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4-Stroke Engine
MPE 850 OFF-ROAD
This installation manual is valid for the following engine variants:
409135 I2 846 UTV NA-80
TD409135_EHB
Rev A
04.08.2015
en_English
Before you begin installing the engine, read the installation manual. Pay
particular attention to the safety messages.
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
Daimlerstrae 5
88677 Markdorf
Deutschland
www.weber-motor.com
Table of contents
Table of contents
1 About this document
1.1
2 Safety
7
2.1
2.2
10
4 Description
11
11
11
11
12
12
15
15
16
17
18
19
19
20
21
23
23
24
24
25
27
27
28
28
29
29
30
31
31
32
32
33
34
35
35
37
Table of contents
Installation data
5.1 Requirements for the engine compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1.1 Accessibility engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Installation engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.1 Installation position engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.2 Mounting engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.2.1 Decoupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.2.2 Mounting points at the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.2.3 Interface drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initial operation
38
40
40
42
43
48
49
49
50
51
51
51
52
52
52
52
53
55
56
58
Engine manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Overview of revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Meaning
The signal word NOTICE indicates potential property damage.
2
2.1
Safety
Safety
This engine is state-of-the-art and built according to recognized safety-technical regulations. Inappropriate
installation of the engine may result in personal injury or property damage. The engine installation to the
vehicle must be approved by Textron Motors, before the serial production of the vehicle.
This installation manual is only intended for using by the vehicle manufacturer. All tasks on the engine must
be performed by appropriately trained personnel.
Observe all generally applicable laws and regulations in addition to the information in this installation manual:
Accident prevention
Environmental protection
Handling of hazardous materials
Personal safety equipment
Traffic laws
2.1
Meaning
WARNING
The signal word WARNING indicates a potentially dangerous situation that may
lead to a serious or fatal injury.
CAUTION
The signal word CAUTION indicates a potentially dangerous situation that may
lead to a minor or moderately severe injury.
2 Safety
2.2
2.2
Service tasks
Spare parts
All the components in your engine have been carefully tested and fulfill
strict quality and safety requirements.
Textron Motors offers spare parts to the highest quality. Ensure that
equivalent spare parts corresponds with this quality requirements.
Always wash your hands prior to eating, smoking and using the
restroom as well as at the end of the working shift when working
with operating materials.
Operating materials are hazardous to the environment.
2
2.2
Safety
Fuel
Do not smoke in the vicinity of the engine and do not allow open
flames or sparks near the engine or the fuel system.
Do not start the engine if there is a smell of fuel or you suspect that
fuel is leaking.
Do not extinguish with water. In the event of a fire, use foam, dry
chemical or carbon dioxide extinguishers.
Engine oil
Engine oil is flammable. During heating or in case of fire, toxic gases may
form.
Do not smoke in the vicinity of the engine and do not allow open
flames or sparks near the engine.
Do not extinguish with water. In the event of a fire, use foam, dry
chemical or carbon dioxide extinguishers.
California Proposition 65
Vehicle specification
Interaction
Drive train
10
4
4.1
Description
Description
4.1
4.1.1 Temperature
Ambient temperature
-25 45 C
Temperature engine
compartment
4.1.2
30 1
35
30 1
20 minutes at idle
40
60 1
30 1
20 minutes at idle
40
Clutch engaged
45
11
4 Description
4.2 Cooling system
4.2
Cooling system
4.2.1
System
The closed coolant circuit is a full flow bypass arrangement. During warmup no coolant leaves the engine, except through the permanent vent. Not
until the operating temperature is reached, the internal thermostat directs
the main current through the external heat exchanger. For this reason
the intended operating temperature of the engine is achieved as early as
possible. The thermostat is fitted with a wax element:
Opening temperature from 82 C
Fully open at 88 C
The heat exchanger engine oil/coolant (oil cooler) uses a permanent
bypass flow for cooling the engine oil.
The coolant pump is a radial pump driven by the balance shaft.
Flow rate
Operating pressure
Operating temperature
85 110 C
Expansion tank
(not in scope of supply)
12
4
4.2
Description
Cooling system
Coolant
(not in scope of supply)
Information of coolant specification and mixing ratio you will find in the
service manual of the engine.
Coolant lines
(not in scope of supply)
13
4
4.2
Description
Cooling system
ku2
ku6
ku1
ku4
ku3
ku8
ku5
ku7
ku5
ku6
ku7
ku8
Thermostat, closed
Permanent vent coolant circuit
Expansion tank
Expansion volume of the expansion tank
ku9
14
4
4.2
4.2.1.1
Description
Cooling system
1
2
4.2.1.2
15
Description
4.2
Cooling system
4.2.1.3
of the
4
5
16
4.3
Description
4.3
Fuel system
Fuel system
System
Operating pressure
4 bar
Permissible operating
temperature
Fuel pump
(not in scope of supply)
4 bar
Fuel main-filter
(not in scope of supply)
Textron Motors offers a suitable fuel main -filter TM 408338 with the
following specification:
Textron Motors offers a suitable fuel main filter with integrated pressure
regulator.
Fuel
(not in scope of supply)
Information of fuel specification you will find in the service manual of the
engine.
Textron Motors recommends to place the recommended fuel quality for
the vehicle user permanently and good visible on the fuel tank.
17
4 Description
4.3
Fuel system
Fuel line
(not in scope of supply)
kr1
kr2
kr8
kr7
kr3
kr4
kr5
kr6
4.3.1
kr5
kr6
kr7
kr8
Back-pressure valve
Fuel pump
Fuel pre-filter
Fuel tank (not in scope of supply)
18
4.3.2
Description
4.3
Fuel system
4.3.3
19
4 Description
4.3 Fuel system
4.3.4
Electrical connections 2
threaded bolts 6-32 UNC-2A
20
4
4.4
4.4
Description
Lubrication system
Lubrication system
System
Dry sump engine with 2 separate oil pumps. A rotor pump builds up oil
pressure and conveys the engine oil to the lubrication points in the engine.
The suction pump conveys the engine oil from the crankcase to the oil
tank. This air/engine-oil-mix will be separated in the oil tank.
Operating pressure
Operating temperature
Oil tank
(not in scope of supply)
For operating a dry sump engine, an oil tank is required, which ensures a
continuous engine oil supply during operation.
Textron Motors offers a suitable oil tank TM 404653 with the following
specification:
Oil separator system (cyclone)
Internal baffles
Oil drain plug
Oil dipstick for the level measurement
Oil filter
Engine oil
(not in scope of supply)
Information of engine oil grade you will find in the service manual of the
engine.
Hoses
(not in scope of supply)
21
4 Description
4.4
Lubrication system
s4
s15
s6
s14
s3
s2
s13
s12
s5
s9
s10
s1
s7
s11
s8
22
s8
s9
s10
s11
s12
s13
s14
s15
4
4.4
4.4.1
Description
Lubrication system
Installation engine oil supply and return with a Textron Motors oil tank
1
2
4.4.2
Installation crankcase ventilation / engine oil return with a Textron Motors oil tank
23
4 Description
4.4 Lubrication system
4.4.3
is rotatable by 180.
4.4.4
hose inner
24
4
4.4
4.4.5
Description
Lubrication system
Determination of the fill quantity engine oil with a Textron Motors oil tank
Tightening torque:
9 Nm +2 Nm [6.6 lbf ft +1.5 lbf ft]
2
25
4 Description
4.4
Lubrication system
26
4
4.5
4.5
4.5.1
Description
Intake system
Intake system
Intake system naturally aspirated engines (NA)
System
Installation condition
Air cleaner
(not in scope of supply)
Hoses
(not in scope of supply)
an2
an1
an4
an5
an6
an7
an3
Scheme intake system
an1 Engine
an2 Intake manifold
an3 Sensor pressure/temperature
an4 Throttle body, electronic
an5
an6
an7
Air cleaner
Intake air
Blow-by-return from lubrication system
27
4 Description
4.5 Intake system
4.5.1.1
Inner
4.5.1.2
Installation blow-by-return
28
4
4.6
4.6
4.6.1
Description
Exhaust system
Exhaust system
Exhaust system naturally aspirated engines (NA)
Recommended dimensioning:
Exhaust pipes
(not in scope of supply)
Sensor lambda
(not in scope of supply)
Muffler
(not in scope of supply)
Catalyzer
(not in scope of supply)
ag1
ag6
ag7
ag2
ag3
ag5
ag4
ag5
ag6
ag7
29
4 Description
4.6 Exhaust system
4.6.1.1
30
4
4.7
4.7
Description
Electrical system
Electrical system
System
12 V, negative earth
Throttle body
Ignition system
Starter
Generator, internal
4.7.1
System
System
31
4 Description
4.7 Electrical system
4.7.2
4.7.2.1
The Textron Motors engine control unit is in scope of supply of the engine.
Observe that the engine's serial number is saved in the engine control
unit.
Voltage regulator
(Additional part)
Sensor lambda
(Additional part)
Relay starter
(Additional part)
Wire harness
(not in scope of supply)
Diagnostic connector
(Component wire harness)
32
4
4.7
4.7.2.2
Description
Electrical system
*Use30ampsrelayswithinternalparallel
connectedresistortocoil
(e.g.SongChuan3011ADR112VDC)
**Userelayswithinternalparallel
connectedresistortocoil
14
85
Mainrelay*
86
87
15A
Service
30
Battery+
15A
VBR
15A
VBD
1
6
10
17
16
15
30A
Main
26
33
21
23
28
27
CruisecontrolON/OFF
Cruisecontrolresume
Cruisecontrolset+
Cruisecontrolset
CruisecontrolGND
11
Engine/Chassisconnector
Delphi13601803
24
30
Brakelightswitch
GND
Brakelight
Powerlimit
Reverselimiter
GND
GND
Neutralswitch
18
Vehiclespeedinput
12
Rolloversensor
GND
22
85
15
Key
switch
30
35
31
CANhigh
Outputandfusing
customerspecific
87
GND
Fanrelay**
86
32
34 36 37 38 39 40
50
30
10A
VBK
85
86
30
10A
twisted
87
Max.20mA
5Voutput
Fuelpump
CANlow
Fuelpumprelay*
Service
PPS2Signal
PPS25V
PPS1Signal
PPS15V
PPS2GND
MIL
ByusingLEDsits
recommendedtoconnecta
10kOhmsresistor
PPS1GND
RPMoutput
Pedalvaluesensor
ConnectorforWeberPedalvalue
sensorTyco19676161
Watertemp.
Oilpressure
33
Description
4.7
Electrical system
4.7.2.3
X**
G
K
M
*
**
Cross section
<2m
16 mm
>2m
25 mm
thread M6
34
4
4.7
4.7.2.4
Description
Electrical system
Electrical connections:
to battery
thread M6
thread M6
1
2
4.7.2.5
X
G
35
4
4.7
Description
Electrical system
on a cold and
must be arranged
(Minus)
to Generator, internal
to battery direct
(AC Voltage)
(Plus)
36
4
4.7
4.7.2.6
Description
Electrical system
1
2
37
4 Description
4.7 Electrical system
4.7.2.7
38
4
4.7
Description
Electrical system
39
4 Description
4.7 Electrical system
4.7.3
4.7.3.1
Battery
Minimum 12 V 20 Ah
12 V 40 Ah at low ambient temperatures.
Cranking amps minimum 260 A
Ignition switch
Relays
40
4
4.7
Lights
Description
Electrical system
41
4 Description
4.7 Electrical system
4.7.3.2
*Use30ampsrelayswithinternalparallel
connectedresistortocoil
(e.g.SongChuan3011ADR112VDC)
**Userelayswithinternalparallel
connectedresistortocoil
14
85
Mainrelay*
86
87
15A
Service
30
Battery+
15A
VBR
15A
VBD
1
6
10
17
16
15
30A
Main
26
33
21
23
28
27
CruisecontrolON/OFF
Cruisecontrolresume
Cruisecontrolset+
Cruisecontrolset
CruisecontrolGND
11
Engine/Chassisconnector
Delphi13601803
24
30
Brakelightswitch
GND
Brakelight
Powerlimit
Reverselimiter
GND
GND
Neutralswitch
18
Vehiclespeedinput
12
Rolloversensor
GND
22
85
15
Key
switch
87
30
35
31
CANhigh
Outputandfusing
customerspecific
86
GND
Fanrelay**
32
34 36 37 38 39 40
50
30
10A
VBK
85
86
30
10A
twisted
87
Max.20mA
5Voutput
Fuelpump
CANlow
Fuelpumprelay*
Service
PPS2Signal
PPS25V
PPS1Signal
PPS15V
ByusingLEDsits
recommendedtoconnecta
10kOhmsresistor
PPS2GND
MIL
PPS1GND
RPMoutput
Pedalvaluesensor
ConnectorforWeberPedalvalue
sensorTyco19676161
Watertemp.
Oilpressure
42
4
4.7
4.7.3.3
Description
Electrical system
Observe the additional information about vehicle components in chapter 4.7.3.1 Electrical equipment
vehicle.
Vehicle component
Contact
Engine
chassis
Wire
harness
cct
Using
Connection instructions
Description
30
required
The terminal 15 signal is used to start up or shut down the engine control unit.
Observe that the signal at engine start must not be interrupted. When the
terminal 15 signal disappears during operation the injection will be deactivated
immediately and engine will be turned off.
Terminal 30 Plus Battery
6
33
required
The direct battery connection is required for the function of the engine control
device.
Terminal 50 Plus Starter Signal
5
66
required
By using terminal 50 at the ignition switch, the relay starter will be controlled
by the engine control unit. Cranking the engine is only possible when the
signal of the neutral switch is active.
See the service manual of the engine.
43
4 Description
4.7 Electrical system
Vehicle component
Contact
Engine
chassis
Wire
harness
cct
Using
Connection instructions
Description
Main Relay
1
73
required
The main relay supplies the actuators of the engine, for example fuel injectors
and ignition coils.
The relay is switched on when terminal 85 is switched by the engine control
unit to ground.
6
33
required
78
required
The terminal 87 is the output of the main circuit of the main relay and supplies
the engine control unit.
4
16
required
The fuse Service is intended for deactivation the ignition coils and injectors
during service tasks.
The terminal 87 is the output of the main circuit of the main relay and
disconnects the power supply to the actuators, for example fuel injectors and
ignition coils.
Fuel Pump Relay
33
107
required
The relay is switched on by the engine control unit 3 seconds after ignition
switch on or when engine speed is detected.
Fan Relay
26
48
required
The relay is switched on by the engine control unit when coolant temperature
reached 95 C. The relay is switched off when coolant temperature has cooled
down to 90 C.
44
4
4.7
Description
Electrical system
Vehicle component
Contact
Engine
chassis
Wire
harness
cct
Using
Connection instructions
Description
55
required
The malfunction indicator light is activated when the control unit diagnostics
detects an active fault. The fault will be saved and can be displayed with the
Textron Motors Diagnostic Tool.
See the service manual of the engine.
Service Light
23
38
required
63
required
54
required
45
4 Description
4.7 Electrical system
Vehicle component
Contact
Engine
chassis
Wire
harness
cct
Using
Connection instructions
Description
Spare 5 V Output
8
60
optional
This 5 V output can be used to supply external sensors. For example the roll
over sensor.
49
optional
When the input signal is within a defined voltage range ignition, injection and
the fuel pump will be turned off. The exact voltage range must be defined.
See the service manual of the engine.
Pedal Value Sensor
34
92
required
35
optional
Available ground
36
91
required
37
94
required
38
95
required
39
93
required
40
90
required
For the connection of a Textron Motors throttle request unit or Textron Motors
approved throttle control pedal with integrated pedal value sensor.
See the service manual of the engine.
Vehicle Speed Sensor Input
18
59
required
A digital vehicle speed signal from gear or a driven wheel is expected that
returns a certain number pulses per meter driven.
Specification vehicle speed signal:
46
135
120
10
108
11
98
12
90
13
83
14
77
4
4.7
Description
Electrical system
Vehicle component
Contact
Engine
chassis
Wire
harness
cct
Using
Connection instructions
Description
RPM Output
22
45
optional
Output 2 impulses/rotation.
For example for connecting an engine speed indicator.
Brake Light Switch
14
62
required
This signal is used to detect if the brake is activated. If the brake is actuated
in combination with the gas, the engine power will be reduced after a short
delay. The engine power reduction acts as a safety function for example if the
throttle control pedal mechanically locks up.
Observe the service manual of the engine.
Neutral Switch
30
43
required
An engine start is only possible when the signal at the input is active. The
signal must not stay active when other gears are engaged.
Observe the service manual of the engine.
Reverse Limiter Switch
24
37
optional
An engine speed limitation will be active, when the reverse gear is engaged
and the switch is active.
Observe the service manual of the engine.
Power Limit Switch
11
53
optional
This signal is used to apply a lower engine torque curve. Possible application:
Beginner mode (Learner Mode), with reduced power.
CAN-Bus
31
40
optional
CAN High
32
50
optional
CAN Low
47
4 Description
4.7
Electrical system
4.7.3.4
48
4
4.8
4.8
4.8.1
Description
Fill quantities
Inform the customer about the fill quantities of engine oil and coolant.
Service light
The service light does not indicate the 1st service and the yearly service
intervals. Inform the customer, when the first service must be performed.
(See chapter 4.7.3.3 Description of vehicle components at vehicle
connector Engine-Chassis.)
Service intervals
Inform the customer about the coolant and fuel filter service intervals.
The procedure how to check the coolant level with a Textron Motors
expansion tank is described in the service manual. If another expansion
tank will be installed, inform the customer about checking the coolant
level.
The procedure how to check the oil level with a Textron Motors oil tank is
described in the service manual. If another oil tank will be installed, inform
the customer about checking the oil level.
49
4 Description
4.8
4.8.2
Workshop
Service tasks
Inform the workshop about replacing the engine oil, coolant and fuel filter.
Rotating crankshaft
Pay attention that the camshaft must be rotated in the workshop while
service tasks. Devise a suitable procedure that the camshaft will be turned
with the crankshaft.
Changing coolant
Provide a drain device at the heat exchanger or coolant lines below the
coolant level of the engine.
The procedure how to change the coolant with a Textron Motors
expansion tank is described in the service manual. If another expansion
tank will be installed, inform the workshop about changing the coolant.
Inform the workshop about the minimum quantity of engine oil that needs
to be filled in after draining. Observe that is sufficient engine oil in the
engine to warm up the engine without risk of overfill the engine.
The procedure how to change the engine oil with a Textron Motors oil tank
is described in the service manual. If another oil tank will be installed,
inform the workshop about changing the engine oil.
Repairing work
All repair manual works are described with an engine removed from the
vehicle. Consider the interfaces to vehicle.
50
5
5.1
5
5.1
Installation data
Installation data
Requirements for the engine compartment
51
5 Installation data
5.2 Installation engine
5.2
Installation engine
5.2.1
Pay attention when installing to the operating positions of the engine during constant operation. (See
chapter 4.1.2 Operating positions engine.)
5.2.2
5.2.2.1
Mounting engine
Decoupling
Textron Motors recommends to install the engine with rubber elements for decoupling of vibrations and
noise.
52
5
5.2
5.2.2.2
Installation data
Installation engine
Internal thread M8 3
(only engine model I2 846 UTV NA-80)
1
2
3
4
5
7
8
53
5 Installation data
5.2 Installation engine
10
12
13
9
11
10
11
14
12
13
14
54
5
5.2
5.2.2.3
Installation data
Installation engine
Interface drawing
55
6 Initial operation
6.1 Transport and storage | 6.2
6
6.1
Lift engine
Initial operation
Transport and storage
6.2
Lift engine
56
Initial operation
6.3
6.3
Completion
Completion
At the time the engine in the vehicle is fully installed and connected, proceed as follows:
Connect the Textron Motors Diagnostic Tool. (See the Textron Motors Diagnostic Tool manual.)
Turn on ignition.
Compare the serial number in the calibration with the serial number on the valve cover label. The
serial numbers must be identical. (See the service manual of the engine.)
Turn off the ignition until the engine control unit is out of service. The main relay is switched off.
Turn on ignition and check the trouble codes. No trouble codes must be available.
Turn off the ignition until the engine control unit is out of service. The main relay is switched off.
Calibrate the throttle body. Turn the ignition on for about a minute, until the throttle body opens and
closes again.
Select the value Pedal Value Sensor Value with the Textron Motors Diagnostic Tool in the view Data
Items.
With not operated throttle control pedal, the value 0 must be displayed. With full operated throttle
pedal, the value 99.9 must be displayed. If the displayed values are different, check the throttle cable
to the throttle request unit.
If the coolant level is not reached, switch off the engine and fill in coolant until the coolant level is
reached. Restart the engine and run the engine at idle.
Select the value Engine Coolant Temperature with the Textron Motors Diagnostic Tool in the view
Data Items.
Allow the engine to warm up at low engine speeds. The coolant temperature needs to stabilize at
80 83 C. If the coolant temperature increases quickly over this temperature there is still air in the
coolant circuit. The coolant circuit must be ventilated.
Fill in engine oil in several stages, until the filling level is reached.
57
Appendix
Engine manufacturer
Appendix
Engine manufacturer
Engine manufacturer
58
Appendix
Overview of revisions
Overview of revisions
Revision
Rev A
Date
Chapter
04.08.2015
Description
1st edition installation manual
59
Appendix
Index
Index
A
Air cleaner, description 27
B
Battery, description 40
Battery, electrical connection 34
Battery isolator switch, description 40
Blow-by-return, installation 24, 28
Brake light switch, electrical connection 47
C
CAN-Bus, electrical connection 47
Catalyzer, description 29
Completion 57
Connection scheme, vehicle 42
Coolant circuit, description 12
Coolant lines, specification 13
Coolant, specification 13
Cooling system, description 12
Cooling system, scheme 14
Crankcase ventilation / engine oil return,
installation 23
D
Diagnostic connector, description 32
E
Electrical system, description 31
Engine compartment, accessibility 51
Engine compartment, requirements 51
Engine control unit, installation 37
Engine, electrical connection 32
Engine ground, electrical connection 34
Engine management system 31
Engine oil, specification 21
Engine speed output, electrical connection 47
Exhaust back pressure 29
Exhaust pipes, dimensioning 29
Expansion tank, description 12
Expansion tank, installation 16
F
Fan relay, electrical connection 44
Fill quantity engine oil, determining 24
Fill quantity engine oil, determining with a Weber
Motor oil tank 25
Flow rate, coolant 12
Fuel main filter, description 17
60
Appendix
Index
O
Oil filter, description 21
Oil pressure 21
Oil pressure light, electrical connection 45
Oil tank, description 21
Oil tank, installation 23
Operating conditions, permissible 11
Operating-hour counter, vehicle 41
Operating positions, engine 11
Operating pressure, coolant system 12
Operating pressure, fuel 17
Operating pressure, lubrication system 21
Operating temperature, coolant 12
Operating temperature, fuel 17
Operating temperature, lubrication system 21
P
61