Hyundai Seasall S250S User manual

INSTALLATION & OPERATION MANUAL
S250 and S220 Series Engines
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TABLE OF CONTENTS
PAGE NUMBER
ABOUT THIS MANUAL ………………………………………………………………….....….
SAFETY PRECAUTIONS ………………………………………………………………………
CHAPTER 1 ENGINE OVERVIEW ………………………………………………………………
1. ENGINE COMPONENTS ………………………………………………………
2. ENGINE SUSPENSION EYES ………………………………………………..
3. ENGINE IDENTIFICATION …………………………………………………….
4. SCHEMATIC DIAGRAM OF COMMON RAIL DIESEL ENGINE ……..
5. TECHNICAL DATA ……………………………………………...…………
6. PERFORMANCE CURVES …………………………………………………
7. ENGINE DIMENSIONS ………………………………………………...…
CHAPTER 2 ENGINE MOUNT SYSTEM .………………………………………………..
1. ENGINE MOUNTING REQUIREMENTS ……………………………….
2. MOUNT DIMENSIONS ……………………………………………………
3. ENGINE MOUNT TOOL FOR STERNDRIVE MODEL ………………..
CHAPTER 3 COOLING & EXHAUST SYSTEM ………………………………………….
1. SCHEMATIC DIAGRAM OF ENGINE COOLING CIRCUIT ……..…...
2. SEAWATER FLOW.……………………………………………………..…
2.1 WATER PICKUP ………………………………………………..
2.2 SEAWATER STRAINER ……………………………………….
2.3 SEAWATER PUMP ………………………………………..……
3. ENGINE COOLANT FLOW…………………………………………..…...
3.1 ENGINE COOLANT …………………………………………..…
3.2 REMOVING AIR BUBBLES.…………………………………...
3.3 CABIN HEATER CONNECTION ………………………………
4. EXHAUST SYSTEM …………………………………………………….....
CHAPTER 4 FUEL SYSTEM ………………………………………………………………..
1. FUEL FLOW.….……..…………………………..………………………….
2. LOW PRESSURE FUEL LINE …………………....………………………
3. ACCELERATION SENSOR AND CONTROL LEVER ………………….
4. RECOMMENDED FUEL QUALITY ………………....……………………
5. DRAINING WATER FROM FUEL FILTER ………………………………
CHAPTER 5 AIR INTAKE SYSTEM ………………………………………………………..
1. ENGINE ROOM VENTILATION …………………………………………..
2. AIR FILTER MAINTENANCE …………………………..…………………
CHAPTER 6 LUBRICATION SYSTEM ……………………………………………………
1. ENGINE OIL FLOW…………..……………………………………………
2. ENGINE OIL LEVEL CHECKS ……………………….…………………
3. RECOMMENDED OIL QUALITY …………………….....………………
4. ENGINE OIL EXTACTION PUMP ………………………..…………….
5. OIL FILTER REPLACEMENT …………………………….…………….
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INSTALLATION & OPERATION MANUAL
S250 and S220 Series Engines
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TABLE OF CONTENTS
PAGE NUMBER
CHAPTER 7 ELECTRICAL SYSTEM …………………………………………………….
1. BATTERY CABLE CONNECTIONS ……………………………...…….
2. BATTERY CHECKS ………………………………………………..…….
3. FUSE AND RELAY …………………………………………………...…..
CHAPTER 8 INSTRUMENT SYSTEM ……………………...………………………........
1. INSTRUMENT CONNECTIONS …………..……………………………
2. CUT-OUT FOR GAUGE ……………………...………………………….
3. CUT-OUT FOR EOI SYSTEM …………………..………………………
CHAPTER 9 EOI SYSTEM …………………………………………..…………………….
1. OVERVIEW OF EOI SYSTEM ……………………..……………………
1.1 INFORMATION LCD ……..……………………...…………………..
1.2 SWITCHES ………………………………………......……………….
1.3 ALARM LAMPS ………………………………………..……………..
2. EOI CONNECTIONS ………………………………………......………….
3. EOI PIN ASSIGNMENT …………..……………………………......…….
4. NEUTRAL SWITCH AND DUAL EOI CONNECTION …………..…….
5. TRIM WIRING CONNECTION DIAGRAM …………………………….
6. ALARM AND DTC(DIAGNOSIS TROUBLE CODE) ……………......…
6.1 ALARM AND DTC(DIAGNOSIS TROUBLE CODE) ……………..
6.2 DTC(DIAGNOSIS TROUBLE CODE) LIST……….. ……………..
CHAPTER 10 ANTI CORROSION SYSTEM ……………………………………………...
CHAPTER 11 ENGINE OPERATION …………………………………………..…………..
1. ENGINE ON/OFF …………………………………………………..………
2. ENGINE BREAK-IN ………………………………………………………..
3. STOPPING THE ENGINE …………………………………………………
4. EMERGENCY STOP …………………..…………………………….…….
5. WINTER OPERATION AND STORAGE ……………………….………..
CHAPTER 12 ENGINE STORAGE …………………………………………………..………
CHAPTER 13 MAINTENANCE ………………………………………………………..……
1. PREDELIVERY INSPECTION LIST .………………………..…………..
2. MAINTENANCE SCHEDULE ………………………………………..…..
3. STERNDRIVE & TRANSMISSION MAINTENANCE SCHEDULE ..…
4. MAINTENANCE LOG……………………………………………………..
CHAPTER 14 TROUBLESHOOTING GUIDE ………………………………………….....
CHAPTER 15 WARRANTY ………………………………………………………………..
WARRANTY REGISTRATION CARD ………………………………….…
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INSTALLATION & OPERATION MANUAL
S250 and S220 Series Engines
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ABOUT THIS MANUAL
This engine installation and operation manual is provided as guidance for the installation of
Hyundai SeasAll engine in a boat, and to describe engine operation. Its purpose is to provide
technical information to aid in performing an effective engine installation so as to achieve both
maximum performance and service life. For information on installation, operation and maintenance
of the ZF Marine Transmissions and Sterndrive Bravo Models, please see the separate booklets
included in the original packaging of your Hyundai SeasAll purchase.
Hyundai SeasAll is committed to making clear and accurate information available for those who
own,maintain and repair the S250 & S220 Series engines. Hyundai SeasAll values your input
regarding revisions and additional information for our manuals.
!
!WARNING
DEVIATION FROM INSTALLATION INSTRUCTIONS AND OPERATION
GUIDELINES MAY LEAD TO PERSONAL INJURY OR DEATH TO
OPERATORS AND NEARBY PERSONNEL.
WARNING
DEVIATION FROM INSTALLATION INSTRUCTIONS AND OPERATION
GUIDELINES MAY LEAD TO PERSONAL INJURY OR DEATH TO
OPERATORS AND NEARBY PERSONNEL.
!
!CAUTION
DEVIATION FROM INSTALLATION INSTRUCTIONS AND OPERATION
GUIDELINES MAY LEAD TO IMPROPER OPERATION, DAMAGE OR
DESTRUCTION OF THE ENGINE.
CAUTION
DEVIATION FROM INSTALLATION INSTRUCTIONS AND OPERATION
GUIDELINES MAY LEAD TO IMPROPER OPERATION, DAMAGE OR
DESTRUCTION OF THE ENGINE.
The manufacturer is not liable for any damages or losses caused by faulty installation, wrong
handling of the equipment and/or deficient maintenance.
The operator is responsible for the correct and safe operation of the engine and safety of its
occupants and general public.
It is strongly recommended that each operator read and understand this manual before
installing and operating the engine.
This manual as well as safety labels posted on the engine use the following safety alerts to
draw your attention to special safety instructions that should be followed.

INSTALLATION & OPERATION MANUAL
S250 and S220 Series Engines
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SAFETY PRECAUTIONS
• Read and understand this operator’s manual
as well as other information supplied by
Hyundai SeasAll for safer use of these
products. Be sure to check your engine
regularly.
• Do not use the engine for a purpose other
than what is intended by Hyundai SeasAll. Do
not modify the performance of the supplied
engine without the express permission of
Hyundai SeasAll. This can be dangerous, can
shorten the life of your engine and can
invalidate your warranty.
• Original and genuine parts supplied from
Hyundai SeasAll must be used for
inspections and maintenance. Hyundai
SeasAll does not guarantee any damage
caused by the use of imitation parts.
• Engine inspection and maintenance should
be carried out by properly trained and factory
approved service engineers.
• The engine should be inspected if the
electronic engine control unit shuts down the
engine or puts it into the “limp home” mode.
HOT SURFACES AND FLUIDS
• There is always a risk of burns when working
with a hot engine. Be aware of hot parts like
the turbocharger system, the exhaust system,
hot coolant hoses, etc. Wait until the engine
is fully cool to do inspection and maintenance.
REFUELING
• Refuel only after the engine completely stops.
• Use only the recommended fuel. The wrong
grade of fuel can cause operating problems,
can cause the engine to stop and can cause
engine damage.
• Pay special attention to safe practices when
refueling.
PAINT DAMAGE
• Damage of the engine or parts paint during
maintenance and inspection can cause
corrosion. Any damage must be repainted
after inspection and maintenance.
WELDING ON ENGINE
• Welding directly on the engine block can
cause damage to the engine control systems.
The ECU and related electronic devices must
be disconnected and removed if unavoidable
welding is needed.

INSTALLATION & OPERATION MANUAL
S250 and S220 Series Engines
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CHAPTER 1
ENGINE OVERVIEW
1. ENGINE COMPONENTS
1. ECU Box
2. Coolant Expansion Tank
3. Engine Oil Cap
4. Engine Oil Filter
5. E-VGT & Cooler
6. Air Filter
7. Engine Oil Gauge
8. Acceleration Lever Sensor
9. Seawater Pump
10. Intercooler
11. Heat Exchanger
12. Alternator
1. Turbo Heat Protector
2. Exhaust Elbow
3. Bell Housing (Sterndrive Model)
4. Drive Coupler (Sterndrive Model)
5. Engine Oil Extraction Pump
Button
6. Engine Emergency Stop Button
7. P/STRG Oil Reservoir Tank(Sterndrive Model)
8. Shift Plate (Sterndrive Model)
9. Main Fuel Filter with Water Detection Sensor
10. T/M Oil Cooler or P/STRG Oil Cooler
11. Cabin Heater Connector
12. BPS & IATS

INSTALLATION & OPERATION MANUAL
S250 and S220 Series Engines
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2. ENGINE SUSPENSION EYES
1) To lift the engine, first remove the engine cover. You will find three engine eyes (see
figure).
2) To avoid engine damage, take care that engine lift chains or belts do not hit or touch
surrounding parts during engine lifting.

INSTALLATION & OPERATION MANUAL
S250 and S220 Series Engines
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3. ENGINE IDENTIFICATION
SERIAL NUMBER ON THE ENGINE BLOCK
NAME PLATE ON THE ECU BOX
Engine identification is affixed to the engine block and the ECU box (see figure).
Worldwide

INSTALLATION & OPERATION MANUAL
S250 and S220 Series Engines
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4. SCHEMATIC DIAGRAM OF COMMON RAIL DIESEL ENGINE
ECU
Fuel feed (low)
Fuel feed (high)
Fuel return
Fuel temperature sensor
Boost pressure & air temp. sensor
Glow Plug
Coolant temperature sensor
Cam position sensor
Crankshaft position sensor
EVGT actuator
Rail pressure sensor
Water sensor in fuel
Feed
pump
Injector
Intercooler
Common rail
High pressure pump
Main fuel filter
Air filter
VGT
Pump pressure regulator valve
Acc. position sensor
Air temp. sensor
Sensor
Actuator
Rail pressure regulator valve
Fuel tank
return feed
return
return
return

INSTALLATION & OPERATION MANUAL
S250 and S220 Series Engines
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5. TECHNICAL DATA
Engine type
S250 / 220S S250 / 220P S250J
4-stroke, 4-valve
After-cooled, direct-injection, water cooled
Output ps(kW) 250ps (184) / 220ps (162)
rpm at full load 3800/3200
Cylinders V-6
Ignition sequence 1-2-3-4-5-6
Displacement [cm3] 2959
Bore [mm] 84
Stroke [mm] 89
Compression ratio 17.5 : 1
Max. torque [kgm]
@ speed [rpm] 50 48
2500 3500
Injection system Common rail direct injection (Piezo injector)
Diesel fuel at least CN 51 as per DIN EN 590
Intake air pressure (abs. bar)
@ speed [rpm] 2.5 2.5 2.5
3800/3200 3800/3200 3800
Coolant quantity (liter) 11.5
Coolant cap opening pressure (bar) 1.1
Engine oil (liter) 7.2
Engine oil pressure (bar) 2~3 at 1750rpm, 100 ℃(oil temp.)
Exhaust gas pressure (kPa) Max. 50
Alternator [A] 150
Engine diagnosis Yes
Weight(kg) 334
Battery capacity (AH) 12V, 200AH recommended
Thermostat opening temp. (℃) 82 (starting to open), 92 (fully open)
Idle rpm warmed up (rev/min) 680
Permissible engine oil temp (℃) 137
Permissible engine coolant temp (℃) 105
Propulsion system Sterndrive Shaftdrive Waterjet

INSTALLATION & OPERATION MANUAL
S250 and S220 Series Engines
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6. PERFORMANCE CURVES
S250S & S250P MODEL
*BSFC : Brake Specific Fuel Consumption *FC : Fuel Consumption

INSTALLATION & OPERATION MANUAL
S250 and S220 Series Engines
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S250J MODEL
*BSFC : Brake Specific Fuel Consumption *FC : Fuel Consumption

INSTALLATION & OPERATION MANUAL
S250 and S220 Series Engines
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S220S & S220P MODEL
*BSFC : Brake Specific Fuel Consumption *FC : Fuel Consumption

INSTALLATION & OPERATION MANUAL
S250 and S220 Series Engines
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7. ENGINE DIMENSIONS
MerCruiser Bravo One X Diesel
MerCruiser Bravo Two X Diesel
Front view Side view
Front view Side view

INSTALLATION & OPERATION MANUAL
S250 and S220 Series Engines
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MerCruiser Bravo Three X Diesel
ZF 63 A
Front view Side view
Front view Side view

INSTALLATION & OPERATION MANUAL
S250 and S220 Series Engines
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ZF 63 C
Front view Side view
Front view Side view
Waterjet adapter without ZF 45C / ZF 63C

INSTALLATION & OPERATION MANUAL
S250 and S220 Series Engines
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CHAPTER 2
ENGINE MOUNT SYSTEM
The mount must be strong enough to carry the loads applied by the weight and power of the
engine. It also must be stiff enough that the engine does not sag or move too much when
power is applied.
The mount must position the engine at the correct height and angle so that the engine’s
thrust line suits the boat.
2. ENGINE MOUNT DIMENSIONS
1. ENGINE MOUNTING REQUIRMENTS
!
!
CAUTION
USE ONLY THE ORIGINAL HYUNDAI SEASALL ENGINE MOUNTS THAT
WERE SUPPLIED WITH THE INITIAL PURCHASE.
AFTER INSTALLATION AND ALIGNMENT OF THE ENGINE, MAKE SURE
THAT NO RESIDUAL TENSION EXISTS IN THE DRIVETRAIN.
CAUTION
USE ONLY THE ORIGINAL HYUNDAI SEASALL ENGINE MOUNTS THAT
WERE SUPPLIED WITH THE INITIAL PURCHASE.
AFTER INSTALLATION AND ALIGNMENT OF THE ENGINE, MAKE SURE
THAT NO RESIDUAL TENSION EXISTS IN THE DRIVETRAIN.

INSTALLATION & OPERATION MANUAL
S250 and S220 Series Engines
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3. ENGINE MOUNT TOOL FOR STERNDRIVE MODEL
!
!
Mounting hole for S250 and S220 model
Mount ting hole for D170 and D150 model
CAUTION
IT IS ESSENTIAL THAT THE ENGINE BED IS PERFECTLY FLAT BEFORE
USING ENGINE MOUNT TOOL.
FOR INFORMATION ON INSTALLATION OF THE STERNDRIVE BRAVO
MODELS, PLEASE SEE THE SEPARATE BOOKLETS INCLUDED IN THE
ORIGINAL PACKAGING OF YOUR HYUNDAI SEASALL PURCHASE.
CAUTION
IT IS ESSENTIAL THAT THE ENGINE BED IS PERFECTLY FLAT BEFORE
USING ENGINE MOUNT TOOL.
FOR INFORMATION ON INSTALLATION OF THE STERNDRIVE BRAVO
MODELS, PLEASE SEE THE SEPARATE BOOKLETS INCLUDED IN THE
ORIGINAL PACKAGING OF YOUR HYUNDAI SEASALL PURCHASE.

INSTALLATION & OPERATION MANUAL
S250 and S220 Series Engines
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CHAPTER 3
COOLING & EXHAUST SYSTEM
1. SCHEMATIC DIAGRAM OF ENGINE COOLING CIRCUIT
IN-MANIFOLD
Pc
COOLANT
PUMP
HEAT EXCHANGER
INTERCOOLER
OIL COOLER
TURBO CHARGER
AIR FILTER
PsSEA WATER
PUMP
THERMOSTAT
EXHAUST ELBOW
EX-MANIFOLD
EX-MANIFOLD
OIL
SEAWATER
INTAKE AIR
EXHAUST AIR
COOLANT ( THERMOSTAT CLOSED & OPENED )
COOLANT (THERMOSTAT OPENED )
CABIN HEATER
CONNECTOR
SEAWATER
EXPANSION TANK
AIR
E-VGT COOLER

INSTALLATION & OPERATION MANUAL
S250 and S220 Series Engines
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Water strainer ←Water valve ←Water pickup
↓
①Seawater pump
↓
②Intercooler
↓
③Heat exchanger ⑤EVGT cooler
↓
④Oil cooler
↓
⑥Exhaust elbow
↓
Seawater
2. SEAWATER FLOW – OPEN COOLING CIRCUIT
EVGT cooler
2.1 WATER PICKUP
!
!
2.2 WATER STRAINER
1) Water pickup should be installed in an area where it won’t pickup air bubbles and will
access clean water during all phases of the engine operation.
2) For use in sterndrive models, please see the section “Installing Sterndrive Seawater
Pickup” of the Bravo Sterndrive Installation Manual included in the original packaging.
3) For further safety, you can use an additional transom or bottom mounted clamshell-type
water pickup.
1) Strainer should be located in an area where it
will be easily accessible for periodic seawater
flow inspection and cleaning.
2) The size of strainer must be of sufficient capacity
to pass the seawater (a flow rate over 200 liters
per minute flow rate).
3) A water inlet shutoff valve (seacock) must be
installed before the seawater strainer in order to
allow user to shut off seawater when cleaning
the strainer filter.
CAUTION
IF THE SEAWATER STRAINER IS NOT PROPERLY ASSEMBLED, AIR
CAN BE SUCKED INTO THE COOLING CIRCUIT, DISTURBING THE
VACUUM PROCESS. THIS CAN CAUSE THE ENGINE TO OVERHEAT.
CAUTION
IF THE SEAWATER STRAINER IS NOT PROPERLY ASSEMBLED, AIR
CAN BE SUCKED INTO THE COOLING CIRCUIT, DISTURBING THE
VACUUM PROCESS. THIS CAN CAUSE THE ENGINE TO OVERHEAT.