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Westerbeke Diesel 55a Four Parts Manual




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SERVICE MANUAL
55A FOUR
MARINE DIESEL ENGINE
PUBLICATION 43377
1st Edition September 1998
WESTCRBEKE CORPORATION MYLES STANDISH INDUSTRIAL PARK
150 JOHN HANCOCK ROAD TAUNTON MA 027807319 USA
CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some
of its constituents are known to
the State of California to cause
cancer birth defects and other
reproductive harm
A gasses contain Carbon Monoxide an odorless and
colorless gas Carbon Monoxide is poisonous and can and death Symptoms of Carbon can Throbbing in Muscular
Vomiting
Weakness and Sleepiness Inability to Think YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS
GET OUT INTO THE FRESH AIR IMMEDIATELY symptoms persist
seek medical attention Shut down the unit and do not restart
until it has been inspected and repaired
SAFETY PREVENT BURNS FIRE
Read these safety instructions carefully Most accidents are
caused by failure to follow furuklmental rules and Know when dangerous conditions exist and take the
A WARNING Fire can cause injury or precautions to protect yourself your personne
and your machinery Prevent flash fires Do not smoke or permit flames or
sparks to occur near the carburetor fuel line filter fuel
The following safety instructions are in complWnce with pump or other potential sources of spilled fuel or fuel
the American Boat and Yacht Council ABYC staruklrds vapors Use a suitable container to catch all fuel when
removing the fuel line carburetor or fuel ELECTRIC SHOCK Do not operate with a Coast Guard Approved
flame
arrester removed Backfire can cause severe injury or
death
A WARNING Do not touch AC electrical connections Do not operate with the air removed
while engine is running or when connected to shore
power Lethal voltage is present at these connections Backfire can cause severe injury or death
Do not smoke or permit flames or sparks to occur near the
Do not operate this machinery without electrical fuel system Keep the compartment and the enclosures and covers in place
ator clean and free of debris to minimize the chances of
fire Wipe up all spilled fuel and engine oil
Shut off electrical power before accessing electrical
equipment Be aware diesel fuel will bum
Use insulated mats whenever working on electrical PREVENT BURNS EXPLOSION
equipment
Make sure your clothing and skin are dry not damp
particularly shoes when handling electrical equipment A WARNING Explosions from fuel vapors can cause
injury or death
Remove wristwatch and all jewelry when working on
electrical equipment
Follow refueling safety instructions Keep the vessels
Do not connect utility shore power to vessels AC hatches closed when fueling Open and ventilate cabin
circuits except through a shiptoshore double throw after fueling Check below for fumesvapor before run
transfer switch Damage to vessels AC generator may ning the blower Run the blower for four minutes before
result if this procedure is not followed starting your engine
Electrical shock results from handling a charged capacitor
All fuel vapors are highly explosive Use extreme care when
Discharge capacitor by shorting terminals together handling and storing fuels Store fuel in a BURNS HOT ENGINE
area away from equipment and out of
the reach of children
Do not fill the fuel tanks while the engine is running
A WARNING Do not touch hot engine parts or Shut off the fuel service valve at the engine when servicing
exhaust system components A running engine gets
the fuel system Take care in catching any fuel that might
very hot
spill DO NOT allow any smoking open flames or other
sources of fire near the fuel system or engine when servic
Always check the engine coolant level at the coolant ing Ensure proper ventilation exists when servicing the
recovery tank fuel system
Do not alter or modify the fuel system
A WARNING Steam can cause injury or death Be sure all fuel supplies have a positive shutoff valve
Be certain fuel line fittings are adequately tightened and
In case of an engine overheat allow the engine to cool free of leaks
before touching the engine or checking the coolant Make sure a fire extinguisher is installed nearby and is
properly maintained Be familiar with its proper use
Extinguishers rated ABC by the NFPA are appropriate
for all applications encountered in this Engines Generators
SAFETY STARTING TOXIC EXHAUST GASES
A WARNING Accidental starting can cause injury A WARNING CarbDn mDnDxide CO is a deadly gas
Dr death
Ensure that the exhaust system is adequate to expel gases
Disconnect the battery cables before servicing the engine discharged from the engine Check the exhaust system
generator Remove the negative lead first and reconnect regularly for leaks and make sure the exhaust manifolds
it last are securely attached and no warping exists Pay close
attention to the manifold water injection elbow and
Make certain all personnel are clear of the engine before exhaust pipe nipple
starting
Be sure the unit and its surroundings are well ventilated
Make certain all covers guards and hatches are re
installed before starting the engine In addition to routine inspection of the exhaust system
install a carbon monoxide detector Consult your boat
BAnERY EXPLOSION builder or dealer for installation of approved detectors
For additional information refer to ABYC T22 educa
A WARNING Battery explDsiDn can cause injury tional information on Carbon Monoxide
Dr death
Do not smoke or allow an open flame near the battery
A WARNING CarbDn mDnDxide CO is an invisible
DdDrless gas InhalatiDn prDduces flulike symptDms
being serviced Lead acid batteries emit hydrogen a nausea Dr death
highly explosive gas which can be ignited by electrical
arcing or by lit tobacco products Shut off all electrical
Do not use copper tubing in diesel exhaust systems Diesel
equipment in the vicinity to prevent electrical arcing dur
fumes can rapidly destroy copper tubing in exhaust sys
ing servicing tems Exhaust sulfur causes rapid deterioration of copper
Never connect the negative battery cable to the posi tubing resulting in exhaustwater leakage
tive connection terminal of the starter solenoid Do Do not install exhaust outlet where exhaust can be drawn
not test the battery condition by shorting the terminals through portholes vents or air conditioners If the engine
together Sparks could ignite battery gases or fuel vapors exhaust discharge outlet is near the waterline water could
Ventilate any compartment containing batteries to prevent enter the exhaust discharge outlet and close or restrict the
accumulation of explosive gases To avoid sparks do not flow of exhaust Avoid overloading the craft
disturb the battery charger connections while the battery
is being charged Although diesel engine exhaust gases are not as toxic as
exhaust fumes from gasoline engines carbon monoxide
Avoid contacting the terminals with tools etc to prevent gas is present in diesel exhaust fumes Some of the symp
burns or sparks that could cause an explosion Remove toms or signs of carbon monoxide inhalation or poison
wristwatch rings and any other jewelry before handling ing are
the battery
Vomiting
Always turn the battery charger off before disconnecting Dizziness
the battery connections Remove the negative lead first
and reconnect it last when servicing the battery Throbbing in
Muscular twitching
Intense headache
A WARNING Sulphuric acid in batteries can cause Weakness and sleepiness
severe injury Dr death AVOID MOVING PARTS
When servicing the battery or checking the electrolyte
level wear rubber gloves a rubber apron and eye protec A WARNING Rotating parts can cause injury
tion Batteries contain sulfuric acid which is destructive If Dr death
it comes in contact with your skin wash it off at once
with water Acid may splash on the skin or into the eyes Do not service the engine while it is running If a situation
inadvertently when removing electrolyte caps arises in which it is absolutely necessary to make operat
Engines Generators
SAFETY INSTRUCTIONS
ing adjustments use extreme care to avoid touching ABYC NFPA AND USCG PUBLICATIONS FOR
moving parts and hot exhaust system components
INSTALLING DIESEL ENGINES
Do not wear loose clothing or jewelry when servicing Read the following ABYC NFPA and USCG publications
equipment avoid wearing loose jackets shirts sleeves for safety codes and standards Follow their recommenda
rings necklaces or bracelets that could be caught in tions when installing your engine
moving parts ABYC American Boat and Yacht Council
Make sure all attaching hardware is properly tightened Safety Standards for Small Craft
Keep protective shields and guards in their respective Order From
places at all times
ABYC
Do not check fluid levels or the drive belts tension while 3069 Solomons Island Rd
the engine is operating Edgewater MD 21037
Stay clear of the drive shaft and the transmission coupling NFPA National Fire Protection Association
when the engine is running hair and clothing can easily Fire Protection Standard for Motor Craft
be caught in these rotating parts
Order NOISE NFPA
11 Tracy Drive
A WARNING High noise levels can cause hearing Avon Industrial Park
Avon MA 02322
loss
USCG United States Coast Guard
USCG 33CFR183
Never operate an engine without its muffler installed
Order From
Do not run an engine with the air intake silencer
US Government Printing Office
removed
Washington DC 20404
Do not run engines for long periods with their enclosures
open
A WARNING 00 not work on machinery when you
are mentally or physically incapacitated by MANUAL
Many of the preceding safety tips and warnings are repeated
in your Operators Manual along with other cautions and
notes to highlight critical information Read your maintain your equipment and follow all to install an engine should begin with a thor
ough examination of the American Boat and Yacht standards These standards are a combination of
sources including the USCG and the of the ABYC standards of particular interest are
H2 Ventilation
P1 Exhaust systems
P4 Inboard engines
E9 DC Electrical systems
All installations must comply with the Federal Code FCR
Engines Generators
installing WESTERBEKE engines and generators it is important that be paid to the following AND federal regulations ABYC guidelines and safety codes
must be complied with
when installing engines and generators in a marine installations where the exhaust injected exhaust elbow is close to
or below the vessels waterline provisions must be made to install a siphonbreak in
the raw water supply hose to the exhaust elbow This hose must be looped a minimum
of 18 above the vessels waterline Failure to use a siphonbreak when the injection port is at or below the load waterline will result in raw water
damage to the engine and possible flooding of the SYSTEM
The exhaust hose must be certified for marine use The system must be designed to
prevent water from entering the exhaust under any sea conditions and at any angle
of the vessels hull
A detailed 40 page Marine Installation Manual covering gasoline and
diesel engines and generators is available from your WESTERBEKE
dealer
Engines Generators
TABLE OF 2
55A FOUR 4
Parts 5
Testing for Overhaul 6
Engine 7
Engine Disassembly 11
Engine Inspection and Repair 16
Engine Reassembly 26
Engine Adjustments 42
Glow Plugs System 52
Remote Oil Filter Optional 57
Coolant Pump 58
Raw Water Pump 59
Heat Exchanger Manifold 61
Tachometer 62
Starter Motor 63
DC Electrical 67
DC Electrical System Wiring Diagram 70
DC Electrical System Wiring Schematic 72
Service Standards 73
Metric Conversions 77
55A FOUR Torques 78
Standard Hardware Torques General Screws Sealants 80
Engines Generators
OVERHAUL CUSTOMER CARD
This service manual contains detailed information relating to
the overhaul of the 55A FOUR Diesel Engine For the procedure refer to the ENGINE DISASSEMBLY
INSPECTION AND REPAIR and sections Additional service information for
Customer components and systems may be found by referring
to the Table of Contents and the Index Refer also to your MR ENGINE Parts Catalog MAIN
STREET
These service procedures are intended for the guidance of HOMETOWN USA
suitably equipped and staffed marine engine service and Model 55A FOUR Ser facilities and should only be
undertaken by such Expires and their SOFTWARE The WESTERBEKE engine serial number is
an alphanu
meric number that can assist in determining the date of man
Product software tech data parts lists manuals brochures
ufacture of your WESTERBEKE engine The catalogs provided from sources other than WESTER
date code is placed at the end of the engine serial number and
BEKE are not within WESTERBEKES control
consists of a character followed by three numbers The CANNOT BE RESPONSIBLE FOR THE acter indicates the decade A1960s
B1970s OF SUCH SOFTWARE MAKES NO WAR D1990s the first number represents the year in the OR WITH RESPECT
and the second and third numbers represent the month of
THERETO INCLUDING ACCURACY TIMELINESS OR THEREOF AND WILL IN NO EVENT
BE LIABLE FOR ANY TYPE OF DAMAGE OR INJURY ORDERING PARTSSERIAL NUMBER IN CONNECTION WITH OR ARISING OUT
Whenever replacement parts are needed always provide the
OF THE FURNISHING OR USE OF SUCH SOFTWARE engine model number and engine serial number as customers should also keep in
mind the appear on the silver and black span between printings of WESTERBEKE product soft located on the side of
the manifold The engine serial number
ware and the unavoidable existence of earlier WESTER can also be found stamped into the engine block just above
BEKE manuals Product software provided with the injection pumpYou must provide us with this products whether from
WESTERBEKE or tion so we may properly identify your engine In suppliers must not and cannot be relied upon exclu
include a complete part description and part number for each
sively as the definitive authority on the respective product It part needed see the separately furnished Parts List Also
not only makes good sense but is imperative that appropriate insist upon WESTERBEKE packaged parts because will of WESTERBEKE or the
supplier in question or generic parts are frequently not made to the same specifi
be consulted to determine the accuracy and currentness of the cations as original software being consulted by the customer
NOTE Component locations in this manual are CAUTIONS AND WARNINGS from the front of the engine which is
the pulleydrive belt end
Left and right sides are determined as follows imagine
As this manual takes you through the service procedures and straddling the engine facing in the same direction as of your marine engine
critical information front of the engine the left side is at your left the right side
will be highlighted by NOTES CAUTIONS and WARNINGS is at your right
An explanation follows
Owners may find it convenient to fill in the engine An operating procedure essential to note tion nameplate shown below to
provide a quick reference
when using this service manual
A CAUTION Procedures which if not strictly
observed can result in the damage or destruction of
your engine
A WARNING Procedures which if not properly fol
lowed can result in personal injury or loss of life
Engines Generators
55A FOUR DIESEL ENGINE
SPRING RETAINER
INJECTION NOZZLE
CYLINOER HEAD BOLT
SPRING SEAT
COMBUSTION
CHAMBER INSERT
Engines Generators
55A FOUR ENGINE COOLING SYSTEM
Engine Type Diesel fourcycle fresh General block thermostati
watercooled vertical inline 55 hp at cally controlled with raw water
3600 rpm maximum exchanger Integral with the injection pump
Operating Temperature 170 190F 77 88C
mechanical centrifugal flyweight type Coolant Pump Centrifugal type metal impeller belt
Valve Mechanism Direct drive OHC Chamber Swirl chamber type
Raw Water Pump Positive displacement rubber impeller
belt driven
Bore and Stroke 338 x 370 inches 860 x 940 mm
Raw Water Flow 160 gpm 605 Ipm Displacement 1332 cubic inches 218 liters at 3600 rpm
Firing Order 1342 measured before of Rotation Clockwise when viewed from the front
ing into exhaust elbow
of the engine pulley drive belt end Coolant System Capacity 95 US qts 90 Torque 931bft 129 kgm
at 1920 rpm ELECTRICAL Ratio 2271
Starting Battery 12volt DC negative Pressure 426 psi 30 kgcm2 at 200 rpm BaHery Capacity
300 400 Cold cranking amps CCA
Valve Seat Angle Intake 45 Exhaust 45 min
Valve Clearance Intake 008 0012 in 020 030mm Starter Motor 12volt 16kw SOlenoid actuated shift
engine cold Exhaust 00120016 in 030040 mm reduction Height 2678 inches 6802 mm
Starting Aid 12 volt sheathed type glow plug
Width 500 inches 5461 mm DC NoLoad Current 100 amps at 115 volts 3000 rpm
Length 350 inches 8890 mm Continuous 14 Temporary 25 Cold Cranking
Current 280 300 amps at 10 volts 250 rpm
not to exceed 30 min
Dry Weight 470 Ibs 2132 kgs Alternator standard 12volt DC 50 amps
Engine Speed Idle speed 750 1000 rpm Regulator Internal regulator built into alternator
Cruising speed 2500 3000 rpm
Fuel Consumption 15 US gph 56 Iph running at 2500 TRANSMISSION
rpm approximate when the propeller
allows 3600 rpm at full open throttle General Hurth Standard Transmission Case
while underway in forward gear hardened helical gears with a servo
operated multiple disc clutch
Gear ratio standard 274 1 HBW250 3R
FUEL SYSTEM Propell er Shaft Right handed standard No2 diesel oil
Direction of Rotation
cetane rating of 45 or higher Propeller 20 D x 13 P 2 blade or 200 x 11 P 3
Injection Pump Zexel mechanical governed blade propeller should allow the Timing OOTDC
using standard to reach its full rated rpm 3600 000
transmission 100 at full open throttle while Throttle type 2741 reduction
way in forward Pressure 1920 psi 71 psi Lubricating Fluid ATF type A or Dextron I or 11
135 kgcm2 5 kgcm2
Transmission Sump 079 US qts 075 liters Pump 12 volt plunger type
Fuel Filter on engine Spinon type Supply and 250 in 635 mm 10 minimum
Return Piping 375 in 925 mm 10 maximum Oil Pump Crescent type directly driven by the
Air Cleaner Replaceable paper filter element Flow
Oil Filter Full flow paper element spinon type
engine combustion 140 cfm 39 cmm at 3600 rpm Lube Oil Cooler Fresh water cooling 250 cfm 70 cmm
Lubricant Capacity 175 US gal 66 liters
Sump Capacity 50 US qts 48 liters not including filter
EXHAUST SYSTEM Operating Oil Pressure 30 60 psi 21 42 kgcm2 at maxi
mum engine rpm and at normal oper
Exhaust Elbow 90 elbow 45 elbow and exhaust riser ating Hose Size 2 inch 10 hose
Oil Grade API Specification CF or CG4
Muffler Size min 14 inch x 14 inch SAE 30 10W30 15W40
Engines Generators
PARTS I M U OIL DRAIN HOSE
BATTERY GROUND CONNECTION
OIL PRESSURE SENDER STARTER WITH SOLENOID
FRONT LEFT SIDE REAR
UNIT I D PLATE AIR CLEANER HOUSING MANIFOLD PRESSURE CAP
DOMESTIC
WATER HEATER
CONNECTION POINTS
RAW WATER LEVER
LUBE OIL FILTER
OIL COOLER
REAR RIGHT SIDE
FRONT
Engines Generators
TESTING FOR OVERHAUL
HOW TO DETERMINE WHEN NOTE Do not guess the conditions of other cylinders from a
TO OVERHAUL THE ENGINE result of testing one cylinder Be sure to measure the com
pression pressure for each cylinder Look for cylinders with
dramatically at least 20 lower compression than the aver
Cause of Low Compression age of the other cylinders If the weak cylinder is flanked by
Generally the time at which an engine should be overhauled healthy cylinders the problem is either valve or determined by various
conditions such as lowered engine related Very low compression in an adjacent cylinder indi
power output decreased compression pressure and increased cates gasket failure Abnormally high readings on all cylin
fuel and oil consumption The lowered engine power output ders indicate heavy carbon a condition that
in the case of diesel engines is not necessarily due to trouble might be accompanied by high pressures and noise
with the engine itself but is sometimes caused by injector NOTE In case of severe vibrations and detonation noise
nozzle wear or injection pump wear It is most reasonable to have the injectors overhauled by an by a decrease in compression pressure The
decrease in service center Poor fuel quality contaminates and loss pressure is caused by many factors Itis there positive fuel
pressure to the injection pump will result in
fore necessary to determine a cause or causes on the basis of injector faults
data produced by periodic inspection and maintenance Oil
analysis on a seasonal basis is a good means of monitoring OVERHAUL internal wear When caused by worn cylinders or pis
Compression pressure tends to increase a little in a new
ton rings the following symptoms will occur
engine until the piston rings and valve seats have been bro
Low engine power output ken in Thereafter it decreases gradually with the progressive
wear of these parts Engine compression should be 30 kgcm2
Increased fuel consumption
at 200 rpm
Increased oil consumption
When the decrease of compression pressure reaches its limit
Hard engine starting see SERVICE STANDARDS the engine must be over
Noisy engine operation hauled The engine also requires an overhaul when oil con
sumption is high when blowby is evident and when
These symptoms often appear together Increased fuel con
compression values are at minimum or and hard engine starting can result also from exces
sive fuel injection improper injection timing and wear of NOTE Refer to the SERVICE STANDARDS chart during an
plugs and nozzles They are caused also by defective electri engine overhaul It gives the measurements and values for
cal devices such as the battery alternator starter and glow the repair or replacement of the engine Therefore it is desirable to judge the
optimum time by the lowered compression pressure caused
by worn cylinders and pistons plus increased oil In diesel engines satisfactory combustion is obtained
only under sufficient compression pressure If an engine
lacks compression pressure incomplete combustion of fuel
will take place even if other parts of the engine are To determine the period of engine overhaul it is
important to measure the engine compression pressure regu
larly At the same time the engine speed at which the mea
surement of compression pressure is made should be the compression pressure varies with engine rpm
The engine rpm can be measured at the front end of Compression Pressure
To check the compression pressure see under ENGINE Engines Generators
ENGINE following table describes certain Note The engines electrical system is protected by a 20
problems relating to engine service the probable causes of ampere manual reset circuit breaker The preheat solenoid is
these problems and the to overcome mounted on the same PROBLEM PROBABLE CAUSE
HARD STARTING LOW CRANKING SPEED
1 Engine oil viscosity too high 1 Replace engine oil with less viscous oil
2 Rundown battery 2 Recharge battery
3 Worn battery 3 Replace battery
4 Battery terminals loosely connected 4 Clean terminals and correct cables
5 Defective starter 5 Repair or replace starter
6 Defective main drive section 6 Check clutch for DEFECTIVE INJECTION SYSTEM
1 Air trapped in fuel passage 1 Bleed air from fuel system
2 Clogged fuel filter 2 Clean or replace filter
3 Low injection pressure 3 Adjust injection pressure
4 Inadequate spray 4 Clean or replace nozzle
5 Injection pump delivering insufficient fuel 5 Repair or replace injection pump
6 Injection too early 6 Adjust injection timing
ENGINE TROUBLES
1 Low compression
a Incorrect valve clearance a Adjust valve clearance
b Inadequate contact of valve seat b Lap valve
c Valve stem seized c Replace valve and valve guide
d Broken valve spring d Replace valve spring
e Compression leaks through cylinder head gasket e Replace gasket
I Cracked or distorted cylinder head I Replace cylinder head
g Piston ring seized g Replace piston and piston ring
h Worn piston ring and cylinder h Overhaul engine
i Cracked or wom piston i Replace piston
2 Burnt glow plug 2 Replace glow plug
3 Faulty glow plug operation 3 Check glow plugs and solenoid
4 Incorrect governor lever pOSition 4 Set lever to starting position
5 Governor spring out of position 5 Correct spring
POOR IDLING 1 Improper valve clearance 1 Adjust valve clearance
2 Poor valve to valve seat contact 2 Repair or replace
3 Failure of cylinder head gasket 3 Replace gasket
4 Malfunction of fuel system 4 See LOW OUTPUT and ROUGH OPERATION
LDW OUTPUT LOW COMPRESSION See Low Compression under HARD STARTING
INJECTION SYSTEM OUT OF ADJUSTMENT
1 Incorrect injection timing 1 Adjust injection timing
2 Insufficient injection 2 Repair or replace injection pump
3 Low injection pressure 3 Check injection nozzle and adjust pressure
INSUFFICIENT FUEL
1 Air trapped in fuel system 1 Check and retighten connector
2 Clogged filter 2 Clean or replace filter
3 Contaminated fuel tank 3 Clean tank
INSUFFICIENT INTAKE AIR
1 Clogged air cleaner 1 Clean or replace air cleaner
Engines Generators
ENGINE PROBLEM PROBABLE CAUSE OUTPUT cont OVERHEATING
1 Low coolant level 1 Add coolant
2 Loose Vbelt 2 Adjust or replace Vbelt
3 Incorrect injection timing 3 Adjust injection timing
4 Low engine oil level 4 Add engine OIL OIL 1 Defective oil seals 1
Replace oil seals
2 Loose oil filter 2 Tighten
3 Broken cylinder head cover gasket 3 Replace gasket
4 Damaged cylinder head cover 4 Replace
5 Damaged front housing gasket 5 Replace
6 Loose oil pipe connector 6 Retighten oil connections
7 Loose bolts at oil pump body cylinder head 7 Tighten
covers or oil pan
8 Loose or damaged oil pressure switch 8 Tighten or replace
9 Defective seal at oil pan and cylinder block 9 Repair
10 Loose drain plug 10 Retighten or replace
OIL LEVEL RISING
1 Incorrectly positioned piston ring gaps 1 Correct ring gap positions
2 Displaced or twisted connecting rod 2 Replace connecting rod
3 Worn piston ring 3 Replace ring
4 Worn piston or cylinder 4 Replace piston and rebore cylinder
OIL LEVEL FALLING
1 Defective stem seal 1 Replace stem seal
2 Worn valve and valve guide 2 Replace valve and valve guide
OIL PRESSURE DROP 1 Oil leak 1 See OIL LEAKAGE
2 Insufficient oil 2 Add oil
3 Worn andor damaged oil pump gear 3 Replace
4 Worn oil pump plunger or weak spring 4 Replace
5 Clogged oil strainer 5 Clean
6 Excessive lubrication clearance between main 6 See Crankshaft Assembly under
bearing and connecting rod bearing ENGINE FUEL ENGINE BODY 1 Noisy knocking
1 See KNOCKING
2 Smoky exhaust 2 See SMOKY EXHAUST
3 Moving parts nearly seized or excessively worn 3 Repair or replace
4 Poor compression 4 See Low compression under HARD STARTING
5 Improper valve timing 5 Adjust
6 Improper valve clearance 6 Adjust
INSUFFICIENT INTAKE AIR
1 Air intake obstructed 1 Clean and remove obstruction
NOZZLE TROUBLES
1 Seized nozzle 1 Replace
2 Worn nozzle 2 Replace
IMPROPER FUEL Replace with proper fuel
FUEL LEAKS Find fuel leaks
SMOKY EXHAUST WHITISH OR PURPLISH
1 Excessive engine oil 1 Correct oil level
2 Excessive rise of oil into combustion chamber
a Poor piston contact a Check
b Seized piston ring b Replace or clean
c Excessive clearance c Replace or correct
continued
Engines Generators
ENGINE PROBLEM PROBABLE CAUSE EXHAUST cont WHITISH OR PURPLISH cont
d Worn valve stem and valve guide d Replace
e Low engine oil viscosity e Replace
f Excessive oil pressure f Correct
3 Injection timing is too late 3 Adjust
4 Insufficient compression 4 See Low compression under HARD STARTING
BLACKISH OR DARK GRAYISH
1 Engine body troubles
a Poor compression a See Low compression under HARD STARTING
b Improper valve clearance b Adjust
2 Insufficient intake air air cleaner clogged 2 Clean air cleaner
3 Improper fuel 3 Replace with proper SOUND CRANKSHAFT AND MAIN BEARING
OR NOISE 1 Main bearing worn heatdamaged or seized 1 Replace bearing and grind crankshaft
2 Excessive main bearing oil clearance 2 Replace bearing
3 Melted main bearing 3 Replace bearing and check lubrication system
4 Badly worn crankshaft 4 Grind crankshaft
5 Excessive crankshaft end play 5 Adjust end play
CONNECTING ROD AND CONNECTING ROD BEARING
1 Connecting rod big end bearing worn 1 Replace bearing
heatdamaged or seized
2 Worn crankpin 2 Grind crankshaft
3 Bent connecting rod 3 Correct bend or replace
PISTON PISTON PIN AND PISTON RING
1 Worn cylinder 1 Rebore cylinder to oversize and replace piston
2 Worn piston or piston pin 2 Replace piston
3 Piston seized 3 Replace piston and rebore cylinder
4 Piston seized and rings worn or damaged 4 Replace piston and rings
5 Bent connecting rod 5 Replace connecting rod
VALVE MECHANISM
1 Worn camshaft 1 Replace camshaft
2 Excessive valve clearance 2 Adjust valve clearance
3 Broken valve spring 3 Replace valve spring
4 Worn timing gear 4 Replace timing gear
OTHER
1 Fresh water pump bearing malfunction 1 Replace bearing
2 Incorrect drive belt tension 2 Adjust
3 Alternator bearing malfunction 3 Replace bearing
4 Exhaust gas leakage 4 Repair
5 Timing belt tensioner malfunction 5 Replace OPERATION INJECTION PUMP 1 Uneven injection
1 Adjust injection or replace parts
2 Control rack 2 Disassemble check and correct injection pump
3 Worn delivery valve 3 Replace delivery valve
4 Inadequate injection nozzle spray 4 Replace injection nozzle
GOVERNING SYSTEM
1 Governor lever 1 Check governor shaft and correct operation
2 Fatigued governor spring 2 Replace spring
Engines Generators
ENGINE PROBLEM PROBABLE CAUSE ENGINE KNOCKS WITHOUT MUCH SMOKE
1 Engine troubles
8 Overheated cylinder 8 See OVERHEATING LOW OUTPUT
b Carbon deposits in cylinder b Clean
2 Too early injection timing 2 Correct
3 Too high injection pressure 3 Correct
4 Improper fuel 4 Replace with proper fuel
KNOCKING WITH DARK SMOKE
1 Poor compression 1 See Low compression under HARD STARTING
2 Injection pump 8 Worn plunger 8 Replace
b Pinion is not in mesh with control rack b Correct
c Broken delivery valve spring c Replace
d Worn delivery valve seat d Replace
3 Improper nozzle
8 Poor spray 8 Clean or replace nozzle
b Poor chattering b Repair or replace nozzle
c drip c Repair or replace nozzle
d Nozzle needle valve seized d 1 Fuel filter clogged 1 Clean or SOUND 2 Fuel pipe sucks
air 2 Retighten pipe joints or replace pipe
3 Water mixed in fuel 3 Replace 1 Vbelt slackening or slippery with oil 1 Adjust replace or clean
2 Damaged water pump 2 Replace
3 Lack of coolant 3 Add
4 Low oil level or poor oil quality 4 Add or change
5 Knocking 5 See KNOCKING
6 Moving parts seized or damaged 6 Replace
Engines Generators
ENGINE Before disassembly and cleaning carefully check 9 Remove the flywheel
for defects which cannot be found after disassembly and 10 Remove the engine back
11 Unclamp the exhaust elbow the two coolant hoses on the
GENERAL DISASSEMBLY PROCEDURE exhaust manifold and the coolant recovery tank hose
then remove the manifold in its entirety
All disassembled parts should be carefully arranged in with its four gaskets
the order of reassembly Mark or label the parts as
COOLANT
needed to insure proper mating and reassembly in the RECOVERY
proper directions and positions TANK
If the disassembly procedure is complex requiring many
parts to be disassembled the parts should be disassem
bled in a way that will allow them to be efficiently
reassembled without any change in the engines external
appearance or its Do not remove or disassemble parts that require no disas
sembly
Carefully inspect each part after removal for damage
4eformation and other problems
Be careful not to damage the disassembled parts Keep
the parts clean
Use the proper tools Apply oil when necessary Take special care to keep the fuel system parts
free from the MANIFOLD
intrusion of dust and dirt
Remove the transmission first then disassemble the
engine
REMOVAL ELBOW
1 Unplug the instrument panel wiring harness
12 Remove the Drain the transmission fluid and the transmissin oil
cooler hoses 13 Remove the raw water pump
3 Detach the oil cooler hoses 14 Remove the engine mounted fuel filter and the fuel line
to the injection pump Note the arrangement of the seal
4 Unbolt the transmission from the engine ing washers on the banjo bolts at the fuel filter and the
NOTE For transmission service and maintenance refer to injection pump Remove the fuel lift pump
your transmission owner manual To rebuild a transmis 15 Remove the thermostat housing gasket and the thermo
sion contact your WESTERBEKE dealer or a qualified stat Leave the temperature sending unit in place
marine transmission service Clean the exterior of the engine of any deposits of dirt
and oil
2 Mount the engine on a suitable engine stand for disas
sembly
3 Drain the coolant from the engine and the heat
exchanger Drain the fuel and the engine oil
4 Remove the engine wiring harness in its entirety Label
the terminal connections to insure proper Remove the engine heat exchanger and the engine oil
cooleroil filter assembly If possible leave one end of
each hose connection attached to the part being removed
6 Remove the starter motor
7 Remove the engine Remove the transmission damper plate
Engines Generators
ENGINE Remove the idler pulley bracket and idler pulley 3 Remove the two timing belt covers
17 Remove the seal plate b Loosen the two injection pump holddown nuts Do
18 Remove the coolant pump not remove them entirely The holddown nut on the
engine side of the pump can be loosened by using a
19 Remove all the high pressure injector lines from the 14 universal socket and extension with a ratchet
injection pump to the injectors Leave the two upper line
clamps in place c Remove the nut and lockwasher from the injection
pump shaft
NOTE Cap the ends of the lines and the connections at
the injection pump and at the injectors to prevent entry d Place the keyway on the injection pump shaft in the 12
offoreign material oclock position using the front crankshaft pulley bolt
before attempting to remove the injection pump
20 Remove the fuel return lines from the top of the injectors
and from the fuel injection pump Note the washer arrange e Using the puDey puDer 49 S120 215A apply suffi
ment on the fuel return line banjo bolts Cap all openings cient pressure to loosen the pump from the pulley The
on the fuel return line injectors and injection pump loose hold down nuts will prevent the pump from
falling from the engine
21 Remove the fuel injectors dust seals and sealing washers
from the cylinder head NOTE If an extractor is not available replace the nut
loosely on the injection pump shaft and with a nylon
22 Remove the glow plugs drift and hammer gently tap the injection pump shaft
23 Remove the cylinder head cover to dislodge it from the keyed pulley
24 Fuel Injection Pump
NOTE The fuel injection pump is a very important compo INJECTION
PUMP PULLEY
nent of the diesel engine requiring the utmost care in
handling It has been thoroltghly benchtested and the
is cautioned not to attempt to service it If
the fuel injection pump requires servicing remove it and
take it to an authorized fuel injection pump service
facility Do not attempt to disassemble and repair it If PULLEY PULLER
49 S120 215A
the pump is defective WESTERBEKE recommends that
you replace the entire pump
The only adjustment the servicing mechanic should
make to the fuel injection pump is the adjustment for
engine idle speed see IDLE SPEED ADJUSTMENT
under ENGINE f Once loosened remove the hold down nuts and wash
ers and carefully withdraw the pump from the pulley
and the engine
25 Remove the following components
3 Oil pressure switch and oil level gauge
b Dipstick tube
c Cylinder head cover
d Crankshaft pulley
e Oil strainer and oil pan
Fua INJECTION PUMP f Oil pump assembly
g Rear cover
Remove the injection pump as follows h Connecting rod caps
NOTE Scribe mating I i Pistons and connecting rods
marks on the pump body
flange and the timing belt j Piston rings
cover before removal k Main bearing caps
L Main bearings
mOiljets
MATING
MARKS D Engines Generators
ENGINE Belt
TIMING MARK
NOTE WESTERBEKE recommends replacing the timing
belt during an engine overhaul Timing belt failure could
result in major damage to the engine
NOTE If the tming belt is to be reused draw an arrow on
the belt pointing in the direction of the belts rotation so it
will be replaced in the same ARROW 01
CRANKSHAFT
Injection Pump Pulley
TIMING
BELT 1 Put two bolts size M8 x 125 x 35 40 mm through the
arms of the injection pump pulley and insert them in the
thread hole of the injection pump bracket
NOTE This is to prevent the injection pump pulley from
1 Loosen the timing belt tensioner lock bolt push the tim turning while loosening the injection pump pulley lock bolt
ing belt tensioner left as far as it will go then temporarily 2 Loosen the injection pump pulley lock bolt
retighten the lock bolt
3 Using the pulley puller 49 S120 215A separate the
2 Remove the timing belt injection pump pulley from the injection pump shaft
3 Remove the timing belt tensioner
4 Tum the crankshaft clockwise about 45 from the timing INJECTION
mark which is marked on the oil pump housing NOTE Turning the crankshaft
prevents the pistons and
valves from contacting one another
PULLEY PULLER
S120 215A
Engines Generators
ENGINE Pulley Timing Belt Pulley Cylinder Head Bolts
1 Hold the camshaft with a wrench 29 mm 11 in and 1 Loosen the cylinder head bolts in the numbered sequence
loosen the camshaft pulley lock bolt shown in the ilustration Loosen them a little at a time in
sequence
1 3 5 4 2
CAMSHAFT
PULLEY CYLINDER HEAD BOLTS
LOCK Cylinder Head and Gasket
1 Remove the cylinder head by tapping it with a plastic
A CAUTION Do not damage the edge of the hammer
cylinder head with the wrench If it is damaged 2 Remove the cylinder head gasket
engine oil may leak
Camshaft
1 Gradually loosen the camshaft cap nuts in the numbered
sequence shown in the A CAUTION Before removing the camshaft pul
2 Remove the caps
ley turn the crankshaft 45 clockwise to prevent
damage to the valves 3 Remove the camshaft and oil seals
3 7 10 6 2
2 Remove the camshaft pulley from the camshaft using the
same procedure described under Injection Pump Pulley
above
A CAUTION Do not hit the camshaft pulley with
a hammer
CAMSHAFT PULLEY 4 8 9 5 1
LOOSENING THE CAMSHAFT CAP NUTS
Adjusting Discs and Tappets
1 Remove the adjusting discs and tappets as a set
A CAUTION All adiing discs and tappets
should be disassembled in a way thatCOllect
reassembly can be performed Remove the timing belt pulley
Engines Generators
ENGINE DISASSEMBLY
Valve Seals
1 Move the piston of the valve seal to be replaced to
approximately top dead center
2 After removing the lower spring seats remove the valve
seals by using the valve seal remover 49 S120 170 to
grasp and work them out
NOTE The valve seal remover 49 S120 170 cannot
grasp the valve seals unless the lower spring seats have
0000000 been removed
ADJUSTING DISCS AND Remove the springs
2 Remove the valves lower spring seats and spring retain VALVE SEAL
ers from the cylinder head by using an appropriate valve REMOVER
49 S120 170
spring compression tool
VALVE SPRING LIFTER
Combustion Chamber Inserts
1 Remove the combustion chamber inserts from the bottom
surface of the cylinder head by using a suitable mandrel
PIVOT
49 S120 222
NOTE The valve guides are to be removed only after mea
suring the valve guidevalve stem see Valve Guides under
ENGINE Engines Generators
ENGINE INSPECTION AND INSPECTION PROCEDURE 4 Measure the manifold contact surface distortion in the
three directions shown in the illustration If the distortion
1 Before inspection clean each part taking care to remove exceeds the limit grind the surface or replace the cylin
any gasket fragments dirt oil or grease carbon moisture der head
residue or other foreign materials
Distortion limit 020 mm 0008 in
2 Be careful not to damage the joints or sliding parts of
aluminum alloy components such as the cylinder head
and the pistons
3 Inspection and repair should be done in the order indi
INSPECTION
MANIFDLD CONTACT SURFACE Head
1 Inspect for water leakage fuel leakage damage and 5 Measure the oil clearance of the camshaft
cracks If a problem is found replace the part a Remove the tappets and adjusting discs from the cylin
2 Measure the cylinder head for distortion in six directions der head and separate them by cylinder
using a thickness gauge as shown in the Distortion limit 010 mm 0004 in
000 000 0
TAPPETS AND ADJUSTING DISCS REMOVAL
CYUNDER HEAD DISTDRTIDN
STRAIGHTEDGE b Clean away oil and dirt from the camshaft and cylinder
head journals
c Set a plastigauge on the camshaft journal in the axial
direction of the journal
d Set the camshaft caps and tighten the nuts to the speci
fied torque
CYUNDER HEAD DISTDRTIDN j
3 If cylinder head distortion exceeds the limit replace the
cylinder head
CAMSHAFT CAPS
A CAUTION Do not attempt to repair the cylin
der head by milling or grinding Handle the cylinder
head carefully taking special care not to damage Camshaft cap nut tightening torque
its lower surface 20 27 kgm 15 20 ftIb
Engines Generators
ENGINE INSPECTION AND REPAIR
A CAUTION When installing the camshaft
caps note the correct sequence and the aow
maries When tightening the camshaft cap nuts
do so evenly and in the sequence shown in the
10 6 2 3 7
MEASURING THE CAMSHAFT END PLAY
7 Measure the amount that the combustion chamber insert
9 5 1 4 8 has receded
TIGHTENING THE CAMSHAFT CAP NUTS
a Clean the lower side so that the surface of the combus
tion chamber insert wont be scarred
e Removethe camshaft caps and measure the oil clearance h Measure using a dial gauge
Standard oil clearance limits
O025 0066 mil 098 09260 in Receded amount 004 mm 00016 in
limit 01 mm 00039 in Projection amount 005 mm 00024 in
f If the oil clearance exceeds the limit replace the c If either limit is exceeded replace the combustion
cylinder head or the camshaft chamber insert or the cylinder head
COMBUSTION
CHAMBER INSERT
MEASURING THE DlL CLEARANCE
Valve Seats
6 Measure the end play of the camshaft If the end play 1 Use a thickness guage and a straightedge as shown in the
exceeds the limit replace the camshaft or the cylinder illustration to measure the amount the valve has receded
head from the cylinder head surface
Standard camshaft end play
002 015 mm 000079 000591 in
limit 02 mm 00079 in
Engines Generators
ENGINE INSPECTION AND REPAIR
If the receded amount is 155 255 mm 0061 0100 Standard valve seat contact width
in use an equivalent washer at the valve spring seat If 17 23 mm 0067 0091 in
the receded amount is 255 mm 0100 in or more
replace the cylinder head
Standard amount of valve recession
Intake and exhaust cold engine
075 105 mm 0030 0041 in
3 To seat the valve apply a thin coating of engine oil
THICKNESS mixed with a small amount of compound to the seat sur
GAUGE face then lightly tap while turning the valve
2 Check the surface which contacts the valve face for
roughness or damage If necessary use a valve seat cutter
or valve seat grinder to repair to the specified shape
A CAUTION When seating the valve be careful
not to let compound ahere to the valve stem
NOTE To check the contact width apply a thin coating of The valve contact position in relation to the valve
red lead to the valve seat and press the valve against the seat must be at the center of the valve seat Be sure not to turn the valve
when doing so
and the contact width must be the standard value
Check to be sure that the amount of valve reces
sion is within the RED LEAD
VALVESEAT
NOTE When grinding the valve seat use a 15 45 or 60
valve seat cutter or valve seat grinder to grind away the
roughness andor scars to the minimum limit of the seat
surface always checking the contact width and contact
position while grinding
Valves
1 Inspect each valve and replace any that show valve stem
wear damage bending or dents
Engines Generators
ENGINE INSPECTION AND REPAIR
2 Inspect each valve for roughness or damage on its faces 2 To replace the valve guide tap it to the side opposite the
If the problem is slight repair the valve with a valve combustion chamber using the valve guide remover 49
refacer Standard valve stem diameter
Intake 7970 7985 mm 03138 03144 in
Exhaust 7965 7980 mm 03136 03142 in To install fit the clip onto the valve guide Use the valve
guide installer 490552 165 to tap the valve guide in
EXHAUST INTAKE from the side opposite the combustion chamber until the
clip barely contacts the cylinder head
D CLIP
CYLINDER
Guides
1 Measure the difference between the inner diameter of
each valve guide and the diameter of the stem This difference is the stemtoguide clearance
Replace the valve guide if this clearance exceeds the
limit
Stemtoguide clearance limit 010 mm 0004 in
A CAUTION After the valve guide is replaced
recheck the gap between the valve and the valve
guide
The valve seals should be installed after inspection
and repair of the valve seats
Dont confuse the valve guides intake and
exhaust valve guides have different lengths
The intake valve guide is longer
The exhaust valve guide is shorter
Engines Generators
ENGINE INSPECTION AND REPAIR
INTAKE
Tappets and Adjusting Discs
EXHAUST 1 Measure the outer diameter of the tappet replace it if the
limit is exceeded
2 Measure the diameter of the tappet hole in the cylinder
head and calculate the difference clearance between it
405mm
and the outer diameter of the tappet if this clearance is
159 in 376mm the limit value or more replace the tappet or the cylinder
148 in head
Standard tappet outer diameter
3496 3498 mm 13763 13771 in
Standard tappet hole
LONGER SHORTER 3499 3502 mm 13776 13787 in
VALVE GUIDES
Standard clearance
002 006 mm 00008 00024 in
Valve Springs
Clearance limit 010 mm 00040 in
1 Inspect each valve spring for cracks or other damage
Replace if Check each spring for free length and angle limit
Replace if necessary
Free length limit 448 mm 1764 in
DlAMmR
OF TAPPET
Camshaft
1 Check the camshaft for wear or damage Replace if
necessary
Standard cam height
Intake 4431 mm 1744 in
Angle limit 158 mm 0062 in Exhaust 4530 mm 1783 in
Cam height limit
Intake 4390 mm 1728 in
Exhaust 4490 mm 1768 in
ANGLE VARIATION
FROM VALVE SPRING
Engines Generators
ENGINE INSPECTION AND REPAIR
2 Measure the wear of each journal at the four locations 2 Measure the distortion degree of flatness of the top sur
shown in the illustration directions A and B Front and face of the cylinder block in six directions using a feeler
Rear Replace the camshaft if necessary gauge and a straightedge as shown in the Journal 005 mm 0002 in
Distortion limit 010 mm 00040 in
Standard journal diameters
3196 3198 mm 1258 1259 in
Journal diameter limit 3186 mm 1254 in
3 Check the camshaft deflection
Camshaft deflection limit
010 mm 00040 in
NOTE Place the front and rear journals on Vblocks to
make the 3 If the distortion exceeds the limit replace the cylinder
block
A CAUTION Dont glind the surface of the cylin
del block If ground the vares will hit the pistollS
4 Check the cylinder walls for scoring or signs of seizure
If a problem exists reboring or replacement is Block 5 If the upper part of the cylinder wall
shows uneven wear
use a ridge reamer to repair
1 Check each cylinder for dampness damage and cracks
Replace if necessary 6 Measure the cylinder diameter at the six locations shown
in the illustration Check the amount of wear The amount
of wear is the difference between the maximum and min
imum diameters If the amount of wear exceeds the limit
the cylinder must be rebored
Standard cylinder bore 8600 mm 339 in
Cylinder bore wear limit 8617 mm 392 in
cylinder bores
0022 mm 000090 in
Engines Generators
ENGINE INSPECTION AND REPAIR
3 Inspect the piston rings for damage abnormal wear or
A CAUTION The boring size should be based on breakage Replace if necessary
4 Insert the piston rings into the cylinder by hand and push
the size of an oversize piston
them in by using the piston
Oversize pistions 025 mm 0010 in
050 mm O020n 5 Measure the ring opening clearance
Ring opening clearance limit 10 mm 0039 in
RING OPENING
CYLINDER BLOCK and Piston Rings
1 Inspect the outer of all the pistons for
seizure or scoring Replace if necessary 6 Measure the clearance of the piston ring to the ring
groove
2 Measure the outside diameter of each piston and be sure
the clearance between the piston and cylinder is correct Clearance limit 02 mm 0008 in
Piston standard outside diameter
8595 8598 mm 3384 3385 in
Piston and cylinder clearance limit
A CAUTION Measure the clearance around the
entire circumference of the ring groove
015 0006 in
A CAUTION Measure the piston outside diame
ter in the thrust direction 19 mm 075 in above
the bottom of the piston If the piston is replaced
replace the piston rings also
Oversize Piston Rings
025 mm 0010 in 050 mm 0020 in
075 in
Engines Generators
ENGINE INSPECTION AND Rods 2 To replace the connecting rod bushing use a press and a
suitable pipe diameter 27 275 mm 106 188 in
1 Check each connecting rod for bending or torsion
Connecting rod bending limit
016 mm 0006 in per 100 mm 394 in A CAUTION Before assembling apply a coat
ing of clean engine oil to the connecting rod
bushing and connecting rod Align the oil hole of
the connecting rod bushing with the connecting
rod oil hole
3 After pressing the bushing in correct the bushings inner
diameter by using a spiral expansion reamer so that the
clearance will come within the standard value
CHECKING
CONNECTING ROO
BENDING LIMIT
Connecting rod torsion limit
016 mm 0006 in per 100 mm 394 in
Crankshaft
1 Check around the journals and pins for damage and scor
ing and the oil passages for 2 Check the crankshaft deflection and each diameter
Replace if necessary
Deflection limit 005 mm 0002 Rod Bushings
1 Measure the clearance between the outside diameter of
the piston pin and the inside diameter of the bushing If
the clearance exceeds the limit replace the connecting
rod bushing
Standard connecting rod bushing inner diameter
2501 2503 mm 09846 09854 in
Clearance limit 005 mm 0002 in
PISTON PIN
CHECKING CRANKSHAFT Engines Generators
ENGINE INSPECTION AND REPAIR
Standard journal diameters Timing belt
1 Main journal diameter
5994 5996 mm 2360 2361 in Replace the timing belt if it is contaminated with oil grease
2 Crankshaft pin diameter or water or if any of the following conditions exist
5094 5096 mm 2006 2007 in 1 Premature severance
3 Rear housing oil seal sliding surface a Check for proper 8995 9000 mm 3541 3543 in
b Check the timing belt cover gaskets for damage and
2 PREMATURE

1 2 Check the teeth for damage cracks peeling and harden
ing and check for any missing teeth
JOURNAl DIAMETERS
CRACKED
MISSING TOOTH
Journal wear limit 005 mm 00020 in TOOTH
If the wear exceeds the limit replace or grind the crank
shaft to agree with the undersize bearing
Journal grinding limit 075 mm 00295 in
Undersize bearings 025 mm 0010 in 050 mm 0020 in 075 mm 00295 in
A CAUTION When grinding the journal or pin pay
attention to each Fillet R dimension
Fillet R dimension
26 30 mm 0102 0118 in
CRACKED
TOOTH
Main Bearings and Connecting Rod Bearings 3 Check for noticeable wear or cracks on the belt face
1 Check the main bearings and connecting rod bearings
2 Check the bearing inside surfaces for streaking flaking
pin holes etc replace all bearings as a set if there is a
problem
UPPER SIDE
j m OO l 4 Check for wear or damage on only one side of the belt
JID mOO
LOWER SIDE
MAIN BEARINGS AND
CONNECTING ROD BEARINGS
WEAR OR DAMAGE
Engines Generators
ENGINE INSPECTION AND REPAIR
5 Check for noticeable wear on the belt teeth TIming Belt Camshaft and Injection Pump Pulleys
1 Inspect the teeth on each pulley for wear deformation or
other damage Replace if necessary
A CAUTION Do not clean the pulleys If they
ale dirty use a clean rag to wipe them clean
TOOTH WEAR
TIming Belt Covers left right
A CAUTION Nevel fOlcefully twist the timing 1 Inspect each timing belt cover for deformation or cracks
belt tUln it inside out 01 bend it Be caleful not to Replace if necessary
allow Oil glease 01 moistule on the belt 2 Inspect the gasket for deformation cracks or hardening
Replace if necessary
DO NOT BEND DO NOT TWIST DO NOT TURN
INSIDE OUT
25mm10in
DO NOT Belt Tensioner
1 Check the rotation of the timing belt tensioner pulley and
check for play or abnormal noise Replace if necessary
A CAUTION Do not clean the tensionel with
cleaning solvents If it is dirty use a clean rag to
wipe it clean Avoid scratching the surface the
belt travels over
TIMING BELT Engines Generators
ENGINE REASSEMBLY PROCEDURE
Clean or wash the parts to be reassembled Apply lubri
cating oil when specified or as needed to the surfaces of
A CAUTION Be sure to use the special tool for
the installation of the valve seals If they are not
moving parts during reassembly Heavily oil sliding
turning rotating and reciprocating parts lightly oil head installed correctly oil might leak down into the
bolts and other fasteners except those that penetrate into cylindelS during operation
the water jacket Make sure that moving parts after
assembly onto the engine are not subject to binding or
excessive tension
Carefully check gaskets packings and oil seals even if
checking is not specified Use new gaskets lockwashers
and Orings
Be careful not to mix bolts and nuts Both metric and
SAE bolts are used on various engine assemblies
Replace plain bearings if they are peeling burned or oth
erwise damaged
Reassemble parts eg pistons piston rings bearings
bearing caps in their proper order positions and direc
tions relative to the engine block Note that the cylinder
head gasket head bolt washers and thermostat are assy
metrical Any mating marks that were drawn or scribed
Valves
during disassembly should be positioned correctly for Install the valves onto the cylinder head as follows
reassembly Position gaskets carefully especially the
head gasket so they will not be damaged during 1 Install the lower spring seat
assembly 2 Insert the valve after applying molybdenum disulphide
grease to the valve stem
Inspect all critical clearances end plays oil clearances
and bends 3 Install the valve spring and upper spring seat
Use liquid sealants when specified or needed on nuts 4 Press the valve spring using the valve spring lifter 49
bolts and gaskets Use Permatex No2 or equivalent 0636 100A and pivot 49 S120 222 Then install the
Dont use tape sealants spring retainer securely
Tighten the bolts and nuts on the important parts of the VAlVE SPRING LlmR
490636100A
engine to the specified torques using a reliable torque
wrench Tighten fasteners in the specified torque
sequences and in three steps 12 23 and 11 torque
an exception is head bolts Where a tight
ening torque is not specified tighten evenly to an ordi
nary torque
After completion of reassembly recheck for any abnor
malities Prepare for starting the engine and idle the
engine sufficiently for a test run
ENGINE Seals
NOTE Always replace the valve seals during an engine 5 Move the No 1 piston to top dead center and then
the crankshaft approximately 45
1 Apply a coat of engine oil to the valve guides and the
inside surfaces of the valve seals
2 Using the valve seal pusber 49 S120 160 install the
A CAUTION If this is not done the valves may
valve seals be damaged by the pistons when tightening the
camshaft cap nuts
Engines Generators
ENGINE REASSEMBLY
Tappets and Adjusting Discs TOP RING AND
EXPANDER
1 Apply engine oil to the tappets then install the tappets to
the tappet holes
2 Install the adjusting discs
A CAUTION Apply a liberal coat of engine oil
during installation The rings must be mounted so
the 8 or 8N marks face and Connecting Rods
R DR RN
1 Assemble the piston and connecting rod jrfnp RING MARKS FACE UP
8 Align the oil hole in the large end of the connecting
rod with the F mark on the piston SECDNDRING
b Apply a coat of engine oil to the small end of the con
necting rod and all over the piston OIL RING PISTDN RING
c Insert a snap ring into one of the piston pin holes in the EXPANDER
piston
d Connect the piston and connecting rod by the piston
pin then lock the snap ring so it wont come out 3 Install the piston and connecting rod
When doing this the piston should be heated to
SO7SoC a Fit the connecting rod bearing to the connecting rod
then apply a coating of engine oil
b After cleaning the inner surface of the cylinder apply a
coating of engine oil
c Insert each piston and connecting rod into the cylinder
block using a piston insertion tool
A CAUTION The pistons must be inserted so
that the F marks face the front of the cylinder
block Apply a liberal coating of engine oil to the
cylinder walls piston and rings
2 Assembly of the piston rings
8 Assemble each piston ring to the piston by using a pis
ton ring inlerting tool commercially available The
order of assembly is oil ring expander oil ring second
ring top ring
b Align the piston ring end gaps as shown in the
ENGINE FRONT SIDE
Engines Generators
ENGINE Assembly d Remove the main bearing cap and measure the oil
clearance
1 Install the oil jets to the cylinder block
Oil jet tightening torque Standard oil clearance
0031 0049 mm 00012 00019 in
12 18 kgm 9 13 ftIb
Oil clearance limit 008 mm 00031 in
2 Install the main bearings
e If the oil clearance exceeds the limit replace the main
bearings with new ones and measure the oil clearance
again
A CAUTION No oil dirt etc should be on the f In case the oil clearance exceeds the limit even when
back surface of the bearings the main bearings are replaced repair the crankshaft by
The center main bearings cannot be interchanged grinding and use undersize bearings
with the other main bearings because thttir widths
are MEASURING CRANKSHAfT AND
MAIN BEARINGS OIL CLEARANCE
MAIN BEARINGS INSTALLATION
3 Check the oil clearance of the crankshaft and main bear
ings with a plastigauge A CAUTION Position the plastigauge horizon
a Remove any foreign material from the journal or tally on the crankshaft away from the oil hole
bearing Do not rotate the crankshaft when measuring the oil
b Position the plastigauge on top of the journal in the clearance
journal axial direction Install the main bearing cap according to the cylin
c Set the main bearing caps in position then tighten der number and the CJ mark
them to the specified torque in the sequence shown in
the Main bearing cap bolt tightening torque
84 90 kgm 61 65 ftlb
FRONT
CYLINDER NUMBER
MAIN BEARING
MAIN BEARING CAPS
Engines Generators
28
ENGINE REASSEMBLY
4 After checking and correcting the oil clearance apply a 8 If the end play is not within the standard range select
coating of engine oil to the main bearing and main jour another thrust bearing
nal and then install the crankshaft Undersize thrust bearing width
5 Apply a coat of engine oil to the thrust bearing and 218 223 mm 00858 00878 in
install it to the center part of the main journal Standard thrust bearing width
200 205 mm 00787 00807 in
A CAUTION Install the thrust bearing so that the
inner surface of the oil groove faces toward the
cylinder block side
A CAUTION FilSt replace the rear thrust bear
ings if the end play is still not within the limit
replace the front thrust bearings also
CRANKSHAFT SIDE
THRUST BEARING
IDTH
LOWER SIDE
6 With the main bearing cap in the set condition manually
push the crankshaft toward the front then with it pulled 9 Use a suitable piece of pipe to tap the pilot bearing onto
toward the rear tighten the bolt to the specified torque the crankshaft
Main bearing cap bolt tightening torque
84 90 kgm 61 65 ftIb
7 Measure the end play of the crankshaft and confirm that A CAUTION Apply a coating of engine oil to the
it is within the standard range At this time check to be outer circumference of the pilot bearing and the
sure that the crankshaft can be lightly turned crankshaft Set a piece of pipe against the outer
Standard crankshaft end play race of the bearing and tap evenly After installa
004 028 mm 00016 00111 in
tion apply grease to the bearing
End play limit 03 mm 00118 in
MEASURING
CRANKSHAFT
END PLAY PIPE
Engines Generators
ENGINE Install each connecting rod bearing cap as follows
a Measure and adjust the connecting rod bearing and
crankshaft pin journal oil clearance by the same pro
cedure used to measure and adjust the crankshaft and
main bearing oil CONNECTING
ROD CAP
c Install the connecting rod bearing cap and tighten to
J PLASTiGAUGE
the specified torque Before installing apply a coating
of engine oil to the bolt threads nuts and bearing
L CONNECTING surfaces
Connecting rod bearing cap tightening torque
70 75 kgm 51 54 ftIb
Standard oil clearance
A CAUTION When installing the connecting
003 006 mm 00012 00024 in rod cap fim align the cap and connecting rod
matching marks
Oil clearance limit 008 mm 00031 in
Before installation be absolutely SUfe to apply a
Undersize connecting rod bearings
025 mm 0010 in 050 mm 0020 in coating of engine oil to the bearing
075 mm 0030 in
MATCHING
MARKS
INSTAWNG CONNECTING
MEASURING CONNECTING ROD BEARING AND ROD BEARING CAP
CRANKSHAn PIN JOURNAL OIL CLEARANCE
Rear Cover Assembly
b Check the end play of the connecting rod
1 Apply engine oil to the rear cover and the oil seal
Sdard connecting rod end play
011 026 mm 00043 00102 in
End play limit 035 mm 0014 in A CAUTION Remember that when engine oil is
applied to the cover and seal it must also be
applied to the oil seal lip
A CAUTION Measure the connecting rod end
play before installing the connecting rod cap
Engines Generators
ENGINE REASSEMBLY
2 Press the oil seal into the rear cover 3 Install the oil pump assembly
Oil pump assembly tightening torque
M8 smaller bolts
16 23 kgm 12 17 ftlb
MI0 bigger bolts
32 47 kgm 23 34 ftlb
REAR
COVER
3 Install the rear cover assembly over the gasket
Rear cover assembly tightening torque BOLTS
07 10 kgm 5 7 ftlb
OIL PUMP ASSEMBLY
A CAUTION Do not let sealant get into the
oil hole
Apply engine oil to the oil seal lip
Before applying the sealant use a rag to tholoughly
clean away any dirt 01 glease from the contact SUI
faces of the cylinder block and oil pump assembly
Apply the sealant continuously without any inteup
tion around the bead as shown in the Aftel installation clean away any
sealant which
Oil Pump Assembly oozes out
NOTE If it is necessary to service the oil pump see OIL PUMP
under LUBRICATION SYSTEM Oil Strainer and Oil Pan
1 Install an Oring applied with grease lithium base NLGI NOTE See OIL PAN under LUBRICATION SYSTEM for addi
No2 onto the oil pump assembly tional Apply sealant 1016 77 739 to the surface shown by the 1 Install the
oil strainer on the oil pump body and cylinder
shading in the illustration block then tighten it to the specified torque
Oil strainer tightening torque
07 10 kgm 5 7 ftlb
OIL STRAINER
Engines Generators
ENGINE REASSEMBLY
2 Cut away that part of the gasket which projects out from 2 Install the flywheel assembly using the ring gear brake
the rear cover assembly to the oil pan 49 VIOl 060
Flywheel tightening torque
A CAUTION Do not scratch the rear cover 18 19 kgm 130 137 ftIb
Follow this procedure to install the oil pan
A CAUTION Sealant part No 8530 77 743 must
be applied to the lock bolt threads to prevent oil
a Apply sealant where the oil pan and cylinder block leakage from the lock bolts
meet Put it on continuously thickness 2 4 mm
008 016 in rimming the surface inside the bolt After installation do not remove the ring gear brake
holes the end should overlap
RING GEAR BRAKE
49 V101 060
REAR COVER
ASSEMBLY
3 Install the damper plate onto the flyWheel
A CAUTION Before application remove any dirt Damper plate tightening torque
22 33 kgm 1624 ftIb
or grease from the contact surfaces with II rag
Apply sealant only to the cylinder block or the oil
pan not to both After the sealant is applied the
pan must be secured within 30 minutes
b If a gasket is used apply sealant to the areas shown by
the shading in the illustration Then install the gasket
and the oil pan tightening to the specified torque
Oil pan tightening torque
07 10 kgm 5 7 ftIb
Timing Belt Pulley
Back Plate and Flywheel
1 Install the back plate
Back plate tightening torque
16 23 kgm 12 17 ftIb
Engines Generators
ENGINE REASSEMBLY
2 Release the ring gear brake tum the flywheel move the
No1 piston to the top position and then tum the crank
shaft clockwise approximately 45
A CAUTION If the length of the bon below the
head exceeds the limit the bolt must be replaced
A CAUTION This is to prevent damage to the APPLY ENGINE OIL
piston and valve when the cylinder head is
installed
m1l I
CYLINDER HEAD BOLT LENGTH
6 TIghten the cylinder head bolts in the sequence shown in
the Cylinder head tightening torque
30 kgm 217 ftlb
8 4 1 5 head
1 Thoroughly remove all dirt and grease from the top of
the cylinder block with a rag
2 Place the cylinder head gasket in position
7 3 2 6 10
TIGHTENING THE CYUNDER HEAD BOLTS
A CAUTION Use a new cylinder head gasket 7 Make paint marks on the bolt heads as shown in the
illustration below
8 With the paint marks as reference points tum the cylin
der head bolts another 90 90 105 in the tightening
direction turning them in the sequence shown in the
illustration above
9 Then tighten them once again 90 more 90 105 in
the tightening sequence shown above
GASKET A CAUTION Be absolutely sure to tighten all
bolts in the sequence shown in the Remove any dirt or grease from the bottom surface of the
cylinder head
4 Place the cylinder head in position
5 Measure the length of the cylinder head bolt below the
head If the measured value is within the limit apply a
coating of engine oil to the threaded part and install
Cylinder head bolt length
Standard length
1127 1133 mm 4437 4460 in
limit 1145 mm 4508 in
Engines Generators
ENGINE 10 6 2 3 7
1 Apply a coat of engine oil to the camshaft and the cylin
der head journals
2 Insert the seal cap and then apply sealant 1016 77 739
to the areas shown by the shading in the 9 5 1
4 8
TIGHTENING THE CAMSHAFT CAP NUTS
Glow Plugs
APPLYING SEAlANT TO THE CYLINDER HEAD NOTE See GLOW PLUGS page for additional information
1 Install the glow plugs and glow plug connectors Use
3 Set the camshaft and camshaft cap in position then
antiseize compound on the threads
loosely tighten the camshaft cap nuts
Glow plug tightening torque
NOTE Set the camshaft so that the key groove faces
directly upward 15 20 kgm 11 15 ftIb
4 Apply a coat of engine oil to the lip of the camshaft oil
seal and then insert the oil seal
Injection Nozzles
Nm For testing information see TESTING FUEL INJEC
5 Tighten the camshaft cap nuts to the specified torque See WRS under ENGINE ADJUSTMENTS
Cylinder Head 5 under ENGINE INSPECTION AND 1 Install the heat shield washers copper gaskets injection
REPAIR for measurement of the oil clearance nozzles and fuel return lines as shown in the Camshaft cap nut tightening
torque
20 27 kgm 15 20 ftlb
A CAUTION Be sure that the heat shield washer
is positioned in the direction shown in the illustra
A CAUTION Tighten the camshaft cap nuts tion The heat shield washer and copper gasket
gradually and eveny and in the sequence shown in must be replaced each time the injection nozzle is
the illustration removed
The adjustment of the lillve clearance should be
made only after the camsliait pulley injecion pump Injection nozzle tightening torque
60 70 kgm 43 51 ftIb
pulley and timing belt have been Engines Generators
ENGINE REASSEMBLY
Fuel Injection Lines
1 Install the high pressure fuel injection lines from the
injection pump to the injectors
Fuel injection line tightening torque
18 23 kgm 13 17 ftIb
A CAUTION Check to be sure that no dirt or
other foreign material has adhered to the fuel line
coupling
2 Tighten the clip Pressure Switch and Oil Dipstick Tube
1 Install the oil pressure switch
Oil pressure switch tightening torque
12 18 kgm 9 13 ftIb
2 Install the oil dipstick tube
Fua INJECTION UNES
Coolant Pump
NOTE For additional information see the COOLANT
PUMP page
1 Install the coolant pump with its gasket and tighten it to
the specified Pump Coolant pump tightening torque
32 47 kgm 23 34 ftIb
1 Install the injection pump with the fuel feed line and the
injection pump bracket
NOTE In case the fuel injection pump bracket and the fuel
injection pump are separated an injection timing adjust
A CAUTION Before installation remove any dirt
from the contact surface lise a new gasket
ment will be installing the timing belt
Injection pump tightening torque
32 47 kgm 23 34 ftIb
FUEL INJECTION PUMP
FUEL INJECTION M1
PUMP BRACKET
Engines Generators
ENGINE Plate 4 Check the thermostat for proper operation by placing it in
1 Install the seal plate a pan of cold water and then raising the temperature of
the water to a boil The thermostat should open notice
Seal plate tightening torque ably with approximate travel between 14 12 and
08 12 kgm 6 9 ftlb be fully opened when the water is boiling
A CAUTION Be sure that the seal plate sealing
rubbers are installed in Pulley Bracket
1 Install the idler pulley bracket
Idler pulley bracket tightening torque Camshaft Pulley
32 47 kgm 23 34 ftlb
1 Install the camshaft pulley onto the camshaft with the
NOTE There are two different lengths of idler pulley semicircular woodruff key
bracket bolts
2 Hold the camshaft with a wrench 29 mm 114 in then
tighten the camshaft pulley lock bolt to the specified
torque
IDLER PULLEY Camshaft pulley bolt tightening torque
BRACKET
56 66 kgm 41 48 ftlb
A CAUTION Be sure that the mark on the
camshaft pulley aligns with the mark on the seal
plate Dont damage the cylinder head edge with the
Assembly
1 Install a new thermostat and a new gasket the old ther
mostat can become a spare Apply a thin coat of sealant
to both sides of the gasket
2 Inspect the thermostat housig then install it
Thennostat housing tightening torque
16 23 kgm 12 17 ftlb CAMSHAFT
PULLEY
3 Install the temperature switch and sender and reconnect
their wires
Engines Generators
ENGINE Pump Pulley SPRING
1 Install the injection pump pulley with the semicircular
woodruff key to the injection pump shaft
2 Rotate the injection pump pulley until the timing mark on
the injection pump pulley aligns with the timing mark on
the seal plate
3 Attach the injection pump pulley to the injection pump
bracket using the two bolts 35 40 mm long and
tighten it to the specified torque
Injection pump pulley tightening torque
60 70 kgm 43 52 ftIb
Timing Belt
1 Return the crankshaft approximately 45 to the timing
mark which is marked on the oil pump housing
A CAUTION Check to ensure that the timing
maries on the camshaft pulley and the injection
pump pulley are aligned with the timing maries on
the seal plate
INJECTION PUMP
Belt Tensioner
1 Check to ensure that the timing marks on the pulleys are
aligned with the timing marks on the seal plate
7 N
TIMING MARKS
TIMING MARKS 2 Install the timing belt
A CAUTION reinstalling the original belt be
sure the arrow that was drawn on the belt points in
the direction of the engines rotation
2 Install the timing belt tensioner locking bolt and spring
3 Push the timing belt tensioner to the left toward the water
pump as far as it will go and then tighten the locking bolt
to temporarily hold the tensioner in place
Engines Generators
ENGINE REASSEMBLY
3 Remove the two attaching bolts from the injection pump 9 Install the left timing belt cover with its rubber seal
pulley 10 Install the right timing belt cover with its rubber seal
4 Loosen the tensioner lock bolt so that tension is applied TIming belt cover bolts tightening torque
to the timing belt by the tensioner spring 07 10 kgm 5 7 ftIb
5 Tum the crankshaft twice in the direction of normal
engine rotation clockwise to equalize tension on the
timing belt
A CAUTION Do NOT rotate the crankshaft in the
reverse of its nonnal rotation
6 Tighten the timing belt tensioner lock bolt
TIming belt tensioner lock bolt tightening torque
32 47 kgm 23 34 ftIb
Crankshaft Pulley and Torsional Damper
1 Install the crankshaft pulley and the torsional damper
onto the timing belt drive gear with the semicircular
woodruff key Tighten the attachment
Crankshaft pulley bolt tightening torque
23 33 kgm 17 24 ftIb
NOTE When installing the torsional damper onto the tim
ing belt drive gear align the mark on the damper with
the knock pin on the gear
7 Recheck the timing mark positions on the crankshaft
camshaft pulley and injection pump pulley with the tim
ing marks on the gear case
8 Check the timing belt deflection at the position shown in
the Standard timing belt deflection engine is cold
108 129 mm 043 051 in10kg 22 Ib
A CAUTION If the deflection isnt within the
CRANKSHAFT PULLEY
repeat the procedure from Step 1
Manifold Assembly
NOTE For additional information see the
MANIFOW page
1 Remove the air intake manifold clean the two air filters
then reassemble
2 Place the manifold gaskets in position
3 Install the manifold in its entirety and
tighten it to the specified torque
Intake exhaust manifold tightening torque
22 27 kgm 16 20 ftIb
Engines Generators
ENGINE REASSEMBLY
4 Attach the exhaust elbow the two exhaust manifold
hoses and the coolant recovery tank hose
For additional servicing information see the
MANIFOLD page
COOLANT
RECOVERY
TANK HOSE
5 Install the water hose with a new gasket
Water hose tightening torque
Oil CoolerOil Filter Assembly Bracket 19 26 kgm 14 19 ftIb
Flange 08 11 kgm 58 80 ftIb
NOTE For additional see OIL COOLER SYSTEM Alternator
1 Install three new Orings into the oil cooler and apply a NOTE For additional see DC ELECTRICAL
coating of engine oil to them Install the oil cooler assembly and tighten it to the speci 1 Install
the alternator bracket and tighten it to the speci
fied torque fied torque
Oil cooler tightening torque Alternator bracket tightening torque
M10 bolt bigger 32 47 kgm 23 34 ftlb 32 47 kgm 23 34 ftIb
M6 bolt smaller 07 10 kgm 5 7 ftIb
2 Install the alternator and drive belt Insure that the belt is
3 Before installing a new spinon oil filter wipe the filter in proper alignment with the crankshaft pulley and the
gaskets sealing surface on the oil cooler free of oil and idler pulley Check the belt tension
apply a thin coat of clean engine oil to the rubber gasket
on the new oil filter Alternator drive belt deflection
New 1112 mm 044 047 in10 kg 22Ib
4 Screw the oil filter onto the threaded stub and tighten Used 12 14 mm 047 055 in10kg 22Ib
firmly by hand
Engines Generators
ENGINE REASSEMBLY
4 Install the PCV hose
S Remove the engine from the engine hanger
49 G030 005
Engine Mounts
1 Install the engine mounts and tighten them to the speci
fied torque
Engine mount tightening torque
32 47 kgm 23 34 ftIb
Valve Clearance Adjustment
1 Measure the valve clearance and adjust it see
VAL VE CLEARANCE ADJUSTMENT under ENGINE
Fuel Filter
Mount the fuel filter assembly then connect the fuel supply
line to the filter
Plate
1 Install the bellhousing
VALVE CLEARANCE ADJUSTMENT
2 Mount the heat exchanger on the bellhousing
3 Mount the transmission damper plate to the Head Cover
Cooling System
1 Apply sealant to the areas shown by the shading in the
illustration 1 Install the raw water pump and its drive belt Make sure
the belt is in proper alignment with the crankshaft pulley
2 Place the gasket in position Check the belt tension
3 Install the cylinder head cover and tighten it to the 2 Install new hose connections and clamps for the cooling
specified torque system
Cylinder head cover tightening torque
07 10 kgm S 7 ftIb Electrical Equipment
GASKET 1 Install the oil and water senders and switches
2 Install the starter motor
CYLINDER APPLY
1IIl I SWNT 3 Install the breaker panel and the preheat solenoid
4 Install the engine wiring harness
A CAUTION Check all AC and DC wiring connec
tions Refer to Westerbekes wiring schematics and
Engines Generators
ENGINE Idle Speed the HBW marine transmission and fill with ATF Check the
idle speed adjustment after the engine has had a
Dextron III test run see IDLE SPEED ADJUSTMENT under ENGINE
NOTE Some transmissions such as the Borg Warner Velvet require oil coolers Oil coolers should be tested and repainted at engine
overhauL The oil cooler hoses should also be inspected refer to
HEAT TYPICAL TRANSMISSION
OIL Fill the engine cooling system with antifreeze mixture
2 Fill the engine oil sump with lube oil
Lubrication system oil grade
API Specification CF or CG4
SAE30 IOW30 15W40
Test Run
Test run the engine under load prior to reinstalling Check for
oil leaks
Engines Generators
ENGINE BELT ADJUSTMENT VALVE CLEARANCE ADJUSTMENT
1 Remove the cylinder head cover
A CAUTION Drive belts must be properly tensioned 2 Manually rotate the engine crankshaft and bring the 1
Loose drive belts will not provide proper alternator piston up to the IDC of its compression stroke
charging and will eventually damage the alternator NOTE When this occurs the intake and exhaust cam
lobes will face upwards
Drive belts that are too tight will pull the alternator out
IKTAKE CAM LOBE
of alignment andor cause the alternator to wear out
check the belt tension apply moderate pressure 10 kg 22
lb midway between the pulleys Check the deflection and
adjust it if CAUTION Replace the drive belt if it has become
worn cracked or frayed
Belt Deflection
New Belt Used Belt
1112mm 1214 mm 3 Measure the valve clearance of the 1 cylinder by using a
044 047 in 047 055 in thickness gauge
Belt tension adjustment is made by pivoting the alternator on Standard valve clearances engine is cold
its base mounting bolt Intake 020 030mm 0008 0012 in
Exhaust 030 040 mm 0012 0016 in
1 Loosen the alternator adjusting strap bolt and the base
mounting bolt
2 Pivot the alternator on the base mounting bolt to the left
VALVE
or right as required CLEARANCE
Tighten the base mounting bolt and the adjusting strap
bolt
4 Operate the engine for about 5 minutes at idle then shut
down and recheck the belt tension
A CAUTION Use only genuine WESTERBEKE drive
belts poor quality belts will lead to premature wear
and belt elongation resulting in alternator damage
If the valves clearances are not within the standard val
ues use the following procedure to adjust the valves
4 Rotate the intake valve cam lobe so that it points
straight up
S Rotate the tappet so that one of the notches is facing the
exhaust manifold This allows for better access to the
adjusting disc
6 Using the tappet holder WESTERBEKE 41978 press
the tappet down to the position where the adjusting disc
becomes accessible
12 DEflECTION
APPROX
BELT TENSION
Engines Generators
ENGINE Using a small screwdriver or magnet remove the adjust TIMING BELT
ing disc
S Select an appropriate disc thckness for the valve clear
NOTE WESTERBEKE recommends replacing the timing belt
during an engine overhaul Tuning belt failure could result in
ance measured Install the disc and verify the correct
major damage to the engine
clearance
Removal
NOTE In case the timing belt is to be reused draw an arrow
on the belt pointing in the direction of the belts rotation so it
will be replaced in the same EXAMPLE Intake Valve The thickness of the disc
removed plus the clearance measured minus the standard
clearance will give the thickness of the new adjusting
disc
400 mm 030 025 mm 405 mm
0157 in 0012 0010 in 0159 in 1 Before removing the timing belt rotate the engine crank
shaft by hand in the direction of the engines normal rota
tion clockwise and align the three pairs of timing marks
as shown in the TIMING MARKS
NOTE The number marked on the disc indicates its thick
ness Example 3825 means 3825 mm 01056 in
Adjusting discs are available in 25 different thicknesses
between 340 and 460 mm 01339 01811 in at varia
tions of 0050 mm 0002 in
9 Measure andajust as needed the valves in cylinders 3
4 and 2 following the instructions above
2 Loosen the timing belt tensioner lock bolt push the tim
CAMINTAKE ing belt tensioner left as far as it will go then temporarily
retighten the lockbolt
VALVE
CLEARANCE
ADJUSTlNGrt tJ
DISC Engines Generators
ENGINE Remove the timing belt 4 Check for wear or damage on only one side of the belt
A CAUTION After removal of the timing belt
DO NOT rotate the crankshaft pulley or the
camshaft pulley if they are rotated the pistons
will damage the opened lIallles
Inspection
WEAR OR the timing belt if it is contaminated with oil grease
or water or if any of the following conditions exist
1 Premature severance
a Check for proper 5 Check for noticeable wear on the belt teeth
h Check the timing belt cover gaskets for damage and
PREMATURE SEVERANCE
TOOTH WEAR
2 Check the teeth for damage cracks peeling and harden
ing and check for any missing teeth A CAUTION Neller forcefully twist the timing
CRACKED belt turn it inside out or bend it Be careful not to
MISSING TOOTH
TOOTH allow Oil grease or moisture on the belt
00 NOT BEND DO NOT TWIST DO NOT TURN
INSIDE OUT
CRACKED
TOOTH
3 Check for noticeable wear or cracks on the belt face
25MM10IN
DO NOT BEND
Engines Generators
ENGINE 6 Recheck the timing mark positions between the three pul
leys and the seal plate Check the timing belt deflection
1 Check to ensure that the timing marks on the pulleys are with a pushing force of 10 kg 221b at the point on the
aligned with the timing marks on the seal plate belt shown in the Install the timing belt
Standard deflection engine is cold
NOTE If reinstalling the original belt be sure to install 108 129 mm 043 051 in
with the arrow in the correct direction of belt 7 Install the left timing belt
cover with its rubber seal
3 Loosen the timing belt tensioner lock bolt to allow the 8 Install the right timing belt cover with its rubber seal
timing belt tensioner to bring pressure on the timing belt Bolt torque for the timing belt cover bolts
07 10 kgm 5 7 ftIb
LEFT TIMING
Tum the crankshaft twice in the direction of normal
engine rotation clockwise to equalize tension on the
timing belt
9 Install the crankshaft pulley and the torsional damper
NOTE Do not turn the engine in the reverse of its normal onto the timing belt drive gear with the semicircular
rotation woodruff key Tighten the Tighten the timing belt tensioner lock bolt
Crankshaft pulley bolt torque
Lock bolt torque 32 47 kgm 23 34 ftIb 23 33 kgm 17 24 ftIb
NOTE When installing the torsional damper onto the tim
ing belt drive pulley align the mark on the damper with
the knock pin on the pulley
CRANKSHAFT PULLEY
TORSIONAL DAMPER
8 MM ALLEN HEAD SOCKET
Engines Generators
ENGINE TEST NOTE In case of severe vibrations and detonation noise have
the injectors overhauled by an authorized fuel injection facil
NOTE When performing the compression test shut off the ity Poor fuel quality contaminates and loss ofpositive fuel
raw water supply to the raw water pump pressure to the injection pump will result in injector faults
This is to prevent raw water from filling the exhaust system
If the glow plugs were removed use antiseize testing
when reinstalling them
1 Warm the engine up to operating Stop the engine TESTING THE OIL PRESSURE
3 Remove all four fuel injectors or all four glow plugs NOTE Insure that the oil meets the following standards API
4 Disconnect the DC power connection to the fuel shutoff Specification CF or CG4 SAE 30 10W30 15W40
solenoid on the fuel injection pump 1 Remove the oil pressure sender and then install a
S Install the compression gauge adapter 49 1456 010 in mechanical oil pressure gauge in its place
the injector hole or glow plug opening of 1 cylinder 2 Start the engine and let it thoroughly warm up
Connect the compression tester to the adapter
3 Check for oil leaks at the filter and pump assembly
6 Crank the engine with the starter and allow the gauge to
4 Maintain the engine rpm at 3000 and note the gauge
reach its maximum reading
reading
7 Record the reading and proceed to the next cylinder
Repeat this process for each cylinder Oil Pressure
41 49 kgcmz S8 70 IhinZ
8 Compare the readings to the table below Take corrective
S If the pressure does not come up to the specified pres
action as needed
sure check the lubrication system and repair if necessary
see ENGINE Compression pressure
A gradual loss of oil pressure usually indicates a specific
Standard 30 426 200
bearing failure For additional information on low oil pres
Limit 27 384 200 sure readings see OIL PRESSURE DROP under ENGINE
COMPRESSION
Do not guess the conditions of other cylinders from a
result of testing one cylinder Be sure to measure the com
pression pressure for each cylinder Look for cylinders at least 20 lower compression than the aver
age of the other cylinders If the weak cylinder is flanked by
healthy cylinders the problem is either valve or Very low compression in an adjacent cylinder indi
cates gasket failure Abnormally high readings on all cylin
ders indicate heavy carbon a condition that
might be accompanied by high pressures and noise
Engines Generators
ENGINE FUEL a nozzle tester check the injection starting pressure of
the nozzle and if it exceeds the limit adjust or replace the
PRESSURE
TEST
NOTE The fuel injectors must be serviced in a clean the Fuel Injectors
1 Disconnect the high pressure lines from the injectors
then loosen the lines at their attachment to the injection
pump and move them out of the way of the injectors
Avoid bending the lines
2 Remove the fuel return line in its entirety from the top of
7 If the injection starting pressure of the nozzle is not
the injectors Take care not to lose the two sealing wash
within the limit loosen the cap nut on the nozzle holder
ers and banjo bolt that attaches the fuel return line to
insert a flat screwdriver through the bolt hole of the cap
each injector
nut then tum the pressure adjusting screw to set the
3 Unscrew the injector from the cylinder head using a 27 injection starting pressure to 200 kglcm2 2844 Ibin2
mm clamp socket Then gradually decrease the pressure until the injection
NOTE Clean the area around the base of the injector starting pressure is 135 kglcm2 1920 Ibin2
prior to lifting it out of the cylinder head to help prevent After the injection starting pressure has been adjusted
any rust or debris from falling down into the injector hold the pressure adjusting screw with a flat screwdriver
hole If the injector will not lift out easily and is held in then tighten the cap nut Then check the injection starting
by carbon buildup or the like work the injector sideto pressure again if it does not change
side with the aid of the socket wrench to free i and then
lift it out
The injector seats in the cylinder head on a copper seal
ing washer This washer should be removed with the
injector and replaced with a new washer when the injec PRESSURE
ADJUSTING
tor is reinstalled Testing
1 Set the nozzle tester in a clean place where there is no 1
21 I
dust or dirt
Inspecting the Spray Pattern
2 Mount the nozzle and nozzle holder on the nozzle tester
3 Use new fuel that has an approximate temperature of 1 Operate the hand lever of the nozzle tester at intervals of
20C 68F one stroke per second to check if the fuel is injected cor
rectly in its axial direction A nozzle is defective if it
4 Operate the hand lever of the nozzle tester several times injects fuel in an oblique direction or in several separate
to bleed the air in the nozzle line then move the hand streams Also a spray in the form of particles indicates a
lever at intervals of one stroke per second while reading defect These defects may sometimes be caused by clog
the injection starting pressure ging with dust therefore all parts should be carefully
5 If the diesel fuel of the nozzle tester is stained replace cleaned before reassembly Care should be taken not to
the fuel At the same time clean or replace the fuel filter expose ones skin to this spray as it may penetrate the
skin and cause infection
A CAUTION The spray injected from the nozzle
is of such velocity that it may penetrate deeply
into the skin of the fingers and hands destroying
tissue If it enters the bloodstream it may cause
blood Check the spray pattern and injection starting pressure of
the nozzle and if the injection starting pressure exceeds
the limit adjust or replace the nozzle
NORMAl FAULTY ANGLE FAUlTY DIRECTION
Injection starting pressure
135 140 kgcmz 19201990 IhinZ
Engines Generators
ENGINE Apply a pressure of 115 to the noz 3 Check that there are no flaws or other damage on mating
zle by operating the hand lever and check the drips from surfaces and the sliding surfaces of the nozzle body and
the nozzle tip If it drips or has a large accumulation of needle valve if any are present replace the nozzle
fuel on the bottom it is considered defective and should assembly
be replaced A very small amount of fuel may sometimes
remain on the tip of the nozzle however this does not
indicate a defect
BODY
SHIM
CORRECT
AFTER DRIP TEST
INCORRECT PIN
NOZZLE
Disassembly SEAT
1 Clamp the nozzle holder in a vise then remove the cap
INJECTION
nut NOZZLE
2 Remove the pressure adjusting screw then pull out the
upper seat the spring and the push rod NOZZLE
3 With the nozzle holder in the vise remove the nozzle nut
then pull the nozzle out COPPER
WASHERS
FUEL INJECTOR
NOZZLE Injector Reassembly
TESTER
To reassemble reverse the order of disassembly and include
the following
1 To assemble the nozzle and nozzle holder first assemble
VISE
the pressure adjusting nut side and temporarily tighten
the nut Mount the nozzle and set the needle valve to its
proper position then mount the nozzle nut
NOTE The greatest posible care should be taken when
handling the nozzles as they are very precisely machined Nozzle nut tightening torque
The nozzle and the needle valve are matched pairs do 8 10 kgm 58 72 ftlb
not mix their original combinations Cap nut tightening torque
4 5 kgm 29 36 Inspection
2 After the nozzle and nozzle holder have been assembled
1 Disassemble and clean each nozzle assembly separately check the injection starting pressure and spray condition
Clean the disassembled parts with clean diesel fuel then
Injector Installation
remove the carbon adhering to the nozzle with a piece of
hard wood Do not use a metal tool to remove the carbon 1 Use new copper washers when installing the injectors
NOTE It is advisable not to clean the surrounding area of 2 TIghten the injectors to the specified torque
the nozzle orifice to avoid possible damage to the orifice Injectors tightening torque
Iron dust on the magnetic filter top must be completely 16 24 mkg 116 174 ftlb
removed
2 After cleaning set the nozzle body in an upright position
insert the needle valve then check to make sure the nee
dle valve comes down into the valve seat by its own
weight If it does not replace the entire nozzle assembly
Engines Generators
ENGINE SPEED the Idle Speed
1 Warm up the engine to normal operating temperature
Remove any specks on the crankshaft pulley with a
clean cloth and place a piece of suitable reflecting tape
on the pulley to facilitate use of a photoelectric type
Start and idle the engine
3 Aim the light of the tachometer onto the reflecting tape to
confirm the engine speed
4 Adjust the idle speed if the engine speed is not within the
specified value
Normal Idle Speed 750 1000 the Idle Speed
1 Loosen the locknut on the idle adjustment bolt on the
fuel injection pump
2 Tum the idle adjustment bolt until the idling speed is
within the standard range
3 Tighten the locknut
4 Race the engine several times to ensure the idle speed
remains as set
NOTE Should engine rpm be in question verify the
tachometer readings as shown at the instrument panel
with a mechanical or strobetype tachometer at the
engine crankshaft
IDLE ADJUSTMENT
BOLT LOCKNUT
IDLE ADJUSTMENT BOLT
ADJUSTING IDLE SPEED
Engines Generators
ENGINE PUMP TIMING ADJUSTMENT feeler needle of the measuring device is in contact with
the plunger inside the pump Zero the measuring scale
4 Tum the crankshaft in the direction of normal rotation
1 Remove the air intake silencer assembly until the No 1 piston is at IDe by referencing the indi
2 Remove the four high pressure injector lines that connect cator on the valve stem
the injection pump with the injectors The measuring device indicator needle should move 100
3 Remove the bolt and gasket installed on the distributor mm from the zero setting
head of the injection pump Beginning of Static Injection
4 Remove the valve rocker cover Cam lift 100 mm 00394 in
5 Rotate the crankshaft in its normal direction of rotation NOTE If the measuring device shows movement at the
use the front crankshaft pulley nut and place the No1 plunger to be more or less than specified above the
piston at IDe of its compression stroke injection pump must be adjusted to correct the movement
NOTE To verify the rocker arms of No4 cylinder should Timing Adjustment
be rocking one opening the other closing
6 Remove the snap ring circlip from the end of the rocker 1 Disconnect the fuel supply and return line connections
shaft at cylinder No 1 along with the retaining washer from the injection pump
7 Loosen the rocker arm adjusting bolt to allow the arm to 2 Disconnect the support bracket at the back of the injec
be removed from the push rod and slide it off the rocker tion pump where it attaches to the lube oil filter adapter
shaft 3 Loosen the two injection pump holddown nuts that
8 Press down on the valve and spring assembly and note secure the injection pump to the engine
that the valve is hitting the top of No 1 piston Then 4 Rotate the injection pump either toward the engine or
remove the cap keepers and valve springs from the No1 away from the engine to adjust the measuring device
valve indicator to show 10 mm of movement
NOTE Insure the valve moves freely in its guide Take 5 Secure the pump by tightening the two holddown nuts
care not to drop the keepers down the push rod hole
6 Remove the measuring device replace the bolt and ket and reattach all fuel lines using
a new sealing washer
1 Position a dial indicator gauge on the valve stem and Reassembly
using tne front crankshaft pulley nut rock the crankshaft
To reassemble reverse the order of disassembly and include
and clockwise to locate exact IDe of
the following
the compression stroke for the No 1 piston and then
zero the dial indicator gauge to the valve stem The 1 TIghten the lock nut of the injection pump drive gear to
gauge should be able to measure up to 300 inch of valve the specified torque
movement Injection pump tightening torque
40 74 kgm 29 51 ftIb
2 After the injection pump has been installed loosen
the overflow valve and bleed the air by operating the
priming pump
2 Tum the crankshaft until the indicator shows the valve
drop to be at 264 inch This is 30 BIDe
3 Install the measuring device Diesel Kit 57828 3520
in the bolt hole of the injection pump distributor head
refer back to step 3 under Disassembly Insure that the
INJECTION PUMP
Engines Generators
GLOW Reinstall the plugs in the engine and test them again The
plugs should get very hot at the terminal end within 20 to
The glow plugs are wired through the preheat solenoid 25 seconds If the plugs dont heat up quickly check for a
When PREHEAT is pressed at the control panel this solenoid short circuit When reinstalling the glow plugs use click on and the glow plugs
should begin to get hot compound on the inspect the plug remove the electrical terminal then unscrew or unclamp each plug from the cylinder
A WARNING Do not keep a glow plug on for more
than 30 Thoroughly clean each plugs tip and threads with a
soft brush and cleaning solution to remove all the carbon and
oil deposits While cleaning examine the tip for wear and
bum erosion if it has eroded too much replace the plug TERMINAL accurate way to test glow plugs is with an
on prod to the glow plugs wire connection and the
other to the body of the glow plug as shown in the A good glow plug will have a 10 15 ohm method can be used with the plug in or out of the
Tightening You can also use an ammeter to test the power drain
8 to 9 amps per plug 10 105mkg 7 11 ftIb
A WARNING These glow plugs will become very
hot to the touch Be careful not to burn your fingers TIP
when testing the plugs
GLOW PLUG
OHMMETER TEST
Engines Generators
LUBRICATION DESCRIPTION oil pump is the crescent type directly driven by the 1 After
cleaning the surfaces where the oil pan and The oil cooler is watercooled Oil jets are pro cylinder block meet apply PERMATEX sealant or
vided to cool the pistons equivalent to the oil pan as shown in the illustration and
then install the oil pan
OIL PAN
NOTE Tighten the oil pan bolts within 30 minutes application of the sealant
1 Mount the engine on a suitable engine stand
2 Drain the engine oil
3 To remove the oil pan and its gasket remove the oil pan
mounting bolts then insert a flattipped scraper between
the oil pan and the cylinder block to separate them
2 If a gasket is used apply PERMATEX sealant or equiva
lent to the areas indicated by the arrows in the illustra
tion after first cleaning the surface where the oil pan
meets the cylinder block
Oil for the following conditions and repair or replace the
oil pan if necessary
1 Cracks deformation damage at bolt Damaged drain plug threads
SEALANT AREAS
DRAIN
PLUG
Engines Generators
LUBRICATION SYSTEM
OIL PUMP 2 Loosen the screws by an impact driver or similar tool so
that the oil pump body is not Mount the engine on a suitable engine stand
2 After draining the engine oil remove the parts in the
numbered sequence as shown in the NOTE The installation sequence of these parts is the
reverse of the removal sequence
1 millNG BELT PULLEY
CAMSHAFT PULLEY NOT SHOWN LOOSENING
THE SCREWS
Inspection
1 Check for the following conditions and repair or replace
the oil pump if necessary
a Distortion or damage to the pump body or cover
h Worn or damaged plunger
c Weak or broken plunger spring
2 Measure the gear clearances
Outer gear tooth tip to crescent clearance limit
035 mm 0013 in
Inner gear tooth tip to crescent clearance limit
3 OIL STRAINER 035 mm 0013 in
2 OILPAN
OIL PUMP REMOVAL SEQUENCE
Disassemble the oil pump in the numbered sequence
shown in the INNER GEAR TO
CRESCENT CLEARANCE
3 Measure the side clearance
Side clearance limit
015 mm 0006 in
3 OUTER GEAR
OIL PUMP DISASSEMBLY SEQUENCE
MEASURING THE SIDE CLEARANCE
Engines Generators
LUBRICATION SYSTEM
4 Measure the body clearance 4 Coat the oil seal lip with engine oil then install the seal
Outer gear to pump body clearance limit taking care not to damage the lip
020 mm 0008 in
MEASURING THE APPLY
BODY CLEARANCE
Oil Seal Replacement The installation sequence is the reverse of the removal
a Remove the oil seal by using a screwdriver or similar sequence
tool to pry it out
OIL COOLER
b Press in the new oil seal by using a pipe or round rod
with an outer diameter of 45 m q7 nL Disassembly
With the coolant drained remove each part in the numbered
A CAUTION Press the oil seal in until the front sequence shown in the end is aligned with the front end of the pump body
1 OIL FILTER
OIL SEAL
2 OIL reassembly sequence is the reverse of the and should include the following
1 Install the outer gear with the mark indicated by the
punch holes facing toward the oil pump cover
2 Apply a thin coating of grease to the Oring and position
it at the location shown in the illustration
3 Apply a coat of PERMATEX sealant or equivalent
to the oil pump surface shown by the shading in the
illustration Inspection
NOTE Be careful not to let the sealant get into the Replace all Orings Apply engine oil to the new Orings
oil hole
Engines Generators
LUBRICATION OIL PRESSURE SWITCH OIL PRESSURE SENDER
The reassembly sequence is the reverse of the disassembly 1 The engine has a twoprong oil
ture switch The oil pressure switch is normally open it
When installing the oil cooler align the oil cooler holes with closes when the oil pressure rises to 5 10 psi
the projections on the oil filter body
PROJECTIOtjS HOLES
OIL PRESSURE SWITCH
PRESSURE
When the oil pressure drops to 5 10 psi too low this
switch interrupts the circuit for the fuel run solenoid by
opening thereby shutting down the engine This switch
also activates an alarm that emits a pulsating signal when
the oil pressure drops to 5 10 psi
NOTE This alarm will also emit a pulsating signal when
Removal the engine starts up as the oil has not yet reached its
Remove each part in the following sequence normal pressure a good check othe alarm
1 Remove the oil pan see the OIL PAN section When performing an engine overhaul replace the oil
pressure switch and the oil pressure sender When
2 Remove the oil jet valves installing the new parts apply a teflon sealant to the
3 Remove the oil jets threaded ends being careful not to close off the oil hole
in the sender
Oil pressure switch and sender torque
PISTOtj
12 18 kgm 9 13 ftlb
ASSEMBLY
A CAUTION Oil pressure switch 00 not use
lock pliers vise grips or pipe wrenches on the oil
pressure switch Use the correct socket which is
available from SnapOn Proto New Britain and
SEALING
BANJO BOiT I i i WASHERS
others Damage to the switch will cause oil leaks
andor switch Make sure that the oil passage is not clogged
2 Check and ensure that the spring inside the oil jet valve is
not stuck or damaged
SEALING
WASHERS
BANJO BOLT I
The installation sequence is the reverse of the
removal sequence
Engines Generators
LUBRICATION THE OIL Insure that the oil meets the following standards CF or CG4 SAE 30 lOW30 l5W40
1 Remove the oil pressure sender and then install a
mechanical oil pressure gauge in its place
TESTING THE OIL PRESSURE
2 Start the engine and let it thoroughly warm up
3 Check for oil leaks at the filter and pump assembly
4 Maintain the engine rpm at 3000 and note the gauge
reading
S If the pressure does not come up to the specified pres
sure check the lubrication system and repair if necessary
see ENGINE Oil pressure
41 49 kglcmz S8 70 IhinZ
A gradual loss of oil pressure usually indicates a failure For additional information on low oil pres
sure readings see OIL PRESSURE DROP under Engines Generators
REMOTE OIL FILTER To install simply remove the engine oil filter and thread on
WESTERBEKEs remote oil filter kit as shown Always
This popular accessory is used to relocate the engines oil fil install this kit with the oil filter facing down as from the engine to a more
convenient location such as an
engine room bulkhead Contact your WESTERBEKE dealer for more Refer to ENGINE OIL CHANGE in this
manual for NOTE Westerbeke is not responsible for engine failure due on removing the oil filter
imorrect installation of the Remote Oil Filter
FASTEN SECURELY TO A BULKHEAD
SCREWS ARE APPLY A THIN COAT OF CLEAN OIL TO THE ORING
WHEN INSTALLING THIS ADAPTER THREAD THE
ADAPTER ON THEN HANDTIGHTEN AN ADDI
TIONAL 34 TURN AFTER THE ORING CONTACTS
THE BASE
APPLY A THIN COAT OF CLEAN OIL TO
THE FILTER GASKET WHEN INSTALLING
AFTER THE FILTER CONTACTS THE BASE
TIGHTEN IT AN ADDITIONAL 34 TURN
Engines Generators
COOLANT PUMP
REMOVAL REASSEMBLY
1 Tum the crankshaft so that the No 1 cylinder is at IDC Reassemble the pump cover withitsnew gasket
top dead center of Drain the engine coolant into a suitable container
Remove the following components in the order listed The installation sequence of the coolant pump and the other
components that were removed is the reverse of the removal
a Alternator drive belt
sequence
h Alternator
Coolant pump tightening torque
c Coolant Hose 32 47 kgm 23 34 ftIb
d Crankshaft pulley After installing the coolant pump fill the cooling system with
e Upper and lower timing belt covers coolant and operate the engine to check for leaks
TIming belt tensioner and spring
g TIming belt
h Coolant pump and alternator the pump cover and the gasket
A CAUTION Io not disassemble the coolant pump
body Replace it as an assembly if the cover gasket
Engines Generators
RAW WATER PUMP
PUMP OVERHAUL 6 Inspect all parts and replace those showing wear
or 7 Use the illustration below to assist in reassembling the raw
The pump as removed from the engine will have hose water nipples threaded into its inlet and outlet port a apply a small
amount of petroleum jelly to the seals
They may be left in place or removed if they interfere with inner race and to the impeller shaft at pump disassembly Note the port
location and positioning
b When positioning the cam in the housing use a small
if removed
amount of Permatex 1 on the inner cam surface and
1 Loosen the set screw with an allen wrench and remove the cam screw threads remove any excess from the
water pump pulley from the shaft impeller housing
2 Remove the 4 cover plate screws cover plate c Apply a light film of silicone or petroleum jelly to the
and cover gasket inner surface of the housing for the impeller
NOTE Replacement of the cover plate gasket is S When the pump is assembled reposition and tighten the
recommended however if you are going to reuse it keep the hose nipples Assemble the pump to the engine and attach
gasket well lubricated until the pump is reassembled If its the hoses and belt
allowed to dry the gasket will shrink and not be reusable
COVER PLATE
3 Pull out the impeller with long nose pliers or pry out with COVER
a pair of screwdrivers GASKET
4 Remove the two screws that hold the bearing assembly
this will release the shaft bearing and seal assembly
Removing the retaining rings will allow the bearings and
seals to be disassembled for inspection
NOTE It may be necessary to use a drift and arbor press to
press the bearing and seal assembly from the shaft
IMPELLER
RAW WATER AT ASSEMBLY
SEAL ASSEMBLY
RETIUNIIG Engines Generators
HEAT EXCHANGER
The heat exchanger should be inspected and serviced during REASSEMBLY
an engine overhaul
1 When reassembling install new gaskets and Apply some lubricant to the new gaskets and to
the pet
cock and fittings as you install them
1 Disconnect the hoses and remove the hose fittings drain
plugs and zinc anodes Also remove the end fittings and 2 Install a new zinc anode
gaskets NOTE All of the above service can be accomplished by send
ing the heat exchanger to a heat exchanger service They will also service transmissions and
engine oil coolers
1 Inspect the tube casing for wear and dents Replace the 3 Repaint the assembled heat exchanger with WESTER
heat exchanger if there is any doubt about its perfor BEKE heat resistant spray enamel
mance 4 To ensure that the above heat exchanger service is satis
2 Oear out any zinc debris and pressure test the coolant factory follow this procedure
and raw water passages a Reconnect all hoses replacing them as needed use
new hose clamps
h Refill the system with coolant
c Pressure test the system and check for leaks
COOLANT HEAT
DRAIN END CAP
Engines Generators
S Clean the passage that connects to the coolant recovery
tank tubing
1 Unclamp the exhaust elbow the two coolant hoses on the
6 Flush out the coolant recovery tank and its tubing
exhaust manifold and the coolant recovery tank hose Be
sure to note the positions of these components to ensure 7 Examine all other parts for defects corrosion and wear
that they will be properly aligned during reassembly and replace as needed
2 Remove the single hex bolt that attaches the air intake to REASSEMBLY
the exhaust manifold then remove the air intake and the
dual air filters 1 Install the manifold drain plug
3 Remove the exhaust manifold and its gaskets from the 2 Install the manifold pressure cap
cylinder head 3 Place the manifold gaskets in position using new gas
4 Remove the manifold pressure cap kets Do not use any gasket sealant
S Remove the manifold drain plug 4 Loosely attach the exhaust manifold to the cylinder
S Gradually tighten making sure all parts are properly
aligned do this in three steps Tighten to the specified
1 Use a liquid cleaner to flush out the exhaust manifold and torque
to clean the intake manifold then rinse both manifolds manifold tightening torque
thoroughly with fresh water 22 27 mkg 16 20 fIlb
2 Clean and inspect the dual air filters replace if necessary 6 Install the air intake and the dual air filters When
3 Clean and inspect the exhaust elbow for cracks and reassembling make certain the filters are positioned
defects replace if necessary properly and do not overtighten when refastening the
bolt
4 Check the manifold pressure cap Open the valve by
pulling it and make sure it closes when released Make 7 Attach the exhaust elbow the two exhaust manifold
certain the upper and lower seals are in good condition If hoses and the coolant recovery tank hose
in any doubt replace the cap S Repaint the reassembled manifold with
WESTERBEKE heat resistant spray enamel
PRESSURE
AIR FILTER
ELEMENT
PLATE
PLUG
EXHAUST
ELBOW
Engines Generators
Tachometer used in propulsion engine instru 1 With a handheld tach on the front of the crankshaft pul
ment panels contains two separate electrical circuits with a ley retaining nut or with a strobetype tach read the front
common ground One circuit operates the hourmeter and the crankshaft pulley rpm Set the engine with a hand or
other the tachometer The hourmeter circuit operates on 12 strobe tach at 15001800 rpm
volts alternator charging voltage supplied to the terminal 2 Adjust the tachometer with a sIllall Phillips type screw
on the back of the instrument driver through the calibration acess hole in the rear of the
The tachometer circuit operates on AC voltage 68 volts fed tachometer Zero the tach and bring it to the rpm set by
from one of the diodes in the alternator and supplied to the the strobe or hand tach Verify the rpm at idle and at
tachometer input terminal while the engine is running and high speed 25003000 rpm Adjust the tach as needed
the alternator producing battery charging voltage DC
Use the following procedures when a fault in
either of the two circuits in a Inoperative
for the proper DC voltage between and
TERMINAL
1 Voltage present meter is defective repair or replace
riDA1 TERMINAL
2 Voltage not present trace and electrical con
nections for fault Jump 12 volts DC to meter
terminal to verify the operation
CURRENT for the proper AC voltage between tachometer and the terminal with the engine running
1 Voltage present attempt adjusting the meter through the
calibration access hole If no results repair or replace the
meter
2 AC voltage not present check for proper alternator DC
output voltage
3 Check for AC voltage at the tach terminal on the alterna
tor to ground
4 Check the electrical connections from the tachometer
input terminal to the alternator Sticking EARLY MODEL TACHOMETER
GROUND
1 Check for proper AC voltage between the tachometer
input terminal and the terminal
2 Check for a good ground connection between the meter
terminal and the Check that the alternator is well grounded to the engine
block at the alternator pivot bolt
GROUND
TERMINAL
TACHOMETER INPUT
AC VOLTAGE
EARLY MODEL Engines Generators
STARTER NoLoad Test
The starter can be roughly divided into the following sections 1 Connect the ammeter voltmeter and battery to the starter
A motor section which generates a drive power as An overrunning clutch section which transmits an arma 2 When
the switch is closed the pinion must protrude and
ture torque preventing motor overrun after starting the starter must run smoothly at 3000 rpm or more If
A switch section solenoid which is operated when actu the current or starter speed is out of disas
ating the overrunning clutch through a lever and which semble the starter and repair it
supplies load current to the motor
The starter is a new type small lightweight and is called a
highspeed starter The pinion shaft is sep
arate from the motor shaft the pinion slides only on the pin
ion shaft A reduction gear is installed between the motor
shaft and a pinion shaft The pinion sliding part is not
exposed outside the starter so that the pinion may without becoming fouled with dust and grease The
motor shaft is supported at both ends on ball bearings The
lever mechanism switch and overrunning clutch inner circuit
are identical to conventional ones AND REPAIR
A CAUTION Use thick wires as much as possible and
tighten every terminal securely This is a solenoid shift
If any abnormality is found by the following tests the starter type starter which makes a rotating sound louder than
should be disassembled and repaired that of a directdrive type starter When detecting
starter rotation at the pinion tip be careful not to come
Pinion Gap Inspection in contact with the pinion gear when it protrudes
1 Connect a battery 12V between the starter terminal S
and the starter body and the pinion drive should rotate out
and stop SOLENOID
Perform the following tests If any test result is not
satisfactory replace the solenoid assembly
A CAUTION Never apply battery voltage for over 10 1 Inspect the solenoid for continuity between terminals
seconds and and between terminals S and the body and
M and the body There should be no continuity found
2 Lightly push the pinion back and measure the return between terminals S and M Continuity will be found
stroke called pinion gap between terminals S and the body and terminal M and
the body
3 If the pinion gap is not within the standard range 05 to
20 mm adjust it by increasing or decreasing the number
of shims on the solenoid The gap is decreased as the
number of shims MUlTIMETER
NOTE Disconnect the wire from terminal M
2 Connect a battery to the solenoids terminal S for
and M for Have a switch in the lead and close it
The pinion drive should extend fully out
05 20 mm
A CAUTION Do not apply battery current for more
than 10 seconds when testing the solenoid
PINION GAP
Engines Generators
STARTER MOTOR
4 Return test With a battery connected to the solenoid ter
minal M and to the starter body manually pull out the
pinion fully The pinion must return to its original position
when released from holding by hand
3 Holding test With a battery connected to the solenoid ter
minal S and to the starter body manually pull out the
pinion fully The pinion must remain at that position even
when releaSed from holding with your hand
RETURN TEST
HOLDING TEST
STARTER DISASSEMBLY 7 Pull out the reduction gear lever and lever spring from the
front bracket
1 Disconnect the wire from the solenoid terminal M
S On the pinion side pry the snap ring out and pull out the
2 Loosen the two screws fastening the solenoid Remove
pinion and pinion shaft
the solenoid assembly
9 At each end of the armature remove the ball bearing with
3 Remove the two long through bolts and two screws
a bearing puller It is impossible to replace the ball bearing
fastening the brush holder Remove the rear bracket
pressfitted in the front bracket If that bearing has worn
4 With the brushes pulled away from the armature off replace the front bracket assembly
remove the yoke and brush holder assembly Then pull
the armature out
SOLENOID
5 Remove the cover pry the snap ring out and remove the
washer
6 Unscrew the bolts and remove the center bracket At the
same time the washers for tpe pinion shaft end play
adjustment will come off
Ill
INSPECT FOR ADJUSTING
WEAR CHIPPING
SHIMS
STARTER
MOTOR
NOTE lnspect clean and replace
if necessary brush commuter
solenoid armature etc See the
following Engines Generators
STARTER the solenoid for continuity between terminals S and
M and between terminals S and body No continuity should
be found between S and M Continuity should be found
between S and the body and M and the body
Brush and Brush Holder Inspection
1 Check the brushes If worn out beyond the service limit
replace the brushes
Brush Height
Standard 17 mm 0669 in
Limit 6 mm 0236 in
CONTINUITY CHECK
The Armature NEW USED
1 Check the annature with a growler tester If its short
circuited replace the annature Also check for insulation 2 Check the brush spring tension A weak or defective
between the communicator and its shaft If poorly spring will cause excessive brush wear replace the springs
insulated replace the annature if suspect
ARMATURE BRUSH HOLDER
CHECK ASSEMBLY
3 Check for insulation between the positive brush holder
2 Measure the commutator OD and the depth of undercut and holder base If poorly insulated replace the holder
Repair or replace it if the service limit is exceeded Also assembly Also check the brush holders for proper staking
check the commutator outside surface for dirtiness and
roughness If rough polish the commutator with fine
crocus cloth
Commutar OD Standard
Standard 387 mm 1523 in
Service limit 10 mm 0039 00
Engines Generators
STARTER MOTOR
Field Coil Inspection 2 Greasing Whenever the starter has been overhauled
1 Check for insulation between one end brush of the apply grease to the following parts
coil and yoke a Armature shaft gear and reduction gear
2 Check for continuity between both ends brushes b All bearings
of the coil c Bearing shaft washers and snap rings
3 Check the poles and coil for tightness d Bearing sleeves
e Pinion
f Sliding portion of lever
MULTIMETER
A CAUTION Never smear the starter fitting surface
tenninalsl brushes or commutator with grease
3 After reassembly check by conducting a noload test
COIL TEST
STARTER ADJUSTMENT AND REASSEMBLY SNAP RING
A CAUTION Before insfalling thoroughly clean the
ID5 mm MAX
starter flange and mounting surfacesl remove al oill
old paint and rust Starter perfonnance largely
depends on the quality of the wiring Use wire of suffi PINION SHAFT END PLAY
cient size and grade between the battery and starter
and fully tighten to the tenninal
Reassemble the starter assembly in the reverse order of
disassembly making sure of the following
1 Pinion shaft end play adjustment Set the end play thrust
gap to between 05 to 2 mm by inserting an adjusting
washer between the center bracket and the reduction gear
a Fit the pinion shaft reduction gear washer and snap
ring to the center bracket
b Measure end play by moving the pinion shaft in the
axial direction If the end play exceeds 05 mm
increase the number of adjusting washers Engines Generators
DC ELECTRICAL DESCRIPTION 1 Start the Engine
The charging system consists of an alternator with a voltage 2 After a few minutes of running measure the starting bat
regulator an engine DC wiring harness a mounted DC cir tery voltage at the battery terminals using a multimeter
cuit breaker and a battery with connecting cables Because set on DC volts
of the use of integrated circuits ICs the electronic voltage The voltage should be increasing toward 14 volts If it is
regulator is very compact and is mounted internally or on the your alternator is working
back of the alternator
3 Tum to step 5 on the next page
14 BROWH
MULTIMffiR
14 51 AMP DC
ALTERNATOR
GENERATOR TESTING THE STARTING
ENGINE RUNNING
GROUND
AWARNQj A failed altemator can become very 4 If the starting battery voltage remains around 12 volts
hot Do not touch until the alternator has cooled down after the engine is started and run for a few minutes a
problem exists with the alternator or the charging circuit
This section is to determine if a problems A Thm otT the engine Inspect all wiring and connec
exists with the charging circuit or with the alternator If iUs tions Insure that the battery terminals and the engine
determined that the alternator or voltage regulator is bad it is ground connections are tight and clean
best to have a qualified technician check it out
The alternator charging circuit charges the starting battery and
the service battery An isolator with a diode a solenoid or a A CAUTION To avoid damage to the battery
battery selector switch is usually mounted in the circuit to iso chaTging circuii never shut off the engine battery
late the batteries so the starting battery is not discharged switch when the engi is running
along with the service battery If the alternator is charging the
starting battery but not the service battery the problem is in
the service battery charging circuit and not with the alternator B If a battery selector switch is in the charging circuit
insure that it is on the correct setting
Testing the Alternator C Thm on the ignition switch but do not start the
engine
D Check the battery voltage If your battery is in good
A WARNING Before starting the engine malee cer condition the reading should be 12 to 13 volts
tain that everyone is clear of moving paris Keep away
from sheaves and belts during test procedures
0 MULTIMffiR
NOTE Multimeters and DC Circuits COM
DC andAC circuits are often mixed together in marine appli
cations Always disconnect shore power cords isolate DC
TESTING THE ALTERNATOR
andAC converters and shutdown generators before perform VOLTAGE
ing DC testing No A C tests should be made without proper IGNITION ON ENGINE OFF
knowLedge ofAC STARTING
BATTERY
Engines Generators GROUND
DC ELECTRICAL Now check the voltage between the alternator output Alternator is Working
terminal B and ground If the circuit is good the
5 Check the voltage of the service battery This battery
voltage at the alternator should be the same as the bat
should have a voltage between 13 and 14 voltswhen the
tery or if an isolator is in the circuit the alternator volt
age will be zero If not a problem exists in the circuit engine is running If not there is a problem in the service
battery charging circuit Troubleshoot the service battery
between the alternator and the battery Check all con
charging circuit by checking the wiring and connections
nections look for an opening in the charging circuit
the solenoid isolator battery switch and the battery itself
MUlTIMETER
THE ENGINE RUNNING ENGINE
CO GROUND
SERVICE
F Start the engine again Check the voltage between the BAITERY
alternator output and ground
TESTING THE SERVICE
The voltage reading for a properly operating alternator BATTERY ENGINE RUNNING
should be between 135 and 145 volts If your alterna
tor is over or have it repaired at a reli
able service shop
NOTE Before removing the alternator for repair use your A CAUTION When pedorming tests on the to ensure that 12 volts DC excitation
is present tor charging circuit do not use a high voltage tester fie
at the XC terminal if the previous test showed only bat
Megger You can damage the altemator diodes
tery voltage at the B output terminaL
If 12 volts is not present at the XC terminal trace the
wiring look for breaks and poor connections ALTERNATOR INSPECTION
When rebuilding the engine the alternator should be cleaned
and inspected the housing can be wiped off with a solvent
and the alternator terminals cleaned with a wire brush make certain
the electrical studs are tight Also clean the wiring
connections that connect to the wiring harness Tum the
rotor pulley by hand it should tum smoothly Depending
on when the alternator was last serviced the brushes may
need replacing If the alternator is at all suspect send it to
a service shop for testing and Engines Generators
This page has been intentionally left blank
Engines Generators
DC ELECTRICAL SYSTEM
WIRING DIAGRAM 39144
10 110 R
114 Ilk
JCE MODELS
NOTE
AN ONOFF SWITCH NOTE 2 I
SHOULD BE IN 1 J
STALLED BETWEEN 1
THE BATTERY AND 1
STARTER TO DIS
CONNECTTHE BAT
TERY IN AN EMER
12 VDC
GENCY AND WHEN THE BOAT
A SWITCH WITH A
CONTINUOUS
RATING OF 175
AMPS AT 12 VDC
WILL SERVE THIS
SWITCH SHOULD ALARM ADMIRAL
NOT BE USED TO
C BUZZER
PANEL
MAKE OR BREAK
THE CIRCUIT
CAPTAIN
PANEL
r T
0
elle
I elK
I DLK
l t au I
Engines Generators
DC ELECTRICAL SYSTEM
WIRING SCHEMATIC 39144
12 YOC START
SOL STAlTER
FUEL
LIFT UM
IIIIEII U D i
HM I
IgLw I
FUEL
Eno I I
I I
I 2BO iiP mIQNL T I
L I
ADM I RAL
TACHOMETER
KEY S IMD PANEL
c
Cl ALARIt
4UGE
PISrl nzII 11
CAPTAIN
PANEL
TEST
51 AMP ALTERNATOR Q9PRESTOlTE 72 AMP AIT
STANDARD ALTERNATOR ON THE
mBC IC ii n 82e n
114 8RN
114 GRA
114 PINK
114 LT BL
Q9 UN I VERSAl PROPULS ION
PRESTOt I TE 51 AMP ALI
OPT ONAl At TERNATORS
IlA I ItOA USTE AlTRMATOItS
AVUAlf 9M TME up IX x a 111 xr nD rr OfD n IRISzr ONLY
Engines Generators
uses a variety of marine transmissions made
by wellknown marine manufacturers such as HURTH ZF
BORG WARNER PARAGON and others If you parts repair work or an overhaul we recom
mend contacting the transmission manufacturer directly on the locations of authorized service addresses of two of these manufacturers are given
below
HURTH Marine Gear
ZF Industries
1018 Carolina Drive
West Chicago IL 60185 USA
Tel 8746343500
Fax 8749131039
BORG WARNER Marine and Industrial 200 Theodore Rice Blvd
New Bedford MA 02745 USA
Tel 5089794881 Customer Service
Tel 5089794826 Technical Service
Engines Generators
SERVICE STANDARDS
DESCRIPTION STANDARD VALUE PRESSURE 30 kgcm2 rpm
27kgcm2384 IbfinZ200 DIFFERENCE max 427 psi 30 ORDER TIMING HEAD
Bottom surtace distortion 10 mm 0004 in
Manifold contact surface distortion 020 mm 0008 in
Valve seat angles IN and EX 45
Valve seat width IN and EX 1723 mm 00670091 in
Valve seat recession IN and EX 075105 mm 00300041 in
Valve seat contact 1723 mm 00670091 in
Combustion chamber insert recession Receded amount
004 mm 00016 in
Projection amount
005 mm 00024 in
Cylinder head bolt length 11271133 mm 44374460 in 1145 mm 4508 in
VALVE CLEARANCE
Intake 020030 mm 0008Q012 in
Exhaust 030040 mm 00120016 in
VALVE TIMING
Intake open BTDC 13
Intake closed ABDC 39
Exhaust open BBDC 600
Exhaust closed ATDC 8
VALVE
Stem 00 Intake 79707985 mm in
Exhaust 79657980 mm in
Stem to guide clearance 00510075 mm 00020003 in 010 mm 0004 in
Valve face angle IN and EX 45
Valve head thickness margin width 15 mm 0059 in 10 mm 0039 in
Valve recession IN and EX 075105 mm 00300041 in 155255 mm 00610100 in
VALVE SPRING
Free length 448 mm 1764 in
Angle Limit 158 mm 0062 in
CYLINDER BLOCK
Cylinder bore 8600 mm 339 in 8617 mm 392 in
Difference between cylinder bores 0022 mm 00009 in
Cylinder bore oversize finish tolerance 025 mm 0010 in 050 mm 0020 in
Taper of cylinder
Top surface distortion 010 mm 00040 in
Engines Generators
SERVICE STANDARDS
DESCRIPTION STANDARD VALUE 00 skirt end 85958598 mm 33842385 in
Piston to cylinder clearance 007008 mm 00020003 in 015 mm 0006 in
Oversize piston rings 025 mm 0010 in 050 mm 0020 in
PISTON PIN
Type Full Floating
00 2502501 mm in
Piston to pin clearance 0003 0006 mm in
Pin to connecting rod clearance 0012003 mm 000050001 in
PISTON RINGS
Number of compression rings Two
Number of oil rings One
Ring side clearance 02 mm 0008 in
Compression ring No 1 003 006 mm 00010002 in
Compression ring No2 003 006 mm 00010002 in
Oil ring 003 006 mm 00010002 in
Ring end gap 0305 mm 00120020 in 10 mm 0039 ROD
Bending or torsion 016 mm 0006 in per
100 mm 394 in
Bushing inner diameter 25012503 mm in
End play 011026 mm in 035 mm 0014 in
Sideplay clearance 005 mm 0002 ROD BEARING
Standard Type Kelmet metal
Oil clearance 003006 mm in 008 mm 00031 in
Undersize 025 mm 0010 in 050 mm 0020 in
075 mm 0030 Deflection 005 mm 0002 in
End play 004028 mm in 003 mm 00118 in
Thrust bearing width
Undersize 218223 mm in
Standard 200205 mm in
Main journal 00 59945996 mm 23602361 in 005 mm 00020 in
Pin 00 50945096 mm 20062007 in
Rear housing oil seal sliding surface 88959000 mm 35413543 in
Journal grinding limit 075 mm 00295 in
Undersize finish tolerance 025 mm 0010 in 050 mm 0020 in
075 mm 00295 in
Engines Generators
SERVICE STANDARDS
DESCRIPTION STANDARD VALUE LIMIT
MAIN BEARING
Standard type Kelmet metal
Oil clearance 00310049 mm in 008 mm 00031 in
Undersize 025 mm 0010 in 050 mm 0020 in
CAMSHAFT 075 mm 0030 in
Front bearing Lead bronze alloy
Oil clearance 0025 0066 mm in
Cam lobe height Intake 4431 mm 1744 in 4390 mm 1728 in
Exhaust 4530 mm 1783 in 4490 mm 1768 in
End play 002015 mm in 02 mm 00079 in
Journal elliptical 005 mm 0002 in
Journal diameters 31963198 mm 12581259 in 3186 mm 1254 in
Deflection 010 mm 00040 in
TAPPET
00 34963498 mm 13763 13771 in
Hole 34993502 mm in
Tappet to cylinder block clearance 002006 mm in 010 mm 00040 in
TIMING BELT DEFLECTION 108129 mm 043051 in10 kg DRIVE BELT DEFLECTION
New 1112 mm 044047 in10 kg 22Ib
Used 1214 mm 047055 in10 kg 22Ib
Engines Generators
SERVICE STANDARDS
LUBRICATION System Forcefed type
Type Crescent inner gear
Oil pump
Oil pressure control valve opening pressure 80 kgcm2114 Ibin2
Type Fullflow type spinon paper element
Oil filter relief valve opening pressure 10 kgcm214 IbM
Outer gear tooth tip to crescent clearance limit 035 mm 0013 in
Oil filter
Inner gear tooth tip to crescent clearance limit 035 mm 0013 in
Side clearance limit 015 mm 0006 in
Outer gear to pump body clearance limit 020 mm 0008 in
Oil bypass filter Type Fullflow type paper element
Oil cooler Type Water cooled
Oil pressure control valve opening pressure 45 kgcm2 64 IbM
Oil filter body Oil filter relief valve opening pressure 10 kgcm2 14 IbM
Oil cooler relief valve opening pressure 20 kgcm2 28 Ibin2
Oil alarm switch activation pressure 035070 kgcm2 510 Ibin2
Total oil capacity 64 liters 676 US quarts 563 Imp quarts
Oil pan capacity 50 liters 528 US quarts 440 Imp quarts
Oil filter capacity 04 liters 042 US quarts 035 Imp quarts
Oil bypass filter capacity 04 liters 042 US quarts 035 Imp quarts
Engine oil API Specification CF or CG4 SAE 30 10W30 15W40
Engines Generators
METRIC CONVERSIONS
INCHES TO MILLIMETERS MILLIMETERS TO INCHES
Inches mm Inches mm mm Inches mm Inches
1 2540 15 38100 1 00394 15 05906
2 5080 20 50800 2 00787 20 07874
3 7620 25 63500 3 01181 25 09843
4 10160 30 76200 4 01575 30 11811
5 12700 35 88900 5 01969 35 13780
10 25400 40 101600 10 03937 40 15748
10 MILLIMETERS 1 CENTIMETER 100 CENTIMETERS 1 METER 3937 INCHES 33 FEET
INCHES TO METERS METERS TO INCHES
Inches Meters Inches Meters Meters Inches Meters Inches
1 00254 7 0ln8 01 3937 07 27559
2 00508 8 02032 02 7874 08 31496
3 00762 9 02286 03 11811 09 35433
4 01016 10 02540 04 15748 10 39370
5 01270 11 02794 05 19685 11 43307
6 01524 12 03048 06 23622 12 47244
TO CONVERT METERS TO CENTIMETERS MOVE DECIMAl POINT TWO PLACES TO THE RIGHT
YARDS TO METERS METERS TO YARDS
Yards Meters Yards Meters Meters Yards Meters Yards
1 091440 6 548640 1 109361 6 656168
2 182880 7 640080 2 218723 7 765529
3 274320 8 731520 3 328084 8 874891
4 365760 9 822960 4 437445 9 984252
5 457200 10 914400 5 546807 10 1093614
I MOVE DECIMAL POINT FOR HIGHER VALUES eg 6000 METERS 656168 YAReS
POUNDS TO KILOGRAMS KILOGRAMS TO POUNDS
Ib kg Ib kg kg Ib kg Ib
1 0454 6 2722 1 2205 6 13228
2 0907 7 3175 2 4409 7 15432
3 1361 8 3629 3 6614 8 17637
4 1814 9 4082 4 8818 9 19842
5 2268 10 4536 5 11023 10 22046
GALLONS TO UTERS UTERS TO GALLONS
Gallons Liters Gallons Liters Liters Gallons Liters Gallons
1 379 10 3786 1 026 60 1566
2 757 20 7571 2 053 90 2377
3 1136 30 11357 5 132 120 3132
4 1514 40 15142 10 264 150 3962
5 1893 50 18928 20 528 180 4754
PINTS TO UTERS LITERS TO PINTS
Pints Liters Pints Liters Liters Pints Liters Pints
1 047 6 284 1 211 6 1268
2 095 7 331 2 423 7 1479
3 142 8 379 3 634 8 1691
4 189 9 426 4 845 9 1902
5 237 10 473 5 1057 10 2113
TEMPERATURE
32 40 50 60 70 75 85 95 105 140 175 212 of
I I I I I I I I I I I I
I I I I I I I I I I I I
0 5 10 15 20 25 30 35 40 60 80 100 C
Engines Generators
55A FOUR TORQUES
kgm head NOTE The cylinder head bolts are not retorqued They are torqued 30
only at the original engine assembly and during an engine head cover 0710
rod bearing cap 7075 5154
Main bearing cap 8490
1819 plate
1926 pulley 2333
cap 2027
pulley 5666 4148
Timing belt pulley 1617 116123
Idler pulley 3247 2334
Timing belt tensioner 3247 2334
Timing belt covers 0710 57
Seal plate 0812 69
Back plate 1623 1217
Rear oil seal housing 0710 57
Oil pump assembly M10 bolt 3247 2334
M8 bolt 1623 1217
Oil cooler assembly M10 bolt 3247 2334
M6 bolt 0710 57
Oil filter Tighten firmly by hand
Block oil jets 1218 913
Oil strainer pickup 0710 57
Oil pan 0710 57
Oil drain hose 2733 2024
Oil pressure sender 1218 913
Oil pressure switch 1218 913
Fuel injection pump 3247 2334
Fuel injection pump pulley 6070 4352
Fuel injectors 6070 4351
Fuel injector HP line 1823 1317
Glow plugs 1520 1115
Coolant Pump 3247 housing
1623 1217
Coolant temperature sender 1218 913
Coolant temperature switch 1218 bracket
3853 manifold
2227 1620
Engine mounts 3247 2334
Engines Generators
STANDARD HARDWARE TORQUES
NOTE Unless stated otherwise for a specific assembly use the following torque values when tightening standard 4 Pitch Ibft
kgm Grade IT 8T and 88 Pitch Ibft kgm
6mm bolt headnut 1 2951 0407 6mm bolt headnut 1 5SS7 0S12
Smm bolt headnut 125 72116 1016 Smm bolt headnut 125 145217 2030
10mm bolt headnut 125 137224 1931 10mm bolt headnut 125 2S939S 4055
10mm bolt headnut 15 130217 1S30 10mm bolt headnut 15 26S376 3752
12mm bolt headnut 125 ISO 25339S 3555 12mm bolt headnut 125 ISO 542759 75105
12mm bolt headnut 15 25339S 3555 12mm bolt headnut 15 506651 7090
12mm bolt headnut 175 217362 3050 12mm bolt headnut 175 434615 60S5
13mm bolt headnut 15 325506 4570 13mm bolt headnut 15 579S6S S0120
14mm bolt headnut 15 362579 5DS0 14mm bolt headnut 15 72310S5 100150
14mm bolt headnut 2 340557 4777 14mm bolt headnut 2 6871013 95140
16mm bolt headnut 15 542796 75110 16mm bolt headnut 15 10S51664 150230
16mm bolt headnut 2 514767 71106 16mm bolt headnut 2 10131591 6T
Grade 5 Cap Screw
6mm bolt headnut 1 4365 0609 14 UNC 911 1215
Smm bolt headnut 125 10S159 1522 14 UNF 1113 151S
10mm bolt headnut 125 217325 3045 5116 UNC 1820 252S
10mm bolt headnut 15 195304 2742 5116 UNF 2123 2932
12mm bolt headnut 125 ISO 362579 5080 3S UNC 2S33 3746
12mm bolt headnut 15 362506 5070 3S UNF 3035 414S
12mm bolt headnut 175 347492 4S6S 716 UNC 4449 616S
716 UNF 5055 6976
112 UNC 6S73 94101
112 UNF 7380 101111
GENERAL SCREWS
BOLT DlA BOLT HEAD MARK
4 7 10
M6 0305 08 10 1013
M8 10 13 15 22 2535
Ml0 18 25 3042 5070
M12 3042 5575 95 120
M14 5070 80 110 160 190
SEALANTS
PARTS REQUIRING SEALANT SURFACES REQUIRING SEALANT SEALANT
where to mount sealant coated parts
Taper screw 12 Thread portion Gear case Liquid Teflon
Taper screw 14 Thread portion Cylinder block right side pump cover Liquid Teflon
Taper screw 18 Thread portion Cylinder head rear surface Liquid Teflon
Water drain plug Thread portion Cylinder block right side rear middle portion Liquid Teflon
Oil pressure switch Thread portion Cylinder block right side surface Liquid Teflon
Side seal Periphery Main bearing caps No 1 and No5 Permatex 6B
Bearing cap No 1 Contact surface with cylinder block Permatex 6B
Engines Generators
Discs Fuel Injection Pump
Removal 14 Removal 12
Inspection 20 Reassembly 35
Reassembly 27 Fuel Injection Pump Engine 42 Removal 13
Alternator 3967 Inspection 25
Back Plate 32 Reassembly 40 Fuel Injection Pump Timing Adjustment 50
Camshaft Fuel Injectors Testing 47
Removal 14 GlowPlugs 3451
Inspection 20 Heat Exchanger 40 60
Reassembly 34 Idle Speed Adjustment 49
Camshaft Pulley Idler Pulley Bracket 36
Removal 14 Injection Nozzles 34
Reassembly 36 Injection Pump Chamber Inserts 15 Removal Test 46
Inspection 25
Connecting Rods Reassembly 37
Removal 12 Injection Pump Timing Adjustment 50
Inspection 23 Inspection and Repair Engine 16
Reassembly 27 Rod Bearings 24 Lubrication System 52
Connecting Rod Bushings 23 Main Bearings 24
Coolant Pump 35 58 Metric Conversions 77
Crankshaft Mounts Engine 40
Removal 12 Oil Cooler 39 54
Inspection 23 Oil Dipstick Tube 35
Reassembly 28 Oil Filter 39
Crankshaft Pulley 38 Oil Filter Remote 57
Cylinder Block 21 Oil Jets 55
Cylinder Head Oil Pan 3152
Removal 14 Oil Pressure Sender 55
Inspection 16 Oil Pressure Switch 35 55
Reassembly 33 Oil Pressure Test 46 56
Cylinder Head Bolts 14 Oil Pump Head 40 Oil Strainer
Cylinder Head Gasket 14 Parts 5
Damper Plate 40 Parts Ordering Engine 11 Piston Rings 22
Drive Belt Adjustment 42 Pistons 22 27
Engine 42 Product Software 2
Engine Disassembly 11 Raw Water Pump 40 59
Engine Mounts 40 Rear Cover Assembly 30
Flywheel 32 Reassembly 26
Fuel Filter 40 Seal Plate 36
Fuel Injection lines 35 Service Standards 73
Fuel Injection Nozzles 34 4
Engines Generators
INDEX
Starter Motor 63
Tachometer 62
Tappets
Removal 14
Inspection 20
Reassembly 27
Testing for Overhaul 6
Thermostat 36
Timing Belt
Removal 13
Inspection 24
Reassembly 37
Timing Belt Adjustment 43
Timing Belt Camshaft 25
Timing Belt Covers 25
Timing Belt Pulley
Removal 14
Reassembly 32
Timing Belt Tensioner
Removal 13
Inspection 25
Reassembly 37
Torques 55A FOUR 78
Torques Standard Hardware 79
Torsional Damper Removal ll
Reassembly Engine 7
Valves
Removal 15
Inspection 18
Reassembly 26
Valve Oearance Adjustment 42
Valve Guides 19
Valve Seals 15
Valve Seats 17
Valve Springs 20
Wiring 70
Wiring Schematic 71
Engines Generators
Engines 998

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Disclaimer:
The information on this web site has not been checked for accuracy. It is for entertainment purposes only and should be independently verified before using for any other reason. There are five sources. 1) Documents and manuals from a variety of sources. These have not been checked for accuracy and in many cases have not even been read by anyone associated with L-36.com. I have no idea of they are useful or accurate, I leave that to the reader. 2) Articles others have written and submitted. If you have questions on these, please contact the author. 3) Articles that represent my personal opinions. These are intended to promote thought and for entertainment. These are not intended to be fact, they are my opinions. 4) Small programs that generate result presented on a web page. Like any computer program, these may and in some cases do have errors. Almost all of these also make simplifying assumptions so they are not totally accurate even if there are no errors. Please verify all results. 5) Weather information is from numerious of sources and is presented automatically. It is not checked for accuracy either by anyone at L-36.com or by the source which is typically the US Government. See the NOAA web site for their disclaimer. Finally, tide and current data on this site is from 2007 and 2008 data bases, which may contain even older data. Changes in harbors due to building or dredging change tides and currents and for that reason many of the locations presented are no longer supported by newer data bases. For example, there is very little tidal current data in newer data bases so current data is likely wrong to some extent. This data is NOT FOR NAVIGATION. See the XTide disclaimer for details. In addition, tide and current are influenced by storms, river flow, and other factors beyond the ability of any predictive program.