MR 700

MR 700
Common Rail MArine Diesel Engines
repair manual

Ed. 1 - 12/2012
 Introduction
 MR 700

SUMMARY
service manual updating ................................................................................................................. 6
engine identification..................................................................................................7
engine serial number ...................................................................................................................... 7
dataplate location . ........................................................................................................................ 8
meaning of mr700........................................................................................................................... 8
engine layout. ..........................................................................................................9
Flywheel side................................................................................................................................. 10
Exhaust side................................................................................................................................... 11
Timing side - mr706......................................................................................................................... 12
Timing side - mr704......................................................................................................................... 13
injection side - mr706..................................................................................................................... 14
injection side - mr704..................................................................................................................... 15

component locator...................................................................................................16
engine cover protection................................................................................................................. 16
engine mounting bracket................................................................................................................. 16
flywheel and flywheel housing. ...................................................................................................... 17
oil sump and counter balance shaft................................................................................................ 18
crankcase - crankshaft - camshaft................................................................................................. 19
cylinder liner - piston - cylinder head - push rod - rocker arm....................................................... 20
Timing System................................................................................................................................. 21
turbocharger - exhaust manifold.................................................................................................... 22
air filter - riser - engine coupler.................................................................................................... 23
fluid heat exchanger - expansion coolant tank................................................................................ 24
oil separator - fuel return lines - alternator................................................................................. 25
intercooler - rail - injector - high pressure injection pump - coolant pump..................................... 26
oil cooler - oil pressure sensor - camshaft sensor - rpm engine sensor - thermostatic valve. ........ 27
crankshaft pulley - seawater pump - idler pulley - oil filter - belt tensioner.................................. 28
poly-v alternator belt - injection wiring harness - ecu - magnetothermic breakers. ........................ 29
starter motor - fuel filter............................................................................................................. 30

maintenance..............................................................................................................31
maintenance schedule..................................................................................................................... 32
inspection and engine cover removal............................................................................................... 33
engine oil and filter........................................................................................................................ 34
engine coolant. .............................................................................................................................. 36
changing/draining the closed cooling system.................................................................................. 37
air filter. ....................................................................................................................................... 39
fuel filter...................................................................................................................................... 40
seawater system............................................................................................................................. 43
draining the seawater system.......................................................................................................... 43
corrosion protection - anode plug................................................................................................. 47
alternator poly-v belt ................................................................................................................... 48
engine protection treatment........................................................................................................... 49
Transmission Fluid. ........................................................................................................................ 52
engine specifications.................................................................................................55
engine specifications....................................................................................................................... 55
fastener tightening specifications. ................................................................................................. 57

 Introduction
 MR 700
base engine. .............................................................................................................59
Establishing TDC (Top Dead Center)............................................................................................. 61
Engine Compression Testing........................................................................................................... 63
Valve Cover................................................................................................................................... 64
Oil Separator Application Kit......................................................................................................... 64
Oil Separator and Vent System...................................................................................................... 65
Coolant Manifold and Coolant Temperature Sensor..................................................................... 66
Cylinder Heads.............................................................................................................................. 67
Resurfacing................................................................................................................................... 68
Cylinder Head Gasket Thickness selection. ................................................................................... 69
Torque Procedure After the First 20‑30 Minutes of Operation.................................................... 75
Cylinder Head Parts - disassembling.............................................................................................. 76
Expansion Plugs............................................................................................................................. 77
Valve Guides.................................................................................................................................. 78
Valves - Intake and Exhaust. .......................................................................................................... 79
Valve Seats.................................................................................................................................... 81
Valve Springs. ............................................................................................................................... 84
Rocker Arm. .................................................................................................................................. 85
Crankshaft pulley - Engine Front Bracket and Timing Gear Cover................................................ 87
Timing Gears.................................................................................................................................. 92
Oil Pump........................................................................................................................................ 94
Idler Gear. .................................................................................................................................... 96
Injection pump Idler gear (between the camshaft and injection pump gears).................................... 98
Crankshaft gear............................................................................................................................ 99
Oil Pan, Oil Pickup, and Related Components................................................................................ 100
Oil Pan. ......................................................................................................................................... 100
Oil Pick-up Tube............................................................................................................................. 101
Balance Shaft Assembly (only on mr704)....................................................................................... 102
Oil Pressure Relief Valve. ............................................................................................................ 106
Camshaft........................................................................................................................................ 108
Camshaft Bearings......................................................................................................................... 112
Valve Lifters.................................................................................................................................. 113
Valve Push Rods............................................................................................................................ 115
Connecting Rod - fractured type................................................................................................... 116
Connecting Rod And Piston Pin..................................................................................................... 120
Pistons And Rings.......................................................................................................................... 121
Piston and Connecting Rod............................................................................................................ 125
Piston Cooling Jets (Oil Spray Nozzles)........................................................................................ 127
Flywheel housing, Flywheel and Rear Oil Seal.............................................................................. 129
Flywheel Ring Gear....................................................................................................................... 135
Flywheel Runout............................................................................................................................ 135
Crankshaft End Play (Axial Clearance) - THRUST WASHERS.................................................... 136
Rear main bearing carrier. ............................................................................................................. 137
REAR MAIN BEARING ................................................................................................................ 138
Cps target wheel bolt.................................................................................................................... 138
Crankshaft. ................................................................................................................................... 139
Crankshaft Journals and Main Bearings (Front, Center, Rear) . .................................................. 141
Balance shaft gear drive ............................................................................................................... 146
Crankshaft Front Main Bearing..................................................................................................... 147
Cylinder Liners.............................................................................................................................. 148
Engine Mounts and Brackets. ........................................................................................................ 151
Engine lifting eye Brackets............................................................................................................ 152

 Introduction
 MR 700

cooling system.........................................................................................................153
Cooling System Flow Diagram—Typical. ....................................................................................... 154
Exploded View—Seawater Pump and Related Components............................................................. 155
Seawater Pump............................................................................................................................... 156
Coolant Expansion Tank and Reservoir.......................................................................................... 161
Thermostat..................................................................................................................................... 164
Heat Exchanger and Fluid Cooler Assembly................................................................................... 166
Exploded View - Heat Exchanger and Fluid Cooler Assembly......................................................... 167
Thermostatic housing..................................................................................................................... 174
Fuel Cooler................................................................................................................................... 175
Engine Water Circulating Pump..................................................................................................... 176
Oil Cooler and Oil Filter Assembly................................................................................................ 178
intake and exhaust system........................................................................................185
Aftercooler................................................................................................................................... 186
Exploded view - Aftercooler.......................................................................................................... 188
Intake And Exhaust Manifold, turbocharger, risers, wastegate valve.....................195
Exploded view - Intake And Exhaust Manifold. ............................................................................... 195
Intake And Exhaust Manifold.......................................................................................................... 196
turbocharger. .........................................................................................................199
Specifications................................................................................................................................. 199
Testing Turbocharger Boost Pressure. ........................................................................................ 199
Turbocharger oil pipes................................................................................................................... 208
Wastegate Valve............................................................................................................................ 209
Wastegate. .................................................................................................................................... 211
electrical system.....................................................................................................213
Starter.......................................................................................................................................... 214
Alternator..................................................................................................................................... 215
Alternator bracket........................................................................................................................ 216
Alternator pulley.......................................................................................................................... 216
Electrical diagram - mr706 (16662036F)....................................................................................... 217
Electrical diagram - mr706 (with box relay and fuses - 16662053F).............................................. 218
Electrical diagram - mr704 (16662035F)....................................................................................... 219
Electrical diagram - mr704 (with box relay and fuses - 16662052F).............................................. 220
Interface wiring harness ECU terminal - side “k”............................................................................ 221
Injection wiring harness ECU terminal - side “a”............................................................................. 222
Injection wiring harness - mr704 (18852225G).............................................................................. 223
Injection wiring harness - mr706 (18852226F)............................................................................... 224
Interface wiring harness (18852227F)........................................................................................... 225
Interface wiring harness with box relay (18852267F).................................................................... 226
Accelerator potentiometer............................................................................................................ 227
Wiring harness extension............................................................................................................... 228
Dash board. ................................................................................................................................... 229
Main rele’....................................................................................................................................... 230
ECU diagnosis connector. ............................................................................................................. 231
fuel system..............................................................................................................233
Injector. ........................................................................................................................................ 234
High pressure pump........................................................................................................................ 236
Rail................................................................................................................................................ 239
High Pressure fuel pipes tightening procedure.............................................................................. 240
Fuel return pipes........................................................................................................................... 241

 Introduction
 MR 700
engine instrumentation..............................................................................................243
Digital Gauges............................................................................................................................... 243
Audio & light Warning System. ...................................................................................................... 245
Tachometer / Speedometer............................................................................................................. 245
SPN Error codes list.................................................................................................................... 246
Engine start................................................................................................................................... 252
Maintenance service interval simbol. .............................................................................................. 253
Resetting of package instrumentation............................................................................................. 254
Engine Electrical System Overload Protection. ........................................................................... 255
special tools............................................................................................................257
labour time guide. ....................................................................................................261
Flate Rate Table Instruction . ....................................................................................................... 261
Operation No. Interpretation......................................................................................................... 261
engine control.........................................................................................................269
Diagnostic Trouble Codes . ........................................................................................................... 269
Electrical sensor.......................................................................................................................... 275

 Introduction
 MR 700
service manual updating

Ed. 0 - 07/2010
Date Chapter - Paragraph Description of updating
Jul 1, 1st Issue
2010

Ed. 1 - 12/2012
Date Chapter - Paragraph Description of updating
Dec, 3 ENGINE SPECIFICATIONS Engine performances (updating)
2012 MAINTENANCE - Engine Engine storage procedure (updating)
Storage, Engine Protective
Treatment

 Introduction
 MR 700
engine identification
The serial numbers are the manufacture’s keys to numerous engineering details which apply to your VM Motori diesel
engine. When contacting VM Motori dealer or workshop about service, always specify model and serial numbers.
engine serial number
VM serial number stamped in the crankcase
P) Engine serial number (punched on the crankcase)
q) Engine code
r) Consecutive number

The table helps you to identify the model through the engine code.

Engine code Engine model

65 C MR704LX
68 C MR704LH
69 C MR704LS
71 C MR706LX
72 C MR706LH
74 C MR706LS

p
65C 01001

q r

 Engine Identification
 MR 700
dataplate location
The engine dataplate is located on the side of the
MR706
integrated exhaust manifold and expansion tank
assembly.

Engine dataplate and emissions

information location on the
integrated exhaust manifold and
expansion tank assembly

A) Manufacturer identification
B) Serial number
C) Weight
D) Type
E) Family
F) Model
G) Version
H) Maximum power (kW) MR704
L) Maximum number of revolutions
M) Homologation number
N) Lubricating oil features

meaning of mr700
Example MR 704 LX

M = Marine engine
R = Common Rail diesel engine
700 = Unitary displacement \ 10 (cm3)
4 = 4 cylinders
L = Electronic Engine Management
X = Extra engine performance
H = High engine performance
X = Soft engine performance

2
2

b c
d
e f
h l
g
m

 Engine Identification
 MR 700
engine layout

 Engine Layout
 MR 700
Flywheel side

6
1

3
8
4 9
10

1. Fuel Filter 6. Raiser

2. Crankcase oil pump 7. Turbocharger
3. Flywheel Housing 8. Air filter housing
4. Flywheel 9. Engine Power Supply Socket
5. Intercooler - Elbow 10. Engine wiring extension Socket

10 Engine Layout
 MR 700
Exhaust side

10

13

11
12

1 4 6
3

1. Crankshaft position sensor

2. Oil Outlet hose from turbocharger
3. Oil Pan
4. Oil heat exchanger (Gear Box Oil / Seawater)
5. Serpentine Alternatore Belt (Protection)
6. Fluid Exchanger (Seawater / Freshwater)
7. Coolant Expansion Tank
8. Thermostat housing
9. Engine Rear Eye lifting bracket
10. Turbocharger
11. Exhaust Manifold
12. Waste Gate Valve
13. Riser

11 Engine Layout
 MR 700
Timing side - mr706
1

2
3

10

8
9

1. Coolant Filling Cap

2. Coolant Expansion Tank
3. Alternator
4. Serpentine Alternator Belt
5. Idler Pulley
6. Coolant Pump - Pulley
7. Automatic Alternator Belt Tensioner
8. Sea Water pump - Pulley
9. Crankshaft Pulley - Damper
10. Thermostatic Valve Housing

12 Engine Layout
 MR 700
Timing side - mr704

12
11
1

2 3

6
10

9 7 8

1. Coolant Filling Cap

2. Coolant Expansion Tank
3. Alternator
4. Serpentine Alternator Belt
5. Idler Pulley
6. Coolant Pump - Pulley
7. Automatic Alternator Belt Tensioner
8. Sea Water pump - Pulley
9. Crankshaft Pulley - Damper
10. Thermostatic Valve Housing
11. Oil Filling Cap
12. Engine Oil Dipstick

13 Engine Layout
 MR 700
injection side - mr706
3
16

11

1
10
2
14

15

9
4

8 6
17 13 7
12

1. Air filter housing

2. Oil separator
3. ECU
4. Accelerator potentiometer
5. Flywheel housing
6. Starter Motor
7. Fuel filter
8. Seawater pump
9. Accessory Belt
10. Alternator
11. Heat exchanger seawater/fuel
12. Oil Filter
13. Heat exchanger seawater/engine oil
14. Fuel Accumulator Pressure (RAIL)
15. High Pressure Fuel Injection Pump
16. Engine Front Eye lifting bracket
17. Oil pressure and temperature sensor

14 Engine Layout
 MR 700
injection side - mr704

16 1

11

10 2

14

15
4
9

6
7
8
17 13 12

1. Air filter housing

2. Oil separator
3. ECU
4. Accelerator potentiometer
5. Flywheel housing
6. Starter Motor
7. Fuel filter
8. Seawater pump
9. Accessory Belt
10. Alternator
11. Heat exchanger seawater/fuel
12. Oil Filter
13. Heat exchanger seawater/engine oil
14. Fuel Accumulator Pressure (RAIL)
15. High Pressure Fuel Injection Pump
16. Engine Front Eye lifting bracket
17. Oil pressure and temperature sensor

15 Engine Layout
 MR 700
component locator
engine cover protection
1. Engine oil filling cap
2. Upper engine cover protection
3. Poly-v belt cover protection

1
1
2 2

engine mounting bracket

4. Engine mounting bracket - Exhaust side
5. Engine mounting bracket - Injection side

16 Engine Layout
 MR 700
flywheel and flywheel housing
1. Flywheel
2. Flywheel Housing
3. OR Flywheel
1
4. OR Camshaft / Flywheel Housing
5. Rear main bearing carrier
6. Crankshaft position sensor (CPS) target wheel

3
2

4
5

17 Engine Layout
 MR 700
oil sump and counter balance shaft
1. Oil sump
2. Oil pickup tube
3. Counter balance shaft
4. Piston cooling jets (oil spray nozzles)

2 4

18 Engine Layout
 MR 700
crankcase - crankshaft - camshaft

1. Crankcase
2. Camshaft
3. Oil Pressure Relief Valve
4. Camshaft thrust plate thickness
5. Camshaft Gear
6. Crankshaft
7. Main center bearing carrier (halves)
8. Main Center Bearing
9. Crankshaft Gear

5 7
8
4
3

9
6

19 Engine Layout
 MR 700
cylinder liner - piston - cylinder head - push rod - rocker arm
1. Cylinder head 7. Rocker arm cover
2. Cylinder head gasket 8. Rocker arm cover gasket
3. Piston and Con Rod 9. Coolant Manifold
4. Cylnder Liner 10. Rocker Arm
5. Hydraulic Tappet 11. Rocker Arm oil feeding pipe
6. Con Rod Cap

7
2

9
10

11

20 Engine Layout
 MR 700
Timing System
1. Timing Belt Cover
2. Timing Belt Cover Gasket
3. Idler Gear
4. Oil Pump
5. Camshaft Gear
6. Crankshaft Gear
7. Idler Gear assembly

4 6 5

21 Engine Layout
 MR 700
turbocharger - exhaust manifold

1. Air filter complete (filter element + housing)

2. Turbocharger
3. Oil feeding turbocharger pipe
4. Oil drain turbocharger pipe
5. Exhaust manifold
6. Waste gate valve

22 Engine Layout
 MR 700
air filter - riser - engine coupler

1. Air Filter complete (cartridge + housing)

2. Turbocharger
3. Riser
4. Gear Box Flywheel
5. Engine Coupler

4 5

2
3

23 Engine Layout
 MR 700
fluid heat exchanger - expansion coolant tank
1. Fluid heat exchanger - seawater/fresh water
2. Coolant Expansion tank

24 Engine Layout
 MR 700
oil separator - fuel return lines - alternator
1 - Oil separator
2 - Fuel Heat Exchanger - Fuel / Seawater
3 - Alternator
4 - Fuel return box (from high fuel pressure pump, rail and injector)

4 2

25 Engine Layout
 MR 700
intercooler - rail - injector - high pressure injection pump -
coolant pump
1 - Injector 5 - Air Temprerature and Pressure sensor
2 - Intercooler 6 - Rail pressure sensor
3 - Rail 7 - High injection pressure pump
4 - Coolant pump
2 5

6
3
7

26 Engine Layout
 MR 700
oil cooler - oil pressure sensor - camshaft sensor - rpm engine
sensor - thermostatic valve

1 - Camshaft sensor
2 - Oil pressure and temperature sensor
3 - Engine oil cooler 6
4 - Thermostatic oil valve
5 - Thermostatic coolant valve - housing
6 - Fuel return line from injectors
7 - Crankshaft position / RPM engine sensor

27 Engine Layout
 MR 700
crankshaft pulley - seawater pump - idler pulley - oil filter -
belt tensioner
1. Oil filter assembly 4. Idler pulley
2. Seawater pump 5. Crankshaft pulley
3. Belt tensioner

3
1

3 2

28 Engine Layout
 MR 700
poly-v alternator belt - injection wiring harness - ecu
- magnetothermic breakers
1. ECU 4. Poly-v alternator belt
2. Magnetothermic breakers 5. Seawater pump belt
3. Injection wiring harness

1
2

4 5

29 Engine Layout
 MR 700
starter motor - fuel filter
1. Fuel filter
2. Starter motor

30 Engine Layout
 MR 700
maintenance

31 Maintenance
 MR 700
maintenance schedule

Top up, if
Engine oil Level control necessary See “Engine oil ”
Every 10 hours Top up, if
Coolant Level control necessary See “Engine coolant ”
After the first 50
hours (at the end Engine oil (1) ( )
of run-ning-in) Oil filter(2) Replacement See “Engine oil”

Integrity Replace, if See “Corrosion Protection

Every 50 hours Anode Plug control necessary - Anode Plug”
Seawater pump Integrity Replace, if necessary - See “Seawater
Every 100 hours impeller control System”
Accessory belt (2) Replace See “Accessory Belt”
Seawater pump
impeller(1) Replace See “Seawater system”
Engine oil (1) ( ) Replace See “Engine oil”
Replace oil
Oil filter (2) filter See “Engine Oil”
Every 300 hours Air filter (2) Replace Air See “Air filter”
Filter
Fuel filter (1) Replace See “Fuel filter”
Fuel circuit unions
- low pressure Check
injection system tightening
Anode Plug Replace See “Corrosion Protection - Anode Plug”
Heat exchangers
See “Fluid heat exchanger & AIr charge
(engine oil,
Every 500 hours Cleaning cooler (Intercooler)”into Base Engine
fresh water) (3)
Section”
Intercooler (3)

Every 600 hours Coolant (2) Replace See “Engine Coolant”

(1) Even if the engine has not been run for the prescribed period, it is equally necessary to carry
out the replacement at least once per year.
(2) Even if the engine has not been run for the prescribed period, it is equally necessary to carry
out the replacement at least once every 24 months.
(3) If the engine has not been in operation for the length of time indicated, the heat exchangers
must still be cleaned at least once every 5 years.
(4) If an hour counter is not available, the frequency of the interventions should be calculated on
the basis of a calendar day: one calendar day corresponds to 12 hours of operation.
When replace engine lube oil, VM Motori reccomends to replace always oil filter ( ).

32 Maintenance
 MR 700
inspection and engine cover removal
Inspect your engine often and at regular
intervals to help maintain its top operating
performance and to correct potential problems
before they occur. The entire engine should e
be checked carefully, including all accessible
engine parts.
1. Check for loose, damaged, or missing
parts, hoses and clamps; tighten or replace as
necessary.
2. Check electrical connections and leads for
damage or corrosion.
3. Repair nicks and corrosion damage on
engine exterior finish.

NOTE: The engine cover contains an

access panel which can be used to access
the engine circuit breakers and the oil fill
cap and dipstick without removing the entire
engine cover.

NOTE: In the lastest engine models has

been installed a box where inside the fuses d
and relay are installed. Refer to chapter
ENGINE INSTRUMENTATION
c

a - Engine circuit breaker panel

b - Oil fill cap
c - Oil dipstick
d - Engine cover with access panel removed
e - access panel

33 Maintenance
 MR 700
engine oil and filter
checking oil level
1. To check the engine oil level, stop the engine
and allow some minutes for the oil to drain into
the pan.
2. Remove the dipstick. Wipe clean and reinstall
into the dipstick tube.
3. Remove the dipstick and observe the oil
level. The oil level must be between the marks d
(minimum and maximum) on the dipstick. If
necessary, add oil. See Filling.
c
4. Install engine oil dipstick

Filling

IMPORTANT: Do not overfill the engine with

oil.
a
1. Remove the oil fill cap.
2. Add the specified oil to bring the oil level b
up to, but not over, the maximum mark on the
dipstick.

IMPORTANT: Refer to Engine Specifications a - Engine circuit breaker panel

- Engine Oil to know the capacity and oil
b - Oil fill cap
specifications.
c - Oil dipstick
IMPORTANT: When refilling the engine with d - Engine cover with access panel removed
oil always use the dipstick to confirm how
much oil is required.
x
3. Install the oil fill cap.

y z

Engine oil dipstick markings

x - Dipstick
y - Minimum operating level
z - Full mark & maximum operation level

34 Maintenance
 MR 700
Changing Oil and Filter
b
See the Maintenance Schedule for the change interval.
You should change the engine oil before placing the boat
in storage.

IMPORTANT:
when replace engine oil lube, VM
reccomends to replace also the oil filter c
cartridge..

IMPORTANT: Change the engine oil when the

engine is warm from operation. Warm oil flows
more freely, carrying away more impurities. Use
a
only recommended engine oil. See Engine Oil
Specifications into Section “Engine Specifiactions”.
a - Engine oil drain hose
1. Start the engine and allow it to warm up to normal
operating temperature.
b - Engine oil cap (not visible - open the
2. Stop the engine and allow some time for the oil to drain Engine circuit breaker panel)
into the oil pan (approximately five minutes).Remove the c - Crankcase oil pump (Aids in the
oil filler cap and oil dipstick. removal of engine oil without draining the
3. Remove the fitting from the end of crankcase oil drain
hose.
crankcase.)
4. Install the crankcase oil pump (order separately) onto
d
the threaded fitting of the oil
dipstick tube. a
5. Pump the oil out of the oil pan.
6. Contain and dispose of the oil or oil waste as directed
by local authorities.
7. Remove the crankcase oil pump and install the
b
crankcase oil drain hose fitting when the crankcase is
empty. Tighten securely.
8. Install the oil dipstick.
9. Place a suitable container under the oil filter housing
to contain any oil leakage that may occur. Use an
appropriate socket to loosen the oil filter top piece.
10. Remove the top piece and cartridge type oil filter.
11. Disconnect and discard the old filter element. Discard
the old O‑ring from the top piece.
12. Install the new O‑ring. Apply lubricant to the O‑ring.
13. Push the filter element onto the top piece until it is
locked. Listen for a click.
14. Install the top piece with the new filter element into a - Oil filter housing
the oil filter housing.
15. Turn the oil filter top piece until the sealing surface b - Complete Oil filter
contacts the housing. Torque the top piece using an c - Oil filter cartridge (element)
appropriate socket.
d - oil filter housing top piece
IMPORTANT: Overtightening the top piece will cause e - O-ring
deformation resulting in oil leakage.
e
Engine oil filter housing top piece 25 Nm

16. Refill the engine with new oil. See Filling.

d
IMPORTANT: When refilling the engine with oil,
always use the dipstick to determine how much oil is
required.
a
17. Reinstall the oil filler cap and oil dipstick and start the
engine and check for leaks.

35 Maintenance
 MR 700
engine coolant
Checking a

IMPORTANT: Check the engine coolant

before starting the engine.
1. Allow the engine to cool. c
2. Remove the pressure cap from the coolant
25 mm
expansion tank.
3. The coolant level in the coolant expansion
tank should be
within 25 mm of the top of the fill neck.
4. If the coolant level is low:
b
a. Inspect the coolant recovery system for
leaks.
b. Inspect the gasket in the pressure cap for a - Pressure cap
damage and replace if necessary.
b - Coolant expansion tank
c. The pressure cap maintains pressure on
c - Bottom of fill neck
the cooling system and may not be holding
pressure properly. Test the cap. d - Gasket
d. Add the specified coolant as necessary. See
Filling.
IMPORTANT: When installing the pressure
cap, be sure to tighten it securely to prevent
coolant loss.
5. If the coolant level is correct, install the d
pressure cap and tighten securely.
6. Recheck the coolant level after the first
wide open throttle boat test and add coolant, if
necessary with cold engine.

36 Maintenance
 MR 700
changing/draining the closed cooling system

Change (replace) the engine coolant at the prescribed interval.

NOTE: For instructions on draining the seawater section, see Seawater System in this
section.
• Ensure that the engine is as level as possible to promote complete draining of the cooling
system.
• The closed cooling section must be filled year‑round with the required coolant. Refer to Engine
Specifications Section to know the proper solution of antifreeze and water properly mixed to
protect the engine to the lowest temperature and for corrosion.
Allow the engine to cool.
Remove the engine coolant drain plug and drain the coolant into a suitable container.
Ensure that the coolant has drained completely.
Install and tighten the engine coolant drain plug.
Fill the system with the specified coolant. See Filling the Closed Cooling System.

a - Engine coolant drain plug

a - Engine coolant drain plug

37 Maintenance
 MR 700
Filling the Closed Cooling System
a
1. Remove the pressure cap with cold engine.
IMPORTANT: Use only the specified coolant.
refer to Engine Specification Section.
2. If the coolant is being replaced or the level is c
low, slowly add the specified coolant to the level
25 mm
indicated in the table.
within 25 mm of the bottom of the fill neck.
3. Do not install the pressure cap. Start and
operate the engine at fast idle speed between
600 and 1400 RPM. Add coolant as necessary b
to maintain the coolant at the level specified
previously.
IMPORTANT: When installing the pressure a - Pressure cap
cap, be sure to tighten it securely to avoid b - Coolant expansion tank
coolant loss. c - Bottom of fill neck
4. Install the pressure cap after the engine has
reached normal operating temperature (with
the thermostat fully open) and the coolant level
remains constant.
5. Test the engine operation. Observe
the temperature gauge and check the
engine for coolant leaks. If the temperature
gauge indicates the presence of excessive
temperature or coolant is leaking, stop the
engine immediately and inspect for the cause.
6. After the first operation, allow the engine to
cool.
7. Remove the pressure cap and add the
specified coolant to the level indicated in the
table.
within 25 mm of the bottom of the fill neck.

8. Install and securely tighten the pressure cap.

38 Maintenance
 MR 700
air filter
Removal
1. Loosen the clamp and remove the oil
separator vent hose.
2. Loosen the clamp and remove the air filter
housing from the turbocharger inlet.
a c
3. Remove the air filter element (sponge or
foam) from the air filter housing
Inspection
1. The air filter cannot be cleaned. Replace the
air filter if it is dirty or contaminated.
2. Replace the air filter if the foam element is
deteriorated or torn.
3. Replace the air filter at the recommended
interval. See Maintenance Schedules for the
replacement interval under normal conditions.

Installation

IMPORTANT: The foam cover is an integral

component of the air filter element. The
b
foam cover must be clean and dry for proper
filtration and engine performance. Do not a
treat the foam filter cover with oil.
1. Slide the filter element into the air filter
housing. Ensure that the element is seated fully
into the air filter housing. a - Air filter housing
2. Install the air filter housing on to the b - Oil separator vent hose
turbocharger inlet. c - Air intake retaining clamp
3. Torque the air filter housing clamp. d - Air filter housing
e - Air filter element
air filter housing clamp screw 5.6 Nm
MR704

4. Install the oil separator vent house. Tighten e

the oil separator vent hose clamp securely.
MR704

MR706

39 Maintenance
 MR 700
fuel filter
The engine‑mounted water‑separating fuel filter
is equipped with a water‑in‑fuel (WIF) sensor
that should alert the operator when water is
present in the filter. This fuel filter needs to be
replaced at specified intervals or whenever
water is detected in the fuel, whichever comes
first.
The operator may be alerted that the WIF
sensor has detected water in the fuel,
depending upon the boat instrumentation
package and if equipped:
• A fault code is displayed on a system viewer
(LCD dispaly on tachometer).
• The audio warning system sounds.
See Engine Instrumentation section.

Draining
b
The engine‑mounted water‑separating fuel filter
can be drained of water and small dirt particles c
by opening the drain cap on the bottom of the
a
filter.
NOTE: To ensure complete draining in warm a - WIF sensor wire connection
weather, drain the filter before starting daily b - Filter
operations. In cold weather, where there is
c - Drain cap
a possibility that the condensed water will
freeze, drain the filter shortly after the end of
daily operations.
1. Place a container under the drain cap on the
filter.
2. Open the drain by turning the drain cap
counterclockwise (as viewed from the bottom
of the filter) until fuel starts draining. Do not
remove the drain cap.
3. Drain until the fuel is clear in appearance.
4. Close the drain cap by turning clockwise.
Tighten securely.
5. Fill the fuel filter. See Filling.

40 Maintenance
 MR 700
Replacing Removal of the drain cap from used
fuel filter

IMPORTANT: The element cannot be cleaned

and reused. It must be replaced.
1. Disconnect both battery cables from the
battery.
2. Disconnect the WIF sensor wires, if equipped
3. Remove the water‑separating fuel filter and
sealing ring from the mounting bracket. Do not
use a filter wrench.
NOTE: It may be necessary to keep the
existing drain cap and use it on the new
filter. Be sure to replace the O‑ring on the installation of the drain cap on
drain cap. new fuel filter
4. Remove the drain cap and O‑ring seal from
the bottom of the existing fuel filter. Note the
position of the O‑ring seal..
5. Discard the used filter and O‑ring seal as
defined by local authorities.
6. Install the O‑ring and drain cap on the new
water‑separating fuel filter.
7. Lubricate the fuel filter seals.
8. Align the filter to the bracket. Twist the filter
by hand to secure the filter to the bracket. Do
not use a filter wrench.
9. Ensure that the drain cap is securely a - Drain cap
tightened. b - O‑ring seal
10. Connect the WIF sensor wires, if equipped.
11. Fill the water‑separating fuel filter with fuel.
See Filling.
12. Check the filter and drain cap for fuel leaks. c
13. Connect the battery cables.
14. Start and operate the engine. Check the
filter connection for fuel leaks. If leaks exist,
recheck filter installation. If leaks continue, stop
the engine immediately. d

c - Water‑separating fuel filter

d - Seals

41 Maintenance
 MR 700
Filling

A type of hand pump and primer plunger is

located on the fuel filter bracket and is used to:
• Refill the fuel filter when draining or changing
the filter.
• Refill the fuel system on the engine if the
system was run dry.
• Prime the fuel system if the engine has not
been run for an extended period.
IMPORTANT: Only fill the fuel filter with the
hand pump and primer plunger to ensure
that unfiltered fuel does not get into the fuel
system.

bleeding

NOTE: Follow this procedure after installing

a new filter or if the fuel has been drained
from the filter checking for water.

1. Loosen the air vent (bleed) screw on the fuel

filter bracket.
2. Move the primer plunger up and down a - Air vent screw
repeatedly. The filter is full when an air‑free b - Primer plunger
stream of fuel flows from the air vent screw.
3. Securely tighten the air vent screw.

Priming / refill of fuel filter

Prime the engine if it has not been run for an
extended period or if the engine will not start.
1. Move the primer plunger up and down
repeatedly.

42 Maintenance
 MR 700
seawater system

draining the seawater system

IMPORTANT: The engine must be as level as

possible to ensure complete draining of the
cooling system.
Drain the seawater system of the power
package before flushing or prior to cold weather
(freezing temperature), seasonal storage, or
extended storage.
IMPORTANT: The boat must not be operating
during this procedure. a

. Attach a temporary drain hose to the barbed

fitting of the seawater drain valve. a - Seawater drain valve
. Open the seawater drain valve.
. On models equipped with a seawater strainer,
remove the hoses at the seawater strainer and
drain them completely. Drain and empty the
seawater strainer. Reconnect the hoses and
tighten the hose clamps securely.
. After the seawater has completely drained,
remove the temporary drain hose and close the
heat exchanger seawater drain valve.
. Reconnect all seawater hoses. Tighten the
hose clamps securely.

43 Maintenance
 MR 700
Engine Seawater Pump Inspection
Remove and inspect the engine seawater
pump at the interval specified, as indicated in
maintenance schedule..

44 Maintenance
 MR 700

45 Maintenance
 MR 700

46 Maintenance
 MR 700
corrosion protection - anode
plug
IMPORTANT: Replace sacrificial anodes if
eroded 50% or more.
The engine is equipped with 2 sacrificial anodes
located in the end cover of the engine aftercooler
and in the end cover of the fluid heat exchanger,
to assist in protecting the engine and the seawater
cooling system from corrosion. a
REMOVAL
1. Allow the engine to cool.
2. With the engine off, close the seacock, if
equipped, or remove and plug the seawater inlet
hose.
3. Drain the seawater system. See Draining the
Seawater System . a - Sacrificial anode
4. Remove the anode assembly (anode plug,
sealing washer, and the sacrificial anode) from the
aftercooler end cover.
CLEANING AND INSPECTION
a
NOTE: Using sandpaper, fiber brush, or cleaning
pad, remove the deposits from the surface of the
anode before trying to determine the amount of
erosion. Do not use a mild steel brush which might
leave deposits that could accelerate corrosion.
1. Remove the deposits.
2. Inspect and measure the anode. Compare the
measurements to the specifications for a new
sacrificial anode and replace the anode assembly
when deteriorated 50%.
NOTE: Sacrificial anodes are available only as an
assembly. Replace both the plug and anode as a
unit.
Sacrificial anode measurements (new)
Length 19 mm
Diameter 16 mm

3. Discard the sealing washer.

a - Anode plug d - Diameter
b - Sacrificial anode e - Sealing washer
INSTALLATION
c - Length
1. Install a new sealing washer on the anode
assembly (anode plug with the sacrificial anode).
2. Install the anode assembly and washer. Tighten a - Anode assembly
securely. b - Sealing washer
3. Unplug and connect the seawater inlet hose, or
open the seacock if equipped.

47 Maintenance
 MR 700
alternator poly-v belt
Refer to Base Engine Section for futher
information.

1. Inspect the accessory belt for the following: a

• Excessive wear
d
• Cracks
• Fiber fraying
• Glazed surfaces c

2. Replace the belt if worn or damaged.

3. Check the operation of the automatic
tensioner and associated components.
a. Position a suitable tool on the automatic b e
tensioner hole.
b. Rotate the automatic tensioner a - Accessory belt
counterclockwise. b - Automatic tensioner
c. Release the automatic tensioner allowing it to c - Idler pulley
return to a load position on the serpentine belt.
d - Alternator
d. The automatic tensioner must return to
the initial position and hold tension on the e - Sea water pump pulley
serpentine belt. If the automatic tensioner does
not operate smoothly or does not return to a
loaded position providing tension on the belt it
must be replaced.
IMPORTANT: For a correct alignment of
3. There is no adjustment available for the the serpentine belt it must be positioned on
accessory belt. If the belt becomes loose or the inner races of the alternator.
noisy it has worn out and must be replaced.
Only on MR704 the serpentine belt it must
also be positioned on the inner races
crankshaft pulley.
.

MR704 MR706

MR704 MR706

48 Maintenance
 MR 700
engine protection treatment
Storage Information

The manufacturer supplies the engine with a protection treatment which is valid for 6 months from the delivery date.
If the engine is still not being used 6 months after delivery, then a specific “protection procedure” must be
carried out in order to extend the storage period for a further 6 months.

– All packaging components should be disposed of in accordance with the legislation in force in the country
where disposal takes place.
The protection procedure is only considered complete when all the following tasks have been performed:
1) protection against external corrosion
2) protection against internal corrosion
3) packaging and storage
This procedure is valid for the following engine situations:
• on a vehicle
• on a pallet
For engines on pallets, it is necessary to install the following accessories for engine start-up:
• battery
• fuel tank
• cooling radiator (for liquid-cooled engines only)
• command belt for the alternating current generator
• command belt for the water pump (for liquid-cooled engines only)
1) EXTERNAL PROTECTION

UNPAINTED SURFACES: the unpainted metal components and surfaces (for instance the engine handwheel)
must be protected with “FL MECA FLUID / P118V” anticorrosion oil.
RUBBER COMPONENTS: unpainted manifolds and pipes must be protected with talcum powder. Check the
tightening of the relative fixing clips.
DRIVE BELTS: after applying the internal protection, remove the belts and put them into storage. Protect the
surfaces of the metal pulleys with “FL MECA FLUID / P118V” spray.
ENGINE OPENINGS: Seal all the engine openings, including the exhaust. Use cardboard, plywood or metal
covers, making sure they do not leave behind any fragments of material. All the engine openings (e.g. air
suction ducts or turbocharger air inlet) must be protected with covers or guards to prevent the entry of sol-
ids, liquids or dusts that delay the evaporation of the anticorrosion agents. Apply plugs to the fuel inlet and
outlet pipes of the injection system.
BATTERY: Disconnect the battery. When it is fully charged, store it in a safe place. Before doing this, protect
the terminals against corrosion by applying an anti-rust spray.
2) INTERNAL PROTECTION

COMBUSTION CHAMBER: Remove the heating glowplugs from the head, check the piston is in its lowest
stroke position (lower standstill point), then spray with Petronas PROT 30 M protective oil. Repeat the opera-
tion for the other cylinders, then reinstall the glowplugs.
TURBOCHARGER: Remove the inlet plug from the pipe that delivers oil to the turbocharger, and fill with
Petronas PROT 30 M protective oil. Replace the inlet plug, applying the correct tightening torque.
ELECTRIC COMPONENTS: Apply anticorrosion spray to the electric contacts and connectors.
AIR SUCTION SYSTEM: check the air filter is in good condition, and no foreign bodies/liquids are present:
• If the air filter is damaged, replace it
• If there are any foreign bodies, remove them

49 Maintenance
 MR 700
LUBRICATION SYSTEM: this procedure must be carried out together with the injection system protection
procedure.
• Using the oil dipstick and check whether there is engine oil in the sump.
• Drain the oil from the sump.
• Fill the engine with Petronas PROT 30 M protective oil.
• Check the coolant level (for water-cooled engines only). The coolant mixture must be 50% demineralised or
distilled water and 50% Petronas Paraflu Up (protective radiator fluid with monoethylene glycol and organic
inhibitor formulation complying with ASTM D 3306 type 1 Standards).
• Start up the engine and run it until it reaches the right temperature for water-cooled engines (about 70°-
80°C); for air-cooled engines, run the engine for about 20 (twenty) minutes.
• With the engine up to temperature, carry on for about 5 minutes so that the system components are lubri-
cated.
• Switch off the engine and wait for it to cool down.
• Drain the oil from the sump.
• Drain off the coolant.
• Check for any fluid leakage (and make any necessary repairs).
• Disconnect the engine from all the components used for the test.
INJECTION SYSTEM: this procedure must be carried out together with the lubrication system protection
procedure.
• Make sure there are no deposits or sediments in the fuel tank.
• Prepare a mixture of diesel fuel complying with the DIN EN 590 specifications, and Petronas DIESEL TMF
PLUS additive. The ratio must be at least 1:400 (1 litre of additive to 400 litres of fuel). If you use Biodiesel
(complying with the UNI EN 14214 specifications), it must be mixed with diesel fuel up to 5%;

VM Motori, however, recommends the use of diesel without Biodiesel.

The use of any other fuel is forbidden.

• Fill the tank with this fuel mixture.
• Where relevant, check there is no interference between the radiator fan blades and the relative air duct.
Start up the engine and run it until it reaches the right temperature for water-cooled engines (about 70°-
80°C); for air-cooled engines, run the engine for about 20 (twenty) minutes.
• Drain the fuel tank.
• Check for any fluid leakage (and make any necessary repairs).
• Switch off the engine and wait for it to cool down.

50 Maintenance
 MR 700
SEAWATER SYSTEM (for marine engines and on-board auxiliary units only): this procedure must be carried
out together with the injection system protection procedure.
• Connect the seawater intake of the seawater pump to an auxiliary tank containing a mixture of 40% fresh-
water and 60% Petronas Paraflu Up (protective radiator fluid with monoethylene glycol and organic inhibi-
tor formulation complying with ASTM D 3306 type 1 Standards), making sure it seeps out from the drainage
point.
• Check for any fluid leakage (and make any necessary repairs).
• Switch off the engine and wait for it to cool down.
• Disconnect the engine from all the components used for the test

3) STORAGE CONDITIONS

- Engines on pallets

After applying the anticorrosion protection, the engine must be placed in a dry, well-ventilated environment
and adequately covered. The covering must be applied in such a way that air can circulate around the en-
gine, preventing the formation of condensation.
- Engines on vehicles

The vehicle must be stored so as to minimise exposure to atmospheric agents

START-UP
- Engines on pallets
Remove the covers and protective elements applied to the engine openings (for instance, air suction ducts
or turbocharger air inlet, exhaust gas ducts or turbocharger guard).
Check there is no damage to the external engine components; make any necessary repairs.
Clean the throats of the metal belt pulleys, using a suitable solvent. Install the service belts
Check the rubber tubes and manifolds are in good condition, and check the tightening of the relative fixing
clips; if they are damaged, replace them.
All surfaces and components protected with “FL MECAFLUID / P118 V” protective oil can be cleaned with a
suitable solvent.
Check the level of the fluids: engine oil and coolant. Top up if necessary.

- Engines on vehicles
Check there is no damage to the external engine components; make any necessary repairs.
Clean the throats of the metal belt pulleys, using a suitable solvent. Install the service belts.
Check the rubber tubes and manifolds are in good condition, and check the tightening of the relative fixing
clips; if they are damaged, replace them.
All surfaces and components protected with “FL MECAFLUID / P118 V” protective oil can be cleaned with a
suitable solvent.
Check the level of the fluids: engine oil and coolant. Top up if necessary.

Nothing needs to be done to remove the internal protection (either for engines on pallets or on vehicles).

51 Maintenance
 MR 700
Transmission Fluid
Checking
1. Remove the dipstick.

IMPORTANT: When checking the fluid level, rest

the dipstick on top of the threaded housing hole. Do not
screw the dipstick into the threaded housing hole.
2. Check the fluid level as indicated on the dipstick with
the dipstick resting on the top of the threaded hole.

NOTE: The fluid level may be somewhat over the

maximum mark, as some of the fluid from the transmis-
sion fluid cooler and hoses may have drained back into
the transmission.
3. If low, add transmission fluid to bring the level up to the
maximum mark on the dipstick. a - Dipstick
b - Threaded hole
IMPORTANT: To accurately check the fluid level, c - Maximum fluid level
the engine must be operated at 1500 RPM for two minu- d - Minimum fluid level
tes immediately prior to checking the level.
4. Start the engine and operate at 1500 RPM for two
minutes to fill all the hydraulic circuits.
5. Stop the engine and quickly check the fluid level with
the dipstick resting on the top of the threaded hole.
6. If the fluid level is low, refer to Filling and add transmis-
sion fluid to bring the level up to the maximum mark on
the dipstick.
7. Install the dipstick.

Filling
1. If necessary, add specified automatic transmission fluid
through the dipstick threaded
hole to bring the level up to the maximum mark on the
dipstick.

IMPORTANT: Use only specified Automatic Tran-

smission Fluid (ATF).

NOTE: Always use the dipstick to determine the

exact quantity of oil or fluid required.

Model Capacity Fluid type

ZF Marine 45A 3 liters Dexron III Automatic
ZF Marine 63A 4.5 liters Transmission Fluid or
Equivalent
ZF Marine 63IV 4.9 liters
Technodrive TM 2.6 liters Engine Lube Oil
485A
Technodrive TM 1.6 liters
385A
Technodrive TM 3.7 liters
880A

2. Install the dipstick.

IMPORTANT: To accurately check the fluid level,

the engine must be run at 1500 rpm for 2 minutes imme-
diately prior to checking the level.
3. Refer to Checking and check the fluid level.

52 Maintenance
 MR 700
Changing
1. Clean the exterior of the transmission around the fluid
filter assembly.
2. Use a 6 mm allen wrench and remove the fluid filter
assembly by turning the assembly nut counterclockwise
and pulling at the same time.
3. Push the hose of a suction pump through the suction
pipe and down to the bottom of the housing.
4. Pump the fluid from the housing into a suitable contai-
ner. Dispose of fluid properly.
5. Remove and discard the filter element and the O‑rings.
6. Coat the new O‑rings with transmission fluid.
7. Install the new O‑rings and filter element.
CAUTION
The transmission fluid filter assembly must be pro- a - Assembly nut
perly seated to avoid fluid foaming or loss of fluid b - Fluid filter assembly
resulting in decreased efficiency and damage to
transmission.
8. Install the fluid filter assembly in the transmission cavi-
ty by turning clockwise and pushing at the same time.
9. Using a 6 mm allen wrench turn the filter assembly nut
clockwise to tighten. Torque the nut.

Description Nm
Filter assembly nut 5-8

10. Fill the transmission to the proper level with the speci-
fied fluid. Refer to Filling.

a - Suction pipe
b - Suction pump

a - Filter element
b - Cover
c - O‑rings!

a - Assembly nut
b - Fluid filter assembly

53 Maintenance
 MR 700

54 Maintenance
 MR 700
engine specifications
engine specifications. ..................................................................................................................1
fastener tightening specifications. ..............................................................................................3

engine specifications
Application Description
MR704 MR706
Engine Type In–line 4 cylinder In–line 6 cylinder
Cylinder Bore 94 mm
Stroke 100 mm
Displacement 2776 cc 4164 cc
Compression Ratio 17,5:1
LX - 169.1 kW=230.0 CV LX - 257.3 kW=350.0 CV @
@ 3800 rpm 3800 rpm
Maximum Power (UNI EN ISO 9665) LH - 154.4 kW=210.0 CV LH - 235.3 kW=320.0 CV @
- kW (CV) @ rpm @ 3800 rpm 3800 rpm
Engine LS - 125.0 kW=170.0 CV LS - 198.6 kW=270.0 CV @
Performance @ 3800 rpm 3800 rpm
LX - 480 Nm @ 2600
rpm
Maximum Torque (UNI EN ISO LX - 700 Nm @ 2600 rpm
9665)) LH - 480 Nm @ 2600
LH - 700 Nm @ 2600 rpm
rpm
Nm (kgm) @ rpm LS - 670 Nm @ 2400 rpm
LS - 450 Nm @ 2200
rpm
Idle Speed 700 ± 0 rpm.
Engine rotation Counterclockwise facing flywheel
Firing Order 1-3-4-2 (MR704) / 1-5-3-6-2-4 (MR706)

2 - 2.2 bar @ 3800 RPM (MR704LX)

1.7 - 2 bar @ 3800 RPM (MR704LS)
2 - 2.2 bar @ 3800 RPM (MR704LH)
Overboost pressure -----------------------------------------------------------------
2 - 2.3 bar @ 3800 RPM (MR706LX)
2 - 2.2 bar @ 3800 RPM (MR706LS)
2 - 2.3 bar @ 3800 RPM (MR706LH)

a - Flywheel end
b - Water pump end

55 Engine Specifications
 MR 700
Fuel Pump Type
Fuel Flow Rate
Fuel Flow Pressure
Fuel Filter Type
The engine has been designed to be
powered by standard fuels
Low Fuel
available on the European market
Pressure Line (according to specifications

Fuel Type DIN EN 590). If it is to be powered by

Fuel BIODIESEL fuels (according
to specifications UNI EN14214), it can be
mixed, up to 5%, with fuel available on the
European market (according to regulation
DIN EN 590).
Fuel Pump Type 3 – cylinder radial plunger
Delivery/Pump Rotation
High Fuel
Common Rail Pressure max 1600 bar
Pressure Line
Injection Pressure max 1600 bar
Injector Type solenoid type
Cooling Type Forced Water Cooling
SAE 10W40
Specifications ACEA A3/B4
API CG-4, CH-4, CI-4
Oil change including filter 8 Litres (MR704) /
Engine Part (standard sump) 12.3 Litres (MR706)
Oil quantity at maximum
6.5 Litres (MR704)
level
11 Litres (MR706)
(standard sump)
Oil quantity at minimum level 5 Litres (MR704)
(standard sump) 8 Litres (MR706)
Oil Pump Type Internal Rotor
Total capacity of the cooling
Capacity 13 Litres (MR704) / 18 Litres (MR706)
circuit
Demineralised cold water 50% + anti-
Specifications freeze fluid 50% (Inhibited glycol ethylene
in compliance with ASTM D 3306)

Coolant Temperature (Opened

80 ± 2 °C - (176 ± 35.6 °F)
System initially)
Temperature (perpectly
Thermostat 95 °C - (203 °F)
opened)
Temperature (Completely
75 °C - (167 °F) or more
closed)
Stroke (perpectly closed) 8 mm (0.315 in) or more
Battery 12V
Alternator 14V - 110A
Type
Electric
System Output(Capacity) 2.3 Kw
Starter No load test at 12 volts
condition
Drive Pinion Speed

56 Engine Specifications
 MR 700
fastener tightening specifications

Component Nm
Oil Pump bolt 27.5
Idler gear bolt (between crankshaft gear and camshaft gear) 32.4
Engine Oil pressure relief valve 53.9 (Loctite 510)
4.1 (MOLYguard LMP
Main center bearing carriers - bolt 180)
Idler gear bolt (between camshaft gear and injection pump gear) 35 (see procedure)
Camshaft Flange Bolt 27.5
Air heat exchanger (InterCooler) nuts 24.5
Seawater/Engine oil Heat exchanger (see procedure)
10+30+40° (see
Connecting Rod Fractured Cap - Bolt procedure)
27.5 nuts
86.3 bolt M10
19.6 bolt M8
Fluid Heat exchanger retaining (see procedure)
CPS Target Wheel bolt 14.6
Crankshaft Balancer Bolts 32.4 (see procedure)
Main center bearing fittings - oil feeding special bolts 53.9

Crankshaft front hub nut 400/600 (see procedure)

Cylinder Head Bolt (see procedure)

Rocker Arm Cover Bolt 11.8

Engine Mount Bracket Fixing Bolt 78.5 (see procedure)

Exhaust Manifold fixing Nuts 27.5
Flywheel Tightening Bolt 50 / 20 + 75°
Flywheel Housing Tightening Bolts 68.6
Rear Main bearing carrier - nuts 24.5

57 Engine Specifications
 MR 700

Component Nm
Injection Pump Gear Nut 86.3
Injection Pump Fixing Flange Nuts 27.5
WASTE GATE fixing nuts 10.8
Oil Filter Cap 22.5
Automatic poly -v belt tensioner - bolt 24.5
Oil Filter Housing 35
Seawater pump 47.1
Seawater pump pulley 24.5
Oil Nozzle Tube Retaining Bolt (oil cooling piston jet) 12.7
Oil Pan Tightening Bolt 12.7

Oil Pan Strainer/Suction pipe - Bolt 12.7

Timing Belt Cover - M6x60 Bolt 27.5

Timing Belt Cover - M6x35 Bolt 12.7
Idler Plastic Pulley - poly-v belt 47.1

Turbocharger mounting flange nut 49

24.5 on turbocharger
Turbocharger Wheel Bearing Oil Inlet Pipe 39.2 on crankcase
27.5 on turbocharger
Turbocharger Wheel Bearing Oil Outlet Pipe 49 on crankcase
Elbow (RISER) fixing clamp 10.8
Crankshaft front pulley fixing bolts 32.4

Starter motor fixing bolts 47.1

Alternator fixing bolts / nuts 27.5
Alternator Bracket fixing bolt 47.1
Coolant Manifold - bolt 11.8
Rocker Arms assembly fixing nuts 29
Rocker arms assembly - Oil feed pipe - hollow bolts 14 (M8) / 23.5 (M10)
Injector clamp bolt (see procedure)
High pressure injection pipes (see procedure)
Rail (see procedure)
Eye Engine lifting bracket (installed on exhaust manifold) 27.5
Eye Engine lifting bracket (installed on intercooler) 47.1
Eye Engine lifting bracket (installed on alternator bracket) 83.4
Fresh water pump 32.4 (see procedure)
Thermostatic valve body - fixing nuts 24.5
Belt Tensioner (Automatic) - fixing nut 78.5

58 Engine Specifications
 MR 700
base engine

59 Base Engine
 MR 700

60 Base Engine
 MR 700
Establishing TDC (Top Dead Center)
To avoid component damage, some procedures require the engine to be set at cylinder number 1 TDC (Top Dead
Center). Other procedures require individual cylinders to be set at TDC, such as during the measurement of piston
protrusion from the block in order to choose the cylinder head gasket thickness.

The special tool, Flywheel Pin Tool, uses a pin that engages a two‑step drilling in the flywheel when cylinders num-
ber 1 or 4 (for engine with 4 cylinders) and, 1 or 6 (for engine with 6 cylinders) are at TDC. This tool threads into the
flywheel housing and is used during some assembly procedures. This tool is used, as an example, to keep the engine
from rotating during counter balance shaft assembly installation (Only for MR704 engine model).
NOTE: The screw plugs, in the glow plug holes, may be removed to release compression when turning the crankshaft.

1. Insert the form fitted Crankshaft Rotation (Barring) Tool into the front of the crankshaft pulley. (Only for MR704
engine model)

a - Crankshaft Rotation (Barring) Tool

(only for MR704)

2. On partially assembled engines:

a. Temporarily insert a push rod into both cylinder number 1 lifters.
b. Slowly rotate the crankshaft clockwise (as viewed from the water pump end looking toward the flywheel) whi-
le watching the front‑most valve push rod for cylinder number 1 intake valve.
c. Continue to rotate the engine until after the intake valve push rod moved up (intake valve opened) and then the
valve push rod moved down (intake valve closed). Turn the cranckshaft for one complete revolution.
d. Temporarily stop rotating the crankshaft and proceed as instructed in step 4.

3. On assembled engines:
a. Remove the cylinder number 1 glow plug, or screw plug if equipped.
b. With finger on glow plug hole, slowly rotate the crankshaft CLOCKWISE until compression is felt in cylinder num-
ber 1.
c. Temporarily stop rotating the crankshaft and proceed as instructed in step 4.

61 Base Engine
 MR 700
4. Remove the plug from A the flywheel housing.
5. While looking through the flywheel housing plug hole,
slowly rotate the engine clockwise using the Crankshaft
Barring Tool (Only for MR704 engine model) until the
Flywheel Pin Tool pin can be inserted into drilling 1 and 2
located in the flywheel.
A - Plug

a - Drilling 1
b - Drilling 2

6. Thread the Flywheel Pin Tool into the flywheel housing, a - Flywheel Pin Tool
A
until the pin enters into drilling 1 and 2 located in the
flywheel.

At this moment, cylinder number 1

piston is at compression stroke TDC.

IMPORTANT: Remove the Flywheel Pin Tool from the

flywheel and housing when the procedure is completed.

7. Make a reference mark on the crankshaft pulley and timing cover.

8. Remove the Flywheel Pin Tool.
9. When appropriate, turn the crankshaft clockwise 180 degrees to bring the next cylinder in firing order up to TDC.
(Refer to Engine Specifications - Firing Order)
10. Repeat step 9 for the remaining cylinders if TDC needs to be established.

62 Base Engine
 MR 700
Engine Compression Testing
A loss of engine compression pressure causes loss of power, greater fuel consumption, smoke at the exhaust, low
acceleration, an unsteady slow idle, difficulty in starting and bearing seizure because of engine overheating.
Periodically check engine compression pressure.
1. Start the engine and allow it to reach normal operating temperature.
2. Stop the engine and shut off the fuel supply.
3. Ensure that the battery is fully charged.
IMPORTANT: To achieve the cranking RPMs needed (300 RPM minimum) for a proper compression test, it will be
necessary to remove all of the injectors prior to testing.
4. While observing the precautions listed, remove all the fuel injectors.
5. Clean the injector bore and install the Compression Tester Adapter Tool. (Refer to Special Tools)
6. Install and torque the injector clamp. (Refer to Fuel System - Fuel Injector- Section for torquing value).
7. Connect the compression gauge to the Compression Tester Adapter Tool and set the gauge to zero “0” reading.
8. Operate the starter. The engine should be cranking at approximately 300 RPM minimum.
9. Check the compression gauge reading and compare to the following specifications.

Engine compression

Compression at approximately 300 RPM minimum 30‑32 bar (435‑464 psi)
Pressure difference between cylinders 500 kPa (72 psi) maximum

10. Remove the compression gauge and the Compression Tester Adapter Tool.
11. Readings lower than specified, or pressure differences between cylinders greater than specified, indicate engine
problems exist (such as faulty rings, valves, cylinders and pistons). Refer to the appropriate Sections and repair as
needed.
12. If readings are within specifications, install the injectors in the cylinder heads from which removed previously.
(Refer to Fuel System - Fuel Injector- Section for the installation and torquing clamp value).
13. Purge the air from the fuel sistem. (Refer to Maintenance ‑ Fuel Filter - Bleeding).

63 Base Engine
 MR 700
Valve Cover
Removal
Remove any components hindering the removal of the
cover.
Remove the injectors. Refer to “Injector” section.
a - Head valve cover screws
Remove the screws retaining the valve cover to the cylin-
b - Flange screw
der head.
c - Vent hose adapter
Using a rubber mallet, tap against the side of the valve
d - Oil fill extension tube
cover to loosen.
e - Sealing washer
Lift the valve cover from the heads.

Installation
1. Install a new valve cover gasket as needed.
2. Install the valve cover on the cylinder heads.
3. Install and finger tighten the head valve cover screws.
4. Torque the valve cover screws, in a diagonal pattern.

valve cover screws 11.8 Nm

Oil Separator Application Kit

Align the SLOT “A” so that it is opposite to hose CONNECTION “B”

78.5
Nm

64 Base Engine
 MR 700
Oil Separator and Vent System
Removal
1. Disconnect the oil drain hose and the valve cover vent
hose from the oil separator.
2. Disconnect the air cleaner vent hose from the oil sepa-
rator.
3. Remove the oil separator flange nut and bolt retaining
the oil separator to the bracket. A
4. Remove the oil separator.
5. Disconnect the oil drain hose from the oil separator
lower fitting.

a - Oil separator
b - Oil separator flange nut and bolt
c - Oil drain hose
d - Valve cover vent hose
E D
e - Air cleaner vent hose
f - Air cleaner

C E F

Installation
1. Install the oil drain hose on the cylinder block fitting.
2. Install the oil separator on the bracket. Torque the oil
separator flange nut.
3. Connect the oil drain hose and the valve cover vent
hose to the oil separator.
4. Connect the air cleaner vent hose to the oil separator.
5. Tighten all hose clamps securely.
E

65 Base Engine
 MR 700
Coolant Manifold and Coolant Temperature Sensor
1. Drain the engine coolant.
2. Remove the screws retaining the coolant manifold assembly to the cylinder heads.
7. Using a rubber mallet, tap against the side of the coolant manifold assembly to loosen from the cylinder heads.
8. Remove the coolant manifold assembly.
9. Remove the four screws and washers and separate the end cover from the coolant manifold.
Inspection
1. Inspect the sealing surfaces for deep nicks and scratches.
2. Inspect the castings for cracks or corrosion that might prevent a proper seal.
3. Inspect the vent pipe, vent hose, and water hose for signs of damage.
4. Replace or repair components as needed.
Installation
1. Use a new gasket and install the end cover on the coolant manifold using the screws and washers. Finger tighten
the screws. Apply Loctite 510 on both surfaces of the gasket.
IMPORTANT: The end cover and the coolant manifold gasket flanges must align for proper sealing on the
cylinder heads. Align the flanges using a straight edge as shown.
2. Align the coolant manifold end cover and the coolant manifold using a straight edge device and then, torque the
coolant manifold end cover screws evenly in a diagonal pattern.
3. Place new gaskets in position on the cylinder heads.
4. Install the coolant manifold assembly, finger tighten the coolant manifold screws.
5. Torque the coolant manifold screws in a diagonal pattern from the center to the outer ends.
6. Connect all pipes, hoses and tighten proper clamps securely.

Nm 14.7
Nm 27

Nm 11.8

B
F
C

A B

A
C

Nm 10.8 a - Coolant manifold end cover

b - Gasket
E c - Coolant manifold
d - Typical straight edge device
F e - Coolant manifold end cover screw and washer
Nm 10.8 f - Coolant temperature sensor
Nm 19.6 E
Loctite 510

66 Base Engine
 MR 700
Cylinder Heads
Removal
1. Remove the valve cover.
IMPORTANT: Mark or store the components to aid diagnosis and for reassembly in their original location.
2. Mark the location of the rocker arm assemblies and cylinder heads for reassembly.
3. Remove the rocker arm oil feed pipe hollow bolts with sealing washers.
4. Remove the oil feed pipe from the cylinder heads and from the rear of cylinder block.

a - Oil feed pipe b

b - Hollow bolts with sealing washers a

5. Unscrew the rocker arm support flanged nuts.

6. Remove the rocker arm assembly.

a - Flanged nuts a
b - Rocker arm assembly

7. Remove the valve push rods. Mark or store the components for reassembly in their original location.
8. Remove the coolant manifold.
9. Remove the intake and exhaust manifold.
IMPORTANT: To avoid distorting the cylinder heads, remove the cylinder heads only when the engine is cold.

67 Base Engine
 MR 700
10. Note the shape and the location of the formed spacer washers and first and last cylinder head end spacers (pla-
tes).
11. Starting at one end of the engine:
a. Remove the 12M cylinder head side bolts.
b. Remove the 14M cylinder head center bolts and formed spacer washers, except for the two outer, center bolts and
formed spacer washers holding the two end spacers (plates) in place.
c. Remove the two outer, center bolts and end spacers (plates).

a - Formed spacer washer

b - End spacer (plate)
c - 12M cylinder head side bolt
d - 14M cylinder head center bolt b

d
a
c

12. Tap on the side of the cylinder heads with a rubber mallet to loosen.
13. Remove the cylinder heads.
14. Place the cylinder heads on wooden blocks to prevent damage to the gasket surfaces.

Resurfacing
IMPORTANT: The cylinder heads on these marine diesel engines are treated with a protective nickel coating to
resist corrosion and should not be resurfaced. Resurfacing would remove the nickel coating. Do not resurfa-
ce the cylinder heads.

68 Base Engine
 MR 700
Cylinder Head Gasket Thickness selection
CAUTION
The thickness of the head gasket installed on these engines is critical. Severe engine damage may result if
the head gaskets installed are too thin or too thick. Precisely measure the appropriate engine components to
select a cylinder head gasket of the required thickness.

1. Use the dial indicator and Support Block tool (liner gauge bar) (refer to Special Tools) to measure piston height
above the cylinder block with the piston at Top Dead Center (TDC).

2. Place Support Block on cylinder block surface and set the dial indicator to zero 0.

3.Move the Support Block tool to the piston surface with the piston at TDC point as shown.Record the measurement.

4. Measure the piston protrusion (height) of all pistons. Use the average measurement to
determine the gasket thickness required for all cylinders.

Cylinder head gasket a - Support Block tool

b - Dial indicator
Piston protrusion (height) Gasket thickness required c - piston
above cylinder block
b
a
0.63 ‑ 0.74 mm 1.42 mm
0.73 ‑ 0.82 mm 1.52 mm
0.83 ‑ 0.92 mm 1.62 mm

Cylinder head gasket thickness identification

6. After determining the head gasket thickness required, identify

and select the proper the cylinder head gasket.

Note the identification marks in the lower right

hand corner.
a
No notches/holes indicates a thickness of 1.42 mm
Two notches/holes indicates a thickness of 1.52 mm
One notch/hole indicates a thickness of 1.62 mm
Two notches/holes gasket shown

a - Notches/holes

69 Base Engine
 MR 700
Installation
1. Clean out bolt holes in cylinder block. Be certain no contaminants (dirt, old oil or coolant) remain in the holes.
2. Clean the gasket surfaces on block and heads.
3. Oil the cylinder bores with lubricant.

IMPORTANT: Cylinder head bolts may be installed as many as three times, and then must be replaced with
new bolts. Replace if any doubt exists or the thread is stretched.

NOTE: New cylinder head bolts are already lubricated with an anti‑seizing lubricant from the manufacturer,
and do not require additional lubrication.
If the bolts are reusable, lubricate the thread bolts, underside head of the bolts with Molykote G Rapid Plus
Paste.

Center bolts Side bolts (injection side) Side bolts (intake/exhaust side)

70 Base Engine
 MR 700
4. Thoroughly clean all existing cylinder head bolts and washers, including all formed
spacer‑washers (terminal bridges, three types) and cylinder head spacers (for ends of first and last cylinder heads).

5-6 Lubricate with Molykote G Rapid Plus Paste the bolt threads and underside of bolt heads of all 12M (12 mm)
cylinder head bolts (side bolts) and 14M (14 mm) cylinder head bolts (center bolts)

7. Place all the parts on a clean surface or lint‑free shop cloth.

IMPORTANT: Cylinder head gasket must be installed dry. Do not use any sealant or adhesive on the gasket.

8. Position the cylinder head gasket on the cylinder block.

9. Install the Cylinder Head Guide Pins (refer to Special Tools) into the 12 mm bolt holes in the gasket and cylinder
block at each cylinder location. These pins will align the gasket and cylinder heads.

10. Beginning with cylinder number 1, install the cylinder heads over the guide pins.

11. Repeat for each cylinder head and corresponding cylinder 2 through 4 or 6.

a - Cylinder head gasket b c

b - Guide pin locations (two at each cylinder)
c - Cylinder head

12. One at a time, remove the Cylinder Head Guide Pins and install the lubricated 12M cylinder head side bolts, finger
tight. Do not disturb the cylinder head placement.

13. Install and finger tighten all lubricated 14M cylinder head center bolts, including the proper formed spacer washers
(terminal bridges, three types) and cylinder head spacers, for the ends of the first and last cylinder heads, as shown in
the picture.

a - Spacer, first and last cylinder head ends

b - Formed spacer washers

(terminal bridges, three types)

71 Base Engine
 MR 700
14. Using the appropriate tools/sockets (refer to Special Tools), lightly hand tighten bolts in the numbered torque
sequence shown.

Numbered torque sequence

Engine with 4 cylinder heads

Center Bolts

Side Bolts

Numbered torque sequence

Engine with 6 cylinder

heads

15. Correctly align the cylinder heads by temporarily installing the exhaust manifold with
gaskets and finger‑tighten each flange nut.

16. Slightly loosen the 12M and 14M bolts as needed, to allow the cylinder heads to align.

Max disalignement 0.2 mm (measured on intake/exhaust flanges manifold)

17. Hand tighten the exhaust manifold nuts sufficiently to align the cylinder heads to the
exhaust manifold.

18. Using the appropriate tools (refer to Special Tools), hand tighten all 14M and 12M cylinder head bolts in the num-
bered torque sequence.

72 Base Engine
 MR 700
19. Torque the center bolt set as specified and in the sequence shown, following steps a, b, and c. Do not torque the
side bolt 12M set at this time.

CENTER BOLTS

a. First pass torque and sequence:

Torque Value - Center bolts 30 Nm
Torque Sequence
• 3‑2‑1‑4‑5‑8‑9‑10‑7‑6 (4 cylinder heads engine)
• 11, 12, 13, 14, 10, 9, 8, 4, 3, 2, 1, 5, 6, 7 (6 cylinder heads engine)

b. Second pass torque and sequence:

Torque Angle - Center bolts + 65°
Sequence
• 1‑2‑3‑4‑5‑6‑7‑8‑9‑10 (4 cylinder heads engine)
• 1‑2‑3‑4‑5‑6‑7‑8‑9‑10-11-12-13-14 (6 cylinder heads engine)

c. Final pass and sequence:

Torque Angle - Center bolts + 65°
Torque Sequence
• 1‑2‑3‑4‑5‑6‑7‑8‑9‑10 (4 cylinder heads engine)
• 1‑2‑3‑4‑5‑6‑7‑8‑9‑10-11-12-13-14 (6 cylinder heads engine)

Numbered torque sequence

Engine with 4 cylinder heads

Center Bolts

Side Bolts

Numbered torque sequence

Engine with 6 cylinder

heads

Center Bolts

73 Base Engine
 MR 700
20. Now, torque the side bolt numbered sets as specified and in the sequence shown,
following steps a, b, c and d.

SIDE BOLTS c. Third pass and sequence:

Torque value 30 Nm
a. First pass and sequence: Sequence - Side bolts numbered
Torque value 30 Nm 15, 16, 17, and 18 (4 cylinder heads engine)
Sequence - Side bolts numbered 21, 22, 23, 24, 25 and 26 (6 cylinder heads engine)
11, 12, 13, and 14 (4 cylinder heads engine)
15, 16, 17, 18, 19 and 20 (6 cylinder heads engine) d. Final pass and sequence:
Torque angle + 85°
b. Second pass and sequence: Sequence - Side bolts numbered
Torque angle + 85° 15, 16, 17, and 18 (4 cylinder heads engine)
Sequence - Side bolts numbered 21, 22, 23, 24, 25 and 26 (6 cylinder heads engine)
11, 12, 13, and 14 (4 cylinder heads engine)
15, 16, 17, 18, 19 and 20 (6 cylinder heads engine)

Numbered torque sequence

Engine with 4 cylinder heads

Center Bolts

Side Bolts

Numbered torque
sequence

Engine with
6 cylinder heads

21. Using the hollow bolts and new sealing washers, install the rocker arm oil feed pipe onto the cylinder heads and
the rear of the cylinder block.
22. Complete the engine assembly.

74 Base Engine
 MR 700
Torque Procedure After the First 20‑30 Minutes of Operation
CAUTION
When the cylinder heads are replaced or disassembled an additional angular torque and conventional torque
must be applied after the first 20-30 min. of operation. Torque the cylinder head mounting bolts as specified
after the first 20‑30 minutes of operation.

1. Operate the engine at a fast idle until water temperature reaches 70 degrees C (158 degrees F.). Then operate the
engine at 2000 RPM for approximately 20‑30 minutes at normal operating temperature.
2. Let the engine cool down completely (inoperative overnight, if possible, or at least less than 40° C [104° F]).
3. Following the sequence shown and one at a time, completely loosen each M14 center bolt and torque as indicated
in steps a and b.

a. First pass:

(center Bolts)

Slackening Sequence
• 1‑2‑3‑4‑5‑6‑7‑8‑9‑10 (4 cylinder heads engine)
• 1‑2‑3‑4‑5‑6‑7‑8‑9‑10-11-12-13-14 (6 cylinder heads engine)
•
Torque Value 30 Nm
Torque Sequence
• 1‑2‑3‑4‑5‑6‑7‑8‑9‑10 (4 cylinder heads engine)
• 1‑2‑3‑4‑5‑6‑7‑8‑9‑10-11-12-13-14 (6 cylinder heads engine)

b. Final pass:
Torque Angle 120° or 60°+60°
Torque Sequence
• 1‑2‑3‑4‑5‑6‑7‑8‑9‑10 (4 cylinder heads engine)
• 1‑2‑3‑4‑5‑6‑7‑8‑9‑10-11-12-13-14 (6 cylinder heads engine)

(SIDE Bolts)

NOTE: The 12M side bolts numbered 11‑ 18 (4 cylinder heads engine) or 15 - 26 (6
cylinder heads engine) do not require tightening again.
If necessary, check the 12M side bolts with a conventional torque wrench, checking
the torque on each side bolt as indicated.

Torque Value 90 Nm
Torque Sequence
• 11-12-13-14-15-16-17-18 (4 cylinder heads engine)
• 15-16-17-18-19-20-21-22-23-24-25-26 (6 cylinder heads engine)

75 Base Engine
 MR 700
Cylinder Head Parts - disassembling
1. Using a valve spring compressor, remove the valve locks, the retainers, the springs, and the spring plates.
2. Remove the valves from the cylinder head and place in a rack or label the parts in order for reassembly in their
original locations.

a - Typical valve spring

a
compressor
b - Valve spring and related
b
components

Cleaning
1. Clean the gasket material and the sealer from the engi-
ne block and cylinder head sealing surfaces.
2. Clean all the carbon from the combustion chambers
and valve ports using a carbon remover brush.
3. Clean the carbon from valves using a wire wheel.
4. Wash the cylinder head and components in a cleaning
solvent.
5. Clean the cylinder head bolt threads and engine block
bolt hole threads to ensure that no dirt, old oil, or coolant
remain.
6. Put on safety glasses and dry the components with
compressed air, including cylinder head bolt threads and
engine block bolt hole threads.
Inspection
GENERAL
1. Inspect the glow plug seats for damage.
2. Inspect the injector seats for damage.
3. Inspect all of the gasket surfaces for deep grooves or
pitting.
4. Inspect for melting of aluminum by faulty fuel injectors.
5. Inspect the rocker arm support journals for scoring.
6. Inspect the rocker arm bushings for excessive wear.
7. Ensure that the rocker pedestal guide pin is present.
8. Replace or repair damaged parts.

76 Base Engine
 MR 700
Expansion Plugs
Removal
1. Remove expansion plugs if leaking or damaged.
NOTE: These plugs may be removed with a sharp punch or they may be drilled and pried out.

a - Expansion plugs

Repair
1. Apply sealant (Loctite 290) to the outer diameter of the expansion plugs.
2. Install the plugs flush to the outer surface of the cylinder head.

77 Base Engine
 MR 700
Valve Guides
1. Inspect the valve guides for cracks or chips.
2. Inspect the valve guide bores for seizure marks, carbon
deposits or scoring.
3. Inspect the valve guide height.
4. Remove the valve stem seals.
5. Insert a new valve into guide.
6. Measure the valve stem clearance as follows:

a. Attach a dial indicator to cylinder head. Position it again-

st the valve stem and close to the valve guide.
b. While holding the valve head off of the seat by about 2
mm move valve stem back and forth in directions shown.
Compare stem clearance with specifications.

Valve guide maximum clearance with new

engine
Exhaust 0.061 - 0.094 mm
Intake 0.040 - 0.075 mm a - Spring seat counterbore
y - Intake guide height measurement
c. Measure the valve guide inner diameter with a valve x - Exhaust guide height measurement
guide bore gauge. b - Exhaust valve
If service limit exceeds the value as specified, replace c - Intake valve
the valve guide. d - Exhaust valve seat
Valve guide inner diameter - new guide e - Intake valve seat
Exhaust 8.00 - 8.015 mm
X-Y
Intake
Replacement
CAUTION
Aluminum cylinder heads can be distorted or melted when
heated improperly or unevenly.
A torch will improperly and unevenly heat an aluminum
cylinder head. Do not use a torch to heat an aluminum
cylinder head. To heat an aluminum cylinder head during
valve seat or valve guide replacement, use an oven appro-
priately designed and constructed for the purpose.
1. Remove the valve stem seals.
2. Heat the cylinder head in an oven to 85 degrees C (185
degrees F).
3. Using a suitable drift, drive out the old guide from the
underside of the cylinder head.
4. With the cylinder head temperature at 85 degrees C
(185 degrees F), press the new guide in to obtain measu-
rement as shown.
Guide height measurement “x - Y” (above Y
X
cylinder head top surface)
A
Exhaust 1.5 - 2 mm
Intake A

Guide lenght measurement

Exhaust 54.75 - 55.25 mm
Intake

IMPORTANT: If the valve guides have been repla-

ced, both the valves, the valves seats must be repla- D E
B C
ced as a set.

78 Base Engine
 MR 700
Valves - Intake and Exhaust
1. Inspect valves for damage, warpage, or both. Replace if necessary.
2. Measure the valve. If measured values are not as specified, repair the valve. Refer to Valve Refacing. Replace
the valve if it cannot be repaired.
INTAKE
a - Stem diameter ‑ intake valve
a1 e1
b - Face width ‑ intake valve
c - Margin thickness ‑ intake valve
d - Face angle ‑ intake valve
i - Head diameter ‑ intake valve

EXHAUST
e - Stem diameter ‑ exhaust valve
f - Face width ‑ exhaust valve
g - Margin thickness ‑ exhaust valve
h - Face angle ‑ exhaust valve
j - Head diameter ‑ exhaust valve
Stem diameter (production, new)
e. Exhaust 7.921 - 7.939 mm
a. Intake 7.94 - 7.96 mm
e1 Exhaust 7.89 - 7.93 mm INTAKE EXHAUST
a1 Intake 7.92 - 7.95 mm

Face width (production, new)

f. Exhaust 2.640 - 2.992 mm
b. Intake 3.57 - 3.85 mm

Margin thickness (Production, new)

g. Exhaust 1.73 mm
c. Intake 1.82 mm
Service limit 1.30 mm

Face angle (production, new)

h. Exhaust 44 degrees 30 minutes
d. Intake 60 degrees 30 minutes

Head diameter (production, new)

j. Exhaust 37.900 - 38.100 mm
i. Intake 40.8 - 41 mm

Valve Refacing
Pitted valves can be refaced to proper angle on a valve grinder, that ensuring the correct relation between the cylin-
der head seat and the valve mating surface.
Replace valves with excessive wear on stems or valves that are warped excessively. When an excessively‑warped
valve head is refaced, a knife edge will be ground on part or all of the valve head due to the amount of metal that
must be removed to completely reface. Knife edges lead to breakage or burning.
NOTE: Various equipment is available for refacing valves. Manufacturer’s recommendations should be
carefully followed to attain proper results.
After refacing, measure the valves and replace if out of specifications.

1. Recondition the valve face to the proper angle if the valve face is pitted or worn.
NOTE: When refacing do not thin the valve margin thickness less than 1.30 mm.
After reconditioning, measure the valve margin. If the valve margin is less than the specified above
amount, replace the valve.

IMPORTANT: If the valves have been replaced, both the guide valves and the valves seats must be
replaced as a set.

79 Base Engine
 MR 700
Assembly
NOTE: Valve stem seals are used on intake and exhaust valves.
1. Lubricate valve guides and valve stems with engine oil.
2. Install each valve in the port from which it was removed or for which it has been fitted.
3. Install the valve guide seal onto the valve stem and push down until seated against the
guide.

a
a - Valve stem seal
b - Seal installed on guide

4. Install the plate washer, the valve spring, and the retainer on valve stem.
5. Compress the valve spring using valve spring compressor.
NOTE: Lubricant may be used to hold valve locks in place while releasing compressor tool
6. Coat the valve stem locks with lubricant to hold in place.
7. Install the valve stem locks.

a - Plate washer b c d d
a
b - Valve spring
c - Retainer
d - Valve locks

8. Slowly release the valve spring compressor, ensuring that the valve locks seat properly
in the valve stem groove.

80 Base Engine
 MR 700
Valve Seats
1. Inspect the valve seats for cracks, excessive wear, and looseness in counterbore.
2. Measure exhaust and intake valve seats. Refer to valve seat specifications.
3. If measured values are not as specified, recondition the valve seat. If the valve seats
cannot be repaired, it will be necessary to replace the cylinder head. Refer to Repair ‑ Valve Seat Reconditioning.

Valve Seat Reconditioning

NOTE: Several different types of equipment are available for reconditioning valve seats.
Equipment manufacturer’s recommendations should be followed carefully to attain proper results.
IMPORTANT: Regardless of type of equipment, it is essential that valve guide bores be free of carbon or dirt
to achieve proper centering of pilot in valve guide, ensuring concentricity when reconditioning valve seats.
Recondition pitted or worn valve seats to the following specified angles.

Valve seat angle - See picture below

Exhaust 45 degrees
Intake 30 degrees

If during seats valve reconditioning excessively lowers valve recess or if the seat widht is wider than above specified
measures, replace valve seat insert. During replacement operation, special care should be taken not to damage seat
insert counterbore.
Install seat valve inserts after heating cylinder head in an oven at 150°C or cooling them down at -170°C in liquid
nytrogen athmosphere.
Seat installation into head bore must be free, no requiring pressure for installation if above conditions are maintained.

IMPORTANT: If the seats valves have been replaced, both the guide valves and the valves must be
replaced as a set.

EXHAUST - SCARICO ASPIRAZIONE- INTAKE

DETTAGLIO E
DETTAGLIO D
DETAIL E
DETAIL D

D
D

X X

X - Counterbore inner diameter X - Counterbore inner diameter

Exhaust 38.96 - 38.99 mm Intake 41.96 - 41.99 mm

81 Base Engine
 MR 700
Seat outer diameter - x Seat height - y
Exhaust 39.050 - 39.066 mm Exhaust 7.85 - 7.95 mm
Intake 42.070 - 42.086 mm Intake 7.73 ‑ 7.83 mm

EXHAUST - VALVE SEAT

X
INTAKE - VALVE SEAT

82 Base Engine
 MR 700
Valve recession
Exhaust - Intake 0.08 ÷ 0.22 mm

83 Base Engine
 MR 700
Valve Springs
1. Inspect the valve springs for discoloration due to excessive heat.
2. Inspect the valve spring valve locks, the retainers, and the washer for wear, distortion,
or cracks.
3. Measure the free standing height of each spring. Replace the spring if measured value
is other than specified.
4. Measure the spring inclination (distortion). If the measured value exceeds the specified
limit, the valve spring must be replaced.

a - Free standing height b - Spring inclination

Free standing height

Exhaust - Intake 44.65 mm

Spring Inclination
Exhaust - Intake Service limit 2 mm

5. Use a spring tester to measure the spring tension when the valve is open. Replace the
spring if measured value is less than specified at the height shown.

6. Use a spring tester to measure the spring tension when the valve is closed. Replace
the spring if measured value is less than specified at the height shown.

Valve open Valve closed

a - Applied pressure b - Height a - Applied pressure b - Height

Applied pressure 88.8 ‑ 96.2 kg pressure Applied pressure 32 ‑ 36 kg pressure

Height 28.20 mm Height 38.60 mm

84 Base Engine
 MR 700
Rocker Arm
Removal
NOTE: When servicing the rocker arms of only one cylinder, bring that cylinder to approximately 90° before
TDC before removing the rocker arms. When servicing all rocker arms, turn the crankshaft until cylinder
number 1 piston is approximately 40°‑ 45°, before TDC.

1. Remove the valve covers.

IMPORTANT: Mark or store the components during removal for reassembly in their original location.

2. Remove the rocker arm assemblies and valve push rods. Place the components in a
numbered rack according to their position in the engine or mark the parts in order for
reassembly to the original location.
Cleaning
1. Wash the components in cleaning solvent.
2. Put on safety glasses and dry the components with compressed air.
Inspection
1. Inspect components for excessive wear, cracks or damage.

NOTE: The push rods are hollow and serve as oil galleries to lubricate each individual rocker arm assem-
bly.

2. Visually inspect each pushrod for wear and deposits. Ensure the valve pushrod oil
passage is not restricted.

3. Roll each valve pushrod on a flat surface and inspect the shaft for bends.

4. Replace all damaged parts.

5. Using a micrometer, measure the outside diameter of rocker arm support journals.
Replace the rocker arm support if the journal outside diameter is less than specified.

a - Rocker arm support journal outside diameter

Rocker arm support journal

Outside diameter 24.979‑25.000 mm

6. Using an inside micrometer, measure inside diameter of the rocker arm bushing.
a - Rocker arm bushing inside diameter

Rocker arm bushing

Inside diameter (Production) 25.020 ‑ 25.041 mm
7. Replace the rocker arm bushing if the difference between the bushing inside diameter
and journal outside diameter is less than or greater than specified.

Rocker arm bushing and journal clearance

Minimum 0.020 mm
Maximum 0.062 mm
Wear limit 0.2 mm

85 Base Engine
 MR 700
Assembly
1. Lubricate with engine oil the rocker arm bushings and
rocker arm support journals.
2. Install the rocker arms on the rocker arm support jour-
nals. Position as shown.
3. Install the strap around the rocker arm assembly. En-
sure that the strap is not spread
open or the valve cover will not fit.

a - Rocker arm
b - Rocker arm support
c - Strap

Installation
NOTE: When servicing or installing the rocker arms
of only one cylinder, bring that cylinder to approxi-
mately 90° before TDC . When servicing or installing
all rocker arms, turn the crankshaft in the direction of
rotation until cylinder number 1 piston is approxima-
tely 40° ‑ 45°, before TDC.

1. Turn the crankshaft in the direction of rotation until

cylinder number 1 piston is
approximately 40° ‑ 45°, before TDC.
2. Lubricate the outer surfaces and ends of the valve
pushrods.
3. Lubricate the valve lifter contact surfaces.
4. Install the valve pushrods in their original locations.
Ensure that the valve pushrods d
seat are in the lifter sockets.
5. Lubricate the rocker arm and rocker arm contact surfa-
ces.
6. Lubricate the threads of the rocker arm support studs. a - Rocker arm assembly
7. Install the rocker arm assembly onto the rocker arm b - Pushrod
support studs. Simultaneously align the valve pushrods c - Rocker arm socket
with the rocker arm sockets. d - Pushrod Lifter socket

8. Install both rocker arm support nuts on the rocker arm

support. Torque the rocker arm support nuts evenly.
Rocker arm support nuts
29 Nm

IMPORTANT: Valve lash adjustment, or valve clearan-

ce, is hydraulically controlled and automatically set
when the rocker arm support flanged nuts are properly
torqued.

9. Repeat the steps for the rocker arm assembly on each

cylinder. No valve lash
adjustment is required. a - rocker arm support nut
b - Rocker arm support
10. Install the valve cover and related components.
11. Check for leaks upon first operating the engine.

86 Base Engine
 MR 700
Crankshaft pulley - Engine Front Bracket and Timing
Gear Cover
Removal
1. Remove the power steering pump belt if fitted.
2. Position a suitable tool in the automatic tensioner a - Automatic tensioner
release slot. Move (rotate) clockwise the tensioner pulley b - Release slot
and remove the serpentine belt.
3. Release the automatic tensioner slowly.
4. Remove the automatic tensioner assembly from the
engine front bracket.

5. Close the seacock, if equipped. If the boat is not equip-

ped with a seacock, remove and plug the seawater inlet
hose
6. Remove the seawater pump.
a - Automatic tensioner
IMPORTANT: The idler pulley mounting screw is b - Engine front bracket
left‑hand thread. Do not damage the threads in the
engine front bracket.

7. Remove the left‑hand thread idler pulley screw.

NOTE: There is a spacer mounted between the engi-

ne front bracket and the block on the flange screw .
Note the spacer and flange screw positions.

a - Flange screw
b - Spacer

b
a

87 Base Engine
 MR 700
8. Remove the 2 engine front bracket flange nuts and the
flange screw, with a spacer.
9. Remove the engine front bracket.
10. Block the rotation of the crankshaft by following step
a:

a. Install the Flywheel Holder Tool in place of the starter

motor. Refer to Special Tools.

IMPORTANT: The crankshaft damper and/or front

pulley mounting nut is left‑hand thread.

11. Remove the crankshaft damper and/or front pulley

nut, using a suitable 41 mm socket. Remove the large,
left‑hand thread crankshaft pulley nut.
12. Remove the timing gear cover screws. Note size and
position of fasteners for reassembly.
13. Remove the timing gear cover assembly.
a - Engine front bracket flange nut
Installation b - End of engine front bracket flange screw
c - Engine front bracket flange screw, with spacer
CAUTION
Oil seals and the sealing lip of an oil seal can be
damaged by grease on your hands or the dirt from
gloves. A damaged oil seal or oil seal lip could result
in an oil leak. When fitting or replacing an oil seal, do
not touch inside the oil seal or touch the oil seal lip
with your bare hands or with dirty gloves.

Using a suitable tool remove and replace the timing gear

cover oil seal, if needed. Do not touch inside the oil seal
or touch the oil seal lip with your bare hands or with dirty c
gloves. c
Install a new timing gear cover gasket on the engine.
Install the timing gear cover.
Torque the timing gear cover flange and allen screws
evenly, in a cross pattern.

timing gear cover flange screws a - Timing gear cover gasket

b - Timing gear cover
Allen screw “d” 12.7 Nm
c - Timing gear cover flange screw
Flange screw “c” 27.5 Nm d - Allen head screw
e - Oil seal
c d
a

88 Base Engine
 MR 700
Install the crankshaft pulley.
Install the Flywheel Holder Tool in place of the starter motor.

IMPORTANT: Remove the Flywheel Holder Tool from the flywheel

whenever the crankshaft pulley tightening procedure is carried out.
Clean the nut and proper thread, contact surface beetwen nut and
hub, and beetwen hub and crankshaft gear

Apply lubricant Molykote G Rapid Plus Paste to the left‑hand thread

crankshaft pulley nut threads and on the crankshaft pulley contact
side.

a - left‑hand thread crankshaft pulley nut threads

b - crankshaft hub

Molykote G Rapid Plus Paste

Install the nut with proper shoulder X toward the hub.

Install and torque the left‑hand thread crankshaft pulley nut following the x
steps a and b

1st step (a) 400 Nm

Slacken the nut and torque again.

2nd step (b) 600 Nm

Ensure the power steering belt is in proper position, if fitted.

Install the crankshaft damper only on MR706 or Remove the Flywheel Pin Tool or Flywheel Holder Tool
crankshaft pulley on MR704 used to block the cranckshaft rotation.
Torque the Allen‑head crankshaft damper or pulley flan-
ge screws.
crankshaft damper or pulley screws 32.4 Nm

a1 a

b a - Crankshaft damper
a1 - Crankshaft damper screws
b - Crankshaft pulley
b1
b1 - Crankshaft pulley screws

89 Base Engine
 MR 700
Install the front bracket flange screw with spacer, on the block.

a - Flange screw
b - Spacer

a
b

Ensure the engine front bracket aligns with the dowel pin on the timing gear cover and install the front bracket.
Install the engine front bracket flange nuts and thread the flange screw into the engine front bracket.
Torque the flange nuts and flange screw.

a - Engine front bracket flange nut

b-c - Flange screw threaded into engine front brac-
ket

24.5
Nm
a

b-c

47.1 Nm

90 Base Engine
 MR 700

IMPORTANT: The idler pulley mounting screw is

left‑hand thread. Do not damage the threads in the
engine front bracket.

Install the idler pulley. Torque the left‑hand thread idler

pulley mounting screw.

idler pulley 47.1 Nm

Align the pin with the drilling in the engine front bracket and install the automatic
tensioner assembly. Torque the automatic tensioner mounting screw.

automatic tensioner mounting screw 78.5 Nm

a - Automatic tensioner assembly

b - Pin
c - Drilling

Install the seawater pump.

Position a suitable tool in the automatic tensioner release slot and move (rotate) the tensioner counterclockwise.
Install the serpentine belt.
NOTE: For the correct alignment of the serpentine belt, refer to Maintenance section - Installation Serpen-
tine Belt
Release the automatic tensioner slowly.

a - Automatic tensioner
b - Release slot

Install and tension the power steering pump belt, if fitted

91 Base Engine
 MR 700
Timing Gears
1 - Oil pump gear
2 - Crankshaft gear
3 - Idler gear
4 - Camshaft gear
5 - Idler gear
6 - High pressure injection pump gear

timing reference marks - punched dots on the gears

segni di riferimento per la fase - punti punzonati sugli ingranaggi

5
4

2 3

2
1
1

92 Base Engine
 MR 700
Timing gears with cylinder number 1 piston is at compression stroke TDC.

Timing reference punched dots

camshft gear

idler gear

crankshaft gear

camshft gear
idler gear

idler gear

crankshaft
gear

93 Base Engine
 MR 700
Oil Pump
Removal
1. Remove the timing gear cover.
2. Loosen the oil pump screws.
3. Remove the oil pump with screws and spring washers a - Oil pump
from the cylinder block. b - Screw and
lockwasher
Inspection
1. Inspect the oil pump shaft, rotors, and housing for
excessive wear or damage. Replace the oil pump assem-
bly if excessive wear or damage is found.
2. Check clearance between the inner and outer oil pump
rotors.
3. Check clearance between the outer rotor and housing. a Screw
4. Check the outer and inner rotor end float. b Spring washer
5. If the measured values are greater than specified, the c Oil pump
pump is faulty and must be
replaced as a complete unit.
6. Check the rotor and gear coupling rolling torque.

Specifications
Clearance between rotors
0.070 ‑ 0.200 mm
Clearance between housing and outer rotor
0.130 ‑ 0.230 mm, limit 0.500 mm
Clearance between pump support and gear (axial)
0.150 ‑ 0.250 mm
Outer/Inner rotor end float
0.030 ‑ 0.087 mm
Inside diameter of rotor housing
58.130 ‑ 58.180 mm
Rotor and gear coupling rolling torque resistance
9 kgm
f

a - Shaft e - Clearance between

b - Inner rotor housing and outer rotor
c - Outer rotor f - Outer/Inner rotor end
d - Clearance between float
rotors g - Rotor housing

Reassembly
1. Lubricate with engine oil the oil pump rotor
housing and the inner and outer rotor surfaces. a - Bevelled (champfered) end

IMPORTANT b - Rotor housing

2. Install the bevelled (chamfered) end of the

outer rotor towards the seat (the inside) of the
rotor housing.

94 Base Engine
 MR 700
Installation
a - Screw
1. Install the screws and spring washers into the mounting
b - Spring washer
holes on the oil pump.
c - Oil pump
2. Install the oil pump in the cylinder block.

3. Torque the oil pump screws evenly in a diagonal pattern.

oil pump screws 27.5 Nm

a - Oil pump
4. Check that the oil pump gear is not in a bind by ensu- b - Screw
ring that there is some clearance (backlash) between the
crankshaft gear and oil pump gear. Verify the installation if
no backlash exists between the gears.

5. Install the timing gear cover.

6. Complete the engine assembly.

95 Base Engine
 MR 700
Idler Gear
Remove the 2 idler gear bushing screws..
Before removing the gear make a reference mark on all
3 gears, crankshaft, idler and camshaft gear or align the
3 gears as shown in the picture so that the timing dots
(punched on each gear) are properly aligned, timed.
Remove the idler gear bushing and idler gear assembly.

Separate the idler gear bushing from the idler gear

assembly.

Timing gears with cylinder number 1 piston is

e at compression stroke TDC.
a timing reference punched dots on the gears
coated by a dot of felt-tip pen, carried out
during assembling process.

a
c

a - Idler gear bushing

b - Idler gear assembly

f c - Idler gear bushing screw

e d - crankshaft gear and idler gear assembly timing

dots aligned (dots punched on the gear)

e - Idler gear assembly and camshaft gear timing

dots aligned (dots punched on the gears)
d
f - timing reference dots punched on the gears
(facing outside)

96 Base Engine
 MR 700
Installation
Lubricate the idler gear assembly (bearing and idler a
gear bushing).
Install the idler gear bushing into the idler gear assem- b
bly. Verify that the bushing rotates freely.
Ensure that the timing reference dots are facing outsi-
de, not towards the block.
Install the idler gear assembly. Ensure the timing dots
on the adjacent gears (crankshaft and camshaft gear)
are properly aligned or that the reference marks car-
ried out previously are properly aligned.

Torque the 2 idler gear bushing screws

Idler gear bushing screws 32.4 Nm

x - idler gear bushing screws

a - Idler gear bushing
b - Idler gear
Specifications
c - timing reference dots punched on the gear
(facing outside) Inner diameter - Idler gear 53.465 - 53.480 mm
bushing
Inner diameter - Idler gear 53.500 - 53.519 mm
Clerance - Installation 0.02 - 0.054 mm
Wear Limit 0.2 mm

97 Base Engine
 MR 700
Injection pump Idler gear (between the camshaft and
injection pump gears)
Removal
Remove the idler gear fixing screw, at the bottom of c
the injection pump.

a - Idler gear (between the camshaft and injection b

pump gears) a
b - camshaft gear
c - injection pump gear
d - injection pump
e - idler gear fixing screw

Installation
Install the gear between the camshaft gear and injec-
tion pump gear.

This gear must not to be timed.

Thread the bolt with a new O-ring, grease it with Mo-

liykote 111 grease, and torque the bolt as follows: d

1st Step - tightening 35 Nm

Loosen the bolt with an angle of: 30° ÷ 90°
2nd Step - re-tightening 35 Nm
e
f - O-ring
g - screw

a
a
f

g g

98 Base Engine
 MR 700
Crankshaft gear
Removal a

NOTE: Replace the timing gear only if worn or

damaged.
Before removing the gear make the reference marks
on it and idler gear, so that its installation results easier
in order to mantain the gears timing.
Take the oil pump driving gear off.
Remove the oil pump and the idler gear if nedeed.
b
Install the Crankshaft Gear Puller onto the gear.
Tighten the four clamping screws securely.
Turn the Crankshaft Gear Puller screw and remove the
timing gear.

a - Crankshaft gear puller with clamping screws

b - crankshaft gear

Installation
Remark new gear making the same reference pre-
viously made on replaced gear and align the reference
marks on the gear with idler gear reference marks, or if
necessary, time the crankshaft gear with the idler gear
and camshaft gear (Refer to Timing gears with cylinder
number 1 piston is at compression stroke TDC.).

Clean the crankshaft gear and front crankshaft end.

Heat the gear at 70°C and insert it on crankshaft, by
aligning the keyway gear with the crankshaft spline,
against the crankshaft and let cool it for 10-15 secon-
ds.

99 Base Engine
 MR 700
Oil Pan, Oil Pickup, and Related Components
Oil Pan
Removal
1. Drain or pump the oil out of the engine. Refer to the Maintenance section.
2. Remove the oil drain hose from the oil pan
3. Remove the oil pan screws.
4. Cut through oil pan sealant on pan rails using a suitable tool.
5. Remove the oil pan.
Installation
6. Wipe off all excess oil and foreign matter from sealing surface on crankcase and oil
pan. Thoroughly de‑grease all sealing surfaces prior to application of sealant.
CAUTION
Excessive amounts of sealant could loosen and become lodged on the oil pickup strainer resulting in a
restricted oil flow. Do not apply excessive amounts of sealant.

7. Apply a continuous bead of sealant

Silicon type DOW CORNING 9071

around the oil pan flange on the inside of the bolt holes as shown.

a - Oil pan flange

b - Continuous bead of sealant

8. Install the oil pan.

9. Install oil pan screws finger tight. Torque the oil pan screws evenly, in a diagonal
pattern.

oil pan screws 12.7 Nm

a - Oil pan screws

b - Oil pan

100 Base Engine

 MR 700
Oil Pick-up Tube
Removal
1. Remove the oil pick‑up tube and strainer mounting
screws.
2. Remove the oil pickup tube and strainer. a - Oil pickup tube
3. Remove the old oil pickup tube O‑ring. b - Oil pickup tube screw
c - Oil strainer
d - Oil strainer and balance shaft assembly screw
(balance shaft assembly only installed on MR704)

a - O‑ring

b - Oil pick‑up tube

Installation
12.7 Nm
1. Install new oil pickup tube O‑ring.
2. Lubricate the oil pickup tube O‑ring.
3. Install the oil pick‑up tube and strainer 32.4 Nm
on the engine block and balance shaft assembly.
4. Install the oil pick‑up tube and strainer screws.
Torque the screws.

balance shaft fixing screw 32.4 Nm

Oil pick‑up tube fixing screw 12.7 Nm

101 Base Engine

 MR 700
Balance Shaft Assembly (only on mr704)
Removal
1. Before removing the balance shaft assembly position the engine at cylinder number 1 TDC. Refer to Establishing
TDC (Top Dead Center) Section or installation of balance shaft assembly .
2. Remove the oil pan.
3. Remove the bolts retaining the oil pickup and the balance shaft assembly to the cylinder block.

a - Oil pickup
b - Balance shaft assembly
c - Oil pickup bolt (1)
d - Balance shaft assembly bolt

4. Lift the balance shaft assembly from the cylinder block. Note the position of the oil
supply tubes and O‑ring seals between the engine block and balance shaft assembly.

a - Balance shaft assembly

b - Oil supply tube
c - O‑ring seal

Cleaning
1. Wash the balance shaft assembly in cleaning solvent.
2. Wash the oil supply tubes. Discard the O‑ring seals.
3. Put on safety glasses and dry the components with compressed air.
Inspection
NOTE: There are no individual replacement components for the balance shaft assembly. If worn, cracked,
or damaged, the complete balance shaft assembly must be replaced.

1. Inspect the gears on the crankshaft and balance shaft assembly for wear or damage.
2. Inspect the balance shaft assembly housing for cracks or damage.
3. Replace the crankshaft and balance shaft assembly if worn, cracked or damaged.

102 Base Engine

 MR 700
Installation
1. Remove the plug from the flywheel housing.

a - Plug a

2. While looking through the flywheel housing plug hole, slowly rotate the engine clockwise using the Crankshaft Bar-
ring Tool (only for MR704) until the Flywheel Pin Tool pin can be inserted into drilling 1 and 2 located in the flywheel.

a - Drilling 1
b - Drilling 2

3. Thread the Flywheel Pin Tool into the flywheel housing, until the pin enters into the drilling 1 and 2 located in the
flywheel. At this moment, cylinder number 1 piston is at TDC.

a - Flywheel Pin Tool a

4. Position a new O‑ring seal around the center of each of the 3 oil supply tubes.
5. Insert the 3 oil supply tubes with O‑ring seals into the cylinder block counterbores.

a - Oil supply tube

b - O‑ring

103 Base Engine

 MR 700
6. Thoroughly lubricate with engine oil the balance shaft assembly.

7. Do not align the counterweights as shown. In this view the counterweights are not properly aligned.

Improperly aligned counterweights

visible counterweights

a - Balance shaft assembly

b - Counterweights ‑ improperly align
b

8. Turn the balance shaft assembly gear and align the counterweights as shown.
In this view the counterweights are properly aligned.

Properly aligned counterweights

not visible counterweights

a - Balance shaft assembly gear

b - Counterweights ‑ properly aligned (NOT VISIBLE)

104 Base Engine

 MR 700
9. After aligning the Balance shaft assembly Counterweights, insert the special Counterweight Alignment Tool into ei-
ther the front or rear set of 2 holes in the balance shaft assembly housing, to keep the counterweights aligned during
installation.

a - Front and rear set of 2 holes

b - Counterweight Alignment Tool

10. Ensure the engine is set on cylinder number 1 TDC with the Flywheel Pin Tool installed. Mesh the balance shaft
assembly gear with the crankshaft gear and install the balance shaft assembly onto the cylinder block.

a - Balance shaft assembly

b - Counterweight Alignment Tool

11. Remove the Counterweight Alignment Tool.

12. Install a new O‑ring on the oil pickup tube.
13. Install the oil pickup.
14. Install the bolts retaining the balance shaft assembly and oil pickup to the cylinder block. Torque the oil pickup
bolt and the balance shaft assembly bolts in the numbered sequence shown.

a - Balance shaft assembly bolt

b - Oil pickup bolt
c - Torque sequence

Balance shaft assembly bolts 32.4 Nm

Oil pickup bolt 12.7 Nm

15. Install the oil pan. Refer to Oil Pan, Oil Pickup, And Related Components.

16. IMPORTANT: Remove the Flywheel Pin Tool.

105 Base Engine

 MR 700
Oil Pressure Relief Valve
The oil pressure relief valve (oil pressure regulator valve) is installed vertically in the underside of the crankcase.
Removal
1. Remove the oil pan.
2. Clean old gasket material from the area around the relief valve.
3. If removing only the relief valve and spring, or springs: proceed to “Disassembly”.
Observe all precautions and perform all steps except step 1.
4. If removing the complete pressure relief valve assembly:
a. Unscrew the oil pressure relief valve assembly from the crankcase using a suitable tool. The tool should engage the
2 slots opposite each other on the edge of the valve assembly.

NOTE: Locking compound (LOCTITE 510) is used during installation of the oil pressure relief valve assembly.
Area around the assembly may need to be heated to aid in removal.

a - Example of suitable tool

b - Valve assembly
c - Slots

b. Remove the pressure relief valve assembly from the crankcase.

c. Proceed to Disassembly.

Disassembly
1. Lock the pressure relief valve assembly in a soft‑jawed vise, if the complete assembly was removed.

CAUTION
The oil pressure relief valve cap and high pressure spring are retained by a snap‑ring. If released suddenly
the spring could propel the valve cap with enough force to cause injury. Use caution when removing or in-
stalling the snap‑ring. Wear safety glasses.
2. Push the cap in against the high pressure spring and hold. Remove snap‑ring.
3. Release spring pressure slowly.

a - Cap
b - Snap‑ring
c - Valve body

4. Remove cap, springs and relief valve from bore of the valve body.

NOTE: Some oil pressure relief valves have only one spring.

a - Cap
b - Spring (inner ‑ if dual spring equipped)
c - Spring (outer ‑ if dual spring equipped)
d - Relief valve

106 Base Engine

 MR 700
Assembly
1. Coat the inside of the oil pressure relief valve seat and body bore with lubricant engine oil.
Liberally coat the remaining components.

2. Assemble the valve, springs, and cap. Install parts into valve seat and body.

a - Relief valve
b - Spring (inner ‑ if dual spring equipped)
c - Spring (outer ‑ if dual spring equipped)
d - Cap
e - Snap‑ring
f - Valve seat and body

3. Push the cap in against the high pressure spring and hold.
4. Install the snap‑ring.
Installation
1. If installing only the oil pressure relief valve and spring, or springs: refer to “Assembly”.
Observe all precautions and perform all steps with the valve body still in the crankcase.

2. If installing the complete oil pressure relief valve assembly:

a. Apply sealant (Loctite 510) to the threads when replacing the complete oil pressure relief valve assembly.
Screw the complete assembly into the crankcase.

a - Oil pressure relief valve assembly

b - Threads

b. Using a suitable tool, torque the oil pressure relief valve assembly into the crankcase.

Oil pressure relief valve assembly 53.9 Nm

3. Install the oil pan and related hardware.

4. Check for leaks when you start the engine.

107 Base Engine

 MR 700
Camshaft
Testing ‑ Measuring Lobe Lift
IMPORTANT: Camshaft replacement will be necessary if lobe dimensions are less than 0.05 mm of the
values specified.

Lobe lift “C”

Intake 6.850 mm
Exhaust 7.303 mm

a - Total camshaft height

b - Lobe diameter
c - Lobe lift

Camshaft Height
Lobe diameter “B”
Exhaust 38.550 ‑ 38.650 mm
Intake 39.450 ‑ 39.550 mm

108 Base Engine

 MR 700
Removal
1. Before removing the camshaft make a reference mark on all 3 gears, crankshaft, idler and camshaft gear or ali-
gn the 3 gears as shown in the picture so that the timing dots (punched on each gear) are properly aligned, timed
(crankshaft to cylinder number 1 TDC of its compression stroke)
2. Remove the timing cover.

IMPORTANT: Place rocker arm assemblies, valve push rods and lifters in a rack for reassembly in their origi-
nal locations.

3. Remove the rocker arm assemblies and valve push rods.

4. Remove the valve roller lifters.
5. Remove the oil level dipstick.
6. Remove camshaft thrust plate mounting screws and lock washers.

Timing gears with cylinder number 1 piston is

e at compression stroke TDC.
a timing reference punched dots on the gears
coated by a dot of felt-tip pen, carried out
during assembling process.
a - Idler gear bushing
c c - Idler gear bushing screw
d - crankshaft gear and idler gear assembly timing
dots aligned (dots punched on the gear)
e - Idler gear assembly and camshaft gear timing
d dots aligned (dots punched on the gears)
f - timing reference dots punched on the gears
(facing outside)

a
c f

d
d

a
a - Camshaft gear
b - Camshaft thrust plate mounting
screw with lockwasher

109 Base Engine

 MR 700

8. Carefully withdraw the camshaft. Take care not to da-

mage the camshaft bearings.
9. Remove the idler gear assembly if complete engine
disassembly is required, or if idler
gear assembly is worn or damaged. Refer to Idler Gear
Section.
Inspection
GENERAL
1. Inspect the valve lifters and pushrods and replace if
necessary.
2. Inspect the camshaft bearings and replace if neces-
sary.
3. Check the camshaft and the gear for wear and replace
if necessary.
4. Check the idler gear assembly for wear and replace if
necessary.
Camshaft Journal Diameter
1. Use a micrometer to measure each camshaft journal
diameter in two directions (“X‑X”) and (“Y‑Y”). If the mea-
sured value is less than specified, the camshaft must be
replaced.

NOTE: Camshaft bearings are available in 0.250 mm

undersized.

Journal diameter
Front 53.495 ‑ 53.510 mm
Center 53.450 ‑ 53.470 mm
Rear 53.480 ‑ 53.500 mm

Wear limit 0.200 mm

110 Base Engine

 MR 700
Clearance between thrust plate and camshaft
1. Measure clearance between thrust plate and camshaft.

Thrust plate and camshaft clearance

Production 0.030‑0.095 mm
Wear limit 0.200 mm

IMPORTANT: The thrust plate is a press fit on shaft. If removal is needed, upon reassembly the camshaft
gear must be heated in an oven to 180‑200 degrees C (360‑390 degrees F) for 10 minutes and pressed on
the shaft. After installing the proper thrust plate and positioning the key, press the gear until it is tight
against the shoulder.
2. If the measured value exceeds specification, remove and inspect the thrust plate
thickness at four opposite points. Replace the plate if assembly clearance is less than
specified at any point.

a - Camshaft thrust plate thickness

b - Thickness dimension at four opposite points

Camshaft thrust plate thickness 3.95 ‑ 4.05 mm

Installation
1. Install the idler gear, if previously removed. Refer to Idler
Gear.
2. Lubricate the camshaft lobes with a mixture of lubricants.
3. Lubricate the camshaft bearings.
4. Install the camshaft. Be careful not to damage the bearings.
5. Align the timing marks on camshaft gear and idler gear and
crankshaft gear as shown.

a - Crankshaft and idler gear timing marks aligned

b - Idler gear assembly and camshaft timing marks aligned

6. Install the thrust plate mounting screws using the

lockwashers. Torque the screws.

27.5 Nm

111 Base Engine

 MR 700
Camshaft Bearings
Inspection
1. Remove the camshaft.
2. Inspect the camshaft bearings. Replace the bearings if they are worn or damaged.
3. Measure the inner diameter of the camshaft bearings and compare to the camshaft
journal dimensions. Calculate the bearing clearance.

Camshaft Front Bushing

Bushing inner diameter (Bushing bored into the block) 53.59 - 53.62 mm
Clearance (bushing - journal) 0.08 - 0.125 mm
Camshaft Rear and Center Bearing
Bearing inner diameter (bearings installed in the block) 53.550 - 53.600 mm
Clearance (Center Bearing) 0.08 - 0.15 mm
Clearance (Rear Bearing) 0.05 - 0.12 mm
First oversized Bushing 0.25 mm

Removal
NOTE: Camshaft bearings can only be removed and installed with crankshaft removed.
1. Using the Front Main Bearing and Camshaft Bearing Puller Tool (refer to Special Tool section) with appropriate
hardware, remove the camshaft bearings into the receiver end of the tool (not shown).

a
a - Cylinder block
b - Front Main Bearing and Camshaft Bearing Puller Tool
c - Camshaft bearing bore
d - Oil supply hole
c

Installation
IMPORTANT: In service when replacing the front camshaft bushing it must be bored once that is
installed into its cranckcase seat. Install the front bushing by aligning the lubrication oil hole in the block
with the bushing hole.

1. Clean the camshaft bearing bores in the cylinder block with solvent.
2. Put on safety glasses and blow out the bearing bores with compressed air. Ensure that the drilled oil passages
are clean.
3. Apply Loctite 601 on outer surface of new camshaft bearings.
4. Align the camshaft bearing oil supply holes with the drilled oil passages in the cylinder block.
5. Using the Front Main Bearing and Camshaft Bearing Puller Tool with appropriate hardware, install the new
camshaft bearings.
6. Check the position of the oil hole in each bearing and drilling in block to ensure that the bearings are positioned
correctly.
7. Recheck the bearing inner dimensions to verify proper installation.
8. Install the camshaft. Refer to Camshaft.
9. Install all other components removed in the repair process.
10. Check for leaks when you start the engine.

112 Base Engine

 MR 700
Valve Lifters
CAUTION
Camshafts and valve lifters develop matched wear patterns during engine operation. Mismatching worn
camshafts and valve lifters or using worn components with new components can cause rapid and excessi-
ve wear resulting in engine component failure. Always use new camshafts and valve lifters whenever any
of the components are replaced.
The hydraulic roller valve lifters are held in position and prevented from rotation by special retainers. There is one
retainer for each cylinder head. Care should be exercised when installing the retainers to ensure that the flat por-
tions of the lifters are properly positioned in the retainers.

a - flat portion c
b - hidraulic roller valve
c - retainer

c a

Removal
1. Remove the valve covers. a - Push rod
IMPORTANT: Place rocker arm assemblies, pushro- b - Retainer
ds and valve lifters in a rack for reassembly in their c - Valve lifter
original locations. d - Roller
2. Remove the rocker arm assemblies and the valve
pushrods. Keep parts in matched sets.
IMPORTANT: Lifters must be reassembled in the
exact same position on the camshaft lobes so that
the roller will operate in the same direction on the
same lobe, if reused.
3. Make matching marks on all retainers and valve
lifters showing the location and orientation in the bores.
4. Lift the retainer piece away from around the top of
the valve lifters. Do not disturb the valve lifters at this
time.
5. Insert the Valve Lifter Tool (refert to Special Tools
section) firmly into the valve lifter. Press downward on
the internal spring until the top of the tool is lower than
the stop. Turn the tool 90° and remove the valve lifter.
6. Remove the remaining valve lifters while keeping
them in order for reassembly.

113 Base Engine

 MR 700
Inspection
1. Inspect the valve push rod seat. If the valve push rod seat is scuffed or worn,
inspect
the valve push rod.
2. Inspect the outer valve lifter body wall. If wall is scuffed or worn, inspect
engine block a
valve lifter bore.
3. Inspect the roller of the valve lifter. If the roller is scuffed or worn, inspect
camshaft lobe.
4. Measure the outer diameter of the valve lifter. If the measured value is less
than
specified, replace the valve lifter.

Valve lifter
a - Outer diameter (new valve lifter) 22.195 ‑ 22.212 mm

5. Inspect all parts carefully. If any parts are

damaged or worn, the entire valve lifter assembly
must be replaced.

Installation
a - Drain hole
CAUTION b - Valve Lifter Tool
Camshafts and valve lifters develop matched
wear patterns during engine operation. Misma-
tching worn camshafts and valve lifters or using
worn components with new components can cau-
se rapid and excessive wear resulting in engine
component failure. Always use new camshafts
and valve lifters whenever any of the components
are replaced.

1. Drain all of the residual oil in the valve lifter out of

the drain hole in the valve lifter, by
compressing the valve lifter, using the Valve Lifter
Tool, see Removal. (refer to Special Tool section ).
2. Before installing the valve lifters, coat the entire
valve lifter with engine oil.
3. Pour a grease over the valve lifters and camshaft
lobes, if all are new.
4. Install the valve lifters in the bores in order of re-
moval, using the Valve Lifter Tool. Align the matching
marks made prior to disassembly. Ensure the valve
lifter drain hole is a - Valve lifter
pointing towards the crankshaft. b - Retainer
c - Valve push rod
d - Flat portion
5. Install the retainers around the square top of the
lifters to prevent them from rotating. Ensure that the
flat portions of the valve lifters are properly positio-
ned in the retainers.

6. Lubricate and install the valve push rods.

Ensure the valve push rods seat in the valve
lifter sockets.

114 Base Engine

 MR 700
Valve Push Rods
Removal
1. Remove the valve covers.
IMPORTANT: Organize rocker arm assemblies and valve push rods in a rack for reassembly in their original
locations.
2. Remove the rocker arm assemblies.
3. Lift the valve push rods from their seat in the valve lifter.

a - Valve push rod

b - Valve lifter seat (not visible here)

Cleaning
1. Clean the rocker arm assemblies and push rods.
2. Clean the valve push rod oil passages.
3. Put on safety glasses and dry the components with compressed air.
Inspection
1. Inspect all contact surfaces for excessive wear or scoring.
2. Ensure that the valve push rod oil passage is not restricted.
3. Roll the valve push rod on a flat surface and inspect shafts for bends.
4. Replace all damaged parts.
Installation
1. Lubricate the outer surfaces and ends of valve push rods.
2. Install the valve push rods in their original locations. Ensure that the
push rods seat in
the valve lifter seat.
3. Install the rocker arms.
4. Install the valve covers and related components.
5. Check for leaks when you start the engine.

115 Base Engine

 MR 700
Connecting Rod - fractured type
Preparation
1. Remove the oil pan.
2. Remove the oil pickup tube assembly.
3. Remove the balance shaft assembly, only for MR704. IMPORTANT: before attempting to remove the counter
balance shaft refer to proper section “ BALANCE SHAFT ASSEMBLY”.
4. Turn crankshaft to gain access to connecting rod screws.
5. One cylinder at a time, remove rod caps and inspect bearings. Make a reference mark on con rod shaft and con
rod cap for each cylinder in order to reassemble proper parts in their original position

IMPORTANT: Each connecting rod assembly must

be reassembled in the same original location.
Mark or identify each connecting rod assembly to
ensure placement in the original cylinder number
location during reassembly. Retain the rod cap and
bearings with the connecting rod and piston as-
sembly. Do not mix the components.
Remove the connecting rod bearings. Keep the bea-
rings, with the original connecting rod and connec-
ting rod cap, together as a matched set.

IMPORTANT: The connecting rod can damage the

crankshaft journal, the cylinder bore, and piston
cooling jet. Ensure no components are damaged
during connecting rod removal. x x - piston cooling jet

While protecting the crankshaft journal, cylinder bore,

and piston cooling jets from damage, push the piston
and connecting rod out of the cylinder.

IMPORTANT: The mating surfaces of the connecting

rods and the connecting rod bearing caps form an
individual fit and as a result must not be interchan-
ged or damaged under any circumstances. To avoid
damage, do not lay connecting rods or connecting
rod bearing caps on their mating surfaces.

116 Base Engine

 MR 700
Disassembly
1. Clamp the connecting rod in a soft‑-jawed vise.
2. Use the Piston Ring Expander Tool to remove the
first and second compression rings and the oil control
ring with spring.
3. Remove the snap rings retaining the piston pin.
Push the piston pin out of the connecting rod and
piston.
4. Note the orientation of the piston combustion cham-
ber recess in relation to the casting node, paint mark
on con rod shaft, and the connecting rod number.

FRACTURED CONNECTING RODS a - Combustion chamber recess orientation

b - Connecting rod number
a c - Casting Node
d - Paint mark (for weight classification)
e - matching marks on the connecting rod cap
and connecting rod shaft

FRACTURE

d
b c

b
e c

117 Base Engine

 MR 700
Inspection (fractured Connecting Rod)

IMPORTANT: Measurements should be taken when

components are at room temperature. 978 992.9 1007.9 1022.9
Coloured paint marks on the connecting rods
shaft identify the weight classification. Ensure all
connecting rods have the same color paint mark. 992.9 1007.9 1022.9 1038
Replace connecting rods that are not the same
weight classification and do not have the same co-
lor paint mark. If only one connecting is replaced,
replace however all connecting rods.

Check for twisted or bent connecting rods.

Peform Magnaflux inspection of all rods and caps if
any doubts exixst.

Torque temporarirly the bolts at 88 Nm (Refer to

Connecting Rod Assembly for the correct tighte-
ning procedure and torque value)

Parallelism deviation between 0.15 mm

piston pin end and bearing
end
x - Lenght 158.975 - 159.025 x
mm

Use an inside dial indicator to measure the connec-

ting rod crankshaft journal bore inside diameter, out of
round and taper.

a - Connecting rod crankshaft journal bore

Inner diameter (without 57.563 ‑ 57.582 mm

bearings)
Maximum allowable 0.02 mm
wear or taper

IMPORTANT: Refer to Crankshaft Section to

determine the Connecting Rod Crankshaft Jour-
nal Outer Diameter and Connecting Rod Bearing
Clearance.

Inspect for damage to the bearing cap and bolt threa-

ds.
Measure connecting rod bushing inner diameter and
piston pin outer diameter.
Replace the connecting rod bushing if clearance
exceeds specification.

a - Rod bushing inner diameter

b - Piston pin outer diameter

Bushing inner diameter 32.035 - 32.050 mm

Piston pin outer dia- 31.990 - 31.996 mm
meter
Piston pin bore 36 - 36.025 mm
Maximum allowable 0.01 mm
wear or taper

118 Base Engine

 MR 700
Connecting Rod Bearing Clearance

Crankshaft Connecting Rod Journal

(with new crankshaft)
Outside diameter 53.940 - 53.955 mm
Clearance between jour- 0.012 - 0.066 mm
nal and con rod
Maximum wear 0.1 mm

Se il diametro dei perni eccede il limite di usura, rettificare i perni e installare delle bronzine maggiorate (-0.25mm).

IMPORTANT:
After a seizure, overheating or grinding, crankshaft must be Magnafluxed to verify no surface cracks are
present.
After grinding perform “SURSULF” treatment (hardness HV 587 with load of 500 gr. corresponding to HRc
53)
It is forbidden the crankshaft straightening after SURSULF treatment.
No material may be removed, either by hand or machine grinding, from thrust faces of crankshaft. Replace
crankshaft if machined surfaces on front and rear ends or threaded areas of crankshaft ends are out-of-
round, worn or damaged.

119 Base Engine

 MR 700
Connecting Rod And Piston Pin
Inspection
IMPORTANT: Measurements should be taken when components are at room temperature.
1. Green, blue, white, or yellow paint marks on the connecting rods identify the weight classification. Ensure all
connecting rods have the same color paint mark. Replace connecting rods that are not the same weight classification
and do not have the same color paint mark.

a - Paint
mark area
2. Check for twisted or bent connecting rods.

Peform Magnaflux inspection of all rods and caps if any doubts exixst.

Parallelism deviation between piston pin end and bearing end a

0.15 mm

b
b - Lenght
158.975 - 159.025 mm

3. Inspect for nicks or cracks.

4. Inspect for damage to the bearing cap and bolt threads.
5. Replace damaged connecting rods.
6. Measure connecting rod bushing inner diameter and piston pin outer diameter.
7. Replace the connecting rod bushing if clearance exceeds specification.

Bushing inner diameter 32.005 ‑ 32.035 mm a - Rod bushing inner diameter

Piston pin outer diameter 31.990‑ 31.996 mm b - Piston pin outer diameter

Clearance
Minimum 0.009 - 0.045 mm
Limit 0.060 mm

8. Use an inside dial indicator to measure the connecting rod crankshaft journal bore inside diameter, out of round
and taper.

a - Connecting rod crankshaft journal bore

Connecting Rod Crankshaft Journal Bore

Inner diameter 57.563 ‑ 57.582 mm (without bearings fitted)
Maximum allowable wear or taper 0.01 mm

9. Replace the connecting rod if measurements exceed specifications.

120 Base Engine

 MR 700
Pistons And Rings
Inspection
Inspect the piston for cracked ring lands, skirts or pin bosses, wavy worn ring lands, scuffed or damaged skirts or
eroded areas at top of piston. Replace pistons that are damaged or show signs of excessive wear.

NOTE: Do not mistake tapered or different ring design characteristics for unusual wear patterns. The first
(upper) compression ring is trapezoidal (tapered) in design. That is, it has a taper on both upper and lower
surfaces. Correspondingly, the first compression ring groove is tapered on top and bottom. The second
(scraper) compression ring and the oil control ring are more typical in design.

a - First compression ring

IMPORTANT: Always install rings

with ring markings
(“MTOP”, “PIP” or a dot) facing
the top of piston.

b - Second compression ring

IMPORTANT: Always install rings

with ring markings
(“MTOP”, “PIP” or a dot) facing
the top of piston.

c - Oil control ring (third)

IMPORTANT: Always install rings

with ring markings
(“MTOP”, “PIP” or a dot) facing
the top of piston.

121 Base Engine

 MR 700
Measure the piston outer diameter 12.5 mm from the bottom and 90 degrees to the piston pin .
Replace the piston if measurement is less than specified.

a - Outer diameter measurement point

Outer diameter 93.908 ‑ 93.922 mm

12.5 mm

Measure the thickness of the rings. Replace piston rings as a set if out of
specification.

Piston Ring Thickness (Production)

2.568 ‑2.597 mm
a- First compression (tapered ‑ outer edge) 2.568 ‑2.597 mm

b - Second compression 1.970 ‑ 1.990 mm

c - Oil control 2.970 ‑ 2.995 mm

1st ring

1.5 mm

2nd ring

Oil control

122 Base Engine

 MR 700

Measure the piston ring groove width.

Piston Ring Groove Width (Production)

a - First compression (tapered ‑ outer edge) 2.695 ± 0.015 mm
b - Second compression 2.06 ‑ 2.08 mm
c - Oil control 3.03 ‑ 3.05 mm

Using a feeler gauge, measure the clearance between the serviceable, or new, second compression and oil control
piston rings and ring groove at several points around the piston. Replace the piston if the measured values exceed
the specification.

Piston Ring Groove - Clearance

First compression Not applicable (tapered)
Second compression 0.070 - 0.11 mm
Oil control 0.035 - 0.08 mm

123 Base Engine

 MR 700

Check the piston ring end gap:

a. Position the selected ring in the cylinder bore.

NOTE: The ring must be level (at right angles to the bore surface) for measurement. Push the ring 6 mm
into the bore with the crown of the piston.

b. Measure the gap between the ends of the ring with a feeler gauge as shown.

Piston Ring End Gap

First compression 0.5 mm maximum
Second compression 0.5 mm maximum
Oil control 0.6 mm maximum

c. If the gap between the ends of the piston ring is less than
specified, remove the
ring and try to fit another. Check the cylinder bore if the specifi-
cation cannot be
met with new rings. Refer to Cylinder Liners.
d. Fit each ring to the cylinder in which it is going to be instal-
led.

Cleaning
IMPORTANT: Do not wire brush on any part of a piston.
1. Wash the components in cleaning solvent.
2. Clean varnish from piston skirts and pins with a suitable cleaning solvent.
3. Clean the ring grooves.
4. Clean the piston oil lubrication holes and slots.
5. Put on safety glasses and dry the components with compressed air.

a - First compression ring groove ‑ (tapered)

b - Second compression ring groove
c - Oil control (lower) ring
d - Oil ring holes

Installation
1. Before installing pistons into cylinders, ring gaps must be positioned as follows:

a. First compression ring (trapezoidal) gap, 20° to the right of combustion chamber recess.
b. Second compression ring gap, centered on the combustion chamber recess.
c. Oil control ring gap, 20° to the left of combustion chamber recess.

a - First compression ring (trapezoidal) gap

b - Second compression ring gap
c - Oil control ring gap

124 Base Engine

 MR 700
Piston and Connecting Rod
Assembly
Assemble the piston to the connecting rod with the combustion chamber recess, the paint mark on con-rod, the
casting node, and the con-rod / con-rod cap numbers, all components oriented as noted during disassembly.
Assemble the piston to the connecting rod with the combustion chamber recess orientated towards intake &
exhaust side and the connecting rod with the casting node positioned as shown in the picture.
Insert the piston pin and install the snap ring.

Piston and connecting rod assembly orientation

FRACTURED CONNECTING RODS a - Combustion chamber recess orientation

b - Connecting rod number
a c - Casting Node
d - Paint mark (for weight classification)
e - matching marks on the connecting rod cap
and connecting rod shaft

FRACTURE

d
b c

b
e c

Lubricate the cylinder bores and piston rings with engine oil.
Each piston and connecting rod assembly must be installed in the cylinder from which it was removed.
Turn the crankshaft to position the crank pin away from the cylinder so the connecting rod will not damage it du-
ring installation.
Using a ring compressor, install the piston by tapping on the piston‑top with a suitable device.

125 Base Engine

 MR 700
IMPORTANT: The connecting rod can damage the crankshaft journal, the cylinder bore, and the piston
cooling jet. Ensure no components are damaged during connecting rod installation.
Align the connecting rod with the crankshaft journal and tap on the piston top until the connecting rod bearing
contacts the journal. Do not scratch or nick the crankshaft journal.
Ensure that the rod cap numbers point toward the camshaft/injection side.
The casting node on the rod cap must point to the rear/flywheel side of the engine.

Tightening Procedure
IMPORTANT: New connecting rod screw threads do not require lubrication. An anti‑friction product has
been applied by the factory.

Usually replace the bolts.

If bolts are reused, verify that the screw threads are not stretched, and the top or bottom of the bolt head
does not show damage. When reusing a connecting rod screw, lubricate the threads and bottom of the
screw head with engine oil.

Install the connecting rod cap.

Install and torque the connecting rod screws.

Connecting rod screw Nm

First pass 10
Second pass 30
Final pass (Angle Torque) + 40°

Verify that proper torque was achieved by testing the torque setting of each connecting rod screw to be at least as
specified in the following table. Do not apply more than this specified amount during the validation test.

Connecting rod screw validation test torque 88 Nm

Ensure that the connecting rod assembly and the crankshaft journal are not binding
and that there is proper side‑to‑side movement.
Install the remaining piston and connecting rod assemblies.
Measure for head gasket thickness.
Refer to section “Cylinder Head Gasket - Thickness Selection”.

Connecting rod bolt lenght

a 9.75 - 10 mm
b 47.4 - 48.6 mm

a b

126 Base Engine

 MR 700
Piston Cooling Jets (Oil Spray Nozzles)
Removal
1. Remove the piston cooling jet assembly from near the cylinder bore.

a d

b
c

a - Cooling jet assembly

b - Nozzle
c - Plate
d - Bolt

2. Remove and discard the O‑ring seal on the piston cooling jet.

Inspection
1. Ensure the check valve ball moves freely against the spring in the bore.

a - Spring
b - Check valve ball

2. Check for a cracked, bent or damaged tube or nozzle.

a - Tube
b - Nozzle

3. Replace if necessary.

127 Base Engine

 MR 700
Installation
1. Install a new O‑ring in the piston cooling jet groove.

a - O‑ring
b - Piston cooling jet groove

2. Lubricate with engine oil the piston cooling jet O‑ring.

3. Insert the piston cooling jet assembly into the cylinder block.
4. Ensure that the piston cooling jet assembly is correctly seated.
5. Position the tube and nozzle as shown.
6. Apply sealant to the piston cooling jet assembly screw threads.
7. Install and torque the piston cooling jet assembly screw.

Piston cooling jet assembly screw 12.7 Nm

a - Piston cooling jet assembly

b - Piston cooling jet assembly screw
c - Tube and nozzle position

128 Base Engine

 MR 700
Flywheel housing, Flywheel and Rear Oil Seal
Removal
Remove the starter.
Install the special tool “flywheel holder tool” in place of starter motor. (Refer to “Special “Tools” Section)
Remove the flange screws retaining the engine harness connector bracket.
Remove the two turbocharger support bracket screws.

a - Engine harness connector bracket

b - Engine harness connector bracket screws
c - Turbocharger support bracket
d - Turbocharger support bracket screws

a d c
b

Remove 2 opposing flywheel bolts and install the 2 Flywheel Assembly Guide Pins to assist in removing the
flywheel. (Refer to “Special “Tools” Section for guide pins)
Remove the remaining flywheel bolts.
Remove the flywheel from the crankshaft and off of the Flywheel Assembly Guide Pins.

a - Flywheel bolts
b - Flywheel

Remove the flywheel housing fixing bolts .

Using a rubber mallet, tap evenly around the housing.
The flywheel housing togheter with rear main bearing
carrier will be pulled from the cylinder block.

a - flywheel housing fixing bolts

b - Flywheel housing

129 Base Engine

 MR 700

IMPORTANT: To remove the rear main bearing

carrier, refer to section “Rear Main Carrier and
bearing”.
Otherwise remove the no. 6 flange nuts fixing rear
main beraing carrier from flywheel housing.

Using a suitable device, carefully pry out the old rear oil seal. Do
not damage the rear main bearing carrier or thrust washers. Refer
to Crankshaf End Play or Rear Main Bearing Carrier Sections
if for any reason it is necessary to repair or replace the thrust
washers or rear main bearing carrier.

a - Rear oil seal

b - Rear main bearing carrier
c - Thrust washers

130 Base Engine

 MR 700
Inspection
Inspect the flywheel housing for cracks or damage.
Inspect the conditions of thrust washers installed on rear main beraing
carrier.

Verify the condition of thrust plate on rear side of flywheel.

Check the flywheel ring gear for worn and missing teeth (Refer to
flywheel ring gear).
Repair or replace worn or damaged components.

a. thrust washers
b. thrust plate

131 Base Engine

 MR 700
Installation
IMPORTANT: The rear seal is made of special compounds; do not touch or handle the lips of the seal. Do
not attempt to install rear main seal using a hammer or mallet. Damage to the seal or rear main bearing
carrier could result.
Do not touch or handle the lips of the seal. Install the new rear oil seal in the bearing carrier using the Flywheel
Seal Installer. The seal will stop when seated.
Ensure that there are no scratches, nicks, cracks, or seizure marks on the flywheel mating surface. Only minor
scratches, nicks, or seizure marks can be removed.
Replace the flywheel if damaged.

NOTE: Refer to Crankshaft End Play (Axial Clearance) to set the crankshaft end play if the flywheel is
being replaced.
IMPORTANT: Whenever the flywheel and flywheel housing are removed, replace the O‑rings.

Install a new O‑ring into the groove of the flywheel to seal the crankshaft. Install a new O‑ring into the groove of
the flywheel housing. Install a new O‑ring into the groove of the rear main bearing carrier.
A small amount of grease, such as Molykote, may be used to hold the O‑ring in position during installation.

a. O-rings to be replaced
a - O‑ring
b - Groove
c - Flywheel housing

132 Base Engine

 MR 700

IMPORTANT: Whenever the flywheel and flywheel A O-ring

housing are removed, replace all installed O‑-rings.

Ensure that thrust washers are not damaged or worn

and are properly seated into the rear main bearing
carrier. Replace them if any doubt exists (Refer to Rear
Main Bearing Carrier).
Apply silicon Dow Corning 7091 on flywheel housing
groove where the O-ring seats. PHOTO A.
Install a new O‑-ring into the groove of the flywheel
housing.
Apply a bead of sealant (thickness 2 mm) around the
O-ring as shown in the photo B.

Install a new O-ring into the groove around the rear

main bearing carrier.
Apply a bead of sealant (thickness 2 mm) around the B O-ring
O-ring as shown in the photo C.

Lubricate the rear crankshaft journal and rear main

bearing.
Install the flywheel housing.
Install and torque the flywheel housing bolts evenly in a
diagonal pattern.

flywheel housing bolts 68.6 Nm

cordone di silicone
- bead of silicon

133 Base Engine

 MR 700
Install the flywheel housing with rear main bearing carrier aligning the rolled
pin present on the carrier.
Install and torque the flywheel housing bolts.
Install the 6 rear main bearing carrier flange nuts if the rear main carrier was
removed from flywheel housing. Torque the flange nuts evenly in a diagonal
pattern.

Rear main bearing carrier fixing flange nuts 24.5 Nm

Flange Nuts (b) 24.5 Nm

a - Flywheel housing
b - Rear main bearing carrier flange nuts
c - Flywheel housing bolts

Flywheel housing bolts

Bolts (c) 68.6 Nm 68.6 Nm

Install the 2 Flywheel Assembly Guide Pins opposite to each other to assist in installing the flywheel.
Align the flywheel with the rolled pin (if installed on crankshaft) and install the flywheel with O‑ring onto the
crankshaft using the Flywheel Assembly Guide Pins for alignment. Install the flywheel bolts hand tight.

IMPORTANT: Flywheel bolts may be installed as many as three times, and then must be replaced with new
bolts. Replace if any doubt exists or the thread is stretched.

NOTE: New bolts are already lubricated with an anti‑seizing lubricant from the manufacturer, and do not
require additional lubrication.
If the bolts are reusable, lubricate the thread bolts, underside head of the bolts with engine oil.

Remove the Flywheel Assembly Guide Pins and install the 2 opposing flywheel bolts hand tight.
Torque the flywheel bolts evenly, in a crosswise pattern as specified.
Remove the Flywheel Holder installed in palce of starter motore.

Flywheel bolt
First pass 50 Nm
Second pass: loosen one bolt at a time and torque to: 20 Nm + 75° angular torque

Flywheel bolt specifications

134 Base Engine

 MR 700
Flywheel Ring Gear
1. Heat the ring gear with a torch on the engine side of the ring gear.
2. Once heated, knock the ring gear off the flywheel. Do not strike the flywheel when
removing the ring gear.

CAUTION
Some components are made of steel that has been heat treated to increase hardness. Applying excessive
heat to the hardened steel will alter the hardness and make the steel weaker. Do not heat any portion of
these hardened steel components, such as a flywheel ring gear, to a temperature higher than 200 °C.

3. Heat the new ring gear for 20 minutes in an oven preheated to 190 - 210° C , or heat
evenly until the gear expands enough to slip onto the flywheel. Do not overheat the ring
gear.
IMPORTANT: The ring gear must be installed so the bevel on the teeth is toward the crankshaft side of the
flywheel.
4. Install the ring gear. Ensure that the ring gear is seated properly against the flywheel
shoulder. The ring gear can move away from the flywheel shoulder no more than 0.50 mm.

Flywheel Runout
1. Attach a dial indicator to the engine block.
2. Record the measurements around outer edge of the flywheel.
3. If the flywheel runout exceeds the specified limit, the flywheel must be replaced.

a - Dial indicator

Runout 0.10 mm

135 Base Engine

 MR 700
Crankshaft End Play (Axial Clearance) - THRUST WASHERS
NOTE: Install the flywheel. Ensure crankshaft runout is within specifications before setting crankshaft
end play (axial clearance).
1. Attach the Dial Indicator to the cylinder block to check the installed crankshaft end play (axial clearance). Mea-
surement can be made from the crankshaft counter weight or outer flywheel surface.
2. Firmly force the crankshaft rearward. Record the measurement.
3. Firmly force the crankshaft forward. Record the measurement.
4. Subtract the measurements to determine the crankshaft end play (axial clearance).

End play (axial clearance) 0.080 ‑ 0.280 mm

5. If the end play (axial clearance) is incorrect, calculate the necessary thickness of the
thrust washers needed.
6. Install different thickness thrust washers in rear main carrier and recheck the end play (axial clearance).

Thrust Washer - Thickness

Standard 2.310 ‑ 2.360 mm
First oversized 2.410 ‑ 2.460 mm
Second oversized 2.510 ‑ 2.560 mm

7. Repeat the steps until the proper end play (axial clearance) is obtained.

Removal
Using a suitable device, carefully pry out the washer
halves. Do not damage the rear main bearing carrier or
rear oil seal.
a
Installation b
Ensure that the washer halves are properly seated
c d
in the rear main carrier and that the oil passages are
towards outside as shown in the picture.
Align the tab of a washer half with the notch in the rear
main bearing carrier
Press the washer halves simultaneously into the car-
rier.

a - tab
b / c - washer halves
d - oil passages (grooves)

136 Base Engine

 MR 700
Rear main bearing carrier
Removal

Remove the flywheel and flywheel housing. (Refer to proper section).

Disassemble the rear main bearing carrier from the flywheel housing by removing the flange nuts

Installation
Check the thrust washers condition and that they are properly seated into the rear main bearing carrier.
Replace them if any doubt exists.
Install a new O‑ring around the groove of the carrier. and apply silicon (Refer to Flywheel Housing).
Align the flywheel housing with the rolled pin installed in the rear carrier.
Install the flange nut and torque them.
Rear Main Bearing Carrier fixing flange nut 24.5 Nm

a - Rear main bearing carrier flange nuts

b- Rolled pin install in the rear carrier
a b

137 Base Engine

 MR 700
REAR MAIN BEARING
Removal
Using a suitable mandrel, press the rear main bearing a - lubricating oil passage
out of the carrier.
Installation
Align the hole of a new rear main bearing with the oil
passage in the rear main bearing carrier and press the
new bearing into the carrier.
Specifications
a
Rear main bearing inner 80.045 - 80.07
diameter (installed into the mm
carrier)
First oversized bearing 0.25 mm

IMPORTANT: Refer to Crankshaft Section to

determine the Rear Main Bearing Crankshaft Jour-
nal Outside Diameter and Rear Main Bearing
Clearance.

Cps target wheel bolt

removal
Remove the flywheel, flywheel housing with rear main bea-
ring carrier. a
Slacken and remove no. 3 bolts retaining the CPS
(Crankshaft Position Sensor) target wheel.
a - CPS (Crankshaft Position Sensor) target wheel bolts

installation
Usually replace the old bolts.
Replace the old bolts and apply loctite 510 on the bolt
thread.
Install the bolts and torque them.

CPS (Crankshaft Position 14.7 Nm

Sensor) target wheel bolts

138 Base Engine

 MR 700
Crankshaft
Removal
IMPORTANT: Before removing the crankshaft make a reference mark on all 3 gears, crankshaft, idler and camshaft
gear or align the 3 gears as shown in the picture so that the timing dots (punched on each gear) are properly aligned,
timed.
IMPORTANT: Before removing the crankshaft from the block, number or mark the bearing carriers according
to the journal upon which they are fitted. Also make matching marks on both bearing carrier halves for correct reas-
sembly.
IMPORTANT: When removing the crankshaft do not damage the piston cooling jet. Ensure to remove
the oil piston cooling jet. (Refer to Oil Piston cooling Jets Section)

Timing gears with cylinder number 1 piston is

e at compression stroke TDC.
a timing reference punched dots on the gears
coated by a dot of felt-tip pen, carried out
during assembling process.

a
c

a - Idler gear bushing

b - Idler gear assembly

f c - Idler gear bushing screw

e d - crankshaft gear and idler gear assembly timing

dots aligned (dots punched on the gear)

e - Idler gear assembly and camshaft gear timing

dots aligned (dots punched on the gears)
d
f - timing reference dots punched on the gears
(facing outside)

139 Base Engine

 MR 700
Remove the main bearing locating screws and special
locating screws that hold the main bearing carriers in
cylinder block.

a - Locating screw ‑ standard

b - Special locating screw
c - Oil supply hose ‑ turbocharger
d - Adapter on special locating screw
e - Oil supply pipe ‑ rocker arms

IMPORTANT: Before removing the crankshaft from the

block, number or mark the bearing carriers according z
to the journal upon which they are fitted. Also make
matching marks on both bearing carrier halves for
correct reassembly.

IMPORTANT: When removing the crankshaft do not

damage the piston cooling jet. Ensure to remove x
the oil piston cooling jet. (Refer to Oil Piston cooling
Jets Section) y
x= matching marks on both bearing carrier halves
y= matching marks on all main bearing carriers
(between carrier and block)
z= number all main center bearing carrier according
to the journal upon which they are fitted

Withdraw the crankshaft so that the main bearing

carries can be disassembled.
Disassemble all main bearing carriers.
Take crankshaft off from the cylinder block. w

w= main bearing carriers removed proper block bore

140 Base Engine

 MR 700
Install the Crankshaft Installer Tool over the crankshaft gear to protect front main bearing.

a - Crankshaft Installer Tool

b - Timing gear

Inspection
1. Inspect crankshaft for deep grooves, scratches, pitted surfaces or uneven wear.
2. Inspect crankshaft rear oil seal surface for scoring or damage.
3. Inspect crankshaft oil passages for restrictions.
4. Inspect the crankshaft threaded bolt holes for damage.
5. Inspect the crankshaft balancer keyway for damage (only for MR704).
6. After a seizure, overheating or grinding, crankshaft must be Magnafluxed to verify no
surface cracks are present.

After grinding perform “SURSULF” treatment (hardness HV 587 with load of 500 gr. corresponding to HRc
53)

IMPORTANT: It is forbidden the crankshaft straightening after SURSULF treatment. No material may be re-
moved, either by hand or machine grinding, from
thrust faces of crankshaft. Replace crankshaft if machined surfaces on front and rear ends or threaded areas
of crankshaft ends are out-of-round, worn or damaged.

Measure the journals of the crankshaft to determine if replacement or grinding is

necessary. Refer to Connecting Rod Journal Diameter and Crankshaft Journal ‑ Main Bearings.
Crankshaft Journals and Main Bearings (Front, Center, Rear)
Specifications
Lenght (4 cylinders) 595.1 mm
Lenght (6 cylinders) 819.1 mm

Crankshaft Front Main Bearing Journal Outer diameter 62.985 - 63.005 mm

First Oversized Bearing 0.25 mm

Center Main Bearing Crankshaft Journal Outer diameter 62.980 - 62.995 mm

First Oversized Bearing 0.25 mm

Rear Main Bearing Crankshaft Journal Outer diameter 79.985 - 80 mm

First Oversized Bearing 0.25 mm

Crankshaft Connecting Rod Journal Outer diameter 53.940 - 53.955 mm

First Oversized Bearing 0.25 mm
Wear limit 0.10 mm

Front Main Bearing Clearance (between crankshaft Front Main Bearing Journal Outer diameter and crankshaft
Front Main Bearing inner diameter) 0.023 - 0.083 mm

Center Main Bearing Clearance (between Center Main Bearing Crankshaft Journal Outer diameter and main bea-
rings carrier inner diameter) 0.008 - 0.051 mm

Rear Main Bearing Clerance (between Rear Main Bearing Crankshaft Journal Outer diameter and Rear Main Bea-
ring carrier inner diameter) 0.045 - 0.085 mm

Connecting Rod Bearing Clerance (between Crankshaft Connecting Rod Journal Outer diameter and connecting
ros bearings inner diameter) 0.012 ‑ 0.066 mm

141 Base Engine

 MR 700

142 Base Engine

 MR 700

143 Base Engine

 MR 700
Installation
a - Brush dipped in lubricant
Lubricate with grease the main bearing bores in the b - Main bearing bore
cylinder block.
Install the matching main bearing carrier halves on
crankshaft journals in their original locations (marked
during disassembly) and by referencing the factory paint
marks on the side.
Ensure that all carriers were positioned so that the front
of the carrier halve is toward the crankshaft gear after
installing them on the journal.
Lubricate with MOLYguard LMP 180 grease the bearing
carrier underside bolts and thread and torque them.

Bearing carrier bolt 44.1 Nm

a- Reference paint marks made by factory or opera-

tor during disassembly
b-‑ Reference that identifies the front of the carrier,
it must be pointed toward the crankshaft gear.
c- crankshaft gear

a - Special Tool

Install the Crankshaft Installer Tool over the timing

gear to protect the front main bearing.
Position the engine cylinder block horizontal with the
oil pan flange facing up.
Carefully insert the crankshaft with the main bearing
carriers attached into the cylinder block.

a - Crankshaft assembly
b - Main bearing carrier entering cylinder block

144 Base Engine

 MR 700

a - Round holes through the castings

Rotate the bearing carriers to align the holes with

marks made during disassembly. If no marks are pre- z
sent, position the bearing carriers with the round hole
through the casting pointing as shown in the picture.

x
y

x - matching marks on both bearing carrier halves

y - matching marks on all main bearing carriers (between
carrier and block)
z - Round holes through the castings

Install new sealing washers on all main bearing locating

screws and special locating screws. a
To avoid damaging the threads, hand thread the main
bearing locating screws and special locating screws
into the block. b
Torque all main bearing locating screws and special
locating screws.

Locating screw 53.9 Nm

a - Bearing carrier locating screw

b - Sealing washer

145 Base Engine

 MR 700

Balance shaft gear drive

1. Warm the drive gear in a suitable oven to max 180° C . Press-fitting drive gear on- crankshaft . At the end verify
the value as specified.

a. Crankshaft gear
b. Balance shaft gear drive

± 0° 30’

69.25 ± 0.4 mm

146 Base Engine

 MR 700
Crankshaft Front Main Bearing
Removal
Install a new bearing on bearing puller tool.
Align the oil passage in the engine block with the hole of
the new bearing.
To aid installation retain bearing halves on tool
with a rubber band or similar.
Assemble the Front Main Bearing and Camshaft Bearing
Puller into front main bearing. a b a

a - Bearing puller tool

b - Front main bearing

Apply Loctite 601 on the bearing outer surface.

Using two wrenches, hold the puller screw and then,
turn the nut until the old bearing has been pulled out
from proper seat.
The Front Main Bearing and Camshaft Bearing Tool will
install the bearing to the correct depth.

IMPORTANT: While removing/install a new bearing

(Crankshaft Front Main Bearing or Camshaft
Bearing) ensure that the oil hole in the bearing is
positioned correctly. The oil hole in the bearing
must be aligned with the oil passage in the engine
block for proper lubrication.

a - Oil passage
b - Bearing hole
c - Front Main Bearing and Camshaft Bearing Puller Tool
d - Bearing halves (on tool)
e - Bearing bore

147 Base Engine

 MR 700

Cylinder Liners
Removal
Remove the liners by using the special tool
Remove engine components as needed, including pistons. a
Remove the piston cooling jets (oil spray nozzles).
Remove the plate from Cylinder Liner Puller Tool.
a - Cylinder Liner Puller Tool
b - Plate
IMPORTANT: To avoid mismatching cylinder liners and pi-
stons upon reassembly, mark the liners in a suitable fashion
as to the cylinder number and orientation in the cylinder
block.
b
Install the Cylinder Liner Puller Tool into the cylinder liner and
attach the plate to the tool at bottom of the cylinder liner.
Screw the nut of the tool to the plate and remove the cylinder
liners. Note the O‑rings on the cylinder liner lower part.
c
Specifications
Remove old sealant from the cylinder liners.
Clean the cylinder liners, especially at areas where shown,
and in the areas where the O‑rings fit.
c - Areas for special cleanliness
Wash the liners in cleaning solvent.
Put on safety glasses and dry the components with compres-
sed air.
Inspect the cylinder liners for abnormal wear or cracks.
Inspect the cylinder liners for a ridge at the top of the ring
travel. Remove the ridge if the cylinder liners are within
specification.
Measure the cylinder liners for taper and out of round using a
dial indicator or inside micrometer. If wear exceeds specifica-
tion replace the cylinder liners.
NOTE: Carefully move the gauge up and down in the cylin-
der liner bore to determine taper.
Measure the taper at three different vertical positions and at
opposite sides of the cylinder liner bore. Turn the gauge to
different points around the cylinder liner wall to determine the
out of round condition.
Maximum measurement depth is 108 mm down from the
top edge of the cylinder liner.

Cylinder Liner
Production diameter - inner 93.995 ‑ 94.015 mm
Wear limit 0.10 mm
Production out of round or taper 0.008 mm
Maximum out of round or taper 0.10 mm

148 Base Engine

 MR 700
Installation
a - Cylinder liner recess
Cylinder liners on all engines are required to protrude, or rise
b - Cylinder liner
above, the surface of the cylinder block.
c - Cylinder block
d - Cylinder head mounting sur-
CAUTION :Cylinder liner protrusion can only be
face
correctly measured with the cylinder liners fully seated in the
cylinder block.
Incorrect measurements will result in engine performance
problems or severe engine damage. Ensure the cylinder
liners are fully seated in the cylinder block before measuring
cylinder liner protrusion.
NOTE: The cylinder liners will rotate freely in the bore when
the cylinder block and cylinder liner (without Orings) are
completely clean and ready for measuring cylinder liner
protrusion.
a. install the cylinder liners without O‑rings a - Support Block tool
b. Using a precision depth gauge measure and record the b - dial indicator
amount of cylinder liner recess (the depth below the cylinder
head mounting surface of the cylinder block) of each liner.
a
1. Use the dial indicator and Support Block tool (liner gauge
bar) (Refer to Special Tools Section) to measure the liner
protrusion above the cylinder block.
2. Place Support Block with the dial indicator feeler gauge on
the cylinder block.
3. Set the dial indicator to zero (0).
4. Move the dial indicator to the liner on the liner neck. Re-
b
cord the measurement.
5. Measure the liner protrusion of all liners.
6. Verify the amount of liner protrusion for each liner as
specified:

Cylinder liner protrusion - 0.01 ÷ + 0.07 mm

If the amount is incorrect, replace the liner and install another

x
one.
If the amount is correct to procede with the installation of all
liners as follows:
7. Install two coloured O‑ rings (same colour) in the liner y
grooves lower part and another O‑ ring (different colour than
previous 2 O-rings) in liner groove lower part. (see picture).
IMPORTANT: The first two O-rings have a different thickness
and colour than the second one. Do not mix O-rings one
another.

8. Lubricate with lubricant lower centering collars in cylinder

block (those areas where lower liner O‑ rings seal against
the bore).
x - two coloured O‑ rings in the liner grooves lower part
(same colour)
y - O‑ ring in liner groove lower part. (different colour
than other 2 o-rings with same colour)

IMPORTANT: Do not lubricate upper bore area where sea-

lant (LOCTITE 986) will be applied later.(see next step 9).

9. Apply sealant (LOCTITE 986) to the liner surfaces, as

shown in the picture. LOCTITE 986

149 Base Engine

 MR 700
10. Install the cylinder liners in the cylinder block, being care-
ful not to damage the O‑ rings.
11. Once the liners are installed, hold the liners securely in
position with the bolts and formed spacer‑washers.
Temporarily torque the bolts and allow the sealant to get dry.
a - Cylinder liner
b - Suitable bolt
c - Formed spacer washer

IMPORTANT: If the cylinder heads are not installed

within 1 hour, the cylinder liners must remain clamped by the
spacer washers and bolts for roughly 8 hours, so that the
sealant can properly cure. After 8 hours the spacer washers
and bolts can be removed and the cylinder heads can be
installed.
12. After the sealant is dry, verify the cylinder liner protrusion
as stated before.
13. If the cylinder liner protrusion is correct, continue the
engine assembling.

150 Base Engine

 MR 700
Engine Mounts and Brackets

Engine mounts Bolts (a) - Flywheel side

Fixing Bolts 78.5 Nm
a

Engine mounts Bolts (b) - Timing Side

1st pass 78.5 Nm
2nd pass (slacken and tighten again) 78.5 Nm

b
b

151 Base Engine

 MR 700
Engine lifting eye Brackets

Engine lifting bracket fixing bolts

Bolts (a) 83.4 Nm
Bolts (b) 47.1 Nm
Bolts (c) 27 Nm

a
b

152 Base Engine

 MR 700

cooling system
Cooling System Flow Diagram—Typical.....................................................................................2
Exploded View—Seawater Pump and Related Components..........................................................3
Seawater Pump. ..........................................................................................................................4
Coolant Expansion Tank and Reservoir. .....................................................................................9
Thermostat.................................................................................................................................12
Heat Exchanger and Fluid Cooler Assembly. ..............................................................................14
Exploded View - Heat Exchanger and Fluid Cooler Assembly. ....................................................15
thermostatic housing...................................................................................................................22
Fuel Cooler. ..............................................................................................................................23
Engine Water Circulating Pump..................................................................................................24
Oil Cooler and Oil Filter Assembly. ...........................................................................................26

153 Cooling System

 MR 700

Cooling System Flow Diagram—Typical

Closed cooling system Seawater system

a ‑ Engine water circulating pump (fresh water pump) 1 ‑ Seawater pump (seawater inlet)
b ‑ Engine block 2 ‑ Engine oil cooler
c ‑ Cylinder heads 3 ‑ Fuel cooler
d ‑ Coolant manifold 4 ‑ Aftercooler
e ‑ Intake and exhaust manifold assembly 5 ‑ Heat exchanger
f ‑ Thermostat housing 6 ‑ Fluid cooler
g ‑ Heat exchanger 7 ‑ Sterndrive model exhaust riser, or inboard model
h ‑ Fluid cooler exhaust elbow (seawater overboard)
i ‑ Expansion tank

154 Cooling System

 MR 700
Exploded View—Seawater Pump and Related Components

155 Cooling System

 MR 700
Seawater Pump
Removal
Close the seacock if equipped, or disconnect and plug the seawater inlet hose, if the boat is to remain in the water.
Refer to Draining the Seawater System (Maintenance Section) and drain the seawater from the cooling system.
Remove the serpentine drive belt. Refer to Maintenance section.
Remove the seawater pump inlet and outlet hose. Drain the seawater into a suitable container.
Loosen the seawater pump mounting screws.
Remove the seawater pump.

a - Inlet hose
b - Outlet hose
c - Seawater pump
d - Seawater pump mounting screws

c a

Disassembly
1. Clamp the seawater pump in a soft‑jawed vise.
2. Remove the impeller housing screws.
3. Slide the impeller housing off of the bearing housing and shaft assembly.
4. Remove and discard the O‑ring from the groove in the impeller housing.

a - Screw
b - Impeller housing
c - Bearing housing and shaft assembly
d - O‑ring

IMPORTANT: Be careful not to damage the impeller or

impeller housing during removal.

5. Note the direction of the impeller vane rotation for

installation later and suitably mark the outer surface of
the impeller. Then, remove the impeller from the impel-
ler housing using a pair of pliers to grasp the hub of the b
impeller, or two screwdrivers to pry the impeller out of the
impeller housing. Ensure the impeller or impeller housing
is not damaged.
a - Impeller
b - Impeller housing

156 Cooling System

 MR 700
13. Using a suitable device and hardware, press the brass and carbon ring of the pump shaft seal from the bearing
housing.

a - Brass and carbon ring

b - Bearing housing

Assembly
1. Lightly lubricate the seawater pump shaft.
IMPORTANT: Ensure the bearings are installed in their original positions if being reu-
sed.
2. Press the bearings on the pump shaft using an arbor press and suitable hardware.
Press only on the inner race of the bearings.
3. Using a suitable device and hardware, press the brass and carbon seal ring into the bea-
ring housing. The brass side of the seal will face toward the impeller. Press on the seal until
the carbon side of the seal is flush with the bottom (inside) of the bearing housing.

a - Brass and carbon ring—carbon side

b - Bearing housing
c - Bottom (inside)

157 Cooling System

 MR 700
4. Slide the white ceramic part of the seal on the spline end of the shaft. Ensure the
smooth side of the seal faces the spline end of the shaft and the side with the quad‑ring
rubber seal faces the bearing.

a - White ceramic part of the seal—smooth side

b - Spline end
c - Quad‑ring rubber seal

IMPORTANT: To avoid interference with the pulley assembly, do not damage the end
of the pump shaft during bearing installation. Do not damage either part of the seal.
5. Insert the spline end into the bearing housing. Lightly tap, using a plastic or brass ham-
mer, or press the pulley end of the pump shaft into the bearing housing until the bearings
seat in the housing.

a - Pump shaft
b - Spline end
c - Bearing housing

6. Install the internal snap ring into the bearing housing.

a - Internal snap ring
b - Bearing housing

7. Using an arbor press and suitable hardware, press the seawater pump pulley flange
onto the pump shaft. The outer edge of the pulley flange will be parallel to the end of the
pump shaft when correctly installed.
a - Pulley flange
b - Pump shaft
c - Parallel

158 Cooling System

 MR 700
8. Apply sealant to the seawater pump cam screw and to the area on the backside of the
cam, as indicated.
9. Install the cam into the impeller housing.
10. Install and securely tighten the cam screw.

a - Cam screw
b - Cam
c - Impeller housing
d - Sealant area

IMPORTANT: If the outer surface of the impeller was not marked during removal and
the original direction of rotation cannot be determined, replace the impeller.
11. Push the rubber seal into the end of the impeller that will enter the impeller housing first
during installation.
a - Rubber seal

12. Install the impeller and rubber seal into the impeller housing by turning the impeller
clockwise while simultaneously pushing inward. After installation, the blades should be
flexed in the direction shown.

a - Direction of blade flex

OUT
IN

159 Cooling System

 MR 700
13. Install the O‑ring into the groove of the impeller housing.
14. Insert the spline end of the pump shaft into the impeller. Slide the bearing housing assembly over the impeller
and onto the impeller housing using a twisting motion, if necessary, in the direction of engine rotation.

a - O‑ring
b - Pump shaft spline end
c - Impeller housing
d - Bearing housing assembly

15. Turn the assembly to align the mounting flanges in‑line with the pump outlet and inlet
fittings as shown.
16. Install and securely tighten the three screws with lockwashers.

a - Alignment reference marks

b - Screw and lockwasher

Installation
1. Position the seawater pump on the engine front bracket.
2. Ensure the spacers, If equipped, are present on the two seawater pump mounting screws prior to installation.

a - Mounting screw
b - Spacer, if equipped

3. Install and torque the seawater pump mounting

screws.
4. Install the serpentine drive belt. Ensure that the
seawater pump pulley is properly aligned with the ser- 47.1 Nm
pentine belt. Refer to Section “Maintenance”
5. Install the seawater pump inlet and outlet hose. Ti-
ghten the hose clamps securely.

a - Serpentine belt
b - Inlet hose
c - Outlet hose
d - Seawater pump mounting screw
e - Seawater pump

160 Cooling System

 MR 700
Coolant Expansion Tank and Reservoir
Removal
1. Allow the engine to cool.
2. Drain the seawater system.
3. Drain the closed cooling system. Disposed of the coolant properly.
4. Disconnect the turbocharger coolant vent hose.
NOTE: Removing the seawater hose in the next step will allow sufficient upward movement of the coolant
expansion tank for removal from the engine water circulating pump
5. Remove the seawater hose between the aftercooler end cover and the fuel cooler.

a - Turbocharger
coolant vent hose
b - Seawater hose

6. Remove the screws, the screw and nut on the front

engine lifting eye bracket and the screw on cylinder
head end spacer that retain the coolant expansion tank.

a - Screw and hardware

b - Screw and nut

b
b

7. Lift the coolant expansion tank up and away from the

engine water circulating pump fitting.
8. Locate and retain the coolant expansion tank mounting
O‑rings and hardware for use during installation.

a - O‑ring
b - Spacer
c - Grommet
d - Screw and washer
e - Lower bracket

161 Cooling System

 MR 700
Installation
1. Install the rear bracket with O‑ring isolators in position shown.
2. Install the grommet into the upper bracket and install the bracket onto the coolant
reservoir using the washer and screw. Torque the upper bracket screw.

a - Upper bracket
b - Grommet
c - Washer and screw

3. Install the grommet into the lower bracket and install the bracket onto the coolant reservoir using the washer
and screw. Torque the lower bracket screw.

a - Lower bracket
b - Grommet
c - Washer and
screw

162 Cooling System

 MR 700
4. Install the new O‑rings on the fitting used between the coolant reservoir and the engine water circulating pump.

a - Fitting
b - O‑ring

5. Install the coolant expansion tank. Ensure the fitting and O‑rings used between the coolant expansion tank and the
engine water circulating pump are properly seated.

6. With all mounting hardware in position, install the 2 screws, the screw and nut on the front engine lifting eye bracket
and the screw on cylinder head end spacer, that retain the coolant expansion tank. Torque the screws and nut secu-
rely.

a - Screw and hardware

b - Screw and nut

b
b

7. Connect the turbocharger coolant vent hose.

8. Install the seawater hose between the aftercooler end
cover and the fuel cooler.

a - Turbocharger coolant vent hose

b - Seawater hose

163 Cooling System

 MR 700
Thermostat
Removal
1. Allow the engine to cool.
2. Drain the seawater system.
3. Drain the closed cooling system. Dispose of the coo-
lant properly.
4. Remove the coolant expansion tank.
5. Remove the three thermostat housing cover screws.
b

a
a - Thermostat housing cover
b - Screws

6. Remove the thermostat housing cover.

7. Remove and discard the old O‑ring.

a - O‑ring
b - Thermostat housing cover

a - Seal
b - Thermostat

8. Remove the thermostat and seal.

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 MR 700
Installation
1. Install the seal around the thermostat.
2. Install the thermostat and seal.
a - Seal
b - Thermostat

NOTE: Always use a new thermostat housing cover O‑ring.

3. Install a new thermostat housing cover O‑ring.
4. Install the thermostat housing cover using the 3 screws.
5. Torque the thermostat housing cover screws evenly in a diagonal pattern.
a - Thermostat housing cover O‑ring
b - Thermostat housing cover

24.5 Nm

6. Install the coolant expansion tank.

7. Fill the closed cooling system.
8. Open the seacock if equipped, or unplug and reconnect the seawater inlet hose.

165 Cooling System

 MR 700
Heat Exchanger and Fluid Cooler Assembly
Removal

1. Close the seacock, if equipped, or disconnect and plug the seawater inlet hose if the
boat is to remain in the water.
2. Drain the seawater system.
3. Drain the closed cooling system. Dispose of the coolant properly.
4. Disconnect the seawater hose between the heat exchanger front cover and the
aftercooler.
NOTE: Obtain clean, suitable material or plugs, and plug hoses to avoid loss of fluid.
5. Disconnect the fluid lines from the fluid cooler fittings. Quickly plug the fluid lines.
6. Remove the heat exchanger to intake and exhaust manifold bracket.
7. Disconnect the seawater hose between the fluid cooler and exhaust system.

Sterndrive shown, inboard similar

a - Seawater hose
b - Fluid lines
c - Heat exchanger to intake and exhaust manifold
bracket
d - Seawater hose

8. Remove the two heat exchanger mounting screws

9. Lift and remove the combination heat exchanger and fluid cooler from the bracket.

a - Heat exchanger mounting screws

b - Heat exchanger and fluid cooler
c - Bracket

166 Cooling System

 MR 700
Exploded View - Heat Exchanger and Fluid Cooler Assembly

11
14 7
12

13 7
13 10
9 6

6
2
3 4

1 5

1 - Sacrificial anode zinc

2 - Seawater outlet tap
3 - Radiator insert (fluid cooler core)
4 - Fluid cooler
5 - Fluid cooler end cover (discharge to exhaust elbow)
6 - Plate
7 - O-ring
8 - Radiator insert (heat exchanger core)
9 - Heat exchanger
10 - Heat exchanger front cover (inlet from aftercooler)
11 - Freshwater outlet - to boiler
12 - Heat exchanger to intake and exhaust manifold bracket
13 - Heat exchanger bracket
14 - Heat Exchanger and Fluid Cooler Assembly

167 Cooling System

 MR 700
Disassembly
CAUTION
Whenever the heat exchanger is disassembled, or the radiator insert (core) is re-
moved from the heat exchanger, all O‑ring seals must be replaced to prevent loss
of engine coolant into the seawater circuit, which could result in severe engine
damage.
1. Remove the four fluid cooler end cover flange nuts.

a - Fluid cooler
b - End cover
c - Flange nuts

2. Remove the fluid cooler end cover.

NOTE: To aid in assembly using new O‑rings, note the position of the old O‑rings
during disassembly.

a - End cover
b - O‑ring
c - Fluid cooler assembly

3. Separate the fluid cooler assembly from the spacer between the fluid cooler and heat
exchanger.

a - Fluid cooler assembly

b - Spacer
c - Heat exchanger
d - O‑ring

168 Cooling System

 MR 700
4. Remove the radiator insert (core) from the fluid cooler housing.
a - Radiator insert (core)
b - Fluid cooler housing
c - O‑ring

5. Remove the heat exchanger front cover.

a - Heat exchanger front cover
b - Screw

6. Remove the plate and O‑ring from around the heat exchanger radiator insert.
a - O‑ring
b - Plate

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 MR 700
7. Remove the heat exchanger radiator insert (core) from the rear of the heat exchanger housing. Note the position
of the O‑ring.

a - O‑ring
b - Heat exchanger radiator insert

Cleaning and Inspection

1. Remove the old O‑rings and clean the sealing flanges.
2. Use a suitable long rod or brush to clean out the radiator insert tubes.
3. Inspect each part for cracks, corrosion, or other damage. Replace as necessary.
4. Clean and paint the exterior surfaces as required to prevent corrosion.
Assembly
CAUTION
Some components use O‑rings to form seals. Rolling or twisting an O‑ring during installation may form an
improper seal resulting in component damage or failure causing additional problems that could be more se-
rious. Do not roll or twist an O‑ring during installation.
1. Place the O‑ring around the heat exchanger radiator insert.
2. Insert the heat exchanger radiator insert (core) into the rear of the heat exchanger
housing.

a - O‑ring
b - Heat exchanger radiator insert

3. Install an O‑ring around the fluid cooler radiator insert (core).

4. Install the radiator insert into the fluid cooler housing.
a - O‑ring
b - Radiator insert
c - Fluid cooler housing

170 Cooling System

 MR 700

5. Place an O‑ring around the end of the heat exchanger radiator insert.
6. Place an O‑ring around the fluid cooler radiator insert.
7. Install the plate around the fluid cooler radiator insert.
8. Install another O‑ring around the end of the fluid cooler radiator insert next to the plate.
IMPORTANT: The spacer has a deeper relief cut on the side that faces the fluid coo-
ler than on the side towards the heat exchanger. Ensure the deep relief contacts
the O‑ring and plate near the fluid cooler.
9. Slide the spacer onto the studs with the shallow relief cut facing the heat exchanger.
10. Ensure the deeper relief cut of the spacer faces the plate on the end of the fluid coo-
ler.
11. Install the fluid cooler, O‑rings, and plate onto the heat exchanger studs.

a - O‑ring
b - Spacer
c - Deep relief cut
d - Shallow relief cut
e - O‑Ring (not visible here)
f - Plate
g - O‑ring

12. Push the parts together. Ensure the O‑rings remain in the proper positions and no
unusual gaps exist between the components.
13. While holding the fluid cooler and heat exchanger parts assembled, place the O‑ring
around the aft end of the fluid cooler radiator insert.
a - O‑ring
b - Fluid cooler radiator insert

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 MR 700
14. Install the fluid cooler end cover and the four flange
nuts. Torque the fluid cooler end cover flange nuts evenly,
in a diagonal pattern.

a - Fluid cooler
b - End cover
c - Flange nuts

24.5 Nm

15. Place an O‑ring around the front of the heat exchan-

ger radiator insert.
16. Install the plate around the heat exchanger radiator
insert.

a - O‑ring
b - Plate

17. Place an O‑ring around the front of the heat exchan-

ger radiator insert and against the plate.

a - O‑ring
b - Plate

18. Install the heat exchanger front cover and the four
front cover screws. Torque the front cover screws evenly,
in a diagonal pattern.

a - Heat exchanger front cover

b - Screw 24.5 Nm

172 Cooling System

 MR 700
Installation

IMPORTANT: before mounting the Heat Exchanger and Fluid Cooler Assembly (1) install the thermostatic
housing (6) to exhaust manifold (4)

• Secure the Heat Exchanger and Fluid Cooler Assembly (1) to exhaust manifold (4) using the bracket (2).
• Torque the nuts (3) to 27.5 Nm
• Move the heat exchanger (1) towards thermostatic housing (6)
• Maintaing the heat exchanger (1) against to thermostatic housing (6) move the heat exchanger upwards and
torque the bolts (7) to 24.5 Nm
• Position the bracket (8) on heat exchanger and torque bolts (9) to 86.3 Nm
• Torque the bolts (10) to 19.6 Nm
• Torque nut (5) to 27.5 Nm

3. Unplug the fluid lines and quickly connect the fluid

lines to the appropriate fluid cooler
fitting.
Sterndrive shown, inboard similar

a - Fluid line (to fluid reservoir on sterndrive, or

transmission on inboard)

b - Fluid line (from power steering control valve

on sterndrive, or transmission on inboard)

c - Fluid cooler fittings

d - Fluid cooler

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 MR 700
Thermostatic housing

24.5 Nm

removal
Remove the sepentine belt.
Remove the expansion tank.
Remove the thermostatic housing.

installation
Install new O-rings on thermostatic housing and grease
them.
Insert the thermostatic housing into coolant pump.
Apply new gasket with Loctite 510 between thermostatic
housing and exhaust manifold..
Torque the 7 bolts fixing the thermostatic housing

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 MR 700
Fuel Cooler

Removal

Mark the fuel return hoses to aid in reassembly.

Disconnect the fuel return hoses. Plug the hoses quickly.
Remove the clamp fixing seawater hose to oil cooler
Disconnect seatwater hoses

Remove the fuel cooler.

a
b2
a

c
c
d
b
b1

a - Fuel return hoses

b1 - Seawater hoses - inlet
b2 - Seawater hoses - outlet
c - Fuel cooler
d - clamp fixing seawater hose to oil cooler

Installation
Position the fuel cooler on the engine and connect the fluid cooler seawater inlet and outlet hoses. Torque the fuel
cooler seawater hose clamps.

Connect the previously marked, fuel return hoses. Torque the fuel hose clamps.

Install clamp fixing seawater hose to oil cooler. Torque the clamp.

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 MR 700

Engine Water Circulating Pump

Removal
Remove the serpentine drive belt.
Remove the coolant expansion tank. ”
Remove the thermostat housing.
Remove the connector fitting with O‑rings.

a - Connector fitting with O‑rings

Remove the water circulating pump.

a - Flange screw (six)

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 MR 700
Installation
1. Apply sealant to both both sides of the new water circulating pump gasket.
2. Install the new new water circulating pump gasket on the engine block.
a - Water circulating pump gasket

3. Install the water circulating pump.

4. Torque the six water circulating pump flange screws evenly, in a diagonal pattern.
a - Flange screw (six)

32.4 Nm

5. Install the connector fitting with new O‑rings into the water circulating pump.
a - O‑rings
b - Connector fitting
c - Water circulating pump.

6. Install the thermostat housing.

7. Install the coolant expansion tank.
8. Install the serpentine drive belt.

177 Cooling System

 MR 700
Oil Cooler and Oil Filter Assembly
Removal
1. Close the seacock if equipped, or disconnect and plug
the seawater inlet hose, if the boat is to remain in the
water.
2. Drain the seawater from the cooling system. Refer to
section “MAINTENANCE”
3. Remove the seawater pump outlet hose to the oil coo-
a
ler assembly.
4. Disconnect the oil cooler outlet seawater hose from the
oil cooler assembly.
5. Remove the drain plug from the end cover of the oil
cooler.

6. Unscrew and remove the oil filter assembly.

7. Disconnect the oil pressure sensor wire terminal.

a - Engine oil cooler

b - Drain plug
b

a - Seawater pump outlet hose

b - Oil cooler outlet seawater hose
c - Oil filter assembly
d - Oil pressure & temperature sensor

c
b
a

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 MR 700
9. Remove the support bracket to cylinder block screw, under the oil cooler assembly.
10. Remove the flange nuts holding the oil cooler header to the cylinder block.
11. Remove the oil cooler assembly and O‑ring.
12. Remove the support bracket to oil cooler screw and remove the support bracket.

a - Support bracket to cylinder block screw

b - Flange nuts
c - Oil cooler assembly
d - O‑ring
e - Support bracket to oil cooler screw
f - Support bracket

Disassembly
Loosen the special retaining nut and remove the oil filter housing from the oil cooler assembly.

a - Oil filter housing

b - Special retaining nut

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 MR 700
Remove the oil cooler front cover screws.
Remove the oil cooler front cover and O‑ring.
Remove the oil cooler rear cover screws.
Remove the oil cooler rear cover. Note the position of the first O‑ring, gasket and second O‑ring..

a - Screw b - Oil cooler front cover

c - O‑ring d - Oil cooler insert
e - Oil cooler rear cover f - Gasket

Assembly
IMPORTANT: Do not roll or twist the O‑rings when installing around the oil cooler insert.
Install the O‑ring “b” behind the front flange of the oil cooler insert
Slide the oil cooler insert into the front of the oil cooler.
Align the insert passages as shown.
Place the O‑ring “f” into the groove on the oil cooler front cover.
Install the oil cooler front cover. Torque the oil cooler front cover screws.

Oil cooler front cover 24.5 Nm

screws

a - Oil cooler insert

b - O‑ring
c - Front flange
d - Oil cooler
e - Passage alignment reference
f - Front cover O‑ring (for groove of front cover)
g - Oil cooler front cover
h - Oil cooler front cover screw

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 MR 700
Install the O‑ring “b” around the oil cooler insert and against the rear of the oil cooler.
Install the plate around the oil cooler insert.
Install the second O‑ring “d” around the oil cooler rear cover and against the plate.
Install the oil cooler rear cover. Torque the oil cooler rear cover screws.

Oil cooler rear cover 24.5 Nm

screws

a - Oil cooler
b - O‑ring
c - Plate
d - O‑ring
e - Oil cooler rear cover
f - Oil cooler rear cover screw

Apply sealant (Loctite 576) to the threads of the oil thermostat.

Install the oil thermostat using a new sealing washer. Torque the oil thermostat.

Oil Thermostat 88.3 Nm

a - Sealing washer
b - Oil thermostat

Install the oil filter assembly threaded fitting.

a - Oil cooler assembly
Put Loctite 638 on threads.
b - Oil filter assembly threaded fitting

181 Cooling System

 MR 700
Installation
• Install a new O‑ring “3” in the groove on the oil cooler header (housing).
• Follow the steps to install the oil cooler assembly:
• Finger tighten competely the flange nuts “2”
• Hold the support bracket “4” firmly up and against the oil cooler assembly and cylinder block
• Finger tighten competely the screws “7” and “5” of the oil cooler support bracket “4”
• Torque the support bracket to oil cooler screw “7” at 24.5 Nm
• Torque the flange nuts “2” at 24.5 Nm
• Torque the support bracket to cylinder block screw “5” at 24.5 Nm

1 - Oil cooler assembly

2 - Flange nuts
3 - Oring
4 - Support bracket
5 - Support bracket to cylinder block screw 3
6 - cylinder block
7 - Support bracket to oil cooler screw

1 7 5 4 6

182 Cooling System

 MR 700

a - Oil filter housing

b - Special retaining nut

Before installing the oil filter housing “b” verify the presence and the correct position of OR “c” inside the oil filter
hosing.
Lubrificate the OR “c”.
Torque special retaining nut “b”

Special retaining nut “b” 35 Nm

183 Cooling System

 MR 700

184 Cooling System

 MR 700
intake and exhaust system

Aftercooler. ..............................................................................................................................2
exploded view - Aftercooler.......................................................................................................4
exploded view - Intake And Exhaust Manifold..............................................................................11
Intake And Exhaust Manifold. .....................................................................................................12
Specifications. ............................................................................................................................15
Testing Turbocharger Boost Pressure......................................................................................15
turbocharger oil pipes................................................................................................................24
Wastegate Valve.........................................................................................................................25
Wastegate..................................................................................................................................27

185 Intake & Exhaust System

 MR 700

Aftercooler a
Removal
Disconnect the MAP/IAT sensor connector.

a - MAP/IAT sensor connector

Remove the hollow bolt and sealing washers from wa- b

stegate valve pressure line.
c
b - Aftercooler d
c - Hollow bolt and sealing washers
d - Pressure line

Disconnect the seawater hose from the aftercooler to

the heat exchanger. f

e - Seawater hose
f - Aftercooler
e
g - Heat exchanger (seawater/freshwater)

Disconnect the seawater hose from the fuel cooler to the

aftercooler.

h - Seawater hose

186 Intake & Exhaust System

 MR 700
Loosen the hose clamp on the intake duct to turbochar-
ger hose.

a - Hose
b - Hose clamp

b a

Remove the inner and outer flange nuts, including the

special engine cover hex nut, that retain the aftercooler
housing to the intake and exhaust manifold.
a

c
b

a - Aftercooler housing
b - Intake and exhaust manifold
c - Flange nuts
d - Special engine cover hex nut

d
c

Remove the aftercooler. a

187 Intake & Exhaust System

 MR 700
Exploded view - Aftercooler

O-RINGS

O-RINGS

188 Intake & Exhaust System

 MR 700
Disassembly
CAUTION
Whenever aftercooler is disassembled or radiator insert
(aftercooler core) is removed from the aftercooler, all
O‑ring seals must be replaced to prevent seawater from
leaking into intake air duct and manifold which could
result in severe engine damage.

1. Loosen the two screws with washers, and remove the

MAP/IAT sensor from the aftercooler.
2. Remove the intake duct from rear of the aftercooler.
b
a - Intake duct screws
b - Intake duct

3. Remove the rear cover. Note the position of O‑ring in

d
the cover, the plate and second O‑ring. b

a e
Make reference marks on plate and aftercooler housing/
insert
c

Typical

a - Rear cover
b - Rear cover screws
c - O‑ring in rear cover (not shown)
d - O‑ring, behind plate (shown)
e - Plate

4. Remove the front cover. Note the position of O‑ring.

a - Front cover b
b - Front cover screws

189 Intake & Exhaust System

 MR 700
Loosen the special allen bolt fixing the aftercooler insert
(core)

a - Front cover
b - Front cover screws

Make reference marks on aftercooler insert flange and

aftercoler housing

5. Slide the aftercooler insert (core) out of the front of

the aftercooler housing. Note the position of the O‑ring.

a - Aftercooler insert
b - O‑ring
a

Cleaning and Inspection b

IMPORTANT: Be careful not to drop anything into the
intake ports.

1. Clean the old gasket material from the aftercooler hou-

sing flanges and the intake and
exhaust manifold. Do not nick or gouge the surfaces
which would cause intake or water
leaks.
2. Use a long rod to clean out the aftercooler insert (core)
tubes, or take to a radiator shop for cleaning.
3. Inspect each part for cracks or other damage which
would render it unserviceable.
4. Refer to Section MAINTENANCE and check the ano-
des.
5. Clean and paint the exterior surfaces as required to
prevent corrosion.

190 Intake & Exhaust System

 MR 700

Assembly

1. Install the O‑ring on the aftercooler insert against the

front flange.
2. Install the aftercooler insert into the aftercooler hou-
sing.

a - O‑ring
b - flangia frontale fascio tubiero
c - fascio tubiero
d - intercooler

3. Align the insert passages as shown. Align the refe-

rence marks on aftercooler insert flange and aftercoler
housing
Place the O‑ring into the groove on the front of the
aftercooler insert.

a - O‑ring

4. Install the front cover. Torque the front cover screws

evenly, in a cross pattern.

Typical
a - Front cover
b - Front cover screws
15 Nm

191 Intake & Exhaust System

 MR 700
5. Install the O‑ring around the rear of the aftercooler
insert.
6. Install the plate on the rear of the aftercooler.
Align reference marks on plate and aftercooler housing/
insert

a - O‑ring
b - Rear of aftercooler insert
c - Plate

7. Install the second O‑ring around the aftercooler insert

and against the plate.

a - O‑ring
b - Plate

8. Install the rear cover. Torque the four rear cover

screws evenly, in a cross pattern.
9. Install the drain plug with a new sealing washer.
15 Nm
Typical
a - Rear cover
b - Rear cover screws
c - Drain plug and sealing washer

10. Apply sealant Loctite on the aftercooler housing

mating surface for the intake duct.
11. Install the intake duct gasket.
12. Install the intake duct. Torque the intake duct
screws.
15 Nm
a - Intake duct screws
b - Intake duct
c - Gasket (not visible in this view)

192 Intake & Exhaust System

 MR 700
Installation
1. If the MAP/IAT sensor was removed previously, install a new O‑ring.
2. Install the sensor in the aftercooler using the two screws and washers. Torque the
MAP/ IAT sensor screws.

a - MAP/IAT sensor
b - O‑ring 5.6 Nm

3. Install new intake port gaskets.

a - Intake and exhaust manifold

b - Intake port gaskets

4. Align the intake duct with the turbocharger to intake duct hose and install the aftercooler.
5. Install the aftercooler flange nuts and the special engine cover hex nut where previously removed. Torque the
aftercooler flange nuts and special engine cover hex nut.

24.5 Nm

24.5 Nm 24.5 Nm

a - Aftercooler housing
b - Intake and exhaust manifold
c - Flange nuts
d - Special engine cover hex nut

6. Securely tighten the hose clamp on the

turbocharger to intake duct hose.

a - Hose
b - Hose clamp

193 Intake & Exhaust System

 MR 700
7. Install the aftercooler rear cover drain plug, using a
new sealing washer. b
8. Connect wastegate valve pressure line using the
hollow bolt with two new sealing washers. Torque the c
hollow bolt. d

b - Aftercooler
c - Hollow bolt and sealing washers
d - Pressure line

9. Connect the seawater hose from the aftercooler to the

heat exchanger.
f
e - Seawater hose
f - Aftercooler
g- Heat exchanger e

10. Install the coolant expansion tank. Refer to Section

COOLING SYSTEM.
11. Connect the seawater hose from the fuel cooler to the
aftercooler.

a - Seawater hose
b - Fuel cooler
c - Aftercooler

12. Install the engine lifting eye bracket with the fluid
reservoir and bracket if equipped, on to aftercooler end
cover. Torque the engine lifting eye bracket screws.

b - Engine lifting eye bracket screws

47.1 Nm

194 Intake & Exhaust System

 MR 700

Intake And Exhaust Manifold, turbocharger, risers,

wastegate valve
Exploded view - Intake And Exhaust Manifold

195 Intake & Exhaust System

 MR 700
Intake And Exhaust Manifold
Removal
NOTE: Refer to draining instructions in Section MAINTENANCE and precautions in this section, before
proceeding.
1. Drain the seawater cooling system.
2. Drain the closed cooling system.
3. Remove the aftercooler.
4. Remove the wastegate and valve.
5. Remove the turbocharger.
6. Loosen the hose clamp on the coolant manifold strip hose connected to the intake and exhaust manifold rear
cover.

a - Hose clamp
b - Coolant manifold strip hose
c - Intake and exhaust manifold rear cover
d - turbocharger

b c
a

7. Remove the heat exchanger to intake and exhaust

manifold support bracket.
8. On sterndrive models: remove the J‑clip and isolator
with the power steering hose. b

a - Intake and exhaust manifold support bracket

b - Flange nut
c - J‑clip and isolator

c
a

9. Remove the intake and exhaust manifold flange nuts

from the short and long studs.
b
a - Flange nut on long stud
b - Flange nut on short stud

196 Intake & Exhaust System

 MR 700
Cleaning and Inspection
1. Clean the gasket material from all surfaces and wash parts in solvent.
2. Inspect all parts carefully. Machined surfaces must be clean and free of all marks and deep scratches, or water and
exhaust leaks may result.
3. Check the water passages for contamination. Passages must be clean for efficient cooling.
IMPORTANT: If plugs are removed, coat threads with Perfect Seal before reinstalling.
4. If a more thorough inspection is desired, the pipe plugs may be removed from exhaust manifold and exhaust elbow.
5. Check for cracks.
6. Ensure the mating surfaces of the cylinder heads are clean and free of all old gasket material.
7. To test the manifold body for leaks, block off plates, plugs, or short hoses with plugged ends must be used. One
block off plate must have a threaded hole for attaching compressed air hose. Use new gaskets when installing the
block off plate, or plates.
Apply 2,76 bar 276 kPa (40 psi) of air pressure and submerge manifold in water. Air bubbles will indicate a leak.

Installation
1. Install new intake and exhaust manifold gaskets.

a - Gaskets

2. Install the intake and exhaust manifold on the intake and exhaust manifold studs.
3. Position the heat exchanger to intake and exhaust manifold support bracket, where removed previously.
4. On sterndrive models: Position the J‑clip and isolator with the power steering hose where remove previously.
5. Install the intake and exhaust manifold flange nuts on the short and long studs that do not have attachments.

a - Short studs
b - Long studs

a - Intake and exhaust manifold support bracket

b - Flange nut
c - J‑clip and isolator

c
a

197 Intake & Exhaust System

 MR 700
6. Install the intake and exhaust manifold support brac-
ket using the three flange nuts.
7. On sterndrive models: install the J‑clip and isolator
with the power steering hose.

a - Intake and exhaust manifold support bracket

b - Flange nut
c - J‑clip and isolator

8. Securely tighten the flange nut retaining the intake and

exhaust support bracket to the heat exchanger.
9. Torque the intake and exhaust manifold nuts evenly in
a diagonal pattern to specification.

Intake and exhaust manifold flange nuts

torque 27.5 Nm

10. Install the hose clamp on the coolant manifold strip

hose connected to the intake and exhaust manifold rear
cover.

a - Hose clamp
b - Coolant manifold strip hose
c - Intake and exhaust manifold rear cover

a
c

11. Install the turbocharger.

12. Install the wastegate and valve.
13. Install the aftercooler.
14. Fill the closed cooling system.
15. Open the seacock if equipped, or unplug and connect the seawater inlet hose.
16. Ensure the seawater pickup is supplied cooling water.
17. Connect the battery cables.
18. Start engine and check for leaks.

198 Intake & Exhaust System

 MR 700
turbocharger
Specifications

Model Maximum boost at Engine RPM when boost starts

3800 RPM (BAR)
MR704LX MIN 2,05 - 1,95 3800 - 3000
MAX 2,25 - 2,15
MR704LH MIN 2,02 - 1,95 3800 - 3000
MAX 2,22 - 2,15
MR704LS MIN 1,9 - 1,6 3800 - 3000
MAX 2,1 - 1,9
MR706LX MIN 2,10 - 1,98 3800 - 3000
MAX 2,30 - 2,18
MR706LH MIN 2,10 - 1,98 3800 - 3000
MAX 2,30 - 2,18
MR706LS MIN 2,05 - 1,95 3800 - 3000
MAX 2,25 - 2,15

Testing Turbocharger Boost

Pressure
The following should be observed prior to testing:
• Engine should be at normal operating temperature.
• Engine air cleaner should be clean (or replaced if it
cannot be cleaned). a

1. Remove the plug and sealing washer from aftercooler

housing as shown.
b
a - Plug and sealing washer
b - Aftercooler

2. Install a 0 - 2.75 bars (0‑40 psi) pressure gauge into

aftercooler where the plug was removed in Step 1.
3. Start engine and watch pressure gauge.
Maximum boost should be as specified as above indica-
ted chart.

If no engine problem exists, such as incorrect valve

operation or a blockage in the exhaust system, readings
lower than specified above indicate possible turbocharger
problems or boost pressure control system problems.

199 Intake & Exhaust System

 MR 700
Removal
1. Disconnect both battery cables from the battery termi-
nals.
2. Drain the seawater cooling system.
3. Disconnect the seawater hose from the exhaust riser,
or the exhaust elbow, depending upon the model.
4. Loosen the exhaust riser, or exhaust elbow, hose
clamps.

Sterndrive shown (inboard similar)

a - Hose clamp
b - Seawater hose
c - Hose clamp
d - Exhaust riser, or exhaust elbow
e - Exhaust hose

5. Loosen the spring retaining the heat‑shield blanket

around the wastegate exhaust pipe.
6. Remove flange screws retaining the wastegate
a
exhaust pipe to exhaust riser, or exhaust elbow.
b
Sterndrive shown (inboard similar)
a - Spring
b - Heat‑shield blanket c
c - Flange nut (not visible)
d - Wastegate exhaust pipe

7. Make matching marks on the exhaust riser, or exhaust elbow, and the turbocharger housing for ease of align-
ment during reassembly.
8. Loosen the clamp on the exhaust riser, or exhaust elbow.
9. Remove the exhaust riser, or exhaust elbow, clamp and gasket.

Sterndrive shown (inboard similar)

a - Matching marks
c
b - Clamp
c - Exhaust gasket (not visible)
a

200 Intake & Exhaust System

 MR 700
Removing The Turbocharger Unit
1. Drain the closed cooling system.
2. Remove exhaust riser, or exhaust elbow, as previously
outlined.
3. Remove the air filter bracket flange nuts and loosen
the air filter clamp.

MR 706
a - Bracket
b - Clamp
c - Flange nut
MR 704

201 Intake & Exhaust System

 MR 700
4. Remove the turbocharger oil delivery pipe.
5. Remove the hollow bolt and sealing washers from coolant vent pipe at the turbocharger.
6. Loosen the aftercooler intake duct hose clamps.
a - Flange screw
b - Oil delivery pipe
c - Coolant vent pipe
d - Hollow bolt and sealing washers
e - Intake duct hose clamp

7. Remove the oil drain pipe on the bottom of the turbocharger.

a - Oil drain pipe

b - flange nut

8. Remove the aftercooler intake duct.

b
a - Aftercooler intake duct
b - Screw (4)
a

202 Intake & Exhaust System

 MR 700

9. Remove the turbocharger to exhaust manifold

mounting flange nuts.

a - Flange nuts (4 total, 2 not shown)

10. Remove the two support bracket mounting flange screws as shown.

a - Support bracket
b - Flange screws

b
a

11. Remove turbocharger unit.

Cleaning
IMPORTANT: Never use a caustic cleaning solution, as it may attack aluminum. Also, never use a wire bru-
sh which could damage impeller or mating surfaces.

1. Before cleaning, inspect the disassembled parts for burning, abrasion, carbon deposits, gas and oil leakage.
CAUTION
Always wear safety glasses when using compressed air to protect from hose rupturing or flying debris.
WARNING
When using compressed air to dry components, do not spin turbine, or allow turbine to spin, since no oil is
being provided to the bearings and could result in damage to the bearings.

2. Thoroughly clean all the parts with clean diesel fuel, using a soft brush. Dry with compressed air.

203 Intake & Exhaust System

 MR 700
Assembly
IMPORTANT: When installing turbocharger, it may be necessary to turn intake and exhaust housings to line
up with intake air duct and exhaust manifolds on engine.
1. Install a new gasket on the intake and exhaust manifold.
2. Install the turbocharger on the intake and exhaust manifold. Torque the flange nuts evenly, in a diagonal pattern.

a - Flange nuts (4 total, 2 not shown)

b - Gasket

49 Nm

3. Install a new O‑ring on top of the spacer and slide it on the studs of the turbocharger.
a - Studs
b - O‑ring
c - Spacer

204 Intake & Exhaust System

 MR 700
4. Using a new O‑ring, install the oil drain pipe on the bottom of the turbocharger. Torque the oil drain pipe flange
nuts.

a - O‑ring
b - Oil drain pipe
c - Flange nut

27.5 Nm

5. Install the spacer to the support bracket. Torque spacer to support bracket flange screws securely.

a - Spacer
b - Spacer to support bracket flange screw
c - Support bracket

27.5 Nm

IMPORTANT: If it became necessary to remove the entire aftercooler housing from the intake and exhaust
manifold during disassembly (to gain better access to turbocharger mounting nuts) refer to Section —Af-
tercooler, at this time for proper aftercooler installation.

6. Install a new gasket on the aftercooler and install the intake duct. Torque the hex head screws evenly, in a diago-
nal pattern.

a - Gasket (not visible in this view)

b - Intake duct
c - Screw

10 Nm

205 Intake & Exhaust System

 MR 700
7. Using new sealing washers on the hollow bolt, install the coolant vent line to turbocharger exhaust housing as
shown. Torque the coolant vent line hollow bolt securely.
8. Clean the sealing surfaces and using a new gasket, install the oil delivery pipe as shown. Torque the oil delivery
pipe flange screws.
9. Position the turbocharger to intake duct hose as shown. Tighten the hose clamps securely.

a - Sealing washer (two)

b - Coolant vent line hollow bolt
c - Coolant vent line
d - Gasket
e - Oil delivery pipe
f - Screw (two)
8 Nm
g - Intake duct hose
h - Clamp

27.5 Nm

10. Install the air cleaner onto the turbocharger and tighten the clamp securely.
11. Install the air filter bracket to support the air filter. Torque the air filter bracket flange nuts.

a - Air filter bracket

b - Clamp
c - Air filter bracket flange nut

10.8 Nm
10.8 Nm

12. Using a new gasket, install the exhaust riser, or exhaust elbow. Align the matching marks made previously.
Simultaneously, align the exhaust riser, or exhaust elbow with the exhaust pipe. Torque the exhaust elbow clamp.

Sterndrive shown (inboard similar)

a - Matching marks
b - Exhaust elbow clamp
c - Exhaust gasket

10.8 Nm

206 Intake & Exhaust System

 MR 700
13. Using a new gasket, install the wastegate exhaust a
pipe. Torque the wastegate exhaust pipe flange screws.

a - Gasket
b - Wastegate exhaust pipe flange screws b
c - Wastegate exhaust pipe

10.8 Nm c

14. Wrap the wastegate exhaust pipe with the heat shield
blanket.
Fasten the spring to retain the heat shield blanket.
b
Sterndrive shown (inboard similar)
a - Wastegate exhaust pipe a
b - Heat shield blanket
c - Spring

15. Install seawater hose from fluid cooler to the exhaust riser, or exhaust elbow if equipped. Tighten the hose clamp
securely.
16. Position the exhaust hose as shown. Tighten the hose clamps securely.

Sterndrive shown (inboard similar)

a - Hose clamp
b - Seawater hose
c - Hose clamp
d - Exhaust riser, or exhaust elbow
e - Exhaust hose

17. Fill the closed cooling system.

18. Connect the battery cables to the battery.
19. Start engine and check for leaks.
20. Test the turbocharger boost pressure as previously
outlined.

207 Intake & Exhaust System

 MR 700
Turbocharger oil pipes
turbocharger oil return pipe

a - Exhaust manifold
b - Turbocharger oil return pipe nut b
49 Nm
c - Fluid cooler a

27.5 Nm c

turbocharger oil delivery pipe

z

x - Exhaust manifold
y - Turbocharger oil delivery pipe nut
z - Aftercooler

x
39.2 Nm y

27.5 Nm

208 Intake & Exhaust System

 MR 700
Wastegate Valve
Removal b
1. Remove the hollow bolt with sealing washers from a
pressure line on bottom of aftercooler housing. d
2. Remove the hollow bolt with sealing washers from
pressure line on valve.
3. Remove the pressure line.
c
e
a - Hollow bolt a
b - Sealing washer (two)
c - Pressure line f
d - Aftercooler housing
e - Wastegate
f - Wastegate valve

4. Remove the screws and washers retaining wastegate

valve to wastegate.
5. Remove the wastegate valve.
6. Remove the retaining wastegate to exhaust manifold
flange nuts

a - Screw with washer (one not shown)

b - Valve
d
c - Wastegate
d - wastegate to exhaust manifold flange
nuts a

c b

209 Intake & Exhaust System

 MR 700
Installation
1. Install the wastegate valve on the wastegate using the Allen‑head screws and washers. Position the pressure
line fitting on the valve toward the front of the engine.

2. Install the pressure line on the wastegate valve using the hollow bolt with new sealing
washers. Finger‑tighten.
3. Install the pressure line on the aftercooler using the hollow bolt with new sealing washers. Finger‑tighten.
4. Torque both hollow bolts.

a - hollow bolt a
c
b - wastegate fixing nuts to exhaust manifold b
c - wastegate valve fixing allen-head screw to 10.8 Nm 14.7 Nm
wastegate 10.8 Nm

5. Start the engine and check for leaks.

6. Test the turbocharger boost pressure as previously
outlined.

210 Intake & Exhaust System

 MR 700
Wastegate
Removal
1. Drain closed cooling system.
2. Remove the exhaust elbow.
3. Remove the wastegate exhaust pipe.
4. Remove the wastegate valve.
5. Remove the four flange nuts retaining wastegate to
exhaust manifold.

a - Flange nuts
b - Wastegate
c - Exhaust manifold

Cleaning
1. Clean all traces of old gasket material from the intake and exhaust manifold flange.
a - Gasket
b - Intake and exhaust manifold flange

2. Clean old gasket material from wastegate.

Installation
1. Using a new gasket install the wastegate on the exhaust manifold
as shown. Torque the four wastegate flange nuts.
2. Install the wastegate valve.
3. Install the wastegate exhaust pipe.
4. Install the exhaust elbow or riser.
5. Start the engine and check for leaks.
6. Test turbocharger boost pressure. 10.8 Nm

a - Wastegate
b - Gasket
c - Wastegate flange nuts

211 Intake & Exhaust System

 MR 700

212 Intake & Exhaust System

 MR 700
electrical system

Starter.......................................................................................................................................2
Alternator..................................................................................................................................3
Alternator bracket.....................................................................................................................4
Alternator pulley.......................................................................................................................4
electrical diagram - mr706..........................................................................................................5
electrical diagram - mr706 (with box relay and fuses).................................................................6
electrical diagram - mr704..........................................................................................................7
electrical diagram - mr704 (with box relay and fuses).................................................................8
interface wiring harness ECU terminal - side “k”.........................................................................9
injection wiring harness ECU terminal - side “a”..........................................................................10
injection wiring harness - mr704.................................................................................................11
injection wiring harness - mr706.................................................................................................12
interface wiring harness.............................................................................................................13
interface wiring harness with box relay. .....................................................................................14
accelerator potentiometer..........................................................................................................15
wiring harness extension.............................................................................................................16
dash board..................................................................................................................................17
main rele’.....................................................................................................................................18
ECU diagnosis connector...........................................................................................................19

213 Electrical System

 MR 700

Starter
Starter Removal

WARNING
Avoid injury or death and product damage from an electri-
cal shock, fire or explosion.
Always disconnect both battery cables from the battery
before servicing the power package.

1. Disconnect the battery cables from the battery.

2. Slide the protective rubber boot off of the cable ends
and disconnect the positive (+) battery cable and wires a
from the starter solenoid.
b
a - Positive (+) battery cable
b - solenoid wire

3. Remove the upper and lower starter mounting screws.

c - starter mounting screws

4. Remove the starter from the engine.

Installation
1. Clean the starter mounting surfaces and the mounting screws prior to installation.
2. Position the starter on the engine.
3. Install and evenly torque the upper and lower starter mounting screws.

Description Nm
Starter mounting screw 47.1

4. Connect the positive (+) battery cable and wires to the starter solenoid. Tighten the fasteners securely.
5. Apply sealant to the exposed electrical terminals and connections.
6. Slide the protective rubber boot over the positive (+) terminal connection after the sealant is dry.
7. Connect the battery cables to the battery.

214 Electrical System

 MR 700
Alternator
Alternator Identification
a - alternator identification
B1 - 12 volt (+) output terminal
B2 - 12 volt (+) output terminal (available) L
L - Excitation circuit b1

Alternator Specifications
Alternator ‑ Bosch
Identification number 0 124 325 178 a
Current output 110 A
Voltage output 14 V b2

Exploded View—Alternator
Alternator Removal
! WARNING
Avoid injury or death and product damage from an electrical shock,
fire or explosion.
Always disconnect both battery cables from the battery before ser-
vicing the power package.

1. Disconnect both battery cables from the battery.

2. Position a suitable tool in the tensioner release slot and move (rotate)
the tensioner pulley counterclockwise. Refer to “Maintenance” section.
3. Remove the drive belt. Refer to “Maintenance” section.
4. Slowly release the tensioner to return to the original position.

5. Remove the alternator upper and lower mounting screws.

1 - Alternator
2 - Upper mounting screw 1
3 - Lower mounting screw

6. Remove the alternator.

7. Remove the protective rubber boot and disconnect the output lead.
8. Disconnect the excitation circuit
2
a - Protective rubber boot
b - Output lead B+
c - 2‑Way connector
3
Alternator Installation
1. Position the alternator in the mounting bracket.
2. Connect the output lead. Ensure the output cable is positioned as
shown. Tighten the
nut securely.
3. Connect the excitation circuit 2‑way connector to the alternator.
4. Apply sealant to the exposed electrical terminals and connections
5. When the sealant is dry, install the protective rubber boot over the
output lead.
6. Install the upper and lower mounting screws. Torque the screws.

Description
Alternator upper and lower moun- 27.5 Nm
ting screw

7. Position a suitable tool in the tensioner release slot and move (rotate)
the tensioner pulley in the direction of the arrow.
8. Install the drive belt.
9. Slowly release the tensioner to return to the original position.

215 Electrical System

 MR 700

Alternator bracket
Bolt Tightening
Description
Alternator Bracket Bolt 47.1 Nm

Alternator pulley
Removal
The alternator pulley is idle type: it can be identified by the
front cover installed on the pulley.
a - front cover on alternator pulley
Remove the cover and install the special tool 68420022F
and dissamble the pulley.

Installation
Thread the pulley on the alternator shaft.
Tighten the pulley. a
Alternator idle pulley 80 ± 5 Nm

216 Electrical System

 MR 700

Electrical diagram - mr706 (16662036F)

217 Electrical System

 MR 700
Electrical diagram - mr706 (with box relay and fuses - 16662053F)

218 Electrical System

 MR 700
Electrical diagram - mr704 (16662035F)

219 Electrical System

 MR 700
Electrical diagram - mr704 (with box relay and fuses - 16662052F)

220 Electrical System

 MR 700

Interface wiring harness ECU terminal - side “k”

DAVANTI-
FRONT

RETRO - REAR

5 6 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94

51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72

3 4

29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

221 Electrical System

 MR 700

Injection wiring harness ECU terminal - side “a”

222 Electrical System

 MR 700
Injection wiring harness - mr704 (18852225G)

223 Electrical System

 MR 700
Injection wiring harness - mr706 (18852226F)

224 Electrical System

 MR 700
Interface wiring harness (18852227F)

225 Electrical System

 MR 700

Interface wiring harness with box relay (18852267F)

226 Electrical System

 MR 700
Accelerator potentiometer

227 Electrical System

 MR 700
Wiring harness extension

228 Electrical System

 MR 700
Dash board

229 Electrical System

 MR 700
Main rele’

a - main relè and engine starter relè

b - potentiometer accelerator and fuel filter
B

New solution Box relay and fuses

a - box relay and fuses

K2 main
relay K1 starter a
F3 - 10A relay
F4 - 15A
F5 - 15A
F2 - 10A
F6 - 5A
F1 - 20A

230 Electrical System

 MR 700

ECU diagnosis connector

231 Electrical System

 MR 700

232 Electrical System

 MR 700
fuel system

233 Fuel System

 MR 700
Injector

Removal

IMPORTANT: Whenever injectors are removed for

service, they must be retained in order. At the time of
installation, they must be installed in the same locations
as when removed, because each injector has a proper
IMA code. a
Loosen the injector fixing screw and remove the clamp. c
Loosen the high pressure fuel pipe nut.

IMPORTANT: When loosing high pressure pipe

nut on injector retain injector feed connector with a
wrench 13 mm.

b
Push the fuel return hose clamp to remove it.
Take the injector off by hand.

a - injector fixing screw and the clamp

b - fuel return hose clamp
c - high pressure fuel pipe nut
d - IMA code
e - injector feed connector
b

IMPORTANT:
e
IMA code is composed by number 6 digit

234 Fuel System

 MR 700

Installation
Verify the cleaning into cylinder head bore where the injector
is located.
d
Install a new O-ring in proper groove in the injector and apply
Molykote P 1500 paste as shown in the photo.
Verify that the washer is installed at the end of the injector.
Install the injector into the cylinder head.
Verify the presence of the plaque on rocker arm cover.
Install the injector clamp and fixing screw with spherical f
washer, to be installed as shown in the photos.
a - injector clamp
b - injector washer
c - injector fixing screw and proper spherical washer
d - plaque on rocker arm cover
a c
e - injector O-ring with Molikote P 1500 paste
f - cylinder head bore where the injector is located.
g - IMA code

Finger tighten completely the injector fixing screws and

torque them.

injector fixing screw 23 Nm

c a

WARNING: When the injector is removed a speci-

fic procedure must be performed to install correctly high d
pressure fuel delivery pipes.
Before installing the injector high pressure fuel pipes
from rail to injectors a specific procedure must be
observed. (Refer to High Pressure fuel pipes Tightening
Procedure)

NOTE: Whenever each of these components such

as the high pressure pump, injectors, rail and any high
pressure fuel pipe (pipe from pump to rail and pipes
from rail to injectors) are loose and/or removed, a spe-
cific procedure must be performed in order to avoid fuel
leakage in the high pressure fuel system, high pressure
fuel delivery pipes. b e
(REFER TO HIGH PRESSURE FUEL PIPES TIGHTENING
PROCEDURE)

IMPORTANT: Whenever one or all injectors are

replaced, new IMA code must be re-written inside ECU g
by diagnostic tool.

235 Fuel System

 MR 700
High pressure pump
removal
Release the clamp and disconnect the fuel delivery rubber
hose from the pump.
Loosen and remove the fuel return hose hollow bolt and
proper washers from the pump.
Loosen and remove the fuel delivery pipe nut from high
pressure pump to rail.
Loosen and remove the 3 fixing flange screws.
b
Take the pump off. Replace the gasket install on the studs.
a - fuel delivery rubber hose clamp d
b - fuel return rubber hose hollow bolt and proper washers
c - fuel delivery pipe from high pressure pump to rail. a
d - fixing flange nut

d
c

Loosen the flange nut and use a normal gear extractor to

remove the injection pump gear.
Remove the collar out without damaging the body flange of
the pump. At the spare parts the pump will supply as assem-
bly: pump and collar.

e - collar

236 Fuel System

 MR 700
Installation

Install the collar with bevelled side towards outside.

Press the collar till it goes in contact with body flange pump.
a - bevel

Install the gear on the pump shaft.

IMPORTANT: The spline is not installed on the

pump shaft keyway.
b - keyway
Install the nut and torque it.

High pressure pump gear nut 86.4 Nm

237 Fuel System

 MR 700

Install a new gasket on the studs.

c - gasket
Install the high pressure pump on studs, thread the flange
nuts and torque them.
d - flange nut

High pressure pump flange nut 27.5 Nm

NOTE: The pump must not be timed.

Install with proper clamp the fuel return rubber hose to the
pump.
Install the fuel delivery hose hollow bolt with proper washers
to the body pump and torque it.
x - fuel delivery hose hollow bolt
y - fuel return hose hollow bolt

fuel delivery hose hollow bolt 27.5 Nm

fuel return hose hollow bolt x
y
WARNING: When the pump is removed a specific
procedure must be performed to install correctly high
pressure fuel delivery pipes.
Before installing the high pressure pipe from pump
to rail and high pressure pipes from rail to injectors a
specific procedure must be observed. (Refer to High d
Pressure fuel components Tightening Procedure)

NOTE: Whenever each of these components such

as the high pressure pump, injectors, rail and any high
pressure fuel pipe (pipe from pump to rail and pipes
from rail to injectors) are loose and/or removed, a spe-
cific procedure must be performed in order to avoid fuel
leakage in the high pressure fuel system, high pressure
fuel delivery pipes.

(REFER TO HIGH PRESSURE FUEL PIPES TIGHTENING

PROCEDURE)

238 Fuel System

 MR 700
Rail
Removal
Remove any component wich hinders the rail removal.
Remove high pressure pipes from the rail: from rail to injector
and from high pressure pump to rail.
Remove the bolts fixing to rail bracket.
Remove the rail.
c/d - high pressure pipes (from rail to injectors)
f - high pressure pipes (from rail to high pressure pump)
b - rail fixing bolt to rail bracket
NOTE: Whenever each of these components such
Installation as the high pressure pump, injectors, rail and any high
pressure fuel pipe (pipe from pump to rail and pipes
WARNING: When the rail is removed a specific from rail to injectors) are loose and/or removed, a spe-
procedure must be performed to install correctly high cific procedure must be performed in order to avoid fuel
pressure fuel delivery pipes. leakage in the high pressure fuel system, high pressure
fuel delivery pipes.
Before installing the high pressure pipe from pump
to rail and high pressure pipes from rail to injectors a (REFER TO HIGH PRESSURE FUEL PIPES TIGHTENING
specific procedure must be observed. (Refer to High PROCEDURE)
Pressure fuel pipes Tightening Procedure)

239 Fuel System

 MR 700
High Pressure fuel pipes tightening procedure

NOTE: Whenever each of these components such as the high pressure pump, injectors, rail and any high pres-
sure fuel pipe (pipe from pump to rail and pipes from rail to injectors) are loose and/or removed, a specific procedure
must be performed in order to avoid fuel leakage in the high pressure fuel system, high pressure fuel delivery pipes.
If this procedure is observed, a correct alignment of high fuel pressure pipes is carried out so that the fuel leakage in
high pressure fuel system is avoided.

IMPORTANT: Whenever any high pressure fuel delivery pipe (pipe from pump to rail and pipes from rail to
injectors) is loose and/or removed, it must be replaced in order to avoid fuel leakage in the high pressure fuel system.

1 - Verify that the injectors are properly tight (23 Nm). (Refer to Injector Section).
2 - Verify that the high pressure pump is properly tight.(27,5 Nm) (Refer to High pressure Pump Section).
3 - Even if the following screws are tight, therefore loosen them:
• the screws fixing the rail to the bracket
• the screws fixing the rail bracket to crankcase.
4 - Finger tighten completely and simultaneously every high pressure pipes nuts.
5 - Install the clamp on the high pressure pipe from pump to rail and finger tighten proper screw.
6 - Torque the high pressure pipe nut no. 3 (for engine with 4 cylinders) no. 4 (for engine with 6 cylinders) at RAIL SIDE 19 ± 2
Nm
7 - Torque the high pressure pipe remaining nuts at RAIL SIDE (no. 1,2,4,5 for engine with 4 cylinders and 1,2,3,5,6,7 for engi-
ne with 6 cylinder.) 19 ± 2 Nm
8 - Torque the high pressure pipe nuts at INJECTOR SIDE (no.1,2,3,4 for engine with 4 cylinders and 1,2,3,4,5,6 for engine
with 6 cylinder.) 27 ± 2 Nm
9 - Torque the high pressure pipe nut at HIGH PRESSURE PUMP 20.5 ± 2 .5 Nm
10 - Torque the screw of the clamp fixing the high pressure pipe from pump to rail to rail bracket 14.7 ± 2 Nm
11 - Torque the screws fixing the rail to the bracket and the screws fixing the rail bracket to crankcase 33 ± 2 Nm

INJECTOR SIDE

RAIL SIDE

240 Fuel System

 MR 700
Fuel return pipes

Removal
1. Remove the injector return hose.

Important : Do not pull the clip out but push it and

simultaneously disconnect the injector return hoses.

2. Disconnect the injection pump return hose.

3. Disconnect the common rail return hose.
4. Remove the junction block assembly.
5. Remove the fuel return line assembly.
Installation
1. Install the fuel return line assembly.
2. Connect the common rail return hose.

Important : Press injector return line by hand from

above and vertically down to the injector until you
hear the connection piece snaps in place.

3. Connect the injection pump return hose.

4. Install the junction block

Uscita Acqua Mare

Da Serbatoio
Entrata Acqua
Mare

241 Fuel System

 MR 700

242 Fuel System

 MR 700
engine instrumentation
Digital Gauges
A VM Motori instrument package is provided with this product. the LCD of tachometer will display :
engine RPM, engine coolant temperature, engine oil pressure, battery voltage, DTC codes, engine operating hours .

a - Speedmeter/Tachometer (LCD system view display. It will display: engine RPM, engine coolant
temperature, engine oil pressure, battery voltage, DTC codes, engine operating hours and engine RPM)

The instrument package will also aid in identifying the fault codes associated with the sounding of the engine audio
warning system. The instrument package will display critical engine alarm data and relate other potential problem
areas on its LCD display. Refer to Tachometer - Speedmeter.

Instruments
The following types of gauges are included in instrument package:

b Engine Oil pressure gauge: Indicates engine oil pressure.

c Battery meter: Indicates battery voltage.
d Engine Coolant temperature gauge: Indicates engine operating temperature.

d
b

b c d

243 Engine Instrumentation

 MR 700
When a problem related to engine coolant temperature,
engine oil pressure or battery voltage occurs, the specific
gauge lamps on and an audio warning will active (Red
colours when active).
Also the LCD of tachometer will display an specific icon
and relate faulty code in the specific DTC menu.
Refer to below table to identify when the gauge lamps on
and audio warning (buzzer) will active.

example:
• battery voltage low
• gauge lamps on (A) B
• specific icon is present in LDC tachometer (B) A

Instrument Thresold Warning Thresold Alarm

Voltage Gauge V 13 Voltage Battery gauge 12 Voltage Battery gauge Warning:
Battery ----------------- lamp on. lamp on and buzzer on. <= 13V without RPM
Tachometer ----------------- -----------------
display Tachometer displays an Tachometer displays an Alarm:
icon on LCD display icon on LCD display
<= 12V with RPM

Coolant Gauge °C 100 Engine Coolant 105 Engine Coolant Warning:

Temperature ----------------- temperature gauge lamp temperature gauge lamp >= 100 °C without RPM
on. on and buzzer on.
Tachometer
display ----------------- -----------------
Alarm:
Tachometer displays an Tachometer displays an
icon on LCD display icon on LCD display >= 105 °C without RPM

Engine Oil Gauge Bar 1.1 Engine Oil pressure 1 Engine Oil pressure Warning:
Pressure ----------------- gauge lamp on. gauge lamp on and <= 1.1 bar without RPM
----------------- buzzer on.
Tachometer
display Tachometer displays an -----------------
Alarm:
icon on LCD display Tachometer displays an
icon on LCD display <= 1 bar with RPM

Engine Gauge 4200 Engine speed gauge Alarm: >= 4200 RPM
Speed ----------------- lamp on and buzzer on.
Tachometer -----------------
display Tachometer displays an
icon on LCD display
Engine Tachometer
Hours display

244 Engine Instrumentation

 MR 700
Audio & light Warning System
Your engine is be equipped with an audio and light
warning system. The audio warning system will not
protect the engine from damage. It is designed to warn
the operator that a problem has occurred.
The audio warning system will sound if the Engine
Control Module (ECM) detects a malfunction. Your engine
is be equipped with one of the following system views
that can be used to indicate the fault codes:
• System Tachometer or Speedometer
NOTE: Refer to System Tachometer or Speedometer
to identify the information provided by LDC display of
tachometer.

Tachometer / Speedometer
The LCD on the system tachometer, displays active fault
codes DTC. To indicate an active fault code is present the
following screen appears on the tachometer display.
Press button “MODE” untill DTC menu appears.
a - DTC menu c
Keep pressed for about 3 seconds the MODE button to
enter the list of active fauty codes
b - MENU button
c - number of DTC code stored
After pressing the “MODE” button, the DTC code appears
and also the number appears in the upper right hand
corner on the digital display screen means the first active
fault. a
Furthermore the number at the left bottom corner
identifies as many as times the DTC code is stored. b
d - faulty code
e - first code stored
f - times the DTC code has been stored
To view other faulty codes, press MENU button.
A major fault is also accompanied by the audio warning e
system.
d
DTC Code Description DTC
Accelerator percentual pedal position 91
Engine percent load at current speed 92 f
Water in fuel detection 97
Engine Oil pressure is too low 100
Turbo charger pressure 102
Engine intake manifold temperature 105
Barometric pressure 108
Cooling water temperature 110
Low fuel pressure 157
Battery voltage 168
Fuel temperature 174
Engine oil temperature 175
Engine fuel rate 183
Tachometer 190
Engine hours 247
Actual engine percent torque 513
Starter relay error 677
Engine demand percent torque 2432

245 Engine Instrumentation

 MR 700
SPN Error codes list

SPN English Description Control

1079 Sensor Supply Voltage 1 Check Error ECU, wire-harness and power supply circuit
Sensor Supply Voltage 2 Check Error ECU, wire-harness and power supply circuit
Sensor Supply Voltage 3 Check Error ECU, wire-harness and power supply circuit
1109 Invalid Data Received from Transmission Controller Unit wire-harness and CAN line
TCU
1137 DPF Particulate Filter - Exhaust Gas Temperature Sensor (vuoto)
Error
Exhaust Gas Temperature Sensor Plausibility Check Error (vuoto)
- Position 1
Exhaust Gas Temperature Sensor Plausibility Check Error (vuoto)
- Position 2
Exhaust Gas Temperature Sensor Error - Bank 1 - Posi- (vuoto)
tion 1
1138 Exhaust Gas Temperature Sensor Plausibility Check Error (vuoto)
- Position 2
Exhaust Gas Temperature Sensor Error - Bank 1 - Posi- (vuoto)
tion 2
1213 MIL Lamp Circuit Malfunction wire-harness and MIL lamp
1347 Metering Unit Solenoid Analogic/Digital Converter Error ECU
Metering Unit Solenoid PWM Control Circuit Malfunction ECU
1351 Air Conditioning Relay Circuit Malfunction wire-harness air conditioning relay
1484 Transmission Controller Unit TCU Solenoid Circuit Error (vuoto)
Transmission Controller Unit TCU Pressure Switch Check (vuoto)
Error
Transmission Controller Unit TCU Relay Error (vuoto)
Transmission Controller Unit TCU Engine/Turbine Speed (vuoto)
Sensor Error
Transmission Controller Unit TCU Pressure Switch Test (vuoto)
Failed
Transmission Controller Unit TCU Torque Converted (vuoto)
Clutch out of Tolerance
Transmission Controller Unit TCU Solenoid Switch Valve (vuoto)
Latched
Transmission Controller Unit TCU Generic Error Gear control box
Transmission Controller Unit TCU Internal Error Gear control box
Transmission Controller Unit TCU Gear Incorrect Ratio (vuoto)
CAN Message Timeout Error from Transmission Controller wire-harness and CAN line
Unit TCU
TSC1-TE CAN Message Timeout Error from Transmission wire-harness and CAN line
Controller Unit TCU
1485 Main Relay Control Error Main relay, wire-harness and power supply circuit
1680 Add-on heater Circuit Malfunction (vuoto)

246 Engine Instrumentation

 MR 700
0000 Injector Bank 1 Circuit Malfunction Warning Injector and fuel line
Injector Bank 2 Circuit Malfunction Warning Injector and fuel line
Incorrect Immobilizer Key (vuoto)
Cylinder 5 - Injector Circuit Malfunction Specific Error Injector and fuel line
Cylinder 6 - Injector Circuit Malfunction Specific Error Injector and fuel line
Lost Communication with Vehicle Immobilizer Control Comunication line, wire-harness, ECU and Immobilizer
Module
Lost Communication with Vehicle Immobilizer Control (vuoto)
Module
Fan Control Critical Condition (vuoto)
Invalid Data Received from Vehicle Immobilizer Control ECU and Immobilizer
Module (EEPROM Error)
Invalid Data Received from Vehicle Immobilizer Control (vuoto)
Module (EEPROM Error)
ECU Overrun Monitoring Error ECU and power supply circuit
ECU Redundant Engine Speed Monitoring Error (vuoto)
ECU Internal EEPROM Memory Error ECU
ECU Internal Supply Voltage Error (vuoto)
ECU Redundant Shut Off Test Error during Initialization (vuoto)
Fuel Rail Pressure Sensor Offset Monitoring Error Fuel line, fuel rail pressure sensor and M-Prop
Metering Unit Solenoid Analogic/Digital Converter Error ECU
Plausibility Error on Base Map for Torque to Quantity (vuoto)
Conversion
Raw Air Mass Signal Plausability Error Inlet air line and TVA
T15 Terminal Signal Plausibility Error Wire-harness and power supply circuit
Crankshaft/Camshaft Position Sensor Offset Error Cranck shaft sensor, cam shaft sensor and shafts position
ECU Internal Watchdog/Controller Error ECU
Exhaust Gas Temperature Sensor Plausibility Check Error (vuoto)
- Position 1
Fuel Rail Pressure Monitoring Error for Active Pressure Fuel line, fuel rail pressure sensor and M-Prop
Control by Metering Unit Governor
Oil Temperature Sensor Signal Error Oil temperature sensor and oil circuit
Main Clutch Signal Error Clutch switch
Battery Voltage Error Battery
Shut Off Test Error (vuoto)
EGR Cooler By-pass Valve Actuator Malfunction Inlet air line, turbine and EGR valve
EGR Cooler By-pass Valve Actuator Malfunction Inlet air line, electo-pneumatic circuit of TVA and EGR and
turbine
EGR Exhaust Gas Recirculation Actuator Malfunction TVA, EGR, inlet air line and turbine
TVA Throttle Valve Actuator Circuit Malfunction Inlet air line and electo-pneumatic circuit of TVA and EGR
TVA Throttle Valve Actuator Circuit Malfunction Inlet air line and electo-pneumatic circuit of TVA and EGR
VSA Variable Swirl Actuator Circuit Malfunction Inlet air line and swirl actuator
Metering Unit Solenoid PWM Control Circuit Malfunction ECU
Electric Presupply Fuel Pump Primary Circuit Malfunction wire-harness and fuel pump
EGR Exhaust Gas Recirculation Flow Insufficient Detected Inlet air line, electo-pneumatic circuit of TVA and EGR and
turbine
High Pressure Test (vuoto)
Misfire Detection Deactivated during Run Up Test (vuoto)

247 Engine Instrumentation


0027 EGR Exhaust Gas Recirculation Actuator Malfunction
TVA Throttle Valve Actuator Circuit Malfunction
EGR Exhaust Gas Recirculation Flow Excessive or Inlet
Air Circuit Malfunction Detected
EGR Exhaust Gas Recirculation Flow Insufficient Detected
0081 DPF Particulate Filter - Low System Efficiency
DPF Particulate Filter - Engine Protection Active
0084 Vehicle Speed Sensor Malfunction
0091 EEC2 Message or Accelerator Pedal not Present
Accelerator Pedal Position Sensors Synchronization Error
Accelerator Pedal Position Sensor 1 Error
Accelerator Pedal Position Sensor 2 Error
Accelerator Pedal Position/Brake not plausible
RXEEC2 CAN Message Timeout Error
RXEEC2 CAN Message Out of Range
Accelerator Pedal Signal Above Threshold Value
0097 Water Level in Fuel Actuator Malfunction
Water in Fuel Sensor Circuit Malfunction
Water in Fuel Detection
0098 Critical Oil Mass Check Error
Critical Oil Viscosity Check Error
0100 Low Engine Oil Pressure Warning
Critical Engine Oil Pressure Warning
Engine Oil Pressure Sensor/Switch Signal Error
0102 Boost Pressure Warning
Boost Pressure Sensor Error
0105 Intake Air Temperature Sensor Warning
Intake Air Temperature Sensor Error
0108 Barometric Pressure Sensor Error
0110 Engine Coolant Temperature Warning
Engine Coolant Sensor Error
Engine Coolant Sensor Malfunction
0131 DPF Particulate Filter - Low System Efficiency
DPF Particulate Filter - Exhaust Gas Temperature Sensor
Error
DPF Particulate Filter - Filter Dismounted or Defective
DPF Particulate Filter - Differential Pressure not Plausible
DPF Particulate Filter - Differential Pressure not Plausible
DPF Particulate Filter - Engine Protection Active
DPF Particulate Filter - Engine Protection Active
DPF Particulate Filter - Differential Pressure Sensor
Defective
DPF Particulate Filter - Differential Pressure Sensor
Defective
0132 Raw Air Mass Signal Plausability Error
Battery Voltage Signal Range Check Error
Raw Air Mass Signal Error
Air Mass Signal Range Check Error of Reference Signal
248
MR 700
TVA, EGR, inlet air line and turbine
TVA, EGR, inlet air line and turbine
TVA, EGR, inlet air line and turbine
TVA, EGR, inlet air line and turbine
DPF sensor, DPF filter and exahust line
DPF sensor, DPF filter and exahust line
Speed sensor
wire-harness and CAN line
Pedal accelerator
Pedal accelerator
Pedal accelerator
(vuoto)
wire-harness and CAN line
wire-harness and CAN line
Pedal potentiometer circuit
Fuel line, fuel filter and fuel filter components
Fuel line, fuel filter and fuel filter components
Fuel line, fuel filter and fuel filter components
(vuoto)
(vuoto)
Oil sensor and oil circuit
Oil sensor and oil circuit
Oil sensor and oil circuit
Pressure sensor and inlet air line
Exahust line, inlet air line, turbine’s valve, turbine, pressu-
re sensor
Inlet air line, turbine, turbine’s valve and air teperature
sensors
Air temperature sensor
ECU
Water temperature sensor and cooling water circuit
Water temperature sensor and cooling water circuit
Water temperature sensor and cooling water circuit
DPF, DPF sensor, exahust line, TVA and EGR circuit
DPF, DPF sensor, exahust line, TVA and EGR circuit
DPF, DPF sensor, exahust line, TVA and EGR circuit
DPF, DPF sensor, exahust line, TVA and EGR circuit
DPF sensor, DPF filter and exahust line
DPF, DPF sensor, exahust line, TVA and EGR circuit
DPF sensor, DPF filter and exahust line
DPF, DPF sensor, exahust line, TVA and EGR circuit
DPF sensor, DPF filter and exahust line
Inlet air line
Power supply, ground, battery and voltage
Inlet air line
Inlet air line
Engine Instrumentation
 MR 700
0157 Fuel Rail Pressure Monitoring Error for Active Pressure Fuel line, fuel M-Prop valve
Control by Metering Unit Governor
PRV Rail Pressure Relief Valve Error Fuel line, PRV valve and fuel rail pressure sensor
0164 Fuel Rail Pressure Sensor Offset Monitoring Error Fuel line, fuel rail pressure sensor and M-Prop
Fuel Rail Pressure Signal Error Fuel line, fuel rail pressure sensor
0168 Battery Voltage Error Battery voltage, wire-harness and power supply circuit
0172 Air Temperature Signal Duty Cycle Error Air temperature sensor
0173 Exhaust Gas Temperature Sensor Error - Bank 1 - Posi- (vuoto)
tion 1
0174 Fuel Temperature Sensor Error Fuel line and fuel temperature sensor
0175 Engine Oil Temperature Warning Oil temperature sensor and oil level
Oil Temperature Sensor Signal Error Oil temperature sensor and oil level
0190 Engine Overspeed Warning RPM over limit
Crankshaft Position Sensor Error Cranck shaft sensor and startability
0228 Crankshaft/Camshaft Position Sensor Offset Error Cranck shaft sensor, cam shaft sensor and shafts position
0527 CCVS CAN Error on Cruise Control wire-harness and CAN line
Cruise Control Multi-Function Input “A”/”B” Correlation (vuoto)
Error (Invalid Switch Combination Detected)
0597 Brake Signal Error Break switch and pedal accelerator
0598 Main Clutch Signal Error Clutch switch
0604 Transmission Controller Unit TCU Neutral Lamp Error (vuoto)
0624 System Lamp Circuit Malfunction Sys lamp and wire-harness
0627 ECU Internal Supply Voltage Error ECU and wire-harness
ECU Internal Communication Error Between Function ECU
Computer and Monitoring Module
0628 ECU Internal EEPROM Memory Error ECU
Dataset Variant Coding Plausibility Error ECU
0629 ECU - Fuel Injector Control Module A Performance Error ECU
ECU - Fuel Injector Control Module B Performance Error ECU
ECU Overrun Monitoring Error ECU
ECU Redundant Engine Speed Monitoring Error ECU
ECU Internal Communication Error - SPI ECU
ECU Redundant Shut Off Test Error during Initialization ECU
ECU Processor Recovery Suppressed ECU
ECU Processor Recovery Locked ECU
E.C.U. Analogic/Digital Converter Error ECU
TPU Time Processing Unit Monitoring Error ECU
ECU Internal Watchdog/Controller Error ECU
ECU Internal Communication Error Between Function ECU
Computer and Monitoring Module
0633 PCV Pressure Control Valve Analogic/Digital Channel ECU
Error
PCV Pressure Control Valve PWM Circuit Malfunction ECU
0634 TVA Throttle Valve Actuator Monitoring Error Indicated by TVA, EGR, inlet air line and turbine
Digital Status Signal
TVA Throttle Valve Actuator Circuit Malfunction Inlet air line and electo-pneumatic circuit of TVA and EGR
TVA Throttle Valve Actuator Circuit Malfunction TVA, EGR, inlet air line and turbine

249 Engine Instrumentation

 MR 700
0639 CAN A Controller Error wire-harness and CAN line
CAN B Controller Error wire-harness and CAN line
CAN C Controller Error wire-harness and CAN line
CAN Messages Error from Communication Manager wire-harness and CAN line
0641 Turbo/Super Charger Overboost Condition Exahust line, inlet air line, turbine’s valve, turbine, pressu-
re sensor
Turbo/Super Charger Underboost Condition Inlet air line, turbine, turbine’s valve and air pressure
sensors
Air Temperature Sensor Error Air temperature sensor, oil temperature sensor and water
teperature sensor
BPA Boost Pressure Actuator Solenoid Circuit Malfunction Inlet air line, turbine and turbine’s valve
0651 Cylinder 1 - Injector Circuit Malfunction Warning Injector and fuel line
Cylinder 1 - Injector Circuit Malfunction Specific Error Injector and fuel line
0652 Cylinder 2 - Injector Circuit Malfunction Warning Injector and fuel line
Cylinder 2 - Injector Circuit Malfunction Specific Error Injector and fuel line
0653 Cylinder 3 - Injector Circuit Malfunction Warning Injector and fuel line
Cylinder 3 - Injector Circuit Malfunction Specific Error Injector and fuel line
0654 Cylinder 4 - Injector Circuit Malfunction Warning Injector and fuel line
Cylinder 4 - Injector Circuit Malfunction Specific Error Injector and fuel line
0655 Cylinder 5 - Injector Circuit Malfunction Warning Injector and fuel line
Cylinder 5 - Injector Circuit Malfunction Specific Error Injector and fuel line
0656 Cylinder 6 - Injector Circuit Malfunction Warning Injector and fuel line
Cylinder 6 - Injector Circuit Malfunction Specific Error Injector and fuel line
ECU - Fuel Injector Control Module A Performance Error ECU
ECU - Fuel Injector Control Module B Performance Error ECU
Energizing Time Calibration Error ECU
0657 Injector Bank 1 Circuit Malfunction Warning Injector and fuel line
Injector Bank 1 Circuit Malfunction Specific Error Injector and fuel line
0658 Injector Bank 2 Circuit Malfunction Warning Injector and fuel line
Injector Bank 2 Circuit Malfunction Specific Error Injector and fuel line
0675 Glow Lamp Indicator Malfunction Glow lamp and wire-harness
0676 GCU Glow Control Unit - Glow Plug GSK Diagnosis Tran- Glow plug system circuit
smission Error
GCU-R Glow Control Unit - Standard Voltage System Glow plug system circuit
Relay Circuit Malfunction
Glow Plug Circuit Malfunction Cylinder 1 Glow plug system circuit
Glow Plug Circuit Malfunction Cylinder 2 Glow plug system circuit
Glow Plug Circuit Malfunction Cylinder 3 Glow plug system circuit
Glow Plug Circuit Malfunction Cylinder 4 Glow plug system circuit
Glow Plug Circuit Malfunction Cylinder 5 Glow plug system circuit
Glow Plug Circuit Malfunction Cylinder 6 Glow plug system circuit

250 Engine Instrumentation

 MR 700
0677 T15 Terminal Signal Plausibility Error Wire-harness and power supply circuit
T50 Terminal Signal Plausibility Error Wire-harness and power supply circuit
Starter Relay Circuit Malfunction (high Side Power Stage) Wire-harness, starter relay
Starter Relay Circuit Malfunction (Low Side Power Stage) Wire-harness, starter relay
0679 Fuel Rail Pressure Monitoring Error for Active Pressure (vuoto)
Control by Pressure Control Valve Governor
PRV Rail Pressure Relief Valve Error Fuel line, PRV valve and fuel rail pressure sensor
0723 Camshaft Position Sensor Error Cranck shaft sensor, cam shaft sensor and shafts position
0767 Reverse Gear Switch Error (vuoto)
0835 Engine Oil Pressure Lamp Malfunction Oil lamp and wire-harness
0859 Fuel Filter Heating Relay Circuit Malfunction Fuel warmer relay
0898 TSC1-PE Torque/Speed Override Control Module PTO wire-harness and CAN line
Error Message
TSC1-VE Speed Override Vehicle Dynamic Control Modu- wire-harness and CAN line
le VC Error Message
0970 EBC1 CAN Message Timeout Error wire-harness and CAN line
0976 PTO CAN Message Timeout Error wire-harness and CAN line
0977 Fan 1 Control Relay Malfunction Fan circuit and relay
Fan 1 Control Relay Malfunction Fun relay and wire-harness
Fan 2 Control Relay Malfunction Fan circuit and relay
Fan 3 Control Relay Malfunction Fan circuit and relay
0979 PTO Enable Switch Circuit Malfunction (vuoto)

251 Engine Instrumentation

 MR 700

Engine start
When turning the key switch in ON position, it
happens as foloows:
• the tachometer diplays the VM logo and
then the partial and total engine operating
hours.
• engine oil pressure gauge alarm red light
lamps on but the buzzer does not sound.
• voltage battery gauge alarm red light lamps
on but the buzzer does not sound.
When the engine starts, it happens as follows:
• buzzer sounds and the tachometer dispalys
the alarm symbol alternately with the a a
low engine oil pressure symbol for about 1
second untill the engine oil pressure reaches
the nominal values.
• tachometer displays the the partial and total
engine operating hours
b c
Press the MENU button to view other menus:
a - RPM engine
b - battery voltage
c - OPS - oil pressure sensor - engine oil
pressure
d - CTS - coolant tempearture sensor - d e
engine coolant temperature
e - engine operating hours (total & partial)

252 Engine Instrumentation

 MR 700
Maintenance service interval simbol
After first 50 engine operating hours (running
in end) the service interval simbol appears on
tachometer/speedometer display as shown in
the picture.
This simbol indicates that the maintenance
service interval has to be carried out. Refer to
owner, engine operating manual to know the
maintenance operations.

Reset the tachometer/speedometer instrument

after carrying out the maintenance. Refer
to the following procedure to delete the
“Maintenance Interval Simbol - Key”

. Engine start key in position OFF

. Press the MENU button A for 2 seconds
and turn the engine start key in ON
position. The buzzer sounds. On display
appears “001 Code” + Key Simbol a
. Release the MENU button and press it
again for 5 seconds. The buzzer does
not sound and on display 001 Code” +
Key Simbol disappear “”

253 Engine Instrumentation

 MR 700
Resetting of package instrumentation
The resetting of the instrumentation package
is necessary when install it at first engine
operation or when it is disconnected from
electrical system.

Press for about 3 seconds the MENU button.

Turn the key switch in ON position.
A continuos beep sounds.
The LCD of tachometer get black. (see photo)
All 3 gauges lamp on (see photo).
Release the MENU button.
All 4 dials instruments come to full range.
When dials indicators of the instruments come
back to 0, the LCD of tachometer will display
the software version loaded in the tachometer.

a - version loaded in the tachometer (s12.A7)

a

254 Engine Instrumentation

 MR 700
Engine Electrical System Overload Protection
NOTE: The engine cover contains an access
panel which can be used to access the
engine circuit breakers and the oil fill cap
and dipstick without removing the entire
engine cover.

a - Engine circuit breaker panel

b - Oil fill cap
c - Oil dipstick
d - Engine cover with access panel removed
e - access panel

b c d

f
a

a 20 amp Un switched power to helm

b 10 amp Switched power to ECM
c 10 amp Keyed power to ECM
d 15 amp Switched power to ECM
e 15 amp ECM switched power to SIM
f 5 amp Power—diagnostic connector

255 Engine Instrumentation

 MR 700
Box relay and fuses - new solution

a - box relay and fuses

K2 main
relay K1 starter a
F3 - 10A relay
F4 - 15A
F5 - 15A
F2 - 10A
F6 - 5A
F1 - 20A

256 Engine Instrumentation

 MR 700
special tools
Picture Description Action VM order number

Diagnostic tool

The software
updating is available Aids in deleting DTC er-
68500010F
on VM Motori web rors and ECU diagnosis
site, Customer Re‑
served Area “EXTRA‑
NET”

Screws into the flywheel

housing to prevent
Flywheel Pin Tool crankshaft rotation during 6 848 0016 F
certain service procedu-
res.

Crankshaft Rotation Used to rotate the

(Barring) Tool (ONLY FOR crankshaft on assembled 6 840 0039 F
MR704) engines.

Dial Indicator Commercial tool

Holds and supports a dial

indicator for various mea-
Support Block 6 849 0007 A
surements; also used as a
base for the dial indicator.

Prevents crankshaft rota-

tion during certain service
Flywheel Holder Tool 6 848 0003 A
procedures; used only
with the starter removed.

Aids in the removal of the

Crankshaft Gear Puller 6 840 0038 F
crankshaft gear.

Removes and installs

Bearing Removal And
crankshaft bearings and 6 840 0015 A
Installation Tool
camshaft bearings

Protects the crankshaft

Crankshaft Gear Cover gear and bearings during
6 841 0006 A
Assembly Tool crankshaft removal and
installation.

Aligns the counterwei-

Balance Shaft Installation ghts on the balance shaft
6 848 0013 F
Tool assembly prior to installa-
tion/removal

257 Special Tools

 MR 700

Picture Description Action VM order number

Removes the cylinder

Cylinder Liner Puller 6 840 0012 A
liners.

Flywheel Assembly Guide Aids in the removal and

6 846 0005 F
Pins installation of the flywheel.

Aids in the removal and

Cylinder Head Assembly
installation of the cylinder 6 846 0003 A
Guide Pins
heads.

Aids in the removal and

Hydraulic Tappet Assem-
installation of the hydrau- 6 841 0012 F
bly tool
lic tappets.

Aids in the removal and 6 842 0016 F (side bolts)

Cylinder Head Bolts
installation of the cylinder 6 842 0015 F (center
wrench
heads bolts)

Aids in the torquing proce-

Angular torque wrench 6 842 0019 F
dure of the cylinder heads

Aids during oil front seal

Front Oil Seal Installer 68410013G
installation

68400040F Injector
Remover (Complete)

Aids in removing 68400046F Body

Injector Remover
injectors
68400044F Stud

68400045G Fork

258 Special Tools

 MR 700

6844009F Cylinder head seal hydraulic

test - without O-rings
68440010F
Cylinder head seal test with
hydraulic O-rings

Test Engine harness

68490035F (without both potentiometer

accelerator and ECU)

68490036F (with potentiometer accelera-

tor and without ECU)

68490037F (with both potentiometer ac-

celerator and with ECU)
68490034F Engine compression adapter
tester tool

Break out box

68500017F (without jumpers)

68500016F (complete of jumpers)

259 Special Tools

 MR 700

260 Special Tools

 MR 700

labour time guide

Flate Rate Table Instruction
EXPLANATION OF TABLE

All VM Motori products have a flate rate table which is used to complete warranty claims for labour reimbursement.

The times listed for each repair include all operations and procedures required to complete that job. The times are
listed in hours and tenth of hours.

VM Motori warranty labour reimbursement is computed at your approved warranty rate currently on record.

The table are arranged by engine sub-systems and related accessories, e.g. ignition system, power head, remote con-
trol, etc.

Diagnostic time needs to be listed along with the removal and replacement time to properly complete most warranty
claims. For example: replacing alternator on a VM Motori engine will have a code listed on the claim:
3Z-SEA Replacing alternator

Repairs requiring an outside expense such as maching, welding or painting will require the amount to be entered as
outside labour. If you have entered a sublet labour amount you must attached the receipt to the appropriate warranty
claim form.

When a repair requires the replacement of more that one part in a related procedure use the flate rate that covers the
entire repair. For example: cylinder block replacement on VM Motori engines code MR504.
Replacing flywheel housing includes removing and replacing of the flywheel. This would result in overlapping of flate
rate time which is not allowed.

Note:
For repairs that are not specified in the table or to request additional time beyond the established rate, you may use
the code NJC (No Job Code) and manually record the time in hours and tenths of hours. Attached a clear description
of the job done.

Operation No. Interpretation

Cod. 3Z — EAA/4
The first code group identifies the operation performed (e.g.:3Z = replacement)
The second group separated by a dash, identifies the component (e.g.: EAA = camshaft)
The number after the slash, identifies the quantity of the components involved in the operation, this number can be
omitted if there are no other similar components on the engine

1°) example: 3Z - EAA

replacement camshaft

This type of code is used when there are no other similar components or multiple components on the engine

2°) example: 10Z - OAA / 1 or 10Z - OAA / 6

test function on 1 injector test function on 6 injector

This type of code is used when there are other similar components or multiple components on the engine

261 Labour Time Guide

 MR 700

OPER. BASIC ENGINE HOURS

No.
7Z-AAA Total overhaul of the engine: 26
Including: (MR 704)
- dismantling all the components
- cleaning all of the components 34
- dimension check of the components subject to wear (MR706)
- checking the state of the other component
- replacing the faulty or worn components
- re-assembly
- functional test

8Z-AAA Partial overhaul of the engine: 12 (MR704)

Including: 14 (MR706)
- dismantling the head
- cleaning all of the components dismantled
- dimension check of the components subject to wear
- checking the state of the other components
- replacing the faulty or worn components
- re-assembly
- functional test

14Z-AAA ENGINE REMOVAL & REINSTALLATION 7 (MR704)

(STANDARD TIME) 8 (MR706)

3Z-ABA Replacing the cylinder block (crankcase): 18 (MR704)

- cleaning the whole engine with steam (high pressure water jet) 20 (MR706)
Dismantling and inspecting the components
- Re-assembly the engine with the crankcase, using the same pistons
or new pistons, new piston rings, a new series of bearings and scrapped
rings, basket and sealing ring
- Tightening to the specific torque
- Engine test and checking for leaks

9Z-DAA Re-tightening heads 0.25 (MR704)

0.30 (MR706)

10Z-DFA Checking one rocker arm: 0.25

- cleaning the removed rocker are group
- inspecting the parts, overhauling or replacing the same, if necessary
- re-assembly

262 Labour Time Guide

 MR 700

10Z- Checking all rocker arms: 0.50 (MR704)

DFA/4/6 - cleaning the removed rocker are group 0.75 (MR706)
- inspecting the parts, overhauling or replacing the same, if necessary
- re-assembly
3Z-BAA Replacing the crankshaft 18 (MR704)
- R/R flywheel cover 20 (MR706)
- R/R oil sump
- R/R heads
- R/R connecting rod cap
3Z-MCE Replacing the front oil seal 0.40

3Z-BIG Replacing the rear oil seal 1

3Z-BHA Replacing the central bed support 18 (MR704)

- R/R oil sump an sump oil pipe (oil suction pipe) 20 (MR706)
- R/R flywheel housing and flywheel
- R/R exchangers
- R/R heads and manifolds
- R/R front cover

11Z-PAA Adjusting the engine speed 0.25

3Z-BIA Replacing rear main bearing: 1

- R/R flywheel housing and flywheel

3Z-QAA Replacing the main front bearing: 18 (MR704)

20 (MR706)

3Z-QBB Replacing connecting rod bearing: 8 (MR704)

- R/R oil sump 10 (MR706)
- R/R heads and manifolds
3Z-BLA Replacing front pulley� 0.25

3Z-JAA Replacing accessory�����

��������������
belt 0.25

3Z-BFA Replacing flywheel assembly 0.25

3Z-BFE Replacing starter ring gear: 0.40

- R/R flywheel

263 Labour Time Guide

 MR 700
3Z-MAA Replacing flywheel housing: 0.30
- R/R flywheel

3Z-MCA Replacing front cover and gasket 1.30

3Z-PAC Replacing fuel pump drive gear: 1.40

- R/R front cover

3Z-BAF Replacing crankshaft gear: 2

- R/R front cover

3Z-LCB Replacing balance shaft unit: MR 704 1.20

- R/R front cover

3Z-GAA Replacing oil pump: 1.20

- R/R front cover

3Z-BFA Replacing timing gear assembly : 8 MR 704

3Z-LCB - R/R front cover 8.30 MR 706
3Z-PAC
3Z-EAC
3Z-CAA/1 Replacing one piston and connecting rod: 10 MR 704
- R/R heads and basket 12 MR 706
- R/R oil sump

3Z-CAA/4 Replacing all pistons and connecting rods: 12 MR 704

3Z-CAA/6 - R/R heads and gasket 14 MR 706
- R/R oil sump
3Z-CAD Replacing piston rings on all pistons: 12 MR 704
- R/R heads 14 MR 706
- R/R front cover
- R/R piston
3Z-EAA Replacing camshaft assembly: 6.30 MR 704
- R/R heads 7 MR 706
- R/R front cover
- R/R tappets

3Z-EAF Replacing camshaft oil seal: 0.40

- R/R flywheel housing

3Z-AIA/1 Replacing one liner 10 MR 704

- R/R heads 12 MR 706
- R/R oil sump
- R/R pistons

3Z-AIA/4 Replacing all liners 12 MR 704

3Z-AIA/6 - R/R heads 14 MR 706
- R/R oil sump
- R/R pistons

264 Labour Time Guide

 MR 700
3Z-DFA/1 Replacing one rocker arm 0.50

3Z- Replacing all rocker arms 1.30 MR 704

DFA/4/6 1.40 MR 706

3Z-ECA Replacing one pushrod 1

- R/R rocker arm
3Z-ECA/8 Replacing all pushrods 1.40 MR 704
3Z- - R/R rocker arm 1.50 MR 706
ECA/12

3Z-EBA Replacing all tappets: 5 MR 704

- R/R heads 6 MR 706
- R/R manifolds
3Z-MHA Replacing valve cover and gasket 0.30

3Z-KHA Replacing intercooler 2 MR 704

2.10 MR 706

3Z-KDA Replacing turbocharger 0.50

3Z-KBA Replacing exhaust manifold: 1.45 MR 704

- R/R intercooler 1.30 MR 706
- R/R turbocharger
3Z-HGA Replacing water/water exchanger 1

3Z-MBA Replacing oil sump 0.25 MR 704

0.30 MR 706

3Z-HAA Replacing fresh water pump 0.30

3Z-HBA Replacing sea water pump 0.25

3Z-HBC Replacing see water pump impeller 0.25

3Z-HDA Replacing water thermostat valve 0.25

3Z-HCA Replacing head water pipe 0.5 MR 704

1. MR 706
1Z-HGA Revision and cleaning water/water exchanger 1

9Z-HGA Re-tightening heads 0.25 MR 704

0.30 MR 706
10Z-AAA

265 Labour Time Guide

 MR 700

OPER. FUEL SYSTEM HOURS

No.
3Z-OHB Fuel pressure accumulator (rail) 0.75
- high pressure fuel delivery pipes tightening procedure

3Z-PAA Replacing high pressure pump 1.30

- check injection pump
- R/R fuel delivery pipes
- high pressure fuel delivery pipes tightening procedure
3Z-PAA

3Z-OFA

11Z-PAA

3Z-OBA

3Z-OBA

3Z-OAA Replacing one injector : 0.75

- high pressure fuel delivery pipes tightening procedure & refresh
IMA code inside ECU

3Z-OAA/4 Replacing all injector : 1.20 MR 704

- high pressure fuel delivery pipes tightening procedure & refresh 1.50 MR 706
IMA code inside ECU
10Z-OAA Check functionality all injectors 0.30

12Z-OEL Bleed fuel system 0.25

3Z-HGU Replacing water/fuel exchanger 0.25

3Z-OEC Replacing fuel filter 0.25

3Z-OCA Replacing high pressure line 0.25

high pressure fuel delivery pipes tightening procedure
3Z-OEA Replacing fuel������������
����������������
return�����
�����������
line
���� 0.25

14F-SLA Diagnosis 0.30

3Z-SMR Mprop replacement 0.25

266 Labour Time Guide

 MR 700

OPER. No. LUBRICATION SYSTEM HOURS

10Z-GGA Check oil pressure relief valve: 0.50

- R/R oil sump

3Z-RAA Replacing rockers arms lubrication pipe 0.25

3Z-RCA Replacing turbocharger oil delivery pipe 0.25

3Z-RCD Replacing turbocharger oil return pipe 0.25

3Z-CRD Replacing oil filter 0.25

OPER. No. ELECTRICAL SYSTEM HOURS

3Z-SEA Replacing alternator 0.25

3Z-SGA Replacing starter motor 0.25

3Z-SGD Replacing starter motor solenoid assembly 0.30

3Z-SAA Replacing wiring ha�����

r����
ness 1

3Z-SAA Replacing injectors wiring harness 0.50

3Z-SLA Replacing electronic control unit (ECU) 0.25

3Z-SHA Replacing dash panel 0.25

NJC No Job Code to be detailed (time

and descriptions)

267 Labour Time Guide

 MR 700

268 Labour Time Guide

 MR 700
engine control
Diagnostic Trouble Codes
NOTE: In VM Motori internet web site Customer Reserved Area “EXTRANET”, section “Diagnostic Tool & Trouble-
shooting Common Rail Engines R750 MR700-500” are available:
• the lastest Diagnostic Tool Software Release for Common Rail Engine Models
• Industrial and Marine Common Rail engine troubleshooting symptoms charts

ENGLISH ITALIANO DTC

Crankshaft/Camshaft Position Sensor Offset
Error
BPA Boost Pressure Actuator Solenoid Circuit
Malfunction
BPA Boost Pressure Actuator Solenoid Circuit
Malfunction
BPA Boost Pressure Actuator Solenoid Circuit
Malfunction
Air Temperature Signal Duty Cycle Error
Fuel Rail Pressure Monitoring Error for Active
Pressure Control by Metering Unit Governor
Fuel Rail Pressure Monitoring Error for Active
Pressure Control by Metering Unit Governor
Fuel Rail Pressure Monitoring Error for Active
Pressure Control by Metering Unit Governor
Fuel Rail Pressure Monitoring Error for Active
Pressure Control by Metering Unit Governor
Fuel Rail Pressure Monitoring Error for Active
Pressure Control by Metering Unit Governor
Fuel Rail Pressure Monitoring Error for Active
Pressure Control by Metering Unit Governor
Raw Air Mass Signal Plausability Error
Raw Air Mass Signal Plausability Error
Battery Voltage Signal Range Check Error
Air Mass Signal Range Check Error of Reference Errore Segnale Portata Aria di Riferimento
Signal
Intake Air Temperature Sensor Error
Intake Air Temperature Sensor Warning
Engine Coolant Sensor Error
Engine Coolant Temperature Warning
Accelerator Pedal Position Sensor 1 Error
Fuel Temperature Sensor Error
Fuel Rail Pressure Signal Error
Fuel Rail Pressure Sensor Offset Monitoring
Error
Oil Temperature Sensor Signal Error
Engine Oil Temperature Warning
Errore di Posizione Sensore Albero a Camme/Al- P0016
bero Motore
Malfunzionamento Circuito Solenoide Attuatore P0046
di Controllo Pressione di Sovralimentazione BPA
Malfunzionamento Circuito Solenoide Attuatore P0047
di Controllo Pressione di Sovralimentazione BPA
Malfunzionamento Circuito Solenoide Attuatore P0048
di Controllo Pressione di Sovralimentazione BPA
Errore Duty Cycle Segnale Temperatura Aria P0070
Errore Pressione Rail durante Controllo Pressio- P0087
ne Rail da Regolatore di Pressione
Errore Pressione Rail durante Controllo Pressio- P0088
ne Rail da Regolatore di Pressione
Errore Pressione Rail durante Controllo Pressio- P0089
ne Rail da Regolatore di Pressione
Errore Pressione Rail durante Controllo Pressio- P0090
ne Rail da Regolatore di Pressione
Errore Pressione Rail durante Controllo Pressio- P0091
ne Rail da Regolatore di Pressione
Errore Pressione Rail durante Controllo Pressio- P0092
ne Rail da Regolatore di Pressione
Errore di Plausibilità Segnale Portata Aria P0100
Errore di Plausibilità Segnale Portata Aria P0101
Errore Intervallo di Controllo Segnale Tensione P0103
Batteria
P0104
Errore Sensore Temperatura Aria in Aspirazione P0110
Allarme Sensore Temperatura Aria in Aspirazione P0113
Errore Sensore Acqua Motore P0115
Allarme Temperatura acqua Motore P0118
Errore Posizione Pedale Acceleratore - Sensore P0120
1
Errore Sensore Temperatura Gasolio P0180
Errore Segnale Pressione Rail P0190
Errore Controllo Scostamento Segnale Pressione P0191
Rail
Errore Segnale da Sensore Temperatura Olio P0195
Motore
Allarme Temperatura Olio Motore P0198

269 Engine Control

 MR 700
Cylinder 1 - Injector Circuit Malfunction Warning Cilindro 1 - Allarme di Malfunzionamento Circuito P0201
Iniettore
Cylinder 2 - Injector Circuit Malfunction Warning Cilindro 2 - Allarme di Malfunzionamento Circuito P0202
Iniettore
Cylinder 3 - Injector Circuit Malfunction Warning Cilindro 3 - Allarme di Malfunzionamento Circuito P0203
Iniettore
Cylinder 4 - Injector Circuit Malfunction Warning Cilindro 4 - Allarme di Malfunzionamento Circuito P0204
Iniettore
Cylinder 5 - Injector Circuit Malfunction Warning Cilindro 5 - Allarme di Malfunzionamento Circuito P0205
Iniettore
Cylinder 6 - Injector Circuit Malfunction Warning Cilindro 6 - Allarme di Malfunzionamento Circuito P0206
Iniettore
Accelerator Pedal Position Sensor 2 Error Errore Posizione Pedale Acceleratore - Sensore P0220
2
Accelerator Pedal Position Sensors Synchroniza- Errore di Sincronizzazione Sensori di Posizione P0221
tion Error Pedale Acceleratore
Turbo/Super Charger Overboost Condition Condizioni di Alta Pressione di Sovralimentazio- P0234
ne
Boost Pressure Sensor Error Errore Sensore Pressione di Sovralimentazione P0235
Boost Pressure Warning Allarme Pressione di Sovralimentazione P0238
Metering Unit Solenoid PWM Control Circuit Malfunzionamento Circuito di Controllo PWM P0252
Malfunction Solenoide Regolatore di Pressione
Metering Unit Solenoid PWM Control Circuit Malfunzionamento Circuito di Controllo PWM P0253
Malfunction Solenoide Regolatore di Pressione
Metering Unit Solenoid PWM Control Circuit Malfunzionamento Circuito di Controllo PWM P0254
Malfunction Solenoide Regolatore di Pressione
PCV Pressure Control Valve Analogic/Digital Errore Canale Analogico/Digitale di Controllo P0256
Channel Error Valvola Regolazione Portata Combustibile PCV
PCV Pressure Control Valve PWM Circuit Mal- Malfunzionamento Circuito PWM di Controllo Val- P0257
function vola Regolazione Portata Combustibile PCV
PCV Pressure Control Valve PWM Circuit Mal- Malfunzionamento Circuito PWM di Controllo Val- P0258
function vola Regolazione Portata Combustibile PCV
PCV Pressure Control Valve PWM Circuit Mal- Malfunzionamento Circuito PWM di Controllo Val- P0259
function vola Regolazione Portata Combustibile PCV
Cylinder 1 - Injector Circuit Malfunction Specific Cilindro 1 - Errore Specifico di Malfunzionamento P0262
Error Circuito Iniettore
Cylinder 2 - Injector Circuit Malfunction Specific Cilindro 2 - Errore Specifico di Malfunzionamento P0265
Error Circuito Iniettore
Cylinder 3 - Injector Circuit Malfunction Specific Cilindro 3 - Errore Specifico di Malfunzionamento P0268
Error Circuito Iniettore
Cylinder 4 - Injector Circuit Malfunction Specific Cilindro 4 - Errore Specifico di Malfunzionamento P0271
Error Circuito Iniettore
Cylinder 5 - Injector Circuit Malfunction Specific Cilindro 5 - Errore Specifico di Malfunzionamento P0274
Error Circuito Iniettore
Cylinder 6 - Injector Circuit Malfunction Specific Cilindro 6 - Errore Specifico di Malfunzionamento P0277
Error Circuito Iniettore
Turbo/Super Charger Underboost Condition Condizioni di Bassa Pressione di Sovralimenta- P0299
zione
Crankshaft Position Sensor Error Errore Sensore di Giri Albero Motore P0335
Engine Overspeed Warning Allarme Fuorigiri Motore P0338
Camshaft Position Sensor Error Errore Sensore di Fase Albero a Camme P0340
GCU-R Glow Control Unit - Standard Voltage GCU Unità di Controllo Candelette Malfunziona- P0380
System Relay Circuit Malfunction mento Relè
Glow Lamp Indicator Malfunction Malfunzionamento Spia Candelette P0381

270 Engine Control

 MR 700
EGR Exhaust Gas Recirculation Flow Insufficient Portata Insufficiente del Ricircolo dei Gas di P0401
Detected Scarico EGR
EGR Exhaust Gas Recirculation Flow Excessive Portata Eccessiva del Ricircolo dei Gas di Scari- P0402
or Inlet Air Circuit Malfunction Detected co EGR o Malfunzionamento Impianto di Ingres-
so Aria
EGR Exhaust Gas Recirculation Actuator Malfun- Malfunzionamento Attuatore Ricircolo Gas di P0404
ction Scarico EGR
Fan 1 Control Relay Malfunction Malfunzionamento Circuito Relè Ventola 1 P0480
Fan 2 Control Relay Malfunction Malfunzionamento Circuito Relè Ventola 2 P0481
Fan 3 Control Relay Malfunction Malfunzionamento Circuito Relè Ventola 3 P0482
TVA Throttle Valve Actuator Monitoring Error Errore Attuatore Valvola Parzializzatrice Aspira- P0487
Indicated by Digital Status Signal zione TVA Indicato da Segnale Digitale di Stato
TVA Throttle Valve Actuator Circuit Malfunction Malfunzionamento Circuito Attuatore Valvola P0488
Parzializzatrice Aspirazione TVA
EGR Exhaust Gas Recirculation Actuator Malfun- Malfunzionamento Attuatore Ricircolo Gas di P0489
ction Scarico EGR
EGR Exhaust Gas Recirculation Actuator Malfun- Malfunzionamento Attuatore Ricircolo Gas di P0490
ction Scarico EGR
Vehicle Speed Sensor Malfunction Malfunzionamento Sensore di Velocità Veicolo P0500
Brake Signal Error Errore Segnale Freno P0504
Incorrect Immobilizer Key Chiave Immobilizer non Corretta P0513
Engine Oil Pressure Sensor/Switch Signal Error Errore Segnale da Sensore Pressione Olio Mo- P0520
tore
Engine Oil Pressure Lamp Malfunction Malfunzionamento Spia Pressione Olio Motore P0521
Critical Engine Oil Pressure Warning Allarme Pressione Olio Motore Critica P0522
Low Engine Oil Pressure Warning Allarme Pressione Olio Motore Bassa P0524
Battery Voltage Error Errore Tensione Batteria P0560
Cruise Control Multi-Function Input “A”/”B” Malfunzionamento Circuito di Controllo Cruise P0585
Correlation Error (Invalid Switch Combination Control (Controllo Dati di Input non Valido)
Detected)
Add-on heater Circuit Malfunction Malfunzionamento Circuito Riscaldatore Ausilia- P0597
rio
ECU Internal Communication Error - SPI ECU Errore di Comunicazione Interna - SPI P0600
ECU Internal EEPROM Memory Error ECU Errore Interno Memoria EEPROM P0601
TPU Time Processing Unit Monitoring Error Errore di Verifica Tempo di Attivazione Processo- P0606
re TPU
ECU Internal Watchdog/Controller Error Errore Interno Controllore/Processore ECU P0607
Energizing Time Calibration Error Errore Calibrazione Tempo di Apertura Iniettore P0611
Starter Relay Circuit Malfunction Malfunzionamento Circuito Relè Comando Moto- P0615
rino di Avviamento
Starter Relay Circuit Malfunction (Low Side Malfunzionamento Circuito Relè Comando Moto- P0616
Power Stage) rino di Avviamento (Low Side Power Stage)
Starter Relay Circuit Malfunction (high Side Malfunzionamento Circuito Relè Comando Moto- P0617
Power Stage) rino di Avviamento (high Side Power Stage)
Sensor Supply Voltage 1 Check Error Errore Verifica Tensione di Alimentazione Sensori P0641
1
Air Conditioning Relay Circuit Malfunction Malfunzionamento Circuito Relè Aria Condizio- P0645
nata
MIL Lamp Circuit Malfunction Malfunzionamento Circuito Spia MIL P0650
Sensor Supply Voltage 2 Check Error Errore Verifica Tensione di Alimentazione Sensori P0651
2
GCU Glow Control Unit - Glow Plug GSK Dia- GCU Unità di Controllo Candelette - Errore Tra- P0670
gnosis Transmission Error smissione Diagnosi GSK

271 Engine Control

 MR 700
Glow Plug Circuit Malfunction Cylinder 1 Malfunzionamento Circuito Candeletta Cilindro 1 P0671
Glow Plug Circuit Malfunction Cylinder 2 Malfunzionamento Circuito Candeletta Cilindro 2 P0672
Glow Plug Circuit Malfunction Cylinder 3 Malfunzionamento Circuito Candeletta Cilindro 3 P0673
Glow Plug Circuit Malfunction Cylinder 4 Malfunzionamento Circuito Candeletta Cilindro 4 P0674
Glow Plug Circuit Malfunction Cylinder 5 Malfunzionamento Circuito Candeletta Cilindro 5 P0675
Glow Plug Circuit Malfunction Cylinder 6 Malfunzionamento Circuito Candeletta Cilindro 6 P0676
Main Relay Control Error Errore Controllo Main Relè P0685
Fan 1 Control Relay Malfunction Malfunzionamento Circuito Relè Ventola 1 P0691
Fan 1 Control Relay Malfunction Malfunzionamento Circuito Relè Ventola 1 P0692
Sensor Supply Voltage 3 Check Error Errore Verifica Tensione di Alimentazione Sensori P0697
3
Transmission Controller Unit TCU Generic Error Errore Generico Centralina Cambio TCU P0700
Main Clutch Signal Error Errore Segnale Frizione P0704
Transmission Controller Unit TCU Torque Con- Centralina Cambio TCU Valore di Coppia da P0740
verted Clutch out of Tolerance Convertitore Fuori Tolleranza
Reverse Gear Switch Error Errore Commutatore Inversione di Marcia Cam- P0812
bio
Transmission Controller Unit TCU Neutral Lamp Centralina Cambio TCU Malfunzionamento Spia P1000
Error Cambio in Neutro
Transmission Controller Unit TCU Internal Error Errore Interno Centralina Cambio TCU P1601
E.C.U. Analogic/Digital Converter Error Errore Convertitore Analogico/Digitale E.C.U. P1602
Engine Coolant Sensor Malfunction Malfunzionamento Sensore Acqua Motore P1603
T15 Terminal Signal Plausibility Error Errore di Plausibilità Segnale Terminale T15 P1605
T50 Terminal Signal Plausibility Error Errore di Plausibilità Segnale Terminale T50 P1606
ECU Processor Recovery Locked ECU Ripristino Processore Bloccato P1612
ECU Internal Supply Voltage Error ECU Errore Tensione di Alimentazione Interna P1613
ECU Internal Supply Voltage Error ECU Errore Tensione di Alimentazione Interna P1614
Plausibility Error on Base Map for Torque to Errore di Plausibilità nella Mappa di Conversione P1615
Quantity Conversion Coppia/Introduzioni
ECU - Fuel Injector Control Module A Performan- ECU - Errore Prestazione Modulo A di Controllo P1616
ce Error Iniezioni
ECU - Fuel Injector Control Module B Performan- ECU - Errore Prestazione Modulo B di Controllo P1617
ce Error Iniezioni
ECU Overrun Monitoring Error ECU Errore Contollo Limiti Tempo di Attivazione P1619
Iniettori
ECU Redundant Engine Speed Monitoring Error ECU Errore Controllo di Ridondanza Segnale P161A
Giri Motore
ECU Processor Recovery Suppressed ECU Ripristino Processore Abolito P161B
ECU Redundant Shut Off Test Error during Initia- ECU Errore Test di Ridondanza Disattivazione P1620
lization Iniettori durante Inizializzazione
ECU Internal Communication Error Between Errore Interno di Comunicazione tra Processore P1627
Function Computer and Monitoring Module e Modulo di Controllo
Dataset Variant Coding Plausibility Error Errore di Plausibilità della Codifica Variante P1628
Dataset
System Lamp Circuit Malfunction Malfunzionamento Circuito Spia di Sistema P1650
Transmission Controller Unit TCU Gear Incorrect Errore Interno Centralina Cambio TCU Rapporto P1701
Ratio Marcia Errato
Transmission Controller Unit TCU Solenoid Cir- Centralina Cambio TCU Errore Circuito Solenoidi P1702
cuit Error
Transmission Controller Unit TCU Engine/Turbi- Centralina Cambio TCU Errore Sensore Velocità P1703
ne Speed Sensor Error Turbina

272 Engine Control

 MR 700
Transmission Controller Unit TCU Solenoid Centralina Cambio TCU Valvola Commutatrice P1704
Switch Valve Latched Bloccata
Transmission Controller Unit TCU Relay Error Centralina Cambio TCU Errore Relay P1801
Transmission Controller Unit TCU Pressure Centralina Cambio TCU Errore nella Verifica P1802
Switch Check Error Commutatore di Pressione
Transmission Controller Unit TCU Pressure Centralina Cambio TCU Test Funzionamento P1803
Switch Test Failed Commutatore di Pressione Fallito
DPF Particulate Filter - Filter Dismounted or DPF Filtro Particolato - Filtro Smontato o Difetto- P2002
Defective so
Fuel Filter Heating Relay Circuit Malfunction Malfunzionamento Circuito Relè Riscaldatore P2030
Filtro Gasolio
Exhaust Gas Temperature Sensor Error - Bank 1 Errore Sensore di Temperatura Gas di Scarico P2031
- Position 1 - Bancata 1 - Posizione 1
Exhaust Gas Temperature Sensor Error - Bank 1 Errore Sensore di Temperatura Gas di Scarico P2033
- Position 2 - Bank 1 - Posizione 2
Exhaust Gas Temperature Sensor Plausibility Errore nella Verifica di Plausibilità Sensore di P2080
Check Error - Position 1 Temperatura Gas di Scarico - Posizione 1
Exhaust Gas Temperature Sensor Plausibility Errore nella Verifica di Plausibilità Sensore di P2084
Check Error - Position 2 Temperatura Gas di Scarico - Posizione 2
TVA Throttle Valve Actuator Circuit Malfunction Malfunzionamento Circuito Attuatore Valvola P2141
Parzializzatrice Aspirazione TVA
TVA Throttle Valve Actuator Circuit Malfunction Malfunzionamento Circuito Attuatore Valvola P2142
Parzializzatrice Aspirazione TVA
Injector Bank 1 Circuit Malfunction Warning Allarme di Malfunzionamento Circuito Iniettori P2147
Bancata 1
Injector Bank 1 Circuit Malfunction Specific Error Errore Specifico di Malfunzionamento Circuito P2148
Iniettori Bancata 1
Injector Bank 2 Circuit Malfunction Warning Allarme di Malfunzionamento Circuito Iniettori P2150
Bancata 2
Injector Bank 2 Circuit Malfunction Specific Error Errore Specifico di Malfunzionamento Circuito P2151
Iniettori Bancata 2
Barometric Pressure Sensor Error Errore Sensore Pressione Atmosferica P2226
Water in Fuel Sensor Circuit Malfunction Malfunzionamento Circuito Sensore Acqua nel P2266
Gasolio
Water in Fuel Sensor Circuit Malfunction Malfunzionamento Circuito Sensore Acqua nel P2267
Gasolio
Water in Fuel Detection Rilevamento Acqua nel Gasolio P2269
PRV Rail Pressure Relief Valve Error Errore Valvola di Limitazione Pressione Massima P2293
Rail PRV
PRV Rail Pressure Relief Valve Error Errore Valvola di Limitazione Pressione Massima P2294
Rail PRV
Accelerator Pedal Position/Brake not plausible Posizione Acceleratore/Freno non plausibile P2299
EGR Cooler By-pass Valve Actuator Malfunction Malfunzionamento Attuatore By-pass Radiatore P2425
EGR
EGR Cooler By-pass Valve Actuator Malfunction Malfunzionamento Attuatore By-pass Radiatore P2426
EGR
EGR Cooler By-pass Valve Actuator Malfunction Malfunzionamento Attuatore By-pass Radiatore P2427
EGR
Exhaust Gas Temperature Sensor Error - Bank 1 Errore Sensore di Temperatura Gas di Scarico P2428
- Position 1 - Bancata 1 - Posizione 1
DPF Particulate Filter - Engine Protection Active DPF Filtro Particolato - Protezione Motore Attiva P242F
DPF Particulate Filter - Differential Pressure DPF Filtro Particolato - Sensore Pressione Diffe- P2452
Sensor Defective renziale Difettoso

273 Engine Control

 MR 700
DPF Particulate Filter - Differential Pressure not DPF Filtro Particolato - Pressione Differenziale P2453
Plausible non Plausibile
DPF Particulate Filter - Low System Efficiency DPF Filtro Particolato - Efficienza Sistema Bassa P2458
PTO Enable Switch Circuit Malfunction Malfunzionamento Commutatore PTO P251C
Water Level in Fuel Actuator Malfunction Malfunzionamento Attuatore Livello di Acqua nel P3200
Gasolio
CAN Messages Error from Communication Ma- Errore Messaggi CAN da Gestore Comunicazioni U0001
nager CAN
CAN A Controller Error Errore Controllo Linea CAN A U0028
CAN B Controller Error Errore Controllo Linea CAN B U0037
CAN C Controller Error Errore Controllo Linea CAN C U0046
CAN Message Timeout Error from Transmission Errore Messaggio CAN da Centralina Cambio U0101
Controller Unit TCU TCU
CCVS CAN Error on Cruise Control CCVS Errore Messaggio CAN da Cruise Control U0104
RXEEC2 CAN Message Timeout Error RXEEC2 Errore Messaggio CAN U0107
PTO CAN Message Timeout Error PTO Errore Messaggio CAN U0117
TSC1-VE Speed Override Vehicle Dynamic Con- TSC1-VE Errore Messaggio da Controllo Veicolo U0122
trol Module VC Error Message VC
EBC1 CAN Message Timeout Error EBC1 Errore Messaggio CAN U0129
TSC1-PE Torque/Speed Override Control Module TSC1-PE Errore Messaggio da Controllo Esterno U0140
PTO Error Message di Coppia/Velocità PTO
Lost Communication with Vehicle Immobilizer Comunicazione con Centralina Immobilizer U0167
Control Module Interrotta
Invalid Data Received from Transmission Con- Dati Ricevuti da Centralina Cambio TCU non U0402
troller Unit TCU Coerenti
RXEEC2 CAN Message Out of Range RXEEC2 Messaggio CAN oltre i limiti U0408
Invalid Data Received from Vehicle Immobilizer Dati Ricevuti da Centralina Immobilizer non Coe- U0426
Control Module (EEPROM Error) renti (Errore EEPROM)
EEC2 Message or Accelerator Pedal not Present EEC2 Errore Messaggio CAN o Pedale Accelera- U1001
tore non presente
Accelerator Pedal Signal Above Threshold Value Segnale Pedale Acceleratore Eccede Limite U1002
Superiore

274 Engine Control

 MR 700
Electrical sensor

Sensore di fase
Phase sensor
Sensore presenza acqua
nel combustibile
Sensore pressione/tem- Water in fuel sensor
peratura olio motore
Pressure/temperature
lube oil sensor

275 Engine Control

 MR 700

Sensore temperatura
acqua motore
Coolant temperature
sensor

Sensore posizione albero motore/giri motore

RPM/crankshaft position sensor

276 Engine Control

 MR 700

Sensore temperatura/pressione
aria comburente
Air pressure/temperature sensor

277 Engine Control

 MR 700

Sensore pressione rail

Rail pressure sensor

Valvola MPROP regolazione portata

combustibile
Fuel metering valve

278 Engine Control