OXE 30-0101-200 Manuale utente

SERVICE MANUAL 1.0

Publication No: ODM1004

DIESEL ENGINE

OXE 150/200 HP SERVICE MANUAL

PREFACE

This Service Manual is designed to facilitate competent repair of the outboard

described here in.

The pictures and relevant descriptions show typical work that may not always

be applicable to the outboard at hand. This does not mean that pictures and

descriptions are inaccurate.

Plan and carrie out the repair work in a similar way.

Expert knowledge necessary for handling Diesel engines is a requirement for

correct handling of this powerhead.

NOTE! Only use fuels, lubricants etc. in accordance with Cimco Marine AB

regulations. Otherwise the manufacturer’s liability for defects will not apply!

For basic information on the fuels see table Recommended Fluids and Grease.

Any repair of components such as injection pump, alternator etc. ought to be le to

Cimco certiﬁed , distributors, or OEM service departments.

Best regards

Cimco Marine AB

Metallgatan 19a

SE-262 72 Ängelholm, Sweden

+46 (0)431-371130

[email protected]

Refer to your retailer if other publications are required.

Since our products are in continuous development, we reserve the right to make

technical modiﬁcations.

Reprinting, copying or translation, even of extracts, is not allowed without written

permission from Cimco Marine AB.

All rights under the copyright law are strictly reserved by Cimco Marine AB.

OXE 150/200 HP SERVICE MANUAL

CONTENTS

CONTENT

Preface ________________________________________________________________________________ 3

Safety regulations ______________________________________________________________________ 11

Important! _______________________________________________________________________ 11

Warning signs / levels of warnings ___________________________________________________ 11

Regulations for prevention of accidents with personal injury _______________________________ 11

Regulations to prevent damage to engine and prevent wear________________________________ 12

prevention of environmental damage__________________________________________________ 13

Cleanliness ______________________________________________________________________ 14

Repetitive alerts __________________________________________________________________ 16

Speciﬁcations __________________________________________________________________________ 18

Engine mechanical speciﬁcations_____________________________________________________ 18

Engine Threshold values____________________________________________________________ 22

General tightening torques __________________________________________________________ 23

Fastener tightening speciﬁcations ____________________________________________________ 24

Recommended ﬂuids and grease _____________________________________________________ 28

Tools and equipment ____________________________________________________________________ 29

Special tools _____________________________________________________________________ 30

Engine component description ___________________________________________________________ 36

Outboard overviews_____________________________________________________________________ 38

System and assembly overviews __________________________________________________________ 40

Cooling system ___________________________________________________________________ 40

Engine lubrication system __________________________________________________________ 41

Camsha timing components________________________________________________________ 42

Dry sump, ﬁlter, and tube ___________________________________________________________ 43

Cylinder head assembly ____________________________________________________________ 44

Engine block assembly _____________________________________________________________ 46

Intake manifold ___________________________________________________________________ 48

Turbo charger assembly ____________________________________________________________ 49

Fuel system description _________________________________________________________________ 50

Evacuating air from fuel system______________________________________________________ 51

Transmission component description _________________________________________________ 52

Hydraulic SYSTEM description _______________________________________________________ 53

Repetitive instructions___________________________________________________________________ 54

Replacing gaskets_________________________________________________________________ 54

Remove and install the top cowling ___________________________________________________ 55

OXE 150/200 HP SERVICE MANUAL

CONTENTS

Fuel injection pump replacement__________________________________________________________ 57

Fuel injection pump removal ________________________________________________________ 58

Fuel injection pump bracket removal__________________________________________________ 59

Fuel injection pump installation ______________________________________________________ 62

Fuel ﬁlter _____________________________________________________________________________ 65

Fuel ﬁlter replacement _____________________________________________________________ 65

Replacing fuel ﬁlter element _______________________________________________________ 67

fuel injector feed pipe replacement ________________________________________________________ 68

Feed pipe removal (fuel pump to rail)__________________________________________________ 68

Feed pipe installation (fuel pump to rail) _______________________________________________ 69

Feed pipe removal (rail to injectors) __________________________________________________ 70

Feed pipe installation (rail to injectors) ________________________________________________ 71

Fuel rail assembly replacement __________________________________________________________ 72

Fuel rail assembly removal _________________________________________________________ 72

Fuel rail assembly installation _______________________________________________________ 73

Fuel Rail Pressure Sensor replacement ____________________________________________________ 74

Glow plug replacement __________________________________________________________________ 75

Glow plug removal ________________________________________________________________ 75

Glow plug installation ______________________________________________________________ 76

Draining and ﬁlling coolant _______________________________________________________________ 77

Draining coolant __________________________________________________________________ 78

Filling coolant ____________________________________________________________________ 78

Check coolant system______________________________________________________________ 79

Thermostat replacement_________________________________________________________________ 80

Heat exchanger Replacement_____________________________________________________________ 81

Heat exchanger removal____________________________________________________________ 81

Cleaning the heat exchanger ________________________________________________________ 84

Heat exchanger installation _________________________________________________________ 85

freshWater pump replacement ___________________________________________________________ 86

FreshWater pump removal__________________________________________________________ 86

freshWater pump installation ________________________________________________________ 86

Engine oil and oil ﬁlter replacement _______________________________________________________ 87

Engine oil and oil ﬁlter removal ______________________________________________________ 87

Engine oil and oil ﬁlter installation ____________________________________________________ 89

Oil ﬁlter adapter and oil cooler assembly replacement ________________________________________ 90

Oil ﬁlter adapter and oil cooler assembly removal ________________________________________ 90

Oil ﬁlter adapter and oil cooler assembly installation______________________________________ 92

OXE 150/200 HP SERVICE MANUAL

CONTENTS

Oil pump replacement ___________________________________________________________________ 93

Oil pump removal _________________________________________________________________ 93

Oil pump installation ______________________________________________________________ 95

Filling up with engine oil_________________________________________________________________ 97

Positive crankcase ventilation oil separator replacement ______________________________________ 98

Positive crankcase ventilation oil separator removal _____________________________________ 98

Positive crankcase ventilation oil separator installation ___________________________________ 98

Turbocharger oil feed pipe replacement ____________________________________________________ 99

Turbocharger oil feed pipe removal ___________________________________________________ 99

Turbocharger oil feed pipe installation _________________________________________________ 99

Turbocharger oil return pipe replacement__________________________________________________100

Turbocharger oil return pipe Removal ________________________________________________ 100

Turbocharger oil return pipe installation ______________________________________________ 100

Alternator belt replacement _____________________________________________________________101

Alternator drive belt removal _______________________________________________________ 101

Alternator belt tensioner replacement_____________________________________________________104

Alternator replacement_________________________________________________________________105

Alternator removal _______________________________________________________________ 105

Alternator installation _____________________________________________________________ 105

camsha Timing belt replacement _______________________________________________________106

Water pump and crank sha balancer removal _________________________________________ 106

Timing belt removal ______________________________________________________________ 107

Timing belt inspection_____________________________________________________________ 108

Timing belt removal ______________________________________________________________ 109

Installing a new timimg belt ________________________________________________________ 111

Timing belt idler pulley replacement – lower ___________________________________________ 113

Camsha housing replacement, cleaning and inspection _____________________________________114

Camsha housing removal_________________________________________________________ 114

Camsha cover cleaning___________________________________________________________ 117

Camsha cover inspection _________________________________________________________ 117

Camsha housing installation ______________________________________________________ 119

Valve rocker arm cover replacement ______________________________________________________122

Valve lier roller replacement ___________________________________________________________123

Valve lier roller removal __________________________________________________________ 123

Valve lier roller installation ________________________________________________________ 123

Camsha sprocket replacement__________________________________________________________124

OXE 150/200 HP SERVICE MANUAL

CONTENTS

Camsha rear cover replacement ________________________________________________________125

Camsha rear cover removal _______________________________________________________ 125

Camsha rear cover installation_____________________________________________________ 125

Camsha replacement__________________________________________________________________126

Intake camsha removal __________________________________________________________ 127

Intake camsha installation ________________________________________________________ 128

Exhaust camsha removal _________________________________________________________ 130

Exhaust camsha installation_______________________________________________________ 131

Camsha position sensor replacement ____________________________________________________132

Cylinder head replacement ______________________________________________________________133

Cylinder head removal ____________________________________________________________ 133

Fold away the engine wiring harnesS ________________________________________________ 135

Cylinder head installation __________________________________________________________ 138

Piston, connecting rod, and bearing replacement____________________________________________141

Piston, connecting rod, and bearing removal___________________________________________ 141

Piston and connecting rod disassemble/assemble ______________________________________ 142

Piston, connecting rod, and bearing installation ________________________________________ 143

Engine ﬂywheel replacement ____________________________________________________________144

Engine ﬂywheel removal __________________________________________________________ 144

Engine ﬂywheel installation ________________________________________________________ 145

Cranksha oil seal replacement __________________________________________________________146

Cranksha oil seal removal ________________________________________________________ 146

Cranksha oil seal installation ______________________________________________________ 147

Cranksha and bearing replacement ______________________________________________________148

Cranksha end play measurement __________________________________________________ 148

Cranksha and bearing removal ____________________________________________________ 148

Cranksha and bearing installation __________________________________________________ 150

Piston oil nozzle replacement____________________________________________________________152

Piston oil nozzle removal __________________________________________________________ 152

Piston oil nozzle installation ________________________________________________________ 152

Intake manifold replacement ____________________________________________________________153

Intake manifold removal ___________________________________________________________ 153

Intake manifold disassembly _______________________________________________________ 157

Intake manifold cleaning and inspection ______________________________________________ 158

Intake manifold assemblY__________________________________________________________ 159

Intake manifold installation ________________________________________________________ 160

Dry sump and Oil pan baﬄe replacement __________________________________________________162

Oil pan baﬄe removal _____________________________________________________________ 162

Oil pan baﬄe installation___________________________________________________________ 162

OXE 150/200 HP SERVICE MANUAL

CONTENTS

Propeller replacement__________________________________________________________________163

Propeller removal ________________________________________________________________ 163

Propeller installation______________________________________________________________ 166

Lower belt replacement ________________________________________________________________169

Cowling removal _________________________________________________________________ 169

Upper belt housing removal ________________________________________________________ 170

Draining hydraulic oil in lower housing _______________________________________________ 172

Lower housing disassembly________________________________________________________ 173

Gearbox Disassembling ___________________________________________________________ 174

Lower belt Installation ____________________________________________________________ 178

Reinstalling bearing housing in gearbox ______________________________________________ 183

Reinstalling propellersha components_______________________________________________ 183

Reassembling the gearbox components ______________________________________________ 185

Reﬁll hydraulic oil ________________________________________________________________ 187

Reinstall the upper belt housing _____________________________________________________ 187

Propeller sha bearing replacement ______________________________________________________190

800 h service ____________________________________________________________________ 190

Remove the propeller sha bearing __________________________________________________ 190

Shims, sha sleeves and radial seals replacement in gearbox _________________________________192

800 h service ____________________________________________________________________ 192

Removing and installing the inner gearbox bearings_____________________________________ 193

Removing and installing bearings and oil seals in the bearing housing ______________________ 195

Removing and installing the sleeves _________________________________________________ 196

Removing and installing bearing races and shims in the gearbox lid ________________________ 197

Measuring the axial free play _______________________________________________________ 199

Change lower belt oil___________________________________________________________________201

Change upper belt oil___________________________________________________________________203

Upper belt replacement_________________________________________________________________204

Replace belt pulley seals___________________________________________________________ 205

Replace zinc anodes ______________________________________________________________ 205

Seawater pump impeller replacement_____________________________________________________206

Clean Seawater strainer ________________________________________________________________207

Replace Seawater outlet nipple __________________________________________________________208

Drain and ﬁll coolant ___________________________________________________________________209

Fill coolant______________________________________________________________________ 210

OXE 150/200 HP SERVICE MANUAL

Antifreeze Preservation Of seawater system _______________________________________________212

Short-term storage_______________________________________________________________ 212

Long-term storage _______________________________________________________________ 213

Hydraulic oil ﬁlter Replacement __________________________________________________________214

Hydraulic pump replacement ____________________________________________________________216

Air Filter Replacement _________________________________________________________________217

Air ﬁlter removal _________________________________________________________________ 217

Clean the turbo charger ___________________________________________________________ 217

Air ﬁlter installation_______________________________________________________________ 217

Check power tilt and trim system_________________________________________________________218

Checking the power tilt and trim function _____________________________________________ 218

Electrical system ______________________________________________________________________224

Electrical Components ____________________________________________________________ 224

Engine control unit (ECU) __________________________________________________________ 226

wiring _________________________________________________________________________ 227

Maintenance schedules _________________________________________________________________248

First Inspection __________________________________________________________________ 248

Service at 200 hours ______________________________________________________________ 249

Service at 800 hours ______________________________________________________________ 251

Service record - Lower belt ________________________________________________________ 253

Service record - Lower belt ________________________________________________________ 254

Troubleshooting _______________________________________________________________________255

Operating faults and possible causes_________________________________________________ 255

Fault table ______________________________________________________________________ 256

CONTENTS

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