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M0114K33
STEYR MOTORS M0114K33 User Manual
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STEYR MOTORS GmbH
Im Stadtgut B1, A-4407 Steyr-Gleink, AUSTRIA
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STEYR MARINE ENGINES
SER
VICE MANUAL
P/N Z001019/0 6
th
Edition July 2008
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Table of Contents
Table of Contents
9
Default Chapter
3
Z001019/0_6_July
3
Table of Contents
9
Ageneral Remarks
11
A 1 Model and Serial Numbers
11
A 2 Documentation
12
A 3 Model Summary
13
A 3.1 Model Summary 4 Cylinder Engines
13
A 3.2 Model Summary 6 Cylinder Engines
16
Technical Data and Overview
20
A 4.1 Technical Data and Overview 4 Cylinder Engines
20
A 4.2 Technical Data and Overview 6 Cylinder Engines
24
B Specifications
28
Fuel Requirements
28
How to Select Fuel Oil
28
B 2 Motor Oil
29
C Maintenance and Service
30
Trouble Check Chart
30
C2 Service- and Maintenance Schedule
32
General Information
34
Electronic Engine Management System (ECU)
34
Diagnostic System
35
D 3 Extended Storage Preservation Procedure
36
D 4 Engine Break-In Procedure
38
First Two Hours
38
D 5 Operation after Break-In
40
E 1 Spare Parts Specification
42
E 2 Workshop Profile
42
E Quality Gudelines for Repair
42
E 3 Nomenclature
43
E 4 SI- System
44
E 5 Abbreviations
45
F 1 List of Operating Material
46
F Operating Material and Information on Disposal
46
F 2 Disposal of Automotive Waste Products
47
G 1 General Notes on Safety
48
G 2 Guidelines for Damage Prevention
48
G 3 Legal Rules
48
Gnotes on Safety
48
G 4 Safety in the Use of Operating Material
49
G 5 Measures in Case of Accidents
49
H 1 Listing of Thightening Torques
50
H Thightening Torques
50
General Tightening Torques
55
H 3 Testing of Torque Wrench
56
H 4 Non-Destructive Material Testing
56
H 5 Use of Adhesive and Sealing Materials
56
H 6 Solvent-Free Sealing Materials
56
J Wear Limits
58
J 1 Adjustment Information for Service and Maintenance
59
Table of Contents
61
Engine Timing, Engine Mount
63
Lock Crankshaft
63
Exchange Camshaft Housing Cover Sealing
66
Maintenance Timing-Belt Exchange
67
Remove Timing Belt
75
Timing Adjustment Procedure for Dismantled Engine
76
Replace Engine Mount and Engine Bracket
86
Cylinder Block
88
Replace Valves
88
Adjust Valve Clearance
90
Replace Valve Guide
90
Replace Pressure Regulating Valve for Oil Cooling Jet
91
Replace Stud Bolt for Unit Injector
92
Replace Dowel Pin for Positioning of Unit Injector
93
Replace Dowel Pin for Positioning of Camshaft Housing
94
Replace Coolant Supply Pipe
95
Replace External Screw Adaptor for Oil Cooler
95
Mount Frame Seal
96
Crankshaft, Bearing, Vibration Damper
98
Replace Crankshaft
98
Replace Gear for Oil Pump Drive
102
Flywheel, Housing
103
Replace Flywheel Housing
103
Replace Flywheel
104
Replace Adapter Ring
105
Dismantle Piston and Connecting Rod
106
Piston and Connecting Rod
106
Camshaft, Housing, Valve Gear
108
Replace Camshaft Housing
108
Replace Valve Stem Gasket (on Engine Assembly)
112
Replace Control Rack
114
Replace Camshaft
116
Replace Rocker Arm Shaft
118
Replace Radial Shaft Seal of Camshaft
119
Replace Cam Follower
120
Replace Retainer of Cam Follower
121
Replace Valve Adjusting Element
122
Engine Housing, Oil Pump, Oil Suction Pipe
123
Replace Engine Housing
123
Replace Support Ring Rear
130
Replace Rear Radialshaft Sealing Ring
131
Replace Oil Pump (Front Ring Carrier)
132
Replace Oil Suction Pipe
133
Assembly of Intercooler
134
Intercooler
134
Remove Intercooler
134
Replace Intercooler - Element
139
Auxiliary Drive, in Front (PTO)
141
Engine Oil Cooler
142
Replace Engine Oil Cooler
142
Repair Oil Cooler
144
Change Motor Oil
145
Change Oil Filter
146
Exhaust Manifold, Seals, Heat Exchanger
147
Table of Contents
155
Fuel System / Functional Description
156
Fuel Pump, Unit Injector, Lines
158
Replace Fuel Pump
158
Disassembly and Assembly of Unit Injector
161
Fix Control Rack
168
Adjust Control Link (Injection Quantity)
169
Loosen Fixing of Control Rod
170
Adjust Start of Injection
171
Exchange Check Valve for Fuel Pre-Pressure to Unit Injector
174
Air Filter
175
Change Air Filter
175
Replace Turbocharger
176
Turbocharger
176
Check Bearing Clearance
179
Control Solenoid
180
Remove Control Solenoid
180
Install Control Solenoid
182
Replace Sensor, Indication of Control Rack Position
183
Change Fuel Filter
184
Replace Glow Plug
185
Measurement of Compression Pressure
186
Fuel System Check
188
Manual Injection Test Methode
188
Disengagement Methode of Injection
190
Air Bubble Formation in Fuel System
191
Table of Contents
197
Functional Description Cooling Circuit
198
Raw Water Circuit (External Cooling Circuit)
198
Closed Coolant from Cooling Circuit (Internal Engine Cooling Circuit)
200
Error Detection Cooling System
202
Check Points for Problems in Cooling System
205
Component Check Raw Water System
206
Drain the Coolant System
209
Fill the Cooling System
211
Coolant Tank
212
Cooler, Heat Exchanger, Expansion Tank
212
Disassembly Exhaust Manifold - Heat Exchanger
213
Checks
217
Exchange Heat Exchanger Element
219
Assembly of Exhaust Manifold
220
Exchange Additional Oil Cooler (Only Type 246)
222
Exchange Tandem Cooler
222
Coolant Pipes and Hoses
223
Exchange Triple Cooler
223
Pipes, Thermostat
223
Exchange Thermostat
224
Exchange Sacrificial Anodes
226
Coolant Pump
227
Exchange Coolant Pump
227
Install Coolant Pump
228
Exchange Poly-V-Belt
229
Poly-V-Belt
229
Exchange V-Belts
230
V-Belt
230
Adjust V-Belts
232
Exchange Raw Water Pump
233
Raw Water Pump
233
Check Closed Engine Cooling System for Air
234
Checks
234
Table of Contents
235
Alternator
238
Adjust Poly-V-Belt Tension
238
Technical Data of Alternator
240
Check Alternator (Error Detection for BOSCH Alternator, 4 Cyl. Engines)
248
Replace Starter Motor
250
Check Starter
251
Battery Cable Lengths and Cross-Sections
253
Cables, Wiring Harness - General
253
E - Box Base Plate; to Eng.no.: 482 17 000
254
Components of E - Box
255
Connection Relay Socket for K24, K26-1, K26-2 and K27
255
Connection Start Assist Relay K28
255
Wiring Harness; to Eng.no.: 482 17 000
256
E - Box Base Plate; from Eng.no.: 482 18 000/682 18 000 + SOLAS
262
Components of E - Box
263
Connection Relay Socket for K24, K26-1 and K27
263
Wiring Harness; from Eng.no.: 482 18 000/682 18 000 + SOLAS
264
Electronic Engine Management System
270
Electronics - General
270
Diagnostic System
271
Reading Error Codes
272
Principle Failure Code List
274
Replace Fuses
276
Connection J
277
Connection A5 and X5
278
Fitting Main Connector "J1" Properly
279
Instrument Panel
280
Chart - Error Indication on Instrument Panel
282
Instrument Panel (for SOLAS Only)
286
Used - Old Version
292
Cyl. Wiring Harness Instrument Panel (if Alternator "PRESTOLITE" Is Used - Old Version)
293
Description - Wiring Harness Instrument Panels 4/6 Cyl. Marine Engines (Current Version)
296
Adjust Instruments
302
Tachometer with Running-Time Meter
302
General Notes on Safety
304
Replace Instruments
304
Audible Warner, H22
306
Circuit Diagram Oil Pressure Gauge (Optional, Sensor B19-Gauge P2)
307
Circuit Diagram Voltmeter (Optional)
307
Potentiometer Accelerator, B13
308
Voltage Regulator 24V-12V Equalizer
309
DC-DC Converter
310
Component Configuration 4 Cyl. Engine
312
Component Configuration 6 Cyl. Engine
314
Calibration of Rack Position
316
Potentiometer Accelerator B13
318
Check Rack Position Feedback Sensor B14 (= Connector X14)
319
Check Sensors and Switches
319
Check Throttle Potentiometer B13 (Accelerator) (= Connector X13)
321
Check Speed Sensor B15 And/Or Wiring
323
Check Oil Pressure Sensor B18 And/Or Wiring
324
Check Oil Pressure Sensor "VDO-Instrument" (Option B19)
325
Check Coolant Temperature Sensor, B16
326
Check Audible Warner
327
Battery
328
4
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STEYR MOTORS M0114K33 Specifications
General
Number of Cylinders
4
Engine Type
Diesel
Cooling System
Liquid-cooled
Fuel System
Direct Injection
Cylinders
Inline
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