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Bmw D7 Owners Manual



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Owners Manual
D7


BMW Marine Engines


This copy of the BMW D7 Owners Manual has been re-created using images computer
scanned from a manual rather than original artwork. It has also been re-formatted in
"portrait" style to display and/or print better on computer systems.




                                                                                       1
This manual was written on your behalf in an effort to help you enjoy your new BMW
Marine Engine to the maximum. No marine engine, be it the best in the world, will
perform at it's best during a long life, without proper care and maintenance.

Please read this manual carefully before you set out on the first trip with your new BMW
Marine Engine.

        For the practical boat owner, some maintenance procedures are described in this
   manual. Next to some jobs, you will find this marking which indicates that the work
   will require special tools as well as certain special knowledge. It is, therefore,
   recommended that your authorized BMW Marine Dealer complete these operations.




                                                                                       2
INDEX
ENGINE DESCRIPTION              4

INSTRUMENTS AND CONTROLS        6

STARTING AND OPERATING          7

SERVICE & MAINTENANCE           12

FUEL SYSTEM                     13

LUBRICATION SYSTEM              16

COOLING SYSTEM                  17

VALVE SYSTEM                    19

ELECTRICAL SYSTEM               20

WINTER LAY UP AND RECOMISSION   21




                                     3
ENGINE DESCRIPTION
The BMW D7 is a single-cylinder, four-stroke, direct-injection diesel engine. The engine
is equipped with a raw-water cooling system, fed by an impeller type pump driven by the
crankshaft. Electrical starting and charging systems are standard as is an automatic air
bleeder device in the fuel system.


Technical Data
Displacement                                         280cc                17.0 cu in
Stroke & Bore                                     67 x 73 mm            2.63 x 2.87 in
Max output at min-1 (RPM)                        4.5 kW / 3600           6 HP / 3600
Max torque at min-1 (RPM)                       11.7 Nm / 3300          8.7 lb ft / 3300
                                                1.2 kpm / 3300
Compression Ratio                                     19:1
Weight, dry engine incl. Gearbox                      68 kg                 150 lb.
Gearbox reduction                                      2.7
Maximum engine inclination                           15 deg




                                                                                           4
Specifications                       Engine                     Gearbox
Fuel                                Diesel Oil
                                    DIN 51601
                                    (USA #2)
Fuel Filter                     BMW 13 32 1 329 270
Lubrication oil
Type                            HD-API CC/CD SAE 30            ATF Dexron
Capacity  Litre (US gal)         1 litre (0.26 US Gal)   0.4 litre (0.1 US Gal)
Air Filter                      BMW 13 71 1 329 269
Injector make                              Bosch
Injection pressure                      135 + 8 bar
Injection pump                   Bosch PFE 1 Q 55/19
Starter motor make                         Bosch
Alternator, charging capacity           14v 350w
Battery, rec capacity                   12v 60 Ah
Polarity                           Negative ground
Raw-water pump                           Johnson
Gearbox                                Hurth HBW 5


Adjustment Data
Injection ends                  11.5  12.5 deg BTDC
Tappet clearance                  0.15 mm .006 in


Torque                                   Nm                       lb.ft
Injector retainer                        10                        7.2
Cylinder head bolts                      35                        25




                                                                                   5
INSTRUMENTS & CONTROLS
Instruments

The BMW D7 is equipped with an instrument panel as shown:




   1. Starter Switch  with three positions:
      "O"  the circuit is switched off, and the key can be removed
      "II"  the current is switched on and the alternator charging control lamp lights
      "S"  the started is engaged. When the engine fires the key should be released
      and will automatically return to position "II"
   2. Alternator Charging Control Lamp  is normally out when the engine is running
      above idle speed
   3. Engine Temperature Control Light  should be out at all times except if engine
      temperature exceeds 70oC or 160oF. In such cases the engine must be stopped
      at once or severe damage may occur. Find the trouble before the engine is
      restarted.
   4. The panel also has a reserve lamp marked "OIL", which is not connected


Controls

Throttle and gearshift are both operated by single-lever remote control, which works as
shown:


                                N      =      Neutral
                                F1     =      Forward gear engaged
                                F2     =      The RPM increases
                                B1     =      Reverse gear engaged
                                B2     =      RPM increases




To disengage the gearshift mechanism, push the knob  2  fully in, for instance when
starting the engine.


Aloha Owners Association note  the control fitted to Aloha 27s is not always the
same as this, and in some cases you pull the knob OUT to disengage.



                                                                                          6
STARTING AND OPERATING
The Decompression Valve

The automatic decompression valve makes starting easier, particularly manual starting.
The valve is operated by a twist grip. In the "O" position the valve is closed, while in the
"1" sector it is open, but the automatic control device is not engaged.




Turning the grip further  always clock-wise  will engage the automatic control. When
the engine is cranked, the valve will automatically return notch by notch to the "0"
position. This takes four full turns of the crank handle and the speed gained thereby
should make the engine fire at the first following compression stroke.

Use of the decompression valve is also helpful when the battery is too low for sufficient
cranking speed.




           NOTE  never use the decompression valve to stop the engine




                                                                                               7
Cold Starting Device

Situated next to the injection pump (on the starboard side just forward of the dipstick).
When starting a cold engine, the knob is pulled out fully and the RPM control (throttle) in
cockpit pushed to the "full" position, with the gear disengaged.




Cold Weather Starting Aid

A cold start primer is located on top of the cylinder head. Fill with diesel or lubricating oil
with the cover removed and press the cove r fully down prior to starting.




Engine Shut-Off Control

Pull the handle and hold it in this position until the engine has completely stopped.




                                                                                              8
A running-in period of approximately 10 hours when the maximum RPM should not exceed
3000 min-1 will prolong engine and gearbox life. After these 10 hours, the engine should be
checked by a BMW Marine Dealer in accordance with the instructions in the service section.

Always check the engine oil level, prior to the first starting of the day.




Air Bleeding

The BMW D7 fuel system incorporates a fully automatic air-bleed device.

Prior to starting up after a long rest period or when the fuel system has been worked on,
operate the primer pump some 30  50 strokes, which will save the battery and starter.
(For location of primer pump see diagrams on pages 13 & 15)


Starting A Cold Engine

      Check that the gear-shift is in neutral
      Set the throttle at the "full" position
      Turn the starter switch key to the "II" position ans check that the alternator
       charging control lamp comes on
      Turn the key to the "S" position which will engage the starter motor. When the
       engine fires evenly, release the starter switch key
      Set the throttle at normal idling


Important  see NOTES on next page.



                                                                                        9
NOTE

If outside temperature is extremely low, the primer device on top of the cylinder head
(see diagram on page 8) sgould be filled with diesel or lubricating oil and the plug fully
pressed down to inject the oil into the intake manifold.

NOTE

Since a diesel engine is dependent on a certain compression pressure = heat to ignite
the fule, one may have to operate the starter for longer periods than is the case with a
gasoline engine. Under no circumstances should the starter be engaged for more than
thirty seconds at a time.

A battery too low for sufficient cranking speed will doom the starting from the beginning
and the battery will drain very rapidly. In such a case, try the decompression valve, or
crank the engine manually.



Starting A Warm Engine

      Check that the gear-shift is in neutral
      Set the throttle at the "full" position
      Turn the starter switch key to the "II" position ans check that the alternator
       charging control lamp comes on
      Turn the key to the "S" position which will engage the starter motor.
      Release the key as soon as the engine fires
      Decrease the RPM to normal idling
      Check that the alternator charging control lamp is out and the gear-shift is re-
       engaged




                                                                                             10
Manual Starting

      Prepare the starting according to the instructions for a cold engine on page 9
      Insert the crank handle and make sure it is properly engaged
      Turn the decompression valve twist grip almost 180o clockwise
      Hold the crank handle as shown i.e. with fingers and thumb on the same side of
       the handle thus avoiding spraining the hands should the engine rotate backwards
      Crank the engine as rapidly and vigorously as possible. After four crank handle
       revolutions, the decompression valve will close and the engine will fire normally
      Remove the crank handle and decrease RPM to normal idling




Aloha Owners Association note  owners of some Aloha 27s advise that due to the
close proximity of the bulkhead there may be insufficient clearance to allow insertion of
the crank handle for manual starting


Stopping the engine

      Set the control in neutral and allow the engine a few minutes idling in order to
       even out any thermal stresses
      Pull the shut-off handle fully until the engine has completely stopped




             NOTE  never use the decompression valve to stop the engine




                                                                                          11
SERVICE AND MAINTENANCE
Periodical service and maintenance procedures are listed below.

The      marking indicates that the procedure in question requires special tools and
certain knowledge and should be left to your authorized BMW Marine Dealer.

Jobs to be done                                Engine hours                       Page
Oil level check                                Daily                               16
Oil change, engine                             50 or once yearly                   16
                                               First change after 10 hours
Oil change, gearbox                            150 or once yearly                      16
Fuel primary filter, draining                  Every two weeks                         13
Fuel primary filter, cartridge replacement     100 or once yearly                      13
Fuel screen cleaning (inside the feed pump)    100 or once yearly                      13
Air filter, replacement                        100 or once yearly                      15
    Tappet clearance, checking/adjusting       100 or once yearly                      19
   Injector, cleaning                          When necessary                          14
Sacrificing anodes, checking/replacing         Replaced once yearly                    18
Impeller, raw water pump checking/replacing    100 or once yearly                      17
                                               100 or whenever tappet
    Decompression valve, adjusting                                                     19
                                               clearance is altered




                                                                                            12
FUEL SYSTEM
Fuel flow circuit


                          Number markings refer to corresponding paragraph


   1. The fuel tank  consult the tank manufacturers or boat builders instructions for
      proper draining, cleaning and other maintenance procedures.
      NOTE  diesel fuel should not be left in the tank during the lay-up period due to
      rust, sludge or wax deposits forming.




   2. The fuel pump  (located on the port side of the engine) is of the diaphragm type,
      operated by the camshaft. Underneath the pump housing cover there is a screen
      type pump which needs cleaning at regular intervals. The filter sealing ring as well
      as the gasket at the cover centre should be renewed whenever the parts are
      dismantled. Apart from this, the pump needs no maintenance and is replaced as
      a complete unit if there are any doubts about it's functioning.

   3. The primary fuel filter  with water trap. Water and dirt deposits are drained by
      removing the knurled plud with a suitable container underneath to catch the spill.
      The spin-on type filter cartridge ( Type BMW 13 321 329 270) is replaced at regular
      intervals  see maintenance schedule on page 12.




                                                            NOTE  the filter cartridge
                                                            cannot be cleaned and used
                                                            again.




                                                                                          13
   4. The injection pump  of Bosch make, must not be dealt or tampered with by
     anyone other than an authorised BMW Marine Engine or Bosch diesel dealer.
    Should the pump need to be removed, it is very important that all openings, fuel
           line connectors, etc are properly sealed to prevent contamination.




5. The injector  of Bosch manufacture, will normally need no maintenance except
   for cleaning of the area nect to the atomizer. The injector must not be dismantled,
   since the set injection pressure then could be altered inadvertedly.




 WARNING  when the injector is tested outside the cylinder, the jet must not
 be directed towards unprotected skin, eyes, etc as it is powerful enough to
      penetrate the skin, causing nasty wounds and possible infection.




   When installing the injector, make sure that the cylinder head seal is clean and
   the nuts evenly tightened to 1.0 kpm (7.2 lb.ft.)




                                                                                      14
   6. The return pipes  direct surplus fuel to the tank and evacuate any air locks.

       NOTE  whenever the fuel system has been serviced, bleeding it by operating the
       primer pump some 30  50 strokes is worthwhile. Any air locks trapped in the
       system will otherwise cause trouble or make starting impossible.




NOTE  handling the fuel system requires total cleanliness. The injection pump and
injector tolerances are very fine and any fragment of dirst or the tiniest amount of water
could ruin the injector operation.



Air filter replacement  is easily carried out by undoing the filter housing clasps. The filter
paper element is discarded and cannot be used again. Clean out the filter housing and
install a new element. (Type BMW 13 321 329 269)




                                                                                            15
LUBRICATION SYSTEM
The BMW D7 is equiped with a simple and relaible splash lubrication system.

Oil level check  is done daily with aid of the dipstick




Engine oil change  normally every 50 hours. A brand new engine, however, will require
it's first oil change afte r ten or fifteen hours running. Pump out the oil oil via the dipstick
opening while the engine is warm. Refill via the crankcase filler plug.


Gearbox oil change  is carried out at 150 hour intervals and when the gearbox is still
warm. Remove the drain plug  1  and the filling opening plug  2 -. Allow the oil
enough time to drain completely. Check that the drain plug seal is undamaged prior to
re-installation. Top up the gearbox slowly with 0.4 litres (0.1 US gal) ATF Dexron oil.
Leave the filling opening open for some minutes until any possible air locks have
escaped. Check the plug seal and install the plug.




                                                                                              16
COOLING SYSTEM
The engine has a raw-water direct cooling system fed by an impeller type pump located
on the front of the engine and driven b y the crankshaft. The water is circulated through
the cylinder block and cylinder head jackets and finally discarded via a thermostat
controlled outlet into the exhaust manifold.




Pump impeller change  is possible when the pump housing front cover is removed. Pry
the impeller off its shaft using two scredrivers. Lubricate the shaft and the impeller vanes
with a few drops of oil prior to installation. Bend the vanes opposite to the direction of
rotation in order to avoid distortion. Renew the pump housing gasket and install the
cover.




NOTE  the impeller should be removed prior to lay-up  see instructions on page 21




                                                                                         17
The engine temprature warning light sensor  1  and self-sacrificing anodes  2  are
situated next to the thermostat housing  3  . The anodes resist internal corrosion in
the cooling system.




The self-sacrificing anodes  are checked regularly and replaced if more than 50% has
been eaten away by corrosion. Undo the anodes  2  and replace them with new ones,
including new gaskets.


The thermostat  will open at 55oC (130oF). It is accessible when the exhaust manifold is
removed  3 . Check the thermostat by submerging it in hot water. Always use a new
gasket when re-installing the manifold.


Draining the cooling system  is done by removing the lower sacrificial anode.




                                                                                          18
VALVE SYSTEM
The overhead valves are operated by the camshaft via pushrods and rocker arms.

       Tappet Clearance

       to be checked and adjusted while the engine is cold
       set the decompression valve twist grip in the "0" position
       remove the rocker arm cover, attached with two studs and nuts
       crank the engine until the compression resistance is clearly noticeable
       use a feeler gauge to check the clearance between rocker arm and valve. Correct
        clearance = 0.15mm (.006 in)
       adjust if necessary by loosening the adjustment screw lock nut at the rocker arm
        push-rod end  1 
       turn the adjustment screw either way until the correct clearance is achieved
       hold the screw in position while the lock nut is tightened
       check the clearance once more
       repeat the same procedure at the remaining valve
       re-install the cover with a new gasket




   The Decompression Valve

       is checked and adjusted when the valve mechanism has been worked on or if the
        proper setting has been altered for othe r reasons affecting the correct functioning
        of the valve
       remove the rocker arm cover
       check and adjust the tappet clearance
       turn the decompression handle to position "1"
       undo the decompression valve adjusting screw locknut  2 
       turn the adjustment screw counter-clockwise until the rocker arm clearance is
        clearly noticeable
       turn the adjustment screw clockwise until the rocker arm is just in touch with the
        valve and then another half turn  180o  in the same direction
       hold the screw in position while the locknut is tightened
       install the rocker arm cover and a new gasket
       set the decompression valve twist grip in "0" position
                                                                                          19
ELECTRICAL SYSTEM

The BMW D7 is equipped with a 12 volt electrical system, consisting of a starter motor
operating on the flywheel ring gear and an internal alternator with static charging coils
inside the flywheel. The maximum charging capacity is 14 V 350 W at 2000 RPM.

A panel with rectifier, regulator and fuses completes the installation.




The alternator charging control light i n the instrument panel will light up when the starter
switch key is turned to "II" position, but should go out when the engine runs, indicating
that everything is in order. If not, consult your BMW Marine Dealer as in case of any
starter motor malfunctioning.

Apart from replacing any burned fuses - make sure that the correct type of replacement
is used - the electrical system should need no maintenance. Check, however, that all
visible connections are clean and tightened.

Wiring Diagram




1 Charge Control Lamp   6 Water Temp Switch     11 Flywheel Generator   BL = Blue     RT = Red
2 Water Temp Lamp       7 Regulator             12 Fuse box 25A         BR = Brown    SW = Black
3 Spare (Oil) Lamp      8 Impulse Transmitter   13 Starter              GE = Yellow   WS = White
4 Keyswitch             9 Plug  1 Pin          14 Battery              GN = Green
5 Plug  9 Pin          10 Plug  4 Pin

                                                                                                   20
WINTER LAY-UP AND RECOMISSION
Prior to winter lay-up or any long periods of rest the engine should he prepared for
storage, mainly to fend off corrosion. Either leave this job to the authorized BMW Marine
Dealer or do it you according to the following instructions:

Before the boat is taken out of the water
 warm up the engine and remove the oil, see page 16
 use preservation oil level with the dipstick lower marking
 drain the gearbox oil and refill with ATE Dexron oil
NOTE - before the engine is recomissioned, the preservation oil must be removed and
replaced by recommended engine oil. Some kind of marking is useful as a reminder.
 Mix 2 litres (0.5 US gal.) diesel fuel with 1 litre (0.25 US gal.) preservation oil in a
   suitable container. Connect a hose to the ordinary fuel tank line or directly to the
   primary filter inlet while the other end is inserted into the container
 Start the engine and let it run for approximately 15 minutes

On dry land
 Drain the engine cooling system, but without removing the cooling water pump
  impeller
 Shut off the raw water inlet and disconnect the raw water pipe at the pump
 Mix approximately 12 litres of fresh water with 1.2 litres of emulsifying preservation
  oil in a container. Always mix the oil with water, not the other way round, and stir
  vigorously
 Connect a hose to the raw-water pump and put the open end in the container
 Start the engine and let it idle until the oil/water mixture is nearly gone. Stop the
  engine. Make sure that no liquid remains in the system since it has no anti-freeze
  qualities
 Remove the injector and pour approximately 1 teaspoonful of oil into the cylinder.
  Crank the engine a couple of turns and re-install the injector.
 Give the engine and gearbox a good cleaning and a coat of oil to prevent rust
 Lubricate control cables and linkage.

Recomission before launching
 Remove all preservation oil in the engine and replace with recommended oil
 Install the raw-water pump impeller
 Remove the injector and crank the engine a few turns to get rid of surplus oil in the
  combustion chamber
 Change fuel filters
 Refuel with fresh diesel fuel. Fuel left in the tank during winter storage should never
  be used. Check lines and connectors
 Start the engine after launching - do not forget to reopen the raw-water inlet. Warm
  up the engine and check that there are no leaks in fuel or cooling systems.




                                                                                           21


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