MPE 850 marine Service Manual

7/25/2019 MPE 850 marine Service Manual

1/96

TD407477_SHB

Rev F

06.11.2015

MPE 850 MARINE

408101 I2 846 MAR TC-100 (TC-80) (TC-120)

408014 I2 846 MAR TC-120

408090 I2 846 MAR TC-155

408246 I2 846 MAR NA-80

This service manual is valid for the following engine models:

Read this service manual thoroughly before operating the engine for thefirst time.

SERVICE MANUAL

4-Stroke Engine

en_English


2/96


3/96

Textron Motors GmbH

Daimlerstrae 5

88677 Markdorf

Germany

www.textronmotors.com

Textron Motors GmbH strives to make continual improvements as part of the ongoing technical developmentof its products. All documentation is therefore subject to technical modifications.

Reprints and translations, in whole or in part, require written permission from Textron Motors GmbH.

All rights reserved according to the copyright law.


4/96

4 SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

Table of contents

Table of contents

1 About this document 6

1.1 Meaning of symbols and signal words. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2 Safety 7

2.1 Meaning of safety alert symbol and signal words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.2 Important safety messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3 Description 10

3.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103.2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.3 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123.4 Engine oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123.5 Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133.6 Engine components and information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143.7 Engine fuses and relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203.8 Protective functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213.9 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223.10 Supported vehicle equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243.10.1 Lights in vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

4 Operation 26

4.1 Service intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4.2 Operation during the break-in period. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284.3 Operating engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294.3.1 Inspecting the exhaust and fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294.3.2 Checking coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304.3.3 Put the engine into operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314.3.4 Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324.3.5 Take the engine out of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344.3.6 Flushing sea water cooling circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354.3.7 Corrosion protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364.3.8 Transport and storage of the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

5 Special scenarios 38

5.1 Engine storage for more than 30 days . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385.2 Operating engine without sea water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385.3 Towing vehicle in water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385.4 Measures in case of flooded engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

6 Malfunctions 40

6.1 Malfunctions table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406.2 Checking engine fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42


5/96

5SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

Table of contents

7 Dealer and servicing network 44

7.1 Locating a workshop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447.2 Tools and parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

7.3 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

8 Service tasks in the workshop 45

8.1 Safety messages workshop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458.2 Tools and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468.2.1 Service parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468.2.2 Textron Motors diagnostic case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478.2.3 Equipment workshop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 488.2.4 Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508.3 Changing engine oil and oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518.4 Checking sacrificial anode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 588.5 Checking and adjusting valve lash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 598.5.1 Checking valve lash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 598.5.2 Adjusting valve lash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 638.6 Replacing spark plugs and ignition coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 668.7 Checking spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 688.8 Replacing rubber mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 718.9 Maintenance waste gate valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 768.9.1 Maintaining waste gate valve version 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 778.9.2 Maintaining waste gate valve version 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 798.10 Checking flame arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 818.11 Changing coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 858.12 Replacing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 888.13 Storing engine and returning to operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

8.13.1 Preparing engine for storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 898.13.2 Returning engine to operation after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 918.14 Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

9 Confirmation of service tasks 93

Appendix 95

Engine manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96


6/96

6 SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

This service manual was designed to help you operating the engine safely and reliably.

Observe the following references:

Read this service manual thoroughly before operating the engine for the first time.

Always read the vehicle manufacturers documentation.

This service manual is for the engine in your vehicle. See the vehicle manufacturers documentation forvehicle specific information.

Keep this service manual in a safe place.

Make sure that all persons using the vehicle have access to this service manual.

If you sell the vehicle, always pass on this service manual to the new owner.

The latest version of the servicew manual is available for download in other languages from our web sitewww.textronmotors.com.

Some figures in this service manual are general illustrations and may differ from the actual engine.

1 About this document

1.1 Meaning of symbols and signal words

1 About this document

1.1 Meaning of symbols and signal words

Item Meaning

NOTICE The signal word NOTICEindicates potential property damage.

Information The signal word Informationindicates specific features and recommendations.


7/96

7SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

This engine is state-of-the-art and built according to recognized safety technical and emission 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 Safety

2.1 Meaning of safety alert symbol and signal words

Item Meaning

The safety alert symbol draws your attention to possible dangers.

WARNING

The signal word WARNINGindicates a potentially dangerous situation that maylead to a serious or fatal injury.

CAUTION

The signal word CAUTIONindicates a potentially dangerous situation that maylead to a minor or moderately severe injury.

2 Safety

2.1 Meaning of safety alert symbol and signal words


8/96

8 SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

2.2 Important safety messages

2 Safety


In order to keep your engine in a safe operating condition, regular

servicing is essential. It is your responsibility to ensure that the engine isserviced correctly.

Perform regular inspections and observe the specified serviceintervals.

All tasks described in chapter 8 Service tasks in the workshoprequirespecial technical knowledge of this engine.

Ensure your workshop is qualified to service your engine.

All Textron Motors authorized workshops are qualified to serviceyour engine.

Engine malfunctions pose a safety risk to persons.

Only operate the engine in perfect condition.

Perform all service tasks according to the service intervals in thisservice manual.

You must immediately address all malfunctions to a qualifiedworkshop.

All the components in your engine have been carefully tested and fulfillstrict quality and safety requirements.

Textron Motors offers spare parts to the highest quality. Ensure thatequivalent spare parts corresponds with this quality requirements.

Engine modifications may pose a safety risk to persons. Do not install add-on parts or modify the engine.

Engine components become extremely hot during operation.

Do not touch any engine components during operation.

Turn off the engine and wait until the components have cooledbefore making contact.

Some service tasks require disconnection of the engine from the powersupply. Starting the engine inadvertently may endanger the safety ofpersons. Read the vehicle manufacturers documentation for moreinformation.

Disconnect the engine from the power supply when requested.

Engine exhaust gases contain carbon monoxide (CO). Inhalation ofcarbon monoxide can deprive the body of oxygen and result in organdamage or death by asphyxiation.

Never operate the engine in enclosed spaces.

Service tasks

Service tasks in the workshop

Malfunctions

Spare parts

Add-on parts and modifications

Hot engine components

Engine power supply

Engine exhaust gases


9/96

9SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

2 Safety


Engine fluids pose a health risk.

Always read the manufacturer's instructions.

Always wash your hands prior to eating, smoking and using therestroom as well as at the end of the working shift when workingwith engine fluids.

Engine fluids are hazardous to the environment.

Never allow engine fluids to escape into the groundwater, watercourses or sewage system. Always dispose of engine fluidsaccording to applicable regulations.

Danger of slipping on spilled fluids.

Always use a filler neck or funnel when filling the engine with fluids.

Always clean up any spilled engine fluids immediately.

Fuel is highly flammable. Vapors may ignite and cause an explosion. Do not smoke in the vicinity of the engine and do not allow open

flames or sparks near the engine or the fuel system.

Always turn off the engine before fueling.

Never fill with fuel while the engine is running.

Do not start the engine if you smell fuel or see a fuel leak.

Fuel on hot surfaces can cause fires.

In the event of a fire, use foam, dry chemical or carbon dioxide fireextinguishers. Do not extinguish with water.

Engine oil is flammablew and can emit toxic gases.

Do not smoke in the vicinity of the engine and do not allow openflames or sparks near the engine.

Engine oil on hot surfaces can cause fires.

In the event of a fire, use foam, dry chemical or carbon dioxide fireextinguishers. Do not extinguish with water.

This engine und engine exhaust contains chemicals known to the State ofCalifornia to cause cancer, birth defects, or other reproductive harm.

Fuel, engine oil and coolanthandling

Fuel

Engine oil

California Proposition 65


10/96

10 SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

Date:

Part No.:

Serial No.:

26.10.2012

999999

9999999999

1

5

3

2

4

3 Description

The engine models I2 846 MAR has been designed for powering watercrafts. Any other use is notpermissible.

All specifications in this service manual are only valid for the unmodified engine delivered by Textron Motors.Engine modifications are not permissible and in addition, may void the warranty or violate federal laws.

3.2 Identification

Each engine is assigned two identificationnumbers. Both numbers are printed on a label 1 affixed to the engine.

The part number Part No.: 2 is the number ofthe engine model.

The serial number Serial No.: 3 is an uniquenumber for each individual engine.

Take the time to enter the part number and serialnumber in chapter 9 Confirmation of servicetasks. Both numbers are important in questions

regarding your engine.

3.1 Intended use

3 Description

3.1 Intended use | 3.2 Identification

Engine modelsI2 846 MAR TC-80, TC-100 and TC-120

The label with the part number and the serialnumber is located on the expansion tank 4 .

The serial number is also engraved on thecrankcase 5 .

The Emission Control Information label is locatedon the expansion tank.


11/96

11SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

7

6

8

9

3 Description

3.1 Intended use | 3.2 Identification

Engine model I2 846 MAR TC-155




Engine model I2 846 MAR NA-80





12/96

12 SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

3.3 Fuel

3.4 Engine oil

3 Description

3.3 Fuel | 3.4 Engine oil

Engine models I2 846 MAR NA-80 TC-80 TC-100 TC-120 TC-155

Fuel Unleaded gasoline

Recommended fuel quality 95 ROZ or 85 MOZUSA Premium 91

98 ROZ or 88 MOZUSA Premium 93

Minimum requirement NOTICE!Low octane fuel can cause loss of power and/or increasedfuel consumption.

91 ROZ or 82,5 MOZUSA Regular 87

Permissible share of ethanol NOTICE!A greater concentration can deteriorate the engines fuelsystem and starting performance.

Maximum 10 % (E10)


Engine oil NOTICE!Engine damage due to incorrect engine oil grade. Always usethe recommended engine oil. Do not mix engine oils of different gradesor viscosity.

0W 40 completely synthetic, at least API SJ, ACEA A3/B3

Fill quantity Approximately 3,5 liters [3.7 qt (US)]


13/96

13SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

3.5 Coolant

3 Description

3.5 Coolant


Coolant additive Coolant additive based on ethylene glycol, silicate- and nitrite- free,suitable for aluminium engines.

Suggested coolant additives NOTICE!Insufficient cooling due to incompatibilities of coolant.Combining different coolant additives may trigger a chemical reactionand they may lose their effectiveness. The suggested coolant additivesare laboratory tested for compatibility. If you use another coolantadditive verify the compatibility previously.

BASF Glysantin G 30 Chevron Havoline Extended Life Coolant XLC+B Valvoline Zerex G 30

Mixing ratio NOTICE!An incorrect mixing ratio reduces the cooling capacity. Whentopping up the coolant, do not change the mixing ratio. Use the samecoolant throughout the year in the mixing ratio specified.

50 % water + 50 % coolant additive

Fill quantity Approximately 2,75 liters [2.9 qt (US)]


14/96

14 SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

3

1

6

10

11

4

8

9

2

7

5

3 Description

3.6 Engine components and information


Information! The wire harness is not shown in the figures.

Sacrificial anode 8

Exhaust manifold 9 /Exhaust side

Exhaust pipe 10

Sea water return 11

Engine models I2 846 MARTC-80, TC-100 and TC-120

Oil filter 1

Drainage for storage 2

Fuse box 3

Waste gate valve 4

Flame arrester 5

Connection for sea watercooling circuit flushing device

6

Heat exchanger 7


15/96

15SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

15

13

12

19

21

22

20

18

14

16

17

23

3 Description


1st cylinder 12

Sensor camshaft 13 /2nd cylinder

Fuel supply 14

Engine rotation direction 15

Stub shaft 16 / Power take off

Engine cover 17

Oil tank 18

Coolant expansion tank 19

Sea water supply 20

Engine-Chassis vehicleconnector 21

Relay starter 22

Intake manifold 23 /Intake side


16/96

16 SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

1

9

10

7

2

3

4

5

6

8

3 Description


Sacrificial anode 7


Exhaust pipe 9

Sea water return 10

Engine modelI2 846 MAR TC-155

Oil filter 1


Waste gate valve 3

Flame arrester 4


5

Heat exchanger 6


17/96

17SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

15

12

11

19

21

22

18

13

16

17

14

20

23

3 Description


1st cylinder 11


Fuel supply 13

Fuse Box 14



Engine cover 17

Oil tank 18


Sea water supply 20


Relay starter 22



18/96

18 SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

1

4

7

8

3

5

2

6

Sacrificial anode 5


Exhaust pipe 7

Sea water return 8

Engine modelI2 846 MAR NA-80

Oil filter 1


Heat exchanger 3


4

3 Description



19/96

19SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

13

10

9

17

20

16

11

14

15

12

19

18

21

1st cylinder 9


Fuel supply 11

Fuse Box 12



Engine cover 15

Oil tank 16



Sea water supply 19

Relay starter 20


3 Description



20/96

20 SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

1

3.7 Engine fuses and relays

3 Description

3.7 Engine fuses and relays

Overview configuration fuses and relays

1 Relay MAIN, relay main

2 Relay FUEL, relay fuel pump

3 15 A fuse IGK, terminal 30 key switch

4 15 A fuse VBD, terminal 30 battery

5 15 A fuse SERVICE, electric circuit forignition coils, injectors

6 10 A spare fuse SPARE

7 10 A fuse FUEL, fuel pump

8 15 A fuse VBR, terminal 30 after relay main

9 15 A spare fuse SPARE

The engine fuses and relays are located in the

fuse box on the engine. (See chapter 3.6 Enginecomponents and information.)

Remove the cover 1 from the fuse box.


21/96

21SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

3.8 Protective functions

3 Description

3.8 Protective functions

The engine has an engine diagnostics, which monitors various operating parameters. The protection

functions described in this chapter are intended for your protection and to protect your engine when theoperating parameters exceed defined limits.

Protective function Description

Engine temperature The protective function will be activated, to protect the engine fromoverheating.

Engine temperature > 90 C

The temperature warning light flashes or illuminates. The engine speedis limited. The critical temperature range is reached and an enginedamage caused by overheating is imminent.

Measures are immediately required. (See chapter 3.10.1 Lights in

vehicle.)

Engine speed limitations If a speed limitation is active the engine speed cannot be exceeded,even at full throttle.

In the following operation conditions speed limitations are active:

5000 min-1[rpm] The shift control lever is in reverse gear (optional)

If one of the following speed limitations is active there is a malfunction.

Speed limitations results in decreased driving performance and

can cause unusual vehicle responses. Immediately inspect thecause and repair possible faults by a qualified workshop. All

Textron Motors authorized workshops are qualified to repair your

engine.

6000 min-1[rpm] Electrical fault valve boost pressure control

5000 min-1[rpm] Synchronization fault of sensors camshaft /crankshaft

4500 min-1[rpm] Fault pedal value sensor

4000 min-1[rpm] Fault electronic throttle system (drive-by-wire)

2000 min-1[rpm] Overheating engine (Observe section Engine

temperature.)


22/96

22 SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

3 Description

3.9 Technical specifications

Engine models I2 846 MAR TC-80 TC-100 TC-120 TC-155

Type 4-stroke gasoline engine, parallel twin with balance shaft and singleoverhead camshaft (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 @6600 min-1 [rpm]

74 kW @7200 min-1 [rpm]

91 kW @7500 min-1 [rpm]

112 kW @7500 min-1[rpm]

Engine power SAE J1228 59 kW @6600 min-1 [rpm]

75 kW @7200 min-1 [rpm]

92 kW @7500 min-1 [rpm]

113 kW @7500 min-1[rpm]

Engine speed limit 8000 min-1[rpm]

Idle speed 1600 min-1[rpm]

Fuel system Sequential multipoint manifold injection

Lubrication system Dry sump

Cooling system Closed coolant circuit and open sea water cooling circuit

Engine management system Synerject M3D

Throttle body Electronically controlled throttle body (drive-by-wire), dia. = 44 mm [1.73 in]Ignition system Electronically controlled distributorless ignition system with individual coils

Starter system Electric starter

Generator, internal > 450 W @ 4000 min-1[rpm]

Fuses Automotive fuses mini blade-type 10 A and 15 A

Weight including engine oil andcoolant

95 kg [209 lb] 95 kg [209 lb] 95 kg [209 lb] 100 kg [221 lb]

Dimensions L x B x H 743 mm [30 in] x 539 mm [22 in] x 509 mm [20 in]



23/96

23SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

3 Description


Engine models I2 846 MAR NA-80

Type 4-stroke gasoline engine, parallel twin with balance shaft and singleoverhead camshaft (SOHC)

Displacement 846 cm

Number of cylinders 2

Bore x stroke 89 x 68 mm [3.5 x 2.7 in]

Compression ratio 11,5 : 1

Engine power ISO 8178 58,5 kW @ 7500 min-1 [rpm]

Engine power SAE J1228 59 kW @ 7500 min-1 [rpm]

Engine speed limit 8000 min-1[rpm]

Idle speed 1450 min-1[rpm]

Fuel system Sequential multipoint manifold injection

Lubrication system Dry sump

Cooling system Closed coolant circuit and open sea water cooling circuit

Engine management system Synerject M3D

Throttle body Electronically controlled throttle body (drive-by-wire), dia. = 44 mm [1.73 in]

Ignition system Electronically controlled distributorless ignition system with individual coils

Starter system Electric starter

Generator, internal > 450 W @ 4000 min-1[rpm]

Fuses Automotive fuses mini blade-type 10 A and 15 A

Weight including engine oil andcoolant

90 kg [198 lb]

Dimensions L x B x H 743 mm [30 in] x 539 mm [22 in] x 509 mm [20 in]


24/96

24 SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

3.10.1 Lights in vehicle

3.10 Supported vehicle equipment

3 Description


The lights described in this chapter are controlled by the engine management system. Observe theinformation in the vehicle manufacturers documentation.

Light Description

Service light When the service light is illuminating, the next service interval isreached and service tasks are required.

The required service tasks must be performed in a qualifiedworkshop. All Textron Motors authorized workshops are qualifiedto service your engine.

Observe that only the regular operating hours intervals will be indicated.The service light does not indicate the 1st service and the yearlyservice intervals. (See chapter 4.1 Service intervals.)

Oil pressure light The oil pressure light illuminates after the engine is started until therequired oil pressure is achieved.

NOTICE!Serious engine damage due to insufficient lubrication. If theoil pressure light remains on after starting the engine, the required oilpressure is not built up.

Turn off the engine immediately.

Immediately inspect the cause and repair possible faults by a

qualified workshop. All Textron Motors authorized workshops arequalified to repair your engine.

Malfunction indicator light (MIL) The malfunction indicator light has a self-test function. When youturn on the ignition or start the engine, the malfunction indicator lightilluminates for a few seconds.If the malfunction indicator light doesnot stop illuminating or illuminates during the operation, the enginediagnostics has detected an fault. If the malfunction indicator light isflashing, there is an emission-related fault.

Immediately inspect the cause and repair possible faults by aqualified workshop. All Textron Motors authorized workshops arequalified to repair your engine.


25/96

25SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

3 Description


Light Description

Temperature warning light If the temperature warning light is flashing or illuminating, the enginetemperature has almost been reached the critical temperature range.

Further information can be found in chapter 3.7 Protective functions.

The temperature warning light is illuminating.

Flush the sea water cooling circuit. (See chapter 4.3.6 Flushingsea water cooling circuit.)

Sediments or leaks in the sea water cooling circuit can cause thefault. Immediately inspect the cause and repair possible faults bya qualified workshop. All Textron Motors authorized workshopsare qualified to repair your engine.

The temperature warning light is flashing.

Check the coolant level. (See chapter 4.3.2 Checking coolant

level.)

NOTICE!Engine damage caused by overheating. An empty expansiontank may be an indication of a leaking cooling system. Immediatelyinspect the cause and repair possible faults by a qualified workshop.All Textron Motors authorized workshops are qualified to repair yourengine.

If the expansion tank is empty, turn off the engine immediately.

If the coolant level is significantly below the MIN-marking, let theengine cool down and refill coolant.

If the coolant level is right, adapt the way you operate. Check the

coolant level again after the engine has cooled down.


26/96

26 SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

4.1 Service intervals

4 Operation

Familiarize yourself with the vehicle before operating the engine. Read the vehicle manufacturers

documentation.

4 Operation


Regular service is essential to keep your engine in a safe operating condition. Perform all engine and vehiclerelated service tasks as described in this service manual and the vehicle manufacturers documentation.

Following service tasks you can perform yourself. All activities are described in chapter 4 Operation.

Activity Before every use After every use Every 10 h1

Inspecting exhaust and fuelsystem

Checking coolant level

Checking oil level

Flushing sea water coolingcircuit

2

Applying corrosion protection2

1 h = Hours of operation2 Only after operating in salt water


27/96

27SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

4 Operation


The following service tasks require special technical knowledge of this engine. These service tasks mustbe performed in a qualified workshop. All Textron Motors authorized workshops are qualified to service yourengine.

All activities are described in chapter 8 Service tasks in the workshop.

Activity

1st service Subsequent service intervals

Preparing for

Storage4after 12 h

every 60 hor at least

once a year


every 2 years


every 4 years

Changing engine oil and oilfilter

Checking and adjustingvalve lash

3

Replacing spark plugs

Replacing ignition coils

Replacing rubber mount

Maintaining waste gate valve(all engine modelsI2 846 MAR TC)

Checking flame arrester

Flushing sea water coolingcircuit

Checking sacrificial anode

Applying corrosion protection

Checking spark plugs Fuel stabilizer Engine internal preservation Inspecting exhaust and fuel

system

Changing coolant

After 4 years5

Replacing fuel filter

See the vehicle manufacturers documentation.

3 These service intervals are only required after the specified hours of operation4 If you do not operate the engine for more than 30 days5 Observe the coolant manufacturers recommendations for the following service intervals


28/96

28 SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

The way you operate the engine is a major factor in determining engine performance and useful life.

This affects the way you operate in the

first 5 hours of operation.

first 5 hours of operation after extensive repairs, where the engine was completely disassembled.

first minutes until the engine is warm.

Observe the following guidance to achieve optimal break-in:

Avoid engine speeds over 6000 min-1[rpm]. long periods of idle operation. long periods of operation at low engine speeds.

long periods of operation at the same engine speed. long periods of operation at full load.

Perform vary engine speed. momentary bursts of acceleration, when the engine is warm.

4.2 Operation during the break-in period

4 Operation

4.2 Operation during the break-in period


29/96

29SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

2

3

1

4.3 Operating engine

4.3.1 Inspecting the exhaust and fuel system

Exhaust system

WARNING! Engine exhaust gases contain

carbon monoxide (CO). Inhalation can deprive

the body of oxygen and result in organ damage

or death by asphyxiation.

Check exhaust system 2 hose clamps,bolts and metal parts for corrosion.

Ensure hoses are properly mounted and freeof cracks.

Fuel system

WARNING! Fuel is highly flammable. Vapors

may explosively ignite.

Check fuel system 3 hose clamps, bolts

and metal parts for corrosion.

Ensure hoses are properly mounted and freeof cracks.

Do not start the engine if you smell fuel orsee a fuel leak.

Attach and press down on the engine coveruntil it snaps into place.

4 Operation


Remove the engine cover 1 .


30/96

30 SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

3

2

1

5

4

6

4.3.2 Checking coolant level

4 Operation


Check the coolant level with a cold engine.

Check the coolant level in the expansiontank 1 .

The coolant level must be between theMIN-marking 3 and the MAX-marking

2 .

NOTICE!Overheating damage caused by too lowcoolant level.

If coolant level is below the MIN-marking,follow instructions in Refilling coolant

section.NOTICE!Overfilled coolant increases the coolingsystem pressure and may cause leaks in hoses.

If coolant level exceeds the MAX-marking,pump out excessive coolant using a suctionpump.

Refilling coolant

CAUTION! Scalding caused by hot steam. Open

expansion tank only with a cold engine.

Unscrew the expansion tank cover 4 .

Refill coolant, until the coolant level isbetween the MIN-marking 6 and theMAX-marking 5 .

Close the expansion tank.

Allow the engine to run at idle for

10 seconds. Check the coolant level.


31/96

31SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

4.3.3 Put the engine into operation

4 Operation


The following procedure is not a complete description of the commissioning, it describes only the engine-

specific requirements. Observe strictly the vehicle manufacturer's documentation.

NOTICE!Engine damage caused by overheating. If you operate the engine without sea water, the optimalengine cooling is no longer provided. Observe chapter 5.2 Operating engine without sea water.

The vehicle is placed in the water.

Put the throttle control in neutral position.

Turn on ignition and press the starter button.

or

Turn the ignition switch in the START position.

The engine will start.

Warm up the engine. (See chapter 4.2 Operation during the break-in period.)

Check the oil level. (See chapter 4.3.4 Checking oil level.)


32/96

32 SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

1

2

3

4

4.3.4 Checking oil level

Information! Your engine features a dry sump lubrication system. Engine oil is pumped from theengine into the oil tank while the engine is operating. When the engine is turned off, some engine oil flowsslowly from the oil tank back into the engine. Therefore inspect the oil level immediately after turning offthe engine.

Check the oil level with a warm engine.

Warm up the engine. (See chapter 4.2Operation during the break-in period.)

Turn off the engine.

CAUTION! Scalding caused by hot engine oil.

Wear protective gloves.

Unscrew the oil dipstick 1 from the oiltank.

Wipe the oil dipstick and insert into the oiltank. Do not screw in.

Remove the oil dipstick 2 and check oillevel.

The oil level must be between theMIN-marking 4 and the MAX-marking

3 .

NOTICE!Engine damage caused by a lack ofengine oil.

If oil level is below the MIN-marking, followinstructions in Refilling engine oilsection.

NOTICE!Engine damage caused by too muchengine oil.

If oil level exceeds the MAX-marking, pumpout excessive engine oil using an oil suctionpump.

Screw in the oil dipstick.

4 Operation



33/96

33SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

5

6

7

Refilling engine oil

NOTICE!Engine damage caused by too muchengine oil. Refill engine oil in small quantities with

repeatedly checking. The difference between theMIN-marking 7 and the MAX-marking 6 isapproximately 0,5 liter [0.5 qt (US)] engine oil.

Fill engine oil through the opening 5 of theoil dipstick until the oil level is between theMIN-marking and the MAX-marking.

Check the oil level.

4 Operation



34/96

34 SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

4.3.5 Take the engine out of operation

The following procedure is not a complete description of the decommissioning, it describes only the engine-

specific requirements. Observe strictly the vehicle manufacturer's documentation.

Put the throttle control in neutral position.

Turn off ignition.

or

Turn the ignition switch in the OFF position.

If your vehicle has a battery isolator switch or similar device, observe that after turn off the engine,data must be saved on the engine control unit. Wait at least 30 seconds, until you disconnect thepower supply of the engine from the power supply of the vehicle.

4 Operation



35/96

35SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

1

2

4.3.6 Flushing sea water cooling circuit

Damage in exhaust system caused by deposits.

Sediments may accumulate if the sea water cooling circuit is not flushedregularly after use in salt water. The exhaust system cooling jacket isparticularly susceptible to sediment accumulation.

Flush the sea water cooling circuit after each salt water use.

Take the vehicle out of water.

A 13 mm [1/2] connection 1 or 2 for theflushing device is installed on the engine. Theflushing device is attached at this connection.

Connect the flushing device. (See thevehicle manufacturers documentation.)

NOTICE!Engine damage due to water in theengine. When the engine is turned off, the water

may get into the engine through the exhaustsystem. First start the engine and then open thewater tap.

Start the engine and run the engine at idle.

Open the water tap.

The sea water cooling circuit will be flushed.Textron Motors recommends to flush the seawater cooling circuit at least for 5 minutes.

Close the water tap.


Remove the flushing device.

Information! Regularly use a cleansing concentrate to flush the sea water cooling circuit. Consultyour local vehicle dealer.

4 Operation



36/96

36 SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

4.3.7 Corrosion protection

If you operate your vehicle in salt water, regularly use a corrosion protection spray. (See chapter 4.1 Serviceintervals.)

Information! For information about suitable products and their using, please consult your localvehicle dealer.

4 Operation



37/96

37SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

4.3.8 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. (Seechapter 5.1 Engine storage for more than 30 days.)

Transport and store the vehicle on a preferably stable and flat surface. If you do not have any flatsurface 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].

4 Operation



38/96

38 SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

5.1 Engine storage for more than 30 days

Prepare the engine if you plan to store the engine for 30 days or more. Preparing the engine for storage willprevent the cylinder from corroding and ensure the engine starts again correctly at the end of the storageperiod.

Preparation for storage requires special technical knowledge of this engine. These tasks must be performedin a qualified workshop. All Textron Motors authorized workshops are qualified to prepare your engine forstorage.

5 Special scenarios

5.2 Operating engine without sea water

5.3 Towing vehicle in water

Engine damage caused by overheating.

If you operate the engine without sea water, the optimal engine cooling isno longer provided. Select one of the following procedures.

Operate the engine only at idle and only for a maximum period of30 seconds.

or

Flush the sea water cooling circuit. (See chapter 4.3.6 Flushing seawater cooling circuit.)

Engine damage due to water in the engine.

Water may enter the engine through the exhaust system if you tow thevehicle.

If your vehicle has a towing valve or a similar device, close it. Readthe vehicle manufacturers documentation for more information.

If your vehicle doesnt feature a towing valve, limit towing durationand towing speed to 16 km/h [10 mph] [9 knots].

5 Special scenarios

5.1 Engine storage for more than 30 days |


39/96

39SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

5 Special scenarios

5.4 Measures in case of flooded engine

5.4 Measures in case of flooded engine

Engine damage due to water in the engine.Water may enter the engine through the exhaust system if your vehiclehas been capsized and/or the engine compartment has been flooded. Itcan still happen even if the engine has been partially flooded. The longeryou postpone the necessary service tasks, the more severe will be theengine damage.

Do not try to start the engine.

Remove the water from the engine immediately.

Do not waste your time. Deliver your vehicle to a qualified workshopimmediately.


40/96

40 SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

6 Malfunctions

6.1 Malfunctions table

6 Malfunctions


Follow the remedy guidance or contact a qualified workshop if you cannot correct a malfunction yourself. AllTextron Motors authorized workshops are qualified to repair your engine.

Observe chapter 3.10.1 Lights in vehicle.

Condition Possible cause Remedy

The engine does not crank. The ignition is turned off. Turn on ignition.

The power supply of vehicle isdisconnected for safety reasons.

Depending on equipment of thevehicle there are several options.

Read the vehicle manufacturersdocumentation for more information.For example:

Insert the safety lanyard.

Put the throttle control in neutralposition.

Switch on the battery isolator.

After start failure the starter can staydisabled for a few seconds.

Wait a few seconds and start theengine again.

A fuse is defective. Check the engine fuses. (Seechapter 6.2 Checking engine fuses.)

Check the fuses located inthe vehicle. See the vehiclemanufacturer's documentation.

The battery is discharged ordefective.

Contact a qualified workshop.All Textron Motors authorizedworkshops are qualified to repairyour engine.

The drive train is blocked. Remove the blockage. Seethe vehicle manufacturer'sdocumentation.


41/96

41SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

6 Malfunctions


Condition Possible cause Remedy

The engine cranks, butdoes not start.

A fuse is defective or the servicefuse is unplugged.

Check the engine fuses or plug inthe service fuse. (See chapter 6.2

Checking engine fuses.)

Check the fuses located inthe vehicle. See the vehiclemanufacturer's documentation.

Lack of fuel. Fill up fuel. See the vehiclemanufacturer's documentation.

The battery is discharged ordefective.

Contact a qualified workshop.All Textron Motors authorizedworkshops are qualified to repairyour engine.

The engine stalls, but canbe started again. Lack of fuel. Fill up fuel. See the vehiclemanufacturer's documentation.

The engine stalls andcannot be started again.

No fuel. Fill up fuel. See the vehiclemanufacturer's documentation.

The engine does notprovide the full power.

There is no malfunction. The enginehas not reached the operatingtemperature yet.

There is a malfunction and a speedlimitation is activated.

Contact immediately a qualifiedworkshop. All Textron Motorsauthorized workshops are qualifiedto repair your engine.


42/96

42 SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

1

2

3

2

6 Malfunctions

6.2 Checking engine fuses


Disconnect the engine from the powersupply. (See the vehicle manufacturersdocumentation.)

The engine fuses and relays are located in thefuse box on the engine. (See chapter 3.6 Enginecomponents and information.)


Risk of fire caused by incorrect or bridged fuse.The fuse protects the cable from cable fire. A higher amperage ratingbypasses this protection.

Never use a higher ampere rating.

Never bypass a fuse.

Two spare fuses2

provided by factory can befound in the fuse box. (See chapter 3.7 Enginefuses and relays.)

Remove the fuse 3 .


43/96

43SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

5

6

4

6 Malfunctions


Insert the fuse 5 .

Repeat the procedure with other fuses.

Insert the cover 6 into the fuse box.

Connect the power supply to theengine. (See the vehicle manufacturersdocumentation.)

Check the fuse.

The wire 4 in the fuse must to beintact.

If the wire is damaged, replace the fuse.


44/96

44 SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

7 Dealer and servicing network

7.1 Locating a workshop

An extensive global dealer and servicing network is available. The dealer and servicing network providesassistance with any queries relating to the engine. Visit our web site www.textronmotors.com for a list of allauthorized Textron Motors workshops.

7.2 Tools and parts

Textron Motors offers a selection of accessories to prepare you for the most important situations. Visit yourlocal vehicle dealer or our web site www.textronmotors.com for more information.

7.3 Repairs

Repairs require special technical knowledge of this engine. All Textron Motors authorized workshops arequalified to repair your engine.

7 Dealer and servicing network

7.1 Locating a workshop |


45/96

45SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

8 Service tasks in the workshop

8.1 Safety messages workshop


8.1 Safety messages workshop

All service tasks described in the following chapter require specialtechnical knowledge of this engine.

Ensure your workshop is qualified to service your engine.

All Textron Motors authorized workshops are qualified to serviceyour engine.

Before reading chapter 8 Service tasks in the workshop, you must haveread and understood all other information in the service manual.

Read the entire 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 powersupply. Starting the engine inadvertently may endanger the safety ofpersons.

Read the vehicle manufacturers documentation for moreinformation.

Disconnect the engine from the power supply before performingany 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 mayendanger the safety of persons.

Take the vehicle out of the water to perform any service tasks.

Missing protective equipment poses a safety risk to persons.

Attach all protective equipment after completing the service tasks.

Unsuitable tools pose a safety risk to persons.

Use tools listed in chapter 8.2 Tools and accessoriesor equivalenttools.

Serious eye injuries caused by sudden release of spring band clamps.

All persons in the area must wear protective glasses.

Observe the tool manufacturers instructions.

Service tasks in the workshop

Service manual

Engine power supply

Workspace

Protective equipment

Tools

Spring band clamps


46/96

46 SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

8.2 Tools and accessories

Textron Motors offers a service case that contains the following service parts. Visit your local vehicle dealeror our web site www.textronmotors.com for more information.

8.2.1 Service parts



Figure Description

Oil filter

O-rings for oil filterchange

Spark plugChampion RC7PYCBX

Feeler gauge0,05 2 mm

Sealing kit valve cover

Figure Description

Valve adjustmentshims in different sizes

Serrated lock washer

Valve adjustment kit

Sacrifical anodeincluding seal

Seal for sacrificalanode

For the service intervals every 4 years, you also need the following parts:

Figure Description

Ignition coil

Figure Description

Rubber mount


47/96

47SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |



Textron Motors offers a diagnostic case that

contains the Textron Motors Diagnostic Tool. TheTextron Motors Diagnostic Tool is designed for faultdiagnostics and service tasks for Textron enginesusing a Synerject engine management system.Visit your local vehicle dealer or our web sitewww.textronmotors.com for more information.

8.2.2 Textron Motors diagnostic case


48/96

48 SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

8.2.3 Equipment workshop

Figure Description

Torque wrench2 50 Nm[1 37 lbf ft]with extension andinsert adapter

Reversible ratchetwith extension andinsert adapter

Hexagon screwdriver 5

Hexagon screwdriversocket 5

Torx screwdriverT30

Torx screwdriversocketT30

Hexagon nut-driver7

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.

Figure Description

6-point socket wrench7

Open-end wrench10, 15, 17

Insert open-endwrench15, 17

Caliper

Measuring accuracy0,05 mm

Bar magnet

Spark plug wrenchWrench size 16 mm[5/8]Diameter: maximum22 mm [0.87 in]

Spark plug brush




49/96

49SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |



Figure Description

Oil suction pump

Drain tray

Hose clamp pliers forspring band clamps


50/96

50 SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

You will require the following supplies or equivalents to perform service tasks. Unless otherwise specified,

use the products as directed by the manufacturer.

Supplies Recommended products

Cleansing concentrate for flushing the sea watercooling circuit

Stopsel, Kalyscom France Salt-Away, Salt-Away Products Inc. USA

Anti-Seize assembly paste for lubricating threadedconnections

Weicon Anti-Seize "High-Tech" ASW 040 P Loctite 8150

Engine internal preservative Liqui Moly, Germany

Fuel stabilizer Liqui Moly, Germany

Sealing surface cleaner Liqui Moly brake and parts cleaner AIII, Germany

Corrosion protection spray

Wrth corrosion protection spray, GermanyThe product must be salt water resistant andsuitable 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 K&N Power Kleen, Netherlands

8.2.4 Supplies




51/96

51SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

2

1

8.3 Changing engine oil and oil filter

Information! The engine oil will be pumped out in two stages. First as much as possible engine oilwill be pumped out from the oil tank. The remaining engine oil will be pumped out with the suction pump inthe dry sump.

CAUTION! Scalding caused by hot engine oil.

Wear protective gloves.

Unscrew the oil dipstick 2 from the oiltank.



Warm up the engine. (See chapter 4.2Operation during the break-in period.)




52/96

52 SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

5

6

4

3

The engine fuses and relays are located in thefuse box on the engine. (See chapter 3.6 Enginecomponents and information.)


Ignition coils and injectors are supplied withelectricity through the service fuse. When theservice fuse is removed, you can rotate the engineusing the starter avoiding starting the engine.

Remove the service fuse 6 .



Pumping out engine oil

Insert the suction hose of the oil suctionpump through the opening in oil dipstick 3

until the hose reaches the oil tank bottom4 .

Pump out the engine oil from oil tank.


53/96

53SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

8

9

10

7

7

Lift the oil tank 8 from the oil tank bracket9 .

NOTICE!Breakage risk due to work on the oil tank.When removing the hose from the oil tank, youneed to move the oil tank. This can brake the oiltank pins.

Put the oil tank beside 10 the oil tankbracket.



Unscrew the bolts 7 on the oil tank.


54/96

54 SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

15

16

19

20

18

17

11

12

13

14

Connect the hose 18 with the oil tank.

Close the hose clamp 17 .

Tightening torque:

3 Nm +0,5 Nm [2.2 lbf ft +0.4 lbf ft]

Connect the hose 16 to the oil tank.


Tightening torque:

5 Nm +0,5 Nm [3.7 lbf ft +0.4 lbf ft]

Replacing oil filter

Hold the oil filter 19 .

Unscrew the banjo bolt 20 .

Remove the oil filter.



Open the hose clamps 11 and 13 .

Hold the hoses 12 and 14 over a draintray. Extend hoses if necessary.

Actuate the starter.

The engine cranks and the engine oil will bepumped out of the engine.


55/96

55SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

26

27

28

22

23

21

24

25

25

Hold the oil filter 26 in position.

Screw in the banjo bolt 27 .

Tightening torque:

14 Nm +2 Nm [10.3 lbf ft +1.5 lbf ft]

Insert the service fuse 28 .



Clean the sealing surface 23 with sealingsurface cleaner.

Replace the oil filter 21 .

Coat the oil filter seal 22 lightly with engineoil.

Replace both o-rings 25 on the banjo bolt24 .

Coat the o-rings and thread lightly withengine oil.


56/96

56 SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

30

31

32

32

29

Lift the oil tank 30 and insert it into the oiltank bracket 31 .

Screw in the bolts 32 at the oil tank.

Tightening torque:

8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft]



Insert the cover 29 into the fuse box.


57/96

57SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

35

34

33

Screw in the oil dipstick 35 .

Check the oil level. (See chapter 4.3.4Checking oil level.)

Touch up paintwork defects.

Clear the service counter for service light.(See the Textron Motors Diagnostic Toolmanual.)

Update the engine control unit calibration.(See the Textron Motors Diagnostic Toolmanual.)

Test-drive the vehicle.



Filling with engine oil

Fill 2,5 liter [2.6 qt (US)] of new engine oilthrough the opening 34 of the oil dipstick.

Attach and press down on the engine cover33 until it snaps into place.


58/96

58 SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

2

1

3

4

8.4 Checking sacrificial anode

Unscrew the sacrificial anode 1 .

Information! The water jacket in the exhaust manifold is protected from corrosion by a passivecathodic protection.

Check the sacrificial anode 2 .

At least half of the original size 60 mm[2.4 in], 16 mm [0.6 in] remains.

If the sacrificial anode is less than half of theoriginal size, replace the sacrificial anode.

Replace the seal 4 .

Screw in the sacrificial anode 3 .

Tightening torque:

41 Nm +9 Nm [30.2 lbf ft +6.6 lbf ft]



8.4 Checking sacrificial anode


59/96

59SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

2

4

5

3

1

8.5 Checking and adjusting valve lash

Check valve lash 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 connectorsfrom the ignition coils 2 and sensorcamshaft 3 .

8.5.1 Checking valve lash

Unscrew the bolts 4 .

Pull the ignition coils 5 out.





60/96

60 SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

6

7

10

9

8


Remove the valve cover 7 .

Information! The camshaft is turned by turning the crankshaft. Read the vehicle manufacturersdocumentation for instructions. 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 onerotation of the camshaft.

Check the valve lash 10 of all valves on thecylinder using a feeler gauge.

Required valve lash:

0,2 0,3 mm

If the valve lash of one or more valves is notright, continue with chapter 8.5.2 Adjustingvalve lash.

Checking valve lash on the 2nd cylinder

Turn the camshaft until the position of thecamshaft is as illustrated. (See the vehiclemanufacturers documentation.)

The camshaft is marked at the 2nd cylinder endonly.

The marking 8 ends flush with the crossbar.

All rocker arms 9 on the cylinder have acertain amount of play.




61/96

61SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

13

12

11

14

15

Check the valve lash 13 of all valves on thecylinder using a feeler gauge.

Required valve lash:

0,2 0,3 mm

If the valve lash of one or more valves is notright, continue with chapter 8.5.2 Adjustingvalve lash.

Checking valve lash on the 1st cylinder

Turn the camshaft until the position of thecamshaft is as illustrated. (See the vehicle

manufacturers documentation.)


The inscription 11 is not visible.


Replace the valve cover seals 14 .



Clean the sealing surface 15 with sealingsurface cleaner.


62/96

62 SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

5

3

7

1

8

16

2

6

4

18

22

20

21

17

19

23

24

25

Put the valve cover 16 on.

Apply Anti-Seize assembly paste to all bolts17 .

Screw in the bolts in the sequence asillustrated 18 .

Tightening torque:


Insert the ignition coils 19 .

Replace the serrated lock washers 20 .

Assemble the bolts 21 , washers 22 andserrated lock washers as illustrated.

Tightening torque:


Connect the wire harness connectors to the

ignition coils23

and sensor camshaft24

. Touch up paintwork defects.

Clear the service counter to reset servicelight. (See the Textron Motors DiagnosticTool manual.)







63/96

63SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

2

1

4

3

8.5.2 Adjusting valve lash

Adjusting valve lash 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.



The marking 1 ends flush with the crossbar.


Continue with the section Replacing valve

adjustment shim.

Information! The camshaft is turned by turning the crankshaft. Read the vehicle manufacturersdocumentation for instructions. 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 onerotation of the camshaft.



Adjusting valve lash on the 1st cylinder



The marking 3 ends flush with the cross

bar. Otherwise, no inscription is visible.


Continue with the section Replacing valveadjustment shim.


64/96

64 SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

10

11

12

9

8

5

7

6

Press down on the slide plate 11 using therocker arm pusher 10 until the pin 12 engages.

Replacing valve adjustment shim

NOTICE!Engine damage from small componentsin the engine or cylinder head. Operating the

engine when there are small components in thecrankcase and cylinder head can result in seriousdamage and cause the crank drive to seize.

Cover the chain channel 6 .

Hold the valve adjustment tool 7 inposition.

Screw in the bolts 5 .

Tightening torque:


Position the rocker arm pusher 8 on therocker arm 9 .




65/96

65SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

14

15

16

13

17

18

Remove the valve adjustment shim 13 using a bar magnet.

Measure the valve adjustment shim using a

caliper. Insert the new valve adjustment shim.

Hold the rocker arm pusher 14 in position. Press down on the slide plate 15 slightly

using the rocker arm pusher.

Slide the pin 16 forward by hand.

Slowly release the rocker arm pusher.

The valve spring slides the slide plateupwards again.




Remove the valve adjustment tool 18 .

Remove the cover from the chain channel.

NOTICE!Valve breakage due to insufficientvalve lash.

Check the valve lash.

Continue with chapter 8.5.1 Checkingvalve lash.


66/96

66 SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

2

3

4

1

8.6 Replacing spark plugs and ignition coils

Remove the spark plugs with a cold engine.

Disconnect the wire harness connectorsfrom the ignition coils 2 .

Unscrew the bolts3

. Pull the ignition coils 4 out.





67/96

67SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

10

9

7

8

6

5

11

The ignition coils must not be replaced always.(See chapter 4.1 Service intervals.)

Replace the ignition coils 6 . Insert the ignition coils.

Replace the serrated lock washers 7 .Assemble the bolts 8 , washers 9 andserrated lock washers as illustrated.

Tightening torque:


Connect the wire harness connectors to theignition coils 10 .






Unscrew the spark plugs 5 using a sparkplug wrench.

Replace the spark plugs.

Screw in the spark plugs using a spark plugwrench.

Tightening torque:

22 Nm +10 Nm [16.2 lbf ft +7.4 lbf ft]




68/96

68 SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

2

3

4

1

8.7 Checking spark plugs

Remove the spark plugs with a cold engine.

Disconnect the wire harness connectorsfrom the ignition coils 2 .

Unscrew the bolts3

. Pull the ignition coils 4 out.





69/96

69SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

8

6

7

5

Screw in the spark plugs 8 using a sparkplug wrench.

Tightening torque:

22 Nm +10 Nm [16.2 lbf ft +7.4 lbf ft]

If the electrodes 6 are extremely sooty,clean carefully using a spark plug brush.

Check the spark plug gap 7 using a feelergauge.

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 thespark plugs in pairs.



Unscrew the spark plugs 5 using a sparkplug wrench.


70/96

70 SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

13

12

10

11

9

14

Connect the wire harness connectors to theignition coils 13 .

Touch up paintwork defects. Test-drive the vehicle.



Insert the ignition coils 9 .

Replace the serrated lock washers 10 .Assemble the bolts 11 , washers 12 and

serrated lock washers as illustrated.

Tightening torque:


Attach and press down on the engine cover14

until it snaps into place. Test-drive the vehicle.


71/96

71SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

5

2

4

4

1

3

8

7

6


8.8 Replacing rubber mount


Open the spring band clamps 4 .

Remove the hose 5 .

Engine modelsI2 846 MAR TC-80, TC-100, TC-120 and NA-80

Remove the rubber mount with a cold engine.

Mark 2 the hose 1 and intercooler 3 .

Disconnect the wire harness connector 6 from the throttle body 7 .

Open the hose clamp 8 .


72/96

72 SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

12

13

9

10

11

Insert the hose clamp 13 and throttle body12 .



Remove the throttle body 9 .

Unscrew the bolts 10 . Remove the rubber mount 11 .

Replace the rubber mount.

Hold the rubber mount in position.

Screw in the bolts.

Tightening torque:



73/96

73SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

14

16

15

15

2

1

1




Tightening torque:

3 Nm +0,5 Nm [2.2 lbf ft +0.4 lbf ft]

Insert the hose 16 .

Observe the marking.

Close the spring band clamps 15 .




Turn on the ignition for about a minute, untilthe throttle body opens and closes again.


Engine model I2 846 MAR TC-155

Remove the rubber mount with a cold engine.

Open the hose clamps 1 .

Remove the connecting pipe 2 .


74/96

74 SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

7

8

5

4

3

6


Remove the rubber mount 8 .

Replace the rubber mount.

Hold the rubber mount in position.

Screw in the bolts.

Tightening torque:




Disconnect the wire harness connector 3 from the throttle body 4 .


Remove the throttle body 6 .


75/96

75SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

11

9

10

13

12

12



Insert the hose clamp 10 and throttle body9 .


Tightening torque:

3 Nm +0,5 Nm [2.2 lbf ft +0.4 lbf ft]

Hold the the connecting pipe 13 in position.

Close the hose clamps 12 .

Tightening torque:

3 Nm +0,5 Nm [2.2 lbf ft +0.4 lbf ft]



Update the engine control unit calibration.(See the Textron Motors Diagnostic Tool

manual.)

Turn on the ignition for about a minute, untilthe throttle body opens and closes again.



76/96

76 SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

1

2


8.9 Maintenance waste gate valve


Waste gate valve version 1 1

Waste gate valve version 2 2


77/96

77SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

4

1

2

5

3

Engine models I2 846 MARTC-80, TC-100, TC-120 and TC-155

Maintain the waste gate valve with a cold engine.

Observe the indicated directions of rotation 1 .One nut 4 has a left-hand thread.

Hold the spanner nut 3 with a wrench.

Open the two nuts 2 4 in direction ofrotating.

Open the spanner nut 5 in the indicateddirection of rotation until no longerpretensioning exists

8.9.1 Maintaining waste gate valve version 1




78/96

78 SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

7

8

6

11

9

10

Close the spanner nut in the indicateddirection of rotation until the followingconditions are met.

The lever 7 does not move anymore.

The thread rod 6 has not moved yet.

Attach the marking 8 . Close the spanner nut with two full turns in

the indicated direction of rotation.

Close the two nuts 10 11 in direction ofrotation 9 .








79/96

79SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

3

1

7

6

2

4

5


Maintain the waste gate valve with a cold engine.

Observe the indicated directions of rotation 1 .One nut 4 has a left-hand thread.

Hold the spanner nut 3 with a wrench.

Open the two nuts 2 4 in direction ofrotating.

Open the spanner nut 5 in the indicateddirection of rotation until no longerpretensioning exists

8.9.2 Maintaining waste gate valve version 2



Close the spanner nut in the indicateddirection of rotation until the followingconditions are met.

The lever 7 does not move anymore.

The thread rod 6 has not moved yet.


80/96

80 SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

11

9

10

11

Attach the marking 8 .

Close the spanner nut with two full turns inthe indicated direction of rotation.

Close the two nuts 10 11 in direction ofrotation 9 .








81/96

81SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

3

2

1

4


8.10 Checking flame arrester



Cleaning flame arrester

Open the clamp 3 .

The clamp built in by the engine manufacturerin these place is destroyed during removal. Afterremoving the clamp must be replaced by a hoseclamp.

Remove the hose 2 .


Check the flame arrester 1 .

The fabric must be visible.

If the fabric is no longer visible, followinstructions in Cleaning flame arrestorsection.


82/96

82 SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

5

6

8

7



Remove the flame arrester 5 .

Clean the flame arrester with cleaning sprayaccording to the manufacturer's instructions.

Attach the flame arrester.


Tightening torque:

4,5 Nm +1 Nm [3.3 lbf ft +0.7 lbf ft]

Replace the clamp 8 .

Insert the hose 7 .

Close the hose clamp.

Tightening torque:

3 Nm +0,5 Nm [2.2 lbf ft +0.4 lbf ft]






83/96

83SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

2

4

3

1

Remove the cover 2 . Check the flame arrester 3 .

The fabric must be visible.

When the fabric filter is no longer visible,continue with section Cleaning the flamearrestor.



Cleaning flame arrester


Engine model I2 846 MAR NA-80

Unscrew 7 bolts 1 .


84/96

84 SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

7

6

5

8




Tightening torque:

3 Nm +0,5 Nm [2.2 lbf ft +0.4 lbf ft]

Place the cover 8 .

Screw in 7 bolts 7 .

Tightening torque:

4,5 Nm +1 Nm [3.3 lbf ft +0.7 lbf ft]


Clear the service counter to reset service

light. (See the Textron Motors DiagnosticTool manual.)



Remove the flame arrester 5 .

Clean the flame arrester with cleaning sprayaccording to the manufacturer's instructions.

Attach the flame arrester.


85/96

85SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |

2

1

3

8.11 Changing coolant

Draining coolant

Place the drain tray under the fitting 3 onheat exchanger.


Remove the hose and keep it over the draintray.

Coolant drains off.

Drain the coolant with a cold engine.

Un

Documents

MPE 850 marine Service Manual