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STEYR MOTORS M0164M40 User Manual

STEYR MOTORS M0164M40
329 pages
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www.steyr-motors.com
STEYR MOTORS GmbH
Im Stadtgut B1, A-4407 Steyr-Gleink, AUSTRIA
4 CYLINDERS
+ 6 CYLINDERS
STEYR MARINE ENGINES
SERVICE MANUAL
P/N Z001019/0 6
th
Edition July 2008
4 CYLINDERS
+ 6 CYLINDERS

Table of Contents

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STEYR MOTORS M0164M40 Specifications

General IconGeneral
Engine TypeDiesel
Number of Cylinders4
Displacement1.6 L
Cooling SystemLiquid cooled
AspirationTurbocharged
Fuel SystemCommon Rail
CylindersIn-line

Summary

GENERAL

A General Remarks

General information and remarks about STEYR marine engines.

B Specifications

Details essential specifications including fuel and oil requirements for optimal engine performance.

C Maintenance and Service

Outlines maintenance schedules and troubleshooting procedures for common engine issues.

D General Information

Covers engine management systems, diagnostics, and operational guidelines.

E Quality Gudelines for Repair

Sets standards for spare parts and workshop practices to ensure quality repairs.

F Operating Material and Information on Disposal

Lists necessary operating materials and provides guidance on proper disposal methods.

G Notes on Safety

Emphasizes critical safety instructions and precautions for handling the engine and its systems.

H Tightening Torques

Specifies torque values for critical fasteners to ensure proper assembly and function.

J Wear Limits

Defines acceptable wear limits for engine components to maintain performance and longevity.

ENGINE

01.00 Engine timing, engine mount

Covers procedures for setting engine timing and replacing engine mounts.

01.01 Cylinder block

Details operations related to the engine's cylinder block, including valve replacement.

01.02 Crankshaft, bearing, vibration damper

Describes procedures for replacing the crankshaft, bearings, and vibration damper.

01.03 Flywheel, housing

Covers tasks related to the flywheel and its housing, including replacement.

01.04 Piston and connecting rod

Outlines procedures for dismantling and assembling pistons and connecting rods.

01.05 Camshaft, housing, valve gear

Details operations related to the camshaft, housing, and valve train components.

01.06 Engine housing, oil pump, oil suction pipe

Covers disassembly and assembly of the engine housing, oil pump, and suction pipe.

01.08 Intercooler

Describes procedures for removing and assembling the intercooler.

01.09 Auxiliary drive, in front (PTO)

Details the removal and installation of the auxiliary drive or Power Take-Off (PTO).

01.13 Engine oil cooler

Covers procedures for replacing and repairing the engine oil cooler.

01.14 Exhaust manifold, seals, heat exchanger

Refers to procedures for servicing the exhaust manifold, seals, and heat exchanger.

COUPLING

02.01 Replace torsion coupling

Provides instructions for replacing the torsion coupling for different engine types.

FUEL SYSTEM

03.00 Fuel system / Functional description

Provides a functional overview of the fuel system and its components.

03.02 Fuel pump, unit injector, lines

Covers the replacement and adjustment procedures for the fuel pump, unit injectors, and lines.

03.04 Air filter

Details the process for changing the air filter on STEYR marine engines.

03.05 Turbocharger

Outlines procedures for replacing the turbocharger and checking its bearing clearance.

03.08 Control solenoid

Covers the removal, installation, and replacement of the control solenoid and related sensors.

03.09 Change fuel filter

Provides instructions on how to change the fuel filter to prevent system contamination.

03.11 Replace glow plug

Details the procedure for replacing glow plugs, including torque specifications.

03.12 Measurement of Compression Pressure

Explains how to measure engine compression pressure using specialized tools.

03.14 Fuel system check

Guides on performing manual injection tests and checking for air bubbles in the fuel system.

EXHAUST SYSTEM

04.01 Hi-Riser

Covers the replacement of the Hi-Riser, including disassembly and assembly steps.

04.01.02 Measurement of Exhaust Backpressure

Explains how to measure exhaust backpressure to ensure optimal engine performance.

COOLING SYSTEM

05.00 Functional description cooling circuit

Provides a functional overview of the engine's cooling circuits, including raw water and closed coolant systems.

05.01 Cooler, heat exchanger, expansion tank

Details the components of the cooling system's heat exchange and expansion systems.

05.03 Pipes, thermostat

Covers maintenance and replacement procedures for coolant pipes, hoses, and the thermostat.

05.04 Coolant pump

Outlines the procedures for exchanging and installing the engine's coolant circulating pump.

05.06 Poly-V-Belt

Details the process for exchanging the Poly-V-belt on 4-cylinder engines.

05.07 V-belt

Covers the exchange and adjustment of V-belts for alternators, servopumps, and raw water pumps.

05.10 Raw water pump

Provides instructions for exchanging the raw water pump for different engine versions.

05.12 Checks

Details checks for air in the closed engine cooling system and troubleshooting coolant loss.

ELECTRICAL SYSTEM

06.00 General

Covers general information on wiring, cable numbers, and principal functions according to DIN 72 552.

06.01 Alternator

Details procedures for adjusting belt tension and replacing the alternator.

06.03 Replace starter motor

Outlines the steps for replacing the starter motor and checking its components.

06.05 Cables, wiring harness - general

Provides information on battery cable sizing and general wiring harness considerations.

06.05.02 E - box base plate; to eng.no.: 482 17 000

Illustrates the E-box base plate components and connection details for specific engine numbers.

06.05.03 E - box base plate; from eng.no.: 482 18 000 / 682 18 000 + SOLAS

Shows E-box base plate components and connections for later engine models and SOLAS versions.

06.05.04 Wiring harness; to eng.no.: 482 17 000

Details the wiring harness designations and their functions for specific engine numbers.

06.05.03.04 Wiring harness; from eng.no.: 482 18 000 / 682 18 000 + SOLAS

Lists wiring harness designations and functions for later engine models and SOLAS versions.

06.06 Electronics - general

Provides general information on the Electronic Engine Management System (EMS) and diagnostic procedures.

06.06.01 Electronic Engine Management System

Explains the functions of the EMS, including engine control, self-diagnostics, and power reduction.

06.06.02 Diagnostic system

Details the EMS diagnostic capabilities, fault storage, and error code retrieval.

06.06.03 Reading Error Codes

Explains how to read stored error codes using a diagnostic tool or check engine lamp.

06.06.04 Indication and Cancellation of memorized sensor and circuit faults

Guides on selecting, indicating, and clearing memorized sensor and circuit faults from the EMS.

06.06.05 Principle failure code list

Lists common failure codes, involved devices, and possible causes for engine system faults.

06.06.06 Replace fuses

Provides instructions for replacing automatic circuit breakers and standard fuses.

06.06.07 Connection J1

Details the pin assignments and explanations for the J1 connector.

06.06.08 Connection A5 and X5

Shows the connection details for the A5 and X5 connectors, including pin assignments and component descriptions.

06.06.09 Fitting main connector "J1" properly

Illustrates the correct procedure for fitting the main connector "J1".

06.07 Instrument panel

Describes the components and indicators of the standard instrument panel.

06.07.01 Chart - Operating Status

Explains normal operating status indications and system checks for the instrument panel.

06.07.02 Chart - Error indication on Instrument Panel

Details error indications on the instrument panel for various fault conditions.

06.07.03 Instrument panel (for SOLAS only)

Describes the instrument panel layout and indicators specifically for SOLAS compliant units.

06.07.04 Chart - Operating Status (for SOLAS only)

Explains instrument indications during normal operation for SOLAS compliant systems.

06.07.05 Error Indication - Error indication on instrument panel (for SOLAS only)

Details error indications on the instrument panel for SOLAS systems under various fault conditions.

06.07.10 6 Cyl. Wiring harness instrument panel (if alternator "PRESTOLITE" is used - old version)

Lists components and descriptions for the 6-cylinder instrument panel wiring harness (old version).

06.07.11 Description - Wiring harness instrument panels 4/6 cyl. marine engines (current version)

Describes the wiring harness for 4/6 cylinder marine engines (current version).

06.10 Sender and Sensor Overview

Provides an overview of sender and sensor components for 4-cylinder engines.

06.10.01 Component configuration 4 cyl. engine

Identifies and describes components and their locations on the 4-cylinder engine.

06.10.02 Component configuration 6 cyl. engine

Identifies and describes components and their locations on the 6-cylinder engine.

06.10.03 Calibration of rack position

Guides on calibrating the rack position sensor after component replacement or adjustment.

06.10.04 Replace Senders, Sensors

Covers the replacement procedures for various engine sensors including temperature, speed, and pressure.

06.10.05 Check Sensors and Switches

Details methods for checking the functionality of various sensors and switches.

06.12 Battery

Provides information on battery types, acid tests, capacity, and maintenance procedures.

06.12.01 Battery

Covers battery testing, capacity checks, and essential maintenance for long service life.

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