Spaccato ricambi motore weber 850 MPE Latini Williams Service Center by Latini Group

SPARE PARTS CATALOG 4-Stroke Engine MPE 850 MARINE This spare parts catalog is valid for the following engine models: –– 408014 I2 846 MAR TC-120 –– 408101 I2 846 MAR TC-100 (TC-80) (TC-120) –– 408246 I2 846 MAR NA-80 TD407477_ETK Rev C 03.07.2015 en_English

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. Textron Motors GmbH DaimlerstraĂ&#x;e 5 88677 Markdorf Germany www.weber-motor.com

Table of contents

Table of contents 1 About this document

1.1 Orientation engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Meaning of the symbols in the spare parts lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 Change management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 010 Crankcase

7 8 8 8 9

010.01-1 Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 010.01-2 Crankcase TC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 010.01-2 Crankcase NA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 010.01-3 Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 010.02-1 Oil Cooler Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 010.02-2 Oil Cooler Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 010.03 Generator Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 020 Crank Drive 020.01 020.01 020.02 020.03

16 Crankshaft TC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft NA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stub Shaft Thread M24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

030 Cylinder Head

16 17 18 19 20

030.01 Valve Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 030.02 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 040 Valve Train

040.01 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 040.02 Rocker Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 040.03 Valves TC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 040.03 Valves NA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 050 Cooling System

050.01-1 Thermostat Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 050.01-2 Thermostat Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 050.02 Coolant Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 050.03 Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 050.04 Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 050.05 Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 050.06-1 Hoses Sea Water Supply TC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 050.06-2 Hoses Sea Water Supply TC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 050.06 Hoses Sea Water Supply NA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 050.07 Hoses Sea Water Return Type 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 050.07 Hoses Sea Water Return Type 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 23 24 25

26 27 28 29 30 31 32 33 34 35 36

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

Table of contents

060 Exhaust System 060.01-1 Mounting Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 060.01-2 Mounting Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 060.02 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 060.03-1 Exhaust Manifold TC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 060.03-2 Exhaust Manifold TC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 060.03 Exhaust Manifold NA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 060.04-1 Catalyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 060.04-2 Catalyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 070 Intake Area 070.01 Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 070.02 Throttle Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 070.03 Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 070.04 Flame Arrester TC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 070.05 Air Box NA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 37 38 39 40 41 42 43 44 45 45 46 47 48 49

080 Engine Management System

090 Starter, Generator

090.01 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 090.02 Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 090.03 Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 090.04 Relay Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Fuel Unit

55 56 57 58 59

100.01 Fuel Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 100.02 Additional parts fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 110 Lubrication System 110.01 Dry Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110.02 Oil Pressure Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110.03 Oil Pressure Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110.04-1 Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110.04-2 Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110.05 Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110.07-1 Hoses Oil Supply Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110.07-2 Hoses Oil Supply Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110.08 Hose Crankcase Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110.09 Hoses Oil Supply Turbocharger TC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Engine Mount 120.01 Lifting Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120.02-1 Engine Bracket, Carrier Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120.02-2 Engine Bracket, Carrier Module TC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120.02-2 Engine Bracket, Carrier Module NA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

61 61 62 63 64 65 66 67 68 69 70 71 71 72 73 74

Table of contents

120.03 Additional parts engine mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 900 Tools and accessories

900.01 Cases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 900.02 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 900.03 Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 910 Repair Kits

Appendix 82 Overview of revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

1 About this document

1 About this document In this spare parts catalog are shown all available service parts, spare parts, repair kits and special tools. Observe the following information: –– The spare parts catalog is valid for several engine models. Observe the information to the different engine models. –– Please read carefully the spare parts catalog before ordering spare parts. –– Always use the most current spare parts catalog from the protected area on our web site www.weber-motor.com. –– Some figures in this sspare parts catalog are general illustrations and may differ from the actual engine.

1.1 Orientation engine The arrow 1 helps you orient the illustrated parts in the chapters. The arrow in the chapters always points in the direction as illustrated.

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

1 About this document

1.2 Meaning of the symbols in the spare parts lists Item

Meaning

(e)

If you remove this part, you must replace it.

(t)

The thread is provided with a TufLok coating. The TufLok coating seals the thread. If you have unscrewed the part, the coating is not completely effective any more. Replace this part.

(m)

The thread is provided with a micro encapsulated coating. During fastening the bolt, the microcapsules will burst and the contained adhesive and curing agent are released and mixed. If you have unscrewed the part, the coating is not effective any more. Replace this part.

(p)

Parts with the designation (p) are painted parts. All available colors are listed in the spare parts list.

(s)

You need service parts for service tasks to the engine. Service parts are only identified in the spare parts list in chapter Complete spare parts list. Parts with the designation additional part are optional and not installed in every vehicle.

1.3 Abbreviations Abbreviation

Meaning

Turbocharched engine

Naturally aspirated engine

1.4 Change management Textron Motors GmbH strives to make continual improvements as part of the ongoing technical development of its products. Therefore part numbers can change. All changes are described in the chapter Overview of revisions.

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

010 Crankcase 010.01-1 Crankcase

010 Crankcase

010.01-1 Crankcase 2

incl. Pos. 2 to 7

3 4 5 6

7 8

(1)

8 11

9 11 8 7

9 10 10 9

This chapter is valid for all engine models Pos. Part No Description

Pos. Part No Description

QTY

(p)

105474 Crankcase RAL9010

404297 Centering Pin

100650 Plug M18x1.5

(t)

102992 Plug M10x1

(t)

404359 Welch Plug

406596 Tie Rod M10x1.25

404163 Bolt M6x90 8.8

404870 Bolt M8x90 10.9

QTY

100506 Bolt M6x60 8.8

408004 Bolt M8x50 10.9

Oil Pressure Valve

* see chapter 110.03 Oil Pressure Valve

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

010

010 Crankcase 010.01-2 Crankcase TC

010 Crankcase

010.01-2 Crankcase TC

incl. Pos. 2

This chapter is valid for the following engine models: –– 408014 I2 846 MAR TC-120 –– 408101 I2 846 MAR TC-100 (TC-80) (TC-120) Pos. Part No Description

QTY

404585 Cylinder Liner

402161 O-Ring

(e)

101526 Oil Seal

(e)

403895 Fitting M18x1.5

(t)

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

010 Crankcase 010.01-2 Crankcase NA

010 Crankcase

010.01-2 Crankcase NA

incl. Pos. 2

This chapter is valid for the following engine models: –– 408246 I2 846 MAR NA-80 Pos. Part No Description 1

404585 Cylinder Liner

QTY

2 4

402161 O-Ring

(e)

101526 Oil Seal

(e)

100650 Plug M18x1.5

(t)

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

010

010 Crankcase 010.01-3 Crankcase

010 Crankcase

010.01-3 Crankcase 1 2

3 9

10 4 3

8 6 This chapter is valid for all engine models Pos. Part No Description

Pos. Part No Description

QTY

100433 Nut M10x1.25 10.9

103099 Washer

100650 Plug M18x1.5

(t)

102523 Plug M18x1.5

100454 Seal 18x22x1.5 Al

(e)

1 1

Sensor Crankshaft

O-Ring

408118 Bolt M6x12 10.9

404122 Fitting

100587 Seal 8x12x1 Al

11 12

Sensor Knock

408119 Bolt M8x30 10.9

QTY

(e)

* see chapter 080 Engine Management System

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

010 Crankcase 010.02-1 Oil Cooler Bracket

010 Crankcase

010.02-1 Oil Cooler Bracket

2 1

incl. Pos. 2

5 3

This chapter is valid for all engine models Pos. Part No Description

QTY

105475 Oil Cooler Bracket RAL9010

(p)

403940 Gasket

(e)

100228 Sleeve

100501 Bolt M6x20 8.8

100520 Bolt M6x30 8.8

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

010

010 Crankcase 010.02-2 Oil Cooler Bracket

010 Crankcase

010.02-2 Oil Cooler Bracket 2

INFO

6 7

(3)

Pos. 5 and Pos. 8 The mounting of the blanking cover were changed in summer 2014. Depending on the production date, can be installed pos. 5 or pos. 8. INFO

This chapter is valid for all engine models Pos. Part No Description 1

402938 Plug M14x1.5

(4)

Pos. Part No Description

QTY

100529 Seal 14x18x1.5 Al

(e)

401167 O-Ring

(e)

406231 Blanking Cover

407929 Clamp Ring

407946 Circlip

100648 Bolt M4x10

403346 Bracket

404867 Bolt M6x20 8.8

INFO

QTY

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

010 Crankcase 010.03 Generator Cover

010 Crankcase

010.03 Generator Cover

incl. Pos. 4

5 5 6

This chapter is valid for all engine models Pos. Teilenr. Bezeichnung

Menge

(p)

100228 Sleeve

403792 Plug M10x1

105476 Generator Cover RAL9010

2 3 4

402082 Oil Seal

(e)

404888 Bolt M10x50 8.8

100545 Bolt M6x50 8.8

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

010

020

020 Crank Drive 020.01 Crankshaft TC

020 Crank Drive

020.01 Crankshaft TC 5

incl. Pos. 6

incl. Pos. 8

INFO Pos. 2 and pos. 9 The installed bearing shells have different sizes. Please check the bearing play before ordering.

This chapter is valid for the following engine models: –– 408014 I2 846 MAR TC-120 –– 408101 I2 846 MAR TC-100 (TC-80) (TC-120) Pos. Part No Description

QTY

100013 Main Bearing Shell Red 1.990mm

103694 2x Con Rod Bolt M10x1x38

100012 Main Bearing Shell Yellow 1.995mm

100014 Main Bearing Shell Blue 2.000mm

100008 Con Rod Bearing Shell Red 1.721mm

1 2

402946 Crankshaft

Main Bearing Shell

Pos. Part No Description

QTY

403995 Circlip

401270 Con Rod

(e)

Con Rod Bearing Shell

100015 Main Bearing Shell Green 2.005mm

100007 Con Rod Bearing Shell Yellow 1.726mm

100016 Main Bearing Shell Brown 2.010mm

100009 Con Rod Bearing Shell Blue 1.731mm

404779 Balance Shaft

100010 Con Rod Bearing Shell Green 1.736mm

100017 Bearing Shell Balance Shaft

100011 Con Rod Bearing Shell Brown 1.741mm

407043 Piston TC

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

020 Crank Drive 020.01 Crankshaft NA

020 Crank Drive

020.01 Crankshaft NA 5

incl. Pos. 6

incl. Pos. 8

INFO Pos. 2 and pos. 9 The installed bearing shells have different sizes. Please check the bearing play before ordering.

This chapter is valid for the following engine models: –– 408246 I2 846 MAR NA-80 Pos. Part No Description

QTY

100013 Main Bearing Shell Red 1.990mm

103694 2x Con Rod Bolt M10x1x38

100012 Main Bearing Shell Yellow 1.995mm

100014 Main Bearing Shell Blue 2.000mm

100008 Con Rod Bearing Shell Red 1.721mm

1 2

402946 Crankshaft

Main Bearing Shell

Pos. Part No Description

QTY

403995 Circlip

401270 Con Rod

(e)

Con Rod Bearing Shell

100015 Main Bearing Shell Green 2.005mm

100007 Con Rod Bearing Shell Yellow 1.726mm

100016 Main Bearing Shell Brown 2.010mm

100009 Con Rod Bearing Shell Blue 1.731mm

404779 Balance Shaft

100010 Con Rod Bearing Shell Green 1.736mm

100017 Bearing Shell Balance Shaft

100011 Con Rod Bearing Shell Brown 1.741mm

406413 Piston NA

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

020

020 Crank Drive 020.02 Stub Shaft Thread M24

020 Crank Drive

020.02 Stub Shaft Thread M24

1 2

additional part

This chapter is valid for all engine models Pos. Part No Description

QTY

403350 Bolt M10x1x35

(m)

103421 Drive Coupler

406551 Stub Shaft

2 3

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

020 Crank Drive 020.03 Crankshaft Cover

020 Crank Drive

020.03 Crankshaft Cover

incl. Pos. 2

This chapter is valid for all engine models Pos. Part No Description

QTY

403573 Cover

406817 Gasket

(e)

404867 Bolt M6x20 8.8

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

020

030

030 Cylinder Head 030.01 Valve Cover

030 Cylinder Head

030.01 Valve Cover

1 7

7 6

5 6

5 9 10

7 11

incl. Pos. 3, 4, 5, 6, 12

This chapter is valid for all engine models Pos. Part No Description

Pos. Part No Description

QTY

Valve Cover

105398 Valve Cover RAL9006

(p)

105477 Valve Cover RAL9010

(p)

104961 Sealing Kit Valve Cover

(e)

404037 Engine Badge

103136 Serrated Lock Washer

100448 Washer

1 2

408038 Engine Cover

(e)

QTY

100447 Bolt M6x20

407935 Bolt Engine Cover M6x20

103156 Bolt M6x16

Ignition Coil

Sensor Camshaft

409014 Engine Badge

* see chapter 080 Engine Management System

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

030 Cylinder Head 030.02 Cylinder Head

030 Cylinder Head

030.02 Cylinder Head

2 (1) 3

incl. Pos. 2 to 4

5 This chapter is valid for all engine models Pos. Part No Description 1

Pos. Part No Description

QTY

Cylinder Head

105399 Cylinder Head RAL9006

(p)

105478 Cylinder Head RAL9010

(p)

100520 Bolt M6x30 8.8

100280 Sleeve

400876 Plug M8x1

(t)

403948 Cylinder Head Gasket

(e)

404122 Fitting

QTY 1

100587 Seal 8x12x1 Al

(e)

102992 Plug M10x1

(t)

400876 Plug M8x1

(t)

Spark Plug

* see chapter 080 Engine Management System

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

030

040

040 Valve Train 040.01 Camshaft

040 Valve Train

040.01 Camshaft

3 2

INFO INFO

incl. Pos. 3

4 9

Pos. 2 and Pos. 3 Observe chapter 900.02 Special Tools. INFO

This chapter is valid for all engine models Pos. Part No Description 1

406033 Camshaft

408035 Timing Chain

408219 Chain Link, Single

4 5

Pos. Part No Description

QTY

(e)

402897 Chain Rail

404867 Bolt M6x20 8.8

402614 Chain Guide

404502 Axle Chain Guide

100501 Bolt M6x20 8.8

405005 Chain Tensioner

QTY

(e)

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

040 Valve Train 040.02 Rocker Arms

040 Valve Train

040.02 Rocker Arms

(3)

(4)

(1)

(2) This chapter is valid for all engine models Pos. Part No Description

QTY

402665 Rocker Arm Short

402667 Rocker Arm Long

405918 Cross Bar 1

405917 Cross Bar 2

405911 Rocker Axle

403063 Circlip

100228 Sleeve

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

040

040 Valve Train 040.03 Valves TC

040 Valve Train

040.03 Valves TC

8 7

INFO

6 5 4 3 INFO Pos. 8 The valve adjustment shims will be delivered in packages of 8 parts. Order one of the listed valve adjustment shims then you receive 8 parts.

Pos. Part No Description

QTY

Valve Adjustment Shim

102043 Valve Adjustment Shim 2.50mm

102044 Valve Adjustment Shim 2.55mm

102045 Valve Adjustment Shim 2.60mm

102046 Valve Adjustment Shim 2.65mm

102047 Valve Adjustment Shim 2.70mm

102048 Valve Adjustment Shim 2.75mm

102049 Valve Adjustment Shim 2.80mm

102050 Valve Adjustment Shim 2.85mm

102051 Valve Adjustment Shim 2.90mm

102029 Valve Adjustment Shim 2.95mm

102030 Valve Adjustment Shim 3.00mm

102052 Valve Adjustment Shim 3.05mm

This chapter is valid for the following engine models:

102031 Valve Adjustment Shim 3.10mm

–– 408014 I2 846 MAR TC-120 –– 408101 I2 846 MAR TC-100 (TC-80) (TC-120)

102032 Valve Adjustment Shim 3.15mm

102033 Valve Adjustment Shim 3.20mm

102034 Valve Adjustment Shim 3.25mm

102053 Valve Adjustment Shim 3.30mm

102035 Valve Adjustment Shim 3.35mm

102036 Valve Adjustment Shim 3.40mm

102037 Valve Adjustment Shim 3.45mm

102038 Valve Adjustment Shim 3.50mm

102039 Valve Adjustment Shim 3.55mm

102040 Valve Adjustment Shim 3.60mm

102041 Valve Adjustment Shim 3.65mm

102042 Valve Adjustment Shim 3.70mm

Pos. Part No Description

QTY

401729 Intake Valve

408535 Exhaust Valve TC

100262 Spring Pad

100658 Valve Stem Seal

(e)

406001 Valve Spring

102316 Spring Cup

100129 Collet Valve

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

040 Valve Train 040.03 Valves NA

040 Valve Train

040.03 Valves NA

8 7

INFO

6 5 4 3 INFO Pos. 8 The valve adjustment shims will be delivered in packages of 8 parts. Order one of the listed valve adjustment shims then you receive 8 parts.

Pos. Part No Description

QTY

Valve Adjustment Shim

102043 Valve Adjustment Shim 2.50mm

102044 Valve Adjustment Shim 2.55mm

102045 Valve Adjustment Shim 2.60mm

102046 Valve Adjustment Shim 2.65mm

102047 Valve Adjustment Shim 2.70mm

102048 Valve Adjustment Shim 2.75mm

102049 Valve Adjustment Shim 2.80mm

102050 Valve Adjustment Shim 2.85mm

102051 Valve Adjustment Shim 2.90mm

102029 Valve Adjustment Shim 2.95mm

102030 Valve Adjustment Shim 3.00mm

102052 Valve Adjustment Shim 3.05mm

102031 Valve Adjustment Shim 3.10mm

This chapter is valid for the following engine models:

102032 Valve Adjustment Shim 3.15mm

–– 408246 I2 846 MAR NA-80

102033 Valve Adjustment Shim 3.20mm

102034 Valve Adjustment Shim 3.25mm

102053 Valve Adjustment Shim 3.30mm

102035 Valve Adjustment Shim 3.35mm

102036 Valve Adjustment Shim 3.40mm

102037 Valve Adjustment Shim 3.45mm

102038 Valve Adjustment Shim 3.50mm

102039 Valve Adjustment Shim 3.55mm

102040 Valve Adjustment Shim 3.60mm

102041 Valve Adjustment Shim 3.65mm

102042 Valve Adjustment Shim 3.70mm

Pos. Part No Description

QTY

401729 Intake Valve

401730 Exhaust Valve NA

100262 Spring Pad

100658 Valve Stem Seal

(e)

406001 Valve Spring

102316 Spring Cup

100129 Collet Valve

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

040

050

050 Cooling System 050.01-1 Thermostat Housing

050 Cooling System

050.01-1 Thermostat Housing

2 3 3 1

incl. Pos. 2, 3

This chapter is valid for all engine models Pos. Part No Description 1

105480 Thermostat Housing RAL9010

QTY

(p)

Hose

Hose Clamp

100501 Bolt M6x20 8.8

* see chapter 050.05 Heat Exchanger

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

050 Cooling System 050.01-2 Thermostat Housing

050 Cooling System

050.01-2 Thermostat Housing

2 4 6 3

incl. Pos. 2, 3

3 INFO

9 10

INFO Pos. 5 The long fitting thermostat housing is no longer available.

This chapter is valid for all engine models Pos. Part No Description 1

Pos. Part No Description

105481 Fitting Thermostat Housing

QTY

Hose Clamp

N/A

Fitting Thermostat Housing Long

100516 O-Ring

100150 Thermostat

407094 Distance Washer

Sensor Coolant Temperature

** see chapter 080 Engine Management System

Hose

* see chapter 050.05 Heat Exchanger

404867 Bolt M6x20 8.8

403157 Plug M14x1.5

2 4

9 10

(e)

QTY

(t)

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

050

050 Cooling System 050.02 Coolant Pump

050 Cooling System

050.02 Coolant Pump

5 4

3 2

This chapter is valid for all engine models Pos. Part No Description 1

406200 Impeller

102073 Nut M6

409097 Repair Kit Slide Ring Seal

QTY

(e)

The following parts are included in the repair kit: 3

Slide Ring Seal

Water Pump Axle

Sealing Bracket

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

050 Cooling System 050.03 Oil Cooler

050 Cooling System

050.03 Oil Cooler

This chapter is valid for all engine models Pos. Part No Description 1

QTY

Oil Cooler

105482 Oil Cooler RAL9006

(p)

105483 Oil Cooler RAL9010

(p)

404002 Gasket

(e)

404866 Bolt M6x12 8.8

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

050

050 Cooling System 050.04 Expansion Tank

050 Cooling System

050.04 Expansion Tank

INFO

9 6 INFO

INFO Pos. 7 By the manufacturer installed hose clamps at this locations are destroyed during removal. The hose clamps must be replaced by screw clamps after removing.

This chapter is valid for all engine models Pos. Part No Description

Pos. Part No Description

QTY

101801 Expansion Tank

100550 Cap

404867 Bolt M6x20 8.8

403348 Hose

101806 Hose Clamp 12.6-14.8/7

6 7 8

(e)

405836 Hose

100471 Hose Clamp 16-27/9

408711 Pipe Clamp

102413 Bolt 5x22

QTY

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

050 Cooling System 050.05 Heat Exchanger

050 Cooling System

INFO

050.05 Heat Exchanger

2 3

INFO

3 1

INFO

7 8 5

INFO Pos. 3 By the manufacturer installed hose clamps at this locations are destroyed during removal. The hose clamps must be replaced by screw clamps after removing.

This chapter is valid for all engine models Pos. Part No Description

Pos. Part No Description

QTY

(p)

105629 Heat Exchanger RAL9010

408293 Hose

100473 Hose Clamp 25-40/9

404932 Hose

102084 Hose Clamp 20-32/12

6 7

Rubber

101866 Bail

INFO Pos. 2 The hose is suitable for all thermostat housing fittings. See chapter 050.01-2 Thermostat Housing. When a long fitting is installed, cut the hose at marking.

404531 Bolt 6x20

QTY

* see chapter 120.02-1 Engine Bracket, Carrier Module

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

050

050 Cooling System 050.06-1 Hoses Sea Water Supply TC

050 Cooling System

050.06-1 Hoses Sea Water Supply TC INFO Pos. 2, Pos. 4 and Pos. 11 By the manufacturer installed hose clamps at this locations are destroyed during removal. The hose clamps must be replaced by screw clamps after removing. INFO Pos. 7 and Pos. 8 The hose system were changed in summer 2014. Depending on the production date, can be installed the hose connector pos. 7 or pos. 8. If the hose connector pos. 8 is installed, observe the following chapter 050.06-2. Observe in addition the vehicle manufacturer‘s documentation.

INFO

14 2

INFO

7 14

3 INFO

INFO

2 4

INFO

INFO INFO

10 11

11 12

10 INFO

This chapter is valid for the following engine models:

Pos. Part No Description

–– 408014 I2 846 MAR TC-120 –– 408101 I2 846 MAR TC-100 (TC-80) (TC-120) Pos. Part No Description

QTY

403069 Hose

100471 Hose Clamp 16-27/9

403074 Hose

100473 Hose Clamp 25-40/9

100741 Hose Connector

407601 Hose

QTY

406991 Hose Connector

408629 Hose Connector

406780 Hose

406816 Hose

100474 Hose Clamp 12-22/9

103175 Hose Connector

406593 Hose

404466 Hose Clamp 10-16/9

407113 Closing Plug

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

050 Cooling System 050.06-2 Hoses Sea Water Supply TC

050 Cooling System

050.06-2 Hoses Sea Water Supply TC

INFO Pos. 1 The hose is only installed in engines, which have installed the hose connector pos. 8 in chapter 050.06-1. * Observe that the fitting is installed in the exhaust manifold. INFO Pos. 2 By the manufacturer installed hose clamps at this locations are destroyed during removal. The hose clamps must be replaced by screw clamps after removing.

INFO

5 4

INFO

2 3

This chapter is valid for the following engine models: –– 408014 I2 846 MAR TC-120 –– 408101 I2 846 MAR TC-100 (TC-80) (TC-120) Pos. Part No Description

QTY

408623 Hose

100471 Hose Clamp 16-27/9

408628 Hose Connector

408643 Pipe Clamp

408118 Bolt M6x12 10.9

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

050

050 Cooling System 050.06 Hoses Sea Water Supply NA

050 Cooling System 2 1

050.06 Hoses Sea Water Supply NA

INFO

3 2

INFO

3 2

INFO

INFO INFO

6 INFO INFO Pos. 2, Pos. 4 and Pos. 9 By the manufacturer installed hose clamps at this locations are destroyed during removal. The hose clamps must be replaced by screw clamps after removing.

INFO

This chapter is valid for the following engine models:

INFO

Pos. Part No Description

–– 408246 I2 846 MAR NA-80 Pos. Part No Description

QTY

408629 Hose Connector

100471 Hose Clamp 16-27/9

407601 Hose

100473 Hose Clamp 25-40/9

403074 Hose

100741 Hose Connector

406780 Hose

QTY

406816 Hose

100474 Hose Clamp 12-22/9

103175 Hose Connector

406593 Hose

404466 Hose Clamp 10-16/9

407113 Closing Plug

408804 Hose Connector

408809 Hose

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

050 Cooling System 050.07 Hoses Sea Water Return Type 1

050 Cooling System

050.07 Hoses Sea Water Return Type 1

2 1

INFO

Pos. 4 and Pos. 5 By the manufacturer installed hose clamps at this locations are destroyed during removal. The hose clamps must be replaced by screw clamps after removing. INFO

INFO

This chapter is valid for the following engine models: –– 408014 I2 846 MAR TC-120 Pos. Part No Description 1

408178 Hose

QTY

101806 Hose Clamp 12.6-14.8/7

(e)

407601 Hose

100471 Hose Clamp 16-27/9

100473 Hose Clamp 25-40/9

100741 Hose Connector

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

050

050 Cooling System 050.07 Hoses Sea Water Return Type 2

050 Cooling System

050.07 Hoses Sea Water Return Type 2

INFO

2 5

INFO

INFO Pos. 4 and Pos. 5 By the manufacturer installed hose clamps at this locations are destroyed during removal. The hose clamps must be replaced by screw clamps after removing.

This chapter is valid for the following engine models: –– 408101 I2 846 MAR TC-100 (TC-80) (TC-120) Pos. Part No Description 1

405891 Hose

QTY

101806 Hose Clamp 12.6-14.8/7

(e)

407601 Hose

100471 Hose Clamp 16-27/9

100473 Hose Clamp 25-40/9

100741 Hose Connector

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

060 Exhaust System 060.01-1 Mounting Exhaust Manifold

060 Exhaust System

060.01-1 Mounting Exhaust Manifold

2 3

This chapter is valid for all engine models Pos. Part No Description 1

101446 Exhaust Gasket

100425 Stud M8x69

100737 Nut M8

QTY

(e)

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

060

060 Exhaust System 060.01-2 Mounting Exhaust Manifold

060 Exhaust System

060.01-2 Mounting Exhaust Manifold

This chapter is valid for all engine models. TC engine models are shown in the figure Pos. Part No Description 1

QTY

Turbocharger Bracket

103964 Turbocharger Bracket RAL9006

(p)

103979 Turbocharger Bracket RAL9010

(p)

102477 Bolt M8x20 8.8

100538 Bolt M8x30 8.8

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

060 Exhaust System 060.02 Turbocharger

060 Exhaust System

060.02 Turbocharger

10 8 9

7 4 2 8

This chapter is valid for the following engine models:

Pos. Part No Description

–– 408014 I2 846 MAR TC-120 –– 408101 I2 846 MAR TC-100 (TC-80) (TC-120) Pos. Part No Description 1

105485 Turbocharger RAL9010

101847 Flange

100507 Bolt M6x16 8.8

100490 O-Ring

5 6

Valve Boost Pressure Control

407792 Bracket

QTY

(p)

(e)

QTY

102493 Hose

101579 Hose Clamp 7.8x9.5/5

(e)

101540 Hose Clamp 8.8-10.5/5

(e)

102492 Hose

* see chapter 080 Engine Management System

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

060

060 Exhaust System 060.03-1 Exhaust Manifold TC

060 Exhaust System

INFO

060.03-1 Exhaust Manifold TC

8 INFO

5 9 12

incl. Pos. 2 to 9

Pos. 5 and Pos. 6 The hose system were changed in summer 2014. Depending on the production date, can be installed pos. 5 or pos. 6. Both parts are in scope of supply of the exhaust manifold. INFO

INFO

additional part

Pos. 13 In summer 2014, the installation location of the sensor lambda 1 was moved into the catalyzer housing. See chapter 060.04-1 Catalyzer. If you have repairs at the exhaust system, Textron Motors recommends, to move the installation location of the lambda sensor 1 into the catalyzer housing. Please contact the vehicle manufacturer for further information. INFO

This chapter is valid for the following engine models:

INFO Pos. 10 The thread for the plug will be omitted at the end of 2014. Then the exhaust manifold is closed at this position. If you replace the exhaust manifold, observe that the installation location of the sensor lambda 1 must be in the catalyzer housing.

Pos. Part No Description

–– 408014 I2 846 MAR TC-120 –– 408101 I2 846 MAR TC-100 (TC-80) (TC-120) Pos. Part No Description

additional part

QTY

(p)

105487 Exhaust Manifold TC RAL9010

407882 Fitting M22x1.5

407065 Segment

407739 Bolt M6x10 8.8

408651 Fitting M22x1.5

(e)

408167 Plug M22x1.5

(e)

405979 Fitting M20x1.5

408167 Plug M22x1.5

400926 Stud M8x50

408844 Plug M12x1.25

100449 Seal 12x18x1.5 Al

407938 Sleeve

QTY

(e)

Sensor Lambda 1

Sensor Exhaust Manifold Temperature

* see chapter 080 Engine Management System

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

060 Exhaust System 060.03-2 Exhaust Manifold TC

060 Exhaust System

060.03-2 Exhaust Manifold TC

2 3 4

This chapter is valid for the following engine models:

Pos. Part No Description

–– 408014 I2 846 MAR TC-120 –– 408101 I2 846 MAR TC-100 (TC-80) (TC-120) Pos. Part No Description

QTY

407006 Waste Gate Valve

102073 Nut M6

401425 Spanner Nut

100448 Washer

100569 Nut M6 LH

100570 Uniball

100507 Bolt M6x16 8.8

QTY

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

060

060 Exhaust System 060.03 Exhaust Manifold NA

060 Exhaust System

060.03 Exhaust Manifold NA

4 8 3

3 3

7 1

incl. Pos. 2 to 9

6 2

This chapter is valid for the following engine models:

Pos. Part No Description

–– 408246 I2 846 MAR NA-80 Pos. Part No Description

QTY

410367 Exhaust Manifold NA RAL9010

(p)

408651 Fitting M22x1.5

(e)

408167 Plug M22x1.5

(e)

405979 Fitting M20x1.5

400926 Stud M8x50

102992 Plug M10x1

(t)

407938 Sleeve

Sensor Exhaust Manifold Temperature

* see chapter 080 Engine Management System

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

QTY 1

060 Exhaust System 060.04-1 Catalyzer

060 Exhaust System

060.04-1 Catalyzer 9 2 3 13

INFO

incl. Pos. 2 to 3

8 6 7

12 4 11

INFO Pos. 1 In summer 2014, the installation location of the sensor lambda 1 was moved into the catalyzer housing. See chapter 060.03-1 Exhaust Manifold. Catalyzer housings without connection for a sensor lambda are no longer available. Please contact the vehicle manufacturer for further information.

This chapter is valid for all engine models. TC engine models are shown in the figure Pos. Part No Description

QTY

(p)

105489 Bracket RAL9010

105604 Catalyzer Housing RAL9010

407892 Sacrificial Anode

403603 Seal 20x26x1.5 Al

(e)

405102 Gasket

Pos. Part No Description

QTY

Bracket

105411 Bracket RAL9006

(p)

(e)

100538 Bolt M8x30 8.8

Sleeve

102477 Bolt M8x20 8.8

102481 Nut M8

100468 Washer

* see chapter 060.03 Exhaust Manifold

407877 Catalyzer Insert

** see chapter 080 Engine Management System

404866 Bolt M6x12 8.8

Sensor Lambda 1

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

060

060 Exhaust System 060.04-2 Catalyzer

060 Exhaust System

060.04-2 Catalyzer 10 11 5 3 7

6 8 3 4

This chapter is valid for all engine models. TC engine models are shown in the figure Pos. Part No Description

QTY

Exhaust Cooler

105412 Exhaust Cooler RAL9006

(p)

105490 Exhaust Cooler RAL9010

(p)

408010 Plug M18x1.5

(e)

408169 Plug M30x1.5

(e)

408959 Fitting M18x1.5

102523 Plug M18x1.5

incl. Pos. 2 to 8

Pos. Part No Description

100454 Seal 18x22x1.5 Al

400247 Fitting

QTY

(e)

100459 Seal 10x16x1 Al

(e)

407888 Gasket

(e)

100538 Bolt M8x30 8.8

402903 Washer

Sensor Lambda 2

* see chapter 080 Engine Management System

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

070 Intake Area 070.01 Intake Manifold

070 Intake Area

070.01 Intake Manifold

10 5 11 1

incl. Pos. 2 to 4

4 2 3

7 9

This chapter is valid for all engine models Pos. Part No Description

Pos. Part No Description

QTY

(p)

105491 Intake Manifold RAL9010

407800 Cap

101540 Hose Clamp 8.8-10.5/5

(e)

403158 O-Ring

(e)

100501 Bolt M6x20 8.8

408119 Bolt M8x30 10.9

404710 Intake Manifold Bracket

102477 Bolt M8x20 8.8

QTY

100468 Washer

404531 Bolt 6x20

Sensor Intake Manifold

Pressure/Temperature

* see chapter 080 Engine Management System

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

070

070 Intake Area 070.02 Throttle Body

070 Intake Area

070.02 Throttle Body

6 4

1 2 3

This chapter is valid for all engine models. TC engine models are shown in the figure Pos. Part No Description 1

Throttle Body

QTY

403713 Rubber Mount

100487 Hose Clamp 50-70/9

100539 Bolt M6x45 8.8

405996 Hose

405971 Spring Band Clamp A60x12

* see chapter 080 Engine Management System (e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

070 Intake Area 070.03 Intercooler

070 Intake Area

070.03 Intercooler

9 8

7 6 3 5

4 1

4 2

This chapter is valid for the following engine models:

Pos. Part No Description

–– 408014 I2 846 MAR TC-120 –– 408101 I2 846 MAR TC-100 (TC-80) (TC-120) Pos. Part No Description 1 2

105439 Intercooler RAL9005 *

Rubber

QTY

(p)

408103 Hose

405971 Spring Band Clamp A60x12

101866 Bail

404531 Bolt 6x20

QTY

Fuse Box (Wire Harness)

Sensor Intercooler Pressure

404942 Bracket

100447 Bolt M6x20

* see chapter 120.02-1 Engine Bracket, Carrier Module ** see chapter 080 Engine Management System

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

070

070 Intake Area 070.04 Flame Arrester TC

070 Intake Area

070.04 Flame Arrester TC

INFO

1 INFO Pos. 3 By the manufacturer installed hose clamps at this locations are destroyed during removal. The hose clamps must be replaced by screw clamps after removing.

This chapter is valid for the following engine models: –– 408014 I2 846 MAR TC-120 –– 408101 I2 846 MAR TC-100 (TC-80) (TC-120) Pos. Part No Description

QTY

407852 Flame Arrester TC

101829 Hose Clamp 50-70/13

100471 Hose Clamp 16-27/9

408284 Hose

102472 Hose Clamp 16-27/12

407001 Hose Fixation

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

070 Intake Area 070.05 Air Box NA

070 Intake Area

070.05 Air Box NA

7 (1) 2

9 4 1

incl. Pos. 2 to 4

INFO Pos. 10 By the manufacturer installed hose clamps at this locations are destroyed during removal. The hose clamps must be replaced by screw clamps after removing.

This chapter is valid for the following engine models:

Pos. Part No Description

–– 408246 I2 846 MAR NA-80 Pos. Part No Description

QTY

408870 Air Box

404531 Bolt 6x20

406346 Flame Arrester NA

100487 Hose Clamp 50-70/9

Rubber

404942 Bracket

5 6 7

* **

Fuse Box (Wire Harness)

QTY

407314 Hose

402265 Hose Connector

100471 Hose Clamp 16-27/9

102472 Hose Clamp 16-27/12

* see chapter 120.02-1 Engine Bracket, Carrier Module ** see chapter 080 Engine Management System

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

070

080

080 Engine Management System

080 Engine Management System Sensor Crankshaft

Sensor Camshaft 2

Valid for all engine models

Pos. Part No Description 1

403802 Sensor Crankshaft

403801 O-Ring

QTY

(e)

Pos. Part No Description 1

QTY

(e)

402701 Sensor Camshaft

Installation location, see chapter 030.01 Valve Cover

Installation location, see chapter 010.01-3 Crankcase

Sensor Camshaft Coolant Temperature

Sensor Exhaust Manifold Temperature

Valid for all engine models

Pos. Part No Description 1

402527 Sensor Temperature

QTY

(e)

Installation location, see chapter 050.01 Thermostat Housing

Sensor Lambda 1

Pos. Part No Description 1

402527 Sensor Temperature

Installation location, see chapter 060.03 Exhaust Manifold

Sensor Lambda 2 1

Valid for all engine models Pos. Part No Description 1

406241 Sensor Lambda

Installation location, see chapter 060.04-1 Catalyzer

Valid for all engine models

QTY

Pos. Part No Description 1

406241 Sensor Lambda

QTY

Installation location, see chapter 060.04-2 Catalyzer

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

080 Engine Management System

080 Engine Management System Sensor Intake Camshaft Manifold Pressure/Temperature TC

Sensor Intercooler Camshaft Pressure

Valid for the following engine models:

–– 408014 I2 846 MAR TC-120 –– 408101 I2 846 MAR TC-100 (TC-80) (TC-120)

Pos. Part No Description 1

402528 Sensor Pressure/Temperature TC

QTY

Installation location, see chapter 070.01 Intake Manifold

Pos. Part No Description 1

402528 Sensor Pressure/Temperature TC

QTY

Installation location, see chapter 070.03 Intercooler

Sensor Intake Camshaft Manifold Pressure/Temperature NA

Sensor Knock 1

1 Valid for the following engine models:

Valid for all engine models

–– 408246 I2 846 MAR NA-80 Pos. Part No Description 1

402529 Sensor Pressure/Temperature NA

Pos. Part No Description

QTY

407798 Sensor Knock

Installation location, see chapter 010.01-3 Crankcase

Installation location, see chapter 070.01 Intake Manifold

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

080

080 Engine Management System

080 Engine Management System Throttle Request Unit 1

additional part

Valid for all engine models Pos. Part No Description 1

406547 Throttle Request Unit

QTY

Installation location, see the vehicle manufacturer‘s documentation

Engine Control Unit TC

Engine Control Unit NA

Valid for the following engine models:

–– 408246 I2 846 MAR NA-80

–– 408014 I2 846 MAR TC-120 –– 408101 I2 846 MAR TC-100 (TC-80) (TC-120) Pos. Part No Description 1

Engine Control Unit

Pos. Part No Description

QTY

408294 Engine Control Unit MAR TC-80

408110 Engine Control Unit MAR TC-100

405640 Engine Control Unit MAR TC-120

408782 Engine Control Unit MAR NA-80

QTY

Installation location, see chapter 120.02-2 Engine Bracket

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

080 Engine Management System

080 Engine Management System Ignition Coil

Spark Plug

Valid for all engine models

Pos. Part No Description 1

101884 Ignition Coil

QTY

Installation location, see chapter 030.01 Valve Cover

Pos. Part No Description 1

104258 Spark Plug RC7PYCBX

QTY

Installation location, see chapter 030.02 Cylinder Head

Injector TC

Injector NA 2

2 1

incl. Pos. 2

Valid for the following engine models:

–– 408014 I2 846 MAR NA-80

–– 408014 I2 846 MAR TC-120 –– 408101 I2 846 MAR TC-100 (TC-80) (TC-120)

Pos. Part No Description

QTY

407570 Injector TC

407266 Retaining clip

QTY

403648 Injector NA

407266 Retaining clip

QTY

Installation location, see chapter 100.01 Fuel Rail

Sensor Camshaft Throttle Body

Switch Oil Pressure 1 1

Valid for all engine models Pos. Part No Description 1

103381 Throttle Body RAL9010

Valid for all engine models

QTY

(p)

Installation location, see chapter 070.02 Throttle Body

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

Pos. Part No Description 1

100117 Switch Oil Pressure

Installation location, see chapter 110.04-2 Oil Filter

080

080 Engine Management System

080 Engine Management System Valve Boost Pressure Control

Wire Harness 1

Valid for all engine models

Valid for the following engine models: –– 408014 I2 846 MAR TC-120 –– 408101 I2 846 MAR TC-100 (TC-80) (TC-120) Pos. Part No Description 1

102383 Valve

Pos. Part No Description

QTY

408540 Wire Harness

QTY

Installation location, see chapter 060.02 Turbocharger

Cover Fuse Box

Relay (Fuse Box)

1 1 Valid for all engine models

Valid for all engine models

Pos. Part No Description 1

406186 Cover Fuse Box

QTY

Installation location, see chapter 120.02-2 Engine Bracket

Pos. Part No Description 1

408183 Relay

Installation location, see chapter 120.02-2 Engine Bracket

Fuse (Fuse Box)

Dummy plugs for wire harness 3

Valid for the following engine models:

Valid for all engine models Pos. Part No Description

QTY

405501 Fuse 10 A

405502 Fuse 15 A

Installation location, see chapter 120.02-2 Engine Bracket

–– 408014 I2 846 MAR NA-80 Pos. Part No Description

QTY

408272 Dummy Plug 4 pole

408273 Dummy Plug 2 pole

402272 Cavity Plug

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

090 Starter, Generator 090.01 Starter

090 Starter, Generator

090.01 Starter

5 4

3 This chapter is valid for all engine models Pos. Part No Description

QTY

406359 Starter

404906 Bolt M10x30 8.8

100520 Bolt M6x30 8.8

406312 Bracket

404866 Bolt M6x12 8.8

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

090

090 Starter, Generator 090.02 Generator

090 Starter, Generator

090.02 Generator

3 2 1

This chapter is valid for all engine models Pos. Part No Description

QTY

406350 Rotor

406329 Stator

403396 Distance Washer

100505 Bolt M6x35 8.8

100280 Sleeve

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

090 Starter, Generator 090.03 Voltage Regulator

090 Starter, Generator

090.03 Voltage Regulator

3 2

This chapter is valid for all engine models Pos. Part No Description

QTY

407228 Voltage Regulator

408017 Bolt M6x25

101875 Washer

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

090

090 Starter, Generator 090.01 Relay Starter

090 Starter, Generator

090.04 Relay Starter

7 8

6 7 8

9 7

This chapter is valid for all engine models Pos. Part No Description

Pos. Part No Description

QTY

405225 Relay Starter

100667 Rubber

407609 Bracket

101736 Bolt M6x12

Bolt

103108 Starter Cable

100835 Nut M6

100448 Washer

100388 Rubber Grommet

QTY

* see chapter 010.02-1 Oil Cooler Bracket

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

100 Fuel Unit 100-01 Fuel Rail

100 Fuel Unit

100.01 Fuel Rail

2 1

incl. Pos. 4

This chapter is valid for all engine models. TC engine models are shown in the figure Pos. Part No Description 1

QTY

Fuel Rail

105492 Fuel Rail RAL9006

(p)

105493 Fuel Rail RAL9010

(p)

404866 Bolt M6x12 8.8

Injector

Retaining Clip

* see chapter 080 Engine Management System (e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

100

100 Fuel Unit 100-02 Additional parts fuel supply

100 Fuel Unit

100.02 Additional parts fuel supply

3 6

3 7

8 9

INFO

All parts in this chapter are additional parts and not installed in every vehicle. This chapter is valid for all engine models Pos. Part No Description 1

103584 Fuel Pump

400247 Fitting

101107 Seal 10x14x1 Al

4 5

Pos. Part No Description

QTY

(e)

401091 Banjo Fitting D8/D6 M10

103605 Banjo Bolt M10/3x1x19

408730 Nut ANSI B1.1 6-32 UNC

103397 Fuel Pre-Filter

408338 Fuel Main-Filter 4 bar

104228 Quick Connector 180°

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

QTY

110 Lubrication System 110.01 Dry Sump

110 Lubrication System

110.01 Dry Sump

4 5

9 9 9 7

1 6

This chapter is valid for all engine models Pos. Part No Description

Pos. Teilenr. Bezeichnung

QTY

406877 Oil Suction Pump

404867 Bolt M6x20 8.8

100195 Oil Screen

401428 Intermediate Gear Suction Pump

402727 Axle

Suction Pump Cover

105383 Suction Pump Cover RAL9006

(p)

105494 Suction Pump Cover RAL9010

(p)

Menge

100280 Sleeve

408959 Fitting M18x1.5

100520 Bolt M6x30 8.8

100501 Bolt M6x20 8.8

100454 Seal 18x22x1.5 Al

(e)

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

110

110 Lubrication System 110.02 Oil Pressure Pump

110 Lubrication System

110.02 Oil Pressure Pump

(3) 5

incl. Pos. 4

This chapter is valid for all engine models Pos. Part No Description 1

100137 Timing Insert

403197 Key

100275 Oil Pump

QTY

(e)

102398 O-Ring

(e)

100792 Oil Pump Cover

100294 Circlip

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

110 Lubrication System 110.03 Oil Pressure Valve

110 Lubrication System

110.03 Oil Pressure Valve

3 2

This chapter is valid for all engine models Pos. Part No Description 1

Bolt

404574 Oil Pressure Valve

QTY

The following parts are included in the oil pressure valve: 2

Clamp Plate

Spring

Oil Pressure Piston

* see chapter 010.01-1 Crankcase (e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

110

110 Lubrication System 110.04-1 Oil Filter

110 Lubrication System

110.04-1 Oil Filter

8 7

incl. Pos. 2

2 1

11 12

This chapter is valid for all engine models Pos. Part No Description 1

Oil Filter Bracket

105041 Oil Filter

407571 Banjo Bolt M20x1.5

Pos. Part No Description

QTY

(e)

401167 O-Ring

(e)

403801 O-Ring

(e)

Bracket

Bolt

407263 Bracket

QTY

404866 Bolt M6x12 8.8

403602 Banjo Bolt M20x1.5

403603 Seal 20x26x1.5 Al

(e)

407052 O-Ring

(e)

* see chapter 110.04-2 Oil Filter ** see chapter 120.01 Lifting Eye

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

110 Lubrication System 110.04-2 Oil Filter

110 Lubrication System

110.04-2 Oil Filter

3 2

incl. Pos. 2

INFO

(3)

INFO Pos. 1 At the turn of 2014/2015, the installation location of the switch oil pressure was moved to the opposite side of the oil filter bracket. Both installation positions are usable. Only in combination with harness 408223 or older, the installation position must remain at the old position (3).

This chapter is valid for all engine models Pos. Part No Description

QTY

105495 Oil Filter Bracket RAL9010

(p)

102992 Plug M10x1

(t)

Switch Oil Pressure

* see chapter 080 Engine Management System

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

110

110 Lubrication System 110.05 Oil Tank

110 Lubrication System

110.05 Oil Tank

2 9

incl. Pos. 2

7 3

This chapter is valid for all engine models Pos. Part No Description

Pos. Teilenr. Bezeichnung

QTY

406576 Oil Tank

105188 Oil Dipstick

100358 Rubber

406730 Bracket

407261 Bolt M6x16 8.8

Oil Tank Bracket

105389 Oil Tank Bracket RAL9006

(p)

105496 Oil Tank Bracket RAL9010

(p)

Menge 3

100505 Bolt M6x35 8.8

100667 Rubber

408118 Bolt M6x12 10.9

407953 Bolt M8x16

408459 Oil Level Hang Tag

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

110 Lubrication System 110.07-1 Hoses Oil Supply Engine

110 Lubrication System

110.07-1 Hoses Oil Supply Engine

5 INFO

INFO

3 INFO

INFO

INFO Pos. 2 By the manufacturer installed hose clamps at this locations are destroyed during removal. The hose clamps must be replaced by screw clamps after removing.

This chapter is valid for all engine models Pos. Part No Description

QTY

405396 Hose

100471 Hose Clamp 16-27/9

406757 Hose Connector

405903 Hose

101490 Hose Fixation

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

110

110 Lubrication System 110.07-2 Hoses Oil Supply Engine

110 Lubrication System

110.07-2 Hoses Oil Supply Engine

INFO

INFO Pos. 2 By the manufacturer installed hose clamps at this locations are destroyed during removal. The hose clamps must be replaced by screw clamps after removing.

This chapter is valid for all engine models Pos. Part No Description

QTY

407009 Hose

100471 Hose Clamp 16-27/9

101490 Hose Fixation

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

110 Lubrication System 110.08 Hose Crankcase Vent

110 Lubrication System

110.08 Hose Crankcase Vent

This chapter is valid for all engine models Pos. Part No Description 1

408083 Hose

100471 Hose Clamp 16-27/9

101806 Hose Clamp 12.6-14.8/7

QTY

(e)

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

110

110 Lubrication System 110.09 Hoses Oil Supply Turbocharger TC

110 Lubrication System

110.09 Hoses Oil Supply Turbocharger TC

4 5

7 7

INFO

1 INFO

2 INFO Pos. 2 By the manufacturer installed hose clamps at this locations are destroyed during removal. The hose clamps must be replaced by screw clamps after removing.

This chapter is valid for the following engine models:

Pos. Part No Description

–– 408014 I2 846 MAR TC-120 –– 408101 I2 846 MAR TC-100 (TC-80) (TC-120) Pos. Part No Description

QTY

405896 Hose

100471 Hose Clamp 16-27/9

406987 Hose

407053 Banjo Bolt M12x1.5

100449 Seal 12x18x1.5 Al

(e)

100085 Banjo Bolt M10x1

100459 Seal 10x16x1 Al

QTY

(e)

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

120 Engine Mount 120.01 Lifting Eye

120 Engine Mount

120.01 Lifting Eye

5 1

2 5 3

This chapter is valid for all engine models Pos. Part No Description

QTY

404709 Bracket

404018 Pipe Clamp

408118 Bolt M6x12 10.9

403486 Bracket

100501 Bolt M6x20 8.8

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

120

120 Engine Mount 120.02-1 Engine Bracket, Carrier Module

120 Engine Mount

120.02-1 Engine Bracket, Carrier Module

7 6 5

1 This chapter is valid for all engine models Pos. Part No Description

Pos. Part No Description

QTY

(p)

105497 Engine Bracket RAL9010

404681 Bolt M10x70 8.8

404888 Bolt M10x50 8.8

Carrier Module

105387 Carrier Module RAL9006

(p)

105498 Carrier Module RAL9010

(p)

100358 Rubber

403023 Sleeve

Menge

404868 Bolt M8x30 8.8

105386 Adapter Carrier Module RAL9006 (p)

404906 Bolt M10x30 8.8

100228 Sleeve

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

120 Engine Mount 120.02-2 Engine Bracket, Carrier Module TC

120 Engine Mount

120.02-2 Engine Bracket, Carrier Module TC

4 3 6 5 1

This chapter is valid for the following engine models:

Pos. Part No Description

–– 408014 I2 846 MAR TC-120 –– 408101 I2 846 MAR TC-100 (TC-80) (TC-120) Pos. Part No Description

6 7

QTY

407744 Bracket

404531 Bolt 6x20

404509 Clip Connector

4 5

Vehicle Connector „Engine Chassis“

(Wire Harness)

100667 Rubber

100501 Bolt M6x20 8.8 *

Engine Control Unit

QTY

4 1

* see chapter 080 Engine Management System

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

120

120 Engine Mount 120.02-2 Engine Bracket, Carrier Module NA

120 Engine Mount

120.02-2 Engine Bracket, Carrier Module NA

4 3 6 5 1

This chapter is valid for the following engine models:

Pos. Part No Description

–– 408246 I2 846 MAR NA-80 Pos. Part No Description

QTY

407315 Bracket

404531 Bolt 6x20

404509 Clip Connector

4 5

Vehicle Connector „Engine Chassis“

(Wire Harness)

100667 Rubber

100501 Bolt M6x20 8.8 *

Engine Control Unit

QTY

4 1

* see chapter 080 Engine Management System

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

120 Engine Mount 120.03 Additional parts engine mount

120 Engine Mount

120.03 Additional parts engine mount

5 4 3

2 1

INFO

All parts in this chapter are additional parts and not installed in every vehicle. This chapter is valid for all engine models Pos. Part No Description 1 2

406889 Engine Mount

Shim

QTY

103707 Shim 1mm

103708 Shim 0.5mm

408712 Bolt M10x40

408713 Washer

408714 Lock Washer

(e)

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

120

900

900 Tools and accessories 900.01 Cases

900 Tools and accessories

900.01 Cases

Outer dimensions: 395 mm x 295 mm x 106 mm [15.6 in x 11.6 in x 4.2 in]

Spare Parts Case Synerject TC Marine

Valid for the following engine models: –– 408014 I2 846 MAR TC-120 –– 408101 I2 846 MAR TC-100 (TC-80) (TC-120) Part No Description

QTY

105324 Spare Parts Case Synerject TC Marine

The following parts are included in the spare parts case: 403802 Sensor Crankshaft

402701 Sensor Camshaft

402528 Sensor Pressure/Temperature TC

(e)

101884 Ignition Coil

407570 Injector TC

407798 Sensor Knock

102383 Valve

406241 Sensor Lambda

402527 Sensor Temperature

Service Case MPE 850 Valid for all engine models Part No Description

QTY

105015 Service Case MPE 850

(e)

104258 Spark Plug RC7PYCBX

104961 Sealing Kit Valve Cover

(e)

Valid for the following engine models:

103136 Serrated Lock Washer

(e)

–– 408246 I2 846 MAR NA-80

102050 Valve Adjustment Shim 2.85mm

Part No Description

QTY

102051 Valve Adjustment Shim 2.90mm

105325 Spare Parts Case Synerject NA Marine

The following parts are included in the service case: 105041 Oil Filter

and O-Rings

Spare Parts Case Synerject NA Marine

The following parts are included in the spare parts case:

102029 Valve Adjustment Shim 2.95mm

102030 Valve Adjustment Shim 3.00mm

403802 Sensor Crankshaft

102052 Valve Adjustment Shim 3.05mm

402701 Sensor Camshaft

102031 Valve Adjustment Shim 3.10mm

402529 Sensor Pressure/Temperature NA

402527 Sensor Temperature

102032 Valve Adjustment Shim 3.15mm

(e)

102033 Valve Adjustment Shim 3.20mm

101884 Ignition Coil

102034 Valve Adjustment Shim 3.25mm

403648 Injector NA

102053 Valve Adjustment Shim 3.30mm

407798 Sensor Knock

102035 Valve Adjustment Shim 3.35mm

406241 Sensor Lambda

Valve Adjustment Kit

Feeler Gauge 0.05 - 2mm

407892 Sacrificial Anode

and seals

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

900 Tools and accessories 900.01 Cases

900 Tools and accessories

900.01 Cases

Tool Box MPE 850 Valid for all engine models Part No Description

QTY

105151 Tool Box MPE 850

The following parts are included in the tool box:

Chain Braking Tool

Locking Tool Crankshaft

TDC-Adjusting Tool

Installation Spike Valve Stem Seal

Pin Punch Axle Intermediate Gear

Remover Bearing Cap

Assembling Kit Slide Ring Seal

Assembling Kit Oil Seal Crankshaft

Assembling Kit Oil Seal Hand-start

Part No Description

QTY

105017 Diagnostic Case Synerject

Diagnostic Case Synerject Valid for all engine models

The diagnostic cable with USB-Interface, software and a manual are included in the diagnostic case.

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

900

900 Tools and accessories 900.02 Special Tools

900 Tools and accessories

900.02 Special Tools

Valve Adjustment Kit

TDC-Adjusting Tool

1 2

4 1 Pos. Part No Description

QTY

404494 Valve Adjustment Tool

404515 Rocker Arm Pusher

100501 Bolt M6x20 8.8

100448 Washer

Locking Tool Crankshaft

Pos. Part No Description 1

405877 TDC-Adjusting Tool

QTY

Installation Spike Valve Stem Seal 1

Pos. Part No Description

QTY

405865 Locking Tool

102282 Bolt M10x35 8.8

101682 Washer

Pin Punch Axle Intermediate Gear

Pos. Part No Description 1

105023 Pin Punch

Remover Bearing Cap

Pos. Part No Description

103609 Installation Spike Valve Stem Seal

QTY

Pos. Part No Description 1

406389 Remover Bearing Cap

QTY

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

900 Tools and accessories 900.02 Special Tools

900 Tools and accessories

900.02 Special Tools

Assembling Kit Slide Ring Seal 1

Assembling Kit Oil Seal Crankshaft 2

1 2

3 Pos. Part No Description

QTY

405935 Guide

Pos. Part No Description 1

404621 Guiding Sleeve

405936 Sliding Sleeve

405854 Sliding Sleeve

100164 Nut M10 8.8

Chain Tool 4

incl. Pos. 2 to 5

5 3

Pos. Part No Description

QTY

408331 Chain Tool

408282 Counterpart Break

408283 Thrust Piece

408280 Counterpart Rivet

401383 Spike

INFO Pos. 1 By using of a new timing chain in all engines of the Textron Motors GmbH, the previous model 103701 is no longer operable. If you still have the previous model, modify the tool as described: Replace the counterpart break 401376 by 408282. Replace the counter part rivet 401377 by 408280. Additionally you require the thrust piece 408283. With the new parts the tool is operable for all timing chains. Observe the instruction manual of the chain tool on www.weber-motor.com/en/service/werkzeug-und-zubehoer/

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

900

900 Tools and accessories 900.03 Supplies

900 Tools and accessories

900.03 Supplies

STOPSEL Cleansing Concentrate

Part No Description

QTY

105018 STOPSEL Cleansing Concentrate 1 liter

105021 STOPSEL Cleansing Concentrate 5 liter

105022 STOPSEL AUTOMIX 125ml

Cleansing concentrate for flushing the sea water cooling circuit

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

910 Repair Kits

910 Repair Kits Long Block TC

Long Block NA

Valid for the following engine models:

–– 408014 I2 846 MAR TC-120 –– 408101 I2 846 MAR TC-100 (TC-80) (TC-120)

–– 408246 I2 846 MAR NA-80

Part No Description 105415 Long Block MAR TC RAL9010

Part No Description

QTY

(p)

410072 Long Block MAR NA RAL9010

QTY

(p)

(e) replace part (t) thread TufLok coated (m) thread micro encapsulated (p) part is painted RAL 9005 (black) RAL9006 (silver-gray) RAL9010 (white)

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

910

Appendix Overview of revisions

Revision Rev 1.0

Date

Chapter

27.09.2013 –

Rev 1.1

24.04.2015 010.01-1 Crankcase

Rev 1.1

010.02-1 Oil Cooler 24.04.2015 Bracket

Rev 1.1

010.02-2 Oil Cooler 24.04.2015 Bracket

Rev 1.1

010.03 Generator 24.04.2015 Cover

Pos. Description

Note

–

1st edition spare parts catalog

–

The crankcase 105392 is no longer available in RAL 9006.

Order 105474 in RAL 9010.

The oil cooler bracke 105396 is no longer available in RAL 9006.

Order 105475 in RAL 9010.

The mounting of the blanking cover 5, 8 were changed in summer 2014. 1

The generator cover 105397 is no longer available in RAL 9006.

Observe the information in chapter 010.02-2 Oil Cooler Bracket. Order 105476 in RAL 9010.

The chapter is no longer applicable.

Rev 1.1

020.02 Stub Shaft Inner 24.04.2015 Spline

–

408014 I2 846 MAR TC-120: The stub shaft 408022 was replaced by 406551. The chapter 020.02 Stub Shaft Inner Spline is now valid for all engine models. –

Rev 1.1

24.04.2015 030.01 Valve Cover

The engine badge 409014 was added.

–

The timing chain 100116 was replaced by 408035.

The modified chain tool 408331 is required.

Rev 1.1

24.04.2015 040.01 Camshaft

The chain link 100557 was replaced 2, 3 by 408219.

Observe the information in chapter 900.02 Special Tools.

The chain tool 103701 was replaced by 408331. The counterpart break 401376 was replaced by 408282. The counterpart rivet 401377 was replaced by 408280.

The chain tool 103701 is not usable for the chain link 408219.

Rev 1.1

24.04.2015 900.02 Special Tools

–

The thrust piece 408283 is a new additional part.

Observe the information in chapter 900.02 Special Tools.

Rev 1.1

24.04.2015 040.03 Valves TC

The exhaust valve is 402676 replaced by 408535

–

Rev 1.1

050.01-1 Thermostat 24.04.2015 Housing

The thermostat housing 105400 is no longer available in RAL 9006.

Order 105480 in RAL 9010.

The slide ring seal 403929, water pump axle 407492, sealing bracket 404705 and all seals were replaced by the repair kit slide ring seal 409097.

Change of the scope of supply.

Rev 1.1

24.04.2015 050.02 Coolant Pump

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

Appendix Overview of revisions

Revision

Date

Chapter

Pos. Description

Note

The heat exchanger 105401 is no longer available in RAL 9006. Rev 1.1

24.04.2015 050.05 Heat Exchanger

Rev 1.1

050.06-1 Hoses Sea 24.04.2015 Water Supply

The heat exchanger 105484 in RAL 9010 was replaced by 105629.

7, 8 The hose system were changed.

Order 105629 in RAL 9010. Observe the information in chapter 050.06-1 Hoses Sea Water Supply.

No modification.

Rev 1.1

050.06-2 Hoses Sea 24.04.2015 Water Supply

–

The chapter is an addition to chapter 050.06-1 Hoses Sea Water Supply.

– Order 105485 in RAL 9010. Order 105487 in RAL 9010.

Rev 1.1

24.04.2015 060.02 Turbocharger

The turbocharger 105405 is no longer available in RAL 9006.

Rev 1.1

060.03-1 Exhaust 24.04.2015 Manifold

The exhaust manifold 105407 is no longer available in RAL 9006.

Rev 1.1

060.03-1 Exhaust 24.04.2015 Manifold

Rev 1.1

060.03-1 Exhaust 24.04.2015 Manifold

–

Rev 1.1

060.03-1 Exhaust 24.04.2015 Manifold

–

060.03-1 Exhaust 24.04.2015 Manifold

The plug 408013 was replaced by 408167. The turbocharger bracket was moved to chapter 060.01-2 Mounting Exhaust Manifold. The installation location of the sensor lambda 1 was moved into the catalyzer housing.

The plug 408844 and seal 100449 10, 11 were added. The plug 408013 was replaced by 408167.

–

– Observe the information in chapter 060.04-1 Catalyzer. Observe the information in chapter 060.04-1 Catalyzer. Observe the information in chapter 050.06-2 Hoses Sea Water Supply.

Rev 1.1

060.03-1 Exhaust 24.04.2015 Manifold

Rev 1.1

060.03-1 Exhaust 24.04.2015 Manifold

Rev 1.1

060.03-2 Exhaust 24.04.2015 Manifold

–

Rev 1.1

24.04.2015 060.04-1 Catalyzer

–

The chapter is an addition to chapter 060.03-1 Exhaust Manifold. – The installation location of the sensor lambda 1 was moved into the Observe the information in catalyzer housing. chapter 060.04-2 Catalyzer.

Rev 1.1

24.04.2015 060.04-2 Catalyzer

The plug 408011 was replaced by 408010.

–

Rev 1.1

24.04.2015 060.04-2 Catalyzer

The plug 407891 was replaced by 408169.

–

The fitting 407962 was replaced by 408959.

– Order 105491 in RAL 9010.

Rev 1.1

24.04.2015 060.04-2 Catalyzer

5, 6 The fitting 408651 was added. The plug 408013 was replaced by 408167. No modification.

–

Rev 1.1

24.04.2015 070.01 Intake Manifold

The intake manifold 105382 is no longer available in RAL 9006.

Rev 1.1

24.04.2015 070.03 Intercooler

The hose 405895 was replaced by 408103.

–

Rev 1.1

080 Engine 24.04.2015 Management System

The wire harness 408223 was replaced by 408540.

Observe the information in chapter 110.04-2 Oil Filter.

Rev 1.6

080 Engine 24.04.2015 Management System

The o-ring 403801 at the sensor crankshaft was added.

–

Rev 1.1

080 Engine 24.04.2015 Management System

The throttle body 102117 is no longer available in RAL 9006.

Order 103381 in RAL 9010.

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

Appendix Overview of revisions

Revision

Date

Chapter

Rev 1.1

100.01 Additional parts 24.04.2015 fuel supply

Rev 1.1

24.04.2015 110.1 Dry Sump

Rev 1.1

24.04.2015 110.04-1 Oil Filter

Pos. Description

Note

–

New chapter. The fitting 403895 was replaced by 408959. The seal 100454 was 8, 11 added. 1

All parts of the oil filter bracket was moved to chapter 110.04-2.

–

– –

Rev 1.1

24.04.2015 110.04-2 Oil Filter

At the turn of 2014/2015, the installation location of the switch oil pressure was moved to the opposite Observe the information in side of the oil filter bracket. chapter 110.04-2 Oil Filter.

Rev 1.1

24.04.2015 110.04-2 Oil Filter

The oil filter bracket 105385 is no longer available in RAL 9006.

Order 105495 in RAL 9010. –

Rev 1.1

24.04.2015 110.05 Oil Tank

The oil level hang tag 408459 was added.

Rev 1.1

120.02-1 Engine 24.04.2015 Bracket, Carrier Module

The engine bracket 105388 is no longer available in RAL 9006.

Order 105497 in RAL 9010.

Rev 1.1

24.04.2015 900.03 Supplies

–

New chapter.

–

The long block 105417 is no longer available in RAL 9006.

Order 105415 in RAL 9010.

–

The engine model 408246 was added.

–

New chapter for engine model 408246.

–

New chapter for engine model 408246.

–

New chapter for engine model 408246.

–

New chapter for engine model 408246.

–

New chapter for engine model 408246.

–

The catalyzer housing 105488 was replaced by 105604.

–

The catalyzer housing 105408 is no longer available in RAL 9006.

Order 105604 in RAL 9010.

–

New chapter for engine model 408246.

–

Different parts for engine model 408246 were added.

–

The bracket of the fuse box is now in chapter 070.03 Intercooler. –

–

New chapter for engine model 408246.

–

The spare parts case 105325 for engine model 408246 was added.

– – –

Rev 1.1 Rev C Rev C Rev C

03.07.2015 – 03.07.2015 010.01-2 Crankcase NA 03.07.2015 020.01 Crankshaft NA

Rev C

03.07.2015 040.03 Valves NA

Rev C

050.06 Hoses Sea 03.07.2015 Water Supply

Rev C

060.03 Exhaust 03.07.2015 Manifold NA

Rev C Rev C Rev C

Rev C

Rev C Rev C

24.04.2015 910 Repair Kits

03.07.2015 060.04-1 Catalyzer 03.07.2015 070.05 Air Box NA 080 Engine 03.07.2015 Management System 120.02-2 Engine Bracket, Carrier Module 03.07.2015 TC 120.02-2 Engine Bracket, Carrier Module 03.07.2015 NA 03.07.2015 900.01 Cases

Rev C

03.07.2015 910 Repair Kits

–

The scope of supply was changed for long block TC 105415.

Rev C

03.07.2015 910 Repair Kits

–

The long block NA 410072 for engine model 408246 was added.

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

Appendix Index

Index A

Adapter Carrier Module 72 Air Box 49 Assembling Kit Oil Seal Crankshaft 79 Assembling Kit Slide Ring Seal 79

Balance Shaft 16, 17 Bearing Shell, Balance Shaft 16, 17 Bearing Shell, Con-Rod 16, 17 Bearing Shell, Main Bearing 16, 17

Engine Badge 20 Engine Bracket 72 Engine Control Unit 52, 73, 74 Engine Cover 20 Engine Mount 75 Exhaust Cooler 44 Exhaust Gasket 37 Exhaust Manifold 40, 42 Exhaust Valve 24, 25 Expansion Tank 30

Camshaft 22 Carrier Module 72 Catalyzer Housing 43, 44 Catalyzer Insert 43 Chain Guide 22 Chain Link, Single 22 Chain Rail 22 Chain Tensioner 22 Chain Tool 79 Cleansing Concentrate 80 Collet Valve 24, 25 Con-Rod 16, 17 Con-Rod Bolt 16, 17 Cover, Crankshaft 19 Cover, Fuse Box 54 Crankcase 9 Crankshaft 16, 17 Cross Bar , Rocker Arm 23 Cylinder Head 21 Cylinder Head Gasket 21 Cylinder Liner 10, 11

Flame Arrester NA 49 Flame Arrester TC 48 Fuel Main-Filter 60 Fuel Pre-Filter 60 Fuel Pump 60 Fuel Rail 59 Fuse Box 73, 74 Fuse, Fuse Box 54

D Diagnostic Case 77 Distance Washer 27, 56 Drive Coupler 18 Dummy Plug 54

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

G Generator Cover 15 H Heat Exchanger 31 Hose Fixation 48 I Ignition Coil 20, 53 Impeller 28 Injector 53, 59 Installation Spike Valve Stem Seal 78 Intake Manifold 45 Intake Manifold Bracket 45 Intake Valve 24, 25 Intercooler 47 Intermediate Gear Suction Pump 61

Appendix Index

L Lifting Eye 71 Locking Tool Crankshaft 78 Long Block 81 O Oil Cooler 29 Oil Cooler Bracket 13 Oil Dipstick 66 Oil Filter 64, 66 Oil Filter Bracket 64, 65 Oil Level Hang Tag 66 Oil Pressure Valve 9, 63 Oil Pump 62 Oil Pump Cover 62 Oil Screen 61 Oil Seal 10, 11, 15 Oil Suction Pump 61 Oil Tank 66 Oil Tank Bracket 66 P Pin Punch Axle Intermediate Gear 78 Piston 16, 17 R Relay, Fuse Box 54 Relay Starter 58 Remover Bearing Cap 78 Rocker Arm 23 Rocker Axle 23 Rotor 56 Rubber Mount 46 S Sacrifical Anode 43 Sealing Bracket, Repait Kit 28 Sealing Kit Valve Cover 20 Sensor Camshaft 20, 50 Sensor Coolant Temperature 27, 50 Sensor Crankshaft 12, 50 Sensor Exhaust Manifold Temperature 40, 42, 50

Sensor Intake Manifold Pressure/Temperature 45, 51 Sensor Intercooler Pressure 47, 51 Sensor Knock 12, 51 Sensor Lambda 1 40, 42, 50 Sensor Lambda 2 44, 50 Service Case 76 Shim 75 Slide Ring Seal, Repair Kit 28 Spanner Nut 41 Spare Parts Case 76 Spark Plug 21, 53 Spring Cup 24, 25 Spring Pad 24, 25 Starter 55 Starter Cable 58 Stator 56 Stopsel 80 Stub Shaft, Thread M24 18 Stud 37, 40, 42 Suction Pump Cover 61 Switch Oil Pressure 53, 65 T TDC-Adjusting Tool 78 Thermostat 27 Thermostat Housing 26 Throttle Body 46, 53 Throttle Request Unit 52 Tie Rod 9 Timing Chain 22 Timing Insert 62 Tool Box 77 Turbocharger 39 Turbocharger Bracket 38 U Uniball 41 V Valve Adjustment Kit 78 Valve Adjustment Shim 24, 25 Valve Boost Pressure Control 39, 54

ETK MPE850 Rev C | 408014 | 408101 | 408246 |

Appendix Index

Valve Cover 20 Valve Spring 24, 25 Valve Stem Seal 24, 25 Vehicle Connector â&#x20AC;&#x17E;Engine Chassisâ&#x20AC;&#x153; 73, 74 Voltage Regulator 57 W Waste Gate Valve 41 Water Pump Axle, Repair Kit 28 Welch Plug 9 Wire Harness 54

ETK MPE850 Rev C | 408014 | 408101 | 408246 |