SERVICE MANUAL
Contents
1. SERVICE MANUAL 4 Stroke Engine MPE 850 MARINE This service manual is valid for the following engine variants 408101 I2 846 MAR TC 100 TC 80 TC 120 408014 2 846 MAR TC 120 408090 I2 846 MAR TC 155 407477 SHB Rev 1 2 16 08 2013 Read this service manual thoroughly before operating the engine for the first time en English Weber Motor GmbH strives to make continual improvements as part of the ongoing technical development of its products All documentation is therefore subject to technical modifications Reprints and translations in whole or in part require written permission from Weber Motor GmbH All rights reserved according to the copyright law Weber Motor GmbH Zepernicker Chaussee 23 37 16321 Bernau bei Berlin Germany www weber motor com Table of contents A Weber Motor Table of contents 1 About this document 6 1 14 Meaning of symbols and signal words lille 6 2 Safety 7 2 1 Meaning of safety alert symbol and signal words lille 7 2 2 Important safety messages lille 8 3 Description 11 341 Intended USC sas cios eee RC dye ang aoe WAG pep m equ E Et VR 11 3 2 Identification Binet ear cae edie p Reb deee dine ad pet d node tg Pb b MP REEF URP 11 3 9 WRUCM id nisi tentus Hea attri Hate etude rs diste ats ata mate tele Aina din Defects Aeg 13 3 4 Engine oll oo ke ewe EET rp ERES EXE xa esee EX PA E E HS 13 3 5 XCoolant 3r ehe ins Wa te ena a e2. 408101 25 4 Operation 4 3 Service before driving 4 3 3 Checking oil level Weber Motor Information Your engine uses a dry sump lubrication system Engine oil is pumped from the engine into the oil tank while the engine is operating When the engine is switched off a portion of the engine oil flows from the oil tank slowly back into the engine Therefore inspect the oil level immediately after switching off the engine Check the oil level with a warm engine gt Warm up the engine See the vehicle manufacturer s documentation CAUTION Scalding caused by hot engine oil Wear protective gloves gt Unscrew the oil dipstick Hl at the oil tank Wipe the oil dipstick and insert into the oil tank Do not screw in Remove the oil dipstick Hl and check oil level The oil level must be between the MIN marking Ill and the MAX marking EB NOTICE Engine damage caused by a lack of engine oil When oil level is below the MIN marking continue with the section Refilling engine oil NOTICE Engine damage caused by too much engine oil When oil level is exceeded the MAX marking pump out excessive engine oil with oil suction pump Screw in the oil dipstick 26 SHB MPE850 Rev 1 2 408014 408090 408101 neck 4 Operation Q eper Motor 4 3 Service before driving Refilling engine oil NOTICE Engine damage caused by too much engine oil Refill engine oil in s
3. 7500 min rpm 7500 min rpm Engine speed limit 8000 min rpm Idle speed 1600 min rpm Carburation Sequential multipoint intake manifold injection Lubrication system Dry sump Cooling system Closed coolant circuit and open sea water cooling circuit Engine management system Synerject M3D Throttle body Ignition system Electronically controlled dia 44 mm 1 73 in Electronically controlled distributorless ignition system with single spark ignition coils Starter system Electric starter Generator internal gt 450 W 4000 min rpm Fuses Automotive fuses mini blade type 10 A and 15A Weight including engine oil and coolant 95 kg 209 lb 95kg 209 b 95kg 2091b 100 kg 221 Ib Dimensions L 743 mm 30 in Dimensions B 539 mm 22 in Dimensions H 509 mm 20 in 20 SHB MPE850 Rev 1 2 408014 408090 408101 4 Operation Weber Motor SRS 4 1 Service intervals 4 Operation Familiarize yourself with the vehicle before operating the engine Read the vehicle manufacturer s documentation 4 1 Service intervals In order to keep your engine in a safe operating condition regular servicing is essential Following service tasks you can perform yourself before driving daily every 10 h or after driving E Inspecting exhaust and fuel system Checking coolant level Che
4. observe the coolant manufacturer s recommendations for the following service intervals 22 SHB MPE850 Rev 1 2 408014 408090 408101 Feeria 4 Operation eper Motor 4 2 Operation during the break in period 4 2 Operation during the break in period The way you operate the engine during the first five hours of operation is a major factor in achieving the required performance and extending the service life of the engine Observe the following points to ensure that the engine parts break in properly Avoid engine speeds over 6000 min rpm long periods of idle operation long operating periods at low engine speeds long operating periods at the same engine speed long operating periods at full load Good changes in engine speed when the engine is warm momentary bursts of acceleration SHB MPE850 Rev 1 2 408014 408090 408101 23 4 Operation O pat 4 3 Service before driving D eber Motor 4 3 Service before driving 4 3 1 Inspecting the exhaust and fuel system gt Remove the engine cover Hl Exhaust system WARNING Engine exhaust gases contain carbon monoxide CO Inhalation of carbon monoxide can deprive the body of oxygen and result in organ damage or even death by asphyxiation gt Check if hose clamps bolts or metal parts of the exhaust system Ml have noticeable corrosion Check if hoses are mounted properly and if cracks have been formed on hoses Fuel system WARNING Fuel is
5. 0 5 Nm 2 2 Ibf ft 0 4 Ibf ft SHB MPE850 Rev 1 2 408014 408090 408101 73 8 Service tasks in the workshop 8 11 Changing coolant eber Motor 8 11 Changing coolant Drain the coolant with a cold engine gt Unscrew the expansion tank cover EH Draining coolant gt Put the drain tray under the fitting on heat exchanger gt Open the hose clamp HZ gt Remove the hose and keep it over the drain tray Coolant drains off 74 SHB MPE850 Rev 1 2 408014 408090 408101 Weber M 8 Service tasks in the workshop eber Motor 8 11 Changing coolant Flushing coolant circuit gt Fill the expansion tank Ill with clean fresh water Water drains off through the heat exchanger Repeat the procedure until only clear water drains off through the heat exchanger Insert the hose gt Close the hose clamp EJ Tightening torque 5 Nm 0 5 Nm 3 7 Ibf ft 0 4 Ibf ft SHB MPE850 Rev 1 2 408014 408090 408101 75 8 Service tasks in the workshop 8 11 Changing coolant Filling with coolant Fill coolant to the expansion tank until the MAX marking Ill Close the expansion tank Warm up the engine See the vehicle manufacturer s documentation Check the coolant level CAUTION Scalding caused by hot steam Open expansion tank only with a cold engine NOTICE Danger of overheating caused by a lack of coolant When cool
6. 408014 408090 408101 29 5 Special scenarios RTT 5 1 Engine idle for more than 30 days eber Motor 5 Special scenarios 5 1 Engine idle for more than 30 days If you do not intend to operate the engine for 30 days or more prepare the engine for storage Preparing the engine for storage will prevent the cylinder from corroding and ensure the engine starts again correctly at the end of the storage period Preparations for storage require special technical knowledge Preparations must be performed in a workshop authorized by Weber Motor or the portable fire pump manufacturer 5 2 Operating engine without sea water NOTICE Engine damage caused by overheating If you operate the engine without sea water the optimal engine cooling is no longer provided Select one of the following procedures Operate the engine only at idle and only for a maximum period of 30 seconds Flush the sea water cooling circuit See chapter 4 4 1 Flushing sea water cooling circuit 5 3 Towing vehicle in water NOTICE Engine damage due to water in the engine If you tow the vehicle in water the water may get into the engine through the exhaust system If your vehicle has a towing valve or a similar device close it Read the vehicle manufacturer s documentation for more information Without a towing valve tow the vehicle only for a short time with maximum speed of 16 km h 10 mph 9 knots 30 SHB MPE850 Rev 1 2 408
7. Close the hose clamp Mil Tightening torque 3 Nm 0 5 Nm 2 2 Ibf ft 0 4 Ibf ft Hold the the connecting pipe in position gt Close the hose clamps HE Tightening torque 3 Nm 0 5 Nm 2 2 Ibf ft 0 4 Ibf ft Touch up the paintwork defects Clear the service counter to reset service light See the Weber Diagnostic Tool manual Update the engine control unit calibration See the Weber Diagnostic Tool manual Switch on the ignition for a minute The throttle body is calibrated Test drive the vehicle SHB MPE850 Rev 1 2 408014 408090 408101 69 8 Service tasks in the workshop 8 9 Adjusting waste gate valve 8 9 Adjusting waste gate valve Adjust the waste gate valve with a cold engine Observe the indicated directions of rotation Hl One nut J has a left hand thread gt Hold the threaded rod with a wrench gt Open the two nuts EM EH in direction of rotating gt Open the spanner nut EH in the indicated direction of rotation until no longer pretensioning exists 70 SHB MPE850 Rev 1 2 408014 408090 408101 8 Service tasks in the workshop Weber Motor ae 8 9 Adjusting waste gate valve gt Close the spanner nut in the indicated direction of rotation until the following conditions are met The lever does not move anymore The thread rod Hl has not moved yet gt X Attach the marking EN Close the spanner nut with two full turns in the
8. Engine damage caused by overheating Operate the engine without supply of water only at idle and only for a maximum period of 30 seconds Start the engine and run the engine at idle Open the water tap The sea water cooling circuit will be flushed Weber Motor recommends to flush the sea water cooling circuit at least for 5 minutes Close the water tap v Switch off the engine Remove the flushing device 28 SHB MPE850 Rev 1 2 408014 408090 408101 nok 4 Operation A eber Motor 4 4 Service after driving 4 4 2 Corrosion protection Information For information about suitable products and their using please consult your local vehicle dealer If you operate your vehicle in salt water regularly use a corrosion protection spray See chapter 4 1 Service intervals 4 4 3 Transport and storage of the vehicle If you intend to transport or place the vehicle in storage read the following instructions If you do not intend to operate the engine for 30 days or more prepare the engine for storage See chapter 5 1 Engine idle for more than 30 days Transport and store the vehicle on a preferably stable and flat surface If you do not have any flat surface available note for storage necessarily the angles in the figure Do not exceed these angles Store the vehicle in a clean dry place with an ambient temperature of 30 45 C 22 113 F SHB MPE850 Rev 1 2
9. TC 80 TC 100 and TC 120 Oil filter Zi Drainage for storage Hl Fuse box Waste gate valve EE Flame arrester HE Heat exchanger Gl Connection for flushing device sea water cooling circuit Sacrificial anode Zl Exhaust pipe EM Sea water return HG SHB MPE850 Rev 1 2 408014 408090 408101 15 3 3 6 Engine components and information 16 Description 1st cylinder EEE 2nd cylinder KA Fuel supply Engine rotation direction EES Stub shaft KEJ Engine cover KA Oil tank Expansion tank coolant Sea water supply EH Vehicle connector Engine Chassis HJ Relay starter EE lt SHB MPE850 Rev 1 2 408014 408090 408101 Weber Motor 3 Description 3 6 Engine components and information Engine variant I2 846 MAR TC 155 Oil filter ENIM Drainage for storage Hl Waste gate valve Flame arrester ISI Heat exchanger IE Connection for flushing device sea water cooling circuit EI Sacrificial anode dli Exhaust pipe EM Sea water return BEI SHB MPE850 Rev 1 2 408014 408090 408101 17 3 3 6 Engine components and information 18 Description 1st cylinder KT 2nd cylinder Ei Fuel supply KA Fuse Box Engine rotation direction KE Stub shaft HEH Engine cover KA Oil tank Expansion tank coolant Sea water supply EH Vehicle connect
10. eee 78 8 13 2 Putting engine into operation after storage 0 0 es 80 S214 Disposal debe Weta pect RAE RU es AOU GAS a shat Sad aval a da EA a RR eels 81 9 Confirmation of service tasks 82 Appendix 84 Engine Manutacturen y 5 etre sa po Rr De sex de s sec DR ee ded d POR Ee 84 Exhaust type authorization and certification clle 84 USA EPA EMISSION LIMITED WARRANTY ssssseeee ee ena 85 hbjqeec c c r cC ETE 86 SHB MPE850 Rev 1 2 408014 408090 408101 5 1 About this document Wines 1 1 Meaning of symbols and signal words eber Motor 1 About this document This service manual was designed to help you operate the engine safely and reliably Observe the following information Read this service manual thoroughly before operating the engine for the first time The service manual is for the engine in your vehicle Keep the service manual in a safe place Make sure that all personnel using the vehicle have access to the service manual f you sell the vehicle always pass on the service manual to the new owner The latest version of the service manual is available for download in other languages from our web site www weber motor com Always read the vehicle manufacturer s documentation Some figures in this service manual are general illustrations and may differ from the actual engine 1 4 Meaning of symbols and signal words Item Meaning NOTICE The signal word NOTICE i
11. indicated direction of rotation Close the two nuts KT EIH in direction of rotation EI Touch up the paintwork defects Clear the service counter to reset service light See the Weber Diagnostic Tool manual Update the engine control unit calibration See the Weber Diagnostic Tool manual Test drive the vehicle SHB MPE850 Rev 1 2 408014 408090 408101 71 8 Service tasks in the workshop 8 10 Checking flame arrester 8 10 Checking flame arrester gt Check the flame arrester Hl The fabric must be visible gt When the fabric filter is no longer visible continue with section Cleaning the flame arrestor Cleaning flame arrester gt Open the clamp HE The clamp built in by the engine manufacturer in these place is destroyed during removal After removing the clamp must be replaced by an hose clamp gt Remove the hose IK gt Open the hose clamp ES 72 SHB MPE850 Rev 1 2 408014 408090 408101 Weber Mot 8 Service tasks in the workshop r di Sd 8 10 Checking flame arrester Remove the flame arrester Ill gt Clean the flame arrester with cleaning spray according to the manufacturer s instructions gt Attach the flame arrester gt X Close the hose clamp WJ Tightening torque 4 5 Nm 1 Nm 3 3 Ibf ft 0 7 Ibf ft gt Replace the clamp EJ Insert the hose dll Close the hose clamp v Tightening torque 3 Nm
12. number Serial No is an unique number for each individual engine Take the time to enter the part number and serial EE Date 26 10 2012 Part No 999999 Q TIU UU HL IML DUO ll I Serial No 9999999999 PUTTY UL W U UE WA TILIA number in chapter 9 Confirmation of service tasks Both numbers are required when making queries about your engine Engine variants 12 846 MAR TC 80 TC 100 and TC 120 The label with the part number and the serial number is located on the expansion tank HZ The serial number is also engraved on the crankcase HEE The label Emission Control Information indicates the certification of the engine according to the legal exhaust emission guidelines See in appendix exhaust type authorization and certification The label is located on the expansion tank SHB MPE850 Rev 1 2 408014 408090 408101 11 3 Description 3 1 Intended use 3 2 Identification Engine variant I2 846 MAR TC 155 The label with the part number and the serial number is located on the expansion tank WJ The serial number is also engraved on the crankcase Mia The label Emission Control Information indicates the certification of the engine according to the legal exhaust emission guidelines See in appendix exhaust type authorization and certification The label is located on the expansion tank 12 SHB MPE850 Rev 1 2 4080
13. on the oil tank When removing the hose from the oil tank you need to move the oil tank This can brake the oil tank pins Put the oil tank beside KT the oil tank bracket SHB MPE850 Rev 1 2 408014 408090 408101 47 8 Service tasks in the workshop Weber Mot 8 3 Changing engine oil and oil filter mue gt X Open the hose clamps and KEJ gt Hold the hoses EA and EZ over a drain tray Extend hoses if necessary gt Actuate the starter The engine cranks and the engine oil will be pumped out of the engine The starting sequence will be aborted automatically after a few seconds gt Wait a moment and repeat the procedure until no more engine oil is being pumped out gt Connect the hose MEH with the oil tank gt Close the hose clamp KKA Tightening torque 3 Nm 0 5 Nm 2 2 Ibf ft 0 4 Ibf ft gt X Connect the hose KIJ with the oil tank gt X Close the hose clamp KEJ Tightening torque 5 Nm 0 5 Nm 3 7 Ibf ft 0 4 Ibf ft Replacing oil filter gt X Hold the oil filter KEJ gt X Unscrew the banjo bolt Hall Remove the oil filter 48 SHB MPE850 Rev 1 2 408014 408090 408101 Weber Motor gt SHB MPE850 Rev 1 2 408014 408090 408101 Clean the sealing surface Hl with sealing surface cleaner Replace the oil filter EX Coat the oil filter seal E lightly with engine oil Replace both o rings E on the banjo bolt EA Coat the o rings and
14. play of all valves on the cylinder using a feeler gauge Required valve play 0 2 0 3 mm If the valve play of one or more valves is not right continue with chapter 8 5 2 Adjusting valve play Replace the valve cover seals KEJ gt Clean the sealing surface KEl with sealing surface cleaner SHB MPE850 Rev 1 2 408014 408090 408101 8 Service tasks in the workshop 8 5 Checking and adjusting valve play 55 8 Service tasks in the workshop 8 5 Checking and adjusting valve play 56 Put the valve cover MA on Apply Anti Seize assembly paste to all bolts ETA Screw in the bolts in the sequence as illustrated KEJ Tightening torque 8 Nm 2 Nm 5 9 Ibf ft 1 5 Ibf ft Insert the ignition coils EM Replace the serrated lock washers EJ Assemble the bolts E washers EA and serrated lock washers as illustrated Tightening torque 8 Nm 2 Nm 5 9 Ibf ft 1 5 Ibf ft Connect the wire harness connectors to the ignition coils and sensor camshaft EZB Touch up the paintwork defects Clear the service counter to reset service light See the Weber Diagnostic Tool manual Update the engine control unit calibration See the Weber Diagnostic Tool manual Place the engine cover El and press down the engine cover until it is snapped Test drive the vehicle SHB MPE850 Rev 1 2 408014 408090 40
15. stages First as much as possible engine oil will be pumped out from the oil tank The remaining engine oil will be pumped out with the suction pump in the dry sump gt Warm up the engine See the vehicle manufacturer s documentation gt Remove the engine cover Hl CAUTION Scalding caused by hot engine oil Wear protective gloves gt X Unscrew the oil dipstick Ill at the oil tank SELL IAL LASS SHB MPE850 Rev 1 2 408014 408090 408101 45 8 Service tasks in the workshop 8 3 Changing engine oil and oil filter Pumping out engine oil Insert the suction hose of the oil suction pump through the opening in oil dipstick until the hose reaches the oil tank bottom Pump out the engine oil from oil tank The engine fuses and relays are located in the fuse box on the engine See chapter 3 6 Engine components and information Remove the cover Ill from the fuse box Ignition coils and injectors are supplied with electricity through the service fuse When the service fuse is removed you can rotate the engine using the starter avoiding starting the engine Remove the service fuse Bill 46 SHB MPE850 Rev 1 2 408014 408090 408101 Weber Mot 8 Service tasks in the workshop eer 8 3 Changing engine oil and oil filter gt Unscrew the bolts on the oil tank gt Lift the oil tank IEM from the oil tank bracket EN NOTICE Breakage risk due to work
16. workshop Weber Mot 8 4 Checking sacrificial anode PASE RORO 8 4 Checking sacrificial anode Information The water jacket in the exhaust manifold is protected from corrosion by a passive cathodic protection gt Unscrew the sacrificial anode Hl gt Check the sacrificial anode Hi 60 mm 2 4 in 16 mm 0 6 in At least half of the original size 60 mm 2 4 in 16 mm 0 6 in exists gt Ifthe sacrificial anode is less than half of the EEE original size replace the sacrificial anode gt X Replace the seal HZ Screw in the sacrificial anode EN Tightening torque 41 Nm 9 Nm 30 2 Ibf ft 6 6 Ibf ft Touch up the paintwork defects 52 SHB MPE850 Rev 1 2 408014 408090 408101 Weber Mot 8 Service tasks in the workshop acid 8 5 Checking and adjusting valve play 8 5 Checking and adjusting valve play 8 5 1 Checking valve play gt X Remove the engine cover EH Check valve play with a cold engine WARNING Danger of serious cuts from the gear on the camshaft when the engine is started Disconnect the engine from the power supply Disconnect the wire harness connectors from the ignition coils Hl and sensor camshaft Bl gt Unscrew the bolts IM gt Pull the ignition coils HEM out SHB MPE850 Rev 1 2 408014 408090 408101 53 8 Service tasks in the workshop 8 5 Checking and adjusting valve play Unscrew th
17. 014 408090 408101 berio 5 Special scenarios eber Motor 5 4 Measures in case of flooded engine 5 4 Measures in case of flooded engine NOTICE Engine damage due to water in the engine If your vehicle has been capsized and or the engine has been flooded the water may get into the engine through the exhaust system It can still happen even if the engine has been partially flooded The longer you postpone the necessary service tasks the more severe will be the engine damage Do not try to start the engine Remove the water from the engine immediately Do not waste your time Contact immediately or at least within 24 hours a workshop authorized by Weber Motor or the vehicle manufacturer SHB MPE850 Rev 1 2 408014 408090 408101 31 6 Malfunctions 6 1 Malfunctions table 6 Malfunctions 6 1 Malfunctions table Weber Motor If you cannot correct a malfunction yourself using the malfunctions table below contact a workshop authorized by Weber Motor or the vehicle manufacturer immediately Malfunction Possible cause Remedy The engine warning light MIL is flashing There is an emission related malfunction The engine warning light MIL is illuminating There is a malfunction The engine warning light MIL does not illuminate after engine start The temperature warning light is flashing or illuminating The oil pressure light is on The service light is ill
18. 14 408090 408101 Weber Motor 3 3 Fuel Recommended fuel quality Minimum requirement Permissible share of ethanol 3 4 Engine oil 3 Description 3 3 Fuel 3 4 Engine oil Engine variants I2 846 MAR TC 80 TC 100 and TC 120 Unleaded gasoline super with an octane rating of 95 ROZ or 85 MOZ USA Premium 91 unleaded Engine variant I2 846 MAR TC 155 Unleaded gasoline super with an octane rating of 98 ROZ or 88 MOZ USA Premium 93 unleaded NOTICE Low octane fuel can cause loss of power and or increased fuel consumption Unleaded gasoline with an octane rating of at least 91 ROZ or 82 5 MCZ USA At least Regular 87 unleaded NOTICE An increased share of ethanol can lead to premature abrasion and poor starting performance of the engine Maximum 15 E15 NOTICE Engine oil Fill quantity Engine damage due to incorrect engine oil grade or viscosity An incorrect engine oil grade or viscosity causes excessive wear and moving parts may start to seize up Always use the recommended engine oil Do not mix engine oils of different grades or degrees of viscosity OW 40 completely synthetic at least API SJ ACEA A3 B3 Initial filling 3 5 liters 3 7 qt US After changing oil 2 9 liters 3 1 qt US Information Weber Motor recommends you always to keep a supply of engine oil to hand Consult your local vehicle dealer SHB MPE850 Rev 1 2 408014 408090 408101 13 3 Des
19. 6 SHB MPE850 Rev 1 2 408014 408090 408101 Weber Mot 8 Service tasks in the workshop ai 8 8 Replacing rubber mount gt Close the hose clamp EES Tightening torque 3 Nm 0 5 Nm 2 2 Ibf ft 0 4 Ibf ft gt Insert the hose KIJ Observe the marking gt Close the spring band clamps KEJ gt Touch up the paintwork defects gt Clear the service counter to reset service light See the Weber Diagnostic Tool manual gt Update the engine control unit calibration See the Weber Diagnostic Tool manual gt Switch on the ignition for a minute The throttle body is calibrated gt Test drive the vehicle Engine variant I2 846 MAR TC 155 Remove the rubber mount with a cold engine gt Open the hose clamps Hl gt Remove the connecting pipe E SHB MPE850 Rev 1 2 408014 408090 408101 67 8 Service tasks in the workshop 8 8 Replacing rubber mount gt Disconnect the wire harness connector from the throttle body EN gt Open the hose clamp EJ gt Remove the throttle body HGH Unscrew the bolts Hil Remove the rubber mount EN Replace the rubber mount Hold the rubber mount in position vvvvy Screw in the bolts Tightening torque 8 Nm 2 Nm 5 9 Ibf ft 1 5 Ibf ft 68 SHB MPE850 Rev 1 2 408014 408090 408101 Weber Mot 8 Service tasks in the workshop QR 8 8 Replacing rubber mount gt Insert the hose clamp K and throttle body KB gt
20. 8101 Weber Mot 8 Service tasks in the workshop Ss LUUD 8 5 Checking and adjusting valve play 8 5 2 Adjusting valve play Information The camshaft is turned using the crankshaft The vehicle manufacturer has devised a suitable procedure for this Read the vehicle manufacturer s documentation for more information Always turn the crankshaft in the same direction as the engine rotates See chapter 3 6 Engine components and information Two rotations of the crankshaft correspond to one rotation of the camshaft Adjusting valve play on the 2nd cylinder WARNING Danger of serious cuts from the gear on the camshaft when the engine is started Disconnect the engine from the power supply gt Turn the camshaft until the position of the camshaft is as illustrated See the vehicle manufacturer s documentation The camshaft is marked at the 2nd cylinder end only The marking Kl ends flush with the cross bar All rocker arms EM on the cylinder have a certain amount of play Continue with the section Replacing valve adjustment shim Adjusting valve play on the 1st cylinder Turn the camshaft until the position of the camshaft is as illustrated See the vehicle manufacturer s documentation The camshaft is marked at the 2nd cylinder end only The marking EE ends flush with the cross bar Otherwise no inscription is visible All rocker arms Ill on the cylinder have a certain amount of play Co
21. E850 Rev 1 2 408014 408090 408101 43 8 Service tasks in the workshop 8 2 Tools and accessories 8 2 4 Supplies Weber Motor You will require the following supplies to perform service tasks Unless otherwise specified use the products as directed by the manufacturer All supplies are available from specialist retailers Supplies Recommended products Cleansing concentrate for flushing the sea water cooling circuit Stopsel Kalyscom France Salt Away Salt Away Products Inc USA Anti Seize assembly paste for lubricating threaded connections Weicon Anti Seize High Tech ASW 040 P Loctite 8150 Engine internal preservative Liqui Moly Germany Fuel stabilizer Liqui Moly Germany Sealing surface cleaner Corrosion protection spray Liqui Moly brake and parts cleaner Alll Germany W rth corrosion protection spray Germany The product must be salt water resistant and suitable for different surfaces such as metals paintet surfaces plastic and rubber Lacquer for touching up paintwork defects DUPLI COLOR acrylic lacquer silver RAL 9006 DUPLI COLOR acrylic lacquer white RAL 9010 Flame arrester cleaning spray 44 K amp N Power Kleen Netherlands SHB MPE850 Rev 1 2 408014 408090 408101 Weber Mot 8 Service tasks in the workshop Se er 8 3 Changing engine oil and oil filter 8 3 Changing engine oil and oil filter Information The engine oil will be pumped out in two
22. aler and servicing network See 7 1 Locating a workshop 7 Dealer and servicing network 7 1 Locating a workshop An extensive global dealer and servicing network is available The dealer and servicing network provides assistance with any queries relating to the engine Visit our web site www weber motor com for a list of all authorized Weber Motor workshops 7 2 Service and spare parts Weber Motor offers a selection of accessories to prepare you for the most important situations Visit your local vehicle dealer or our web site www weber motor com for more information 7 3 Repairs Repairs require mechanical knowledge and special technical knowledge of this engine Weber Motor recommends you have any repairs performed by a workshop authorized by Weber Motor or the vehicle manufacturer 7 4 Warranty In the case of warranty claims always consult a workshop authorized by the vehicle manufacturer If that is not possible contact your local vehicle dealer SHB MPE850 Rev 1 2 408014 408090 408101 37 8 Service tasks in the workshop Wishes eber Motor 8 1 Safety messages workshop 8 Service tasks in the workshop 8 1 Safety messages workshop Service tasks in the workshop Service manual Engine power supply Workspace Protective equipment Tools 38 All service tasks described in the following chapter require mechanical knowledge and special technical knowledge of this engine All service tasks describe
23. alve adjustment too MES gt Remove the cover from the chain channel NOTICE Valve breakage due to insufficient valve play gt Check the valve play gt Continue with chapter 8 5 1 Checking valve play SHB MPE850 Rev 1 2 408014 408090 408101 59 8 Service tasks in the workshop s e Weber Motor 8 6 Replacing spark plugs and igition coils 8 6 Replacing spark plugs and igition coils gt X Remove the engine cover Hl Remove the spark plugs with a cold engine Disconnect the wire harness connectors from the ignition coils E gt Unscrew the bolts HEH gt X Pullthe ignition coils HZ out 60 SHB MPE850 Rev 1 2 408014 408090 408101 8 Service tasks in the workshop Weber Motor gt Unscrew the spark plugs BEM using a spark plug wrench 8 6 Replacing spark plugs and igition coils Replace the spark plugs Screw in the spark plugs using a spark plug wrench Tightening torque 22 Nm 10 Nm 16 2 Ibf ft 7 4 Ibf ft The ignition coils must not be replaced always See chapter 4 1 Service intervals gt Replace the ignition coils W3 Insert the ignition coils gt X Replace the serrated lock washers Hil Assemble the bolts Ill washers HEI and serrated lock washers as illustrated Tightening torque 8 Nm 2 Nm 5 9 Ibf ft 1 5 Ibf ft Connect the wire harness connectors to the ignition coils E Touch up the paintw
24. anged Fuel filter replaced LE EIL EI BI BJ BJ BJ BI BD Company seal signature SHB MPE850 Rev 1 2 408014 408090 408101 83 Appendix TUM Engine manufacturer Exhaust type authorization and certification eber Motor Appendix Engine manufacturer Engine manufacturer Weber Motor GmbH Zepernicker Chaussee 23 37 16321 Bernau bei Berlin Germany www weber motor com Exhaust type authorization and certification This engine family complies with U S EPA Exhaust regulation for inboard sterndrive marine engines as defined in 40 CFR 1045 For further details see the Emission Control Information label on engine expansion tank See chapter 3 2 Identification 84 SHB MPE850 Rev 1 2 408014 408090 408101 TT Appendix eber Motor USA EPA EMISSION LIMITED WARRANTY USA EPA EMISSION LIMITED WARRANTY Weber Motor Engine Family DWEBM 850DTG DWEBM 850DTH Model Year 2013 Weber Motor GmbH Weber warrants that the certified sterndrive inboard SD I engines are 1 designed built and equipped to conform at the time of initial sale with the requirements of 40 CFR part 1045 and 2 free from defects in materials and workmanship that may keep it from meeting these requirements This emission limited warranty is in addition into vehicle manufacturer s standard limited warranty for inboard sterndrive SD I applications The emission warranty period for these certified engines begins on the
25. ant level is below the MIN marking HM wait until the engine has cooled down Refill coolant until the coolant level is between the MIN marking and the MAX marking NOTICE Leaks in the hoses due to increased pressure When the MAX marking is exceeded pump out excessive coolant with a suction pump Touch up the paintwork defects Clear the service counter to reset service light See the Weber Diagnostic Tool manual Update the engine control unit calibration See the Weber Diagnostic Tool manual Test drive the vehicle 76 SHB MPE850 Rev 1 2 408014 408090 408101 Weber Mot 8 Service tasks in the workshop Ad 8 12 Replacing fuel filter 8 12 Replacing fuel filter See the vehicle manufacturer s documentation SHB MPE850 Rev 1 2 408014 408090 408101 17 8 Service tasks in the workshop Weber Mot 8 13 Storing engine and putting into operation EN 8 13 Storing engine and putting into operation 8 13 1 Preparing engine for storage Change the engine oil and oil filter See chapter 8 3 Changing engine oil and oil filter Flush the sea water cooling circuit using cleansing concentrate See chapter 4 4 1 Flushing sea water cooling circuit Check the sacrificial anode See chapter 8 4 Checking sacrificial anode Fill up the fuel tank Add a fuel stabilizer according to the manufacturer s instructions Check the spark plugs See chapter 8 7 Chec
26. cking oil level Flushing sea water cooling circuit a Corrosion protection h hours of operation only after operating in salt water Information The engine management system supports the feature of a service light Read the vehicle manufacturer s documentation for more information SHB MPE850 Rev 1 2 408014 408090 408101 21 4 Operation 4 1 Service intervals Weber Motor The following service tasks require mechanical knowledge and special technical knowledge of this engine These service tasks must be performed in a workshop authorized by Weber Motor or the vehicle manufacturer 1st service Subsequent service intervals Preparing for after12h every 60h every 120h every360h storage or not later than oratleastonce or atleast every or atleast every 25h a year 2 years 4 years Changing engine oil and oil filter Checking and adjusting valve play Replacing spark plugs Replacing ignition coils Replacing rubber mount Adjusting waste gate valve Checking flame arrester Flushing sea water cooling circuit Checking sacrificial anode Corrosion protection Checking spark plugs Fuel stabilizer Engine internal preservation Inspecting exhaust and fuel system Changing coolant after 4 years Replacing fuel filter See the vehicle manufacturer s documentation 3 if you do not intend to operate the engine for more than 30 days
27. cription 3 5 Coolant 3 5 Coolant Weber Motor NOTICE Coolant additive Mixing ratio Fill quantity Approved coolant additives Freezing overheating or corrosion due to incorrect mixing ratio or unauthorized coolant additives An incorrect mixing ratio reduces the cooling capacity Combining different coolant additives may trigger a chemical reaction and they may lose their effectiveness gt Use the same coolant throughout the year in the mixing ratio specified gt When topping up the coolant do not change the mixing ratio gt Always use approved coolant additives when topping up the coolant Coolant additive based on ethylene glycol silicate and nitrite free suitable for aluminium engines 50 water 50 coolant additive 2 75 liters 2 9 qt US BASF Glysantin G 30 Chevron Havoline Extended Life Coolant XLC B Valvoline Zerex G 30 Information Weber Motor recommends you always to keep an adequate supply of ready mixed coolant to hand Consult your local vehicle dealer 14 SHB MPE850 Rev 1 2 408014 408090 408101 Weber M 3 Description eber Motor 3 6 Engine components and information 3 6 Engine components and information Information If you remove the vehicle connector Engine Chassis the engine will not be disconnected from the battery The battery is connected separately to the wire harness The wire harness is not shown in the figures Engine variants 12 846 MAR
28. cs and service tasks for Weber engines using a Synerject engine management system Visit your local vehicle dealer or our web site www weber motor com for more information SHB MPE850 Rev 1 2 408014 408090 408101 41 8 Service tasks in the workshop Weber Motor 8 2 Tools and accessories 8 2 3 Equipment workshop In addition to the service case you will require the following tools and accessories for service tasks The figures are only examples of suitable tools All tools and accessories are available from specialist retailers Figure Description Figure Description Torque wrench 2 50 Nm 1 37 Ibf ft with extension and 6 point socket wrench insert adapter e 7 Reversible ratchet a with extension and Open end wrench insert adapter 10 15 17 Insert open end wrench Hexagon screwdriver 5 15 17 e aa eel Caliper Hexagon screwdriver ds Measuring accuracy Socket 5 0 05 mm bu O Torx screwdriver T30 Bar magnet p Spark plug wrench all p 4 Wrench size 16 mm Torx screwdriver m 5 8 Oo Socket E Diameter maximum T30 22 mm 0 87 in Hexagon nut driver 7 Spark plug brush 42 SHB MPE850 Rev 1 2 408014 408090 408101 8 Service tasks in the workshop 8 2 Tools and accessories Description Oil suction pump Drain tray a Hose clamp pliers for S spring band clamps SHB MP
29. d clamps Wear protective glasses also people in the nearby working place Use only suitable tools as described in Section 8 2 Tools and accessories Observe the tool manufacturer s installation instructions SHB MPE850 Rev 1 2 408014 408090 408101 39 8 Service tasks in the workshop 8 2 Tools and accessories 8 2 Tools and accessories 8 2 1 Weber Motor service parts Weber Motor Weber Motor offers a service case that contains the following service parts Visit your local vehicle dealer or our web site www weber motor com for more information Figure Description Figure Description w Valve adjustment oO C Olfiter filter shims in different sizes O rings for oil filter change Serrated lock washer b 00 f Spark plug Champion RC7PYCBX Valve adjustment kit Feeler gauge 0 05 2 mm Sacrifical anode including seal Sealing kit valve cover Seal for sacrifical anode 40 SHB MPE850 Rev 1 2 408014 408090 408101 Weber Motor 8 Service tasks in the workshop 8 2 Tools and accessories For the service intervals every 4 years you also need the following parts Figure Description Figure Description g Ignition coil Rubber mount 8 2 2 Weber Motor diagnostic case Weber Motor offers a diagnostic case that contains the Weber Diagnostic Tool The Weber Diagnostic Tool is designed for fault diagnosti
30. d in chapter 8 Service tasks in the workshop must be performed by a workshop authorized by Weber Motor or the vehicle manufacturer Before reading chapter 8 Service tasks in the workshop you must have read and understood all other information in the service manual Read through the service manual carefully before performing any service tasks Pay particular attention to the safety messages All service tasks require disconnection of the engine from the power supply Starting the engine inadvertently may endanger the safety of personnel Read the vehicle manufacturer s documentation for more information Disconnect the engine from the power supply before performing any servicing tasks Only reconnect the power supply to the engine once all service tasks are complete and all protective equipment is correctly fitted Performing the service tasks on the vehicle located in water may endanger the safety of personnel Take the vehicle out of water to perform any service tasks Missing protective equipment poses a safety risk to personnel Attach all protective equipment after completing the service tasks Unsuitable tools pose a safety risk to personnel Always use tools listed in chapter 8 2 Tools and accessories SHB MPE850 Rev 1 2 408014 408090 408101 8 Service tasks in the workshop Weber Motor 8 1 Safety messages workshop Spring band clamps Serious eye injuries caused by sudden release of spring ban
31. date the engines is first purchased and ends after a period of 48 month or 480 hours of engine use whichever occurs first This emission related warranty covers components whose failure would increase an engine s emissions including electronic controls fuel injection exhaust gas recirculation aftertreatment or any other system developed to control emissions Replacing or repairing other components not covered by this emissions warranty or the standard warranty is the responsibility of the owner including the parts and other costs associated with recommended maintenance The exclusive remedy for breach of this limited warranty shall be at the exclusive option of Weber repair or replacement of any defective materials components or products THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY WEBER MOTOR GMBH SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE ALL IMLPIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN WEBER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above l
32. e bolts EJ gt Remove the valve cover HZ Information The camshaft is turned using the crankshaft The vehicle manufacturer has devised a suitable procedure for this Read the vehicle manufacturer s documentation for more information Always turn the crankshaft in the same direction as the engine rotates See chapter 3 6 Engine components and information Two rotations of the crankshaft correspond to one rotation of the camshaft Checking the valve play on the 2nd cylinder Turn the camshaft until the position of the camshaft is as illustrated See the vehicle manufacturer s documentation The camshaft is marked at the 2nd cylinder end only The marking EM ends flush with the cross bar All rocker arms EM on the cylinder have a certain amount of play gt X Check the valve play HMM of all valves on the cylinder using a feeler gauge Required valve play 0 2 0 3 mm If the valve play of one or more valves is not right continue with chapter 8 5 2 Adjusting valve play 54 SHB MPE850 Rev 1 2 408014 408090 408101 Weber Motor Checking the valve play on the 1st cylinder gt Turn the camshaft until the position of the camshaft is as illustrated See the vehicle manufacturer s documentation The camshaft is marked at the 2nd cylinder end only The inscription Ei is not visible All rocker arms EH on the cylinder have a certain amount of play gt Check the valve
33. e cooled SHB MPE850 Rev 1 2 408014 408090 408101 Weber Motor Engine power supply Engine exhaust gases Handling of fuel engine oil and coolant Fuel 2 Safety 2 2 Important safety messages Some service tasks require disconnection of the engine from the power supply Starting the engine inadvertently may endanger the safety of personnel Read the vehicle manufacturer s documentation for more information Disconnect the engine from the power supply when requested Engine exhaust gases contain carbon monoxide CO Inhalation of carbon monoxide can deprive the body of oxygen and result in organ damage or even death by asphyxiation When operating the engine in enclosed spaces use exhaust hoses to direct the engine exhaust gases into the open Operating materials pose a health risk Always read the manufacturer s instructions Always wash your hands prior to eating smoking and using the toilet as well as at the end of the working shift when working with operating materials Operating materials are hazardous to the environment Never allow operating materials to escape into the groundwater water courses or sewage system Always dispose of operating materials according to applicable national regulations Danger of slipping on spilled fluids Always use a filler neck or funnel when filling components with operating materials Always clean up any spilled operating materials immediatel
34. e vete dung aree dee Ne urat ced 14 3 6 Engine components and information llle 15 3 7 Engine fuses and relays 0 ccna 19 3 8 Technical specifications naaa 000 ns 20 4 Operation 21 AT Sermviceintervals oc rE a iet eme aqaa oma Wet eda ie UE Te t 21 4 2 Operation during the break in period liliis lees 23 4 8 Service before diving Ara das a ea le RR RAE ee eke a 24 4 3 1 Inspecting the exhaust and fuel system nananana naana 24 4 3 2 Checking coolant level 22 0025 beast hiec ede eee beep ee eee Pate 25 4 3 3 Checking oil level corro eee hn ee ar eet de ee eae ee bon ee TR Rd 26 4 4 Serice after driving ke ee a a Soe ba Bade Ae bad xA 28 4 4 14 Flushing sea water cooling circuit nauau uaaa BR 28 4 4 2 Corrosion protection iss eee zu gale Ree ee Aas ante Reg KG LR Ks 29 4 4 3 Transport and storage of the vehicle 0 0 00 cee 29 5 Special scenarios 30 5 1 Engine idle for more than 30 dayS 0 cece re 30 5 2 Operating engine without sea water iiilliel re 30 5 3 Towing vehicle in Water 2 ss ls He ie Ra ee Ei RE E Rage baa oe Rae Fee 30 5 4 Measures in case of flooded engine 0 0 eee 31 6 Malfunctions 32 6 1 Malfunctions table sexu REI C E Ba eae dl ea ea ew ag Ae bas A ace 32 6 2 Checking engine fuses vince ec acm Pee eee ke ee 35 4 SHB MPE850 Rev 1 2 408014 408090 408101 Table of contents Weber Motor 7 Deale
35. heck the engine fuses See chapter 6 2 Checking engine fuses Check the fuses located in the vehicle See the vehicle manufacturer s documentation The battery is discharged or defective Contact immediately a workshop authorized by Weber Motor or the vehicle manufacturer The drive train is blocked Remove the blockage See the vehicle manufacturer s documentation The engine cranks but does not start A fuse is defective or the service fuse is unplugged Check the engine fuses or plug in the service fuse See chapter 6 2 Checking engine fuses Check the fuses located in the vehicle See the vehicle manufacturer s documentation Lack of fuel Fill up fuel See the vehicle manufacturer s documentation The battery is discharged or defective Contact immediately a workshop authorized by Weber Motor or the vehicle manufacturer SHB MPE850 Rev 1 2 408014 408090 408101 33 6 Malfunctions 6 1 Malfunctions table Weber Motor Malfunction Possible cause Remedy The engine stalls and can Lack of fuel Fill up fuel See the vehicle be started again manufacturer s documentation The engine stalls and No fuel Fill up fuel See the vehicle cannot be started again manufacturer s documentation The engine does not provide the full power There is no malfunction The engine has not reached the operating temperature yet There is a malfunction and a
36. highly flammable Vapors may ignite and cause an explosion Check if hose clamps bolts or metal parts of the fuel system have noticeable corrosion Check if hoses are mounted properly and if cracks have been formed on hoses Do not start the engine if there is a smell of fuel or you suspect that fuel is leaking Attach and press down the engine cover until it is snapped 24 SHB MPE850 Rev 1 2 408014 408090 408101 neck 4 Operation Cw eber Motor 4 3 Service before driving 4 3 2 Checking coolant level Check the coolant level with a cold engine Check the coolant level in the expansion tank KB The coolant level must be between the MIN marking and the MAX marking EM NOTICE Danger of overheating caused by a lack of coolant When coolant level is below the MIN marking continue with the section Refilling coolant NOTICE Leaks in the hoses due to increased pressure When the MAX marking is exceeded pump out excessive coolant with a suction pump Refilling coolant CAUTION Scalding caused by hot steam Open expansion tank only with a cold engine gt Unscrew the expansion tank cover EJ Refill coolant until the coolant level is between the MIN marking Bll and the MAX marking HES Close the expansion tank Allow the engine to run at idle for 10 seconds Check the coolant level SHB MPE850 Rev 1 2 408014 408090
37. imitation may not apply if it is inconsistent with controlling state law This limited warranty excludes failures not caused by a defect in material or workmanship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or any engine that has been used in racing competition This limited warranty also does not cover physical damage corrosion or defects caused by fire explosions or similar causes beyond the control of Weber If you have any questions regarding your warranty rights and responsibilities you should contact the Vehicle Manufacturers Warranty Department Weber Motor GmbH Zepernicker Chaussee 23 37 16321 Bernau bei Berlin Germany Parts covered by emission warranty statement for Model Year 2013 Weber Motor personal watercraft engines Spark Plug Turbocharger Sensor P T Ignition Coil Fuel Rail Catalyst Injector Engine Control Unit Catalyst Housing Intake Manifold Lambda Sensor Catalyst End Cap Exhaust Manifold Sensor Crank Throttle SHB MPE850 Rev 1 2 408014 408090 408101 85 Appendix Index Index B Break in period engine 23 C Certification 84 Components engine 15 Coolant change 74 Coolant level check 25 Coolant specification 14 Corrosion protection after driving 29 D Dealer a
38. in the workshop 8 7 Checking spark plugs gt Insert the ignition coils EE gt Replace the serrated lock washers EIJ Assemble the bolts EE washers EA and serrated lock washers as illustrated Tightening torque 8 Nm 2 Nm 5 9 Ibf ft 1 5 Ibf ft Connect the wire harness connectors to the ignition coils HES gt Touch up the paintwork defects gt Test drive the vehicle v Place the engine cover EEJ and press down the engine cover until it is snapped Test drive the vehicle 64 SHB MPE850 Rev 1 2 408014 408090 408101 Weber Mot 8 Service tasks in the workshop QR dd 8 8 Replacing rubber mount 8 8 Replacing rubber mount Engine variants 12 846 MAR TC 80 TC 100 and TC 120 Remove the rubber mount with a cold engine gt Mark E the hose and intercooler EEN gt Open the spring band clamps EE gt Remove the hose HEH gt Disconnect the wire harness connector HG from the throttle body HE gt Open the hose clamp EN SHB MPE850 Rev 1 2 408014 408090 408101 65 8 Service tasks in the workshop 8 8 Replacing rubber mount gt Remove the throttle body EEN Unscrew the bolts KT Remove the rubber mount EIE Replace the rubber mount Hold the rubber mount in position v ww NN Screw in the bolts Tightening torque 8 Nm 2 Nm 5 9 Ibf ft 1 5 Ibf ft gt X Insert the hose clamp and throttle body KA 6
39. king spark plugs Spray engine internal preservative into the cylinder through the spark plug bores Bill according to the manufacturer s instructions Do not start the engine again Perform a visual inspection See chapter 4 3 1 Inspecting the exhaust and fuel system Apply corrosion protection according to the manufacturer s instructions NOTICE Corrosion damage due to stagnant sea water inside the sea water cooling circuit If the sea water does not circulate for a long period of time corrosion can appear in sea water cooling circuit The open drainage hose at the lowest point of the engine compartment allows sea water to drain off gt Pull out the drainage hose HEM from the hose clip HZ 78 SHB MPE850 Rev 1 2 408014 408090 408101 TREN 8 Service tasks in the workshop D eber Motor 8 13 Storing engine and putting into operation gt Open the hose clamp Hl gt X Remove the plug EJ gt X Place the hose W at the lowest point of the engine compartment DES N Do not start the engine again NOTICE Water inside the engine due to open E drainage hose gt Inform the user of the vehicle about the measures before the next drive See chapter 8 13 2 Putting engine into operation after storage SHB MPE850 Rev 1 2 408014 408090 408101 79 8 Service tasks in the workshop Weber Mot eber Motor 8 13 Storing engine and putting into opera
40. lay checked Spark plugs replaced Status Rubber mount replaced hours of operation Waste gate valve adjusted Flame arrester checked Coolant changed Fuel filter replaced opomi0g000000 Company seal signature Work carried out O Engine oil and oil filter changed Date O Sacrificial anode checked O Valve play checked O Spark plugs replaced Status O Rubber mount replaced hours of operation O Waste gate valve adjusted O Flame arrester checked O Coolant changed O Fuel filter replaced Company seal signature Work carried out Engine oil and oil filter changed Sacrificial anode checked Date Valve play checked Spark plugs replaced Status Rubber mount replaced hours of operation Waste gate valve adjusted Flame arrester checked Coolant changed Fuel filter replaced LE EIL EI BI BJ BJ BJ BI BD Company seal signature 82 SHB MPE850 Rev 1 2 408014 408090 408101 Weber Motor 9 Confirmation of service tasks Work carried out O Engine oil and oil filter changed Date O Sacrificial anode checked O Valve play checked O Spark plugs replaced Status O Rubber mount replaced hours of operation L1 Waste gate valve adjusted O Flame arrester checked O Coolant changed O Fuel filter replaced Company seal signature Work carried out Engine oil and oil filter changed Sacrificial anode checked Date Valve play checked Spark pl
41. mall quantities with repeatedly checking The difference between the MIN marking and the MAX marking Kill is P dh pi ao TERE 124 MM approximately 0 5 liter 0 5 qt US engine oil gt Fill engine oil through the opening HE of the oil dipstick until the oil level is between the 4 um 7 MIN marking and the MAX marking LI Check the oil level SACLE SHB MPE850 Rev 1 2 408014 408090 408101 27 4 Operation M 4 4 Service after driving OW eber Motor 4 4 Service after driving 4 4 1 Flushing sea water cooling circuit Information Regularly use a cleansing concentrate to flush the sea water cooling circuit Consult your local vehicle dealer NOTICE Damage in exhaust system caused by deposits If the sea water cooling circuit is not flushed regularly after driving sediments appear Particularly within the cooling jacket of exhaust system Flush the sea water cooling circuit after each drive in salt water Take the vehicle out of water A 13 mm 1 2 connection Hl for the flushing device is installed at the engine The flushing device is attached at this connection Connect the flushing device See the vehicle manufacturer s documentation NOTICE Engine damage due to water in the engine When the engine is switched off the water may get into the engine through the exhaust system First start the engine and then open the water tap NOTICE
42. nd servicing network 37 Diagnostic case 41 Direction of rotation engine 15 Disposal 81 E Engine fuse check 35 Engine oil change 45 Engine oil refill 27 Engine oil specification 13 Exhaust type authorization 84 F Fuel filter replace 77 Fuel specification 13 Fuse check 35 Fuses engine 19 Identifikation engine 11 Ignition coils replace 60 Initial operation 80 Inspection before driving 24 Intended use engine 11 L Locating a workshop 37 M Malfunctions 32 Manufacturer engine 84 O Oil filter replace 45 86 D Weber Motor Oil level check 26 P Part number engine 11 R Relays engine 19 Repairs 37 Rubber mount replace 65 S Sacrificial anode check 52 Sea water cooling circuit flush 28 Serial number engine 11 Service case overview 40 Service intervals 21 Service parts overview 40 Spark plugs check 62 Spark plugs replace 60 Spark plugs spark plug gap 63 Storage 78 Storage vehicle 29 Supplies overview 44 T Technical specifications 20 Tools overview 42 Transport vehicle 29 V Valve play adjust 57 Valve play check 53 Valve play required 54 Ww Warranty 37 Waste gate valve adjust 70 SHB MPE850 Rev 1 2 408014 408090 408101
43. ndicates potential property damage Information The signal word Information indicates specific features and recommendations 6 SHB MPE850 Rev 1 2 408014 408090 408101 Weber M 2 Safety eber Motor 2 1 Meaning of safety alert symbol and signal words 2 Safety This engine is state of the art and built according to recognized safety technical regulations Ignoring the information in this service manual may result in personal injury or property damage Read and observe the following safety messages carefully before operating the engine for the first time Observe all generally applicable laws and regulations in addition to the information in this service manual Accident prevention Environmental protection Handling of hazardous materials Personal safety equipment Traffic laws 2 1 Meaning of safety alert symbol and signal words Item Meaning A The safety alert symbol draws your attention to possible dangers The signal word WARNING indicates a potentially dangerous situation that may WARNING lead to a serious or fatal injury The signal word CAUTION indicates a potentially dangerous situation that may CAUTION lead to a minor or moderately severe injury SHB MPE850 Rev 1 2 408014 408090 408101 2 Safety 2 2 Important safety messages Weber Motor 2 2 Important safety messages Service tasks Service tasks in the workshop Malfunctions Spare parts Add
44. ntinue with the section Replacing valve adjustment shim SHB MPE850 Rev 1 2 408014 408090 408101 57 8 Service tasks in the workshop 8 5 Checking and adjusting valve play Replacing valve adjustment shim NOTICE Engine damage from small components in the engine or cylinder head Operating the engine when there are small components in the crankcase and cylinder head can result in serious damage and cause the crank drive to seize gt Cover the chain channel B gt X Hold the valve adjustment tool in position Screw in the bolts Hl Tightening torque 8 Nm 2 Nm 5 9 Ibf ft 1 5 Ibf ft gt X Position the rocker arm pusher EE on the rocker arm HE gt X Press down the slide plate HM using the rocker arm pusher KT until the pin ZZ engages 58 SHB MPE850 Rev 1 2 408014 408090 408101 Weber M 8 Service tasks in the workshop Se 8 5 Checking and adjusting valve play gt X Remove the valve adjustment shim using a bar magnet Measure the valve adjustment shim using a caliper Insert the new valve adjustment shim gt X Hold the rocker arm pusher EEJ in position gt Press down the slide plate HEM slightly using the rocker arm pusher gt X Slide the pin KIA forward by hand Slowly release the rocker arm pusher The valve spring slides the slide plate upwards again gt Unscrew the bolts KEA gt Remove the v
45. on parts and modifications Hot engine components In order to keep your engine in a safe operating condition regular servicing is essential It is your responsibility to ensure that the engine is serviced correctly Perform regular inspections and observe the specified service intervals All service tasks described in Chapter 8 Service tasks in the workshop require special technical knowledge of the engine All service tasks described in chapter 8 Service tasks in the workshop must be performed by a workshop authorized by Weber Motor or the vehicle manufacturer Engine malfunctions pose a safety risk to personnel Only operate the engine when in perfect condition All malfunctions must be repaired immediately in a workshop authorized by Weber Motor or the vehicle manufacturer All the components in your engine have been carefully tested and fulfill strict quality and safety requirements Externally supplied parts cannot fulfill these requirements Always use original Weber Motor spare parts The consequences of attaching add on parts and making unauthorized modifications to the engine are unknown and pose a safety risk to personnel Modifications and the attachment of add on parts is only permitted if approved or instigated by Weber Motor Engine components become extremely hot during operation Do not touch any engine components during operation Switch off the engine and wait until the components hav
46. or Engine Chassis HJ Relay starter EE SHB MPE850 Rev 1 2 408014 408090 408101 Weber Motor 3 7 Engine fuses and relays The engine fuses and relays are located in the fuse box on the engine See chapter 3 6 Engine components and information gt Remove the cover E from the fuse box Overview configuration fuses and relays Relay MAIN relay main Relay FUEL relay fuel pump 15 A fuse IGK terminal 30 key switch 15 A fuse VBD terminal 30 battery 15 A fuse SERVICE electric circuit for ignition coils injectors 10A spare fuse SPARE 10 A fuse FUEL fuel pump 15 A fuse VBR terminal 30 after relay main 15A spare fuse SPARE ao A OO N gt Oo o N OD SHB MPE850 Rev 1 2 408014 408090 408101 3 Description 3 7 Engine fuses and relays 19 3 Description 3 8 Technical specifications Weber Motor 3 8 Technical specifications Engine variant TC 80 TC 100 TC 120 TC 155 12 846 MAR Type 4 Takt Otto Motor Parallel Twin mit Ausgleichswelle und oben liegender Nockenwelle SOHC Displacement 846 cm Number of cylinders 2 Bore x stroke 89 x 68 mm 3 5 x 2 7 in Compression ratio 9 1 Engine power ISO 8178 58 5 kW 74 kW 91 kW 112 kW 6600 min rpm 7200 min rpm 7500 min rpm 7500 min rpm Engine power SAE J1228 59 kW 75 kW 92 kW 113 kW 6600 min rom 7200 min rpm
47. ork defects Clear the service counter to reset service light See the Weber Diagnostic Tool manual Update the engine control unit calibration See the Weber Diagnostic Tool manual gt Place the engine cover and press down the engine cover until it is snapped Test drive the vehicle SHB MPE850 Rev 1 2 408014 408090 408101 61 8 Service tasks in the workshop ES 8 7 Checking spark plugs eber Motor 8 7 Checking spark plugs gt Remove the engine cover Hil Remove the spark plugs with a cold engine gt Disconnect the wire harness connectors from the ignition coils E gt Unscrew the bolts HEH gt X Pullthe ignition coils HZ out 62 SHB MPE850 Rev 1 2 408014 408090 408101 TUNE 8 Service tasks in the workshop Q eber Motor 8 7 Checking spark plugs gt Unscrew the spark plugs BE using a spark plug wrench gt If the electrodes BGM are extremely sooty clean carefully using a spark plug brush gt Check the spark plug gap using a feeler gauge Required spark plug gap 0 69 0 84 mm 0 028 0 032 in If the spark plug gap is not satisfactory replace the spark plug Always replace the spark plugs in pairs gt Screw in the spark plugs EM using a spark plug wrench Tightening torque 22 Nm 10 Nm 16 2 Ibf ft 7 4 Ibf ft SHB MPE850 Rev 1 2 408014 408090 408101 63 8 Service tasks
48. r and servicing network 37 7 1 Locatinga workshop ilsssseeeee hrs 37 7 2 Service and spare patson ssie aaan aae a e E E a a E SE A aaa a aia 37 Ta Repas Anea twee a EAN doe Ce ed Reed ana a cy Bale A Reese Cet 37 T4 WENI ossei neat Pb ig gy RA EEEO E Y EAEE ARE xd ADAS 37 8 Service tasks in the workshop 38 8 1 Safety messages workshop hr 38 8 2 Toolsand accessories setis e ee ER xe RR RA ad ede Rea 40 8 2 1 Weber Motor service partS 0000 cet eee 40 8 2 2 Weber Motor diagnostic case 6 eee 41 8 2 3 Equipment workshop 2 20 00 cece tenet eee 42 9 2 4 SSUPPIICS i44 oe a pet and eR eU ARE a Abe aod ah Paral ee t A OR BURN S 44 8 3 Changing engine oil and oil filter 2l 45 8 4 Checking sacrificial anode llllieesseeee nae 52 8 5 Checking and adjusting valve play 0 eres 53 8 5 1 Checking valve play eero rr nar rrit NE EEI EEEE hh 53 8 5 2 Adjusting valve play ere oci eee e ae ERTE bee ae ae ee 57 8 6 Replacing spark plugs and igition coils 0 eee 60 8 7 Checkingsparkplugs 0 ee e m 62 8 8 Replacing rubber mount 0 0 00 eee 65 8 9 Adjusting waste gate valve 1 hh 70 8 10 Checking flame arrester lllilssiee eee eae 72 8 11 Changing coolant 0 cent eae 74 8 12 Replacing fuel filter coser xe eR RR ee eee ERA 77 8 13 Storing engine and putting into operation 0 0 0 ee 78 8 13 1 Preparing engine for storage 0 0
49. speed limitation is activated Contact immediately a workshop authorized by Weber Motor or the vehicle manufacturer 34 SHB MPE850 Rev 1 2 408014 408090 408101 Weber M 6 Malfunctions eber Motor 6 2 Checking engine fuses 6 2 Checking engine fuses T Risk of fire caused by incorrect or bridged fuse WARNING The fuse protects the cable from cable fire A higher amperage rating bypasses this protection Never use a higher ampere rating Never bypass a fuse Disconnect the engine from the power supply See the vehicle manufacturer s documentation The engine fuses and relays are located in the fuse box on the engine See chapter 3 6 Engine components and information Remove the cover HE from the fuse box Two spare fuses BZ provided by Weber Motor can be found in the fuse box See chapter 3 7 Engine fuses and relays gt Remove the fuse EN SHB MPE850 Rev 1 2 408014 408090 408101 35 6 Malfunctions Ware r r 6 2 Checking engine fuses ERE em Check the fuse The wire Ill in the fuse must to be intact If the wire is damaged replace the fuse Insert the fuse Hl Repeat the procedure with other fuses Insert the cover WH into the fuse box gt Connect the power supply to the engine See the vehicle manufacturer s documentation 36 SHB MPE850 Rev 1 2 408014 408090 408101 Weber Mot 7 De
50. thread lightly with engine oil Hold the oil filter EJ in position Screw in the banjo bolt Ea Tightening torque 14 Nm 2 Nm 10 3 Ibf ft 1 5 Ibf ft Insert the service fuse Wl 8 Service tasks in the workshop 8 3 Changing engine oil and oil filter 49 8 Service tasks in the workshop 8 3 Changing engine oil and oil filter Insert the cover Ml into the fuse box Lift the oil tank E and insert it into the oil tank bracket EA Screw in the bolts Ell at the oil tank Tightening torque 8 Nm 2 Nm 5 9 Ibf ft 1 5 Ibf ft 50 SHB MPE850 Rev 1 2 408014 408090 408101 Weber Mot 8 Service tasks in the workshop NOE 8 3 Changing engine oil and oil filter gt Place the engine cover and press down the engine cover until it is snapped Filling with engine oil Fill in 2 5 liter 2 6 qt US of new engine oil through the opening of the oil dipstick gt Screw in the oil dipstick El gt Check the oil level See chapter 4 3 3 Checking oil level gt Touch up the paintwork defects gt Clearing service counter for service light aede See the Weber Diagnostic Tool manual WA aaar n NAAN gt Update the engine control unit calibration See the Weber Diagnostic Tool manual gt Test drive the vehicle ddd dd E A AL ve SHB MPE850 Rev 1 2 408014 408090 408101 51 8 Service tasks in the
51. tion 8 13 2 Putting engine into operation after storage gt Insert the plug HE gt X Close the hose clamp E Tightening torque 3 Nm 0 5 Nm 2 2 Ibf ft 0 4 Ibf ft gt Mount the drainage hose E on the hose clip EJ gt Turn on the ignition wait a moment and then turn the ignition off gt Repeat the procedure twice The fuel system is filled 80 SHB MPE850 Rev 1 2 408014 408090 408101 f 8 Service tasks in the workshop Weber Motor 8 14 Disposal 8 14 Disposal When disposing of operating materials replaced parts or the whole engine always comply with the relevant applicable national laws and guidelines SHB MPE850 Rev 1 2 408014 408090 408101 81 9 Confirmation of service tasks 9 Confirmation of service tasks Weber Motor Have the workshop personnel provide certification confirming that your engine was serviced You can use the following documents Engine variant 6 digit Serial number 10 digit Date of initial registration Work carried out O Engine oil and oil filter changed Date L1 Sacrificial anode checked O Valve play checked L1 Spark plugs replaced Status O Rubber mount replaced hours of operation L1 Waste gate valve adjusted O Flame arrester checked O Coolant changed O Fuel filter replaced Company seal signature Work carried out Engine oil and oil filter changed A Sacrificial anode checked Date Valve p
52. ugs replaced Status Rubber mount replaced hours of operation Waste gate valve adjusted Flame arrester checked Coolant changed Fuel filter replaced LE EIL EI BI EJ BJ BJ BJ BD Company seal signature Work carried out O Engine oil and oil filter changed Date L1 Sacrificial anode checked O Valve play checked O Spark plugs replaced Status O Rubber mount replaced hours of operation L1 Waste gate valve adjusted O Flame arrester checked O Coolant changed O Fuel filter replaced Company seal signature Work carried out Engine oil and oil filter changed Sacrificial anode checked Date Valve play checked Spark plugs replaced Status Rubber mount replaced hours of operation Waste gate valve adjusted Flame arrester checked Coolant changed Fuel filter replaced LED DLE BI BI BI BI BI Company seal signature Work carried out O Engine oil and oil filter changed Date O Sacrificial anode checked O Valve play checked O Spark plugs replaced Status O Rubber mount replaced hours of operation O Waste gate valve adjusted O Flame arrester checked O Coolant changed O Fuel filter replaced Company seal signature Work carried out Engine oil and oil filter changed Sacrificial anode checked Date Valve play checked Spark plugs replaced Status Rubber mount replaced hours of operation Waste gate valve adjusted Flame arrester checked Coolant ch
53. uminating The engine warning light comes on after starting the engine for a few seconds If the MIL engine warning light is not on an error has occurred Too high engine temperature The oil pressure light comes on after starting the engine until the required oil pressure has built up If the oil pressure light does not go out an error has occurred There is no malfunction Service tasks must be performed Contact immediately a workshop authorized by Weber Motor or the vehicle manufacturer Do not start the engine Contact immediately a workshop authorized by Weber Motor or the vehicle manufacturer The service tasks must be performed in a workshop authorized by Weber Motor or the vehicle manufacturer 32 SHB MPE850 Rev 1 2 408014 408090 408101 Weber Motor 6 Malfunctions 6 1 Malfunctions table Malfunction Possible cause Remedy The engine does not crank The ignition is turned off Turn on ignition The power supply of vehicle is disconnected for safety reasons Depending on equipment of the vehicle there are several options Read the vehicle manufacturer s documentation for more information For example Insert the safety lanyard Put the throttle control in neutral position Switch on the battery isolator After start failure the starter can stay disabled for a few seconds Wait a few seconds and start the engine again A fuse is defective C
54. y Fuel is highly flammable Vapors may ignite and cause an explosion Do not smoke in the vicinity of the engine and do not allow naked flames or sparks near the engine or the fuel system Never fill with fuel while the engine is running Do not start the engine if there is a smell of fuel or you suspect that fuel is leaking Have a workshop authorized by Weber Motor or the vehicle manufacturer inspect the engine immediately Fuel on hot surfaces can cause fires Do not extinguish with water In the event of a fire use foam dry chemical or carbon dioxide extinguishers SHB MPE850 Rev 1 2 408014 408090 408101 9 2 Safety rM 2 2 Important safety messages eber Motor California Proposition 65 Warning against chemicals hazardous materials according to the law of the state of California This product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm 10 SHB MPE850 Rev 1 2 408014 408090 408101 Weber Motor 3 Description 3 1 Intended use 3 Description 3 1 Identification Intended use 3 2 The MPE 850 MARINE has been designed for powering watercrafts The engine was not designed or intended for any other use 3 2 Identification Each engine is assigned two identification numbers Both numbers are printed on a label IK affixed to the engine The part number Part No Ill is the number of the engine variant The serial
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