW10 Loosen hollow screw ill 3 pos 1 of oil feed line on turbo
6. 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 4 Slightly oil seal of new fuel filter with clean motor oil 1 4 5 Screw on new fuel filter until seal slightly rests on sealing surface of filter head Then tighten filter by hand with 3 4 turn 6 Connect fuel pipe between fuel filter and fuel supply or water separator on filter head ill 1 pos 1 again 7 Ventilate fuel system NOTE Fuel system is ventilated via E fuel pump Turn ignition ON 6times each 10 sec 8 Remove possibly spilled fuel residues Start engine and check fuel system for leakage 09 00 ill 4 Page FUEL SYSTEM 30 Z001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 03 11 REPLACE GLOW PLUG Preparation For4cyl 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 cyl engines only 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
7. load 02 05 ill 3 Page FUEL SYSTEM 16 Z001019 0_6 July 2008 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 03 02 06 Adjust start of injection Preparation Remove camshaft housing cover NOTE The adjustment of start of injection is necessary if unit injector was removed periodically according to maintenance chart if set value has changed see chart 92 06 11 1 Set Values Unit Injector Stroke Adjustment of injection start is to be done prior to adjustment of engine control Special tool 2306031 4 dial gauge rail 4 cyl 2306031 1 dial gauge rail 6 cyl with bossed seal surface 2306031 6 dial gauge rail 6 cyl with plane seal surface 2300899 0 dial gauge 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 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 5 Put pointer onto unit injector plunger guide 02 06 ill 4 Z001019 0 6 July 2008 Page FUEL SYSTEM 17 03 FUEL SYSTEM SERVICE MANUAL MARINE
8. 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 p 11 00 ill 1 NOTE Exactly keep torque of 15 Nm 1 when fixing glow plugs 11 00 ill 2 Z001019 0 6 July 2008 Page FUEL SYSTEM 31 03 FUEL SYSTEM SERVICE MANUAL MARINE ENGINES 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 1 3 4 Remove plug J1 Connect special tool No VR00145 0 instead of plug J1 5 Put into operation compression pressure meter according to operating instructions 6 Start engine by pressing the button for 5 to 10 sec of 12 00 1 2 special tool No VR00145 0 until compression 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 7 Assembly is done in reverse order Page FUEL SYSTEM 32 Z001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM THIS PAGE IS INTENTIONALLY BLANK
9. 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 Page FUEL SYSTEM 8 Z001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 7 Move the rocker arm towards timing belt side of engine and remove the tappet NOTE Adjusting screw and slide cup match exactly and thus have to be removed kept matched 8 Check position of control link s against bulkhead as illustrated 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 fromthe engine block and may be removed manually NOTE For disassembly of the unit injector from cylinder No 1 the control rack is to be moved forward 10 Remove unit injector with mounting flange Z001019 0 6 July 2008 Page FUEL SYSTEM 9 03 FUEL SYSTEM SERVICE MANUAL MARINE ENGINES 11 Remove copper seal washer from bottom side of copper insert by means of hook and lifting tool No VR 00116 0 NOTE Avoid scratches on the sealing surface of the copper insert Assembly 1 In order to secure an appropriate tight fit recheck tighten stud bolt with a torque of 21 Nm 2 Drain possible fuel residues by means of suction device 00121 0 fromthe combustion chamber Suction device
10. to show any pressure or this pressure peak is found in a much higher position of the control rack this is an indication for a possible deficiency on this injector ATTENTION 9 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 Z001019 0 6 July 2008 Page FUEL SYSTEM 35 03 FUEL SYSTEM SERVICE MANUAL MARINE ENGINES 03 14 02 Disengagement methode of injection NOTE Disengagement methode of injection is a simple and effective method to detect defective unit injectors with regard to formation of bubbles in both the fuel system and the engine cooling system or lack of power it related to deficiencies in injection equipment Preparation Remove camshaft housing cover refer 01 00 02 Special tool 4 cyl engines VR00133 1 6 cyl engines with bossed seal surface VR00133 0 6 oyl engines with plane seal surface VR00133 2 14 02 ill 1 1 Mount special tool No VR00133 see list special tool to disconnect injection 2 Start the engine let it run in idle and check if bubbles form NOTE If there are no bubbles at idle speed of engine continue with item 3 3 Bring engine to operating temperature and then test the boat under operating conditions and watch for bubbles to form Keeping this operating condition continue with item 4 4 Loosen nut on cover ill 1 pos 1 screw in with fas
11. 8 01 1 2 08 01 1 3 08 01 11 4 Page FUEL SYSTEM 26 Z001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 6 Loosen 2 hexagon nuts SW1 0 ill 5 pos 1 Remove boost pressure sensor 7 Loosen plug ill 5 pos 2 for potentiometer accelerator 8 Loosen 3 hexagon nuts SW1 0 ill 5 pos 3 Remove bracket with potentiometer accelerator 9 Remove plug ill 5 pos 4 for sensor of control rod 10 Remove plug ill 6 pos 1 from control solenoid 11 Loosen 4 hexagon screws SW13 ill 6 pos 2 on control solenoid housing Remove control solenoid assembly Remove seal and dispose For 4 cyl engines only 12 Loosen 4 hexagon screws 5 13 ill 7 on control solenoid housing remove control solenoid assembly Remove seal and dispose i 08 01 ill 7 Z001019 0 6 July 2008 Page FUEL SYSTEM 27 03 FUEL SYSTEM SERVICE MANUAL MARINE ENGINES 03 08 02 Install control solenoid 10 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 Remove camshaft housing cover Move control rack by hand ill 1 to front position and hold Insert control rack lever in to the solenoid as shown ill 2 pos 1 Bring upcontrol solenoid assembly parallel to sealing surface of camshaft housing put it onto the dowel pin s ill 3 pos 1 and hold Slowly release control rack and fasten con
12. AL MARINE ENGINES 03 FUEL SYSTEM 03 02 04 Adjust Control Link injection quantity Prior to adjustment unit injector must be tightened properly and control rack must be fixed in position with set pin NOTE Readjust all control links even if only one link has been opened STARTING POSITION Loosen left handed setscrew of control link Turn control link against bulkhead on camshaft housing 1 Carefully position end of control link on front side of unit injector control rack possibly use screwdriver 2 Turn control link against unitinjector 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 Z001019 0 6 July 2008 Page FUEL SYSTEM 15 03 FUEL SYSTEM SERVICE MANUAL MARINE ENGINES 03 02 05 Loosen fixing of control rod 1 Unscrew setpin ill 3 pos 2 from bulkhead wall with removing setpin and hold control rack Reinstall setpin in rear camshaft housing bore ill 3 pos 1 2 Tighten setpin with a torque of 7 Nm 3 Check axial flexibility of control rack Control rack is tobe moved easily and should automatically return to reverse position due to spring
13. FUEL SYSTEM 18 Z001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM Engine setting values for engines with a build date from 2007 gt 48227001 gt 68227001 TYPE Unit Injector Stroke Adjustment Engine Timing Valve Clerance New Copper Ring Control Value Inlet amp Outlet MO84K32 2176555 5 8 47 8 52 3 20 0 25 0 25 M094K33 2176555 5 8 47 8 52 3 20 0 25 0 25 M0O114K33 2176557 0 8 47 8 52 3 20 0 25 0 25 M0144V38 2176557 0 8 47 8 52 3 20 0 25 0 25 M0144M38 2176557 0 8 47 8 52 3 20 0 25 0 25 M0164M40 2176557 0 8 37 8 42 3 20 0 25 0 25 MO174V40 2176557 0 8 47 8 52 3 20 0 25 0 25 MO126M28 2176555 5 8 57 8 62 3 20 0 25 0 25 MO126K28 2176555 5 8 57 8 62 3 20 0 25 0 25 MO166M28 2176557 0 8 57 8 62 3 20 0 25 0 25 MO166K28 2176555 5 8 57 8 62 3 20 0 25 0 25 MO196K35 2176555 5 8 47 8 52 3 20 0 25 0 25 MO236K42 2176557 0 8 37 8 42 3 20 0 25 0 25 MO236K43 2176555 5 8 47 8 52 3 20 0 25 0 25 MO256H45 2176557 0 8 27 8 32 3 20 0 25 0 25 MO256K43 2176557 0 8 27 8 32 3 20 0 25 0 25 Tolerance 0 02 0 02 0 05 Recheck stroke adjustment recheck zero value and total stroke adjustment as described in steps 7 and 8 ATTENTION A process In case of deviation repeat setting 2001019 0 6 2008 Page FUEL SYSTEM 19 03 FUEL SYSTEM SERVICE MANUAL MARINE ENGINES 03 02 07 Exchange check valve for fuel pre pressure to unit injector 1 Unscrew valve SW 19 ill 1 pos 1 remove 2 Cu sealing rings
14. Page FUEL SYSTEM 6 Z001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 03 02 02 Disassembly and assembly of unit injector Preparation Remove camshaft housing cover Clean sealing surface of rubber seal and check for hardening and damage Replace seal if required 02 02 ill 1 1 Tumcrankshaftuntilnctorcam atbasecicbas welLntake and exhaustvalve open i omerto pem ta hteralshiftng 2 Before bosenng fangenutsofunmn cibis ventibte fnelsystem Forths purpose open sciew fitng pstenaugh o EtairthiDugh sealmgs between fielomp 1 Etpum pzzm 6 r10 sec Make sure thatairss sucked ATTENTION Close fuel cock on tank if tank is 3 higher than fuel supply on filter head 02 02 ill 4 Z001019 0 6 July 2008 Page FUEL SYSTEM 7 03 FUEL SYSTEM SERVICE MANUAL MARINE ENGINES 3 Remove nuts on unit injector flange 2 hexagon nuts SW 13 4 Loosen left handed hexagon socket securing the control link on the control rack by using a 4 mm hexagon socket wrench Turn control link against bulk head 1 hexagon socket SW 4 LEFT HAND THREAD per unit injector 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 6 Insert screwdriver with small blade into
15. SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 03 00 03 02 03 02 01 03 02 02 03 02 03 03 02 04 03 02 05 03 02 06 03 02 07 03 04 03 04 01 03 05 03 05 01 03 05 02 03 08 03 08 01 03 08 02 03 08 03 03 09 03 11 03 12 03 14 03 14 01 03 14 02 03 14 03 03 FUEL SYSTEM Table of Contents Page Fuel system Functional description eeeeeesssss 2 Fuel pump unit injector lines eeeeeeeeeeeeeen 4 Replace fuel octets ett bete etae bd lee be b ne 4 Disassembly and assembly of unit injector 7 FIX 010 MEE 14 Adjust control link injection quantity 15 Loosen fixing of control rod retentu tr esiste ettet 16 Adjust start of injection a oe olus epus umo rote on iod 17 Exchange check valve for fuel pre pressure to unit injector 20 mide 21 Gharige aso i ek Lo tent obtenta toten 21 Turboch rget RS 22 Replace 22 Check bearing clearance 25 Control Solenoid C 26 Remove control solenoid 26 Install control soleriOltl oa eer epo tom doen cob 28 Replace sensor indication of control rack posit
16. ack position sensor 08 03 ill 1 Assembly 1 Insert new sensor in such a way that rod of potentiometer ill 2 pos 1 is positioned in front of 1 2 solenoid rod ill 2 pos 2 O 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 e ATTENTION Rod of rack rack position sensor is 08 03 ill 2 spring loaded and might easily slip A 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 gt ENGINE FAILURE 4 Remaining assembly is done in reverse oder NOTE The rack position sensor is magnetism sensitive All external magnets must be kept away as the may disturb the sensor Z001019 0 6 July 2008 Page FUEL SYSTEM 29 03 FUEL SYSTEM SERVICE MANUAL MARINE ENGINES 03 09 Change fuel filter Water or other fuel contaminations may form deposits which clogthe fuel filler and may leadto 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 sucked ATTENION Close fuel cock on tank
17. charger Remove plug of oil pressure switch ill 3 pos 2 Loosen hollow screw ill 3 pos 3 of oil feed line on motorblock Dispose Cu sealing rings Loosen two hexagon screws ill 4 of oil return line Dispose seal 05 01 ill 1 05 01 ill 3 05 01 ill 4 Page FUEL SYSTEM 22 Z001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 11 For 6 cyl engines only Loosen 2 hexagon screws on flange of oil feed line 12 For4cyl engines only Loosen hose clamps of hose connection turbocharger intercooler ill 6 pos 1 and remove hose For 6 cyl engines only item 13 17 13 Loosen supportscrew ill 7 pos 1 for raw water pipe 14 Remove covering ill 7 pos 3 to intercooler by loosening 5 hexagon screws SW10 ill 7 pos 2 15 Loosen hose clamp ill 8 pos 1 connection compression housing 16 Loosen 2 hexagon screws ill 8 pos 2 and remove connecting bend 17 Loosen hollow screw ill 8 pos 3 of cooling system vent pipe SW14 Remove pipe 05 01 ill 8 Z001019 0 6 July 2008 Page FUEL SYSTEM 23 03 FUEL SYSTEM SERVICE MANUAL MARINE ENGINES 18 Loosen hose clamp ill 9 pos 1 of hose of oil separator and remove hose 19 Loosen 4 hexagon nuts ill 10 11 pos 1 of turbocharger flange Remove turbocharger and seal dispose seal if seal is used Assembly ATTENTION Check hose connection and hose between turbocharger return pipe
18. d clearance 1 Put test prod of dial gauge onto face of turbine wheel hub 2 Push cursor downwards and set dial gauge to O 3 Push cursor against dial gauge and note deflection of pointer V A D 2222204 N ALI permissible end clearance max 0 16 mm 0 01 05 02 ill 1 Measure radial clearance NOTE Determination of radial clearance is location pomt ired turbine sided 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 strength 4 Repeat measurement by turning cursor by 90 Permissible radial clearance max 0 42 mm 0 04 05 02 ill 2 2001019 0 6 2008 Page FUEL SYSTEM 25 03 FUEL SYSTEM SERVICE MANUAL MARINE ENGINES 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 For 4 cyl engines only item 2 3 2 Loosen plug connection ill 2 pos 1 for control rack potentiometer 3 Remove plug from control solenoid ill 2 pos 2 For6cyl engines only item 4 11 4 Unscrew 3 hexagon screws SW10 ill 3 pos 1 of upper timing belt covering 5 Unscrew 2 hexagon screws SW10 ill 4 pos 1 of front control solenoid covering 08 01 ill 1 e ki NI 0
19. e cup with motor oil putit onto adjustment screw as shown and shift it together with rocker arm onto unit injector 10 Install retainer ring to secure the rocker arm 11 Screw on flange nuts hexagon nuts SW 13 and tighten evenly Absolutely tighten nuts with a torque of 18 2 Nm ATTENTION Pay attention to horizontal installation 9 of mounting flange 02 02 ill 23 1 m 02 02 ill 24 Page FUEL SYSTEM 12 Z001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 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 2001019 0 6 July 2008 Page FUEL SYSTEM 18 03 FUEL SYSTEM SERVICE MANUAL MARINE ENGINES 03 02 03 Fix control rack Preparation Remove camshaft housing cover refer to 01 00 02 1 Unscrew setpin of control rack ill 1 pos 1 at the back of camshaft housing as shown 2 Position bore diameter 4 mm in control rack ill 2 pos 1 overreference bore ill 2 pos 2 inthe bulkhead wall 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 4 Page FUEL SYSTEM 14 Z001019 0 6 July 2008 SERVICE MANU
20. en repeat check 3 If a bubble formation appears during load operation continue with check 3 Start the engine bring it to operating temperature test the boat under operating conditions and observe the glass bulb If it comes to bubble formation search for the problem in the area of unit injectors Defective unit injector s is areto 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 Test the engine in the operating state where bubble formation occurs by disengagement of injection per cylinder one after the other Disengagement methode of injection refer to 03 14 02 Assembly is done in reverse order Page FUEL SYSTEM 38 2001019 0 6 July 2008
21. ion 29 Change fuel filt r ren era pa S ERA a aa 30 Replace glow Plug ius on tih prandia poa eu ra ada e a s Ra ee aad as 31 Measurement of Compression Pressure 32 Fuel system CHECK o tuac ach enda po ck erai a ra aba e ead ras 34 Manual injection test methode 34 Disengagement methode 36 Air bubble formation in fuel system 37 2001019 0 6 July 2008 Page FUEL SYSTEM 1 03 FUEL SYSTEM SERVICE MANUAL MARINE ENGINES 03 00 FUEL SYSTEM e gt EN UNIS 9 35 55 88 382 S o RES og i gt 2 g 85 5 88 QQ ec 26 2x 55 2s 9 og 3 o So 89 zo cs ys Si cS E 9 29 3 S x SP 5 3 X Su Ej N e er iY JS S AY ANV SKW 4 7 f VG q 27 el stop cock raftstoff Filter kschlagventil Kraftstoffzufuhr PD Fuel supply 1 Regelstangensensor Rack position sensor Fuel filter Kraftstoffoumpe Absperrhahn Fuel pump Check valve Pumped se Unit Injector Saugventil Anti siphon valve UC u uw x Page FUEL SYSTEM
22. ion is controlled by EMS Disassembly 1 Ventilate drain fuel system For this purpose open fuel line between fuel filter and fuel pump ill 4 pos 1 and let pump run for approx 6 x 10 sec Make sure that air is sucked into the line ATTENTION Close fuel cock on tank if tank is 9 higher ATTENTION Prior to disassembly disconnect battery cables from battery to avoid A damages to the electronic system Disconnect positive cable and negative cable ill 6 by unscrewing hexagon nuts SW7 8 with washer from terminals of fuel pump Unscrew hollow screw ill 6 pos 1 of fuel feed line Dispose Cu sealing rings Unscrew hollow screw ill 6 pos 2 of fuel line Dis pose Cu sealing rings ATTENTION Hold up with second wrench on hexagon of pump housing to avoid a a damage to the E pump O 0 A 0 02 01 ill 4 02 01 ill 6 Page FUEL SYSTEM 4 Z001019 0_6_July 2008 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 6 For4cyl engines only Unscrew two hexagon screws of filter plate Remove filter plate and holding strap Remove fuel pump For6cyl 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 ATTENTION Mark position of fuel pump on pump 3 support 8 Remove pump bracket ATTENTION Measure heightfor assembly of pump 9 because offitting positionoffuelli
23. must be equipped with a suction hose of atleast 250 mm of length in orderthat possible fuel residues can be sucked from piston recess NOTE Fuel residues in the combustion chamber may cause severe damage to the engine 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 14 02 02 ill 16 Page FUEL SYSTEM 10 Z001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 4 Clean conical part of copper insert with cleaning mandrel No 2300565 0 For this purpose turn cleaning mandrel severaltimes in both directions and then clean copper insert with cleaning tissue 5 ATTENTION Insert new special copper seal was her ill 19 pos 2 from seal kit A Z002031 0 with a screwdriver into copper insert Make sure the copper seal washer is plane 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 A 02 02 ill 20 Z001019 0 6 July 2008 Page FUEL SYSTEM 11 03 FUEL SYSTEM SERVICE MANUAL MARINE ENGINES 8 Pushunit injector firmly downwards in orderto position it correctly with the O rings 9 Lubricate slid
24. nes o1 itg Z001019 0 6 July 2008 Page FUEL SYSTEM 5 03 FUEL SYSTEM SERVICE MANUAL MARINE ENGINES Assembly 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 For 6 cyl engines only item 4 7 Mount bracket in correct position onto new fuel pump Tighten screws of bracket 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 Mount adaptor with Cu sealing rings at top face of fuel pump Attach fuel lines between filter and pump as well as pump and block Tighten hollow screws with a torque of 30 Nm 3 ATTENTION Hold up with second wrench on hexagon of pump housing to avoid a damage to the E pump Always use new Cu sealing rings Connect two cables to negative terminal and to positive terminal 4 Cover the two terminals with neoprene lacquer sealing No P N Z909570 0 Connect battery cables Connect fuel lines and operate electric fuel pump 3 times for 10 sec to bleed fuel system Check fuel system for leakage No 2300719 1 mount fuel return line 02 01 ill 9 02 01 ill 10
25. oduce 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 7 Assembly is done in reverse order 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 I 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
26. t turns screw ill 1 pos 2 until knocking noise disappears Tighten nut ill 1 pos 1 again As a result unit injector is pressed down to such an extent that injector cam can no more touch the rocker arm thus preventing the injection of fuel respectively eliminating combustion 5 Test the boat with disengaged unit injector under operating conditions and observe the returning fuel if bubbles still appear 6 Continue to check all other injectors cylinders in order to detect the defective s unit injector s NOTE Bubble formation will change and or stop as soon as injection of defective unit injector s is disengaged 7 Replace defective unit injector s Replace unit injector refer to 03 02 02 Page FUEL SYSTEM 36 Z001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 03 14 03 Air bubble formation in fuel system Preparation Change fuel filter if necessary refer to 03 09 item 1 ventilate fuel system Special tool Testing device for fuel return 2300719 1 Disconnect hose from fuel return line on fuel cooler outlet to fuel tank ill 2 pos 1 Connect hose ill 1 pos 1 of testing device 2300719 1 to tandem cooler outlet ill 2 pos 1 Connect hose ill 2 pos 2 of testing device 2300719 1 with return hose to fuel tank ill 2 pos 2 Hold testing device glass bulb upwards ill 2 pos 3 or fix it on the boat D 2 14 08 ill 1 Procedure 14 03 ill 2 Check 1 Ventila
27. te fuel system by 6 times ignition ON Observe the sight glass as to complete ventilation of system bubblefree fuel flow Result Ifa bubblefree fuel flow cannot be achieved search for the problem atthe 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 Z001019 0 6 July 2008 Page FUEL SYSTEM 37 03 FUEL SYSTEM SERVICE MANUAL MARINE ENGINES Check Manual Check 3 Result Control Check 4 Defective unit injector s is are to be detected definitely by means of manual injection test methode manual injection test methode refer to 03 14 01 If during disengagement methode of injection of unit injectors a creaky noise is to be heard anda solide resistance pressure point can be felt check the tightening torque of the unit injectors 03 02 02 assembly item 11 Th
28. trol so lenoid housing by means of 4 screws For 4 cyl engines only Secure the 4 screws with LOCTITE 243 and tighten with a torque of 23 Nm 2 For 6 cyl engines only item 8 9 Cover the two lower screws with LOCTITE 243 and slightly tighen 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 Check whether the control rack can be moved over a distance of approx 18 mm ATTENTION Pin of control rack position sensor is spring loaded and might easily slip off A from the face of control rack lever during assembly In such a case the control rack is blocked and thus prevents resetting to zero delivery gt ENGINE FAILURE Remaining assembly is done in reverse order NOTE The rack position sensor is magnetism sensitive All external magnets must be kept away as the may disturb the sensor c 08 02 11 4 2 S 1 08 02 ill 2 08 02 ill 3 Page FUEL SYSTEM 28 Z001019 0 6 July 2008 SERVICE MANUAL MARINE ENGINES 03 FUEL SYSTEM 03 08 03 Replace sensor indication of control rack position Preparation For4cyl engines only remove shift plate refer to 01 08 01 ill 3 For6cyl engines only remove bracket of potentiometer accelerator refer to 03 08 01 ill 5 6 1 Loosen 2 Allen head screws ill 1 pos 1 SWS Remove r
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