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Installation_operating manuals for D170 D150 series(Ver1.2)

1. Rail pressure c sgp l regulator Air V Pump Common rail valve filter pressure regulator I valve Air temp sensor ressure i gt Rail pressure sensor Boost pressure amp air purmp POTUIT temp sensor Cam Position Sensor 4 Injector Intercooler Fuel ae E VGT temperature a aan sensor Glow VGT actuator Main plug fuel filter Water sensor in fuel Coolant temperature sensor Feed Crankshaft HI position pump sensor Vacuum modulator return Fuel tank gt Fuel feed low Fuel return Accel position mew Fuel feed high sensor J HYUNDAI SEASALL f INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL D170 and D150 Series Engines 5 TECHNICAL DATA D170 1505 170 150P 0170 4 stroke 4 valve After cooled direct injection water cooling Output ps KW 170ps 125 150ps 110 3800 3200 4 1 3 4 2 2188 87 92 17 3 1 rpm at full load Cylinders Ignition sequence Displacement cm Bore mm stroke mm Compression ratio 6 2000 3 3500 Max torque kgm speed rom Injection system Common rail direct injection at least CN 51 as per DIN EN 590 Diesel fuel Intake air pressure abs ban speed rpm 3800 3200 3800 3200 3800 Coolant quantity liter 6 5 Coolant cap opening pressure bar LI Engine oil liter Engine oil pressure
2. m Fax 82 70 8244 8555 Mr 70 8520 8035 ryundai semsn leem
3. ENGINE MOUNTING REQUIRMENTS The mount must be strong enough to carry the loads applied by the weight and power of the engine It also must be stiff enough that the engine does not sag or move too much when power is applied The mount must position the engine at the correct height and angle so that the engine s thrust line suits the boat 2 ENGINE MOUNT DIMENSIONS CAUTION USE ONLY THE ORIGINAL HYUNDAI SeasAll MOUNTINGS THAT WERE SUPPLIED WITH THE INITIAL PURCHASE AFTER INSTALLATION AND ALIGNMENT OF THE ENGINE MAKE SURE THAT NO RESIDUAL TENSION EXISTS IN THE DRIVETRAIN 15 7 HYUNDAI SEASALL f INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL D170 and D150 Series Engines 3 ENGINE MOUNT TOOL FOR STERNDRIVE MODEL Mount hole for 5250 and S220 model Mount hole for D170 and D150 model CAUTION FOR INFORMATION ON INSTALLATION OF THE STERNDRIVE BRAVO MODELS PLEASE SEE THE SEPARATE BOOKLETS INCLUDED IN THE ORIGINAL PACKAGING OF YOUR HYUNDAI PURCHASE IF IN DOUBT ABOUT ENGINE INSTALLATION PLEASE CONTACT YOUR NEAREST HYUNDAI SeasAll DEALER 16 7 HYUNDAI SEASALL LJ INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL D170 and D150 Series Engines CHAPTER 3 COOLING amp EXHAUST SYSTEM 1 SCHEMATIC DIAGRAM OF ENGINE COOLING CIRCUIT AIR TT AIR FILTER CABIN HEATER CONNECTOR TURBO CHARGER p TEE
4. Airtemp sensor Boost pressure amp air temp sensor Cam Position Sensor Intercooler actuator Glow plug LE Coolant temperature FT sensor T X 1 Crankshaft position b sensor Vacuum vo modulator 1 ENGINE ROOM VENTILATION 1 Engines with turbo charger air inlet systems require much more air pumped and cooled Maximum air consumption is 600kg h minimum engine room vent area is 40 2 The fresh and cooled air must be pumped into the engine in order to perform at normal power and fuel consumption 3 The temperature at the air inlet should be as low as possible A high temperature of inlet air may reduce engine performance 29 J HYUNDAI SEASALL 7 INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL D170 and D150 Series Engines 2 AIR FILTER MAINTENANCE 1 The air filter must be cleaned regularly If the engine is operated in a dirty environment clean the filter more frequently 2 Blow out the air filter from the inside toward the outside with max 2 0 bar compressed air 3 Never use petrol thinner or other agents for cleaning Such products can destroy the filter CAUTION WHEN REMOVING THE AIR FILTER BE CAREFUL THAT DUST OR DIRT DOES NOT ENTER THE AIR INTAKE OR DAMAGE MAY RESULT AND DO RUN WITHOUT AIR CLEANER THIS COULD RESULT IN EXCESSIVE ENGINE WEAR USE OF NON GENUINE PARTS COULD DAMAGE THE TURBO CHARG
5. J HYUNDAI SEASALL WARRANTY REGISTRATION CARD 5460 25 EE 0 237 815 Korea 62 700244 4555 Date of sale Warranty Transfer Please fill out the following registration card in English Owner s Information Street P O Box ____ meme Guy Telephone Mobile Phone Dealer Information suere Cum jew Teens Engine Information Number of Engines Single O Dual O Engine Model Engine Serial No Engine Model Engine Serial No Boat Information Repower Man Ses Au PRP o od Boat Type Type of Use Pleasure Commercial Planing O Semi 1 Disp 2010 HYUNDAI SEASALL Text figures and standards in this guide are based on information current at the time of printing Reprinting reproduction or translation in whole or in part is not permitted without the written approval of HYUNDAI SeasAll All rights according to the applicable copyright laws are expressly reserved for HYUNDAI SeasAll Subject to alterations www hyundai seasall com 66 7 HYUNDAI SEASALL ABSOLLUTE MARINE POWER LJ HYUNDAI SEASALL TS 440 26 9 Uiwong si Gyeonggi do 437 815 Korea i nyu d
6. HYUNDAISEASALL INSTALLATION amp OPERATION MANUAL D170 amp D150 SERIES ENGINES Applicable to D170S D170P D170J D150S 0150 model f INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL D170 and D150 Series Engines TABLE OF CONTENTS PAGE NUMBER ABOUT THIS MANUAL uuu u u u suasana aa aaa EG ER AR NN Re Gr ee ge si Se Ee 3 CHAPTER1 ENGINE OVERVIEW ee ee ee eek ee eek HI 4 ENGINE EOMPONE u S esse ven We ee is ee ee ee ee ee ee kanqa 4 2 EIN 5 3 ENGINE IDENTIFICA TION uuu u sei sen se Echo medio 6 4 SCHEMATIC DIAGRAM OF COMMON RAIL DIESEL ENGINE 9 8 6 PERFORMANCE CURVE 9 7 ENGINE DIMENSIONS 12 EAT len 2 SS XS SG uu uu 15 1 ENGINE MOUNTING REQUIREMENTS 15 2 MOUNT DIMENSIONS 15 ENGINE MOUNT TOOL FOR STERNDRIVE MODEL 16 GHAPIEHS COOLING amp EXHAUST SYSTEM uuu 9 90 90 800820890 990020890009 Ge Biss 17 1 SCHEMATIC DIAGRAM OF ENGINE COOLING CIRCUIT 17 2 ThE FLOW OF uuu E 18 2 WATER PICKUP uuu uu ua uuu EROR oa d hc nh ata 18 2 2 SEAWATER STRAINE
7. 3 Coolant engine inlet 3 1 ENGINE COOLANT 1 The high pressure cooling system has a reservoir filled with year round antifreeze coolant The reservoir is filled at the factory 2 The coolant level should be between MAX and MIN marks on the side of the coolant reservoir when the engine is cool 21 9 HYUNDAI SEASALL LJ f INSTALLATION amp OPERATION MANUAL HYUNDAISEASALL D170 and D150 Series Engines 3 If the coolant level is low add enough specified coolant to provide protection against freezing and corrosion Bring the level to MAX but do not overfill 4 f frequent additions are required see an authorized dealer for a cooling system inspection 5 Use only soft demineralized water in the coolant mixture 6 The engine has aluminum engine parts and must be protected by an ethylene glycol based coolant to prevent corrosion and freezing 7 DO NOT USE alcohol or methanol coolant or mix them with the specified coolant 8 DO NOT USE a solution that contains more than 6096 antifreeze or less than 3596 antifreeze which would reduce the effectiveness of the solution 9 For mixture percentages refer to the following table Mixture Percentage volume Ambient Temperature eer 9 25G 13 31 F 49 F 10 In order to drain engine coolant please remove clamp and hose D from heat exchanger 11 when reassemble hose please exchange old clamp with
8. Je Clean the air filter ___ Air intake system Clean the pipe bundle of inter cooler o Check the level and leakage e Lubrication system Change the engine oil and filter Je Electrical systems Connection contamination Je Anti corrosion system Check the sacrificial anodes le Driving belt Check the belt conditions Je Battery Check the operating voltage ee Check tightness of the bolts nuts and other fasteners Je Check tightness and corrosion of hose clamps e oteering system Check the oil level and leakage Propulsion system Check the level and leakage 1 If corroded over 60 replace it 2 More detailed maintenance follow manufacturer s specifications CAUTION YOU SHOULD EXERCISE THE UTMOST CARE TO PREVENT ENGINE DAMAGE OR INJURY TO YOURSELF WHENEVER PERFORMING ANY MAINTENANCE A 59 7 HYUNDAI SEASALL f INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL D170 and D150 Series Engines 3 MAINTENANCE LOG DATE MAINTENANCE PERFORMED ENGINE HOURS 60 J HYUNDAI SEASALL f INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL D170 and D150 Series Engines CHAPTER 14 TROUBLESHOOTING GUIDE Starter motor does not crank the engine Possible Causes EE N Engine is not shifted to neutral position Engine stop switch ON position Wrong neutral switch connection to Weak battery or battery connections are
9. 220 205 190 1000 1500 2000 2500 3000 3500 Engine Speed rpm F C BSFC Brake Specific Fuel Consumption FC Fuel Consumption 11 J HYUNDAI SEASALL LJ f INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL D170 and D150 Series Engines 7 ENGINE DIMENSIONS S MerCruiser Bravo One X Diesel Min 246 183 202 5557600 696 Front view Side view MerCruiser Bravo Two X Diesel 521 TIS 202 5557600 696 Front view Side view 12 J HYUNDAI SEASALL INSTALLATION amp OPERATION MANUAL D170 and D150 Series Engines e HYUNDAI SEASALL MerCruiser Bravo Three X Diesel Min 246 202 Kus 5557600 696 Front view Side view BZF 45 A 202 5557600 696 Front view Side view 13 HYUNDAI SEASALL LJ INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL D170 and D150 Series Engines BZF 45 202 5557600 696 Front view Side view 5 Waterjet adapter without ZF 45C ZF 63C 202 5557600 696 Front view Side view 14 J HYUNDAI SEASALL f INSTALLATION amp OPERATION MANUAL HYUNDAISEASALL D170 and D150 Series Engines CHAPTER 2 ENGINE MOUNT SYSTEM
10. Glow Indicator lamp 4 Fuel Consumption h 9 Neutral Lever Alarm lamp Neut 5 Battery Bolt V 10 DTC Diagnosis Trouble Code 40 J HYUNDAI SEASALL LI HYUNDAI SEASALL INSTALLATION amp OPERATION MANUAL D170 and D150 Series Engines 1 2 SWITCHES 1 Buzzer Reset Switch This switch is used for turning off the alarm temporarily 2 Dimmer Switch This switch is used for controlling brightness of the other gauges connected to the EOI 3 Function Switch This switch is used for changing the information display on the LCD 1 3 ALARM LAMPS Alarm may sound when alarm lamps flicker WATER SENSOR LAMP This lamp informs you to extract water from fuel filter If the lamp is on you should stop the engine immediately and extract the water in the fuel filter It is recommended to check and extract the water in the fuel filter at fixed periods before the lamp turns on It can be harmful to drive your engine with this lamp on ALTERNATOR LAMP This lamp informs you to recharge your battery If this lamp turns on you should stop the engine and eliminate electric load as well as check the alternator drive belt system and wiring system ENGINE OIL LAMP 2 his lamp informs you that the engine oil pressure If this lamp is on you should stop the engine and check the oil level with oil gauge If the oil is low refill it If you refill the oil and the lamp still does not turn off yo
11. bar 2 3 at 1800rpm 100 C oil temp Exhaust gas pressure kPa Weight kg 261 Thermostat opening temp 85 starting to open 95 fully open Idle rpom warmed up rev min 700 Permissible eng oil temp 135 Permissible eng coolant temp 104 Sterndrive Shaftdrive Waterjet Propulsion system J HYUNDAI SEASALL INSTALLATION amp OPERATION MANUAL 6 PERFORMANCE CURVE 501705 amp D170P MODEL 40 200 35 175 _ 30 150 P 9 25 125 8 20 100 3 5 15 75 amp 10 50 5 25 0 0 1000 1500 2000 2500 3000 3500 4000 40 310 35 295 30 280 25 265 Z E G 20 250 15 235 i 10 220 5 205 0 190 1000 1500 2000 2500 3000 3500 4000 Engine Speed rpm BSFC Brake Specific Fuel Consumption FC Fuel Consumption 9 HYUNDAI SEASALL LJ 7 INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL D170 and D150 Series Engines 501709 MODEL e e Power hp Torque kg m h3 e Cn 1000 1500 2000 2500 3000 3500 4000 1000 1500 2000 2500 3000 3500 4000 Engine Speed BSFC Brake Specific Fuel Consumption Fuel Consumption 10 J HYUNDAI SEASALL EJ f INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL D170 and D150 Series Engines 01505 amp D150P MODEL 160 140 120 100 Torque kg m e Power hp 1000 1500 2000 2500 3000 3500 250 gt 235 O LL
12. IN A SAFE PLACE AWAY FROM CHILDREN AND FIRE PLACE FLUID IN THE BATTERY IS A CORROSIVE ACID AND MUST BE HANDLED WITH CARE IF SPILLED ON ANY PART OF BODY FLUSH IMMEDIATELY WITH WATER CAUTION DO NOT LOOSEN OR DETACH BATTERY TERMINALS WHILE ENGINE IS RUNNING DOING SO WILL DAMAGE CHARGING SYSTEM AMD OTHER ELECTRONIC DEVICES 34 7 HYUNDAI SEASALL e HYUNDAI SEASALL INSTALLATION amp OPERATION MANUAL D170 and D150 Series Engines 3 FUSE AND RELAY 3 1 FUSE An engine s electrical system is protected from electrical overload damage by fuses If a fuse has blown the element inside the fuse will be melted If the electrical system does not work first check the fuses in ECU box Always replace a blown fuse with one of the same rating Standard Normal Blown If the replacement fuse blows this indicates an electrical problem Avoid using the system involved and immediately consult an authorized Hyundai SeasAll dealer Fuses in the ECU Box 1 W N System Power 30Amp Ignition Power ECM ECU Power 20Amp Main Relay Power 15Amp Spare 30Amp Fuel Filter 30A mp 35 9 HYUNDAI SEASALL INSTALLATION amp OPERATION MANUAL D170 and D150 Series Engines y HYUNDAI SEASALL 3 2 RELAY Relay in the ECU Box 1 Main Relay 30Amp 2 Oil Extract Relay 30Amp 3 Fuel Pump Relay Power 4 S
13. Product has been operated for 1000 hours whichever occurs first This limited warranty is transferable to a subsequent purchaser but only for the remainder of the unused portion of the limited warranty To transfer the warranty to the subsequent owner send or fax a copy of the bill of sale or purchase agreement new owner s information and engine serial number to Hyundai 5 distributor or dealer Upon processing the transfer of warranty Hyundai SeasAll will send registration verification to the new owner of the product by mail WARRANTY REGISTRATION Your selling dealer fills out the Warranty Registration Card and mails it to the distributor responsible for administering the warranty registration for your country Warranty Registration must be made no later than 15 days from the date of sale after purchase from authorized dealer The Warranty Registration Card identifies information on customer and product models and serial numbers date of sale type of use and the selling dealer The distributor or dealer also certifies that you are the original purchaser and user of the product A copy of the Warranty Registration Card designated as the Purchaser s Copy must be given to you immediately after the card has been completely filled out by the selling distributor or dealer This card represents your registration identification and should be retained by you for future use when required Should you ever require warranty service on this pro
14. Water in fuel fuel filter drain out water and check the fuel in fuel tank Warning lamp circuit Water detection sensor error Water detection Water in fuel is detected in fuel P0261 Short circuit Short circuitground Cylinder1 njector PO262 P0262 Short circuit Defect resistance cylinder1 Charging discharging energy error P0264 Short circuit ground Cylinder2 injector P0265 Short circuit battery Defect resistance cylinder1 Chargino discharging energy error Injector circuit Injector L e Injector circuit e Injector lt 46 7 HYUNDAI SEASALL INSTALLATION OPERATION MANUAL HYUNDAI SEASALL D170 and D150 Series Engines Description em Expectation Cause s ote Foos openload load P0267 Short circuit ground N D Cylinder3 injector P0268 Short circuit battery N injector e Injector P0269 Defect resistance cylinder1 Chargino discharging energy error PO270 Short circuit ETE rn Cylinder4 injector P0271 Short circuit battery N vem Injector P0272 Defect resistance cylinder1 Charging discharging energy error PO273 Short circuit Short circuit ground 2 Injector circuit C ylinderb injector P0274 Shortcircuit battery Injactor P0275 Defect resistance cylinder1 Charging discharging energy error PO276 Short c
15. loose P corroded eStarter motor solenoid or slave solenoid failure gnition key switch failure Blown fuse at EOI Wiring or electrical connection fault Defective ECU Engine cranks but does not start Possible Causes Weak battery or bad starter motor ncorrect starting procedure Faulty fuel filter or electric fuel pump ll Engine starts with difficulty or starts and stalls ll Engine idle is rough Possible Causes connected fuel return line at injector compression pressure rail pressure sensor signal Poor tightening of injector clamp Wiring harness open or poor connection Faulty high pressure fuel pump fuel quality or water ingress in fuel Faulty injector Clogged fuel filter air filter eCarbon deposit on the injector 61 7 HYUNDAI SEASALL f INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL D170 and D150 Series Engines Engine rattling noisy engine Possible Causes Compensation of individual injector not N anal adapted engine coolant temperature sensor signa rail pressure sensor signal Faulty injector Poor injector O ring eCarbon deposit on the injector Untimely acceleration deceleration Possible Causes rail pressure sensor signal program error or hardware fault Leakage in intake system gt turbocharger leakage in vacuum Leakage in high pressure fuel circuit In
16. owner s obligation to install operate maintain and care for Hyundai SeasAll engines accordance with the instruction and requirements stated in the Installation and Operation Manual The owner is responsible for providing enough time and cooperation to get the engine repaired by an authorized dealer and to deliver it to a proper facility for repair The owner is responsible for the cost for warranty inspection including landing launching and transport HOW TO OBTAIN WARRANTY COVERAGE The customer must provide Hyundai SeasAll with a reasonable opportunity to repair the engine as well as reasonable access to the product for warranty service Warranty claims shall be made to a Hyundai SeasAll Authorized Repair Facility to service the product Purchaser shall not unless requested by Hyundai SeasAll ship the product or parts of the product directly to Hyundai SeasAll The warranty registration card is the only valid registration identification and must be presented to the dealer at the time warranty service is requested in order to obtain coverage 64 7 HYUNDAI SEASALL f INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL D170 and D150 Series Engines LIMITATIONS EXPENDABLE PARTS Filters fuel filter engine oil filter air filter Engine oil and coolant e Rubber products seawater pump impeller rubber hoses belt Gaskets anode thermostat WHAT IS NOT COVERED Fuel injector or filter cleaning b
17. the fuel filter is over the limit the Water Sensor Lamp on the EOI will light up If this happens you must stop the engine and drain the water in fuel filter yourself or ask the nearest workshop to do this 3 Water and a little fuel will drain at the same time Therefore avoid flames in your workspace 4 If your fuel is not well suited to your engine more frequent drainage will be required 5 To check and drain the water in fuel filter Loosen the drain plug part D and drain water 100 120cc drainage is proper After water is drained securely tighten the drain plug e After starting the engine check to make certain the fuel filter warning light is off CAUTION HYUNDAI SeasAIPS GUARANTEES OR WARRANTIES ARE VOID IN CASES WHERE TO THE FUEL INJECTON COMPONENTS HIGH PRESSURE PUMP INJECTORS ETC CAN BE ATTRIBUTED TO THE USE OF UNQUALIFIED FUELS IF THE WATER ACCUMULATED IN THE FUEL FILTER IS NOT DRAINED AT PROPER TIMES DAMAGE TO MAJOR ENGINE PARTS WHEN REPLACING THE FUEL FILTER CARTRIDGE USE GENUINE PARTS ONLY 28 7 HYUNDAI SEASALL INSTALLATION amp OPERATION MANUAL D170 and D150 Series Engines LJ HYUNDAI SEASALL CHAPTER 5 AIR INTAKE SYSTEM The intake air system of this engine is optimized by VGT and a highly efficient intercooler system The pressure of the air system is up to about abs 2 5 bar in order to optimize engine combustion Air filter
18. 186 P1187 P1188 P1307 P1308 P1309 P1325 P1636 P1652 P1653 P1655 P1670 P1671 Injector IQA Checksum Error P1679 EMS Data Fail Data frame CS Message error P1694 P1695 P1697 HI SCAN message Error P2009 Variable Swirl Actuator Control Circuit Low Bank 1 P2010 Variable Swirl Actuator Control Circuit High Bank 1 P2015 P2016 2017 2122 2123 2127 2128 Minimum Rail Pressure Exceeded Maximum Rail Pressure Exceeded Set Value of PCV not in Plausibility Range Maximum Pressure Exceeded Minimum Pressure at Engine Speed Too Low Regulator Valve Stick Leakage Acceleration Sensor Range Performance Acceleration Sensor Circuit Low Input Acceleration Sensor Circuit High Input Glow Relay Malfunction Voltage Regulator for Injector Ignition Key No Signal After Run Check Error Tachometer Output Fault Invalid Injector 21 EMS Message Error EMS Memory Error Variable Swirl Actuator Position Sensor Switch Circuit Range Performance Variable Swirl Actuator Position Sensor Switch Circuit Low Variable Swirl Actuator Position Sensor Switch Circuit High Throttle Pedal Position Sensor Switch D Circuit Low Input Throttle Pedal Position Sensor Switch D Circuit High Input Throttle Pedal Position Sensor Switch E Circuit Low Input Throttle Pedal Position Sensor Switch E Circuit High Input 32 7 HYUNDAI SEASALL e HYUNDAI SEASALL INSTALLATION amp OPERATION MANUAL D170 a
19. 2 Avoid max rpm and WOT Wide Open Throttle before a cold engine is fully warmed up as it can harm the engine 3 The gauge needle should be in proper range If the outside temperature is high the gauge needle may sit at a higher range As long as the alarm doesn t sound the engine is normal 4 If the gauge blinks and an EOI alarm sounds EOI check the coolant temperature and level If the coolant is low refill it 5 If the temperature of the engine coolant is higher than 105 C the engine power will decrease You should check the engine cooling system 38 HYUNDAI SEASALL LJ INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL D170 and D150 Series Engines 1 3 RPM GAUGE 1 When the key is at ignition ON position this gauge will work 2 This gauge indicates real time engine rpm 3 Avoid rom and Wide Open Throttle before a cold engine is fully warmed up as it can harm the engine 1 4 BATTERY VOLT METER GAUGE 1 When the key is at ignition ON position this gauge will work 2 This gauge indicates real time battery bolt 3 If battery bolt is not sufficient the engine can not be started 4 For a working engine 12 16V bolt is normal If the battery bolt is under 12V you should check battery and alternator 5 At the moment of engine ignition the bolt meter needle may move down to 8V temporarily This is normal 2 CUT OUT FOR GAUGE e RPM Gauge 86 mm Coo
20. 267 P0268 P0269 P0270 P0271 P0272 P0273 P0274 0275 0276 0277 0278 0299 P0300 P0335 P0336 P0340 Fuel Pump Secondary Circuit High Turbocharger Over boost Condition Turbocharger Boost Sensor A Circuit Low Turbocharger Boost Sensor A Circuit High Pump Pressure Regulation Valve Circuit Pump Pressure Regulation Valve Circuit Low Pump Pressure Regulation Valve Circuit High Cylinder 1 Injector Circuit Low Cylinder 1 Injector Circuit High Cylinder 1 Contribution Balance Cylinder 2 Injector Circuit Low Cylinder 2 Injector Circuit High Cylinder 2 Contribution Balance Cylinder 3 Injector Circuit Low Cylinder 3 Injector Circuit High Cylinder 3 Contribution Balance Cylinder 4 Injector Circuit Low Cylinder 4 Injector Circuit High Cylinder 4 Contribution Balance Cylinder 5 Injector Circuit Low Cylinder 5 Injector Circuit High Cylinder 5 Contribution Balance Cylinder 6 Injector Circuit Low Cylinder 6 Injector Circuit High Cylinder 6 Contribution Balance Turbocharger Under boost Random Multiple Cylinder Misfire Detected Crankshaft Position Sensor A Circuit Crankshaft Position Sensor A Circuit Range Performance Camshaft Position Sensor A Circuit Malfunction 50 7 HYUNDAI SEASALL INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL D170 and D150 Series Engines P code DESCRIPTION 61 62 63 64 65 P0341 P0381 P0562 P0563 P0601 P0602 P0604 Internal Contr
21. ER OR ENGINE 30 7 HYUNDAI SEASALL LJ f INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL D170 D150 Series Engines CHAPTER 6 LUBRICATION SYSTEM 1 ENGINE OIL LEVEL CHECKS The engine oil level must be checked at regular Intervals sure the boat is level Start the engine and allow it to reach normal operating temperature Turn the engine off and wait about 5 minutes until the oil has returned to the oil pan Pull the dipstick out wipe it clean and re Insert it fully Pull the dipstick out again and check the level The level should be between F and If it is near or at L add enough oil to bring the level to F Do not fill with engine oil above the F mark 2 RECOMMENDED OIL QUALITY For best performance and maximum protection during all types of operation select only those lubricants which 1 Satisfy the requirement of the API or ACEA classification 2 Have proper SAE grade number for expected ambient temperature range ACEA Above B4 Service oil quality should conform to ACEA or API Above CH 4 Classification 15W 40 15 C above il quality 10W 30 20 40 G SAE 5W 30 25 C 40 C OW 30 10 C below 31 J HYUNDAI SEASALL f INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL D170 and D150 Series Engines 3 ENGINE OIL EXTACTION 1 Allow the engine to warm up at least 5 minutes 2 Remove the engine oil inlet
22. Engine Oil Exchange Button Engine Emergency Stop Button e e o 7 Engine Oil Gauge 8 Acceleration Lever Sensor 9 Seawater Pump 10 Intercooler 11 Heat Exchanger 12 Alternator e 7 Controller 8 Shift Plate 9 Oil Extraction Pump 10 Injector 11 PRV 12 BPS 8 IATS 4 HYUNDAI SEASALL f INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL D170 and D150 Series Engines 2 ENGINE SUSPENSION EYES 1 To lift the engine first remove the engine cover You will find two engine eyes see figure 2 To avoid engine damage take care that engine lift chains or belts do not hit or touch surrounding parts during engine lifting Ek d 5 J HYUNDAI SEASALL LI 7 INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL D170 and D150 Series Engines 3 ENGINE IDENTIFICATION Engine identification is affixed to the engine block and the ECU box see figure S SERIAL NUMBER ON THE ENGINE BLOCK 6 NAME PLATE ON THE ECU BOX J HYUNDAI SEASALL Hyundai SeasAll Co Lid Engine D17 Engine Family 4 Rated Power 1 ps 3a00rpm Engine Weight 261lkg RPM 4200 Mo of cylinders 4 Cylinder bore mm B7 Piston stroke mmy 92 Engine Serial 6 J HYUNDAI SEASALL INSTALLATION OPERATION MANUAL HYUNDAI SEASALL D170 and D150 Series Engines 4 SCHEMATIC DIAGRAM OF COMMON RAIL DIESEL ENGINE
23. ION MANUAL HYUNDAI SEASALL D170 and D150 Series Engines TABLE OF CONTENTS PAGE NUMBER GHAPTER 7 ELECTRICAL SYSTEM 33 1 BATTERY CABLE CONNECTIONS 33 ATI LYC T OE u 34 FUSE AND RELAY 35 CHAPTER S INSTRUMENT SYSTEM 37 1 INSTRUMENTS CONNECTION 37 TOUT FOR GAVC osse ee E ee 39 CUT OUT FOR BOs EMM 39 CHAPTERS VY TEM es se 40 OVERVIEW OP EOI SYSTEM u uu uuu uu u a ssssssssss sasusssssssasas 40 1 1 INFORMATION LCD ITEM 40 ISTIS 41 1 3 ALARM LAMPS 41 2 EOI CONNECTIONS ua ee ee ee ee ence ence ee kana ee ee ee ER ee ee ee ee AD 3 EOI PIN ASSIGNMENT ee EG GE Ee EO EE 43 4 NEUTRAL SWITCH AND DUAL EOI CONNECTION 45 5 ALARM AND DTC DIAGNOSIS TROUBLE 46 5 1 ALARM AND DTC DIAGNOSIS TROUBLE 46 5 2 DIC DIAGNOSIS TROUBLE GODE 49 CHAPTER 10 ANTI CORROSION SYSTEM 54 CHAPTER 11 ENGINE OPERATIO
24. N 55 ENGINE ON OFF oa 55 2 EMERGENCY STOP u uu Ee dee 56 WINTER OPERATION AND STORAGE 56 CHAPTER T2 ENGINE STORAGE GR ___ _ _____ 57 T3 MAINIENANGE 58 1 PREDELIVERY INSPECTION LIST 58 2 MAINTENANCE SCHEDULE 59 3 MAINTENANCE HOE 60 CHAPTER 14 TROUBLESHOOTING GUIDE 61 CHAPTER 15 WARRANTY 63 WARRANTY REGISTRATION 66 2 7 HYUNDAI SEASALL f INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL D170 and D150 Series Engines ABOUT THIS MANUAL This engine installation and operation manual is provided as guidance for the installation of Hyundai SeasAll engine to a boat and to describe engine operation purpose is to provide technical information to aid in performing an effective engine installation so as to achieve both maximum performance and service life For information on installation operation and maintenance of the ZF Marine Transmissions and Sterndrive Bravo Models please see the separate booklets included in the original packaging of your Hyundai SeasAll purchase Hyundai SeasAll is committed to making clear a
25. OSEN COOLANT DRAIN PLUG 54 HYUNDAI SEASALL f INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL D170 and D150 Series Engines CHAPTER 11 ENGINE OPERATION 1 ENGINE ON OFF a x i 5 i Ecke L v i 9 Le 1 Before starting the engine you should check engine oil coolant gearbox oil fuel gauge raw water pump battery and so on 2 When you start the engine check that the engine throttle leverCD is at neutral position If not the engine may not start or there is possibility of shooting off Especially if your boat is equipped with a neutral safety lever when the engine throttle lever is not at neutral position you can t crank You can also check this on the EOI 3 After starting the engine release the key 2 immediately to prevent damage to the start motor 5 Avoid max rpm and WOT Wide Open Throttle before the cold engine is fully warmed up 6 At a cold start it takes a few or more seconds to start the engine 7 If the engine does not start in 10 seconds release the key After 10 seconds try again This method can help avoid start motor damage WARNING DO NOT DRIVE IN SPACE WHERE THERE IS NO AIR CIRCULATION EMISSION GAS IS HARMFUL 99 J HYUNDAI SEASALL LJ f INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL D170 and D150 Series Engines 2 EMERGENCY STOP 1 You can stop the engine by pushing this switch Af
26. R 18 EAVWATEH PUMP 19 3 THE FLOW OF ENGINE COOLANT 21 3 1 ENGINE COOLANT 21 3 2 REMOVING AIR BUBBLE 23 3 3 CABIN HEATER CONNECTION 23 Ai STEM u u uu N SE EG GE GE EE 24 CHAPTER 4 FUEL 5 5 esse ees ee ee see ee ee ee I I Ihrer 25 Te FLOW OF FUEL ecen sa sa de 26 2 LOW PRE SUIE EINE u 26 ACCELERATION SENSOR AND CONTROL LEVER 27 4 RECOMMENDED FUEL QUALITY 28 5 DRAINING WATER FROM FUEL FILTER 28 CHAPTERS AIR INTAKE SYSIEM 29 1ENGINE BOOM VENTILA Seth ded 29 2 AH PIETE REMANTE NANG E esse si ein edit IC IC PP PSOE 30 CHAPTER 6 LUBRICATION SYSTEM 31 1 ENGINE OIL LEVEL CHECKS 31 2 RECOMMENDED OIL QUALITY 31 ENGINE OIL EXTACTION PUMP 32 A OIL FILTER REPLACEMENT sedes ds dde udi GE xi FER 32 4 HYUNDAI SEASALL LI INSTALLATION amp OPERAT
27. ble from the battery to the start motor with the cable from alternator cable 5 Connect the battery cable from the battery to engine block 6 Battery cables should be clean and tightly connected ENGINE GROUND START MOTOR WARNING DO NOT TOUCH OR REMOVE ELECTRICAL PART WHEN STARTING OR DURING OPERATION KEEP HAND HAIR AND CLOTHES AWAY FROM THE FLYWHEEL AND OTHER ROTATING PARTS WHILE THE ENGINE IS RUNNING 33 9 HYUNDAI SEASALL f INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL D170 and D150 Series Engines 2 BATTERY CHECKS Battery inspection is very important in electronic control engines You must check the battery condition regularly LOAD TEST 1 Perform the following steps to complete the load test procedure for maintenance free batteries 2 Connect the load tester clamps to the terminals and proceed with the test as follows a If the battery has been charged remove the surface charge by connecting a 300 ampere load for 15 seconds Connect the voltmeter and apply the specified load Head the voltage after the load has been applied for 15 seconds Disconnect the load Compare the voltage reading with the minimum and replace the battery if the voltage is less than shown in the table replace the battery If the voltage is greater than shown in the table the battery is good ER ICE EE RN aa 126 OF DEI WARNING BATTERY MUST BE STORED AND TREATED
28. cap and oil filter 3 The supplied oil change hose is connected on to the oil extraction pump D and you must route the other end of the hose into the container being used for the oil change 2 4 Turn the ignition key on and press and hold button 3 on the left side of the ECU box with the ignition switched on until the engine oil about is completely pumped out 4 OIL FILTER REPLACEMENT 1 Remove the oil filter A with the oil filter wrench 2 Inspect the threads and O ring to apply a light coat engine oil onto the new filter Wipe off the seat 3 Install the new oil filter by hand 4 After the packing seats tighten the oil filter clockwise with the oil filter wrench 2 3 2 5kgf m 24 5 Nm 5 Complete the reassembly and start the ignition Then check any oil leakage WARNING USED OIL MUST BE STORED IN A SAFE PLACE AWAY FROM CHILDREN AND FIRE PLACE UNTIL ITS PROPER DISPOSAL IF YOU HAVE DISPOSAL PROBLEM PLEASE CARRIED OUT ENGINE OIL CHANGE BY A NEAREST HYUNDAI SEASALL SERVICE NETWORKS 32 J HYUNDAI SEASALL INSTALLATION amp OPERATION MANUAL D170 and D150 Series Engines LI HYUNDAI SEASALL CHAPTER 7 ELECTRICAL SYSTEM 1 BATTERY CABLE CONNECTIONS 1 The diameter of battery cable should be at least 40 within a length of 4m 2 And it should be at least 50mm if the cable is longer than 4m 3 Recommended battery capacity is over 150 amperes 4 Connect the battery ca
29. duct your dealer may ask you for the Warranty Registration Card to verify date of purchase and to use the information on the card to prepare the warranty claim forms 63 7 HYUNDAI SEASALL f INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL D170 and D150 Series Engines CONDITIONS THAT MUST BE MET TO OBTAIN WARRANTY COVERAGE Warranty coverage 15 available only to retail customers who purchase from a dealer authorized by Hyundai SeasAll to distribute the product in the country in which the sale occurred and then only after the Hyundai SeasAll specified pre delivery inspection process is completed and documented Warranty coverage becomes available upon proper registration of the product by the authorized dealer Routine maintenance outlined in the Installation and Operation Manual must be timely performed in order to obtain warranty coverage Hyundai SeasAll reserves the right to make any warranty coverage contingent upon proof of proper maintenance WHAT HYUNDAI SeasAll WILL DO Hyundai SeasAll will pay for all parts and labor needed to repair the damage to the product resulting from a defect in materials or factory workmanship The warranty does not apply to any damage or defect that is the result of abnormal use or carelessness The repair or replacement of parts or the performance of service under this warranty does not extend the life of this warranty beyond its original expiration date OWNER S OBLIGATIONS It is the
30. e e Change engine oil and oil filter e Replace fuel filter Check air filter element and clean if necessary Check engine coolant level and top up if necessary Check impeller and replace if necessary Check anode and replace if necessary Clean the engine Flush and drain seawater cooling system Fill fuel tank until full and inspect the fuel system Remove the battery and store in a cool dry place CAUTION FOR OVER WINTERING SEAWATER SHOULD BE DRAINED FULLY BY LOOSENNING HEAT EXCHAQGER ANODE REFER TO CHAPTER 10 D 7 HYUNDAI SEASALL f INSTALLATION amp OPERATION MANUAL HYUNDAISEASALL D170 and D150 Series Engines CHAPTER 13 MAINTENANCE 1 PREDELIVERY INSPECTION CHECK LIST 1 1 BEFORE THE WATER TEST 1 2 ON THE WATER TEST ENGINE CHECKS Y N ENGINE CHECKS Boat drain plug in place check before putting boat in water seawater inlet valve open Engine coolant level Seawater pump operation Cooling system hose clamps tight Seawater strainer correctly mounted Clean and tightly closed Engine oil level Power steering fluid level Engine alignment propulsion only Drive belt tension Fuel leaks All electrical connections tight Oil leaks warning system operating Coolant leaks Battery fully charged and secured Water leaks All fuel connection tight Exhaust leaks Exhaust system hose clamps tight and gauges operation Engine mount tight Engine emergency
31. e flow rate 3 Strainer must be installed after water inlet valve in order to allow user to shut off seawater when cleaning strainer filter CAUTION IF ASSEMBLY IS NOT CONDUCTED PROPERLY AIR CAN BE SUCKED IN DISTURBING THE VACUUM PROCESS THIS CAN CAUSE THE ENGINE TO OVERHEAT 18 7 HYUNDAI SEASALL INSTALLATION amp OPERATION MANUAL LI HYUNDAI SEASALL D170 and D150 Series Engines 4 To clean strainer filter Stop the engine and close the water valve Remove the filter cap Remove the filter element flush it thoroughly with clean water or compressed air e Insert the cleaned filter element and screw the filter cap e Check the cap and the gasket for correct seating and sealing e Open the water valve Start the engine and check if there is water leakage 2 3 SEAWATER PUMP 1 The internal diameter of hoses from water pick up to seawater pump inlet should be 40mm 2 The cross section of hose may shrink due to inlet pressure drop Therefore the hose from water pickup in the boat s hull to seawater pump inlet should be as short as possible and must be made of steel wire reinforced material 3 The seawater pump impeller must be checked periodically and replaced if necessary 4 To check seawater pump and impeller Stop the engine and close the water valve Remove the impeller housing cover Remove the impeller from inside the seawater pump e Check the condition of impelle
32. e too long or to bend The maximum back pressure of the exhaust gas should be under 350 mbar 3 Make sure that the shortest height between bottom of the exhaust elbow and the center of the crank axis is 30cm 4 If the distance between the bottom of the exhaust elbow and the waterline is less than 15cm or if the waterline is above the water injection point there is a risk of flowing back siphoning by engine stopping and outside seawater entering through the transom exhaust hole 5 In order to avoid this risk an air ventilation unit and exhaust riser are needed If in doubt about exhaust system installation please contact your nearest Hyundai SeasAll dealer plate mount hole Exhaust elbow bol 150mm 304mm oea waterline ocrew plug for sea water extraction Screw plug for exhaust gas extraction x Center of crank axis CAUTION IF IN DOUBT ABOUT EXHAUST SYSTEM INSTALLATION PLEASE CONTACT YOUR NEAREST HYUNDAI DEALER 24 7 HYUNDAI SEASALL INSTALLATION OPERATION MANUAL e HYUNDAI SEASALL D170 and D150 Series Engines CHAPTER 4 FUEL SYSTEM The fuel supply system of this engine is diesel common rail direction injection In order to optimize engine combustion its maximum injection pressure is up to 1600 bar Multi injection is possible thanks to the quick response of the solenoid type injector Rail Pressure regulator valve Common rail Pump pressure reg
33. ed Check lamp 9 Oil pressure signal 10 Gnd 11 Not used 12 Water detection signal J L E BOR CON O O CN2 DUAL EOI CONNECTOR MI m ala Ignition power Main relay power Permanent power Not used Not used Not used Not used Check lamp 9 Oil pressure signal 10 Gnd 11 Not used 12 Water detection signal O 43 s DOER na Ppi OJO INSTALLATION amp OPERATION MANUAL D170 and D150 Series Engines RPM signal Spare Spare Spare Neutral signal K line CAN Changing signal CAN Not used Gnd Not used o RPM signal opare opare opare Neutral signal K CAN Changing signal CAN Not used Gnd Not used J HYUNDAI SEASALL sd HYUNDAI SEASALL INSTALLATION amp OPERATION MANUAL TACHOMETER oe IM Main relay power RPM signal Gnd illumination illumination CAN H CAN L Not used CN4 COOLANT TEMP GAUGE Coolant temperature signal Ignition power Gnd illumination illumination Not used CN5 VOLT GAUGE 1 2 3 4 Ignition power Gnd illumination illumination CN6 SERVICE TOOL DD sw 9 I9 c CAN H CAN L K line Gnd Main relay power Not used CN7 EXTERNAL pe Gnd Permanent power Ignition
34. elt or control adjustments or lubrication checks made in connection with normal services e Damage caused by neglect lack of maintenance accidents abnormal operation improper installation or service or freezing temperatures Haul out launch or towing charges removal and or replacement of boat partitions or material for necessary access to the product when such service is due to boat design all related transportation charges and or travel time etc All incidental and or consequential damages storage charges telephone or rental charges of any type inconvenience or loss of time or income are the owner s responsibility Use of other than Hyundai SeasAll genuine replacement parts when making warranty repairs Participating in or preparing for racing or other competitive activity Water entering the engine via the air inlet filter or exhaust system or submersion Also water in the starter motor Failure of any parts caused by lack of cooling water Use of fuels and lubricants that are not suitable for use with or on the product Please refer to Installation and Operation Manual TRANSMISSION AND STERNDRIVE WARRANTIES The ZF Marine Transmissions and CMD Diesel Sterndrive Bravo Models are covered under separate warranties and serviced by those companies For information on those warranties please see the separate booklets included in the original packaging of your Hyundai purchase 65 J HYUNDAI SEASALL
35. id communication with a Hyundai SeasAll dealer if there is an emergency You should contact your nearest Hyundai SeasAll dealer as soon as possible if a system problem arises 5 1 ALARM LIST Description eum Expectation Cause s ote EVGT controller overheat learning error 2 P2263 e Overload VGT cooling circuit feedback line error VGT actuator adaption error VGT actuator performance error P2563 PWMfailure P0048 Short circuit Short circuit battery variable geometry Short circuit eu ae Circuit turbocharger P0047 actuator Nod Load P0234 Boost pressure Bela Ee ES than target value VGT actuator performance error Air leakage check P0299 Boost pressure lower than target value Intercooler VGT actuator performance error P2138 Plausibility With Aps2 Violated APS1 P2127 Voltage Above Lower Limit acceleration position P2123 Voltage Above Upper Limit P0643 Supply Voltage Above Upper Limit APS1 2 sensor circuit 25 APS sensor P0642 Supply Voltage Below Lower Limit ECM engine control module x 2 lt APS2 P2128 Voltage above upper limit acceleration T position P0653 Supply voltage above upper limit OR P0652 voltage below lower limit M 8 PO340 No camshaft Aocamshatisigaal CMPS circuit sensor P0341 Wrong camshaft signal at sarino ENE CKPS CKPS circuit crank position CKPS sensor Target wheel check
36. ircuit ground P0277 Short circuit battery 4 Cylinder6 injector Injector P0278 Defect resistance cylinder1 Charging discharging energy error battery alternator check Error path for short circuit of charging switch is detected Injectors circuit ECM P0200 poo injector circuit error circuit error P0193 Voltage above upper limit J PRS circuit HPS PO192 Voltage below lower limit pressure P0611 Injectors Circuit L e APS 2 power supply circuit sensor P0653 Supply voltage above upper limit BPS power supply circuit P0652 gt voltage below lower limit e ECM Maximum positive deviation of rail pressure 70857 e Fuel filter RPS check e P PRV check stuck Rail pressure Monitoring Maximum negative deviation of rail pressure exceeded P0088 L P1171 Minimum rail pressure exceeded P1172 Maximum pressure exceeded P0238 N AL id _ above upper limit P0237 Voltage below lower limit BPS circuit BPS J T boost pressure P0069 Not plausible with atmospheric pressure sensor RPS power supply circuit sensor APS 2 power supply circuit PO653 Supply voltage above upper limit ECM P0652 Supply voltage below lower limit duo 7 HYUNDAI SEASALL INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL D170 and D150 Series Engines Description Expectation Cause s N
37. jector needle stuck ll Engine stop Possible Causes Run out of fuel Crank signals missing connected fuel feed line Fuel pressure regulator valve contaminated stuck jam med Leakage in high pressure fuel circuit regulator valve contaminated stuck jam med out of order Faulty alternator or voltage regulator fuel quality or water ingress in fuel Faulty high low pressure fuel pump Clogged low pressure fuel circuit program error or hardware fault B Performance loss Possible Causes Compensation of individual injector not Leakage at the injector adapted Clogged air filter Fuel or intake air temperature too high Oil level too high or too low Engine coolant temperature too high 62 7 HYUNDAI SEASALL f INSTALLATION amp OPERATION MANUAL HYUNDAISEASALL D170 and D150 Series Engines CHAPTER 15 WARRANTY WHAT 15 COVERED Hyundai SeasAll warrants its new products to be free of defects in material and workmanship during the period described below DURATION OF COVERAGE This Limited Warranty provides coverage for two 2 years from the date the product is first sold to a recreational use retail purchaser or when the Product has been operated for 1000 hours whichever occurs first This Limited Warranty provides coverage for one 1 year from the date the product is first sold to a commercial use retail purchaser or when the
38. lant Temperature Gauge 53 mm e Battery Volt Meter Gauge 53 mm e Ignition Key 27 mm 3 CUT OUT FOR EOI SYSTEM You can use an installation template enclosed with EOI for a cut out 39 J HYUNDAI SEASALL INSTALLATION OPERATION MANUAL sd HYUNDAI SEASALL D170 and D150 Series Engines CHAPTER 9 EOI SYSTEM The Engine Operating Indicator system gives you lot of information about the engine s current workings You can hear alarm beeps or see information including RPM coolant temperatures warning lamps error codes and engine working time If the switch is on warning lamps for battery engine oil and so on are flashed on Then if the engine starts normally the lamps all go off If there is a problem the specific lamp will come on You should contact a close dealer and have engine checked as soon as possible in this case 1 OVERVIEW OF EOI SYSTEM GEN Ls 1 Engine pressure Warning Lamp 2 Alternator Charging Warning Lamp 2 Engine Check Lamp rating Indicator 4 Information LCD ain 5 Water detection Warning Lamp 8 p Buzzer Reset Switch 7 Dimmer Switch 8 Function Switch 1 1 INFORMATION LCD ITEM TOTAL FULL RUNNIG TIME QU DE OE EE XL y a 1 Engine rpm RPM 6 Running Time Hr 2 Engine Coolant Temp C 7 Total WOT running Time Hr 3 Lever Position 96 8
39. nd D150 Series Engines P2138 P2228 P2229 P2262 P2263 P2264 2562 2563 2564 2565 2566 00001 00100 Throttle Pedal Position Sensor Switch D E Voltage Correlation Barometric Pressure Circuit Low Input Barometric Pressure Circuit High Input Turbocharger Boost Pressure Not Detected Mechanical Turbocharger Boost System Performance Water in Fuel Sensor Circuit Turbocharger Boost Control Position Sensor A Circuit Turbocharger Boost Control Position Sensor A Circuit Range Performance Turbocharger Boost Control Position Sensor A Circuit Low Turbocharger Boost Control Position Sensor A Circuit High Turbocharger Boost Control Position Sensor A Circuit Intermittent High Speed CAN Communication Bus Faults in CAN a Transmit Messages Pxxxx codes would be applied to only 5250 220 models 5 7 HYUNDAI SEASALL f INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL D170 and D150 Series Engines CHAPTER 10 ANTI CORROSION SYSTEM Intercooler The sacrificial anode must be replaced when more than 60 of it has been used Check especially frequently when used in saltwater It is recommended to replace the sacrificial anode at the start of each season CAUTION DON T DRIVE IN THE ABSENCE OF ANODES IT IS HARMFUL TO YOUR ENGINE e CLOSE THE SEAWATER VALVE BEFORE THIS MAINTEMANCE e MAKE SURE TO CHECK THE ANODE PLUG IN ACCORDANCE WITH THIS MANUAL DON T LO
40. nd accurate information available for those who maintain own and repair the D170 amp D150 Series engines Hyundai SeasAll values your input regarding revisions and additional information for our manuals The manufacturer is not liable for any damages or losses caused by faulty installation wrong handling of the equipment and or deficient maintenance The operator is responsible for the correct and safe operation of the engine and safety of its occupants and general public 5 It is strongly recommended that each operator read and understand this manual before installing and operating the engine This manual as well as safety labels posted on the engine use the following safety alerts to draw your attention to special safety instructions that should be followed WARNING DEVIATION FROM INSTALLATION INSTRUCTIONS AND OPERATION GUIDELINES MAY LEAD TO PERSONAL INJURY OR DEATH TO OPERATORS AND NEARBY PERSONNEL CAUTION DEVIATION FROM INSTALLATION INSTRUCTIONS AND OPERATION GUIDELINES MAY LEAD TO IMPROPER OPERATION DAMAGE OR DESTRUCTION OF THE ENGINE 3 7 HYUNDAI SEASALL LJ HYUNDAI SEASALL INSTALLATION amp OPERATION MANUAL D170 and D150 Series Engines CHAPTER 1 ENGINE OVERVIEW 1 ENGINE COMPONENTS poU ee Co ECU Box Coolant Expansion Tank Engine Oil Cap Engine Oil Filter P S Oil Cooler Fuel Pump VGT Exhaust Elbow Bell Housing Air Filter
41. new one 22 J HYUNDAI SEASALL j INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL D170 and D150 Series Engines 3 2 REMOVING AIR BUBBLES IN COOLANT LINE 1 Start the engine and warm it up at a low rpm up to thermostat opening 2 Next stop the engine and allow the engine to cool enough and then open the cap of the expansion tank carefully NOTE Never open the cap when the engine is hot Doing so may cause scalding 3 Refill with coolant if needed 4 Recap the expansion tank 5 Please check the level of expansion tank regularly while driving 3 3 CABIN HEATER CONNECTION 1 In order to use cabin heater an extra coolant circulation pump is needed 2 After connecting cabin heater lines engine coolant must be refilled and checked 3 Please check coolant flow direction as shown in figure 4 If in doubt please contact your nearest Hyundai SeasAll dealer To heater xd Outer diameter of line is 219 3 mm WARNING NEVER OPEN THE EXPANSION TANK CAP WHEN THE ENGINE IS OPERATING OR HOT IT MAY CAUSE ENGINE DAMAGE AND COULD 23 9 HYUNDAI SEASALL INSTALLATION amp OPERATION MANUAL D170 and D150 Series Engines LI HYUNDAI SEASALL 4 EXHAUST SYSTEM 1 Your Hyundai SeasAll engine s exhaust system consists of a coolant cooled exhaust manifold and a seawater cooled exhaust elbow water injected wet exhaust system 2 The vessel s exhaust pipe line should not be mad
42. ol Module Random Access Memory RAM Error P0605 Internal Control Module Read Only Memory ROM Error P0606 ECM PCM Processor P0611 P062D P062E P0642 P0643 P0650 Malfunction Indicator Lamp MIL Control Circuit P0652 P0653 P0670 P0671 P0672 P0673 P0674 P0675 P0676 P0683 P0684 P0685 P0698 P0699 P1145 Camshaft Position Sensor A Circuit Range Performance Glow Plug Heater Indicator Circuit System Voltage Low System Voltage High Internal Control Module Memory Check Sum Error Control Module Programming Error 67 70 71 72 73 74 75 76 77 78 79 Injector Error Injector Bank1 Error Injector Bank2 Error Sensor Reference Voltage A Circuit Low Sensor Reference Voltage A Circuit High Sensor Reference Voltage B Circuit Low Sensor Reference Voltage B Circuit High Glow Plug Module Control Circuit Cylinder 1 Glow Plug Circuit Cylinder 2 Glow Plug Circuit 81 82 83 84 85 Cylinder 3 Glow Plug Circuit Cylinder 4 Glow Plug Circuit Cylinder 5 Glow Plug Circuit Cylinder 6 Glow Plug Circuit Glow Control Module Signal Glow Control Module Performance 87 Power Relay Control Circuit Open 88 Variable Swirl Actuator Voltage Lower Limit Variable Swirl Actuator Voltage Upper Limit Overrun Monitoring 51 7 HYUNDAI SEASALL INSTALLATION 6 OPERATION MANUAL HYUNDAI SEASALL D170 and D150 Series Engines P code DESCRIPTION P1171 P1172 P1173 P1185 P1
43. ote 1 Lamp CH P0254 Short circuit to Aran o Bakte of MAENG UMEGUIPUE of metering unit output PPRV Sh d of pump pressure BEE ort circuit to ground of metering unit output P PRV circuit fedis or ave Open load of metering unit output Short circuit to battery of pressure control valve output PRV rail pressure Short circuit to ground of pressure control valve PRV circuit regulator vlave output WISE Open load of pressure control valve output of pressure control valve output 0 9 P0089 Powerstage error error sensor Charging Error Charging system error BE Alternator Charging circuit check ECTS circuit Mos m Coolant temperature high above 110 C Depending EOOD e ECTS temp Blinking M temp sensor Cooling line check Note 1 RPM Limit Rated rpm 500rpm O Rated rpm 800rpm Note 2 3 would be applied to 5250 220 models 48 J HYUNDAI SEASALL INSTALLATION 6 OPERATION MANUAL HYUNDAI SEASALL D170 and D150 Series Engines 5 2 DTC DIAGNOSIS TROUBLE CODE LIST P code DESCRIPTION P0016 P0047 P0048 P0069 P0087 P0088 P0089 P0091 P0092 P0097 P0098 P0107 P0108 P0112 P0113 P0116 P0117 P0118 P0182 P0183 P0192 P0193 P0194 P0201 P0202 P0203 P0204 P0205 P0206 P0231 Crankshaft Position Camshaft Position Correlation Turbocharger Boost Control Solenoid Circuit Low Turbocharger Boost Control Solenoid Circuit High Manifold Absolute Pre
44. pare 30Amp FUEL PUMP N 30A I 5 Start Sol Relay_30Amp 6 Fuel Heater Relay _ Using an ohmmeter check that there is continuity between each terminal 85 86 YES Apply 12V to terminal 85 and ground to terminal 86 Check for continuity between terminals 30 and 87 Always replace a damaged relay with one of the same rating 36 J HYUNDAI SEASALL 27 INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL D170 and D150 Series Engines CHAPTER 8 INSTRUMENT SYSTEM 1 INSTRUMENTS CONNECTION One Pu rus 1 Main EOI Dual a Opt 19 gauges only available for dual application Engine to EOI wiring standard 7m option 10m 6 EO to RPM gaugelf 85 wiring amp EOI to coolant temp qauge 52 wiring EO to volt gauge 52 wiring amp EO to ignition key switch 21 4 wiring Dual EOI wiring option Tor dual stage For information about the installation and operation of the Engine Operating Indicator system please refer to Chapter 9 37 9 HYUNDAI SEASALL INSTALLATION OPERATION MANUAL D170 and D150 Series Engines 1 1 Standard instrumentation 136 204 05 RPM Gauge Coolant Temperature Gauge Battery Volt Meter Gauge Ignition Key switch 1 2 COOLANT TEMPERATURE GAUGE 1 When the key is at ignition ON position this gauge will work
45. power Neutral switch Neutral switch Charging signal RPM signal Dimmer 44 D170 and D150 Series Engines Ei m i _s i A OOOOOOOOT 9 HYUNDAI SEASALL LI f INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL D170 and D150 Series Engines CN8 KEY BOX 1 Ignition power 2 Start power 3 Permanent power 4 NEUTRAL SWITCH AND DUAL EOI CONNECTION 1 Neutral switch wires should be connected at pin 4 and 5 of the external connector of the EOI If there is no neutral switch jumper 4 and 5 with short wiring SYSTEM WITH A NEUTRAL SWITCH SYSTEM WITH NO NEUTRAL SWITCH From neutral switch wiring 2 If there is a dual EOI you should connect the wiring between 5 external connector of the main EOI and 5 external connector of the dual Main EOI external connector Dual EOI external connector From neutral switch wiring Additional proper wiring needed CAUTION ENGINE WOULD NOT CRANK AND START FOR USER S SAFETY IF GEAR POSITION IS NOT NEUTRAL OR NOT CONNECTED TO EOI EXTERNAL CONNECTION 45 J HYUNDAI SEASALL INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL D170 and D150 Series Engines 5 ALARM AND DTC DIAGNOSIS TROUBLE CODE If there is a problem with the engine the display audible or visible alarm and related DTC diagnosis trouble code will give you information about it The DTC display is only for initial assistance and to a
46. r and bushing CAUTION IF ASSEMBLY IS NOT CONDUCTED PROPERLY AIR CAN BE SUCKED IN DISTURBING THE VACUUM PROCESS THIS CAN CAUSE THE ENGINE OVERHEAT 19 7 HYUNDAI SEASALL f INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL D170 and D150 Series Engines Apply soapy water to impeller when assembling and reassemble towards rotation direction Replace of the O ring on the impeller housing cover Open the water valve Start the engine and check if there is water leakage CAUTION DO NOT RUN THE ENGINE WITHOUT SEAWATER THE SEAWATER PUMP IMPELLER WILL BE DAMAGED BEFORE STARTING THE ENGINE BE SURE TO SUPPLY SEAWATER TO THE PASSAGES CAUTION IMPELLER DAMAGE MAY OCCUR IF APPROPRIATE TOOLS ARE NOT USED WHEN REMOVING THE IMPELLER MAKE SURE TO CHECK O RING CONDITION AFTER SEAWATER PUMP REASSEMBLY CAUTION DO NOT INSTALL ADDITIONAL DEVICES WHICH COULD OBSTRUCT THE FLOW OF SEAWATER THIS CAUSE THE ENGINE OVERHEAT 20 7 HYUNDAI SEASALL INSTALLATION amp OPERATION MANUAL D170 and D150 Series Engines HYUNDAI SEASALL 3 THE FLOW OF ENGINE COOLANT CLOSED COOLING CIRCUIT THERMOSTAT CLOSED CONDITION CD Coolant engine outlet Thermostat closed opening temp 85 C 2 Engine coolant circulation internally 5 THERMOSTAT OPENED CONDITION CD Coolant engine outlet 4 Expansion tank 2 Heat exchanger l Thermostat opened opening temp 85
47. ssure Barometric Pressure Correlation Fuel Rail System Pressure Too Low Fuel Rail System Pressure Too High Fuel Pressure Regulator 1 Performance Fuel Pressure Regulator 1 Control Circuit Low Fuel Pressure Regulator 1 Control Circuit High Intake Air Temperature Sensor 2 Circuit Low Intake Air Temperature Sensor 2 Circuit High Atmospheric Pressure Sensor Voltage Lower Limit Atmospheric Pressure Sensor Voltage Upper Limit Intake Air Temperature Sensor1 Circuit Low Input Intake Air Temperature Sensor1 Circuit High Input Engine Coolant Temperature Circuit Range Performance Engine Coolant Temperature Circuit Low Input Engine Coolant Temperature Circuit High Input Fuel Temp Sensor A Circuit Low Input Fuel Temp Sensor A Circuit High Input Fuel Rail Pressure Sensor Circuit Low input Fuel Rail Pressure Sensor Circuit High Input Fuel Rail Pressure Sensor Circuit Intermittent Cylinder 1 Injector Open Load Cylinder 2 Injector Open Load Cylinder 3 Injector Open Load Cylinder 4 Injector Open Load Cylinder 5 Injector Open Load Cylinder 6 Injector Open Load Fuel Pump Secondary Circuit Low 49 7 HYUNDAI SEASALL INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL D170 and D150 Series Engines P code DESCRIPTION 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 P0232 P0234 P0237 P0238 P0252 P0253 P0254 P0261 P0262 P0263 P0264 P0265 P0266 P0
48. stop switch Engine alignment operation Correct rotation propeller Installed and torque Pott LLLLLLLL LLLA Idle RPM within specifications WOT RPM within specifications Engine coolant and oil drain plug in forward gear closed Throttle shift and steering system fasteners tightened properly PROPULSION CHECKS Forward Neutral Reverse gear Stern drive unit oil level operation Power trim oil level stern drives 1 3 AFTER THE WATER TEST Drive unit fasteners torque EIE Fuel oil coolant water and fluid leaks PROPULSION CHECKS Steering operation throughout range EE Power trim operation stern drives Power trim cylinders fasteners tight EN Propeller nut torque mM and fluid level Transmission fluid level mE Propeller nut torque 28 7 HYUNDAI SEASALL f INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL D170 and D150 Series Engines 2 MAINTENANCE SCHEDULE Whichever comes first 200 400h Daily 2years Maintenance Maintenance intervals item Check the coolant level and leakage Replace the seawater pump Impeller Cooling system Inspect the thermostat Clean the pipe bundle of heat exchanger Check and clean the seawater strainer Check the leakage Exhaust system Replace the exhaust rubber bellows j Check the leakage _ J Fuel system Replace the fuel filter Je Replace the additional fuel filter
49. ter releasing the switch you can start the engine again 2 When switch is pressed or it doesn t work normally the engine doesn t crank We recommend that you check this switch first if there is any cranking problem 3 You can use this switch to avoid unexpected engine ignition during maintenance 4 You can use this switch for any emergency situation Engine stop Switch 3 WINTER OPERATION AND STORAGE 1 When using or storing your engine under 0 C protect all seawater passing parts seawater pump intercooler heat exchanger and line seawater strainer valve and pipe from freezing the sterndrive models especially should trim down fully to prevent trapped water in gear case from freezing 2 The battery capacity decreases as the temperatures drop We recommend recharging the battery frequently Check and clean all battery cable connections as oxidized connections lead to voltage drops and starting difficulties 56 J HYUNDAI SEASALL f INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL D170 and D150 Series Engines CHAPTER 12 ENGINE STORAGE The major consideration in preparing your engine for storage is to protect it from rust corrosion and damage caused by freezing of trapped water The following storage procedures should be followed to prepare your engine for out of season storage or prolonged storage two months or longer and winter storage CHECK LIST Visual inspection for leaks and damag
50. tion 2 Full load position setting You can make sure that the position value should indicate full load range 90 99 2 adequately at fully forward lever condition not fulfilled you need to disassemble and adjust the base neutral position of control lever by moving it to the rear until fulfilled Base position CAUTION YOU SHOULD PERFORM ABOVE PROCEDURES ON CONDITION ENGINE IS NOT RUNNING BUT IGNITION KEY ON AFTER CONTROL LEVER INSTALLATATION 2 7 HYUNDAI SEASALL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL D170 and D150 Series Engines 4 RECOMMENDED FUEL QUALITY The following fuels should be used for engine operation Standard summer winter diesel fuel according to DIN EN 590 classes A F Diesel fuel according to DIN EN 590 classes 0 4 in arctic climates Summer diesel fuel according to California and U S federal regulations Winter diesel fuel if lubricity is comparable to diesel fuel according to DIN EN 590 Mixture of diesel fuel with 5 Vol RME according to DIN 51606 Later admixing or additional use of additives gasoline or special fuels is not permitted 5 DRAINING WATER FROM FUEL FILTER 1 The fuel filter for a diesel engine plays an important role of separating water from fuel and accumulating the water in its base If water accumulates in the fuel filter a warning light comes on when the ignition switch is at the ON position 2 If the water in
51. tot x OILCOOLER I EXPANSION TANK lt OIL PCM OPE J SEA WATER PUMP gt SEAWATER gt INTAKE AIR N ta 3 _ EXHAUST SEAWATER gt COOLANT THERMOSTAT CLOSED amp OPENED gt COOLANT THERMOSTAT OPENED 17 J HYUNDAI SEASALL f INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL D170 and D150 Series Engines 2 THE FLOW OF SEAWATER OPEN COOLING CIRCUIT Water strainer Water valve Water pickup l D Intercooler 2 Seawater pump 3 Oil cooler 4 exchange 5 Exhaust elbow Sea water 2 1 WATER PICKUP 1 Water pickup should be installed in an area where it won t pickup air bubbles and will access fresh water during the duration of engine operation 2 For use in sterndrive models please see the section Installing Sterndrive Seawater Pickup of the BRAVO MODELS INSTALLATION MANUAL included in the original packaging 3 For further safety you can use an additional transom or bottom type water pickup 2 2 WATER STRAINER 1 Strainer should be located in an area where it will be easily accessible for periodic seawater flow inspection and cleaning 2 The size of strainer must be of sufficient capacity to pass the seawater a flow rate over 150 liters per minut
52. u should ask your local service shop for maintenance CHECK ENGINE LAMP his lamp informs you that the engine has a serious problem You can see the DTC on the LCD of the EOI t is possible to drive at limited rpm The ECU will control the functions to protect the engine You should check the engine at the nearest service shop immediately HYUNDAI SEASALL LI INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL D170 and D150 Series Engines 2 EOI CONNECTIONS 1 Connection plug CN1 from engine 2 Connection plug to dual EOI 3 Connection plug CN3 tachometer 4 Connection plug coolant tem gauge 5 Connection plug CN5 volt gauge Rear view 6 Connection plug CN6 service tool 7 Connection plug CN7 external 8 Connection plug CN8 key box 9 System power fuse 3 amp 10 Buzzer WARNING LISTEN FOR A CLICK WHEN LOCKING CONNECTORS THIS SOUND INDICATES THAT THEY ARE SECURETY LOCKED CAUTION CONNECT EXTRA INSTRUMENTS WHICH CAPACITY IS OVER 1 AMPERE THE E O I WOULD BE DAMAGED BY OVERLOAD 42 J HYUNDAI SEASALL LI HYUNDAI SEASALL 3 EOI PIN ASSIGNMENT CN1 MAIN EOI CONNECTOR FROM ENGINE E Sec OTL Lene xD TRORUPLP 2 46 Ignition power Main relay power Permanent power Not used Not used Coolant temperature signal Not us
53. ulator valve Injector Fuel r Temperature Sensor ESSEN Fuel filter Water in Fuel Sensor O Feed Pump Fuel feed low Fuel return Fuel tank mew Fuel feed high 25 J HYUNDAI SEASALL INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL D170 and D150 Series Engines 1 THE FLOW OF FUEL Fuel tank Auxiliary fuel filter D Fuel pump low pressure 2 Fuel with water detection sensor 3 High nem pump 4 Common rail gt Fuel return Injector or return to fuel tank gt Fuelfeeding 2 LOW PRESSURE FUEL LINE D Return line to fuel tank engine out 2 Feeding line from main fuel filter to high pressure pump 3 Feeding line from fuel tank to electric feed pump low pressure pump The internal diameter of all fuel lines must be at least 8 mm 26 9 HYUNDAI SEASALL LY f INSTALLATION amp OPERATION MANUAL HYUNDAI SEASALL D170 and D150 Series Engines 3 ACCELERATION SENSOR AND CONTROL LEVER When installing control lever cable to acceleration sensor be sure that the acceleration sensor lever is fully released to the idle position and fully pulled to the full load position The swing distance of lever between idle and full load position is 65mm The procedures for control lever installation 1 Idle position setting You can make sure that the position value Engine Operating Indicator should indicate 0 at neutral condi

Installation_operating manuals for D170 D150 series(Ver1.2)

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