Textron Motors MPE 850 OFF-ROAD Instrucciones de funcionamiento

TD409135_RLF

Rev A

04.09.2015

MPE 850 OFF-ROAD

– 409135 I2 846 UTV NA-80

This repair manual is valid for the following engine models:

en_English

REPAIR MANUAL

4-Stroke Engine

Read the introductory chapter before performing the task on the engine.

Pay particular attention to the safety messages.

Textron Motors GmbH

Daimlerstraße 5

88677 Markdorf

Germany

www.weber-motor.com

Textron Motors GmbH strives to make continual improvements as part of the ongoing technical development

of its products. All documentation is therefore subject to technical modifications.

Reprints and translations, in whole or in part, require written permission from Textron Motors GmbH.

4 RLF MPE850 Rev A | 409135 |

Table of contents

1 About this document 9

1.1 Meaning of the symbols and signal words........................................ 9

1.2 Change management .......................................................9

1.3 Finding the required information ..............................................10

2 Safety 11

2.1 Meaning of the safety alert symbol and signal words .............................. 11

2.2 Important safety messages .................................................. 12

3 Basic instructions for working on the engine 15

3.1 Before you begin working ...................................................15

3.1.1 Removing engine from vehicle ..............................................15

3.2 While working ............................................................15

3.2.1 Lift and transport the engine................................................15

3.2.2 Secure the engine while working ............................................15

3.2.3 Tightening torque ........................................................ 16

3.2.4 Cleaning ...............................................................16

3.2.5 Disposal ...............................................................16

3.3 After working .............................................................16

3.3.1 Updating engine control unit calibration ....................................... 16

3.3.2 Checking the work carried out ..............................................16

4 Tools and accessories 17

4.1 Equipment workshop .......................................................17

4.1.1 Textron Motors special tools ................................................17

4.1.2 Textron Motors Diagnostic Tool.............................................. 18

4.1.3 Commercially available workshop equipment and standard tools ...................18

4.1.4 Commercially available special tools .........................................20

4.1.5 Supplies ...............................................................21

5 Overview of activities 22

010 Crankcase ..............................................................22

010.01-1 Crankcase ..........................................................22

Replacing crankcase.........................................................22

Replacing welch plugs .......................................................22

Replacing tie rod ............................................................22

Replacing plugs ............................................................22

010.01-2 Crankcase NA .......................................................22

Replacing cylinder liners ......................................................22

Replacing oil seal ...........................................................23

Replacing plug .............................................................23

010.01-3 Crankcase ..........................................................23

Removing plug .............................................................23

Installing plug ..............................................................23

5RLF MPE850 Rev A | 409135 |

Table of contents

Replacing plugs ............................................................23

Removing fitting ............................................................23

Installing fitting .............................................................23

Removing sensor crankshaft ..................................................23

Installing sensor crankshaft ...................................................23

Removing sensor knock ......................................................23

Installing sensor knock .......................................................23

010.02-1 Oil cooler bracket ..................................................... 24

Removing oil cooler bracket ...................................................24

Installing oil cooler bracket ....................................................24

010.02-2 Oil cooler bracket ..................................................... 24

Replacing blanking cover .....................................................24

Replacing plug .............................................................24

Sealing cover oil cooler bracket ................................................24

010.03 Generator cover........................................................ 24

Removing generator cover ....................................................24

Installing generator cover .....................................................24

Replacing generator cover ....................................................24

Replacing oil seal ...........................................................25

Replacing vent plug .........................................................25

020 Crank drive ..............................................................25

020.01 Crankshaft ............................................................25

Removing crank drive ........................................................25

Installing crank drive .........................................................26

Replacing crankshaft ........................................................26

Replacing balance shaft ......................................................26

Removing pistons and con rods ................................................26

Installing pistons and con rods .................................................27

Replacing piston ............................................................27

Replacing con rod ...........................................................27

Checking con rod bearing play .................................................27

Checking main bearing play ...................................................27

020.02 Stub shaft ............................................................27

Removing stub shaft .........................................................27

Installing stub shaft ..........................................................27

020.03 Abdeckung Kurbelwelle ..................................................28

Removing crankshaft cover....................................................28

Installing crankshaft cover ....................................................28

030 Cylinder head ............................................................28

030.01 Valve cover ........................................................... 28

Removing valve cover........................................................28

Installing valve cover.........................................................28

Replacing valve cover........................................................28

Removing ignition coils .......................................................28

Installing ignition coils ........................................................28

Removing sensor camshaft....................................................28

Installing sensor camshaft ....................................................28

030.02 Cylinder head .........................................................29

Removing cylinder head ......................................................29

Installing cylinder head .......................................................29

Replacing cylinder head ......................................................29

Removing spark plugs........................................................29

6 RLF MPE850 Rev A | 409135 |

Table of contents

Installing spark plugs ........................................................30

Removing switch oil pressure ..................................................30

Installing switch oil pressure ...................................................30

Removing fitting ............................................................30

Installing fitting .............................................................30

Replacing plugs ............................................................30

040 Valve train............................................................... 30

040.01 Camshaft .............................................................30

Replacing camshaft..........................................................30

Replacing timing chain .......................................................31

Checking and setting valve timing ..............................................31

Replacing chain rail..........................................................31

Replacing chain guide........................................................31

040.02 Rocker arms ..........................................................31

Replacing rocker arms .......................................................31

040.03 Valves ...............................................................32

Removing valve.............................................................32

Installing valve..............................................................32

050 Cooling system ...........................................................32

050.01 Thermostat housing.....................................................32

Removing thermostat housing .................................................32

Installing thermostat housing .................................................. 32

Removing fitting ............................................................32

Installing fitting .............................................................32

Replacing thermostat ........................................................33

Replacing sensor coolant temperature ...........................................33

Replacing plug thermostat housing..............................................33

Removing closing cap thermostat housing ........................................33

Installing closing cap thermostat housing .........................................33

050.02 Coolant pump .........................................................33

Removing impeller ..........................................................33

Installing impeller ...........................................................33

Removing coolant pump ......................................................34

Installing coolant pump .......................................................34

050.03 Oil cooler .............................................................34

Removing oil cooler..........................................................34

Installing oil cooler...........................................................34

060 Exhaust system ..........................................................34

060.01 Mounting exhaust manifold ............................................... 34

Removing/Installing exhaust system.............................................34

Replacing studs.............................................................34

070 Intake area .............................................................. 35

070.01 Intake manifold ........................................................35

Removing intake manifold.....................................................35

Installing intake manifold......................................................35

Replacing intake manifold.....................................................35

Removing sensor intake manifold pressure/temperature .............................35

Installing sensor intake manifold pressure/temperature ..............................35

Replacing cap ..............................................................35

070.02 Mounting throttle body ...................................................35

Removing throttle body .......................................................35

Installing throttle body ........................................................35

7RLF MPE850 Rev A | 409135 |

Table of contents

Replacing throttle body .......................................................35

Replacing rubber mount ......................................................35

080 Engine management system ................................................ 36

Sensor crankshaft ...........................................................36

Sensor camshaft ............................................................36

Sensor coolant temperature ...................................................36

Sensor lambda .............................................................36

Sensor intake manifold pressure/temperature NA ..................................36

Sensor knock ..............................................................36

Engine control unit NA .......................................................36

Ignition coils ...............................................................36

Spark plugs ................................................................36

Injectors NA................................................................36

Throttle body ...............................................................36

Switch oil pressure ..........................................................36

090 Starter, Generator......................................................... 36

090.01 Starter ...............................................................36

Removing starter............................................................36

Installing starter.............................................................36

Replacing starter............................................................36

090.02 Generator ............................................................37

Removing generator .........................................................37

Installing generator ..........................................................37

090.03 Voltage regulator ....................................................... 37

Removing/Installing voltage regulator............................................37

090.04 Relay starter ..........................................................37

Removing/Installing relay starter ...............................................37

100 Fuel system .............................................................37

100.01 Fuel rail ..............................................................37

Removing fuel rail ...........................................................37

Installing fuel rail ............................................................37

Replacing injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

110 Lubrication system ........................................................ 37

110.01 Dry sump ............................................................. 37

Removing suction pump cover .................................................37

Installing suction pump cover ..................................................37

Replacing suction pump cover .................................................38

Removing oil suction pump....................................................38

Installing oil suction pump.....................................................38

Stutzen ersetzen ............................................................38

Removing intermediate gear suction pump .......................................38

Installing intermediate gear suction pump ........................................38

110.02 Oil pressure pump ......................................................39

Removing oil pressure pump ..................................................39

Installing oil pressure pump ...................................................39

110.03 Oil pressure valve ...................................................... 39

Removing oil pressure valve...................................................39

Installing oil pressure valve....................................................39

110.04 Oil filter...............................................................39

Removing oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Installing oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Removing threaded sleeve ....................................................39

8 RLF MPE850 Rev A | 409135 |

Table of contents

Installing threaded sleeve .....................................................40

110.05 Oil tank...............................................................40

Removing/Installing oil tank ...................................................40

120 Engine mount ............................................................40

120.01 Lifting eye ............................................................40

Removing bracket on the drive side .............................................40

Installing bracket on the drive side ..............................................40

Removing pipe clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Installing pipe clamp .........................................................40

Removing bracket across from the drive side......................................40

Installing bracket across from the drive side.......................................40

6 Working instructions, single 41

6.1 List of working instructions, single .............................................41

Appendix 231

Overview of revisions ..........................................................231

Index ......................................................................232

This repair manual describes how to safely and correctly remove, install and replace engine components.

Observe the following information:

– Read through the service manual before performing any tasks.

– Some figures in this repair manual are general illustrations and may differ from the actual engine.

1 About this document

1.1 Meaning of the symbols and signal words

Item Meaning

NOTICE The signal word NOTICE indicates potential property damage.

Information The signal word Information indicates specific features and recommendations.

For the activity required special tools.

For the activity additionally required spare parts.

For the activity required supplies.

For the activity additionally required documents.

1About this document

1.1 Meaning of the symbols and signal words | …

1.2 Change management

Textron Motors GmbH strives to make continual improvements as part of the ongoing technical development

of its products. You may find that descriptions in the repair manual are changed or amended. All changes are

described in the chapter Overview of revisions.

Observe the following information:

– Always use the most current repair manual from the protected area on our web site

www.weber-motor.com.

– Always print the required chapter and all chapters referred to completely and then destroy the printouts.

RLF MPE850 Rev A | 409135 |

1About this document

1.3 Finding the required information

►Open chapter 5 Overview of activities in

the repair manual.

►Locate the section with the same

designation 010.01-2 Crankcase NA 3.

In this section you will find the activity

Replacing cylinder liners 5.

►Check whether the activity is valid for the

engine model 4.

►Perform all for the activity required working

instructions 6in the order shown.

Observe the following references:

– A list of all working instructions is located in

chapter 6.1 List of working instructions,

single.

– Each working instruction contains information

on required special tools, additional required

spare parts, supplies and documents.

When you planning a work on the engine, proceed

as follows:

For example, you want to replace the cylinder

liners 2.

►Identify the corresponding component in the

spare parts catalog..

The cylinder liners can be found in the spare

parts catalog in chapter

010.01-2 Crankcase NA 1

10 RLF MPE850 Rev A | 409135 |

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