Workshop Manual BMW D7 BMW Marine This copy of the BMW D7 Workshop Manual has been re-created using images computer scanned from a manual rather than original artwork.
BMW D7 Marine Engine A four-stroke diesel engine with direct injection and open-circuit cooling system. The Neoprene impeller of the coolant pump is driven directly from the crankshaft. Electric starter and flywheel alternator are standard equipment. The injection system is fitted with automatic bleeding. Notes on Use This workshop manual describes complete procedures for dismantling, overhaul and assembly of the BMW D7 marine engine. If only part of the procedure is to be carried out (e.g.
Contents Page Introduction i Summary 1 Removing cylinder head - Preparations - Valve mechanism - Valves - Cylinder head - Cylinder 3 3 4 5 7 7 Removing gearbox - Starter - Reversing gear - Bearing cover - Hand crank mechanism - Connecting rod - Piston - Fuel pump - Timing gear cover - Fuel regulator - Crankshaft - Valve lifters - Camshaft 8 8 8 9 10 11 13 14 14 15 16 19 20 Assemble crankshaft - Camshaft - Crankshaft - Fuel regulator - Timing gear cover - Fuel pump - Piston - Connecting rod - Hand c
Technical data Capacity Bore x stroke Max. power Compression ratio Dry weight with gearbox Gearbox reduction Max. installation angle 280cc / 17.1 cu.in. 73 mm x 67 mm / 2.87 in x 2.64 in 4.5 kw / 6 bhp @ 3600 rpm 22 : 1 68 kg / 150 lbs forward 2.7:1, reverse 1.
List of Special Tools D7 BMW Part No.
Summary BMW Marine Diesel Engine D7 Description: Water cooled single cylinder four stroke producing 4.5 kW (DIN) (6 Hp) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Cylinder head cover Decompression lever Throttle cable mount Hand crank attachment Cover Sea water pump Fitting Hose clips Sea water hose Engine mounts Cylinder head Metering device 13. 14. 15. 16. 17. 18. 19. 20.
Summary 21. 22. 23. 24. 25. 26. 27. 28. Exhaust Starter Retainer yoke Gear box Crankcase Fuel pump Fitting Sea water pipe CAUTION To avoid damage to engine parts, always use special tools as shown in the illustrations. The tools to be used fit only in the position shown.
Cylinder Head Removing cylinder head and cylinder CAUTION - Remove air filter (1) Loosen sea water pipe from exhaust manifold and water pump and remove (2) + (3) - Disconnect fuel return hose from injector and remove (4) Disconnect fuel injection pipe from injector and injection pump and remove (5) Remove clip of crankcase vent hose (6), unscrew both nuts of the rocker cover and remove the rocker cover with gasket (7) - Detach Disassemble Remove Cover all openings in the fuel system Air filter, sea
Cylinder Head - Remove rocker shaft with bushing and retainer yoke and remove rockers (8) and (9) Pull out both pushrods Cylinder Head Repair Data Dimension D7 nominal values Max. allowable wear (mm) 0.05 Rocker arms shaft dia. mm 18 -0.027 Rocker arm internal dia. mm 18 Rockaer arm radius mm 8 Valve seat angle Detach Disassemble Remove o +0.024 +0.006 0.
Cylinder Head, Timing Gear - Remove decompression lever from the underside of the cylinder head (10) Unscrew the M10 nut and unscrew stud bolt. Remove the spring Remove retaining pin with pointed pliers Unscrew inner clamping sleeve on gear segment and remove shaft and gear segment. Remove valves & valve springs (11) Press down the spring retainers WARNING Danger of injury due to spring retainers and valve keys popping out.
Cylinder Head The valves should sit back as measured from the seating surface of the cylinder head, according to the following table: Cylinder Head Dimension Repair Data Valves D7 nominal Max. allowable values wear (mm) Valve clearance cold mm 0.15 Intake valve stem dia mm 7 -0.04 -0.05 0.05 Exhaust valve stem dia mm 7 -0.05 -0.04 0.05 Intake valve disc dia mm 30.5 Exhaust valve disc dia mm 30.5 Valve sit back max mm 0.70 Valve sit back min mm 0.45 Valve guide bore mm 7 +0.
Cylinder Head / Cylinder Remove cylinder head and pull off cylinder (12) The cylinder head is unusable in the following cases: Sealing surface fouled or damaged i.e. uneven Clean the sealing surface and re-grind, observing the tolerances Valve seats worn out or no longer suitable for re-facing.
Bearing cover Remove starter (13) - Remove attaching clamp of the cable to the stator and remove starter Remove the four cyclinder screws M 10 and remove the flywheel (15) and (16) Remove gearbox (14) complete with flywheel cover.
Bearing cover NOTE - After loosening the four M6 hex screws, remove the bearing cover with locking plate and the sealing ring located on the inner face (17) Bearing cover can be replaced when the engine is cold Remove bearing cover Detach 9
Cover to timing gear cover / timing gear cover / hand cranking device - Remove screws from cover of timing gear cover and take off the cover (18) - Remove hand crank mechanism (19) with extractor tool No 666 332 00 Detach Cover of timing gear cover, hand crank device, dipstick, cover on engine bottom, Remove connecting rod 10
Dipstick / cover on engine bottom / connecting rod - Turn the engine on to the flywheel side (23) and remove dipstick (24) - Remove cover and O-ring from crankcase on the engine bottom (25). - Unscrew the two connecting rod screws (26). Take out connecting rod cap with oil pick-up (27) from below and piston and connecting rod (28) from top.
Table: Repair data for connecting rod and connecting rod bearing Repair Data for con-rod bearing and con-rod Con-rod bearing Dimension D7 nominal values Max. allowable wear (mm) Remarks Minimum bearing play = 0.040-0.076mm when new Outer dia mm 46 Inner dia mm 42 Width mm 26.5 Undersize mm 41.5 Con-rod bearing wall thickness normal(W) mm 1.998 Con-rod bearing wall thickness oversize(WU) mm 2.248 +0.02 Gudgeon pin bushing bore dia mm 28 +0.
Piston Note Heat piston to remove piston pin - Remove the gudgeon pin snap rings and press out the gudgeon pin by hand while the parts are still warm (29). In the following cases, the piston is unusable: ring land between the rings broken piston scuffed ring groove worn out and cracked Piston rings are unusable when the gap is too big Repair Data Piston Dimension D7 nominal values Piston dia mm 72.96 Oversize mm +1.
Fuel pump / timing gear cover - Remove fuel pump (29a) - Remove pump plunger (29b) - Unscrew the three M16 hex nuts and remove timing gear cover (29c) Detach Fuel pump, pump plunger, timing gear cover Remove 14
Fuel regulator, gear on crankshaft - Bring engine into the horizontal position, as shown in Fig (29d) Remove gear from crankshaft using extractor tool (29k) Loosen M6 hex nut (29f) on the regulator lever and pull out locking pin with pointed pliers Unscrew both M10 hex nuts (29e) from regulator shaft. Remove regulator shaft together with round nut, spring washer, sealing ring and friction disc. Unscrew M8 hex nut. Withdraw eccentric bolt with cap plate and sealing ring Loosen M20 hex nut.
Ball sleeve / Crankshaft - Remove ball sleeve with sliding disc taking care that no balls fall out (30) Ball hub and spacer washer (31) remain on crankshaft. Detach these parts only when removing the crankshaft. - Turn the engine block into the horizontal position.
Crankshaft The outer race of the straight roller bearing on the timing gear side remains in the crankcase and can be removed with the aid of a press In order to remove the bearing rings which have been shrunk on to the crankshaft (35) heat the crankshaft on a heating plate or with a sufficiently o large gas burner rapidly to about 70 to 80 C After removal of the M8 cylinder head screws, remove the counterweights (36).
Table: Repair data for crankshaft Repair Data for Crankshaft Crankshaft Crank pin dia Dimension mm End float D7 nominal values 42.0 -0.060 -0.070 Max. allowable wear (mm) Remarks Total play 0.15 max Max allowable crank pin out-of-round 0.05mm Grinding finish see page 17 Hardness at least 48 RC 0.3 +0.068 0 Crankshaft crank pin width mm 33.0 Radii on crank pin mm 3.0 Hardness of crank pin RC 50-55 Depth of hardening of crank pin mm 1.1-1.5 Diameter of ball hub (regulator) mm 29.
Valve lifters and camshaft - Remove the plastic plug from the side of the engine block (37) Unscrew the M8 set screw (38) with a 4 mm Allen key and remove together with plug CAUTION When removing the camshaft, lift off both rockers from the camshaft to prevent damage by the cam lobes - Pull out valve rocker shaft with the aid of extractor tool No 74 64 1 333 514 (39) - Remove valve rockers together with washer (39b, 39c) Replace valve rockers if worn.
Crankshaft Camshaft Reassembly of the engine parts is carried out in the reverse order. Installing the crankshaft NOTE The tooth gear on the camshaft is marked with the letter “L”. This indicates the direction of rotation of the engine as viewed from the front. - - CAUTION Drive in the rear camshaft bearing using the assembly punch No 74 64 1 333 516. Install the camshaft. Screw in the set screw and replace the plastic plug.
Fuel Regulator / Gear on the Crankshaft Timing gear cover / Fuel pump - Set the engine block into the horizontal position Insert regulator lever and regulator spring Insert clamping sleeve into the regulating spring with pointed pliers Install start filling sealing ring and tighten M20 hex nut Install eccentric bolt with cap, plate and sealing ring. Insert regulator shaft and tighten both M10 hex nuts. Insert stop pin into the regulator lever and tighten hex nut.
Flywheel / Stator / Reversing Gear / Starter / Cylinder head - Fasten the stator in the crankcase and screw on the attaching clamp Install the flywheel. Tightening torque of the flywheel screws is 7.0 kpm Attach the reversing gear Attach the starter - Adjust the gap with a corresponding cylinder foot gasket The gasket set contains gaskets of various thicknesses. NOTE When installing the cylinder head pay close attention to the following points.
Cylinder head / Injection pipe / Leak-off-line / Water pump / Water hose / Air filter - Press in valve guides from underneath Insert valves Insert valve springs with cap and washer Insert spring plate Insert both valve keys, while applying counter pressure to the valve Insert shaft with gear segment and screw in internal clamping sleeve. Slide handle with ring onto the shaft and screw in external clamping sleeve.
Timing gear adjustment Adjust valve clearance and timing The following must be carried out: - NOTE Carry out the testing and adjusting when the engine is cold.
Decompression lever adjustment If the engine is not decompressed in Position “1” of the decompression lever, adjust the decompression screw as follows: Crank the engine to the same position as in the valve adjustment Turn the decompression lever to Position “1” After loosening the hex nut, turn the adjusting screw to the right until the rocker arm touches the valve shaft From this position, turn the adjusting nut another quarter (¼) revolution to the right and secure by tightening the nut.
Timing gear adjustment Correction is required in the following cases: If the collar pan constantly engages the cog lightly, in the case of running the engine and zero position of the decompression lever (Shaft moves back and forth) In this case, shorten the tappet somewhat and dimension “A” will become larger (see figure) - The decompression shaft is not rotated further properly from position “2” of the handle In this case, lengthen the tappet somewhat and dimension “A” will become smaller (see figure) Co
Injector Injector check Check injection valve for: - CAUTION Function Injection pressure (ref figure with pintle type nozzle) Be sure to observe a maximum of cleanliness when working on the fuel system - Remove injection pipe and leak-off-line Loosen M6 hex nut and remove injector from the cylinder head together with holding bracket NOTE During removal and installation of the injector, pay attention to the sealing washer in the cylinder head Position of the sealing disc: the side with a recess towards
Injection pump - Adjust the injection pressure by inserting or removing shims at the injector spring NOTE A shim with a thickness of 0.1 mm changes the pressure by approx. 15 bar - Injector overhaul Extreme cleanliness is necessary during work on injector. - Unscrew the screw cap and remove the injector nozzle Unscrew sleeve nut F (22 mm) and withdraw injector jet G Clean jet with correct apparatus, not with sharp tool, wire brush or similar. All traces of carbon should be removed.
Injection pump Preliminary tasks before removing the injection pump: The injection pump has two hose connectors and a pipe connection. The lower connection is for the fuel supply, the upper connection is designed for the fuel return hose. The start maximum fuel eccenter must be turned in such a manner that the eccentric arm points vertically upward before installing the injection pump.
Injection pump NOTE Slide the pump in to about the last 4 mm without overcoming any resistance. Only then may resistance occur due to the tension of the tappet spring Preliminary work: - - This tension can be overcome by a small pressure and the pump pushed in completely by hand. Clamp off the fuel supply line Unscrew injection pump pressure valve holder.
Injection pump Adjustment of the delivery end: - - Crank the engine in the direction of rotation until the fuel stops to flow from the adjustment device Slowly crank further, until the fuel just begins to flow again After the adjustment is completed remove the dial indicator and install the completely assembled delivery valve with injection pipe in the correct sequence. NOTE NOTE The number of degrees indicated on the flywheel must correspond with the nominal o values (11.5 – 12.5 BTDC).
Injection pump / Injector - NOTE WARNING Carry out the check with the throttle in the fully open position and with the starting filling not pulled.
Air filter Cleaning the air filter - Loosen clips. Remove filter element. Remove sealing ring from cover and clean groove Install new sealing ring and filter element.
Wiring diagram 34
Generator and generating equipment Preparation Remove starter motor Detach gearbox/clutch cover assembly Remove clutch Remove flywheel Rotor Removal Extract spring clip A from flywheel magnet by inserting snip-nosed pliers into cut-outs provided - Generating Equipment Removal Disconnect leads from temperature sensor and remove stator cable plug C from socket on equipment carrier Remove bolts D (13 & 19 mm), noting position of spacers, washers and injector pipe clip (if fitted) and remove carrier and equi
Generator and generating equipment - Flatten lockwasher/cable clip F (renew on assembly), securing stator cable to bearing housing (SW 13) Remove bolts G (7 mm) and lift off stator - Lay stator harness close to bearing housing, to avoid contact with flywheel Bend tags of stator cable end slightly to ensure firm fit before fitting to plug. Note fitted positions of cables.
Generator and generating equipment Checking Procedure 1 – Impulse Transmitter - Thin red lead of impulse transmitter earths control lamp when engine is stationery. When charge from control unit passes through transmitter, this earth is interrupted. - When no or insufficient charge are shown, control unit and/or generator are defective For further fault location, voltage between each of the 2 black leads, red lead and generator should be checked.
Generator and generating equipment - If reading is not adequate, whereby reading of leads 1 and 2 are different, there are 2 possibilities: - when both leads lie below the correct reading, rotor magnetism is inadequate and rotor should be replaced - when only one lead shows a low reading, a fault in the stator windings is indicated and the stator should be renewed.
Starter Motor Starter Motor Removal - Disconnect cables A from solenoid (connector 19mm) and remove insulation B Remove fixing nuts C (19mm) and detach earth strap D from upper stud Lift off starter motor When faulty renew.
Water pump Service Instructions A. Disassembly B. Assembly - Remove cover screws, cover and gasket Press out impeller with 2 screwdrivers After removing the cam, remove residual traces of sealing compound from cam and pump housing Remove lip seal and O-ring Remove bearing assembly circlip Remove the shaft with ball bearing by pressing in the impeller side of the shaft Press off the ball bearings from the shaft.
Water pump Waterpump 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Sea water pump Cheese head screw M4 x 8 Cover Seal Impeller Cheese head screw Washer Cam Straight pin Sealing plate Sealing ring 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
