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Spare Parts Catalogue MPE 750 Turbo Marine Closed Loop

MPE 750 Turbo Marine - Closed Loop

This spare parts catalogue is valid for the following engine variants: •

103666_I2 749 MAR TC-100 DS V4 2007 3.1 RAL9010

103666_ETK_Rev1.5_100510

Document No: 103666 ETK Revision:

1.5

Date of Issue:

10.05.2010

Spare Parts Catalogue MPE 750 Turbo Marine Closed Loop

Table of Contents 010

Crankcase

1

01 Case 02 Front Cover

1 3

020

Crank Drive

4

030

Cylinder Head

5

01 Valve Cover 02 Rocker Arms 03 Cylinder Head 04 Valves

5 6 7 8

040

Valve Train

9

050

Cooling System

10

01 Expansion Tank 02 Water Manifold 03 Heat Exchanger 04 Water Pump 05 Turbocharger

10 11 12 13 15

Turbocharging

16

01 Turbocharger 02 Intercooler 03 Exhaust Pipe 04 Mounting Intercooler

16 18 19 20

Intake Area

21

01 Intake Manifold 02 Throttle Body

21 22

080

Engine Management System

23

090

Starter, Generator

26

100

Fuel Unit

27

110

Lubrication System

28

01 Oil Tank, Oil Cooler 02 Roll Over Tank 03 Dry Sump 04 Turbocharger, Oil Filter, Oil Pump 05 Mounting Oil Tank

28 29 30 31 32

120

Engine Mount

33

900

Special Tools

34

910

Repair Kits

36

060

070

Overview of Revisions

38

Terminology

41

103666_ETK_Rev1.5_100510

Spare Parts Catalogue MPE 750 Turbo Marine Closed Loop

010

Crankcase

01 Case 1 3

incl. Pos. 2, 4, 5, 6

2

4 5 7 6

6

19

8 9 10

2

2

(3) 11

18 17 16 11

13

15

Pos.

Part No Description

12

14 QTY

Pos.

1

100280

Sleeve

2

11

Part No Description 100468

2

102992

Plug

3

12

3

*

Crankcase

1

4

100287

Welch Plug

5

100070

Tie Rod

6

100225

7

100224

8 9 10

QTY

Washer

4

*

Bolt

1

13

100464

Bolt

2

14

102442

Pin

8

15

100467

Bolt

Centering Pin

2

16

100297

Clamp Plate

1

Tie Rod Sleeve

4

17

100328

Spring

1

*

Fitting

2

18

100072

Oil Pressure Piston

1

*

Seal

2

19

101526

Oil Seal

1

**

Oil Pressure Switch

1

M8x50 10.9

2 1

M8x90 10.9

1

* See next page ** See Chapter Engine Management System

103666_ETK_Rev1.5_100510

Page

Spare Parts Catalogue MPE 750 Turbo Marine Closed Loop

010

Crankcase

01 Case (continuation)

Crankcase Type 1: Water Pump Outlet with a hose.

Crankcase Type 2: Water Pump Outlet with a metal tube.

2 6 3

1 no longer available 5

4

Crankcase Type 2: Fitting 401291 14

Pos. 1

M18x1.5

Crankcase Type 1: Fitting 102980

M18x1.5

7

18

102980

Part No Description (103608) Crankcase Type 1

QTY

Pos.

1

5

103976

Crankcase Type 2

401291

Part No Description

QTY 1

2

102980

Fitting

M18x1.5x14

2

6

401291

Fitting

M18x1.5x18

2

3

100454

Seal

18x22x1.5 Al

2

7

100467

Bolt

M8x90 10.9

1

4

100466

Bolt

M8x70 10.9

1

The crankcase can be differentiated according to the outlet of the water pump.

Device-dependent parts are: • • • • •

Fitting M18x1.5 Bolt M8 Water Pump Cover Impeller Turbocharger Bracket

Along with a change in crankcase type, these parts must also be exchanged.

See Chapter 050 Cooling System 04 Water Pump and Chapter 060 Turbocharging 01 Turbocharger

103666_ETK_Rev1.5_100510

Page

Spare Parts Catalogue MPE 750 Turbo Marine Closed Loop

010

Crankcase

02 Front Cover

1 8 2 5

6

3

8

2

8

8

4

2

9

11

6

6 10

Pos.

6

Part No Description

QTY

Pos.

1

11

1

103628

Front Cover

2

100501

Bolt

M6x20 8.8

9

3

100411

Bolt

M4x6 8.8

1

4

100406

Clamp

1

5

103615

Generator Cover

1

6

100549

Bolt

M6x65 8.8

4

7

100502

Bolt

M6x25 8.8

1

8

100280

Sleeve

4

9

*

Sensor Crankshaft

1

10

*

Bolt

1

*

7

Part No Description *

Conduit

QTY 1

See Chapter Engine Management System

103666_ETK_Rev1.5_100510

Page

Spare Parts Catalogue MPE 750 Turbo Marine Closed Loop

020

Crank Drive Pos. 7: Always replace pistons in pairs. Don‘t mix pistons with varying part no.

6

incl. Pos. 10

7

incl. Pos. 8

9

8

2

order in pairs

3

order in pairs

17

(10)

incl. Pos. 3, 4, 5

13

order in pairs

(10)

10

4

1

16

10

5

15

14

12

Pos. 14: If mounted distance sleeve (8mm) in Stub Shaft 402634, it must be remove.

11 Pos.

QTY

Pos.

1

Part No Description 102868

Balance Shaft

1

10

103694

2x Con-Rod Bolt

M10x1x38

2

2

100017

Bearing Shell Balance Shaft

8

11

101610

Bolt

M10x1x45 10.9

6

3

100463

Key

1

12

101682

Washer

6

4

100112

Gear Balance Shaft

1

13

101608

Flywheel

1

5

100164

Nut

1

14

402634

Stub Shaft

1

6

103974

Con Rod

2

15

100296

Crankshaft

1

7

102660

Piston

2

8

100361

Circlip

4

9 or or or or

100008 100007 100009 100010 100011

Con Rod Bearing Red 1.721 mm Con Rod Bearing Yellow 1.726 mm Con Rod Bearing Blue 1.731 mm Con Rod Bearing Green 1.736 mm Con Rod Bearing Brown 1.741 mm

4

16 or or or or

100013 100012 100014 100015 100016

Main Bearing Red Main Bearing Yellow Main Bearing Blue Main Bearing Green Main Bearing Brown

17

100734

Key

M10 8.8

Part No Description

103666_ETK_Rev1.5_100510

QTY

1.990 mm 1.995 mm 2.000 mm 2.005 mm 2.010 mm

8

1

Page

Valve Cover Valve Cover Seal

Spare Parts Catalogue MPE 750 Turbo Marine Closed Loop

030

Cylinder Head

01 Valve Cover

1 2 3

5

4

13

6 7 8 9

incl. Pos. 10, 11, 12

10 (10) (10)

Pos.

12

QTY

Pos.

1

*

Bolt

4

11

*

Sensor Camshaft

1

2

*

Washer

4

12

*

Bolt

1

3

*

Ignition Coil

2

13

402159

Engine Badge

1

4

101318

Clip

1

5

101119

Clip

1

6

100446

Bolt

7

100448

Washer

10

8

101654

Bracket

1

9

102941

Valve Cover Black

1

10

102134

Valve Cover Seal

1

*

Part No Description

11

M6x45

Part No Description

QTY

10

See Chapter Engine Management System

103666_ETK_Rev1.5_100510

Page

Rocker Arm Rocker Axle Rocker Arm Support

Spare Parts Catalogue MPE 750 Turbo Marine Closed Loop

030

Cylinder Head

02 Rocker Arms

1

2

3 4 4 5

3

8

8

Pos.

Part No Description

7

6

7

QTY

1

101034

Nut

M10x1.25 10.9

8

2

103099

Washer

8

3

102023

Rocker Arm Short

2

4

102024

Rocker Arm Long

5

100605

Bolt

6

100080

Rocker Axle

4

7

101973

Rocker Arm Support 1

2

8

101974

Rocker Arm Support 2

2

2 M6x20 10.9

4

103666_ETK_Rev1.5_100510

Page

Welch Plug Cylinder Head Cylinder Head Gasket

Spare Parts Catalogue MPE 750 Turbo Marine Closed Loop

030

Cylinder Head

03 Cylinder Head

1 2

3

4

3 5

incl. Pos. 1, 3, 6, 8

9

6

10 8

6 11 7

Quod vide chapter 910 Repair Kits Pos.

Part No Description M6x40 10.9

Pos.

4

11

100514

2

*

Spark Plug

2

3

100094

Welch Plug

2

4

100228

Sleeve

8

5

103623

Cylinder Head

1

6

400876

Plug

2

7

101445

Cylinder Head Gasket

1

8

102992

Plug

1

9

103626

Bracket

1

10

101318

Clip

1

*

Bolt

QTY

1

Part No Description 100501

Bolt

QTY M6x20 8.8

1

See Chapter Engine Management System

103666_ETK_Rev1.5_100510

Page

Spare Parts Catalogue MPE 750 Turbo Marine Closed Loop

030

Cylinder Head

04 Valves 1 2 3

4 6

5

Valve Adjustment Shim (8 parts per bag) Part No Description Exhaust Side

Intake Side

7

8

Pos.

*

Part No Description

QTY

102043

Shim

10x2.50

1

102044

Shim

10x2.55

1

102045

Shim

10x2.60

1

102046

Shim

10x2.65

1

102047

Shim

10x2.70

1

102048

Shim

10x2.75

1

102049

Shim

10x2.80

1

102050

Shim

10x2.85

1

102051

Shim

10x2.90

1

102029

Shim

10x2.95

1

102030

Shim

10x3.00

1

102052

Shim

10x3.05

1

102031

Shim

10x3.10

1

QTY

102032

Shim

10x3.15

1

Shim

8

102033

Shim

10x3.20

1

100129

Collet Valve

16

102034

Shim

10x3.25

1

3

102316

Spring Cup

8

102053

Shim

10x3.30

1

4

100081

Valve Spring

8

102035

Shim

10x3.35

1

5

100658

Valve Stem Seal

8

102036

Shim

10x3.40

1

6

100262

Spring Pad

8

102037

Shim

10x3.45

1

7

102542

Intake Valve

4

102038

Shim

10x3.50

1

8

102327

Exhaust Valve

4

102039

Shim

10x3.55

1

102040

Shim

10x3.60

1

102041

Shim

10x3.65

1

102042

Shim

10x3.70

1

1

*

2

See Table Valve Adjustment Shim

103666_ETK_Rev1.5_100510

Page

Spare Parts Catalogue MPE 750 Turbo Marine Closed Loop

040

Valve Train

2 4 5

7

1

8 3

9 10

6 11

Pos.

QTY

Pos.

1

Part No Description 101921

Camshaft

1

11

2

100116

Timing Chain incl. Link

1

3

100557

Chain Link, Single

1

4

100078

Camshaft Axle

5

100502

Bolt

6

100069

Chain Rail

1

7

102456

Chain Guide

1

8

100079

Chain Tensioner

9

100436

Seal

10

100337

Plug

Part No Description 100832

Bolt

QTY M8x25 10.9

1

1 M6x25 8.8

1

1 24x32x2 Al

1 1

103666_ETK_Rev1.5_100510

Page

Expansion Tank

Spare Parts Catalogue MPE 750 Turbo Marine Closed Loop

050

Cooling System

01 Expansion Tank

4

5

3

6 7

2 9 1 8 14 13

13 12

1

8

11 1

15, 16, 17

8

Pos.

Part No Description

8

10

QTY

Pos.

3

11

100417

Hose

1

12

100513

Banjo Bolt

M14x1.5

1

1

13

100529

Seal

14x18x1.5 Al

2

Cap

1

14

100537

Banjo Fitting

D10/D8 M14

1

Expansion Tank

1

15

100418

Hose

1

2

16

101182

Conduit

1

M6x20 8.8

2

17

101576

Cable Tie

2

16-27/9

4

1

100474

Hose Clamp

12-22/9

2

101668

Hose

3

101806

Hose Clamp

4

100550

5

101801

6

100448

Washer

7

100501

Bolt

8

100471

Hose Clamp

9

100416

Hose

1

10

100742

Hose Connector

1

12.6-14.8/7

Part No Description

103666_ETK_Rev1.5_100510

QTY 1

Page 10

Thermostat Water Manifold

Spare Parts Catalogue MPE 750 Turbo Marine Closed Loop

050

Cooling System

02 Water Manifold

9 8

10 12 5

5

11

3

6

1 7

6

11

4 2

Pos.

QTY

Pos.

1

Part No Description 100294

Circleclip

1

11

100470

Hose Clamp

2

103614

Fitting

1

12

100366

Hose

3

100516

O-Ring

1

4

100150

Thermostat

1

5

100517

O-Ring

2

6

100501

Bolt

7

103613

Water Manifold

M6x20 8.8

QTY 32-50/9

2 1

2 1

8

*

Sensor Coolant Temperature

1

9

100459

Seal

1

10

100744

Fitting

*

Part No Description

10x16x1 Al

1

See Chapter Engine Management System

103666_ETK_Rev1.5_100510

Page 11

Heat Exchanger

Spare Parts Catalogue MPE 750 Turbo Marine Closed Loop

050

Cooling System

03 Heat Exchanger

11

10 9 1 8 3 3 4

7 3

1

3

3

6

1

2

1 5

Pos.

Part No Description

Pos.

4

11

100473

Hose Clamp

2

100313

Hose

3

100470

Hose Clamp

4

100376

Hose

1

5

103503

Heat Exchanger

1

6

101786

Hose

1

7

100377

Hose

1

8

100201

Hose Connector

1

9

100346

Hose

1

10

100488

Hose Clamp

*

25-40/9

QTY

1

Part No Description *

Oil Cooler

QTY 1

1 32-50/9

70-90/9

5

1

See Chapter Lubrication System

103666_ETK_Rev1.5_100510

Page 12

Water Pump Cover Impeller Water Pump Axle

Spare Parts Catalogue MPE 750 Turbo Marine Closed Loop

050

Cooling System

04 Water Pump

11

10

10

13 1

9

12 2

8

16

3

6 5

4

4

Part No Description

14

4

7

Pos.

15

QTY

Pos.

1

100826

Bolt

M6x40

2

11

100375

Hose

1

2

100501

Bolt

M6x20 8.8

2

12

100493

O-Ring

1

3

*

1

13

*

Impeller

1

4

100470

Hose Clamp

3

14

103743

Sealing Kit

1

5

100422

Hose

1

15

102948

Water Pump Axle

1

6

100523

Hose Connector

1

16

102870

Intermediate Gear Water Pump

1

7

100346

Hose

1

8

100488

Hose Clamp

9

**

10

100474

Water Pump Cover 32-50/9

70-90/9

Oil Cooler Hose Clamp

Part No Description

QTY

1 1

12-22/9

2

* See next page ** See Chapter Lubrication System

103666_ETK_Rev1.5_100510

Page 13

Spare Parts Catalogue MPE 750 Turbo Marine Closed Loop

050

Cooling System

1

04 Water Pump (continuation)

2 4

3

For Crankcase Type 1

6

5

9

7

8

For Crankcase Type 2

Pos.

Part No Description

QTY

Pos.

2

5

100826

Bolt

Hose

1

6

103978

Water Tube

1

103627

Water Pump Cover Typ 1

1

7

102454

O-Ring

2

101476

Impeller Type 1

1

8

103977

Water Pump Cover Typ 2

1

9

400180

Impeller Type 2

1

1

100470

Hose Clamp

2

100460

3 4

32-50/9

Part No Description

QTY M6x40

1

The water pump cover and the impeller are dependent on the crankcase type.

Along with a change in crankcase type, the water pump cover and the impeller must also be exchanged.

See Chapter 010 Crankcase 01 Case

103666_ETK_Rev1.5_100510

Page 14

Spare Parts Catalogue MPE 750 Turbo Marine Closed Loop

050

Cooling System

05 Turbocharger

4 5 1 2

1

2 4

6

3

incl. Pos. 2

7

Pos.

*

Part No Description

QTY

1

100507

Bolt

M6x16 8.8

2

100836

O-Ring

2

3

101789

Hose

1

4

102084

Hose Clamp

5

102311

Hose

6

404466

Hose Clamp

7

*

Turbocharger

20-32/12

2

2 1

10-16/9

1 1

See Chapter Turbocharging

103666_ETK_Rev1.5_100510

Page 15

Exhaust Gasket Exhaust Manifold Turbocharger Bracket Turbocharger Airbox

Spare Parts Catalogue MPE 750 Turbo Marine Closed Loop

060

Turbocharging

01 Turbocharger

1 3 5 2

7

4

9 10

6

6 18

19

8

22

12

13

21

11 15

14

17 4

20

16

Pos.

Part No Description

QTY

Pos.

2

11

100737

Nut

M8x118

4

12

100575

Segment

Stud

M8x69

4

13

101771

Bolt

M6x10

6

101579

Hose Clamp

7.8x9.5/5

2

14

100632

Bolt

M8x50 8.8

1

102492

Hose

1

15

**

Turbocharger Bracket

1

6

101540

Hose Clamp

2

16

**

Bolt

2

7

*

Valve

1

17

***

Turbocharger

1

8

102493

9

***

10

*

1

101446

Exhaust Gasket

2

100426

Stud

3

100425

4 5

8.8-10.5/5

Part No Description

QTY M8

8 6

Hose

1

18

100529

Seal

Exhaust Manifold

1

19

100670

Fitting

1

Switch 70/65°C

1

20

100203

Airbox

1

21

100448

Washer

1

22

100502

Bolt

* See Chapter Engine Management System ** See next page *** See Chapter Repair Kits

103666_ETK_Rev1.5_100510

14x18x1.5 Al

M6x25 8.8

1

1

Page 16

Spare Parts Catalogue MPE 750 Turbo Marine Closed Loop

060

Turbocharging

01 Turbocharger (continuation)

3

For Crankcase Type 2

1

For Crankcase Type 1

2

Pos.

4

QTY

Pos.

1

Part No Description 103621

Turbocharger Bracket Type 1

1

3

103979

Turbocharger Bracket Type 2

1

2

100524

Bolt

2

4

102490

Bolt

2

M8x40 8.8

Part No Description

QTY M8x25

The Turbocharger Bracket is dependent on the crankcase type.

Along with a change in crankcase type, the Turbocharger Bracket must also be exchanged.

See Chapter 010 Crankcase 01 Case

103666_ETK_Rev1.5_100510

Page 17

Intercooler Catch Rood

Spare Parts Catalogue MPE 750 Turbo Marine Closed Loop

060

Turbocharging

02 Intercooler

6 10

7 8

1

5 4

7

11

3

12

1

13

16 9

1

17

2 16

15

1

11

11

14

Pos.

QTY

Pos.

4

11

101829

Hose Clamp

Hose

1

12

401880

Catch Rood

1

*

Idle Control Valve

1

13

100809

Hose

1

4

*

Bracket

1

14

102169

Intercooler

1

5

*

Bolt

1

15

100370

Hose

1

6

100513

Banjo Bolt

M14x1.5

1

16

100469

Hose Clamp

7

100529

Seal

14x18x1.5 Al

2

17

401751

Pipe Coupling

8

100537

Banjo Fitting

D10/D8 M14

1

9

401445

Hose

1

10

401453

Connecting Pipe

1

*

Part No Description

11

1

100474

Hose Clamp

2

401953

3

12-22/9

Part No Description

QTY 50-70/13

40-60/9

4

2 1

See Chapter Engine Management System

103666_ETK_Rev1.5_100510

Page 18

Exhaust Pipe

Spare Parts Catalogue MPE 750 Turbo Marine Closed Loop

060

Turbocharging

03 Exhaust Pipe

5

2

incl. Pos. 3, 4, 6, 7

3 4

1

6 7

Pos.

Part No Description

QTY

1

401145

Exhaust Gasket

1

2

103641

Exhaust Pipe

1

3

400247

Fitting

1

4

100459

Seal

10x16x1 Al

1

5

100606

Bolt

M8x30

5

6

100449

Seal

12x18x1.5 Al

1

7

100398

Plug

1

103666_ETK_Rev1.5_100510

Page 19

Intercooler Bracket

Spare Parts Catalogue MPE 750 Turbo Marine Closed Loop

060

Turbocharging

04 Mounting Intercooler 2 1

3 15 4

7

5

10

9

11

4

13

15

12

8

17

incl. Pos. 7

14

6

16

Pos.

QTY

Pos.

2

11

*

Washer

2

Bail

1

12

*

Voltage Regulator

1

Rubber

2

13

*

Bracket

1

100358

Rubber

3

14

*

Nut

103622

Intercooler Bracket

1

15

100501

Bolt

6

100502

Bolt

2

16

100596

Clamp

2

7

100667

Rubber

2

17

101010

Rubber

2

8

103620

Intercooler Bracket

9

100525

Bolt

10

*

Bolt

*

Part No Description

1

101736

Bolt

2

101866

3

101000

4 5

M6x12

M6x25 8.8

Part No Description

QTY

2 M6x20 8.8

6

1 M10x60 8.8

2 2

See Chapter Engine Management System

103666_ETK_Rev1.5_100510

Page 20

Spare Parts Catalogue MPE 750 Turbo Marine Closed Loop

070

Intake Area

01 Intake Manifold 1

2 3 2 4

5 7

6

11

9

15

10 8

14

13

12

16

17

19

18

Pos.

Part No Description

QTY

Pos.

1

11

**

Pressure Sensor

1

2

12

**

Bolt

1

Pipe Coupling

1

13

101651

Nut

100345

O-Ring

2

14

101133

Washer

103630

Intake Manifold

1

15

101669

Stud

6

102154

Bolt

M8x70 10.9

1

16

101000

Rubber

2

7

100520

Bolt

M6x30 8.8

4

17

101012

Rubber

2

8

100502

Bolt

M6x25 8.8

2

18

103618

Intake Manifold Bracket

1

9

100459

Seal

10x16x1 Al

1

19

100632

Bolt

2

10

400247

Fitting

1

*

Throttle Body

2

100469

Hose Clamp

3

401750

4 5

40-60/9

Part No Description

QTY

M8

1 1

M8x30

M8x50 8.8

1

1

* See next page ** See Chapter Engine Management System

103666_ETK_Rev1.5_100510

Page 21

Spare Parts Catalogue MPE 750 Turbo Marine Closed Loop

070

Intake Area

02 Throttle Body

1

incl. Pos. 2 - 7

2

3 4 5

6 7

Pos.

Part No Description

QTY

1

103868

Throttle Body

1

2

401828

Gasket

1

3

401829

Oil Seal

1

4

401167

O-Ring

1

5

103169

Throttle Position Sensor

1

6

103152

Washer

2

7

401831

Bolt

M4x16

2

103666_ETK_Rev1.5_100510

Page 22

Spare Parts Catalogue MPE 750 Turbo Marine Closed Loop

080

Engine Management System 2

3

1 1

See Chapter Cylinder Head

See Chapter Cylinder Head Pos. 1

Part No Description 102118

Spark Plug

RC7PYCB

QTY

Pos.

Part No Description

1

1

101884

Ignition Coil

2

2

100448

Washer

4

3

100447

Bolt

1

QTY

M6x20

4

1

2 See Chapter Cylinder Head Pos.

See Chapter Turbocharging

Part No Description

1

100031

Sensor Camshaft

2

102021

Bolt

6x18

QTY

Pos.

Teilenr.

Bezeichnung

1

1

102383

Ventil

Menge 1

1

2

1 1

2 3

See Chapter Intake Area

See Chapter Turbocharging Pos.

Part No Description

QTY

Pos.

1

1

100029

Pressure Sensor

Bracket

1

2

403390

Bolt

Idle Control Valve

1

1

100541

Bolt

2

103826

3

103127

M6x10 8.8

Part No Description

103666_ETK_Rev1.5_100510

QTY 1 M6x12

1

Page 23

Spare Parts Catalogue MPE 750 Turbo Marine Closed Loop

080

Engine Management System

1 1

incl. Pos. 2

2

See Chapter Fuel Unit Pos.

Part No Description

See Chapter Turbocharging QTY

Pos. 1

1

101936

Injector

2

2

100708

O-Ring

2

Part No Description 103128

QTY

Switch 70/65°C

1

1 1 3 2

See Chapter Cooling System Pos. 1

Part No Description 100024

Sensor Coolant Temperature

See Chapter Crankcase QTY

Pos.

Part No Description

1

1

100032

Sensor Crankshaft

2

101736

Bolt

3

100831

Conduit

QTY 1 M6x12

1 1

1 1

See Chapter Crankcase Pos. 1

Part No Description 100690

Oil Pressure Switch

QTY

Pos.

1

1

Part No Description 100030

103666_ETK_Rev1.5_100510

Lambda Probe

QTY 1

Page 24

Spare Parts Catalogue MPE 750 Turbo Marine Closed Loop

080

Engine Management System 1

Pos. 1

Part No Description 403047

Wire Harness

1

QTY 1

Pos.

Part No Description

QTY

1

103655

ECU MAR TC-100 EU-CH

or

401962

ECU MAR TC-104 USA

1

1

1

2

3

4

5

See Chapter Turbocharging Pos. 1

Part No Description 103606

Main Relay

QTY

Pos.

Part No Description

1

1

100520

2

101875

Washer

2

3

100383

Voltage Regulator

1

4

100704

Bracket

1

5

100835

Nut

103666_ETK_Rev1.5_100510

Bolt

QTY M6x30 8.8

M6

2

2

Page 25

Spare Parts Catalogue MPE 750 Turbo Marine Closed Loop

090

Starter, Generator

3

2

7 10

8 1 4

11 5

9 12

6

13 14

Pos.

Part No Description

QTY

Pos.

2

11

101289

Washer

Washer

2

12

100182

Bolt

M12x90 10.9

1

100151

Starter

1

13

100505

Bolt

M6x35 8.8

3

4

103005

Starter Lead

1

14

100384

Stator

5

100835

Nut

6

100388

Rubber Gromet

1

7

101261

Gear

1

1

100545

Bolt

2

103333

3

M6x50 8.8

M6

Part No Description

QTY 1

1

1

8

101117

Axle

1

9

100565

Neadle Bearing

1

10

400700

Rotor

1

103666_ETK_Rev1.5_100510

Page 26

Fuel Rail Fuel Pressure Regulator

Spare Parts Catalogue MPE 750 Turbo Marine Closed Loop

100

Fuel Unit 1 2 4

6

5

7

8

incl. Pos. 6

9

3

10

8

13

Pos.

12

11

QTY

Pos.

2

11

100459

Seal

Washer

2

12

100743

Banjo Fitting

Injector

2

13

100085

Banjo Bolt

103037

Fuel Rail

1

100431

Locking Clip

2

6

102927

O-Ring

1

7

103041

Fuel Pressure Regulator

1

8

101538

Hose Clamp

2

9

100364

Locking Clip

1

10

401497

Hose

1

*

Part No Description

11

1

100447

Bolt

2

100448

3

*

4 5

M6x20

6.8-8/5

Part No Description

QTY 10x16x1 Al

2 1

M10x1

1

See Chapter Engine Management System

103666_ETK_Rev1.5_100510

Page 27

Oil Dipstick Oil Tank Oil Cooler

Spare Parts Catalogue MPE 750 Turbo Marine Closed Loop

110

Lubrication System

01 Oil Tank, Oil Cooler

1

11

2

10 8

3

8 9

8

4

6

7

4

6

4

Pos.

QTY

Pos.

1

Part No Description 102016

Oil Dipstick

1

11

2

102381

Oil Tank

1

3

100115

Oil Cooler

1

4

100471

Hose Clamp

5

101792

Hose

6

100473

Hose Clamp

7

402603

Hose

1

8

101490

Clip

3

9

101316

Clip

1

10

101788

Hose

1

16-27/9

5

Part No Description 102084

Hose Clamp

QTY 20-32/12

1

3 1

25-40/9

2

103666_ETK_Rev1.5_100510

Page 28

Roll Over Tank

Spare Parts Catalogue MPE 750 Turbo Marine Closed Loop

110

Lubrication System

02 Roll Over Tank

1 2 4 3

2

2

2 6, 7, 8

5

9

10

10

11 12 13

13 14

Pos.

Part No Description

QTY

Pos.

1

11

101252

Hose

4

12

101540

Hose Clamp

8.8-10.5/5

1

1

13

100459

Seal

10x16x1 Al

2

1

14

100148

Banjo Fitting

1

15

100085

Banjo Bolt

1

102315

Hose

2

100471

Hose Clamp

3

102309

Hose

4

101490

Clip

5

404466

Hose Clamp

6

102968

Hose

7

101543

Hose Clamp

8

102983

Hose Connector

1

9

101650

Roll Over Tank

1

10

100474

Hose Clamp

16-27/9

10-16/9

15

Part No Description

QTY 1

1 M10x1

1

2 10.1-11.8/5

12-22/9

2

2

103666_ETK_Rev1.5_100510

Page 29

Oil Screen Suction Pump Suction Pump Cover

Spare Parts Catalogue MPE 750 Turbo Marine Closed Loop

110

Lubrication System

03 Dry Sump 1 2 3 4

5

1 6 7

6

8

9 10 13

11

13 13 4 12 Pos.

Part No Description

QTY

Pos.

4

11

100507

Bolt

M6x16 8.8

1

Washer

2

12

100506

Bolt

M6x60 8.8

1

Oil Screen

1

13

100505

Bolt

M6x35 8.8

3

1

100502

Bolt

M6x25 8.8

2

100448

3

100195

4

100501

Bolt

M6x20 8.8

11

5

401428

Intermediate Gear Suction Pump

1

6

100280

Sleeve

4

7

102225

Suction Pump

1

8

103611

Suction Pump Cover

1

9

100491

O-Ring

2

10

103612

Fitting

1

Part No Description

103666_ETK_Rev1.5_100510

QTY

Page 30

Oil Filter Oil Filter Cover Timing Insert Oil Pump Oil Pump Cover

Spare Parts Catalogue MPE 750 Turbo Marine Closed Loop

110

Lubrication System

04 Turbocharger, Oil Filter, Oil Pump

1

1

2

3, 4 13

incl. Pos. 14

5

(14)

6 7 14 8 9 10

18

20

18

16

11 15

17

12

11 Pos.

QTY

Pos.

1

100459

Seal

10x16x1 Al

2

11

100471

Hose Clamp

2

100085

Banjo Bolt

M10x1

1

12

100380

Hose

1

3

100369

Hose

1

13

100071

Oil Filter Cover

1

4

401701

Conduit

1

14

101109

Oil Filter

1

5

100664

Fitting

1

15

100137

Timing Insert

1

6

100449

Seal

1

16

100293

Key

1

7

*

Turbocharger

1

17

100275

Oil Pump

1

8

100490

O-Ring

1

18

102398

O-Ring

2

9

101847

Flange

1

19

103607

Oil Pump Cover

1

10

100507

Bolt

2

20

100294

Circleclip

1

*

Part No Description

12x18x1.5 Al

M6x16 8.8

Part No Description

QTY 16-27/9

2

See Chapter Turbocharging

103666_ETK_Rev1.5_100510

Page 31

Quick Clamp Oil Tank Bracket

Spare Parts Catalogue MPE 750 Turbo Marine Closed Loop

110

Lubrication System

05 Mounting Oil Tank

1

7

4

2

5

6

3

8

9

10

Pos.

Part No Description

QTY

1

101435

Quick Clamp

1

2

101842

Rubber Pad

1

3

*

Oil Tank

1

4

101840

Rubber Pad

5

100502

Bolt

6

103619

Oil Tank Bracket

1

7

103626

Bracket

1

8

102994

Bracket

1

9

100358

Rubber

2

10

102413

Bolt

*

1 M6x25 8.8

5x22

3

2

See Chapter Oil Tank, Oil Cooler

103666_ETK_Rev1.5_100510

Page 32

Spare Parts Catalogue MPE 750 Turbo Marine Closed Loop

120

Engine Mount

5

5

3 6 2

4

6

5 1

Pos.

5

Part No Description

QTY

1

100842

Bolt

M10x80 12.9

2

2

103616

Engine Bracket Front

1

3

100228

Sleeve

2

4

103617

Engine Bracket Rear

5

100555

Bolt

M10x40 8.8

4

6

100538

Bolt

M8x30 8.8

2

1

103666_ETK_Rev1.5_100510

Page 33

Spare Parts Catalogue MPE 750 Turbo Marine Closed Loop

900

Special Tools

1

Pos. 1

Part No Description 401386

Hand Crank

1

QTY

Pos.

1

1

Part No Description 401370

Hook-Wedge

QTY 1

1 1

Pos. 1

Part No Description 401401

Chain Tool

QTY

Pos.

1

1

Part No Description 401402

Valve Installation Tool

QTY 1

1

1

Pos. 1

Part No Description 401355

Removal Tool

QTY

Pos.

1

1

Part No Description 103330

103666_ETK_Rev1.5_100510

Valve Adjustment Tool

QTY 1

Page 34

Spare Parts Catalogue MPE 750 Turbo Marine Closed Loop

900

Special Tools 4

5

9 6

2 7 3

8

3

1 Pos. 1

Pos.

Part No Description 103609

Installation Spike Valve Stem Seal

Part No Description

QTY 1

Pos.

Part No Description

QTY

1

103701

Chain Breaking Tool consisting of Pos. 2 - 9

1

2

402921

Header

1

3

401389

Bolt

4

401376

Counterpart Break

1

5

401377

Counterpart Rivet

1

6

401378

Bolt

M16 12.9

1

7

401381

Bolt

M10x1 12.9

1

8

401383

Spike

9

401391

Bolt

M6x16 8.8

2

1 M16 12.9

1

QTY

1

103927

Engine Diagnostic Kit consisting of Pos. 2, 3, 4

1

2

103328

Diagnostic Cable / Serial Port

1

3

103924

USB Adapter / Serial Port

1

4

103932

CD Diagnostic Program

1

103666_ETK_Rev1.5_100510

Page 35

Spare Parts Catalogue MPE 750 Turbo Marine Closed Loop

910

Repair Kits

Part No Description

QTY

103399

Long Block Type 1

1

103972

Long Block Type 2

1

Oil Level Hang Tag

Cylinder Head

1

The Repair Kit includes: Cylinder Head

100514

Bolt

100094

Welch Plug

2

100228

Sleeve

8

101973

Rocker Arm Support 1

2

101974

Rocker Arm Support 2

2

100605

Bolt

4

102327

Exhaust Valve

4

100090

Intake Valve

4

100262

Spring Pad

8

QTY

100081

Valve Spring

8

1

102316

Spring Cup

8

100129

Collet Valve

16

101921

Camshaft

1

100078

Camshaft Axle

1

102024

Rocker Arm Long

2

102023

Rocker Arm Short

2

100080

Rocker Axle

4

400876

Plug

2

102992

Plug

1

The Long Block Type can be differentiated according to the water pump outlet.

See Chapter 010 Crankcase 01 Case.

Along with a change in Long Block Type, the Turbocharger Bracket must also be exchanged.

See Chapter 060 Turbocharging 01 Turbocharger

401760

103624

QTY

103623

Long block with a black valve cover. Sub system parts like starter, flywheel and engine brackets are not supplied.

Part No Description

Part No Description

103666_ETK_Rev1.5_100510

1 M6x40 10.9

4

Page 36

Spare Parts Catalogue MPE 750 Turbo Marine Closed Loop

910

Repair Kits

Part No Description 103754

QTY

Repair Kit Exhaust Manifold

1

The Repair Kit includes:

Part No Description 103100

QTY

Repair Kit Turbocharger

1

The Repair Kit includes:

Exhaust Manifold

1

Turbocharger with Exhaust Manifold

1

101446

Exhaust Gasket

2

101446

Exhaust Gasket

2

100737

Nut

8

100737

Nut

401145

Exhaust Gasket

1

401145

Exhaust Gasket

5

100606

Bolt

1

102366

Exhaust Gasket

5

100611

Bolt

1

101789

Hose

100606

Bolt

102366

Exhaust Gasket

100611

Bolt

101789

Hose

M8 M8x30 M8x40

103666_ETK_Rev1.5_100510

M8

8 1

M8x30

5 1

M8x40

5 1

Page 37

Spare Parts Catalogue MPE 750 Turbo Marine Closed Loop

Overview of Revisions New Revision Status

Rev1.1

Rev1.1

Revision Date

18.05.2007

18.05.2007

Chapter

Pos.

Modification

Notes

080 Engine Management System

Relay Starter 103123 currently found in document 103666_ ETK_AttachingParts_Williams_ Rev1.2_070518

No modification

120 Engine Mount

Engine Mount 100527 currently found in document 103666_ ETK_AttachingParts_Williams_ Rev1.2_070518

No modification

Shim 0,8mm 102939 replaced by shim 1mm 103707 and shim 0,5mm 103708

Parts in stock can be used

Rev1.1

18.05.2007

120 Engine Mount

Rev1.1

18.05.2007

030 Cylinder head 03 Cylinder head

9

Bracket 100435 replaced by 103626

Colour changed to white

Rev1.1

18.05.2007

110 Lubrication System 05 Mounting Oil Tank

7

Bracket 100435 replaced by 103626

Colour changed to white

3

Crankcase 103608 currently including plugs 102992 and welch plugs 100287

Parts in stock can be used Parts in stock can be used

Rev1.1

18.05.2007

010 Crankcase 01 Case

Rev1.1

18.05.2007

900 Special Tools

Chain Breaking Tool 401379 replaced by 103701

900 Special Tools

Installation Spike Valve Stem Seal 103609 is new

910 Repair Kits

Repair Kit Exhaust Manifold 103823 replaced by 103754

Colour changed to white

110 Lubrication System 01 Oil Tank, Oil Cooler

10

Fitting 102980 currently found in Chapter 010 Crankcase

No modification

No modification

Rev1.1

Rev1.1

Rev1.1

18.05.2007

18.05.2007

18.05.2007

Rev1.1

18.05.2007

110 Lubrication System 01 Oil Tank, Oil Cooler

7

Fitting 103612 currently found in Chapter 110 Lubrication System

Rev1.1

18.05.2007

110 Lubrication System 04 Turbocharger ...

12

Fitting 102980 currently found in Chapter 010 Crankcase

No modification

05.11.2007

110 Lubrication System 04 Turbocharger ...

4

Conduit 401701 is new

Additional hose protection. Can be updraded.

Rev1.2

05.11.2007

030 Cylinder Head 01 Valve Cover

9

Valve Cover currently including Valve Cover Seal and Sensor Camshaft.

Rev1.2

05.11.2007

900 Special Tools

Diagnostic Kit 103927 is new

Pistons 102310 in stock can be used. Always replace pistons in pairs. Don‘t mix pistons with varying order no.

Rev1.2

Rev1.2

05.11.2007

020 Crank Drive

7

Piston 102310 replaced by 102660

Rev1.2

05.11.2007

020 Crank Drive

6

Con Rod 103359 replaced by 103974

Parts in stock can be used

3

Crankcase 103608 replaced by 103976

Parts in stock can be used for type 1. Spare parts for Crankcase type 1 are available

Rev1.2

05.11.2007

010 Crankcase 01 Case

103666_ETK_Rev1.5_100510

Page 38

Spare Parts Catalogue MPE 750 Turbo Marine Closed Loop

Overview of Revisions New Revision Status

Rev1.2

Rev1.2

Rev1.2

Revision Date

05.11.2007

05.11.2007

05.11.2007

Chapter

Pos.

010 Crankcase 01 Case

050 Cooling System 04 Water Pump

050 Cooling System 04 Water Pump

Modification

Notes

8

Fitting 102980 replaced by 401291.

Please note! The Fitting is dependent on the crankcase type.

Parts in stock can be used for type 1. Spare parts for Fitting type 1 are available

3

Water Pump Cover 103627 replaced by 103977.

Please note! The Water Pump Cover is dependent on the crankcase type

Parts in stock can be used for type 1. Spare parts for Water Pump Cover type 1 are available

13

Impeller 101476 replaced by 400180.

Please note! The Water Pump Cover is dependent on the crankcase type

Parts in stock can be used for type 1. Spare parts for Impeller type 1 are available

15

Turbocharger Bracket 103621 replaced by 103979.

Please note! The Turbocharger Bracket is dependent on the crankcase type

Parts in stock can be used for type 1. Spare parts for Turbocharger Bracket type 1 are available

Parts in stock can be used.

05.11.2007

060 Turbocharging 01 Turbocharger

14.05.2008

110 Lubrication System 01 Oil Tank, Oil Cooler

7

Hose 100378 replaced by 402603. Hose currently including conduit.

Rev1.3

14.05.2008

010 Crankcase 01 Case

3

Crankcase type 1 103608 is no longer available

Rev1.3

14.05.2008

020 Crank Drive

15

Crankshaft 401405 replaced by 100296

Parts in stock can be used.

14

Stub Shaft 101609 replaced by 402634

If mounted distance sleeve (8mm) in Stub Shaft 402634, it must be remove.

Note! Modified connection „Terminal 30 Battery“ and supply voltage Sensor Camshaft from 5V to 12V.

Rev1.2

Rev1.3

Rev1.3

14.05.2008

020 Crank Drive

Rev1.3

14.05.2008

080 Engine Management System

Wire Harness 103599 replaced by 402545

Rev1.3

14.05.2008

900 Special Tools

Chain Breaking Tool 103701: Header 402921 is new

060 Turbocharging 01 Turbocharger

9

Exhaust Manifold 103629 replaced by Repair Kit 103754.

Extended scope of supply.

Parts in stock can be used

17

Turbocharger 103100 replaced

by Repair Kit. Extended scope of supply.

Parts in stock can be used

Parts in stock can be used.

Rev1.3

Rev1.3

14.05.2008

14.05.2008

060 Turbocharging 01 Turbocharger

Rev1.3

14.05.2008

110 Lubrication System 01 Oil Tank, Oil Cooler

7

Hose 100378 replaced by 402603. Hose currently including conduit.

Rev1.4

11.02.2009

060 Turbocharging 02 Intercooler

2

Hose 401907 replaced by 401953.

Parts in stock can be used.

Rev1.4

11.02.2009

080 Engine Management System

Wire Harness 402545 replaced by 403047

Parts in stock can be used

103666_ETK_Rev1.5_100510

Page 39

Spare Parts Catalogue MPE 750 Turbo Marine Closed Loop

Overview of Revisions New Revision Status Rev1.4

Rev1.4

Rev1.4 Rev1.4 Rev1.4

Rev1.5

Rev1.5

Rev1.5

Revision Date 11.02.2009

Chapter

Pos.

030 Cylinder head 04 Valves

7

Modification

Notes

Intake Valve 100090 replaced by 102542.

Parts in stock can be used

11.02.2009

070 Intake Area

Two bolts 100520 M6x30 replaced by 100502 M6x25

11.02.2009

080 Engine Management System

Bolt M6x10 100607 at pressure sensor replaced by 403390.

11.02.2009

030 Cylinder head 01 Valve Cover

13

Engine Badge 402159 is new

11.02.2009

070 Intake Area 02 Throttle Body

1

Throttle Body 401680 replaced by 103868

Parts in stock can be used

10.05.2010

050 Cooling System 05 Turbocharger

6

Hose Clamp 6-16/9 100472 replaced by Hose Clamp 10-16/9 404466

Parts in stock can be used

5

Hose Clamp 6-16/9 100472 replaced by Hose Clamp 10-16/9 404466

Parts in stock can be used

Seal 10x14x1 Al 101107 generally replaced by seal 10x16x1 Al 100459.

Parts in stock can be used

10.05.2010

10.05.2010

110 Lubrication System 02 Roll Over Tank

103666_ETK_Rev1.5_100510

Parts in stock can be used

Page 40

Spare Parts Catalogue MPE 750 Turbo Marine Closed Loop

Terminology A

Balance Shaft 4 Bearing Shell Balance Shaft 4

Impeller 13 Injector 24 Installation Spike Valve Stem Seal 35 Intake Manifold 21 Intake Manifold Bracket 21 Intake Valve 8 Intercooler 18 Intercooler Bracket 20

C

L

Camshaft 9 Camshaft Axle 9 Catch Rood 18 Chain Breaking Tool 35 Chain Guide 9 Chain Link 9 Chain Rail 9 Chain Tensioner 9 Chain Tool 34 Collet Valve 8 Con-Rod Bolt 4 Con Rod 4 Con Rod Bearing 4 Crankcase 1 Crankshaft 4 Cylinder Head 7 Cylinder Head Gasket 7

Lambda Probe 24

Airbox 16

B

M Main Bearing 4 Main Relay 25

O

Diagnostic Kit 35

Oil Cooler 28 Oil Dipstick 28 Oil Filter 31 Oil Filter Cover 31 Oil Level Hang Tag 36 Oil Pressure Switch 24 Oil Pump 31 Oil Pump Cover 31 Oil Screen 30 Oil Seal 1 Oil Tank 28 Oil Tank Bracket 32

E

P

ECU 25 Engine Bracket 33 Exhaust Gasket 16 Exhaust Manifold 16 Exhaust Pipe 19 Exhaust Valve 8 Expansion Tank 10

Piston 4 Pressure Sensor 23

D

F

Q Quick Clamp 32

R

Gear 26 Generator Cover 3

Removal Tool 34 Repair Kit Cylinder Head 36 Repair Kit Exhaust Manifold 37 Repair Kit Long Block 36 Repair Kit Turbocharger 37 Rocker Arm 6 Rocker Arm Support 6 Rocker Axle 6 Roll Over Tank 29 Rotor 26

H

S

Hand Crank 34 Heat Exchanger 12 Hook-Wedge 34

Sensor Camshaft 23 Sensor Coolant Temperature 24 Sensor Crankshaft 24 Shim 8 Spark Plug 23 Spring Cup 8 Spring Pad 8 Starter 26

Flywheel 4 Front Cover 3 Fuel Pressure Regulator 27 Fuel Rail 27

G

I Idle Control Valve 23 Ignition Coil 23

103666_ETK_Rev1.5_100510

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Spare Parts Catalogue MPE 750 Turbo Marine Closed Loop

Terminology Starter Lead 26 Stator 26 Stub Shaft 4 Suction Pump 30 Suction Pump Cover 30 Switch 70/65°C 24

T Thermostat 11 Throttle Body 21, 22 Throttle Position Sensor 22 Tie Rod 1 Tie Rod Sleeve 1 Timing Chain 9 Timing Insert 31 Turbocharger 16 Turbocharger Bracket 16

V Valve 23 Valve Adjustment Tool 34 Valve Cover 5 Valve Cover Seal 5 Valve Installation Tool 34 Valve Spring 8 Valve Steam Seal 8 Voltage Regulator 25

W Water Manifold 11 Water Pump Axle 13 Water Pump Cover 13 Welch Plug 1, 7 Wire Harness 25

Manufacturer: Weber Motor GmbH

103666_ETK_Rev1.5_100510

Address:

Otto-Lilienthal-Str.5

88677 Markdorf

Germany

Internet:

www.weber-motor.com

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