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STEYR
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4 CYLINDER
STEYR 4 CYLINDER User Manual
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01 ENGINE
Page ENGINE - 32
Z001019/0_6_July 2008
SERVICE MANUAL MARINE ENGINES
01.01.05
Replace stud bolt for
unit injector
Preparation: Remove camshaft housing cover,
01.05.01
Remove unit injector, 03.02.02
1
Tighten threaded pin with a torque of
21 +/- 1 Nm.
01.05 ill.1
ToC
93
95
Table of Contents
Table of Contents
9
Default Chapter
4
Z001019/0_6_July
4
Table of Contents
9
Engine
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
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
40
D 5 Operation after Break-In
42
E 1 Spare Parts Specification
44
E 2 Workshop Profile
44
E Quality Gudelines for Repair
44
E 3 Nomenclature
45
E 4 SI- System
46
E 5 Abbreviations
47
F 1 List of Operating Material
48
F Operating Material and Information on Disposal
48
F 2 Disposal of Automotive Waste Products
49
G 1 General Notes on Safety
50
G 2 Guidelines for Damage Prevention
50
G 3 Legal Rules
50
Gnotes on Safety
50
G 4 Safety in the Use of Operating Material
51
G 5 Measures in Case of Accidents
51
H 1 Listing of Thightening Torques
52
H Thightening Torques
52
General Tightening Torques
57
H 3 Testing of Torque Wrench
58
H 4 Non-Destructive Material Testing
58
H 5 Use of Adhesive and Sealing Materials
58
H 6 Solvent-Free Sealing Materials
58
J Wear Limits
60
J 1 Adjustment Information for Service and Maintenance
61
Table of Contents
63
Engine Timing, Engine Mount
65
Lock Crankshaft
65
Exchange Camshaft Housing Cover Sealing
68
Maintenance Timing-Belt Exchange
69
Remove Timing Belt
77
Timing Adjustment Procedure for Dismantled Engine
78
Replace Engine Mount and Engine Bracket
88
Cylinder Block
90
Replace Valves
90
Adjust Valve Clearance
92
Replace Valve Guide
92
Replace Pressure Regulating Valve for Oil Cooling Jet
93
Replace Stud Bolt for Unit Injector
94
Replace Dowel Pin for Positioning of Unit Injector
95
Replace Dowel Pin for Positioning of Camshaft Housing
96
Replace Coolant Supply Pipe
97
Replace External Screw Adaptor for Oil Cooler
97
Mount Frame Seal
98
Crankshaft, Bearing, Vibration Damper
100
Replace Crankshaft
100
Replace Gear for Oil Pump Drive
104
Flywheel, Housing
105
Replace Flywheel Housing
105
Coupling
106
Replace Flywheel
106
Replace Adapter Ring
107
Dismantle Piston and Connecting Rod
108
Piston and Connecting Rod
108
Camshaft, Housing, Valve Gear
110
Replace Camshaft Housing
110
Replace Valve Stem Gasket (on Engine Assembly)
114
Replace Control Rack
116
Replace Camshaft
118
Replace Rocker Arm Shaft
120
Replace Radial Shaft Seal of Camshaft
121
Replace Cam Follower
122
Replace Retainer of Cam Follower
123
Replace Valve Adjusting Element
124
Engine Housing, Oil Pump, Oil Suction Pipe
125
Replace Engine Housing
125
Replace Support Ring Rear
132
Replace Rear Radialshaft Sealing Ring
133
Replace Oil Pump (Front Ring Carrier)
134
Replace Oil Suction Pipe
135
Assembly of Intercooler
136
Intercooler
136
Remove Intercooler
136
Replace Intercooler - Element
141
Auxiliary Drive, in Front (PTO)
143
Engine Oil Cooler
144
Replace Engine Oil Cooler
144
Repair Oil Cooler
146
Change Motor Oil
147
Change Oil Filter
148
Exhaust Manifold, Seals, Heat Exchanger
149
Table of Contents
157
Fuel System / Functional Description
158
Fuel Pump, Unit Injector, Lines
160
Replace Fuel Pump
160
Disassembly and Assembly of Unit Injector
163
Fix Control Rack
170
Adjust Control Link (Injection Quantity)
171
Loosen Fixing of Control Rod
172
Adjust Start of Injection
173
Exchange Check Valve for Fuel Pre-Pressure to Unit Injector
176
Change Air Filter
177
Replace Turbocharger
178
Air Filter
177
Turbocharger
178
Check Bearing Clearance
181
Control Solenoid
182
Remove Control Solenoid
182
Install Control Solenoid
184
Replace Sensor, Indication of Control Rack Position
185
Change Fuel Filter
186
Replace Glow Plug
187
Measurement of Compression Pressure
188
Fuel System Check
190
Manual Injection Test Methode
190
Disengagement Methode of Injection
192
Air Bubble Formation in Fuel System
193
Exhaust System
195
Cooling System
199
Functional Description Cooling Circuit
200
Raw Water Circuit (External Cooling Circuit)
200
Closed Coolant from Cooling Circuit (Internal Engine Cooling Circuit)
202
Error Detection Cooling System
204
Check Points for Problems in Cooling System
207
Component Check Raw Water System
208
Drain the Coolant System
211
Fill the Cooling System
213
Coolant Tank
214
Cooler, Heat Exchanger, Expansion Tank
214
Disassembly Exhaust Manifold - Heat Exchanger
215
Checks
219
Exchange Heat Exchanger Element
221
Assembly of Exhaust Manifold
222
Exchange Additional Oil Cooler (Only Type 246)
224
Exchange Tandem Cooler
224
Coolant Pipes and Hoses
225
Exchange Triple Cooler
225
Pipes, Thermostat
225
Exchange Thermostat
226
Exchange Sacrificial Anodes
228
Coolant Pump
229
Exchange Coolant Pump
229
Install Coolant Pump
230
Exchange Poly-V-Belt
231
Poly-V-Belt
231
Exchange V-Belts
232
V-Belt
232
Adjust V-Belts
234
Exchange Raw Water Pump
235
Raw Water Pump
235
Check Closed Engine Cooling System for Air
236
Checks
236
Table of Contents
237
Alternator
240
Adjust Poly-V-Belt Tension
240
Technical Data of Alternator
242
Check Alternator (Error Detection for BOSCH Alternator, 4 Cyl. Engines)
250
Replace Starter Motor
252
Check Starter
253
Battery Cable Lengths and Cross-Sections
255
Cables, Wiring Harness - General
255
E - Box Base Plate; to Eng.no.: 482 17 000
256
Components of E - Box
257
Connection Relay Socket for K24, K26-1, K26-2 and K27
257
Connection Start Assist Relay K28
257
Wiring Harness; to Eng.no.: 482 17 000
258
E - Box Base Plate; from Eng.no.: 482 18 000/682 18 000 + SOLAS
264
Components of E - Box
265
Connection Relay Socket for K24, K26-1 and K27
265
Wiring Harness; from Eng.no.: 482 18 000/682 18 000 + SOLAS
266
Electronic Engine Management System
272
Electronics - General
272
Diagnostic System
273
Reading Error Codes
274
Principle Failure Code List
276
Replace Fuses
278
Connection J
279
Connection A5 and X5
280
Fitting Main Connector "J1" Properly
281
Instrument Panel
282
Chart - Error Indication on Instrument Panel
284
Instrument Panel (for SOLAS Only)
288
Used - Old Version
294
Cyl. Wiring Harness Instrument Panel (if Alternator "PRESTOLITE" Is Used - Old Version)
295
Description - Wiring Harness Instrument Panels 4/6 Cyl. Marine Engines (Current Version)
298
Adjust Instruments
304
Tachometer with Running-Time Meter
304
General Notes on Safety
306
Replace Instruments
306
Audible Warner, H22
308
Circuit Diagram Oil Pressure Gauge (Optional, Sensor B19-Gauge P2)
309
Circuit Diagram Voltmeter (Optional)
309
Potentiometer Accelerator, B13
310
Voltage Regulator 24V-12V Equalizer
311
DC-DC Converter
312
Component Configuration 4 Cyl. Engine
314
Component Configuration 6 Cyl. Engine
316
Calibration of Rack Position
318
Potentiometer Accelerator B13
320
Check Rack Position Feedback Sensor B14 (= Connector X14)
321
Check Sensors and Switches
321
Check Throttle Potentiometer B13 (Accelerator) (= Connector X13)
323
Check Speed Sensor B15 And/Or Wiring
325
Check Oil Pressure Sensor B18 And/Or Wiring
326
Check Oil Pressure Sensor "VDO-Instrument" (Option B19)
327
Check Coolant Temperature Sensor, B16
328
Check Audible Warner
329
Battery
330
Electrical Equipment
330
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STEYR 4 CYLINDER Specifications
General
Brand
STEYR
Model
4 CYLINDER
Category
Engine
Language
English
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