STEYR 4 CYLINDER User manual

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

THIS PAGE IS INTENTIONALLY BLANK

PREFACE
STEYR MOTORS GmbH
After Sales Service
Im Stadtgut B1
4407 STEYR
AUSTRIA
07252/222/52
07252/222/29
vom Inland:
from home country
+43/7252/222/52
+43/7252/222/29
vom Ausland
from foreign
countries:
[email protected]
http://www.steyr-motors.com
STEYR MOTORS GmbH has developed high-performance diesel engines with modulated high-
pressure direct injection, especially for the marine environment. STEYR marine engines are designed to be
adapted to various propulsion systems.
This SERVICE MANUAL is published with the main intention -
to provide information in form of technical data and know-how based on our experience in the marine diesel
engine business, which will enable you in case of possible failure to operate, service and repair the engine
4&6CYLINDERMARINE
ENGINES
to maintain their operating safety and reliability.
To achieve continuous improvement with regard to form and contents of the information required, we are
assigned to your aid.
We, therefore, would much appreciate your comment to the following questions -
- Which descriptions or terms are not understandable?
- Which supplements or completions do you propose ?
- Where did creep in contents-related mistakes ?
Please address your comment to:
Z001019/0_6_July 2008

Z001019/0_6_July 2008
Repair and maintenance works on engine
The descriptions and instructions in this technical documentation should support you in use and repair of our
product. They refer to a specific equipment status of engine componets and accessories. Your individual
engine may be equipped with other or less accessory.
For any component not covered in this manual, please contact STEYR MOTORS GmbH, After Sales Ser-
vice, as to respective documentation.
This manual also contains specific references to your personal safety as user, as well as that of your
customers, their passengers and other persons being close to the engine/boat.
Product specifications, illustrations and technical data
When reference is made in this manual to a brand name, product number, product or specific tool, an
equivalent product may be used in place of the product or tool referred to, unless stated otherwise. To exclude
possible danger, the operator has to provide for adequate safety precautions.
All information, illustrations and specifications in this manual are based on the latest product data available at
the time of printing. It cannot be guaranteed that this manual is constantly updated. Revised versions edited at
a later date will replace all preceding editions.
Illustrations in this manual may not always correspond to actual implements or components and are
mainly intended as reference.
STEYR MOTORS GmbH reserves the right to make changes at any time, without notice, on technical
data or models and/or to discontinue models. The right is also reserved to change technical data or
components at any time, without incurring any obligation to retrofit new parts on models produced
prior to date of such change.
To guarantee proper function of the engine and its attached parts after a repair, correct assembly is of
utmost importance. Such works are to be carried out with greatest care, in accordance with repair
instructions.
WARRANTY: Warranty claims will expire if repair, service and operation of the engine do not
correspond to the guidelines defined by STEYR MOTORS GmbH Please
address your warranty claims, in accordance with warranty regulations, directly to
the After Sales Service of STEYR MOTORS GmbH, Steyr.
Every STEYR dealer is obliged to fill out the warranty registration card enclosed to every sold
STEYR marine engine or every sold boat with a built-in STEYR marine engine.
Part1(WarrantyRegistrationCard)istobehandedovertothecustomer,part2(DealerRecord
Card) remains with the dealer and part 3 is to be sent to the After Sales Service of STEYR
MOTORS GmbH.
This warranty registration card serves as a proof of ownership and is to be submitted in case
of warranty claims.
EverySTEYRdealerisalsoobligedtocarryouttheInstallationandpre-deliveryinspectionlog.
Onecopy(completelyfilledout)ofthisInstallationandpre-deliveryinspectionlogistobesent
to the After Sales Service of STEYR MOTORS GmbH.

Z001019/0_6_July 2008
TABLE OF CONTENTS
(MAIN ASSEMBLY GROUP ENGINE)
GENERAL
01 ENGINE
02 COUPLING
03 FUEL SYSTEM
04 EXHAUST SYSTEM
05 COOLING SYSTEM
06 ELECTRICAL EQUIPMENT

Z001019/0_6_July 2008
Components
01
Engine 01.00
Engine timing,
engine mount
01.01
Cylinder block 01.02 Chrankshaft
bearing,
vibration damper
01.03
Flywheel,
housing
01.04
Piston,
connection rod
01.05
Chamshaft,
housing,
valve drive
01.06
Engine housing,
oil pump,
oil suction pipe
01.08
Intake manifold,
intercooler
01.13
Engine oil cooler,
01.09
Auxiliary drive-PTO
01.14
Exhaust manifold,
seals,
heat exchanger
02
Coupling
03
Fuel system
04
Exhaust system
02.01
Torsion coupling 02.02 Coupler 02.03
Torsion coupling
Centa
03.02
Fuel pump,
unit injector,
pipes
03.04
Air filter 03.05
Turbo charger
03.08
Control solenoid 03.09 Fuel filter 03.11
Glow plugs
04.01
Hi-riser

Z001019/0_6_July 2008
05
Cooling system
06
Electrical
system
05.01
Cooler,
heat exchanger,
expansions tank
05.03
Pipes,
thermostat
05.04
Coolant pump
05.10
Raw water pump,
side mounted
05.11
Raw water pump,
front mounted
06.01
Generator,
alternator
06.03
Starter motor 06.05 Engine harness
06.06
EMS, E-box,
diagnosis system,
fuses
06.07
Instrument panel,
connecting cable
06.10
Sender, sensor
06.12
Battery,
charge equalization

Z001019/0_6_July 2008
VERSIONS OF MANUAL
Version Date Modification
1.0 01. 10. 2000 new edition
2.0 01. 06. 2002 release typ 164, 246
3.0 01. 07. 2005 release typ 256
4.0 01. 07. 2007 modification
5.0 01. 03. 2008 modification
6.0 01. 07. 2008 modification

Z001019/0_8_Octobre 2011 PageGENERAL-1
GENERAL
SERVICE MANUAL MARINE ENGINES
ToC
GENERAL
Table of Contents
A General Remarks .................................................................................. 3
A 1 Model and Serial Numbers ..................................................................... 3
A 2 Documentation........................................................................................ 4
A 3 Model summary ...................................................................................... 5
A 3.1 Model summary 4 cylinder engines ........................................................ 5
A 3.2 Model summary 6 cylinder engines ........................................................ 8
A 4 Technical Data and Overview ................................................................. 12
A 4.1 Technical Data and Overview 4 cylinder engines.................................... 12
A 4.2 Technical Data and Overview 6 cylinder engines.................................... 16
B Specifications ....................................................................................... 20
B 1 Fuel Requirements ................................................................................. 20
B 2 Motor oil .................................................................................................. 21
C Maintenance and Service ..................................................................... 22
C 1 Trouble Check Chart............................................................................... 22
C 2 Service- and Maintenance Schedule ...................................................... 24
D General Information.............................................................................. 26
D 1 Electronic Engine Management System (ECU)...................................... 26
D 2 Diagnostic System .................................................................................. 27
D 3 Extended Storage Preservation Procedure............................................. 28
D 4 EngineBreak-in procedure...................................................................... 32
D 5 Operationafter Break-in .......................................................................... 34
E Quality Gudelines for Repair ................................................................ 36
E 1 Spare parts specification ......................................................................... 36
E 2 Workshopprofile ..................................................................................... 36
E 3 Nomenclature .......................................................................................... 37
E 4 SI-System .............................................................................................. 38
E 5 Abbreviations .......................................................................................... 39
F Operating material and Information on Disposal................................ 40
F 1 List of operating material ......................................................................... 40
F 2 Disposal ofautomotivewaste products.................................................... 41
G Notes on Safety..................................................................................... 42
G 1 Generalnoteson safety ........................................................................... 42
G 2 Guidelines fordamageprevention ........................................................... 42
G 3 Legal rules............................................................................................... 42
G 4 Safety intheuse ofoperatingmaterial ..................................................... 43

GENERAL
PageGENERAL-2 Z001019/0_8_Octobre 2011
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G 5 Measures in case of accidents ................................................................ 43
H Thightening Torques ............................................................................ 44
H 1 ListingofThighteningTorques.................................................................. 44
H 2 GeneralTightening torques ...................................................................... 49
H 3 Testingoftorquewrench .......................................................................... 50
H 4 Non-destructivematerialtesting ............................................................... 50
H 5 Useofadhesive andsealing materials..................................................... 50
H 6 Solvent-freesealingmaterials.................................................................. 50
J Wear Limits ............................................................................................ 52
J 1 Adjustmentinformationforservice andmaintenance................................ 53

Z001019/0_8_Octobre 2011 PageGENERAL-3
GENERAL
SERVICE MANUAL MARINE ENGINES
ToC
A GENERAL REMARKS
A 1 Model and Serial Numbers
01.01 ill.1
01.01 ill.3
01.01 ill.2
FOR ALL
4 CYL. MARINE ENGINES
The primary model and serial number (ill.1 or ill.2) is
located on the engine as illustrated.
These numbers are required for warranty
claims and ordering parts.
Themodelandserialnumberofthemarinegearbox
is located on the marine gearbox housing as illustrated.
Toobtaininstructionsregardingmarinegearbox
operation,refertomarinegearboxownersmanual.
17
06014
08006
1
1
08007
FOR ALL
6 CYL. MARINE ENGINES

GENERAL
PageGENERAL-4 Z001019/0_8_Octobre 2011
SERVICE MANUAL MARINE ENGINES
ToC
ThefollowingdocumentationisavailableinEnglishlanguageonourwebsite:
http://www.steyr-motors.com/technical
technicaldocumentation onCD- ROM P/N Z001009/0
operation-,maintenance&warrantymanual
forallmarineengines P/N Z001022/0
toolcatalogueforallmarineengines P/N Z001002/1
sparepartscatalogue STEYR 94 td diesel marine P/N Z 001023/0
STEYR 144vti/td dieselmarine P/N Z001005/0
STEYR 164 td diesel marine P/N Z 001015/0
STEYR174vtidieselmarine P/N Z001011/0
STEYR 166 td diesel marine P/N Z 011796/1
STEYR 236 FDE P/N Z 011796/0
STEYR 236 td diesel marine P/N Z011796/1-Z011769/2
STEYR 246 td diesel marine P/N Z 011800/0
STEYR256 td dieselmarine P/N Z011810/0
STEYR266 td dieselmarine P/N Z011805/0
installationmanualformarineengines P/N Z001007/0
servicemanualforallmarineengines P/N Z001019/0
operator'smanualmarinegearZF P/N Z001003/0
DiagramsmarineenginefunctionsonCD P/N Z001021/0
A 2 Documentation 4 and 6 cylinder

Z001019/0_8_Octobre 2011 PageGENERAL-5
GENERAL
SERVICE MANUAL MARINE ENGINES
ToC
A 3 Modell summary
A 3.1 Modell summary 4 cylinder engines
03.01 ill.1
03.01 ill.2
03.01 ill.3
Inborder i.e. ZF 45 Marinegear
Down angle
Bobtail - Version
Innenborder i.e. ZF 63 Marinegear
Equipment:
with side mounted raw water
pump or,
with side mounted raw water
pump, power steering pump

GENERAL
PageGENERAL-6 Z001019/0_8_Octobre 2011
SERVICE MANUAL MARINE ENGINES
ToC
03.01 ill.4
03.01 ill.5
03.01 ill.6
Equipment
Bobtail "B"
Direkt gearbox
A-down angle gear box
Parallel offset gearbox
Lifeboat Engine
03.01 ill.7

Z001019/0_8_Octobre 2011 PageGENERAL-7
GENERAL
SERVICE MANUAL MARINE ENGINES
ToC
Stern Drive
Jet Drive
03.01 ill.10
03.01 ill.11
TYPE
Mercury Alpha Bravo I, II & III
Volvo DP 290
Volvo DP 290 Hydraulic
SX - Stern Drive
TYPE
Alamarin
Hamilton
Castoldi
03.01 ill.8
03.01 ill.9

GENERAL
PageGENERAL-8 Z001019/0_8_Octobre 2011
SERVICE MANUAL MARINE ENGINES
ToC
A 3.2 Modell summary 6 cylinder engines
03.02 ill.1
03.02 ill.2
03.02 ill.3
Inborder i.e. ZF 63 Marine gear
Down angle
with side mounted raw water
pump or,
with side mounted raw water
pump, power steering pump
and front mounted auxiliary
drive-PTO
Bobtail - Version

Z001019/0_8_Octobre 2011 PageGENERAL-9
GENERAL
SERVICE MANUAL MARINE ENGINES
ToC
03.02 ill.4
03.02 ill.5
03.02 ill.6
03.02 ill.7
03.02 ill.8
Transmission
Lifeboat Engine
Equipment
Bobtail "B"
Direkt gearbox
A-down angle gear box
Parallel offset gearbox
i = 2.5V, shaft angle 12°
i = 2.0V, shaft angle 12°

GENERAL
PageGENERAL-10 Z001019/0_8_Octobre 2011
SERVICE MANUAL MARINE ENGINES
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03.02 ill.9
03.02 ill.10
03.02 ill.12
Stern drive
Mercury Bravo II & III
Volvo DP 290
Stern Power Drive
Volvo DP 290 ZF
Hydraulic Pump
Volvo SX - Drive
King Cobra Drive
Type
Jet Drive
TYPE
Alamarin
Hamilton
Castoldi
Jet drive
03.02 ill.11

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GENERAL
SERVICE MANUAL MARINE ENGINES
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GENERAL
PageGENERAL-12 Z001019/0_8_Octobre 2011
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A 4.1 Technical data and overview 4 cylinder engines
MAKE STEYRM 14 TCM,TCAM
type MO84K32 MO94K33 MO114K33 MO144V38
displacement 2133cm³
pistondisplacement 85,0 x 94,0 mm
numberofcylinders 4-cylinderin-lineengine(positionofcyl.1atvibrationdamperside)
ignition order 1 - 3 - 4 - 2
senseofrotation,seen from front right
compressionratio 17,5 : 1
full-loadspeedrange(rpm) 3000-3200 3050 - 3800 3200 - 3800 3600 - 3800
idlespeed 650rpm.(adjustable)
injection pump- nozzlewith modellingneedle control
andelectroniccontrol
fuel acc.toCECRF-03-A-84(DINEN590)Cetan>49; dieselfuel
No.2-D,temperatureabove-7°C;No.1-D,temperaturebelow-7°C
fuelfilter P/No.2203710/0
fuelfilterlocation intake-sided
airfilter P/No.2178992/0
oilpressureabove 2000rpm. 400- 700 kPa(60 -100 PSI)microprocessor controlled
filling capacity motor oil approx. 8,0 l engine housing (incl. approx. 1 l oil filter contents)
specificationmotoroil SAE 5W-50/ACEA B4-02/API CF or 10W-40/ACEA, E4, E5, E7,
APICF /P/N0.Z010058/0
oilandoilfilterchangeintervals*) every150operatinghoursand/oronceperseason
oil filter P/No.2178582/1
oilfilter location pressure-sided
electric charging system 14 V / 90 A alternator with transistorized voltage regulator
cooling system dualcoolingcircuit;thermostat-controlled,pressurizedcooling
circuit;circulatingpumpwithheatexchangeronengine;governor
pump,external rawwater circuitto heatexchanger
coolant capacity 11,5 liters
coolant STEYRMOTORSenginecoolant-36C°
P/No.Z011785/0
*) extendedperiodstobeevaluateduponapplicationandtypeofusage
STEYRMOTORS GmbH.reservesthe righttomake changeswithoutnotice or obligations.
**) Efficiencyofgearbox =97,0%,efficiency of Z-drive=95,5%
rated power acc. EN ISO 8665:2006
(impeller **) KW / HP
Jet - Drive / Inboard
Z - Drive 53 / 71
52 / 70 64 / 86
63 / 84 78 / 105
77 / 104 103 / 138
101 / 136