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Bmw D7 Owners Manual




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Owners Marine copy of the BMW D7 Owners Manual has been recreated using images from a manual rather than original artwork It has also been
reformatted in
portrait style to display andor print better on computer systems
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 its best during a long life without proper care and 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
DESCRIPTION AND CONTROLS 6
STARTING AND OPERATING 7
SERVICE MAINTENANCE 12
FUEL SYSTEM SYSTEM 16
COOLING SYSTEM 17
VALVE SYSTEM SYSTEM 20
WINTER LAY UP AND RECOMISSION 21
ENGINE BMW D7 is a fourstroke diesel engine The engine
is equipped with a rawwater cooling system fed by an impeller type pump driven by Electrical starting and charging systems are standard as is an
automatic air
bleeder device in the fuel 280cc 170 cu in
Stroke Bore 67 x 73 mm 263 x 287 in
Max output at min1 RPM 45 kW 3600 6 HP 3600
Max torque at min1 RPM 117 Nm 3300 87 lb ft 3300
12 kpm Ratio 191
Weight dry engine incl Gearbox 68 kg 150 lb
Gearbox reduction 27
Maximum engine inclination 15 deg
Engine Gearbox
Fuel Diesel Oil
DIN 51601
USA 2
Fuel Filter BMW 13 32 1 329 oil
Type HDAPI CCCD SAE 30 ATF Litre US gal 1 litre 026 US Gal 04 litre 01 US Gal
Air Filter BMW 13 71 1 329 269
Injector make pressure 135 8 bar
Injection pump Bosch PFE 1 Q 5519
Starter motor make charging capacity 14v 350w
Battery rec capacity 12v 60 Ah
Polarity Negative pump Hurth HBW ends 115 125
deg BTDC
Tappet clearance 015 mm 006 in
Torque Nm retainer 10 72
Cylinder head bolts 35 25
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 and gearshift are both operated by singlelever remote control which works as
shown
N Neutral
F1 Forward gear engaged
F2 The RPM increases
B1 Reverse gear engaged
B2 RPM disengage the gearshift mechanism push the knob 2 fully in for instance when
starting the 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 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 the grip further always clockwise 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 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 speed
NOTE never use the decompression valve to stop the engine
Cold Starting next to the injection pump on the starboard side just forward of the 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 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 ShutOff Control
Pull the handle and hold it in this position until the engine has completely stopped
A runningin period of approximately 10 hours when the maximum RPM should not exceed
3000 min1 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 check the engine oil level prior to the first starting of the day
Air Bleeding
The BMW D7 fuel system incorporates a fully automatic airbleed 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 A Cold Engine
Check that the gearshift 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 see NOTES on next page
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 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 A Warm Engine
Check that the gearshift 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 gearshift is re
engaged
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 ie 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 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 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 shutoff handle fully until the engine has completely stopped
NOTE never use the decompression valve to stop the engine
SERVICE AND 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 100 or once yearly 19
Injector cleaning When necessary anodes Replaced once yearly 18
Impeller raw water pump 100 or once yearly 17
100 or whenever tappet
Decompression valve adjusting 19
clearance is altered
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 layup 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 its 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 spinon 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
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 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 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 When installing the injector make sure that the cylinder head seal is clean and
the nuts evenly tightened to 10 kpm 72 lbft
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 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 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
SYSTEM
The BMW D7 is equiped with a simple and relaible splash lubrication system
Oil level check is done daily with aid of the oil change normally every 50 hours A brand new engine however will require
its first oil change afte r ten or fifteen hours running Pump out the oil oil via the while the engine is warm Refill via the crankcase filler 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 Top up the gearbox slowly with 04 litres 01 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
COOLING SYSTEM
The engine has a rawwater 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 outlet into the exhaust 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 impeller should be removed prior to layup see instructions on
page 21
The engine temprature warning light sensor 1 and anodes 2 are
situated next to the thermostat housing 3 The anodes resist internal corrosion in
the cooling 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 new 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 reinstalling the the cooling system is done by removing the lower sacrificial anode
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 015mm 006 in
adjust if necessary by loosening the adjustment screw lock nut at the rocker arm
pushrod 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
reinstall 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 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
SYSTEM
The BMW D7 is equipped with a 12 volt electrical system consisting of a starter 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 alternator charging control light i n the instrument panel will light up when the key is
turned to II position but should go out when the engine runs everything is in order If not consult your BMW Marine Dealer as in case of any
starter motor from replacing any burned fuses make sure that the correct type of used the electrical system should need no maintenance Check
however that all
visible connections are clean and 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
WINTER LAYUP AND to winter layup 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 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 the preservation oil must be removed and
replaced by recommended engine oil Some kind of marking is useful as a reminder
Mix 2 litres 05 US gal diesel fuel with 1 litre 025 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 12 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 rawwater pump and put the open end in the container
Start the engine and let it idle until the oilwater mixture is nearly gone Stop the
engine Make sure that no liquid remains in the system since it has no antifreeze
qualities
Remove the injector and pour approximately 1 teaspoonful of oil into the cylinder
Crank the engine a couple of turns and reinstall the injector
Give the engine and gearbox a good cleaning and a coat of oil to prevent rust
Lubricate control cables and before launching
Remove all preservation oil in the engine and replace with recommended oil
Install the rawwater 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 rawwater inlet Warm
up the engine and check that there are no leaks in fuel or cooling systems

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