Textron MPE 850 OFF-ROAD User manual

TD409135_DHB
Rev A
17.12.2015
MPE 850 OFF-ROAD
– 409135 I2 846 UTV NA-80
This diagnostic manual is valid for the following engine models:
en_English
DIAGNOSTIC MANUAL
4-Stroke Engine
Read the introductory chapter before performing the task on the engine.
Pay particular attention to the safety messages.

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 DHB MPE850 UTV Rev A | 409135 |
Table of contents
1 About this document 5
1.1 Meaning of the symbols and signal words........................................ 5
1.2 Change management .......................................................5
2 Safety 6
2.1 Meaning of the safety alert symbol and signal words ...............................6
2.2 Important safety messages ................................................... 7
3 Tools and accessories 9
3.1 Textron Motors diagnostic case ................................................9
3.2 Equipment workshop ........................................................9
4 Lights in vehicle 10
4.1 Oil pressure warning light ...................................................10
4.2 Temperature warning light ...................................................10
4.3 Malfunction indicator light (MIL)............................................... 11
5 Troubleshooting with trouble codes 12
5.1 Displaying trouble codes .................................................... 12
5.2 Description of trouble codes .................................................13
6 Test procedures at engine 33
6.1 Checking voltage regulator ..................................................33
6.2 Checking generator ........................................................34
6.3 Checking crankshaft reluctor .................................................35
6.4 Checking thermostat ....................................................... 36
6.5 Checking cam spike at rocker arm ............................................37
6.6 Checking oil pressure ......................................................38
6.6.1 Troubleshooting guide too low oil pressure .................................... 39
6.6.2 Troubleshooting guide too high oil pressure....................................39
7 Components overview 40
Appendix 46
Overview of revisions ...........................................................46
Index .......................................................................47

5DHB MPE850 UTV Rev A | 409135 |
This diagnostic manual was designed to help you operate the engine safely and reliably.
Observe the following information:
– Read the service manual before you begin working.
– Always you also need the engine’s repair manual and the vehicle manufacturer's documentation.
– Some figures in this diagnostic manual are general illustrations and may differ from the actual engine.
1 About this document
1.1 Meaning of the 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.
1.2 Change management
Textron Motors GmbH strives to make continual improvements as part of the ongoing technical development
of its products. Therefore descriptions in the diagnostic manual can be changed or added. All changes are
described in the chapter Overview of revisions.
Observe the following information:
– Always use the most current diagnostic manual from the protected area on our website
www.textronmotors.com.
1 About this document
1.1 Meaning of the symbols and signal words | 1.2 Change management

6 DHB MPE850 UTV Rev A | 409135 |
This engine is state-of-the-art and built according to recognized safety-technical regulations. Ignoring the
information in this diagnostic manual may result in personal injury or property damage.
This diagnostic manual is solely intended for use in a workshop authorized by Textron Motors or the vehicle
manufacturer. All work on the engine must be performed by appropriately trained personnel.
Before beginning any work, trained personnel authorized to work on the engine must have access to the
complete documentation of the engine. Make sure that trained personnel have read and understand all
introductory chapters and in particular, the chapter on safety.
Observe all generally applicable laws and regulations in addition to the information in this diagnostic manual:
– accident prevention
– environmental protection
– handling of hazardous materials
– personal safety equipment
– traffic laws
2 Safety
2.1 Meaning of the 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 the safety alert symbol and signal words

7DHB MPE850 UTV Rev A | 409135 |
2 Safety
2.2 Important safety messages
2.2 Important safety messages
Operating the engine during diagnostic work poses a safety risk to
persons.
►Pay particular attention to the safety messages in the vehicle
manufacturer‘s documentation.
►All diagnostic tasks on the engine must be performed by
appropriately trained personnel.
►Operate the engine during the diagnostic work only if it is absolutely
necessary.
►Only connect the power supply to the engine if it is absolutely
necessary.
►Always be aware that engines requiring diagnostic work may not be
in expected condition.
Defective engine components can cause serious engine damage and can
pose a safety risk to persons.
►Check all components before installation.
►Always replace defective components.
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.
Missing protective equipment poses a safety risk to persons.
►Attach all protective equipment after completing the service tasks.
Unsuitable tools pose a safety risk to persons.
►Use tools listed in chapter 3 Tools and accessories or equivalent
tools.
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.
Operate the engine
Defective parts
Spare parts
Add-on parts and modifications
Protective equipment
Tools
Hot engine components

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2 Safety
2.2 Important safety messages
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.
Engine fluids pose a health risk.
►Always read the manufacturer‘s instructions.
►Always wash your hands immediately after working on or around an
engine.
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.
Engine exhaust gases
Fuel, engine oil and coolant
handling
Fuel
Engine oil
California Proposition 65

9DHB MPE850 UTV Rev A | 409135 |
3 Tools and accessories
3.1 Textron Motors diagnostic case | 3.2 Equipment workshop
3 Tools and accessories
Textron Motors offers a diagnostic case that contains the following parts. Visit our website
www.textronmotors.com for more information.
3.1 Textron Motors diagnostic case
Figure Description
Textron Motors
diagnostic interface
module
Diagnostic cable
Figure Description
USB cable
Data on USB flash
drive: Textron Motors
Diagnostic Software
(english)
Manual (german and
english)
3.2 Equipment workshop
Figure Description
Digital-multimeter
In addition to the diagnostic case, the following test and diagnostic tools are required. The figures are only
examples of suitable test and diagnostic tools and available from specialist retailers.
Figure Description
Oil pressure tester with
M10x1 adapter

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4 Lights in vehicle
4.1 Oil pressure warning light | 4.2 Temperature warning light
4 Lights in vehicle
4.1 Oil pressure warning light
The following lights are supported by the engine management system. Read the service manual and vehicle
manufacturer‘s documentation for more information.
– Oil pressure warning light
– Malfunction indicator light (MIL)
– Temperature warning light
Description Cause Remedy
Illuminates a few seconds
when the engine is started.
There is no malfunction.
The oil pressure warning light
Illuminates until the required oil
pressure is achieved.
–
Illuminates while the engine is
running.
NOTICE! Oil pressure too low.
Serious engine damage due to
insufficient lubrication.
►Switch off the engine immediately.
►Check the oil pressure. (See
chapter 6 Test procedures at
engine.)
►Check the switch oil pressure.
►Check the oil pressure warning
light and wiring. (See the vehicle
manufacturer‘s documentation.)
4.2 Temperature warning light
Description Cause Remedy
Flashes. NOTICE! The Coolant
temperature is too high.
Serious engine damage
caused by overheating.
►Display the trouble codes. (See
chapter 5.1 Displaying trouble
codes.)

11DHB MPE850 UTV Rev A | 409135 |
4 Lights in vehicle
4.3 Malfunction indicator light (MIL)
4.3 Malfunction indicator light (MIL)
Description Cause Remedy
Illuminated for a few seconds
when the ignition is switched
on.
There is no malfunction.
Self test of the light.
–
Not illuminated when the
ignition is switched on.
The malfunction indicator light
(MIL) or wiring is defective.
►Check the wire harness. (See
the vehicle manufacturer‘s
documentation.)
►Check the malfunction indicator
light (MIL) and wiring. (See
the vehicle manufacturer‘s
documentation.)
Flashes when the ignition is on
and the engine is running.
Emission-related malfunction.
There is at least one trouble
code saved in the control unit.
►Display the trouble codes. (See
chapter 5.1 Displaying trouble
codes.)
Illuminates when the ignition is
on and the engine is running.
Malfunction.
There is at least one trouble
code saved in the control unit.

12 DHB MPE850 UTV Rev A | 409135 |
5 Troubleshooting with trouble codes
5.1 Displaying trouble codes
5 Troubleshooting with trouble codes
5.1 Displaying trouble codes
►Connect the notebook to the engine und start Textron Motors Diagnostic Software. (See the vehicle
manufacturer‘s documentation and Textron Motors Diagnostic Tool manual.)
Information! Trouble codes can be displayed with the Textron Motors Diagnostic Tool.

13DHB MPE850 UTV Rev A | 409135 |
5 Troubleshooting with trouble codes
5.2 Description of trouble codes
5.2 Description of trouble codes
Trouble code
Displayed fault
Trouble code description
Possible consequences
Affected part/system
►Possible consequences/remedy
P0011 Camshaft Position not Valid
Invalid signal at the sensor camshaft.
Sensor camshaft
►Check the valve timing. (See the vehicle
manufacturer‘s documentation.)
►Check wiring in the wire harness to
the affected part. (See the vehicle
manufacturer‘s documentation.)
►Replace the affected part. (See the vehicle
manufacturer‘s documentation.)
P0016 Crankshaft Position – Camshaft Position
Correlation - Synchronisation Loss
The signals sensor crankshaft and sensor
camshaft are not synchronous.
Rough engine running.
Engine does not start or stalls.
Sensor crankshaft
►Check wiring in the wire harness to
the affected part. (See the vehicle
manufacturer‘s documentation.)
►Replace the affected part. (See the vehicle
manufacturer‘s documentation.)
►Check the crankshaft reluctor. (See
chapter 6 Test procedures at engine.)
P0018 Camshaft Position Spike Detected
Additional signal at the sensor camshaft.
Loss of power.
Sensor camshaft
►Check valve springs and rocker arms.
►Check wiring in the wire harness to
the affected part. (See the vehicle
manufacturer‘s documentation.)
►Replace the affected part. (See the vehicle
manufacturer‘s documentation.)
P0030 HO2S Heater Control Circuit Open Sensor 1
Open circuit at part or wire harness.
Loss of power.
Rough engine running.
Sensor lambda 1
►Check wiring in the wire harness to
the affected part. (See the vehicle
manufacturer‘s documentation.)
►Replace the affected part. (See the vehicle
manufacturer‘s documentation.)

14 DHB MPE850 UTV Rev A | 409135 |
5 Troubleshooting with trouble codes
5.2 Description of trouble codes
Trouble code
Displayed fault
Trouble code description
Possible consequences
Affected part/system
►Possible consequences/remedy
P0031 HO2S Heater Control Circuit Low Sensor 1
Short circuit to ground at part or wire harness.
Loss of power.
Rough engine running.
Sensor lambda 1
►Check wiring in the wire harness to
the affected part. (See the vehicle
manufacturer‘s documentation.)
►Replace the affected part. (See the vehicle
manufacturer‘s documentation.)
P0032 HO2S Heater Control Circuit High Sensor 1
Short circuit to plus at part or wire harness.
Loss of power.
Rough engine running.
Sensor lambda 1
►Check wiring in the wire harness to
the affected part. (See the vehicle
manufacturer‘s documentation.)
►Replace the affected part. (See the vehicle
manufacturer‘s documentation.)
P0101 Mass Air Flow Calculation Plausibility Error
Implausible values in air mass calculation.
Loss of power.
Starting difficulties.
Sensor intake manifold pressure/temperature
►Check wiring in the wire harness to
the affected part. (See the vehicle
manufacturer‘s documentation.)
►Replace the affected part. (See the vehicle
manufacturer‘s documentation.)
►Leak air in the intake system can cause the
fault. Check the intake system.
WARNING! The throttle body is a safety
critical component. Improper repair or
cleaning of the throttle body may endanger
the safety of persons. Always replace a
defective throttle body.
►Corrosion or soiling in the throttle body can
cause the fault. Check the throttle body.
P0107 Manifold Absolute Pressure Sensor Circuit
Low
Open circuit or short circuit to ground at part or
wire harness.
Loss of power.
Starting difficulties.
Sensor intake manifold pressure/temperature
►Check wiring in the wire harness to
the affected part. (See the vehicle
manufacturer‘s documentation.)
►Replace the affected part. (See the vehicle
manufacturer‘s documentation.)

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5 Troubleshooting with trouble codes
5.2 Description of trouble codes
Trouble code
Displayed fault
Trouble code description
Possible consequences
Affected part/system
►Possible consequences/remedy
P0108 Manifold Absolute Pressure Sensor Circuit
High
Short circuit to plus at part or wire harness.
Loss of power.
Starting difficulties.
Sensor intake manifold pressure/temperature
►Check wiring in the wire harness to
the affected part. (See the vehicle
manufacturer‘s documentation.)
►Replace the affected part. (See the vehicle
manufacturer‘s documentation.)
P0112 Intake Air Temperature Sensor 1 Circuit Low
Short circuit to ground at part or wire harness.
Loss of power.
Starting difficulties.
Sensor intake manifold pressure/temperature
►Check wiring in the wire harness to
the affected part. (See the vehicle
manufacturer‘s documentation.)
►Replace the affected part. (See the vehicle
manufacturer‘s documentation.)
P0113 Intake Air Temperature Sensor Circuit High/
Open
Open circuit or short circuit to plus at part or
wire harness.
Loss of power.
Starting difficulties.
Sensor intake manifold pressure/temperature
►Check wiring in the wire harness to
the affected part. (See the vehicle
manufacturer‘s documentation.)
►Replace the affected part. (See the vehicle
manufacturer‘s documentation.)
P0116 Engine Coolant Temperature Sensor Stuck
Signal
Measured data implausible.
The fan runs continuously.
Sensor coolant temperature
►Check wiring in the wire harness to
the affected part. (See the vehicle
manufacturer‘s documentation.)
►Replace the affected part. (See the vehicle
manufacturer‘s documentation.)
P0117 Engine Coolant Temperature Circuit Low
Short circuit to ground at part or wire harness.
The fan runs continuously.
Sensor coolant temperature
►Check wiring in the wire harness to
the affected part. (See the vehicle
manufacturer‘s documentation.)
►Replace the affected part. (See the vehicle
manufacturer‘s documentation.)

16 DHB MPE850 UTV Rev A | 409135 |
5 Troubleshooting with trouble codes
5.2 Description of trouble codes
Trouble code
Displayed fault
Trouble code description
Possible consequences
Affected part/system
►Possible consequences/remedy
P0118 Engine Coolant Temperature Circuit High/
Open
Open circuit or short circuit to plus at part or
wire harness.
The fan runs continuously.
Sensor coolant temperature
►Check wiring in the wire harness to
the affected part. (See the vehicle
manufacturer‘s documentation.)
►Replace the affected part. (See the vehicle
manufacturer‘s documentation.)
P0121 Throttle Position 1 to Mass Air Flow Plausibility
Error
Sensor intake manifold pressure/temperature
►Possible consequences/remedy as
described for trouble code P0101.
P0122 Throttle Position Sensor 1 Circuit Low
Open circuit or short circuit to ground at part or
wire harness.
Unusual or no throttle response.
Throttle body
►Check wiring in the wire harness to
the affected part. (See the vehicle
manufacturer‘s documentation.)
►Replace the affected part. (See the vehicle
manufacturer‘s documentation.)
P0123 Throttle Position Sensor 1 Circuit High/Open
Short circuit to plus at part or wire harness.
Unusual or no throttle response.
Throttle body
►Check wiring in the wire harness to
the affected part. (See the vehicle
manufacturer‘s documentation.)
►Replace the affected part. (See the vehicle
manufacturer‘s documentation.)
P0128 Coolant Thermostat Stuck Open
Coolant temperature increase is implausible.
Thermostat
►A permanently open or stuck thermostat
can cause the fault. Check the thermostat.
(See chapter 6 Test procedures at engine.)
P0130 O2 Sensor Circuit Open Sensor 1
Open circuit at part or wire harness.
Loss of power.
Rough engine running.
Sensor lambda 1
►Check wiring in the wire harness to
the affected part. (See the vehicle
manufacturer‘s documentation.)
►Replace the affected part. (See the vehicle
manufacturer‘s documentation.)

17DHB MPE850 UTV Rev A | 409135 |
5 Troubleshooting with trouble codes
5.2 Description of trouble codes
Trouble code
Displayed fault
Trouble code description
Possible consequences
Affected part/system
►Possible consequences/remedy
P0131 O2 Sensor Circuit Low Sensor 1
Short circuit to ground at part or wire harness.
Loss of power.
Rough engine running.
Sensor lambda 1
►Check wiring in the wire harness to
the affected part. (See the vehicle
manufacturer‘s documentation.)
►Replace the affected part. (See the vehicle
manufacturer‘s documentation.)
P0132 O2 Sensor Circuit High Sensor 1
Short circuit to plus at part or wire harness.
Loss of power.
Rough engine running.
Sensor lambda 1
►Check wiring in the wire harness to
the affected part. (See the vehicle
manufacturer‘s documentation.)
►Replace the affected part. (See the vehicle
manufacturer‘s documentation.)
P0133 O2 Sensor Circuit Slow Response Sensor 1
Sensor lambda 1 regulation too slow.
Loss of power.
Rough engine running.
Sensor lambda 1
►The part is defective caused by aging.
Replace the affected part. (See the vehicle
manufacturer‘s documentation.)
P0171 Fuel System Too Lean
Fueling too lean.
The lambda control works outside of
permissible limits.
Loss of power.
Rough engine running.
The engine stalls.
Sensor lambda 1
►A leaky intake system or exhaust system
can cause the fault. Check the intake
system and exhaust system.
►A too low fuel pressure can cause the fault.
Check the fuel pressure. (See the vehicle
manufacturer‘s documentation.)
►Blocked injectors can cause the fault.
Check the injectors.
►Replace the affected part. (See the vehicle
manufacturer‘s documentation.)

18 DHB MPE850 UTV Rev A | 409135 |
5 Troubleshooting with trouble codes
5.2 Description of trouble codes
Trouble code
Displayed fault
Trouble code description
Possible consequences
Affected part/system
►Possible consequences/remedy
P0172 Fuel System Too Rich
Fueling too rich.
The lambda control works outside of
permissible limits.
Loss of power.
Rough engine running.
The engine stalls.
Sensor lambda 1
►A too high fuel pressure can cause the
fault. Check the fuel pressure. (See the
vehicle manufacturer‘s documentation.)
►Leaky injectors can cause the fault. Check
the injectors.
►Replace the affected part. (See the vehicle
manufacturer‘s documentation.)
P0201 Cylinder 1 Injector Circuit Open
Open circuit at part or wire harness.
Engine does not start.
Rough engine running.
Injector 1st cylinder
►Check wiring in the wire harness to
the affected part. (See the vehicle
manufacturer‘s documentation.)
►Replace the affected part. (See the vehicle
manufacturer‘s documentation.)
P0202 Cylinder 2 Injector Circuit Open
Open circuit at part or wire harness.
Engine does not start.
Rough engine running.
Injector 2nd cylinder
►Check wiring in the wire harness to
the affected part. (See the vehicle
manufacturer‘s documentation.)
►Replace the affected part. (See the vehicle
manufacturer‘s documentation.)
P0217 Engine Coolant Over Temperature Condition
Coolant temperature is too high.
The engine speed is limited.
The temperature warning light flashes.
Cooling system
►An insufficient coolant level or leaks can
cause the fault. Check the coolant circuit.
►Check the cylinder head gasket.
►A permanently close or stuck thermostat
can cause the fault. Check the thermostat.
(See chapter 6 Test procedures at engine.)

19DHB MPE850 UTV Rev A | 409135 |
5 Troubleshooting with trouble codes
5.2 Description of trouble codes
Trouble code
Displayed fault
Trouble code description
Possible consequences
Affected part/system
►Possible consequences/remedy
P0219 Engine Overspeed Condition
Engine speed > 9000 min-1 [rpm].
No defect
NOTICE! Subsequent damage are possible.
►Avoid situations where the speed can
exceed the maximum speed.
P0221 Throttle Position 2 to Mass Air Flow Plausibility
Error
Sensor intake manifold pressure/temperature
►Possible consequences/remedy as
described for trouble code P0101.
P0222 Throttle Position Sensor 2 Circuit Low/Open
Open circuit or short circuit to ground at part or
wire harness.
Unusual or no throttle response.
Throttle body
►Check wiring in the wire harness to
the affected part. (See the vehicle
manufacturer‘s documentation.)
►Replace the affected part. (See the vehicle
manufacturer‘s documentation.)
P0223 Throttle Position Sensor 2 Circuit High
Short circuit to plus at part or wire harness.
Unusual or no throttle response.
Throttle body
►Check wiring in the wire harness to
the affected part. (See the vehicle
manufacturer‘s documentation.)
►Replace the affected part. (See the vehicle
manufacturer‘s documentation.)
P025A Fuel Pump Module Control Circuit/Open
Open circuit at part or wire harness.
Engine does not start or stalls.
Relay fuel pump
►Check wiring in the wire harness to
the affected part. (See the vehicle
manufacturer‘s documentation.)
►Replace the affected part. (See the vehicle
manufacturer‘s documentation.)
►Check the fuel pump and wiring. (See the
vehicle manufacturer‘s documentation.)

20 DHB MPE850 UTV Rev A | 409135 |
5 Troubleshooting with trouble codes
5.2 Description of trouble codes
Trouble code
Displayed fault
Trouble code description
Possible consequences
Affected part/system
►Possible consequences/remedy
P025C Fuel Pump Module Control Circuit Low
Short circuit to ground at part or wire harness.
Engine does not start or stalls.
Relay fuel pump
►Check wiring in the wire harness to
the affected part. (See the vehicle
manufacturer‘s documentation.)
►Replace the affected part. (See the vehicle
manufacturer‘s documentation.)
►Check the fuel pump and wiring. (See the
vehicle manufacturer‘s documentation.)
P025D Fuel Pump Module Control Circuit High
Short circuit to plus at part or wire harness.
Engine does not start or stalls.
Relay fuel pump
►Check wiring in the wire harness to
the affected part. (See the vehicle
manufacturer‘s documentation.)
►Replace the affected part. (See the vehicle
manufacturer‘s documentation.)
►Check the fuel pump and wiring. (See the
vehicle manufacturer‘s documentation.)
P0261 Cylinder 1 Injector Circuit Low
Short circuit to ground at part or wire harness.
Engine does not start.
Rough engine running.
Injector 1st cylinder
►Check wiring in the wire harness to
the affected part. (See the vehicle
manufacturer‘s documentation.)
►Replace the affected part. (See the vehicle
manufacturer‘s documentation.)
P0262 Cylinder 1 Injector Circuit High
Short circuit to plus at part or wire harness.
Engine does not start.
Rough engine running.
Injector 1st cylinder
►Check wiring in the wire harness to
the affected part. (See the vehicle
manufacturer‘s documentation.)
►Replace the affected part. (See the vehicle
manufacturer‘s documentation.)