Westerbeke Diesel 55a Four Parts Manual

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SERVICE MANUAL 55A FOURMARINE 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 WARNINGExhaust gasses contain Carbon Monoxide an odorless andcolorless gas Carbon Monoxide is poisonous and can and death Symptoms of Carbon can Throbbing in TemplesNausea Muscular Vomiting Weakness and Sleepiness Inability to Think CoherentlyIF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMSGET OUT INTO THE FRESH AIR IMMEDIATELY symptoms persistseek medical attention Shut down the unit and do not restartuntil it has been inspected and repaired SAFETY PREVENT BURNS FIRERead these safety instructions carefully Most accidents arecaused by failure to follow furuklmental rules and precautions Know when dangerous conditions exist and take the A WARNING Fire can cause injury or deathnecessary precautions to protect yourself your personneand your machinery Prevent flash fires Do not smoke or permit flames or sparks to occur near the carburetor fuel line filter fuelThe following safety instructions are in complWnce with pump or other potential sources of spilled fuel or fuelthe American Boat and Yacht Council ABYC staruklrds vapors Use a suitable container to catch all fuel when removing the fuel line carburetor or fuel filtersPREVENT 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 enginegener 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 sparkproducing 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 environment Engines Generators i 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 boatBAnERY 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 ii 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 FromHAZARDOUS 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 MANUALMany of the preceding safety tips and warnings are repeatedin your Operators Manual along with other cautions andnotes to highlight critical information Read your maintain your equipment and follow all to install an engine should begin with a thorough examination of the American Boat and Yacht CouncilsABYC standards These standards are a combination ofsources including the USCG and the NFPASections of the ABYC standards of particular interest are H2 Ventilation P1 Exhaust systems P4 Inboard engines E9 DC Electrical systemsAll installations must comply with the Federal Code ofRegulations FCR Engines Generators iii 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 withwhen installing engines and generators in a marine installations where the exhaust manifoldwater injected exhaust elbow is close toor below the vessels waterline provisions must be made to install a siphonbreak inthe raw water supply hose to the exhaust elbow This hose must be looped a minimumof 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 waterdamage to the engine and possible flooding of the boatEXHAUST SYSTEMThe exhaust hose must be certified for marine use The system must be designed toprevent water from entering the exhaust under any sea conditions and at any angleof 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 iv TABLE OF 255A FOUR Specifications 4Parts Identification 5Testing for Overhaul 6Engine 7Engine Disassembly 11Engine Inspection and Repair 16Engine Reassembly 26Engine Adjustments 42Glow Plugs 51Lubrication System 52Remote Oil Filter Optional 57Coolant Pump 58Raw Water Pump 59Heat Exchanger Manifold 61Tachometer 62Starter Motor 63DC Electrical 67DC Electrical System Wiring Diagram 70DC Electrical System Wiring Schematic 72Service Standards 73Metric Conversions 7755A FOUR Torques 78Standard Hardware Torques General Screws Sealants 79Index 80 Engines Generators 1 OVERHAUL CUSTOMER IDENTIFICATION CARDThis service manual contains detailed information relating tothe overhaul of the 55A FOUR Diesel Engine For the majoroverhaul procedure refer to the ENGINE DISASSEMBLY INSPECTION AND REPAIR and sections Additional service information for I Customer components and systems may be found by referringto the Table of Contents and the Index Refer also to your MR ENGINE Parts Catalog MAIN STREETThese service procedures are intended for the guidance of HOMETOWN USAsuitably equipped and staffed marine engine service and Model 55A FOUR Ser facilities and should only be undertaken by such Expires 4498facilities and their SOFTWARE The WESTERBEKE engine serial number is an alphanu meric number that can assist in determining the date of manProduct 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 andBEKE are not within WESTERBEKES control consists of a character followed by three numbers The charWESTERBEKE CANNOT BE RESPONSIBLE FOR THE acter indicates the decade A1960s B1970s 01980sCONTENT OF SUCH SOFTWARE MAKES NO WAR D1990s the first number represents the year in the decadeRANTIES OR WITH RESPECT and the second and third numbers represent the month ofTHERETO INCLUDING ACCURACY TIMELINESS OR THEREOF AND WILL IN NO EVENTBE LIABLE FOR ANY TYPE OF DAMAGE OR INJURY ORDERING PARTSSERIAL NUMBER IN CONNECTION WITH OR ARISING OUT Whenever replacement parts are needed always provide theOF THE FURNISHING OR USE OF SUCH SOFTWARE engine model number and engine serial number as theyWESTERBEKE customers should also keep in mind the appear on the silver and black identification nameplatetime span between printings of WESTERBEKE product soft located on the side of the manifold The engine serial numberware and the unavoidable existence of earlier WESTER can also be found stamped into the engine block just aboveBEKE 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 additionother suppliers must not and cannot be relied upon exclu include a complete part description and part number for eachsively as the definitive authority on the respective product It part needed see the separately furnished Parts List Alsonot 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 specifibe 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 imagineAs 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 sidewill be highlighted by NOTES CAUTIONS and WARNINGS is at your rightAn explanation follows Owners may find it convenient to fill in the engine identificaNOTE 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 2 INTRODUCTION 55A FOUR DIESEL ENGINE SPRING RETAINER INJECTION NOZZLE CYLINOER HEAD BOLT SPRING SEAT tjJIrrd COMBUSTION CHAMBER INSERT Engines Generators 3 55A FOUR SPECIFICATIONS ENGINE SPECIFICATIONS COOLING SYSTEMEngine Type Diesel fourcycle fourcylinder fresh General block thermostati watercooled vertical inline 55 hp at cally controlled with raw water 3600 rpm maximum exchanger systemGovernor Integral with the injection pump Operating Temperature 170 190F 77 88C mechanical centrifugal flyweight type Coolant Pump Centrifugal type metal impeller beltValve Mechanism Direct drive OHC Chamber Swirl chamber type Raw Water Pump Positive displacement rubber impeller belt drivenBore 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 rpmFiring 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 litersMaximum Torque 931bft 129 kgmat 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 CCAValve Seat Angle Intake 45 Exhaust 45 minValve Clearance Intake 008 0012 in 020 030mm Starter Motor 12volt 16kw SOlenoid actuated shiftengine cold Exhaust 00120016 in 030040 mm reduction gearDimensions 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 minInClination Continuous 14 Temporary 25 Cold Cranking Current 280 300 amps at 10 volts 250 rpm not to exceed 30 minDry Weight 470 Ibs 2132 kgs Alternator standard 12volt DC 50 ampsEngine Speed Idle speed 750 1000 rpm Regulator Internal regulator built into alternator Cruising speed 2500 3000 rpmFuel 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 3Injection 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 underInjectors Throttle type 2741 reduction way in forward gearInjection 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 typeFuel 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 theAir Cleaner Replaceable paper filter element crankshaftAir Flow Oil Filter Full flow paper element spinon typeengine combustion 140 cfm 39 cmm at 3600 rpm Lube Oil Cooler Fresh water cooledengine 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 operExhaust Elbow 90 elbow 45 elbow and exhaust riser ating Hose Size 2 inch 10 hose Oil Grade API Specification CF or CG4Muffler Size min 14 inch x 14 inch SAE 30 10W30 15W40 Engines Generators 4 PARTS IDENTIFICATION ANODEWATER I M U ISENDERLUBE 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 A FRONT Engines Generators 5 TESTING FOR OVERHAULHOW TO DETERMINE WHEN NOTE Do not guess the conditions of other cylinders from aTO 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 averCause of Low Compression age of the other cylinders If the weak cylinder is flanked byGenerally the time at which an engine should be overhauled healthy cylinders the problem is either valve or headgasketis determined by various conditions such as lowered engine related Very low compression in an adjacent cylinder indipower output decreased compression pressure and increased cates gasket failure Abnormally high readings on all cylinfuel and oil consumption The lowered engine power output ders indicate heavy carbon accumulations a condition thatin the case of diesel engines is not necessarily due to trouble might be accompanied by high pressures and noisewith the engine itself but is sometimes caused by injector NOTE In case of severe vibrations and detonation noisenozzle wear or injection pump wear It is most reasonable to have the injectors overhauled by an authorizedJueI injectionjudge by a decrease in compression pressure The decrease in service center Poor fuel quality contaminates and loss ofcompression pressure is caused by many factors Itis there positive fuel pressure to the injection pump will result infore necessary to determine a cause or causes on the basis of injector faultsdata produced by periodic inspection and maintenance Oilanalysis 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 newton 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 whenThese symptoms often appear together Increased fuel con compression values are at minimum or belowsumption and hard engine starting can result also from excessive fuel injection improper injection timing and wear of NOTE Refer to the SERVICE STANDARDS chart during anplugs and nozzles They are caused also by defective electri engine overhaul It gives the measurements and values forcal devices such as the battery alternator starter and glow the repair or replacement of the engine Therefore it is desirable to judge the optimum engineoverhaul time by the lowered compression pressure causedby worn cylinders and pistons plus increased oil consumption In diesel engines satisfactory combustion is obtainedonly under sufficient compression pressure If an enginelacks compression pressure incomplete combustion of fuelwill take place even if other parts of the engine are To determine the period of engine overhaul it isimportant to measure the engine compression pressure regularly At the same time the engine speed at which the measurement of compression pressure is made should be checkedbecause the compression pressure varies with engine rpmThe engine rpm can be measured at the front end of Compression PressureTo check the compression pressure see under ENGINE ADJUSTMENTS Engines Generators 6 ENGINE following table describes certain Note The engines electrical system is protected by a 20problems relating to engine service the probable causes of ampere manual reset circuit breaker The preheat solenoid isthese problems and the to overcome mounted on the same bracketthese problems 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 disengagement 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 continued Engines Generators 7 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 oilEXCESSIVE 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 guideOIL 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 leaksSMOKY 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 8 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 fuelABNORMAL SOUND CRANKSHAFT AND MAIN BEARINGOR 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 tensionerROUGH OPERATION INJECTION PUMP SYSTEMHUNTING 1 Uneven injection 1 Adjust injection or replace parts 2 Control rack malfunctioning 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 malfunctioning 1 Check governor shaft and correct operation 2 Fatigued governor spring 2 Replace spring continued Engines Generators 9 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 malfunctioning 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 Afterinjection drip c Repair or replace nozzle d Nozzle needle valve seized d 1 Fuel filter clogged 1 Clean or replaceEXHAUST 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 10 ENGINE Before disassembly and cleaning carefully check 9 Remove the flywheelfor defects which cannot be found after disassembly and 10 Remove the engine back platecleaning 11 Unclamp the exhaust elbow the two coolant hoses on theGENERAL DISASSEMBLY PROCEDURE exhaust manifold and the coolant recovery tank hose then remove the intakeexhaust 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 performance 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 INTAKEJEXHAUST 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 ELBOW1 Unplug the instrument panel wiring harness 12 Remove the alternator2 Drain the transmission fluid and the transmissin oil cooler hoses 13 Remove the raw water pump3 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 theNOTE For transmission service and maintenance refer to injection pump Remove the fuel lift pumpyour transmission owner manual To rebuild a transmis 15 Remove the thermostat housing gasket and the thermosion contact your WESTERBEKE dealer or a qualified stat Leave the temperature sending unit in placemarine transmission service facilityENGINE DISASSEMBLY1 Clean the exterior of the engine of any deposits of dirt and oil2 Mount the engine on a suitable engine stand for disas sembly3 Drain the coolant from the engine and the heat exchanger Drain the fuel and the engine oil4 Remove the engine wiring harness in its entirety Label the terminal connections to insure proper reattachment5 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 removed6 Remove the starter motor7 Remove the engine bellhousing8 Remove the transmission damper plate Engines Generators 11 ENGINE DISASSEMBLY16 Remove the idler pulley bracket and idler pulley 3 Remove the two timing belt covers17 Remove the seal plate b Loosen the two injection pump holddown nuts Do18 Remove the coolant pump not remove them entirely The holddown nut on the engine side of the pump can be loosened by using a19 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 pump20 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 engine21 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 nylon22 Remove the glow plugs drift and hammer gently tap the injection pump shaft23 Remove the cylinder head cover to dislodge it from the keyed pulley24 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 owneroperator 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 rfflI 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 ADJUSTMENTS 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 Crankshaft Engines Generators 12 ENGINE Belt TIMING MARKNOTE WESTERBEKE recommends replacing the timingbelt during an engine overhaul Timing belt failure couldresult in major damage to the engineNOTE If the tming belt is to be reused draw an arrow onthe belt pointing in the direction of the belts rotation so itwill 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 from1 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 the2 Remove the timing belt injection pump pulley from the injection pump shaft3 Remove the timing belt tensioner4 Tum the crankshaft clockwise about 45 from the timing INJECTION mark which is marked on the oil pump housing PUMPPULLEt NOTE Turning the crankshaft prevents the pistons and valves from contacting one another n 49 PULLEY PULLER S120 215A Engines Generators 13 ENGINE Pulley Timing Belt Pulley Cylinder Head Bolts1 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 BOLT4IIZ 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 illustration 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 22 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 efficiently3 Remove the timing belt pulley Engines Generators 14 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 TAPPETSValves1 Remove the springs2 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 490636100A 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 222NOTE The valve guides are to be removed only after measuring the valve guidevalve stem see Valve Guides underENGINE INSPECTION Engines Generators 15 ENGINE INSPECTION AND REPAIRGENERAL INSPECTION PROCEDURE 4 Measure the manifold contact surface distortion in the three directions shown in the illustration If the distortion1 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 in2 Be careful not to damage the joints or sliding parts of aluminum alloy components such as the cylinder head and the pistons3 Inspection and repair should be done in the order indi catedENGINE INSPECTION MANIFDLD CONTACT SURFACE Head1 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 cylin2 Measure the cylinder head for distortion in six directions der head and separate them by cylinder using a thickness gauge as shown in the illustrations 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 j3 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 16 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 illustration 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 Seats6 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 17 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 valve2 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 circumference 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 specification 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 18 ENGINE INSPECTION AND REPAIR2 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 0636165A 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 HEADValve Guides1 Measure the difference between the inner diameter of each valve guide and the diameter of the corresponding 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 19 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 1 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 U 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 inValve Springs Clearance limit 010 mm 00040 in1 Inspect each valve spring for cracks or other damage Replace if necessary2 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 PERPENDICULAR VALVE SPRING Engines Generators 20 ENGINE INSPECTION AND REPAIR2 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 illustrations Journal eUipticallimit 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 in3 Check the camshaft deflection Camshaft deflection limit 010 mm 00040 in NOTE Place the front and rear journals on Vblocks to make the measurement 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 repair1 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 21 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 Rings1 Inspect the outer circumferences of all the pistons for seizure or scoring Replace if necessary 6 Measure the clearance of the piston ring to the ring groove2 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 22 ENGINE INSPECTION AND Rods 2 To replace the connecting rod bushing use a press and a suitable pipe diameter 27 275 mm 106 188 in1 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 obstructions 2 Check the crankshaft deflection and each diameter Replace if necessary Deflection limit 005 mm 0002 inConnecting Rod Bushings1 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 o CHECKING CRANKSHAFT DEFLECTION Engines Generators 23 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 installation 8995 9000 mm 3541 3543 in b Check the timing belt cover gaskets for damage and 2 installation PREMATURE SEVERANCE 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 i 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 TOOTHMain Bearings and Connecting Rod Bearings 3 Check for noticeable wear or cracks on the belt face1 Check the main bearings and connecting rod bearings2 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 24 ENGINE INSPECTION AND REPAIR5 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 III 25mm10in DO NOT BENDTIming Belt Tensioner1 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 TENSIONER Engines Generators 25 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 torquetoyield 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 runENGINE SealsNOTE Always replace the valve seals during an engine 5 Move the No 1 piston to top dead center and then rotateoverhauL the crankshaft approximately 451 Apply a coat of engine oil to the valve guides and the inside surfaces of the valve seals2 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 26 ENGINE REASSEMBLY 90Tappets and Adjusting Discs TOP RING AND EXPANDER1 Apply engine oil to the tappets then install the tappets to the tappet holes2 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 upwardPistons and Connecting Rods R DR RN1 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 rJI 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 commercially available 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 circumference and rings2 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 illustration ENGINE FRONT SIDE Engines Generators 27 ENGINE Assembly d Remove the main bearing cap and measure the oil clearance1 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 in2 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 different 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 illustration Main bearing cap bolt tightening torque 84 90 kgm 61 65 ftlb FRONT CYLINDER NUMBER MAIN BEARING MAIN BEARING CAPS Engines Generators 28 ENGINE REASSEMBLY4 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 width5 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 SIDE6 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 ftIb7 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 29 ENGINE REASSEMBLY10 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 clearance 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 ROO 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 30 ENGINE REASSEMBLY2 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 COVER3 Install the rear cover assembly over the gasket M10 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 illustration Aftel installation clean away any sealant whichOil Pump Assembly oozes outNOTE If it is necessary to service the oil pump see OIL PUMPunder LUBRICATION SYSTEM Oil Strainer and Oil Pan1 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 information2 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 31 ENGINE REASSEMBLY2 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 assembly3 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 1Back Plate and Flywheel1 Install the back plate Back plate tightening torque 16 23 kgm 12 17 ftIb Engines Generators 32 ENGINE REASSEMBLY2 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 c1 CYLINDER HEAD BOLT LENGTH 6 TIghten the cylinder head bolts in the sequence shown in the illustration Cylinder head tightening torque 30 kgm 217 ftlb 8 4 1 5 9Cylinder head1 Thoroughly remove all dirt and grease from the top of the cylinder block with a rag2 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 illustration3 Remove any dirt or grease from the bottom surface of the cylinder head4 Place the cylinder head in position5 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 33 ENGINE 10 6 2 3 71 Apply a coat of engine oil to the camshaft and the cylin der head journals2 Insert the seal cap and then apply sealant 1016 77 739 to the areas shown by the shading in the illustration 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 Use3 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 ftIb4 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 INJEC5 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 illustration 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 installed Engines Generators 34 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 channelsOil Pressure Switch and Oil Dipstick Tube1 Install the oil pressure switch Oil pressure switch tightening torque 12 18 kgm 9 13 ftIb2 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 ftIb1 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 necessaryafter installing the timing belt Injection pump tightening torque 32 47 kgm 23 34 ftIb FUEL INJECTION fRst PUMP FUEL INJECTION M1 PUMP BRACKET Engines Generators 35 ENGINE REASSEMBLYSeal Plate 4 Check the thermostat for proper operation by placing it in1 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 positionIdler Pulley Bracket1 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 Assembly1 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 gasket2 Inspect the thermostat housig then install it Thennostat housing tightening torque 16 23 kgm 12 17 ftlb CAMSHAFT PULLEY3 Install the temperature switch and sender and reconnect their wires Engines Generators 36 ENGINE Pump Pulley SPRING1 Install the injection pump pulley with the semicircular woodruff key to the injection pump shaft2 Rotate the injection pump pulley until the timing mark on the injection pump pulley aligns with the timing mark on the seal plate3 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 PULLEYTiming Belt Tensioner1 Check to ensure that the timing marks on the pulleys are aligned with the timing marks on the seal plate 7 N J 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 rotation2 Install the timing belt tensioner locking bolt and spring3 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 37 ENGINE REASSEMBLY3 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 seal4 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 ftIb5 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 rotation6 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 gear7 Recheck the timing mark positions on the crankshaft camshaft pulley and injection pump pulley with the tim ing marks on the gear case8 Check the timing belt deflection at the position shown in the illustration 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 specification repeat the procedure from Step 1 IntakeExhaust Manifold Assembly NOTE For additional information see the INTAKEEXHAUST MANIFOW page 1 Remove the air intake manifold clean the two air filters then reassemble 2 Place the intakeexhaust manifold gaskets in position 3 Install the intakeexhaust manifold in its entirety and tighten it to the specified torque Intake exhaust manifold tightening torque 22 27 kgm 16 20 ftIb Engines Generators 3S ENGINE REASSEMBLY4 Attach the exhaust elbow the two exhaust manifold hoses and the coolant recovery tank hose For additional servicing information see the INTAKEEXHAUST MANIFOLD page COOLANT RECOVERY TANK HOSE 5 Install the water hose with a new gasket Water hose tightening torqueOil CoolerOil Filter Assembly Bracket 19 26 kgm 14 19 ftIb Flange 08 11 kgm 58 80 ftIbNOTE For additional inJorrruztion see OIL COOLER SYSTEM Alternator1 Install three new Orings into the oil cooler and apply a NOTE For additional inJorrruztion 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 is3 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 22Ib4 Screw the oil filter onto the threaded stub and tighten Used 12 14 mm 047 055 in10kg 22Ib firmly by hand Engines Generators 39 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 JValve Clearance Adjustment 1 Measure the valve clearance and adjust it see VAL VE CLEARANCE ADJUSTMENT under ENGINE ADJUSTMENTS 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 System1 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 pulley2 Place the gasket in position Check the belt tension3 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 diagrams Engines Generators 40 ENGINE Idle Speed the HBW marine transmission and fill with ATF Check the idle speed adjustment after the engine has had aDextron III test run see IDLE SPEED ADJUSTMENT under ENGINENOTE Some transmissions such as the Borg Warner Velvet require oil coolers Oil coolers should be tested and repainted at engine overhauL The transmission oil cooler hoses should also be inspected refer toHEAT EXCHANGERS TYPICAL TRANSMISSION OIL COOLERSFluidsI Fill the engine cooling system with antifreeze mixture2 Fill the engine oil sump with lube oil Lubrication system oil grade API Specification CF or CG4 SAE30 IOW30 15W40Test RunTest run the engine under load prior to reinstalling Check foroil leaks Engines Generators 41 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 prematurelyTo check the belt tension apply moderate pressure 10 kg 22lb midway between the pulleys Check the deflection andadjust it if necessaryA 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 gaugeBelt tension adjustment is made by pivoting the alternator on Standard valve clearances engine is coldits base mounting bolt Intake 020 030mm 0008 0012 in Exhaust 030 040 mm 0012 0016 in1 Loosen the alternator adjusting strap bolt and the base mounting bolt2 Pivot the alternator on the base mounting bolt to the left VALVE or right as required CLEARANCE MEASUREMENT3 Tighten the base mounting bolt and the adjusting strap bolt4 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 42 ENGINE ADJUSTMENTS7 Using a small screwdriver or magnet remove the adjust TIMING BELT ing discS 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 direction 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 illustration 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 in9 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 lrf Engines Generators 43 ENGINE ADJUSTMENTS3 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 DAMAGEReplace the timing belt if it is contaminated with oil greaseor water or if any of the following conditions exist1 Premature severance a Check for proper installation 5 Check for noticeable wear on the belt teeth h Check the timing belt cover gaskets for damage and installation PREMATURE SEVERANCE TOOTH WEAR2 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 Yf 00 NOT BEND DO NOT TWIST DO NOT TURN INSIDE OUT CRACKED TOOTH3 Check for noticeable wear or cracks on the belt face 11 25MM10IN DO NOT BEND Engines Generators 44 ENGINE 6 Recheck the timing mark positions between the three pul leys and the seal plate Check the timing belt deflection1 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 illustration2 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 rotation 7 Install the left timing belt cover with its rubber seal3 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 8ELTCOVER4 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 attachment5 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 45 ENGINE TEST NOTE In case of severe vibrations and detonation noise have the injectors overhauled by an authorized fuel injection facilNOTE When performing the compression test shut off the ity Poor fuel quality contaminates and loss ofpositive fuelraw water supply to the enginemounted raw water pump pressure to the injection pump will result in injector faultsThis is to prevent raw water from filling the exhaust system If the glow plugs were removed use antiseize compoundwhile testing when reinstalling them1 Warm the engine up to operating temperature2 Stop the engine TESTING THE OIL PRESSURE3 Remove all four fuel injectors or all four glow plugs NOTE Insure that the oil meets the following standards API4 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 aS 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 assembly6 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 reading7 Record the reading and proceed to the next cylinder Repeat this process for each cylinder Oil Pressure 41 49 kgcmz S8 70 IhinZ8 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 kgem2lbin2rpm 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 TESTERNOTE Do not guess the conditions of other cylinders from aresult of testing one cylinder Be sure to measure the compression pressure for each cylinder Look for cylinders at least 20 lower compression than the average of the other cylinders If the weak cylinder is flanked byhealthy cylinders the problem is either valve or Very low compression in an adjacent cylinder indicates gasket failure Abnormally high readings on all cylinders indicate heavy carbon accumulations a condition thatmight be accompanied by high pressures and noise Engines Generators 46 ENGINE FUEL INJECTORSUsing a nozzle tester check the injection starting pressure ofthe nozzle and if it exceeds the limit adjust or replace the PRESSURE TESTNOTE The fuel injectors must be serviced in a clean the Fuel Injectors1 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 lines2 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 the3 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 CAPNUT4 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 Testing1 Set the nozzle tester in a clean place where there is no 1 1 21 I dust or dirt Inspecting the Spray Pattern2 Mount the nozzle and nozzle holder on the nozzle tester3 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 it4 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 carefully5 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 poisoning6 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 47 ENGINE ADJUSTMENTS2 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 1 BODY NUT SHIM SPRING CORRECT AFTER DRIP TEST INCORRECT PIN NOZZLE SPRINGInjector Disassembly SEAT1 Clamp the nozzle holder in a vise then remove the cap INJECTION nut NOZZLE2 Remove the pressure adjusting screw then pull out the upper seat the spring and the push rod NOZZLE NUT3 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 ftlbInjector Inspection 2 After the nozzle and nozzle holder have been assembled1 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 removed2 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 48 ENGINE SPEED the Idle Speed1 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 tachometer2 Start and idle the engine3 Aim the light of the tachometer onto the reflecting tape to confirm the engine speed4 Adjust the idle speed if the engine speed is not within the specified value Normal Idle Speed 750 1000 rpmAdjusting the Idle Speed1 Loosen the locknut on the idle adjustment bolt on the fuel injection pump2 Tum the idle adjustment bolt until the idling speed is within the standard range3 Tighten the locknut4 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 49 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 rotation1 Remove the air intake silencer assembly until the No 1 piston is at IDe by referencing the indi2 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 1003 Remove the bolt and gasket installed on the distributor mm from the zero setting head of the injection pump Beginning of Static Injection4 Remove the valve rocker cover Cam lift 100 mm 00394 in5 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 closing6 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 pump7 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 that8 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 gasInspection ket and reattach all fuel lines using a new sealing washer1 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 pump2 Tum the crankshaft until the indicator shows the valve drop to be at 264 inch This is 30 BIDe3 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 50 GLOW Reinstall the plugs in the engine and test them again The plugs should get very hot at the terminal end within 20 toThe glow plugs are wired through the preheat solenoid 25 seconds If the plugs dont heat up quickly check for aWhen 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 connections then unscrew or unclamp each plug from the cylinder A WARNING Do not keep a glow plug on for more than 30 secondshead Thoroughly clean each plugs tip and threads with asoft brush and cleaning solution to remove all the carbon andoil deposits While cleaning examine the tip for wear andbum erosion if it has eroded too much replace the plug TERMINAL ENDTESTINGAn accurate way to test glow plugs is with an ohmmeterTouch on prod to the glow plugs wire connection and theother to the body of the glow plug as shown in the illustration A good glow plug will have a 10 15 ohm resistanceThis method can be used with the plug in or out of the Tightening torqueengine You can also use an ammeter to test the power drain8 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 51 LUBRICATION SYSTEMGENERAL DESCRIPTION ReassemblyThe oil pump is the crescent type directly driven by the 1 After cleaning the surfaces where the oil pan and thecrankshaft The oil cooler is watercooled Oil jets are pro cylinder block meet apply PERMATEX sealant orvided to cool the pistons equivalent to the oil pan as shown in the illustration and then install the oil panOIL PAN NOTE Tighten the oil pan bolts within 30 minutes application of the sealant1 Mount the engine on a suitable engine stand2 Drain the engine oil3 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 theoil pan if necessary1 Cracks deformation damage at bolt locations2 Damaged drain plug threads SEALANT AREAS DRAIN PLUG Engines Generators 52 LUBRICATION SYSTEMOIL 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 stand2 After draining the engine oil remove the parts in the numbered sequence as shown in the illustration 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 Disassembly1 Disassemble the oil pump in the numbered sequence shown in the illustration INNER GEAR TO CRESCENT CLEARANCE 3 Measure the side clearance Side clearance limit 015 mm 0006 in e 3 OUTER GEAR OIL PUMP DISASSEMBLY SEQUENCE MEASURING THE SIDE CLEARANCE Engines Generators 53 LUBRICATION SYSTEM4 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 SEALANT BODY CLEARANCE Installation5 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 illustration end is aligned with the front end of the pump body 1 OIL FILTER OIL SEAL REPLACEMENT 2 OIL reassembly sequence is the reverse of the and should include the following1 Install the outer gear with the mark indicated by the punch holes facing toward the oil pump cover2 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 54 LUBRICATION OIL PRESSURE SWITCH OIL PRESSURE SENDERThe reassembly sequence is the reverse of the disassembly 1 The engine has a twoprong oil pressurewater ture switch The oil pressure switch is normally open itWhen installing the oil cooler align the oil cooler holes with closes when the oil pressure rises to 5 10 psithe projections on the oil filter body PROJECTIOtjS HOLES OIL PRESSURE SWITCH OIL 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 whenRemoval the engine starts up as the oil has not yet reached itsRemove each part in the following sequence normal pressure a good check othe alarm1 Remove the oil pan see the OIL PAN section When performing an engine overhaul replace the oil pressure switch and the oil pressure sender When2 Remove the oil jet valves installing the new parts apply a teflon sealant to the3 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 clogged2 Check and ensure that the spring inside the oil jet valve is not stuck or damaged SEALING WASHERS BANJO BOLT Installation IThe installation sequence is the reverse of theremoval sequence Engines Generators 55 LUBRICATION SYSTEMTESTING THE OIL PRESSURENOTE Insure that the oil meets the following standards CF or CG4 SAE 30 lOW30 l5W401 Remove the oil pressure sender and then install a mechanical oil pressure gauge in its place TESTING THE OIL PRESSURE2 Start the engine and let it thoroughly warm up3 Check for oil leaks at the filter and pump assembly4 Maintain the engine rpm at 3000 and note the gauge readingS 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 IhinZA gradual loss of oil pressure usually indicates a failure For additional information on low oil pressure readings see OIL PRESSURE DROP under Engines Generators 56 REMOTE OIL FILTER To install simply remove the engine oil filter and thread on WESTERBEKEs remote oil filter kit as shown AlwaysThis popular accessory is used to relocate the engines oil fil install this kit with the oil filter facing down as illustratedter from the engine to a more convenient location such as anengine 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 toinstructions on removing the oil filter imorrect installation of the Remote Oil Filter FASTEN SECURELY TO A BULKHEAD SCREWS ARE OWNERSUPPLIED 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 57 COOLANT PUMPREMOVAL REASSEMBLY1 Tum the crankshaft so that the No 1 cylinder is at IDC Reassemble the pump cover withitsnew gasket top dead center of compression2 Drain the engine coolant into a suitable container INSTALLATION3 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 58 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 rawThe pump as removed from the engine will have hose water pumpattachment nipples threaded into its inlet and outlet port a apply a small amount of petroleum jelly to the sealsThey may be left in place or removed if they interfere with inner race and to the impeller shaft at reassemblythe pump disassembly Note the port location and positioning b When positioning the cam in the housing use a smallif removed amount of Permatex 1 on the inner cam surface and1 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 PUMPLUBRICATE AT ASSEMBLY SEAL ASSEMBLY RETIUNIIG RINGSSHAFT Engines Generators 59 HEAT EXCHANGERThe heat exchanger should be inspected and serviced during REASSEMBLYan 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 them1 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 shopINSPECTION They will also service transmissions and engine oil coolers1 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 satis2 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 EXCHANGER END CAP Engines Generators 60 INTAKEEXHAUST S Clean the passage that connects to the coolant recovery tank tubing1 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 needed2 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 plug3 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 gas4 Remove the manifold pressure cap kets Do not use any gasket sealantS Remove the manifold drain plug 4 Loosely attach the exhaust manifold to the cylinder headINSPECTION S Gradually tighten making sure all parts are properly aligned do this in three steps Tighten to the specified1 Use a liquid cleaner to flush out the exhaust manifold and torque to clean the intake manifold then rinse both manifolds Intakeexhaust manifold tightening torque thoroughly with fresh water 22 27 mkg 16 20 fIlb2 Clean and inspect the dual air filters replace if necessary 6 Install the air intake and the dual air filters When3 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 bolt4 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 intakeexhaust manifold with WESTERBEKE heat resistant spray enamel PRESSURE CAP AIR FILTER ELEMENT PLATE PLUG EXHAUST ELBOW Engines Generators 61 Tachometer InaccurateThe used in propulsion engine instru 1 With a handheld tach on the front of the crankshaft pulment panels contains two separate electrical circuits with a ley retaining nut or with a strobetype tach read the frontcommon ground One circuit operates the hourmeter and the crankshaft pulley rpm Set the engine with a hand orother the tachometer The hourmeter circuit operates on 12 strobe tach at 15001800 rpmvolts alternator charging voltage supplied to the terminal 2 Adjust the tachometer with a sIllall Phillips type screwon the back of the instrument driver through the calibration acess hole in the rear of theThe tachometer circuit operates on AC voltage 68 volts fed tachometer Zero the tach and bring it to the rpm set byfrom one of the diodes in the alternator and supplied to the the strobe or hand tach Verify the rpm at idle and attachometer input terminal while the engine is running and high speed 25003000 rpm Adjust the tach as neededthe alternator producing battery charging voltage 130148volts DCUse the following procedures when a fault ineither of the two circuits in a Inoperative for the proper DC voltage between and terminals TERMINAL1 Voltage present meter is defective repair or replace riDA1 TERMINAL2 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 inputterminal and the terminal with the engine running1 Voltage present attempt adjusting the meter through the calibration access hole If no results repair or replace the meter2 AC voltage not present check for proper alternator DC output voltage3 Check for AC voltage at the tach terminal on the alterna tor to ground4 Check the electrical connections from the tachometer input terminal to the alternator Sticking EARLY MODEL TACHOMETER GROUND1 Check for proper AC voltage between the tachometer input terminal and the terminal2 Check for a good ground connection between the meter terminal and the alternator3 Check that the alternator is well grounded to the engine block at the alternator pivot bolt GROUND TERMINAL TACHOMETER INPUT AC VOLTAGE EARLY MODEL TACHOMETER Engines Generators 62 STARTER NoLoad TestThe 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 illustrated 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 specification disas ating the overrunning clutch through a lever and which semble the starter and repair it supplies load current to the motorThe starter is a new type small lightweight and is called ahighspeed starter The pinion shaft is separate from the motor shaft the pinion slides only on the pinion shaft A reduction gear is installed between the motorshaft and a pinion shaft The pinion sliding part is notexposed outside the starter so that the pinion may slidesmoothly without becoming fouled with dust and grease Themotor shaft is supported at both ends on ball bearings Thelever mechanism switch and overrunning clutch inner circuitare identical to conventional ones AND REPAIR A CAUTION Use thick wires as much as possible and tighten every terminal securely This is a solenoid shiftIf any abnormality is found by the following tests the starter type starter which makes a rotating sound louder thanshould be disassembled and repaired that of a directdrive type starter When detecting starter rotation at the pinion tip be careful not to comePinion Gap Inspection in contact with the pinion gear when it protrudes1 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 continuously and and between terminals S and the body and M and the body There should be no continuity found2 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 body3 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 increases 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 63 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 TESTHOLDING 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 I r Ill INSPECT FOR ADJUSTING WEAR CHIPPING SHIMS STARTER MOTOR NOTE lnspect clean and replace if necessary brush commuter solenoid armature etc See the following pagesPINION Engines Generators 64STARTER the solenoid for continuity between terminals S andM and between terminals S and body No continuity shouldbe found between S and M Continuity should be foundbetween 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 USED1 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 r ARMATUREH 3 Check for insulation between the positive brush holder2 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 inCOMMUTATOR 00 Engines Generators 65 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 againFIELD COIL TEST STARTER ADJUSTMENT AND REASSEMBLY SNAP RING A CAUTION Before insfalling thoroughly clean the l 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 inserted Engines Generators 66 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 0 COM 14 PURPLE 51 AMP DC ALTERNATOR GENERATOR CONNECTIONS 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 um 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 circuits STARTING BATTERY Engines Generators GROUND 67 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 gQ MUlTIMETER o COMTESTING THE ENGINE RUNNING ENGINE CO GROUND SERVICEF 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 undercharging have it repaired at a reli able service shopNOTE 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 fieat the XC terminal if the previous test showed only bat Megger You can damage the altemator diodestery voltage at the B output terminaLIf 12 volts is not present at the XC terminal trace thewiring 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 overhaul Engines Generators 68This page has been intentionally left blank Engines Generators 69 DC ELECTRICAL SYSTEM WIRING DIAGRAM 39144 10 110 R 114 Ilk r11 JCE MODELS NOTEAN ONOFF SWITCH NOTE 2 ISHOULD BE IN 1 JSTALLED BETWEEN 1THE BATTERY AND 1STARTER TO DIS CONNECTTHE BATTERY IN AN EMER 12 VDCGENCY AND WHEN lWliBlLEAVING THE BOATA SWITCH WITH ACONTINUOUS RATING OF 175 AMPS AT 12 VDCWILL SERVE THISFUNCTION THIS SWITCH SHOULD ALARM ADMIRALNOT BE USED TO C BUZZER PANELMAKE OR BREAKTHE CIRCUIT 1 1 CAPTAIN PANEL r T 0 T elle I elK 1 I DLK l t au I Engines Generators 70 DC ELECTRICAL SYSTEM WIRING SCHEMATIC 39144 12 YOC START SOL STAlTER r M riI IlIoeI FUEL OP LIFT UM IIIIEII U D i I HM I I IgLw I FUEL I I Eno I I I I I 2BO iiP mIQNL T I L I AT ADM I RAL TACHOMETER KEY S IMD PANEL SW c Cl ALARIt 0 4UGE PISrl nzII 11 CAPTAIN PANEL LAN TEST OW T 51 AMP ALTERNATOR Q9PRESTOlTE 72 AMP AIT STANDARD ALTERNATOR ON THE mBC IC ii n 82e n 1 114 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 71 uses a variety of marine transmissions madeby wellknown marine manufacturers such as HURTH ZFBORG WARNER PARAGON and others If you parts repair work or an overhaul we recommend contacting the transmission manufacturer directly forinformation on the locations of authorized service facilitiesThe 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 Transmissions 200 Theodore Rice Blvd New Bedford MA 02745 USA Tel 5089794881 Customer Service Tel 5089794826 Technical Service Engines Generators 72 SERVICE STANDARDS DESCRIPTION STANDARD VALUE PRESSURE 30 kgcm2 426Ibin2200 rpm 27kgcm2384 IbfinZ200 DIFFERENCE max 427 psi 30 kgcm2INJECTION ORDER 1342INJECTION TIMING OOTDCCYLINDER 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 inVALVE CLEARANCE Intake 020030 mm 0008Q012 in Exhaust 030040 mm 00120016 inVALVE TIMING Intake open BTDC 13 Intake closed ABDC 39 Exhaust open BBDC 600 Exhaust closed ATDC 8VALVE Stem 00 Intake 79707985 mm 03138Q3144 in Exhaust 79657980 mm 0313603142 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 inVALVE SPRING Free length 448 mm 1764 in Angle Limit 158 mm 0062 inCYLINDER 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 continued Engines Generators 73 SERVICE STANDARDS DESCRIPTION STANDARD VALUE LIMITPISTON 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 inPISTON PIN Type Full Floating 00 2502501 mm 0984209846 in Piston to pin clearance 0003 0006 mm 0000100002 in Pin to connecting rod clearance 0012003 mm 000050001 inPISTON 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 inCONNECTING ROD Bending or torsion 016 mm 0006 in per 100 mm 394 in Bushing inner diameter 25012503 mm 0984609854 in End play 011026 mm 0004300102 in 035 mm 0014 in Sideplay clearance 005 mm 0002 inCONNECTING ROD BEARING Standard Type Kelmet metal Oil clearance 003006 mm 0001200024 in 008 mm 00031 in Undersize 025 mm 0010 in 050 mm 0020 in 075 mm 0030 inCRANKSHAFT Deflection 005 mm 0002 in End play 004028 mm 0001600111 in 003 mm 00118 in Thrust bearing width Undersize 218223 mm 0085800878 in Standard 200205 mm 0078700807 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 continued Engines Generators 74 SERVICE STANDARDS DESCRIPTION STANDARD VALUE LIMITMAIN BEARING Standard type Kelmet metal Oil clearance 00310049 mm 0001200019 in 008 mm 00031 in Undersize 025 mm 0010 in 050 mm 0020 inCAMSHAFT 075 mm 0030 in Front bearing Lead bronze alloy Oil clearance 0025 0066 mm 0009800260 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 000079000591 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 inTAPPET 00 34963498 mm 13763 13771 in Hole 34993502 mm 1377613787 in Tappet to cylinder block clearance 002006 mm 0000800024 in 010 mm 00040 inTIMING BELT DEFLECTION 108129 mm 043051 in10 kg 22IbALTERNATOR DRIVE BELT DEFLECTION New 1112 mm 044047 in10 kg 22Ib Used 1214 mm 047055 in10 kg 22Ib Engines Generators 75 SERVICE STANDARDS LUBRICATION System Forcefed type Type Crescent inner gearOil 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 inOil 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 inOil bypass filter Type Fullflow type paper elementOil cooler Type Water cooled Oil pressure control valve opening pressure 45 kgcm2 64 IbMOil filter body Oil filter relief valve opening pressure 10 kgcm2 14 IbM Oil cooler relief valve opening pressure 20 kgcm2 28 Ibin2Oil alarm switch activation pressure 035070 kgcm2 510 Ibin2Total oil capacity 64 liters 676 US quarts 563 Imp quartsOil pan capacity 50 liters 528 US quarts 440 Imp quartsOil filter capacity 04 liters 042 US quarts 035 Imp quartsOil bypass filter capacity 04 liters 042 US quarts 035 Imp quartsEngine oil API Specification CF or CG4 SAE 30 10W30 15W40 Engines Generators 76 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 1093614I MOVE DECIMAL POINT FOR HIGHER VALUES eg 6000 METERS 656168 YAReSI 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 77 55A FOUR TORQUES kgm ftIbCylinder head NOTE The cylinder head bolts are not retorqued They are torqued 30 217 only at the original engine assembly and during an engine head cover 0710 57Connecting rod bearing cap 7075 5154Main bearing cap 8490 6165Flywheel 1819 130137Thrust plate 1926 1419Crankshaft pulley 2333 1724Camshaft cap 2027 1520Camshaft pulley 5666 4148Timing belt pulley 1617 116123Idler pulley 3247 2334Timing belt tensioner 3247 2334Timing belt covers 0710 57Seal plate 0812 69Back plate 1623 1217Rear oil seal housing 0710 57Oil pump assembly M10 bolt 3247 2334 M8 bolt 1623 1217Oil cooler assembly M10 bolt 3247 2334 M6 bolt 0710 57Oil filter Tighten firmly by handBlock oil jets 1218 913Oil strainer pickup 0710 57Oil pan 0710 57Oil drain hose 2733 2024Oil pressure sender 1218 913Oil pressure switch 1218 913Fuel injection pump 3247 2334Fuel injection pump pulley 6070 4352Fuel injectors 6070 4351Fuel injector HP line 1823 1317Glow plugs 1520 1115Coolant Pump 3247 2334Thermostat housing 1623 1217Coolant temperature sender 1218 913Coolant temperature switch 1218 913Alternator bracket 3853 manifold 2227 1620Engine mounts 3247 2334 Engines Generators 78 STANDARD HARDWARE TORQUESNOTE Unless stated otherwise for a specific assembly use the following torque values when tightening standard hardwareGrade 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 140220Grade 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 79 INDEXAdjusting Discs Fuel Injection Pump Removal 14 Removal 12 Inspection 20 Reassembly 35 Reassembly 27 Fuel Injection Pump Engine 42 Removal 13Alternator 3967 Inspection 25Back Plate 32 Reassembly 37Bellhousing 40 Fuel Injection Pump Timing Adjustment 50Camshaft Fuel Injectors Testing 47 Removal 14 GlowPlugs 3451 Inspection 20 Heat Exchanger 40 60 Reassembly 34 Idle Speed Adjustment 49Camshaft Pulley Idler Pulley Bracket 36 Removal 14 Injection Nozzles 34 Reassembly 36 Injection Pump Chamber Inserts 15 Removal 13Compression Test 46 Inspection 25Connecting Rods Reassembly 37 Removal 12 Injection Pump Timing Adjustment 50 Inspection 23 Inspection and Repair Engine 16 Reassembly 27 IntakeExhaust Manifold 3861Connecting Rod Bearings 24 Lubrication System 52Connecting Rod Bushings 23 Main Bearings 24Coolant Pump 35 58 Metric Conversions 77Crankshaft Mounts Engine 40 Removal 12 Oil Cooler 39 54 Inspection 23 Oil Dipstick Tube 35 Reassembly 28 Oil Filter 39Crankshaft Pulley 38 Oil Filter Remote Optional 57Cylinder Block 21 Oil Jets 55Cylinder Head Oil Pan 3152 Removal 14 Oil Pressure Sender 55 Inspection 16 Oil Pressure Switch 35 55 Reassembly 33 Oil Pressure Test 46 56Cylinder Head Bolts 14 Oil Pump 3153Cylinder Head Cover 40 Oil Strainer 31Cylinder Head Gasket 14 Parts Identification 5Damper Plate 40 Parts Ordering 2Disassembly Engine 11 Piston Rings 22Drive Belt Adjustment 42 Pistons 22 27Engine Adjustments 42 Product Software 2Engine Disassembly 11 Raw Water Pump 40 59Engine Mounts 40 Rear Cover Assembly 30Flywheel 32 Reassembly Engine 26Fuel Filter 40 Seal Plate 36Fuel Injection lines 35 Service Standards 73Fuel Injection Nozzles 34 Specifications 4 continued Engines Generators 80 INDEXStarter Motor 63Tachometer 62Tappets Removal 14 Inspection 20 Reassembly 27Testing for Overhaul 6Thermostat 36Timing Belt Removal 13 Inspection 24 Reassembly 37Timing Belt Adjustment 43Timing Belt Camshaft 25Timing Belt Covers 25Timing Belt Pulley Removal 14 Reassembly 32Timing Belt Tensioner Removal 13 Inspection 25 Reassembly 37Torques 55A FOUR 78Torques Standard Hardware 79Torsional Damper 38Transmission Removal ll Reassembly Engine 7Valves Removal 15 Inspection 18 Reassembly 26Valve Oearance Adjustment 42Valve Guides 19Valve Seals 15Valve Seats 17Valve Springs 20Wiring Diagram 70Wiring Schematic 71 Engines Generators 81 Engines 998

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