Service manual
ENGINE
ASSEMBLY
Install the
raw
water
pump
and
drive
belt. Insure
it
is
in
proper alignment with the crankshaft pulley. Check tension.
Refer
to
RAW
WATER
PUMP.
Install the oil
and
water
sender
and
switch.
Install the
starter
motor.
Install the
breaker
panel
and
the
preheat
solenoid.
Reinstall the engine electrical harness.
Mount
the complete exhaust manifold
and
the expansion
tank
to
the cylinder head.
Manifold
Mounting
Bolts
Torque
Values
20
-
24
H-lb
(2.
7 -
3.3
m-kg)
See EXHAUST MANIFOLD/HEAT EXCHANGER for ser-
vice and inspection.
Install new hose connections
and
clamps
for
the cooling
system.
A
CAUTION:
Check
all
AC
and
DC
wiring
connections
to
WESTERBEKE's
wiring
schematics
and
diagrams.
ENGINE
TUNING
OPERATION
After re-assembly, the unit must be test run. This
will
ensure
that the engine/generator operates to its specifications. Fill
the engine cooling system with
an
antifreeze mixture
and
the engine oil sump with lube oil API specifications of CI-4
CG-4, CH-4
or C-14 SAE 15-40.
1.
Mount
the engine
on
a test bench
and
cm;mect the fuel
lines.
2.
Connect the electrical wiring. Refer
to
the
WIRING DIAGRAM.
3.
Connect the
air
intake line to the
air
cleaner.
4.
Connect the exhaust pipe.
5.
Crank
the engine with the
starter
(non-ignition
operation)
for
about
twenty seconds. This will
pre-lubricate the engines internal components and
fill
the fuel lines.
6.
Start
the engine
and
allow it to
run
at
1000 to 1200
rpm
for five minutes.
7.
Remove the cylinder head cover while the engine is
running.
8.
Check
that
the engine oil continuously circulating
from the oil
pump
to the valve rockers through the
cylinder head.
If
there
is
no oil circulation or if the oil circulation is
sluggish, stop the engine and make the appropriate repairs
or adjustment.
Re-install the cylinder head cover.
22
9.
Mount
the engine on a test bench
and
connect the fuel
lines.
10.Check the engine for oil, fuel, coolant
and
air
intake
leakage.
11.Check for
abnormal
noise
and
odor.
12.Check for
abnormal
electrical charging.
13.Check the engine fastening
parts
for looseness.
14.When the engine coolant
temperature
reaches
75°C (167°F)
or
more, increase the engine speed to
2000
rpm
and
allow
it
to
run
for twenty seconds.
This will give the engine the essential run-in operating
time.
15.Adjust the engine operation speed to the specific
value.
16.Stop the engine to complete the tuning procedure.
Refer to the following pages
for
details
of
sub-assemblies.
These sections also include: Wiring Diagrams, Engine
Specifications, Torque Diagrams, Starter Motor, Alternator
and
Raw Water Pump.
Be
aware
of
these common problems that can occur during
assembly.
Insufficient Lubrication. Heavily oil sliding and
reciprocating parts, lightly oil head bolts and other fasteners,
except those that penetrate into the water jacket. These
fasteners should be sealed with Permatex
No.
2 or the
high-tech equivalent.
Reversed orientation. Most gaskets, many bolt washers,
and
all thermostats are asymmetrical.
Mechanical damage. Run fasteners down
in
approved
torque sequences and in three steps-1/2, 2/3, and
1/1
torque.
Exceptions are torque-to-yield bolts and rocker arm shaft
fasteners. The former are torqued
as
indicated. The
latter-rocker shaft fasteners should be brought down in very
small increments, working from the center bolts out. Gaskets,
especially head gaskets, might also be damaged during
assembly, they should be positioned with great care.