Textron MPE 850 MARINE User manual

TD407477_SHB
Rev F
06.11.2015
MPE 850 MARINE
– 408101 I2 846 MAR TC-100 (TC-80) (TC-120)
– 408014 I2 846 MAR TC-120
– 408090 I2 846 MAR TC-155
– 408246 I2 846 MAR NA-80
This service manual is valid for the following engine models:
Read this service manual thoroughly before operating the engine for the
first time.
SERVICE MANUAL
4-Stroke Engine
en_English

Textron Motors GmbH
Daimlerstraße 5
88677 Markdorf
Germany
www.textronmotors.com
Textron Motors GmbH strives to make continual improvements as part of the ongoing technical development
of its products. All documentation is therefore subject to technical modifications.
Reprints and translations, in whole or in part, require written permission from Textron Motors GmbH.
All rights reserved according to the copyright law.

4 SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |
Table of contents
Table of contents
1 About this document 6
1.1 Meaning of symbols and signal words........................................... 6
2 Safety 7
2.1 Meaning of safety alert symbol and signal words ..................................7
2.2 Important safety messages ................................................... 8
3 Description 10
3.1 Intended use .............................................................10
3.2 Identification .............................................................10
3.3 Fuel ....................................................................12
3.4 Engine oil................................................................12
3.5 Coolant .................................................................13
3.6 Engine components and information ...........................................14
3.7 Engine fuses and relays ....................................................20
3.8 Protective functions ........................................................21
3.9 Technical specifications .....................................................22
3.10 Supported vehicle equipment ...............................................24
3.10.1 Lights in vehicle ........................................................24
4 Operation 26
4.1 Service intervals ..........................................................26
4.2 Operation during the break-in period...........................................28
4.3 Operating engine ..........................................................29
4.3.1 Inspecting the exhaust and fuel system ....................................... 29
4.3.2 Checking coolant level .................................................... 30
4.3.3 Put the engine into operation ............................................... 31
4.3.4 Checking oil level ........................................................ 32
4.3.5 Take the engine out of operation ............................................34
4.3.6 Flushing sea water cooling circuit............................................ 35
4.3.7 Corrosion protection ......................................................36
4.3.8 Transport and storage of the vehicle ......................................... 37
5 Special scenarios 38
5.1 Engine storage for more than 30 days .........................................38
5.2 Operating engine without sea water ...........................................38
5.3 Towing vehicle in water ..................................................... 38
5.4 Measures in case of flooded engine ...........................................39
6 Malfunctions 40
6.1 Malfunctions table ......................................................... 40
6.2 Checking engine fuses .....................................................42

5SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |
Table of contents
7 Dealer and servicing network 44
7.1 Locating a workshop ....................................................... 44
7.2 Tools and parts ...........................................................44
7.3 Repairs .................................................................44
8 Service tasks in the workshop 45
8.1 Safety messages workshop.................................................. 45
8.2 Tools and accessories ......................................................46
8.2.1 Service parts............................................................ 46
8.2.2 Textron Motors diagnostic case .............................................47
8.2.3 Equipment workshop .....................................................48
8.2.4 Supplies ...............................................................50
8.3 Changing engine oil and oil filter .............................................. 51
8.4 Checking sacrificial anode...................................................58
8.5 Checking and adjusting valve lash ............................................59
8.5.1 Checking valve lash ...................................................... 59
8.5.2 Adjusting valve lash ......................................................63
8.6 Replacing spark plugs and ignition coils ........................................ 66
8.7 Checking spark plugs ......................................................68
8.8 Replacing rubber mount ....................................................71
8.9 Maintenance waste gate valve ...............................................76
8.9.1 Maintaining waste gate valve version 1 .......................................77
8.9.2 Maintaining waste gate valve version 2 .......................................79
8.10 Checking flame arrester ...................................................81
8.11 Changing coolant......................................................... 85
8.12 Replacing fuel filter .......................................................88
8.13 Storing engine and returning to operation ......................................89
8.13.1 Preparing engine for storage ..............................................89
8.13.2 Returning engine to operation after storage ................................... 91
8.14 Disposal................................................................92
9 Confirmation of service tasks 93
Appendix 95
Engine manufacturer ...........................................................95
Index .......................................................................96

6 SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |
This service manual was designed to help you operating the engine safely and reliably.
Observe the following references:
– Read this service manual thoroughly before operating the engine for the first time.
– Always read the vehicle manufacturer‘s documentation.
– This service manual is for the engine in your vehicle. See the vehicle manufacturer‘s documentation for
vehicle specific information.
– Keep this service manual in a safe place.
– Make sure that all persons using the vehicle have access to this service manual.
– If you sell the vehicle, always pass on this service manual to the new owner.
– The latest version of the servicew manual is available for download in other languages from our web site
www.textronmotors.com.
– Some figures in this service manual are general illustrations and may differ from the actual engine.
1 About this document
1.1 Meaning of symbols and signal words
1About this document
1.1 Meaning of symbols and signal words
Item Meaning
NOTICE The signal word NOTICE indicates potential property damage.
Information The signal word Information indicates specific features and recommendations.

7SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |
This engine is state-of-the-art and built according to recognized safety technical and emission regulations.
Ignoring the information in this service manual may result in personal injury or property damage.
Read and observe the following safety messages carefully before operating the engine for the first time.
Observe all generally applicable laws and regulations in addition to the information in this service manual:
– Accident prevention
– Environmental protection
– Handling of hazardous materials
– Personal safety equipment
– Traffic laws
2 Safety
2.1 Meaning of safety alert symbol and signal words
Item Meaning
The safety alert symbol draws your attention to possible dangers.
WARNING
The signal word WARNING indicates a potentially dangerous situation that may
lead to a serious or fatal injury.
CAUTION
The signal word CAUTION indicates a potentially dangerous situation that may
lead to a minor or moderately severe injury.
2Safety
2.1 Meaning of safety alert symbol and signal words

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2.2 Important safety messages
2Safety
2.2 Important safety messages
In order to keep your engine in a safe operating condition, regular
servicing is essential. It is your responsibility to ensure that the engine is
serviced correctly.
►Perform regular inspections and observe the specified service
intervals.
All tasks described in chapter 8 Service tasks in the workshop require
special technical knowledge of this engine.
►Ensure your workshop is qualified to service your engine.
►All Textron Motors authorized workshops are qualified to service
your engine.
Engine malfunctions pose a safety risk to persons.
►Only operate the engine in perfect condition.
►Perform all service tasks according to the service intervals in this
service manual.
►You must immediately address all malfunctions to a qualified
workshop.
All the components in your engine have been carefully tested and fulfill
strict quality and safety requirements.
►Textron Motors offers spare parts to the highest quality. Ensure that
equivalent spare parts corresponds with this quality requirements.
Engine modifications may pose a safety risk to persons.
►Do not install add-on parts or modify the engine.
Engine components become extremely hot during operation.
►Do not touch any engine components during operation.
►Turn off the engine and wait until the components have cooled
before making contact.
Some service tasks require disconnection of the engine from the power
supply. Starting the engine inadvertently may endanger the safety of
persons. Read the vehicle manufacturer‘s documentation for more
information.
►Disconnect the engine from the power supply when requested.
Engine exhaust gases contain carbon monoxide (CO). Inhalation of
carbon monoxide can deprive the body of oxygen and result in organ
damage or death by asphyxiation.
►Never operate the engine in enclosed spaces.
Service tasks
Service tasks in the workshop
Malfunctions
Spare parts
Add-on parts and modifications
Hot engine components
Engine power supply
Engine exhaust gases

9SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |
2Safety
2.2 Important safety messages
Engine fluids pose a health risk.
►Always read the manufacturer's instructions.
►Always wash your hands prior to eating, smoking and using the
restroom as well as at the end of the working shift when working
with engine fluids.
Engine fluids are hazardous to the environment.
►Never allow engine fluids to escape into the groundwater, water
courses or sewage system. Always dispose of engine fluids
according to applicable regulations.
Danger of slipping on spilled fluids.
►Always use a filler neck or funnel when filling the engine with fluids.
►Always clean up any spilled engine fluids immediately.
Fuel is highly flammable. Vapors may ignite and cause an explosion.
►Do not smoke in the vicinity of the engine and do not allow open
flames or sparks near the engine or the fuel system.
►Always turn off the engine before fueling.
►Never fill with fuel while the engine is running.
►Do not start the engine if you smell fuel or see a fuel leak.
►Fuel on hot surfaces can cause fires.
►In the event of a fire, use foam, dry chemical or carbon dioxide fire
extinguishers. Do not extinguish with water.
Engine oil is flammablew and can emit toxic gases.
►Do not smoke in the vicinity of the engine and do not allow open
flames or sparks near the engine.
►Engine oil on hot surfaces can cause fires.
►In the event of a fire, use foam, dry chemical or carbon dioxide fire
extinguishers. Do not extinguish with water.
This engine und engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive harm.
Fuel, engine oil and coolant
handling
Fuel
Engine oil
California Proposition 65

10 SHB MPE850 Rev F | 408014 | 408090 | 408101 | 408246 |
Date:
Part No.:
Serial No.:
26.10.2012
999999
9999999999
1
5
3
2
4
3 Description
The engine models I2 846 MAR has been designed for powering watercrafts. Any other use is not
permissible.
All specifications in this service manual are only valid for the unmodified engine delivered by Textron Motors.
Engine modifications are not permissible and in addition, may void the warranty or violate federal laws.
3.2 Identification
Each engine is assigned two identification
numbers. Both numbers are printed on a label 1
affixed to the engine.
The part number “Part No.:” 2is the number of
the engine model.
The serial number “Serial No.:” 3is an unique
number for each individual engine.
Take the time to enter the part number and serial
number in chapter 9 Confirmation of service
tasks. Both numbers are important in questions
regarding your engine.
3.1 Intended use
3 Description
3.1 Intended use | 3.2 Identification
Engine models
I2 846 MAR TC-80, TC-100 and TC-120
The label with the part number and the serial
number is located on the expansion tank 4.
The serial number is also engraved on the
crankcase 5.
The “Emission Control Information” label is located
on the expansion tank.

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7
6
8
9
3 Description
3.1 Intended use | 3.2 Identification
Engine model I2 846 MAR TC-155
The label with the part number and the serial
number is located on the expansion tank 6.
The serial number is also engraved on the
crankcase 7.
The “Emission Control Information” label is located
on the expansion tank.
Engine model I2 846 MAR NA-80
The label with the part number and the serial
number is located on the expansion tank 8.
The serial number is also engraved on the
crankcase 9.
The “Emission Control Information” label is located
on the expansion tank.

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3.3 Fuel
3.4 Engine oil
3 Description
3.3 Fuel | 3.4 Engine oil
Engine models I2 846 MAR NA-80 TC-80 TC-100 TC-120 TC-155
Fuel Unleaded gasoline
Recommended fuel quality 95 ROZ or 85 MOZ
USA ʺPremium 91ʺ
98 ROZ or 88 MOZ
USA ʺPremium 93ʺ
Minimum requirement NOTICE! Low octane fuel can cause loss of power and/or increased
fuel consumption.
91 ROZ or 82,5 MOZ
USA ʺRegular 87ʺ
Permissible share of ethanol NOTICE! A greater concentration can deteriorate the engine’s fuel
system and starting performance.
Maximum 10 % (E10)
Engine models I2 846 MAR NA-80 TC-80 TC-100 TC-120 TC-155
Engine oil NOTICE! Engine damage due to incorrect engine oil grade. Always use
the recommended engine oil. Do not mix engine oils of different grades
or viscosity.
0W 40 completely synthetic, at least API SJ, ACEA A3/B3
Fill quantity Approximately 3,5 liters [3.7 qt (US)]

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3.5 Coolant
3 Description
3.5 Coolant
Engine models I2 846 MAR NA-80 TC-80 TC-100 TC-120 TC-155
Coolant additive Coolant additive based on ethylene glycol, silicate- and nitrite- free,
suitable for aluminium engines.
Suggested coolant additives NOTICE! Insufficient cooling due to incompatibilities of coolant.
Combining different coolant additives may trigger a chemical reaction
and they may lose their effectiveness. The suggested coolant additives
are laboratory tested for compatibility. If you use another coolant
additive verify the compatibility previously.
– BASF Glysantin G 30
– Chevron Havoline Extended Life Coolant XLC+B
– Valvoline Zerex G 30
Mixing ratio NOTICE! An incorrect mixing ratio reduces the cooling capacity. When
topping up the coolant, do not change the mixing ratio. Use the same
coolant throughout the year in the mixing ratio specified.
50 % water + 50 % coolant additive
Fill quantity Approximately 2,75 liters [2.9 qt (US)]

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3
1
6
10
11
4
8
9
2
7
5
3 Description
3.6 Engine components and information
3.6 Engine components and information
Information! The wire harness is not shown in the figures.
– Sacrificial anode 8
– Exhaust manifold 9/
Exhaust side
– Exhaust pipe 10
– Sea water return 11
Engine models I2 846 MAR
TC-80, TC-100 and TC-120
– Oil filter 1
– Drainage for storage 2
– Fuse box 3
– Waste gate valve 4
– Flame arrester 5
– Connection for sea water
cooling circuit flushing device
6
– Heat exchanger 7

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15
13
12
19
21
22
20
18
14
16
17
23
3 Description
3.6 Engine components and information
– 1st cylinder 12
– Sensor camshaft 13 /
2nd cylinder
– Fuel supply 14
– Engine rotation direction 15
– Stub shaft 16 / Power take off
– Engine cover 17
– Oil tank 18
– Coolant expansion tank 19
– Sea water supply 20
– „Engine-Chassis“ vehicle
connector 21
– Relay starter 22
– Intake manifold 23 /
Intake side

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1
9
10
7
2
3
4
5
6
8
3 Description
3.6 Engine components and information
– Sacrificial anode 7
– Exhaust manifold 8/
Exhaust side
– Exhaust pipe 9
– Sea water return 10
Engine model
I2 846 MAR TC-155
– Oil filter 1
– Drainage for storage 2
– Waste gate valve 3
– Flame arrester 4
– Connection for sea water
cooling circuit flushing device
5
– Heat exchanger 6

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15
12
11
19
21
22
18
13
16
17
14
20
23
3 Description
3.6 Engine components and information
– 1st cylinder 11
– Sensor camshaft 12 /
2nd cylinder
– Fuel supply 13
– Fuse Box 14
– Engine rotation direction 15
– Stub shaft 16 / Power take off
– Engine cover 17
– Oil tank 18
– Coolant expansion tank 19
– Sea water supply 20
– „Engine-Chassis“ vehicle
connector 21
– Relay starter 22
– Intake manifold 23 /
Intake side

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1
4
7
8
3
5
2
6
– Sacrificial anode 5
– Exhaust manifold 6/
Exhaust side
– Exhaust pipe 7
– Sea water return 8
Engine model
I2 846 MAR NA-80
– Oil filter 1
– Drainage for storage 2
– Heat exchanger 3
– Connection for sea water
cooling circuit flushing device
4
3 Description
3.6 Engine components and information

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13
10
9
17
20
16
11
14
15
12
19
18
21
– 1st cylinder 9
– Sensor camshaft 10 /
2nd cylinder
– Fuel supply 11
– Fuse Box 12
– Engine rotation direction 13
– Stub shaft 14 / Power take off
– Engine cover 15
– Oil tank 16
– Coolant expansion tank 17
– „Engine-Chassis“ vehicle
connector 18
– Sea water supply 19
– Relay starter 20
– Intake manifold 21 /
Intake side
3 Description
3.6 Engine components and information

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1
3.7 Engine fuses and relays
3 Description
3.7 Engine fuses and relays
Overview configuration fuses and relays
1 Relay “MAIN”, relay main
2 Relay “FUEL”, relay fuel pump
3 15 A fuse “IGK”, terminal 30 key switch
4 15 A fuse “VBD”, terminal 30 battery
5 15 A fuse “SERVICE”, electric circuit for
ignition coils, injectors
6 10 A spare fuse “SPARE”
7 10 A fuse “FUEL”, fuel pump
8 15 A fuse “VBR”, terminal 30 after relay main
9 15 A spare fuse “SPARE”
The engine fuses and relays are located in the
fuse box on the engine. (See chapter 3.6 Engine
components and information.)
►Remove the cover 1from the fuse box.