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INSTALLATION MANUAL

4-Stroke Engine
MPE 850 OFF-ROAD
This installation manual is valid for the following engine variants:
409135 I2 846 UTV NA-80

TD409135_EHB
Rev A
04.08.2015
en_English

Before you begin installing the engine, read the installation manual. Pay
particular attention to the safety messages.

Textron Motors GmbH strives to make continual improvements as part of the ongoing technical development
of its products. All documentation is therefore subject to technical modifications.
Reprints and translations, in whole or in part, require written permission from Textron Motors GmbH.
All rights reserved according to the copyright law.
Textron Motors GmbH
Daimlerstrae 5
88677 Markdorf
Deutschland
www.weber-motor.com

Table of contents

Table of contents
1 About this document
1.1

Meaning of symbols and signal words. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2 Safety

7
2.1
2.2

Meaning of safety alert symbol and signal words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7


Important safety messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3 For engine function required vehicle parameters

10

4 Description

11

4.1 Permissible operating conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


4.1.1 Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.2 Operating positions engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.1 Closed coolant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.1.1 Installation heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.1.2 Installation permanent vent coolant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.1.3 Installation Textron Motors expansion tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.1 Installation fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.2 Installation Textron Motors fuel main filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.3 Installation Textron Motors fuel pre-filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.4 Installation Textron Motors fuel pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Lubrication system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.1 Installation engine oil supply and return with a Textron Motors oil tank . . . . . . . . . . . . . . .
4.4.2 Installation crankcase ventilation / engine oil return with a Textron Motors oil tank . . . . . .
4.4.3 Installation blow-by-return with a Textron Motors oil tank. . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.4 Determination of the fill quantity engine oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.5 Determination of the fill quantity engine oil with a Textron Motors oil tank . . . . . . . . . . . . .
4.5 Intake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.1 Intake system naturally aspirated engines (NA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.1.1 Installation intake air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.1.2 Installation blow-by-return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6 Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6.1 Exhaust system naturally aspirated engines NA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6.1.1 Installation primary exhaust pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.1 Engine management system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.2 Electrical connection engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.2.1 For operating required additional parts at the engine.. . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.2.2 Wiring diagram engine MPE850 UTV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.2.3 Electrical connection battery, starter, relay starter and engine ground . . . . . . . . . . . . . .
4.7.2.4 Installation and electrical connection Textron Motors relay starter . . . . . . . . . . . . . . . . .
4.7.2.5 Installation and electrical connection Textron Motors voltage regulator . . . . . . . . . . . . .
4.7.2.6 Installation engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11
11
11
12
12
15
15
16
17
18
19
19
20
21
23
23
24
24
25
27
27
28
28
29
29
30
31
31
32
32
33
34
35
35
37

EHB MPE850 Rev A | 409135 |

Table of contents

4.7.2.7 Specification wire harness MPE850 UTV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


4.7.3 Electrical connection vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.3.1 Electrical equipment vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.3.2 Connection scheme vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.3.3 Description of vehicle components at vehicle connector Engine-Chassis . . . . . . . . . .
4.7.3.4 Installation and electrical connection Textron Motors throttle request unit . . . . . . . . . . .
4.8 Required manufacturer's instructions to service tasks and repairs . . . . . . . . . . . . . . . . . . . .
4.8.1 End customer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.8.2 Workshop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5

Installation data
5.1 Requirements for the engine compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1.1 Accessibility engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Installation engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.1 Installation position engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.2 Mounting engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.2.1 Decoupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.2.2 Mounting points at the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.2.3 Interface drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Initial operation

38
40
40
42
43
48
49
49
50
51
51
51
52
52
52
52
53
55
56

6.1 Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56


6.2 Lift engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
6.3 Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Appendix

58
Engine manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Overview of revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

EHB MPE850 Rev A | 409135 |

1 About this document


1.1 Meaning of the symbols and signal words

1 About this document


This installation manual and service manual contains all necessary design information to integrate the engine
into the vehicle.
Observe the following references:
Read this installation manual and service manual before installing the engine in the vehicle.
If chapters of the installation manual are incomprehensible or questions remain unanswered, please
contact directly to Textron Motors.
Make sure that all developers and designers of the vehicle have access to the installation manual and
service manual.
You also need the Textron Motors Diagnostic Tool.
Some figures in this installation manual are general illustrations and may differ from the actual engine.

1.1 Meaning of symbols and signal words


Item
NOTICE

Meaning
The signal word NOTICE indicates potential property damage.

EHB MPE850 Rev A | 409135 |

2
2.1

Safety

Meaning of safety alert symbol and signal words

Safety

This engine is state-of-the-art and built according to recognized safety-technical regulations. Inappropriate
installation of the engine may result in personal injury or property damage. The engine installation to the
vehicle must be approved by Textron Motors, before the serial production of the vehicle.
This installation manual is only intended for using by the vehicle manufacturer. All tasks on the engine must
be performed by appropriately trained personnel.
Observe all generally applicable laws and regulations in addition to the information in this installation manual:
Accident prevention
Environmental protection
Handling of hazardous materials
Personal safety equipment
Traffic laws

2.1

Meaning of safety alert symbol and signal words


Item

Meaning

The safety alert symbol draws your attention to possible dangers.

WARNING

The signal word WARNING indicates a potentially dangerous situation that may
lead to a serious or fatal injury.

CAUTION

The signal word CAUTION indicates a potentially dangerous situation that may
lead to a minor or moderately severe injury.

EHB MPE850 Rev A | 409135 |

2 Safety
2.2

2.2

Important safety messages

Important safety messages

Service tasks

In order to keep your engine in a safe operating condition, regular


servicing is essential. It is your responsibility to ensure that the engine is
serviced correctly.

Perform regular inspections and observe the specified service


intervals.

Spare parts

All the components in your engine have been carefully tested and fulfill
strict quality and safety requirements.

Textron Motors offers spare parts to the highest quality. Ensure that
equivalent spare parts corresponds with this quality requirements.

Add-on parts and modifications

The consequences of attaching add-on parts and making unauthorized


modifications to the engine are unknown and pose a safety risk to
personnel.

Modifications and the attachment of add-on parts is only permitted if


approved or provided by Textron Motors.

Engine exhaust gases

Engine exhaust gases contain carbon monoxide (CO). Inhalation of


carbon monoxide can deprive the body of oxygen and result in organ
damage or death by asphyxiation.

Never operate the engine in enclosed spaces.

Handling of fuel, engine oil and


coolant

Operating materials pose a health risk.

Always read the manufacturer's instructions.

Always wash your hands prior to eating, smoking and using the
restroom as well as at the end of the working shift when working
with operating materials.
Operating materials are hazardous to the environment.

Never allow operating materials to escape into the groundwater,


water courses or sewage system. Always dispose of operating
materials according to applicable national regulations.
Danger of slipping on spilled fluids.

Always use a filler neck or funnel when filling components with


operating materials.

Always clean up any spilled operating materials immediately.

EHB MPE850 Rev A | 409135 |

2
2.2

Safety

Important safety messages

Fuel

Fuel is highly flammable. Vapors may ignite and cause an explosion.

Do not smoke in the vicinity of the engine and do not allow open
flames or sparks near the engine or the fuel system.

Never fill with fuel while the engine is running.

Do not start the engine if there is a smell of fuel or you suspect that
fuel is leaking.

Fuel on hot surfaces can cause fires.

Do not extinguish with water. In the event of a fire, use foam, dry
chemical or carbon dioxide extinguishers.

Engine oil

Engine oil is flammable. During heating or in case of fire, toxic gases may
form.

Do not smoke in the vicinity of the engine and do not allow open
flames or sparks near the engine.

Engine oil on hot surfaces can cause fires.

Do not extinguish with water. In the event of a fire, use foam, dry
chemical or carbon dioxide extinguishers.

California Proposition 65

Warning against chemicals/hazardous materials according to the law of


the state of California. This product contains chemicals known to the State
of California to cause cancer, birth defects, or other reproductive harm.

EHB MPE850 Rev A | 409135 |

For engine function required vehicle parameters

For engine function required vehicle parameters


WARNING! The Textron Motors standard vehicle parameters are
safety critical. The vehicle parameters described in this section are
essential for a safe limp home mode in the event of an error and
must be validated during vehicle testing.

Vehicle specification

Vehicle curb weight minimum of 500 kg


Vehicle with 4 wheels. No single track vehicle.

Interaction

The torque request/actuation comes from a Textron Motors throttle


request unit or a Textron Motors approved throttle control pedal. The
electrical connection is done at the control unit. No additional installations
inside of the lines are permitted.
Mechanical actuation is effected by the driver.

Drive train

Only CVTs (Continuously Variable Transmission) are applicable. No direct


drive gearbox with manual or automatic clutch.
Final drive ratio, corresponding to a vehicle top speed for
high gear > 90 km/h @ 8000 min-1 [rpm]
low gear > 40 km/h @ 8000 min-1 [rpm]
CVT engagement speed 1600 2000 min-1 [rpm]
CVT shift speed under full load 7500 100 min-1 [rpm]
Two-wheel drive and four-wheel drive possible

Interfaces electrical system

10

The components that are marked in chapter 4.7.3.3 Description of


vehicle components at vehicle connector Engine-Chassis with
required must be provided by the vehicle manufacturer.

EHB MPE850 Rev A | 409135 |

4
4.1

Description

Permissible operating conditions

Description

4.1

Permissible operating conditions

4.1.1 Temperature
Ambient temperature

-25 45 C

Temperature engine
compartment

Maximum 85 C in continuous operation, short-term 105 C

4.1.2

Operating positions engine

All declared angles refer to the vertical installation of the engine.


Drive angle side tilt

Drive angle ascent

Drive angle incline

Under full load

30 1

Under part load up to 3000 min-1 [rpm]

35

Under full load

30 1

20 minutes at idle

40

3 seconds under full load

60 1

Under full load

30 1

20 minutes at idle

40

Clutch engaged

45

Angles must be validated during vehicle testing

EHB MPE850 Rev A | 409135 |

11

4 Description
4.2 Cooling system

4.2

Cooling system

4.2.1

Closed coolant circuit

System

The closed coolant circuit is a full flow bypass arrangement. During warmup no coolant leaves the engine, except through the permanent vent. Not
until the operating temperature is reached, the internal thermostat directs
the main current through the external heat exchanger. For this reason
the intended operating temperature of the engine is achieved as early as
possible. The thermostat is fitted with a wax element:
Opening temperature from 82 C
Fully open at 88 C
The heat exchanger engine oil/coolant (oil cooler) uses a permanent
bypass flow for cooling the engine oil.
The coolant pump is a radial pump driven by the balance shaft.

Flow rate

At least 65 liter/minute @ 6500 min-1 [rpm] at fully open thermostat

Operating pressure

Maximum 1,2 bar

Operating temperature

85 110 C

Temperature warning light


(not in scope of supply)

The use of a temperature warning light is required. Observe


chapter 4.7.3.3 Description of vehicle components at vehicle
connector Engine-Chassis.

External heat exchanger


(not in scope of supply)

Delta-T heat exchanger 7 8 K at fully open thermostat


Required heat rejection 20 kW
For the heat rejection an additional fan is required. The fan is controlled
via relay activated by the engine control unit. Observe chapter 4.7.3.3
Description of vehicle components at vehicle connector EngineChassis.

Expansion tank
(not in scope of supply)

Textron Motors recommends at least 10 % of the total volume coolant, but


not less than 0,5 liters.
Pressure relief valve 1,2 bar
Textron Motors offers a suitable expansion tank TM 101801 and cover
WM 100550 with integrated pressure relief valve 1,2 bar.

12

EHB MPE850 Rev A | 409135 |

4
4.2

Description

Cooling system

Coolant
(not in scope of supply)

Information of coolant specification and mixing ratio you will find in the
service manual of the engine.

Coolant lines
(not in scope of supply)

Textron Motors standard specification hoses:


Hose material EPDM 65 ShA 5 ShA, reinforced
Pressure range up to 4 bar
Temperature range -50 130 C
Hose length maximum 600 mm
NOTICE! Damage from overheating caused by air in the coolant circuit.
Due to expanded coolant hoses during vehicle operation the coolant in the
expansion tank and heat exchanger can be drawn off. This will allow air
entering the coolant circuit and the cooling performance is deteriorated.
For hoses longer than 600 mm use 70 % rigid pipes.

EHB MPE850 Rev A | 409135 |

13

4
4.2

Description
Cooling system

ku2

ku6
ku1

ku4
ku3

ku8
ku5

ku7

Scheme cooling system with closed thermostat


ku1 Heat exchanger
ku2 Oil cooler
ku3 Coolant pump
ku4 Sensor coolant temperature

ku5
ku6
ku7
ku8

Thermostat, closed
Permanent vent coolant circuit
Expansion tank
Expansion volume of the expansion tank

ku9

Scheme cooling system with opened thermostat


ku9 Thermostat, opened

14

EHB MPE850 Rev A | 409135 |

4
4.2

4.2.1.1

Description

Cooling system

Installation heat exchanger

The dimensions are on the interface drawing in


chapter 5.2.2 Mounting engine.
Observe the specification of the coolant lines. (See
chapter 4.2.1 Closed coolant circuit.)
Connection to heat exchanger 1
Inner diameter coolant line 25,4 mm
Connection from heat exchanger 2
Inner diameter coolant line 25,4 mm

1
2

4.2.1.2

Installation permanent vent coolant circuit

The venting of the cooling system uses a


permanent vent at the highest point of the internal
coolant circuit.
Connect the permanent vent with the expansion
volume of the expansion tank. Alternatively, the
expansion volume can also be integrated in the
heat exchanger. Please observe however, that
the expansion volume is always located above
the entire coolant circuit. (See chapter 4.2.1.3
Installation Textron Motors expansion tank).
NOTICE! Damage from overheating caused by air
in the coolant circuit. Install the permanent vent,
so that the coolant flow is ensured on the cylinder
head exhaust side.

The dimensions are on the interface drawing in


chapter 5.2.2 Mounting engine.
Observe the specification of the coolant lines. (See
chapter 4.2.1 Closed coolant circuit.)
Connection permanent vent coolant circuit
Inner diameter coolant line 6 mm

EHB MPE850 Rev A | 409135 |

15

Description

4.2

Cooling system

4.2.1.3

Installation Textron Motors expansion tank

NOTICE! Damage from overheating caused by air


in the coolant circuit. Install the permanent vent,
so that the coolant flow is ensured on the cylinder
head exhaust side.
The dimensions are on the interface drawing in
chapter 5.2.2 Mounting engine.

Observe the specification of the coolant lines. (See


chapter 4.2.1 Closed coolant circuit.)
Connection permanent vent coolant circuit
Inner diameter coolant line 6 mm
Expansion tank

Connection coolant circuit to expansion tank


3 Inner diameter coolant line 16 mm
3

Observe that the highest point of the whole cooling


system must be between the MIN-marking and the
MAX-marking 4 .
Highest point internal coolant circuit
engine

of the
4
5

16

EHB MPE850 Rev A | 409135 |

4.3

Description

4.3

Fuel system

Fuel system

System

Sequential multipoint intake manifold injection, no return stroke system

Operating pressure

4 bar

Permissible operating
temperature

Maximum 55 C in fuel tank

Fuel pump
(not in scope of supply)

12 V electric fuel pump:


Flow rate at least 55 liter/hour at 4 bar
Backpressure valve for maintain the operating pressure
Installation in the fuel line
Textron Motors offers a suitable fuel pump TM 103584.

Fuel pressure regulation


(not in scope of supply)

4 bar

Fuel main-filter
(not in scope of supply)

Textron Motors offers a suitable fuel main -filter TM 408338 with the
following specification:

Textron Motors offers a suitable fuel main filter with integrated pressure
regulator.

Integrated fuel pressure regulator 4 bar


Mesh size 15 m
Filter grade 95 %
Installation in the fuel line
Fuel pre-filter
(not in scope of supply)

To protect the fuel pump against contamination Textron Motors


recommends to use a fuel pre-filter.
Textron Motors offers a suitable fuel pre-filter TM 103397 with the
following specification:
Mesh area 7,6 cm
Mesh size 105 m
Installation in the fuel line

Fuel
(not in scope of supply)

Information of fuel specification you will find in the service manual of the
engine.
Textron Motors recommends to place the recommended fuel quality for
the vehicle user permanently and good visible on the fuel tank.

EHB MPE850 Rev A | 409135 |

17

4 Description
4.3

Fuel system

Observe all generally applicable laws and regulations in addition to the


information when selecting hoses and connections.

Fuel line
(not in scope of supply)

Pressure range minimum 4 bar


Inner diameter fuel lines 8 mm

kr1

kr2

kr8
kr7
kr3

kr4

kr5

kr6

Scheme fuel system


kr1 Fuel rail
kr2 Injectors
kr3 Fuel main filter
kr4 Fuel pressure regulator

4.3.1

kr5
kr6
kr7
kr8

Back-pressure valve
Fuel pump
Fuel pre-filter
Fuel tank (not in scope of supply)

Installation fuel supply

The dimensions are on the interface drawing in


chapter 5.2.2 Mounting engine.
Observe the specification of the fuel lines. (See
chapter 4.3 Fuel system.)
Connection fuel supply
line 8 mm
Pipe clamp

18

Inner diameter fuel

for fixing the fuel hose

EHB MPE850 Rev A | 409135 |

4.3.2

Description

4.3

Fuel system

Installation Textron Motors fuel main filter

Observe the specification of the fuel lines. (See


chapter 4.3 Fuel system.)
Inner diameter fuel lines 8 mm

For the installation of the fuel lines quick


connectors are required.

Textron Motors offers quick connectors in straight


design 2 TM 104228 and angled design 3
TM 104227.

The quick connectors are validated by SAE J2044.


3

4.3.3

Installation Textron Motors fuel pre-filter

Observe the specification of the fuel lines. (See


chapter 4.3 Fuel system.)
Inner diameter fuel lines 8 mm

EHB MPE850 Rev A | 409135 |

19

4 Description
4.3 Fuel system

4.3.4

Installation Textron Motors fuel pump

Observe the specification of the fuel lines. (See


chapter 4.3 Fuel system.)
NOTICE! Defective fuel pump caused by dry
operation and corrosion. Install the fuel pump
at a lower level than the fuel tank. Observe
when routing the hoses, that the fuel pump is
permanently filled with fuel, even the turned off fuel
pump.
Both connections internal thread M10x1
Hose fittings are required.

Electrical connections 2
threaded bolts 6-32 UNC-2A

Textron Motors offers a fitting TM 400247 as a


hose fitting. The installation will be done with a seal
TM 101107, which must be replaced after removal.
Inner diameter fuel line 8 mm

The fitting can be used at fuel input and fuel


output.

Textron Motors offers a banjo fitting TM 401091 as


a hose fitting. The installation will be done with a
banjo bolt TM 103605 and 2 seals TM 101107. The
seals must be replaced after removal.
Inner diameter fuel line 8 mm

The banjo fitting can only be used at fuel input.

20

EHB MPE850 Rev A | 409135 |

4
4.4

4.4

Description

Lubrication system

Lubrication system

System

Dry sump engine with 2 separate oil pumps. A rotor pump builds up oil
pressure and conveys the engine oil to the lubrication points in the engine.
The suction pump conveys the engine oil from the crankcase to the oil
tank. This air/engine-oil-mix will be separated in the oil tank.

Operating pressure

Oil pressure at 3000 min-1 [RPM] with engine at operating temperature of


minimum 2,5 bar

Oil pressure light


(not in scope of supply)

The use of an oil pressure light is required. Observe chapter 4.7.3.3


Description of vehicle components at vehicle connector EngineChassis.

Maximum oil pressure

5,5 bar limited by oil pressure valve


With cold engine oil, the maximum pressure can be exceeded.

Operating temperature

125 C in main oil gallery, maximum 135 C in oil tank

Oil tank
(not in scope of supply)

For operating a dry sump engine, an oil tank is required, which ensures a
continuous engine oil supply during operation.
Textron Motors offers a suitable oil tank TM 404653 with the following
specification:
Oil separator system (cyclone)
Internal baffles
Oil drain plug
Oil dipstick for the level measurement

Oil filter

Screw-on oil filter

Engine oil
(not in scope of supply)

Information of engine oil grade you will find in the service manual of the
engine.

Hoses
(not in scope of supply)

Textron Motors standard specification:


Hose material HNBR 65 ShA 5 ShA, reinforced
Pressure range up to 4 bar
Temperature range -40 150 C

EHB MPE850 Rev A | 409135 |

21

4 Description
4.4

Lubrication system

s4
s15
s6

s14

s3

s2

s13
s12
s5
s9
s10

s1
s7

s11
s8

Scheme lubrication system


s1 Oil tank
s2 Internal baffles
s3 Oil separator system (cyclone)
s4 Blow-by-return to intake system
s5 Crankcase ventilation / Engine oil return, inner
diameter 3 mm
s6 Engine
s7 Engine oil, engine to oil tank

22

s8
s9
s10
s11
s12
s13
s14
s15

Engine oil, oil tank to engine


Suction pump
Oil pressure pump (rotor pump)
Oil pressure valve
Oil filter
Oil cooler
Switch oil pressure
Oil pressure light

EHB MPE850 Rev A | 409135 |

4
4.4

4.4.1

Description

Lubrication system

Installation engine oil supply and return with a Textron Motors oil tank

The dimensions are on the interface drawing in


chapter 5.2.2 Mounting engine.
Observe the specification of the hoses. (See
chapter 4.4 Lubrication system.)
Engine oil return, from engine to oil tank
Inner diameter hose 18 mm

Engine oil supply, from oil tank to engine


Inner diameter hose 18 mm

1
2

4.4.2

Installation crankcase ventilation / engine oil return with a Textron Motors oil tank

The dimensions are on the interface drawing in


chapter 5.2.2 Mounting engine.
Observe the specification of the hoses. (See
chapter 4.4 Lubrication system.)
The fitting has an inner diameter of 3 mm. The
inner diameter must not be changed.
Crankcase ventilation / Engine oil return
Inner diameter 6 mm
At oil tank: Inner diameter hose 12 mm

EHB MPE850 Rev A | 409135 |

23

4 Description
4.4 Lubrication system

4.4.3

Installation blow-by-return with a Textron Motors oil tank

Observe the specification of the hoses. (See


chapter 4.4 Lubrication system.)
Install the blow-by-return into the upstream clean
air line of the throttle body or before the air
cleaner. (See chapter 4.5.1.2 Installation blow-byreturn.)

NOTICE! Freezing damages. Observe when


routing the hoses, that no condensation residues
will remain in the hose for example by a sagging
hose.

The oil tank fitting

is rotatable by 180.

Blow-by-return to intake system


diameter 16 mm

4.4.4

hose inner

Determination of the fill quantity engine oil

The engine requires at least 2,5 liter engine oil.


The oil tank and the hoses have to be designed
in that way that during operation at least 2,5 liter
engine oil circulates.
Engine oil ducts

24

EHB MPE850 Rev A | 409135 |

4
4.4

4.4.5

Description

Lubrication system

Determination of the fill quantity engine oil with a Textron Motors oil tank

The engine is fully installed and mounted in the


vehicle.

Fill engine oil through the opening 1 of the


oil dipstick up to the MIN-marking.
1

Unscrew the switch oil pressure

Screw in the adapter M10x1 for oil pressure


tester according to the manufacturer's
instructions.

Tightening torque:
9 Nm +2 Nm [6.6 lbf ft +1.5 lbf ft]
2

Disconnect the ignition coils 3 and


injectors 4 from the power supply.

Crank the engine with starter until the oil


pressure reaches minimum 1 bar.

Fill engine oil up to the MIN-marking.

Connect the power supply of the ignition


coils and injectors.

EHB MPE850 Rev A | 409135 |

25

4 Description
4.4

Lubrication system

Unscrew the adapter M10x1.

Apply Loctite 542 to the thread of switch oil


pressure.

Screw in the switch oil pressure.


Tightening torque:
9 Nm +2 Nm [6.6 lbf ft +1.5 lbf ft]

Warm up the engine. (See the service


manual of the engine.)

Check the oil level.

26

EHB MPE850 Rev A | 409135 |

4
4.5

4.5
4.5.1

Description
Intake system

Intake system
Intake system naturally aspirated engines (NA)

System

Standard intake system for a naturally aspirated engine, consisting of air


cleaner, electronic throttle body, airbox and intake fittings.

Installation condition

For optimal performance, the temperature of the intake air at entry


throttle body must not exceed the ambient temperature from 5 K to
maximum 10 K. Observe the protective functions in service manual of the
engine.

Air cleaner
(not in scope of supply)

Filter quality > 96 % according to SAE J726 test:


Flow rate 850 CFM, PTI Fine test dust
Termination at 30 of water
Maximum pressure drop at 270 kg/h: 15 mbar
Suitable product example: Fleetguard OptiAir Air Cleaner 500 Series

Hoses
(not in scope of supply)

Textron Motors standard specification:


Hose material HNBR 65 ShA 5 ShA, reinforced
Pressure range up to 4 bar
Temperature range -40 150 C

an2

an1

an4

an5
an6

an7

an3
Scheme intake system
an1 Engine
an2 Intake manifold
an3 Sensor pressure/temperature
an4 Throttle body, electronic

EHB MPE850 Rev A | 409135 |

an5
an6
an7

Air cleaner
Intake air
Blow-by-return from lubrication system

27

4 Description
4.5 Intake system

4.5.1.1

Installation intake air

The dimensions are on the interface drawing in


chapter 5.2.2 Mounting engine.
Observe the specification of the hoses. (See
chapter 4.5.1 Intake system naturally aspirated
engines (NA).)
Intake air cleaner to throttle body
diameter hose 50 mm

Inner

Hose length 300 600 mm


Permissible angle x = 90
Radius minimum 100 mm

4.5.1.2

Installation blow-by-return

See chapter 4.4.3 Installation blow-by-return


with a Textron Motors oil tank.

28

EHB MPE850 Rev A | 409135 |

4
4.6

4.6
4.6.1

Description

Exhaust system

Exhaust system
Exhaust system naturally aspirated engines (NA)
Recommended dimensioning:

Exhaust pipes
(not in scope of supply)

Primary exhaust pipes inner diameter 38 mm, length 180 mm


Joint exhaust pipes inner diameter 50,8 mm, length 85 mm
Secondary exhaust pipes total length 400 700 mm

Exhaust back pressure

Under full load 175 mbar 25 mbar

Sensor lambda
(not in scope of supply)

For engine operation a sensor lambda is required. Observe


chapter 4.7.2.1 For operating required additional parts at the engine.

Muffler
(not in scope of supply)

3 chamber resonance damper

Catalyzer
(not in scope of supply)

Metal catalyzer, diameter 63 mm, length 77 mm

Recommended volume 15 18 liter

Cell density 400 cpsi, loading 33 g/ft^3, foil thickness 0,08 mm


Proportion Pt : Pd : Rh 1 : 0 : 1
Distance from catalyzer to the exhaust flange of the cylinder head
300 600 mm

ag1

ag6
ag7

ag2
ag3

ag5
ag4

Layout exhaust pipe and muffler


ag1 Engine
ag2 Primary exhaust pipes
ag3 Sensor lambda, recommended position
ag4 Catalyzer

EHB MPE850 Rev A | 409135 |

ag5
ag6
ag7

Secondary exhaust pipe


Muffler
Exhaust gas flow

29

4 Description
4.6 Exhaust system

4.6.1.1

Installation primary exhaust pipes

The dimensions are on the interface drawing in


chapter 5.2.2 Mounting engine.
Exhaust gaskets 2 and mounting nuts 1 are in
scope of supply of the engine.
Observe that the exhaust gaskets and mounting
nuts must be replaced after removal.
1
2

30

EHB MPE850 Rev A | 409135 |

4
4.7

4.7

Description

Electrical system

Electrical system

System

12 V, negative earth

Throttle body

Electronic throttle body with redundant potentiometers

Ignition system

Electronically controlled distributorless ignition system with single spark


ignition coils (coil-on-plug) at each cylinder.

Starter

Electric starter 800 W, type Bendix


Engagement of the rotor gear ring at the generator

Generator, internal

Internal three-phase generator with permanent magnet


Rotor-stator type, integrated on engine drive side

4.7.1

Engine management system

System
System

Torque control based engine management system with a electronically


controlled throttle body (drive-by-wire)

Engine control unit

Engine control unit Synerject M3D

Textron Motors Diagnostic Tool

Textron Motors offers a diagnosis tool for updating the calibration,


troubleshooting, recording data items and resetting the service light.

SHB MPE850 Rev A | 409135 |

31

4 Description
4.7 Electrical system

4.7.2
4.7.2.1

Electrical connection engine


For operating required additional parts at the engine.

Engine control unit

The Textron Motors engine control unit is in scope of supply of the engine.
Observe that the engine's serial number is saved in the engine control
unit.

Voltage regulator
(Additional part)

Textron Motors 3-phase voltage regulator TM 407227.


Regulated voltage 14,5 V
Rated current 40 A, maximum 48 A
Maximum permissible temperature 90 C
Supply is exclusive with the delivery of the engine. Textron Motors offers
the voltage regulator as an additional part. Order the voltage regulator as
part of the additional parts package or separately.

Sensor lambda
(Additional part)

Sensor Lambda NTK ZFAS TM 406241


No alternative types are permitted.
Installing according to the manufacturer's instructions.
Supply is exclusive with the delivery of the engine. Textron Motors offers
the sensor lambda as an additional part. Order the sensor lambda as part
of the additional parts package or separately.

Relay starter
(Additional part)

Relay starter Tyco 1416010-1 TM 405225.


No alternative types are permitted.
Supply is exclusive with the delivery of the engine. Textron Motors offers
the relay starter as an additional part. Order the relay starter as part of the
additional parts package or separately.

Wire harness
(not in scope of supply)

Observe in the design of the wire harness the chapter 4.7.2.7


Specification wire harness MPE850 UTV.
The wire harness will be currently not offered and will be not available in
the short-term. Please inquire the delivery time.

Diagnostic connector
(Component wire harness)

Engines operated with a Textron Motors calibration, must have a


diagnostic connector for the Textron Motors Diagnostic Tool.
See chapter 4.7.2.7 Specification wire harness MPE850 UTV.

32

SHB MPE850 Rev A | 409135 |

4
4.7

4.7.2.2

Description

Electrical system

Wiring diagram engine MPE850 UTV

The wiring diagram is based on


the specification in chapter 4.7.2.7
Specification wire harness MPE850 UTV.

*Use30ampsrelayswithinternalparallel
connectedresistortocoil
(e.g.SongChuan3011ADR112VDC)
**Userelayswithinternalparallel
connectedresistortocoil
14
85

Mainrelay*

86
87

15A
Service

30

Battery+

15A
VBR

15A
VBD

1
6

10

17

16
15

30A
Main

26
33
21
23
28
27

CruisecontrolON/OFF
Cruisecontrolresume
Cruisecontrolset+
Cruisecontrolset
CruisecontrolGND

11

Engine/Chassisconnector
Delphi13601803

24
30

Brakelightswitch

GND

Brakelight

Powerlimit
Reverselimiter

GND
GND

Neutralswitch

18

Vehiclespeedinput

12

Rolloversensor

GND

22
85

15

Key
switch

30

35

31

CANhigh

Outputandfusing
customerspecific

87

GND

Fanrelay**

86

32

34 36 37 38 39 40

50

30

10A
VBK

85
86

30

10A

twisted

87

Max.20mA

5Voutput

Fuelpump

CANlow

Fuelpumprelay*

Service

PPS2Signal

PPS25V

PPS1Signal

PPS15V

PPS2GND

MIL
ByusingLEDsits
recommendedtoconnecta
10kOhmsresistor

PPS1GND

RPMoutput

Pedalvaluesensor
ConnectorforWeberPedalvalue
sensorTyco19676161

Watertemp.

Oilpressure

EHB MPE850 Rev A | 409135 |

33

Description

4.7

Electrical system

4.7.2.3
X**
G
K
M
*
**

Electrical connection battery, starter, relay starter and engine ground

Connection engine ground


Battery
Relay starter
Starter
Engine ground at crankcase. No separate
wire required.
To connect the engine ground use an
unused internal thread M8. All not used
mounting points are suitable. (See
chapter 5.2.2.2 Mounting points at the
engine.) No shared mounting with other
parts is permitted.

Table: Wire lengths and cross sections


Sum of L1 + L2 + L3

Cross section

<2m

16 mm

>2m

25 mm

Electrical connection starter:


to relay starter

thread M6

NOTICE! Starter damage. The pre-assembled nut


2 at the starter must not be unscrewed. For the
cable connection use an additional nut 3 and
washer.

34

SHB MPE850 Rev A | 409135 |

4
4.7

4.7.2.4

Description

Electrical system

Installation and electrical connection Textron Motors relay starter

Electrical connections:
to battery

thread M6

to engine wire harness


to starter

thread M6

1
2

4.7.2.5
X
G

Installation and electrical connection Textron Motors voltage regulator

Connection voltage regulator


Battery (not in scope of supply)

To connect the voltage regulator to the battery the


following mating connectors are required:
Wire cross section minimum 2 x 2,5 mm
Connector plug 2-pole Metri Pack 630 Delphi
12034269
TPA Delphi 12034364
Male connectors 3,0 mm Delphi 12064737
Male connectors 5,0 mm Delphi 12064736
Single wire seals

SHB MPE850 Rev A | 409135 |

35

4
4.7

Description
Electrical system

Pay attention to the following references during


installation:
Install the voltage regulator
heat-conductive surface.

on a cold and

The voltage regulator must be flush with the


whole base area 3 .

Do not install the voltage regulator near by hot


parts.
The cooling fins
vertically.

must be arranged

Electrical connections voltage regulator:


to engine ground

(Minus)

to Generator, internal
to battery direct

(AC Voltage)

(Plus)

36

SHB MPE850 Rev A | 409135 |

4
4.7

4.7.2.6

Description

Electrical system

Installation engine control unit

Pay attention to the following references during


installation:
Preferably install the engine control unit 1
vibration-resistant not directly to the engine.
The maximum permissible surface temperature
of the engine control unit is 95 C.

1
2

Install the connector plugs of the engine control


unit 2 downwards to prevent moisture
through condensation in the connector plugs.

Dimensions engine control unit

Measuring point surface temperature

SHB MPE850 Rev A | 409135 |

37

4 Description
4.7 Electrical system

4.7.2.7

Specification wire harness MPE850 UTV

WARNING! The wire harness is a safety


critical component. The functional and
electrical compatibility must be tested
during vehicle testing and approved by
Textron Motors.
Textron Motors recommends to implement
the wiring harness of the engine according
to this Specification wire harness MPE850
UTV.

38

EHB MPE850 Rev A | 409135 |

4
4.7

EHB MPE850 Rev A | 409135 |

Description

Electrical system

39

4 Description
4.7 Electrical system

4.7.3
4.7.3.1

Electrical connection vehicle


Electrical equipment vehicle
All components described in this chapter are not in scope of supply of the
engine:

Throttle request unit

For operating the engine, a throttle request unit is required (drive-by-wire).


The throttle request unit sends a torque request to the engine control unit.
Textron Motors offers throttle request units designed for throttle cable
actuation with the following cable runs:
TM 406546 cable run 28 mm
TM 406547 cable run 70 mm
WARNING! The throttle request unit is a safety critical component.
Using another throttle request unit, the functional and electrical
compatibility must be tested and approved by Textron Motors.
Observe the installation instruction.
Alternatively to the Textron Motors throttle request unit are the following
throttle control pedals with integrated pedal value sensor applicable:
Williams Controls PWCS-W092
Continental S7D-016-802

Battery

Minimum 12 V 20 Ah
12 V 40 Ah at low ambient temperatures.
Cranking amps minimum 260 A

Ignition switch

3 position key switch or ignition switch with a separate starter button.


Observe chapter Description of vehicle components at vehicle
connector Engine-Chassis.

Relays

Relays with internal parallel connected resistor to coil are required.


Maximum current consumption 0,5 A.
Textron Motors recommends for the main relay and the relay fuel pump a
30 A relay. For example Song Chuan 35 A 14 VDC 301-1A-C-R1.

External operating-hour counter


vehicle

40

For an external operating-hour counter in the vehicle the hours of


operation can be detected separately at the power supply of fuel pump.

SHB MPE850 Rev A | 409135 |

4
4.7

Lights

Description

Electrical system

Permissible load of each light 5 W.


LED lights need a 10 k parallel resistor.
Observe chapter 4.7.3.3 Description of vehicle components at vehicle
connector Engine-Chassis.

SHB MPE850 Rev A | 409135 |

41

4 Description
4.7 Electrical system

4.7.3.2

Connection scheme vehicle

*Use30ampsrelayswithinternalparallel
connectedresistortocoil
(e.g.SongChuan3011ADR112VDC)
**Userelayswithinternalparallel
connectedresistortocoil
14
85

Mainrelay*

86
87

15A
Service

30

Battery+

15A
VBR

15A
VBD

1
6

10

17

16
15

30A
Main

26
33
21
23
28
27

CruisecontrolON/OFF
Cruisecontrolresume
Cruisecontrolset+
Cruisecontrolset
CruisecontrolGND

11

Engine/Chassisconnector
Delphi13601803

24
30

Brakelightswitch

GND

Brakelight

Powerlimit
Reverselimiter

GND
GND

Neutralswitch

18

Vehiclespeedinput

12

Rolloversensor

GND

22
85

15

Key
switch

87
30

35

31

CANhigh

Outputandfusing
customerspecific

86

GND

Fanrelay**

32

34 36 37 38 39 40

50

30

10A
VBK

85
86

30

10A

twisted

87

Max.20mA

5Voutput

Fuelpump

CANlow

Fuelpumprelay*

Service

PPS2Signal

PPS25V

PPS1Signal

PPS15V

ByusingLEDsits
recommendedtoconnecta
10kOhmsresistor

PPS2GND

MIL

PPS1GND

RPMoutput

Pedalvaluesensor
ConnectorforWeberPedalvalue
sensorTyco19676161

Watertemp.

Oilpressure

42

EHB MPE850 Rev A | 409135 |

4
4.7

4.7.3.3

Description

Electrical system

Description of vehicle components at vehicle connector Engine-Chassis

Observe the additional information about vehicle components in chapter 4.7.3.1 Electrical equipment
vehicle.

Vehicle component
Contact
Engine
chassis

Wire
harness
cct

Using

Connection instructions

Description

Terminal 15 Key Switch Signal


7

30

required

From ignition switch = VBK, Voltage Battery Key

The terminal 15 signal is used to start up or shut down the engine control unit.
Observe that the signal at engine start must not be interrupted. When the
terminal 15 signal disappears during operation the injection will be deactivated
immediately and engine will be turned off.
Terminal 30 Plus Battery
6

33

required

From battery = VBD, Voltage Battery Direct

The direct battery connection is required for the function of the engine control
device.
Terminal 50 Plus Starter Signal
5

66

required

From ignition switch (starter button)

By using terminal 50 at the ignition switch, the relay starter will be controlled
by the engine control unit. Cranking the engine is only possible when the
signal of the neutral switch is active.
See the service manual of the engine.

SHB MPE850 Rev A | 409135 |

43

4 Description
4.7 Electrical system

Vehicle component
Contact
Engine
chassis

Wire
harness
cct

Using

Connection instructions

Description

Main Relay
1

73

required

Main relay terminal 85

The main relay supplies the actuators of the engine, for example fuel injectors
and ignition coils.
The relay is switched on when terminal 85 is switched by the engine control
unit to ground.
6

33

required

Main relay terminal 86 (to engine control unit A G3 =


VBD, Voltage Battery Direct).
Wire fused with 15 A.

78

required

Main relay terminal 87 (to engine control unit B P2 =


VBR, Voltage Battery Relay).
Wire fused with 15 A.

The terminal 87 is the output of the main circuit of the main relay and supplies
the engine control unit.
4

16

required

Main relay terminal 87 (to splice 1 = VBR, Voltage


Battery Relay).
Wire fused with 15 A.

The fuse Service is intended for deactivation the ignition coils and injectors
during service tasks.
The terminal 87 is the output of the main circuit of the main relay and
disconnects the power supply to the actuators, for example fuel injectors and
ignition coils.
Fuel Pump Relay
33

107

required

Relay fuel pump terminal 85 (low side output).


Wire fused with 10 A.

The relay is switched on by the engine control unit 3 seconds after ignition
switch on or when engine speed is detected.
Fan Relay
26

48

required

Fan relay terminal 85 to ground

The relay is switched on by the engine control unit when coolant temperature
reached 95 C. The relay is switched off when coolant temperature has cooled
down to 90 C.

44

SHB MPE850 Rev A | 409135 |

4
4.7

Description

Electrical system

Vehicle component
Contact
Engine
chassis

Wire
harness
cct

Using

Connection instructions

Description

Malfunction Indicator Light MIL


21

55

required

Output light switched to ground

The malfunction indicator light is activated when the control unit diagnostics
detects an active fault. The fault will be saved and can be displayed with the
Textron Motors Diagnostic Tool.
See the service manual of the engine.
Service Light
23

38

required

Output switched to ground

In the calibration an separate operating-hour counter is integrated, counting in


intervals of the yearly service. When the hours are reached, the service light is
illuminating. That indicates to the vehicle user that service tasks are required.
The service light can only be resetted by the Textron Motors Diagnostic Tool.
The service light does not indicate the 1st service and the yearly service
intervals. Observe chapter 4.8 Required manufacturer's instructions to
service tasks and repairs.
See the service manual of the engine.
Water Temperature Warning Light
28

63

required

Low side output.

If a significant engine speed limitation due to a too high coolant temperature is


active, the output is switched by the engine control unit.
See the service manual of the engine.
Oil Pressure Light
27

54

required

Low side output.

The switch oil pressure (switch (NC) to ground) is in scope of supply of


the engine. The contact of the switch oil pressure opens with increasing oil
pressure and the light turns off.
See the service manual of the engine.

SHB MPE850 Rev A | 409135 |

45

4 Description
4.7 Electrical system

Vehicle component
Contact
Engine
chassis

Wire
harness
cct

Using

Connection instructions

Description

Spare 5 V Output
8

60

optional
This 5 V output can be used to supply external sensors. For example the roll
over sensor.

Roll Over Sensor


12

49

optional

Analog input to engine control unit

When the input signal is within a defined voltage range ignition, injection and
the fuel pump will be turned off. The exact voltage range must be defined.
See the service manual of the engine.
Pedal Value Sensor
34

92

required

Pedal value sensor 1 (PPS) ground

35

optional

Available ground

36

91

required

Pedal value sensor 2 (PPS) ground

37

94

required

Pedal value sensor 1 (PPS) 5 V (Sensor supply)

38

95

required

Pedal value sensor 2 (PPS) 5 V (Sensor supply)

39

93

required

Pedal value sensor 1 (PPS) signal

40

90

required

Pedal value sensor 2 (PPS) signal

For the connection of a Textron Motors throttle request unit or Textron Motors
approved throttle control pedal with integrated pedal value sensor.
See the service manual of the engine.
Vehicle Speed Sensor Input
18

59

required

Hall effect vehicle speed sensor

A digital vehicle speed signal from gear or a driven wheel is expected that
returns a certain number pulses per meter driven.
Specification vehicle speed signal:

46

pulses per meter

Maximum vehicle speed in km/h

135

120

10

108

11

98

12

90

13

83

14

77

SHB MPE850 Rev A | 409135 |

4
4.7

Description

Electrical system

Vehicle component
Contact
Engine
chassis

Wire
harness
cct

Using

Connection instructions

Description

RPM Output
22

45

optional

Signal from engine control unit (internal pull-up


resistor in engine control unit (1,5 kOhm) to battery
plus)

Output 2 impulses/rotation.
For example for connecting an engine speed indicator.
Brake Light Switch
14

62

required

Switch (NO) to ground

This signal is used to detect if the brake is activated. If the brake is actuated
in combination with the gas, the engine power will be reduced after a short
delay. The engine power reduction acts as a safety function for example if the
throttle control pedal mechanically locks up.
Observe the service manual of the engine.
Neutral Switch
30

43

required

Switch (NO) to ground

An engine start is only possible when the signal at the input is active. The
signal must not stay active when other gears are engaged.
Observe the service manual of the engine.
Reverse Limiter Switch
24

37

optional

Switch (NO) to ground

An engine speed limitation will be active, when the reverse gear is engaged
and the switch is active.
Observe the service manual of the engine.
Power Limit Switch
11

53

optional

Switch (NO) to ground

This signal is used to apply a lower engine torque curve. Possible application:
Beginner mode (Learner Mode), with reduced power.
CAN-Bus
31

40

optional

CAN High

32

50

optional

CAN Low

For data communication.


Currently, no standard protocol is available.

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47

4 Description
4.7

Electrical system

4.7.3.4

Installation and electrical connection Textron Motors throttle request unit

The throttle cable and throttle control pedal are not


in scope of supply. Connect the throttle cable
according to the manufacturer's instructions to the
throttle request unit 2 .

WARNING! Fault responses of the engine


control unit by magnetic fields. Due to the high
current flow during engine start magnetic fields
can occur. The magnetic fields can affect the
sensor signals to the throttle request unit. Current
carrying wires must be installed with minimum
distance of 30 40 cm to the throttle request
unit.
To connect the Textron Motors throttle request
unit to the vehicle connector "Engine Chassis" the
following mating connectors are required:
Connector plug 6-pole Tyco 1-967616-1
Female terminals 0,5 0,75 mm
Tyco 965906-1
Single wire seals
The throttle request 1 unit must not be installed
firmly attached to the engine.

48

SHB MPE850 Rev A | 409135 |

4
4.8

4.8
4.8.1

Description

Required manufacturer's instructions to service tasks and repairs

Required manufacturer's instructions to service tasks and repairs


End customer

Fill quantities

Inform the customer about the fill quantities of engine oil and coolant.

Service light

The service light does not indicate the 1st service and the yearly service
intervals. Inform the customer, when the first service must be performed.
(See chapter 4.7.3.3 Description of vehicle components at vehicle
connector Engine-Chassis.)

Service intervals

Inform the customer about the coolant and fuel filter service intervals.

Checking coolant level

The procedure how to check the coolant level with a Textron Motors
expansion tank is described in the service manual. If another expansion
tank will be installed, inform the customer about checking the coolant
level.

Checking oil level

The procedure how to check the oil level with a Textron Motors oil tank is
described in the service manual. If another oil tank will be installed, inform
the customer about checking the oil level.

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49

4 Description
4.8

Required manufacturer's instructions to service tasks and repairs

4.8.2

Workshop

Service tasks

Inform the workshop about replacing the engine oil, coolant and fuel filter.

Rotating crankshaft

Pay attention that the camshaft must be rotated in the workshop while
service tasks. Devise a suitable procedure that the camshaft will be turned
with the crankshaft.

Changing coolant

Provide a drain device at the heat exchanger or coolant lines below the
coolant level of the engine.
The procedure how to change the coolant with a Textron Motors
expansion tank is described in the service manual. If another expansion
tank will be installed, inform the workshop about changing the coolant.

Changing engine oil

Inform the workshop about the minimum quantity of engine oil that needs
to be filled in after draining. Observe that is sufficient engine oil in the
engine to warm up the engine without risk of overfill the engine.
The procedure how to change the engine oil with a Textron Motors oil tank
is described in the service manual. If another oil tank will be installed,
inform the workshop about changing the engine oil.

Replacing fuel filter

Inform the workshop about replacing the fuel filter.

Repairing work

All repair manual works are described with an engine removed from the
vehicle. Consider the interfaces to vehicle.

50

SHB MPE850 Rev A | 409135 |

5
5.1

5
5.1

Installation data

Requirements for the engine compartment

Installation data
Requirements for the engine compartment

Observe the following references:


The minimum lateral distance of the engine to
the vehicle hull is 50 mm 1 .
The total area of the ventilation openings must
have at least 9000 mm2. Do not block the air
intake.
Observe in chapter 4.1 Permissible operating
conditions the information about temperature
engine compartment.

Observe in chapter 4.5.1 Intake system


naturally aspirated engines (NA) the
installation condition.

5.1.1 Accessibility engine


For service tasks the following locations on the
engine must be accessible:
The whole area of the valve cover
Oil filter

Diagnostic connector. Observe chapter 4.7.2.1


For operating required additional parts at
the engine.
2

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51

5 Installation data
5.2 Installation engine

5.2

Installation engine

5.2.1

Installation position engine

Pay attention when installing to the operating positions of the engine during constant operation. (See
chapter 4.1.2 Operating positions engine.)

5.2.2
5.2.2.1

Mounting engine
Decoupling

Textron Motors recommends to install the engine with rubber elements for decoupling of vibrations and
noise.

52

SHB MPE850 Rev A | 409135 |

5
5.2

5.2.2.2

Installation data
Installation engine

Mounting points at the engine

The dimensions are on the interface drawing.


The following mounting points at the engine are
available:
Internal thread M8 1
(only engine model I2 846 UTV NA-80)
Internal thread M8

Internal thread M8 3
(only engine model I2 846 UTV NA-80)

1
2
3

Internal thread M10

Internal thread M10

Internal thread M10

Internal thread M10

Internal thread M10

4
5

7
8

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53

5 Installation data
5.2 Installation engine

Internal thread M10

Internal thread M10

10

Through bore-hole for M8


Internal thread M10

12

Internal thread M10

13

Through bore-hole for M8

9
11

10
11

14

12
13

14

54

SHB MPE850 Rev A | 409135 |

5
5.2

5.2.2.3

Installation data
Installation engine

Interface drawing

EHB MPE850 Rev A | 409135 |

55

6 Initial operation
6.1 Transport and storage | 6.2

6
6.1

Lift engine

Initial operation
Transport and storage

Observe the following references:


Transport and store the engine in its original packaging.
Unless otherwise agreed, the engines will be supplied on a euro-pallet. Observe when storing the
respective packaging specifications.
Store the engines in the original packaging in a clean, dry place at a constant ambient temperature of
0 50 C and a relative humidity of 40 60 %. Avoid heat and direct sunlight. Do not remove protective
covers and not damage the foil in which the engine is packed. When the engine is packed in a VCI foil,
the engine can be stored without further procedure for maximum 24 months.
The disposal of packaging must always comply with the relevant applicable national laws and guidelines.

6.2

Lift engine

WARNING! Spinal column injury due to


incorrect lifting of heavy loads. Always lift the
engine using a workshop crane.

NOTICE! Components can break. Lift the engine


only using the brackets.

56

Lift the engine using the brackets

SHB MPE850 Rev A | 409135 |

Initial operation
6.3

6.3

Completion

Completion

At the time the engine in the vehicle is fully installed and connected, proceed as follows:

Fill with engine oil, coolant und fuel.

Connect the Textron Motors Diagnostic Tool. (See the Textron Motors Diagnostic Tool manual.)

Turn on ignition.

Start the Textron Motors Diagnostic Software.

Compare the serial number in the calibration with the serial number on the valve cover label. The
serial numbers must be identical. (See the service manual of the engine.)

Clear the trouble codes.

Turn off the ignition until the engine control unit is out of service. The main relay is switched off.

Turn on ignition and check the trouble codes. No trouble codes must be available.

Update the engine control unit calibration.

Turn off the ignition until the engine control unit is out of service. The main relay is switched off.

Calibrate the throttle body. Turn the ignition on for about a minute, until the throttle body opens and
closes again.

Select the value Pedal Value Sensor Value with the Textron Motors Diagnostic Tool in the view Data
Items.

With not operated throttle control pedal, the value 0 must be displayed. With full operated throttle
pedal, the value 99.9 must be displayed. If the displayed values are different, check the throttle cable
to the throttle request unit.

Start the engine and run the engine at idle.

If the coolant level is not reached, switch off the engine and fill in coolant until the coolant level is
reached. Restart the engine and run the engine at idle.

Check the trouble codes. No trouble codes must be available.

Select the value Engine Coolant Temperature with the Textron Motors Diagnostic Tool in the view
Data Items.

Allow the engine to warm up at low engine speeds. The coolant temperature needs to stabilize at
80 83 C. If the coolant temperature increases quickly over this temperature there is still air in the
coolant circuit. The coolant circuit must be ventilated.

When the engine is warm, check the oil level.

Fill in engine oil in several stages, until the filling level is reached.

Run the engine through all operating modes.

SHB MPE850 Rev A | 409135 |

57

Appendix
Engine manufacturer

Appendix
Engine manufacturer
Engine manufacturer

Textron Motors GmbH


Kautexstrae 52
53229 Bonn
Germany
www.weber-motor.com

58

EHB MPE850 Rev A | 409135 |

Appendix
Overview of revisions

Overview of revisions

Revision
Rev A

Date

Chapter

04.08.2015

EHB MPE850 Rev A | 409135 |

Description
1st edition installation manual

59

Appendix
Index

Index
A
Air cleaner, description 27
B
Battery, description 40
Battery, electrical connection 34
Battery isolator switch, description 40
Blow-by-return, installation 24, 28
Brake light switch, electrical connection 47
C
CAN-Bus, electrical connection 47
Catalyzer, description 29
Completion 57
Connection scheme, vehicle 42
Coolant circuit, description 12
Coolant lines, specification 13
Coolant, specification 13
Cooling system, description 12
Cooling system, scheme 14
Crankcase ventilation / engine oil return,
installation 23
D
Diagnostic connector, description 32
E
Electrical system, description 31
Engine compartment, accessibility 51
Engine compartment, requirements 51
Engine control unit, installation 37
Engine, electrical connection 32
Engine ground, electrical connection 34
Engine management system 31
Engine oil, specification 21
Engine speed output, electrical connection 47
Exhaust back pressure 29
Exhaust pipes, dimensioning 29
Expansion tank, description 12
Expansion tank, installation 16
F
Fan relay, electrical connection 44
Fill quantity engine oil, determining 24
Fill quantity engine oil, determining with a Weber
Motor oil tank 25
Flow rate, coolant 12
Fuel main filter, description 17

60

Fuel main filter, installation 19


Fuel pre-filter, description 17
Fuel pre-filter, installation 20
Fuel pressure regulation, description 17
Fuel pump, description 17
Fuel pump, installation 20
Fuel, specification 18
Fuel supply, installation 19
Fuel system, description 17
Fuel system, scheme 18
G
Gear 10
H
Heat exchanger, description 12
Heat exchanger, installation 15
Hoses, fuel 18
Hoses, intake system 27
Hoses, lubrication system 21
I
Ignition switch, description 40
Ignition switch, electrical connection 43
Initial operation 56
Installation condition, intake system 27
Installation position, engine 52
Intake air, installation 28
Intake system, description 27
Intake system, scheme 27
Interface drawing 55
L
Lights, description 41
Lubrication system, description 21
Lubrication system, scheme 22
M
Main relay, electrical connection 44
Malfunction indicator light, electrical connection 45
Manufacturer, engine 58
Manufacturers instructions, required 49
Mounting points, engine 53
Muffler, description 29
N
Neutral switch, electrical connection 47

EHB MPE850 Rev A | 409135 |

Appendix
Index

O
Oil filter, description 21
Oil pressure 21
Oil pressure light, electrical connection 45
Oil tank, description 21
Oil tank, installation 23
Operating conditions, permissible 11
Operating-hour counter, vehicle 41
Operating positions, engine 11
Operating pressure, coolant system 12
Operating pressure, fuel 17
Operating pressure, lubrication system 21
Operating temperature, coolant 12
Operating temperature, fuel 17
Operating temperature, lubrication system 21
P

Throttle request unit, installation and electrical


connection 48
Transport 56
V
Vehicle curb weight 10
Vehicle, electrical connection 40
Vehicle parameters 10
Vehicle speed sensor, electrical connection 46
Voltage regulator, description 32
Voltage regulator, installation and electrical
connection 35
W
Wire harness, description 32
Wire harness, specification 38
Wiring diagram 33

Pedal value sensor, electrical connection 46


Permanent vent coolant circuit, installation 15
Power limit switch, electrical connection 47
Power train 10
Q
Quick connectors, fuel 19
R
Relay, description 40
Relay fuel pump, electrical connection 44
Relay starter, description 32
Relay starter, electrical connection 34
Relay starter, installation and electrical connection
35
Reverse limiter switch, electrical connection 47
Roll over sensor, electrical connection 46
S
Sensor lambda, description 32
Sensor lambda, exhaust system 29
Service light, electrical connection 45
Starter, electrical connection 34
Storage 56
T
Temperature, ambient 11
Temperature, engine, compartment 11
Temperature warning light, electrical connection
45
Terminal 15, electrical connection 43
Terminal 30, electrical connection 43
Terminal 50, electrical connection 43
Throttle request unit, description 40

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61