Weber MPE 750 Turbo Marine User manual

103160_SHB_Rev2.1_080611
MPE 750 Turbo Marine
Closed Loop
MPE 750 Turbo Marine - Closed Loop
• 103160_MPE 750 Marine SO Closed Loop 3.1
Service Manual
This service manual is valid for the following engine variants:

103160_SHB_Rev2.1_080611
MPE 750 Turbo Marine
Closed Loop
Service Manual
Table of contents
1 About this document 1
1.1 Meaning of the symbols in the text 1
2 Safety 2
2.1 Basic principle 2
2.2 Meaning of the safety symbols 2
2.3 General safety instructions 3
3 Description 4
3.1 Technical specifications 4
3.2 Serial number 4
3.3 Operating materials 5
3.4 Running in the engine 7
3.5 Operating the engine without sea water 7
4 Maintenance 8
4.1 Maintenance work by the user of the vehicle 9
4.2 Maintenance intervals 10
4.3 Decommissioning at the end of the season 11
4.4 Motor oil and oil filter 12
4.5 Engine cooling circuit 19
4.6 Spark plugs 23
4.7 Valve play 26
5 Malfunctions 32
6 Terminology 37
7 Appendix 38
7.1 Directives 38
7.2 Exhaust type authorizations 39
8 Proof of maintenance for work carried out 40

103160_SHB_Rev2.1_080611
MPE 750 Turbo Marine
Closed Loop
Service Manual
Page 1
1 About this document
1.1 Meaning of the symbols in the text
Symbol /
Sign
Use Explanation
Need Required tools for carrying out the activities in
this section.
Need Required spare parts for the activities in this
section.
Information Information about assembly, e.g. tightening
torques.
Information Note about required lubrication.
[ ] Information Alternative measurement units are in square
brackets.
Information This sign indicates recommendations and
particularities.
1.
2.
...
Instruction Here you must do something.
Instructions must be carried out in the
sequence specified. Deviations from the
specified sequence can cause damage to the
engine and accidents.
– Instruction.
List.
Here you must do something.
Enumeration.
See ... Cross-reference References to other chapters and figures.
This chapter will familiarize you with the structure of this document so that you can find
the information it contains quickly and easily.
This document uses symbols and signs that allow you to find information quickly. Please
read the explanations of the symbols and signs in this chapter. Be sure to read all safety
instructions in this service manually especially carefully.
Always keep this documentation handy and make sure it is always in the vehicle. Be sure
to inform other users of all safety provisions.

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MPE 750 Turbo Marine
Closed Loop
Service Manual
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This engine is state-of-the-art and built according to recognized safety-technical
regulations. Nevertheless, people can be injured or the engine damaged if the safety
instructions in this manual are disregarded.
Only put the engine into operation if it is technically perfect. Faults that compromise
the safety of people or of the engine must be eliminated immediately by trained service
personnel.
Arbitrary constructional changes to the engine are not permitted and void the warranty.
In addition to this documentation, heed generally-valid legal and other binding regulations
for accident prevention and environmental protection. Such duties can affect the handling
of hazardous materials or the provision and wearing of personal safety equipment or
traffic regulations, for example.
2 Safety
2.2 Meaning of the safety symbols
2.1 Basic principle
Disregarding this sign can endanger life and
limb.
Disregarding this sign can cause injuries to
persons.
Disregarding this sign can cause damage to the
engine.
DANGER
WARNING
ATTENTION

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MPE 750 Turbo Marine
Closed Loop
Service Manual
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2.3 General safety instructions
The engine may only be operated at idle speed
for a maximum of 30 seconds without sea water.
Engine damage due to overheating.
See Chapter Operating the engine without sea
water.
Lift a submerged engine out of the water as
quickly as possible and take it to a professional
shop for maintenance within 24 hours. Belated
measures can cause severe damage to the
engine.
ATTENTION
ATTENTION

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MPE 750 Turbo Marine
Closed Loop
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The MPE 750 Turbo Marine - Closed Loop is a 2-cylinder in-line engine. It is intended for
recreational watercraft. It is not designed for constant loads at high speeds as can occur
during races, for example.
3 Description
3.1 Technical specifications
Type 2-cylinder parallel twin with vibration compensation shaft
Displacement 749 cm³
Engine power 76 kW (103 PS) [102 HP] SAE 1228 7300 U/min [RPM]
Max. speed 7800 - 8400 U/min [RPM]
Charging Turbocharger
Combustion system Intake-manifold fuel injection
Injection regulation electronic
Lubrication system Dry sump
Cooling system Water-cooled with closed coolant circuit and open sea
water cooling circuit
3.2 Serial number
The 8-digit serial number (1) serves to
identify the engine. It is engraved in the
motor housing (2) and glued on as a label
(3). Using this number, it is possible to
determine the production date and all
parts built into the engine.

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MPE 750 Turbo Marine
Closed Loop
Service Manual
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3.3 Operating materials
The use of other operating materials causes
damage to the engine and the voiding of the
warranty.
ATTENTION
Fuel
Fuel quality Unleaded gasoline according to DIN 51607 („super
unleaded“), with an octane rating of at least 95 ROZ [RON] or
85 MOZ [MON].
In case of emergency, unleaded fuel with 91 ROZ [RON] or
82.5 MOZ [MON] may be used for a short time.
Lower-quality fuels should only be used in case
of emergency. If used regularly, they cause
decreases in performance and possibly damage
to the engine.
ATTENTION
Lubricant
Oil specification Recommendation: 15W 50 completely synthetic, API SH,
JASO MA
Alternative: 0W 50
Minimum requirement: 0W 40
Fill quantity Initial filling 4.2 liters [4.4 qt (US)]
Oil change with filter 3.3 - 3.5 liters [3.5 - 3.7 qt (US)]

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Closed Loop
Service Manual
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Coolant
Coolant additive Coolant additive based on ethylene glycol
Silicate- and nitrite-free. Suitable for aluminium engines.
Anti-freeze mixture 50 % water + 50 % coolant additive
Manufacturer’s fill provides frost protection up to -37 °C [-34.6 °F]
Recommended minimum frost protection up to -30 °C [-22 °F]
Fill quantity 3,3 liters [3.5 qt (US)]
Approved
coolant additives BASF Glysantin G 30
Chevron Havoline Extended Life Coolant XLC+B
Valvoline Zerex G 30
Coolant additives protect not only against frost,
but also against corrosion and amongst other
things. Therefore, the coolant will be filled in the
specified mixture ratio the whole year round. The
mixture ratio may not be reduced by refilling.
ATTENTION
Different types of coolant should not be mixed.
Use only approved coolants for refill. The mixture
of different types of coolant can cause severe
damage to the engine.
ATTENTION

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MPE 750 Turbo Marine
Closed Loop
Service Manual
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3.4 Running in the engine
3.5 Operating the engine without sea water
The engine may only be operated at idle speed
for a maximum of 30 seconds without sea water.
Engine damage due to overheating.
ATTENTION
Weber Automotive GmbH recommends that during the first five hours of operation, you
should not operate the engine over 6,000 U/min [RPM]. This protective running-in has a
positive effect on the engine‘s lifespan.
If it is necessary to operate the engine longer than 30 seconds without sea water, the
vehicle‘s rinsing equipment must be used.
See chapter Flush sea water cooling circuit after driving.

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Closed Loop
Service Manual
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The table in chapter Maintenance intervals provides the manufacturer’s recommended
intervals for maintenance work. If you follow the maintenance recommendations, a
long lifespan of the engine can be achieved and unnecessary environmental damage
prevented. The Maintenance intervals specified in the table should not be exceeded by
more than 10%.
If not stated otherwise, all activities on the engine described in this manual must be carried
out by trained service personnel.
During the warranty period, maintenance and repair work may only be carried out in
Weber Motor service stations or in associated shops. If necessary, contact your vehicle
dealer.
Weber Automotive GmbH reserves the right to demand that proof of warranty be provided
in writing for warranty service. See Proof of maintenance for work carried out.
The vehicle owner or user is responsible for
adhering to the maintenance intervals. Weber
Automotive GmbH assumes no liability for damage
that arises due to maintenance not carried out.
ATTENTION
4 Maintenance

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Closed Loop
Service Manual
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Always check the oil level and coolant level before driving.
See Chapter Oil level check.
See Chapter Coolant level check.
4.1 Maintenance work by the user of the vehicle
Underrunning and exceeding the motor oil and
coolant fill levels specified in this manual can
cause damage to the engine.
ATTENTION
Regular checks before driving
In order to protect the sea water cooling circuit against soiling, calcium deposits and such,
the sea water cooling circuit must be flushed after each use.
Flush sea water cooling circuit after driving
Soiling in the sea water cooling circuit can cause
severe damage to the exhaust manifold.
The flushing is done with a flush kit in the vehicle. See the vehicle manufacturer‘s service
manual.
1. Connect the Flush kit.
2. Start engine and operate only in idle. Do not accelerate.
3. Ensure the water supply within 30 seconds. See Chapter Operating the engine
without sea water.
4. The Weber Automotive GmbH recommends to flush the sea water cooling circuit
for one minute minimum.
5. Discontinue water supply.
6. Stop engine within 30 seconds.
7. Remove the flush kit.
Only flush engine while running, otherwise water
from the exhaust can enter engine and cause
damage.
ATTENTION
ATTENTION

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Closed Loop
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4.2 Maintenance intervals
Activity Procedure see page
1st
mainte-
nance
h 1)
Maintenance interval
h 1)
At end of season 5) after 25 every 50 every 100
Motor oil and oil
filter Change 14 ■ 2) ■ 2) ■
Coolant Change 20 ■ every 4 years 4)
Spark plugs
Check /
clean 23 ■
Change 23 ■ 3)
Valve play Check /
set 26 ■ 3) ■ 3)
Activities on the engine must be carried out by trained service personnel.
1) h = hours of operation
2) or at least once a year if the hours of operation specified above are not reached before
that.
3) or at least every two years if the hours of operation specified above are not reached
before that.
4) Valid for engine manufacturer’s fill. Please note the instructions provided by coolant
manufacturer, when using other coolants.
5) See chapter Decommissioning at the end of the season.

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Closed Loop
Service Manual
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4.3 Decommissioning at the end of the season
ATTENTION
Never fill more motor oil than specified into the
spark plug holes. Too much motor oil can cause
engine damage.
The decommissioning of the vehicle is necessary ...
... at the end of the season if the vehicle will be decommissioned during the winter
months.
... if the vehicle will not be used for more than 30 days.
In addition to the maintenance work described in the maintenance interval table under
end of the season, various other service work is also required.
- Conserve the cylinders
Check spark plugs. See Chapter Checking the spark plugs.
Fill approx. 10 ml [0.34 oz (US)] of clean motor oil directly through the spark plug holes.
Before you replace the spark plugs, crank up the motor briefly with the starter. Replace
the spark plugs.
- Fill the fuel tank all the way
A full fuel tank prevents the formation of condensation inside the tank.
- Add fuel stabilizer
After approx. 30 days, fuel begins to decompose. You can use any common fuel
stabilizer in order to maintain the fuel quality.

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MPE 750 Turbo Marine
Closed Loop
Service Manual
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4.4 Motor oil and oil filter
Oil level check
- Use a clean, lint-free cloth
The oil level must be measured with oil warm from operation (approx. 80 °C
[176 °F]) and with the motor at a standstill. Measurements with cold oil are not
meaningful. The desired motor temperature is achieved after a driving time of
approx. 10 minutes at 4000 - 4500 U/min [RPM].
Measurement with a motor warm from operation is necessary, because
the oil volume changes depending on the temperature. To avoid mistaken
measurements, the vehicle must be level.
If the motor is operated for a longer time under extreme conditions, the oil
level may reach the MAX marking.

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MPE 750 Turbo Marine
Closed Loop
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MAX
MIN
Service Manual
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1) Unscrew the oil dipstick (1) from
the oil tank and wipe it clean with a
cloth.
2) Replace the oil dipstick in the oil
tank. Do not screw it in. Then
remove it again and read the oil
level.
With a motor warm from operation,
the oil level must be just below the
MAX marking.
The difference between MIN and
MAX is approx. 0.5 liter [0.53 qt
(US)].
ATTENTION
Underrunning the MIN marking and exceeding
the MAX marking can cause severe and, under
some circumstances, irreparable damage to the
engine.
0.5 liter [0.53 qt (US)]
Oil level check (continuation)

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Closed Loop
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Changing the motor oil and oil filter
- Oil extraction pump
- Catch basin for old oil, fill volume at least 4 liters [4.3 qt (US)]
- Flathead screwdriver or wrench to open the screw clamps
- Torque wrench to close the screw clamps
- Torque wrench SW27 [1 1/16 “] for oil filter cover
- Possible hose extension for oil feed hose with screw clamps
- Funnel tube for motor oil
- Motor oil, see chapter Operating materials
- Oil filter, see spare parts catalogue
Draining the motor oil
With a motor warm from operation, the greatest oil volume is sucked out of
the motor.
1) Unscrew the oil dipstick from the
oil tank.
See Chapter Oil level check.
2) Insert the suction hose of the oil
extraction pump into the oil tank
through an opening in the cover (1)
until it reaches the bottom of the oil
tank. X = 260 mm [10.25 in.].
3) Pump all the motor oil out.
4) Remove the suction hose and
insert the oil dipstick again.

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Closed Loop
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5) Remove the cable harness from
the spark plugs and the injection
valves. See Chapter Removing
the spark plugs.
6) Remove the oil feed hose (2) on
one side of the oil tank. If necessary,
extend the oil feed hose.
7) Activate the engine’s starter every
10 seconds in order to let the engine
crank and wait 30 seconds.
8) Repeat this procedure until the
motor oil is pumped completely
out.
The motor oil in the dry sump tank is pumped out with the help of the engine
dry sump pump.
 Tightening torque:
3 Nm ± 10 % [2.2 ft. lb.]
ATTENTION
Do not let engine crank longer than necessary
to prevent damage due to insufficient lubrication
and overloading of the starter.
Draining the motor oil (continuation)

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Closed Loop
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9) Remove the screw clamp and sea
water hose (3).
10) Unplug the plug from switch
70/65°C (4).
11) Unscrew the oil filter cover (5).
 Tightening torque:
3 Nm ± 10 % [2.2 ft. lb.]
 Tightening torque:
24 Nm ± 10 % [17.7 ft. lb.]
Changing the oil filter

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Closed Loop
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12) Replace the oil filter (6) and O-ring
(7).
13) Coat the O-ring (7) lightly with
motor oil.
Assembly occurs in reverse order. Please note instructions after this
symbol 
 During reassembly, make sure
that the oil filter snaps in.
Changing the oil filter (continuation)

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Closed Loop
Service Manual
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14) Fill oil tank with 2.5 liters of motor
oil.
15) Close the oil tank with the oil
dipstick.
16) Warm up the motor in a body of
water for approx. 10 minutes at
4000 - 4500 U/min.
17) Fill up the oil level with a motor
warm from operation until just
below the MAX marking.
Refilling the motor oil