Weber Motor MPE 850 User manual

407477_SHB
Rev 1.2
16.08.2013
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
This service manual is valid for the following engine variants:
Read this service manual thoroughly before operating the engine for the
first time.
SERVICE MANUAL
4-Stroke Engine
en_English

Weber Motor GmbH
Zepernicker Chaussee 23-37
16321 Bernau bei Berlin
Germany
www.weber-motor.com
Weber Motor 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 Weber Motor GmbH.
All rights reserved according to the copyright law.

4 SHB MPE850 Rev 1.2 | 408014 | 408090 | 408101 |
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 11
3.1 Intended use ............................................................. 11
3.2 Identification ............................................................. 11
3.3 Fuel ....................................................................13
3.4 Engine oil................................................................13
3.5 Coolant .................................................................14
3.6 Engine components and information ...........................................15
3.7 Engine fuses and relays ....................................................19
3.8 Technical specifications .....................................................20
4 Operation 21
4.1 Service intervals ..........................................................21
4.2 Operation during the break-in period...........................................23
4.3 Service before driving ......................................................24
4.3.1 Inspecting the exhaust and fuel system ....................................... 24
4.3.2 Checking coolant level .................................................... 25
4.3.3 Checking oil level ........................................................ 26
4.4 Service after driving........................................................28
4.4.1 Flushing sea water cooling circuit............................................ 28
4.4.2 Corrosion protection ......................................................29
4.4.3 Transport and storage of the vehicle .........................................29
5 Special scenarios 30
5.1 Engine idle for more than 30 days.............................................30
5.2 Operating engine without sea water ...........................................30
5.3 Towing vehicle in water .....................................................30
5.4 Measures in case of flooded engine ...........................................31
6 Malfunctions 32
6.1 Malfunctions table ......................................................... 32
6.2 Checking engine fuses .....................................................35

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Table of contents
7 Dealer and servicing network 37
7.1 Locating a workshop ....................................................... 37
7.2 Service and spare parts..................................................... 37
7.3 Repairs .................................................................37
7.4 Warranty ................................................................37
8 Service tasks in the workshop 38
8.1 Safety messages workshop.................................................. 38
8.2 Tools and accessories ......................................................40
8.2.1 Weber Motor service parts ................................................. 40
8.2.2 Weber Motor diagnostic case ...............................................41
8.2.3 Equipment workshop .....................................................42
8.2.4 Supplies ...............................................................44
8.3 Changing engine oil and oil filter .............................................. 45
8.4 Checking sacrificial anode...................................................52
8.5 Checking and adjusting valve play ............................................53
8.5.1 Checking valve play ...................................................... 53
8.5.2 Adjusting valve play ......................................................57
8.6 Replacing spark plugs and igition coils ......................................... 60
8.7 Checking spark plugs ......................................................62
8.8 Replacing rubber mount ....................................................65
8.9 Adjusting waste gate valve ..................................................70
8.10 Checking flame arrester ...................................................72
8.11 Changing coolant.........................................................74
8.12 Replacing fuel filter .......................................................77
8.13 Storing engine and putting into operation ......................................78
8.13.1 Preparing engine for storage ..............................................78
8.13.2 Putting engine into operation after storage.................................... 80
8.14 Disposal................................................................81
9 Confirmation of service tasks 82
Appendix 84
Engine manufacturer ...........................................................84
Exhaust type authorization and certification.......................................... 84
USA EPA EMISSION LIMITED WARRANTY.........................................85
Index .......................................................................86

6 SHB MPE850 Rev 1.2 | 408014 | 408090 | 408101 |
This service manual was designed to help you operate the engine safely and reliably.
Observe the following information:
– Read this service manual thoroughly before operating the engine for the first time.
– The service manual is for the engine in your vehicle.
– Keep the service manual in a safe place.
– Make sure that all personnel using the vehicle have access to the service manual.
– If you sell the vehicle, always pass on the service manual to the new owner.
– The latest version of the service manual is available for download in other languages from our web site
www.weber-motor.com.
– Always read the vehicle manufacturer‘s documentation.
– 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
Item Meaning
NOTICE The signal word NOTICE indicates potential property damage.
Information The signal word Information indicates specific features and recommendations.
1About this document
1.1 Meaning of symbols and signal words

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This engine is state-of-the-art and built according to recognized safety-technical 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
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.
Engine malfunctions pose a safety risk to personnel.
►Only operate the engine when in perfect condition.
►All malfunctions must be repaired immediately in a workshop
authorized by Weber Motor or the vehicle manufacturer.
All the components in your engine have been carefully tested and fulfill
strict quality and safety requirements. Externally supplied parts cannot
fulfill these requirements.
►Always use original Weber Motor spare parts.
The consequences of attaching add-on parts and making unauthorized
modifications to the engine are unknown and pose a safety risk to
personnel.
►Modifications and the attachment of add-on parts is only permitted if
approved or instigated by Weber Motor.
Service tasks
Malfunctions
Spare parts
Add-on parts and modifications
All service tasks described in Chapter 8 Service tasks in the workshop
require special technical knowledge of the engine.
►All service tasks described in chapter 8 Service tasks in the
workshop must be performed by a workshop authorized by Weber
Motor or the vehicle manufacturer.
Service tasks in the workshop
Engine components become extremely hot during operation.
►Do not touch any engine components during operation.
►Switch off the engine and wait until the components have cooled.
Hot engine components
2Safety
2.2 Important safety messages

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Handling of fuel, engine oil and
coolant
Operating materials pose a health risk.
►Always read the manufacturer's instructions.
►Always wash your hands prior to eating, smoking and using the
toilet as well as at the end of the working shift when working with
operating materials.
Operating materials are hazardous to the environment.
►Never allow operating materials to escape into the groundwater,
water courses or sewage system. Always dispose of operating
materials according to applicable national regulations.
Danger of slipping on spilled fluids.
►Always use a filler neck or funnel when filling components with
operating materials.
►Always clean up any spilled operating materials immediately.
Engine exhaust gases contain carbon monoxide (CO). Inhalation of
carbon monoxide can deprive the body of oxygen and result in organ
damage or even death by asphyxiation.
►When operating the engine in enclosed spaces, use exhaust hoses
to direct the engine exhaust gases into the open.
Engine exhaust gases
Some service tasks require disconnection of the engine from the power
supply. Starting the engine inadvertently may endanger the safety of
personnel.
Read the vehicle manufacturer‘s documentation for more information.
►Disconnect the engine from the power supply when requested.
Engine power supply
Fuel is highly flammable. Vapors may ignite and cause an explosion.
►Do not smoke in the vicinity of the engine and do not allow naked
flames or sparks near the engine or the fuel system.
►Never fill with fuel while the engine is running.
►Do not start the engine if there is a smell of fuel or you suspect that
fuel is leaking. Have a workshop authorized by Weber Motor or the
vehicle manufacturer inspect the engine immediately.
►Fuel on hot surfaces can cause fires.
►Do not extinguish with water. In the event of a fire, use foam, dry
chemical or carbon dioxide extinguishers.
Fuel
2Safety
2.2 Important safety messages

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Warning against chemicals/hazardous materials according to the law of
the state of California. This product contains chemicals known to the State
of California to cause cancer, birth defects, or other reproductive harm.
California Proposition 65
2Safety
2.2 Important safety messages

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999999
Date:
Part No.:
Serial No.:
26.10.2012
999999
9999999999
9999999999
1
5
3
2
4
3 Description
The MPE 850 MARINE has been designed for powering watercrafts.
The engine was not designed or intended for any other use.
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 variant.
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 required when making
queries about your engine.
3.1 Intended use
3 Description
3.1 Intended use | 3.2 Identification
Engine variants
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 label “Emission Control Information” indicates
the certification of the engine according to the legal
exhaust emission guidelines. (See in appendix
exhaust type authorization and certification.)
The label is located on the expansion tank.

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7
6
3 Description
3.1 Intended use | 3.2 Identification
Engine variant 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 label “Emission Control Information” indicates
the certification of the engine according to the legal
exhaust emission guidelines. (See in appendix
exhaust type authorization and certification.)
The label is located on the expansion tank.

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3.3 Fuel
3.4 Engine oil
Engine damage due to incorrect engine oil grade or viscosity.
An incorrect engine oil grade or viscosity causes excessive wear and
moving parts may start to seize up.
►Always use the recommended engine oil.
►Do not mix engine oils of different grades or degrees of viscosity.
Engine variants I2 846 MAR TC-80, TC-100 and TC-120:
Unleaded gasoline (super) with an octane rating of 95 ROZ or 85 MOZ.
USA: "Premium 91", unleaded
Engine variant I2 846 MAR TC-155:
Unleaded gasoline (super) with an octane rating of 98 ROZ or 88 MOZ.
USA: „Premium 93“, unleaded
NOTICE! Low octane fuel can cause loss of power and/or increased fuel
consumption.
Unleaded gasoline with an octane rating of at least 91 ROZ or 82,5 MOZ.
USA: At least "Regular 87", unleaded
NOTICE! An increased share of ethanol can lead to premature abrasion
and poor starting performance of the engine.
Maximum 15 % (E15)
Recommended fuel quality
Minimum requirement
Permissible share of ethanol
0W 40 completely synthetic, at least API SJ, ACEA A3/B3
Initial filling 3,5 liters [3.7 qt (US)]
After changing oil 2,9 liters [3.1 qt (US)]
Engine oil
Fill quantity
Information! Weber Motor recommends you always to keep a supply of engine oil to hand. Consult
your local vehicle dealer.
3 Description
3.3 Fuel | 3.4 Engine oil

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3.5 Coolant
Freezing, overheating or corrosion due to incorrect mixing ratio or
unauthorized coolant additives.
An incorrect mixing ratio reduces the cooling capacity.
Combining different coolant additives may trigger a chemical reaction and
they may lose their effectiveness.
►Use the same coolant throughout the year in the mixing ratio
specified.
►When topping up the coolant, do not change the mixing ratio.
►Always use approved coolant additives when topping up the
coolant.
Coolant additive based on ethylene glycol, silicate- and nitrite- free,
suitable for aluminium engines.
50 % water + 50 % coolant additive
2,75 liters [2.9 qt (US)]
BASF Glysantin G 30
Chevron Havoline Extended Life Coolant XLC+B
Valvoline Zerex G 30
Coolant additive
Mixing ratio
Fill quantity
Approved coolant additives
Information! Weber Motor recommends you always to keep an adequate supply of ready mixed
coolant to hand. Consult your local vehicle dealer.
3 Description
3.5 Coolant

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3
1
5
7
2
9
10
6
4
8
3 Description
3.6 Engine components and information
3.6 Engine components and information
Information! If you remove the vehicle connector "Engine-Chassis” the engine will not be
disconnected from the battery. The battery is connected separately to the wire harness. The wire harness
is not shown in the figures.
– Sacrificial anode 8
– Exhaust pipe 9
– Sea water return 10
Engine variants 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
– Heat exchanger 6
– Connection for flushing device
sea water cooling circuit 7

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14
12
11
18
20
21
19
17
13
15
16
3 Description
3.6 Engine components and information
– 1st cylinder 11
– 2nd cylinder 12
– Fuel supply 13
– Engine rotation direction 14
– Stub shaft 15
– Engine cover 16
– Oil tank 17
– Expansion tank coolant 18
– Sea water supply 19
– Vehicle connector "Engine-
Chassis" 20
– Relay starter 21

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

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14
11
10
18
20
21
19
17
12
15
16
13
3 Description
3.6 Engine components and information
– 1st cylinder 10
– 2nd cylinder 11
– Fuel supply 12
– Fuse Box 13
– Engine rotation direction 14
– Stub shaft 15
– Engine cover 16
– Oil tank 17
– Expansion tank coolant 18
– Sea water supply 19
– Vehicle connector "Engine-
Chassis" 20
– Relay starter 21

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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.

20 SHB MPE850 Rev 1.2 | 408014 | 408090 | 408101 |
3 Description
3.8 Technical specifications
3.8 Technical specifications
Engine variant
I2 846 MAR
TC-80 TC-100 TC-120 TC-155
Type 4-Takt-Otto-Motor, Parallel-Twin mit Ausgleichswelle und oben liegender
Nockenwelle (SOHC)
Displacement 846 cm³
Number of cylinders 2
Bore x stroke 89 x 68 mm [3.5 x 2.7 in]
Compression ratio 9 : 1
Engine power ISO 8178 58,5 kW @
6600 min-1 [rpm]
74 kW @
7200 min-1 [rpm]
91 kW @
7500 min-1 [rpm]
112 kW @
7500 min-1 [rpm]
Engine power SAE J1228 59 kW @
6600 min-1 [rpm]
75 kW @
7200 min-1 [rpm]
92 kW @
7500 min-1 [rpm]
113 kW @
7500 min-1 [rpm]
Engine speed limit 8000 min-1 [rpm]
Idle speed 1600 min-1 [rpm]
Carburation Sequential multipoint intake manifold injection
Lubrication system Dry sump
Cooling system Closed coolant circuit and open sea water cooling circuit
Engine management system Synerject M3D
Throttle body Electronically controlled, dia. = 44 mm [1.73 in]
Ignition system Electronically controlled distributorless ignition system with single spark
ignition coils
Starter system Electric starter
Generator, internal > 450 W @ 4000 min-1 [rpm]
Fuses Automotive fuses mini blade-type 10 A and 15 A
Weight including engine oil and
coolant
95 kg [209 lb] 95 kg [209 lb] 95 kg [209 lb] 100 kg [221 lb]
Dimensions L 743 mm [30 in]
Dimensions B 539 mm [22 in]
Dimensions H 509 mm [20 in]