Page 1: ...SERVICE MANUAL 55A FOUR MARINE DIESEL ENGINE PUBLICATION 43377 1st Edition September 1998 WESTCRBEKE CORPORATION MYLES STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD TAUNTON MA 02780 7319 U S A...
Page 2: ...rless gas Carbon Monoxide ispoisonousand can cause unconsciousnessand death Symptoms ofCarbon Monoxide exposure can include Dizziness Nausea Headache Weakness andSleepiness Throbbing in Temples Muscul...
Page 3: ...carburetor fuel line filter fuel pump or other potential sources of spilled fuel or fuel vapors Use a suitable container to catch all fuel when removing the fuel line carburetor or fuel filters Do no...
Page 4: ...t with your skin wash it off at once with water Acid may splash on the skin or into the eyes inadvertently when removing electrolyte caps TOXIC EXHAUST GASES A WARNING CarbDn mDnDxide CO is a deadlyga...
Page 5: ...ings are repeated in your Operators Manual along with other cautions and notes to highlight critical information Read your manual carefully maintain your equipment and follow all safety procedures ENG...
Page 6: ...siphon break in the raw water supply hose to the exhaust elbow This hose must be looped a minimum of 18 above the vessel s waterline Failure to use a siphon break when the exhaust manifold injection...
Page 7: ...Lubrication System 52 Remote Oil Filter Optional 57 Coolant Pump 58 Raw Water Pump 59 Heat Exchanger 60 Intake Exhaust Manifold 61 Tachometer 62 Starter Motor 63 DC Electrical System Alternator 67 DC...
Page 8: ...NOTES CAUTIONS and WARNINGS An explanation follows NOTE An operatingprocedure essential to note A CAUTION Procedures which if notstrictly observed can result in the damage or destruction of your engin...
Page 9: ...INTRODUCTION 55A FOUR DIESEL ENGINE SPRING RETAINER INJECTION NOZZLE CYLINOER HEAD BOLT PRE CHAMBER LOWER SPRING SEAT t jJ I r r d COMBUSTION CHAMBER INSERT Engines Generators 3...
Page 10: ...Size min 90 elbow 45 elbow and exhaust riser 2 inch 1 0 hose 14 inch x 14 inch COOLING SYSTEM General Operating Temperature Coolant Pump Raw Water Pump Raw Water Flow at 3600 rpm Freshwater cooled blo...
Page 11: ...RTS IDENTIFICATION OIL PRESSURESENDER STARTERWITHSOLENOID LEFTSIDE UNIT I D PLATE AIR CLEANER HOUSING RIGHTSIDE A Engines Generators 5 ANODE BATTERYGROUND CONNECTION REAR MANIFOLD PRESSURE CAP OILCOOL...
Page 12: ...od of engine overhaul it is important to measure the engine compression pressure regu larly At the same time the engine speed at which the mea surement of compression pressure is made should be checke...
Page 13: ...te 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...
Page 14: ...FALLING 1 Defective stem seal 1 Replace stem seal 2 Worn valve and valve guide 2 Replace valve and valve guide OIL PRESSURE DROP 1 Oil leak 1 See OIL LEAKAGE 2 Insufficient oil 2 Add oil 3 Worn and or...
Page 15: ...kpin 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...
Page 16: ...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 After inj...
Page 17: ...ce refer to your transmission owner manual To rebuild a transmis sion contact your WESTERBEKE dealer or a qualified marine transmission service facility ENGINE DISASSEMBLY 1 Clean the exterior of the...
Page 18: ...ed see IDLE SPEED ADJUSTMENT under ENGINEADJUSTMENTS Fua INJECTION PUMP Remove the injection pump as follows NOTE Scribe mating I marks on the pump body flange and the timing belt cover before removal...
Page 19: ...iming belt tensioner 4 Tum the crankshaft clockwise about 45 from the timing mark which is marked on the oil pump housing NOTE Turning the crankshaft prevents the pistons and valves from contacting on...
Page 20: ...PULLEY 3 Remove the timing belt pulley Cylinder Head Bolts 1 Loosen the cylinder head bolts in the numbered sequence shown in the ilustration Loosen them a little at a time in sequence 1 3 5 4 2 CYLIN...
Page 21: ...uides under ENGINE INSPECTION 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 th...
Page 22: ...on exceeds the limit replace the cylinder head A CAUTION Do notattempt to repair the cylin der headbymilling orgrinding Handle the cylinder head carefully taking special care not to damage its lowersu...
Page 23: ...f the end play exceeds the limit replace the camshaft or the cylinder head Standard camshaft end play 0 02 0 15 mm 0 00079 0 00591 in limit 0 2 mm 0 0079 in MEASURING THE CAMSHAFT END PLAY 7 Measure t...
Page 24: ...en grinding the valve seat use a 15 45 or 60 valve seat cutter or valve seat grinder to grind away the roughness and or scars to the minimum limit ofthe seat surface always checking the contact width...
Page 25: ...rance limit 0 10 mm 0 004 in 2 To replace the valve guide tap it to the side opposite the combustion chamber using the valve guide remover 49 0636165A To install fit the clip onto the valve guide Use...
Page 26: ...iameter 34 96 34 98 mm 1 3763 1 3771 in Standard tappet hole 34 99 35 02 mm 1 3776 1 3787 in Standard clearance 0 02 0 06 mm 0 0008 0 0024 in Clearance limit 0 10 mm 0 0040 in 1 Inspect each valve spr...
Page 27: ...eler gauge and a straightedge as shown in the illustrations Distortion limit 0 10 mm 0 0040 in 3 If the distortion exceeds the limit replace the cylinder block A CAUTION Don tglind the surface of the...
Page 28: ...easure the piston outside diame ter in the thrust direction 19mm 0 75 in above the bottom ofthe piston If the piston is replaced replace the piston rings also Oversize Piston Rings 0 25 mm 0 010 in 0...
Page 29: ...0 05 mm 0 002 in PISTON PIN o 2 To replace the connecting rod bushing use a press and a suitable pipe diameter 27 27 5 mm 1 06 1 88 in A CAUTION Before assembling apply a coat ing of clean engine oil...
Page 30: ...gs and Connecting Rod Bearings 1 Check the main bearings and connecting rod bearings 2 Check the bearing inside surfaces for streaking flaking pin holes etc replace all bearings as a set if there is a...
Page 31: ...ecessary A CAUTION Do not clean the tensionel with cleaning solvents If it is dirty use a clean rag to wipe it clean Avoidscratching the surface the belt travels over TIMING BELT TENSIONER TIming Belt...
Page 32: ...quivalent Don t use tape sealants Tighten the bolts and nuts on the important parts of the engine to the specified torques using a reliable torque wrench Tighten fasteners in the specified torque sequ...
Page 33: ...g 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 TOP RING AND EXPANDER 90 A CAUTION...
Page 34: ...e sequence shown in the illustration Main bearing cap bolt tightening torque 8 4 9 0 kg m 61 65 ft lb MAIN BEARING CAPS d Remove the main bearing cap and measure the oil clearance Standard oil clearan...
Page 35: ...that it is within the standard range At this time check to be sure that the crankshaft can be lightly turned Standard crankshaft end play 0 04 0 28 mm 0 0016 0 0111 in End play limit 0 3 mm 0 0118 in...
Page 36: ...0102 in End play limit 0 35 mm 0 014 in A CAUTION Measure the connecting rod end play before installing the connecting rod cap CONNECTING ROD CAP c Install the connecting rod bearing cap and tighten...
Page 37: ...kg m 12 17 ft lb MI0 bigger bolts 3 2 4 7 kg m 23 34 ft lb OIL PUMP ASSEMBLY A CAUTION Do not let sealantget into the oilhole Apply engine oil to the oilseal lip Before applying the sealant use a rag...
Page 38: ...secured within 30minutes 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 t...
Page 39: ...threaded part and install Cylinder head bolt length Standard length 112 7 113 3 mm 4 437 4 460 in limit 114 5 mm 4 508 in A CAUTION If the length ofthe bon below the head exceeds the limit the boltmus...
Page 40: ...duallyand ev en y andin the sequence shown in the illustration The adjustment ofthe l illve clearance shouldbe made onlyafter the camsliait pulley injec ion pump pulleyand timing belthave been install...
Page 41: ...4 ft Ib FUEL INJECTION f R st PUMP FUEL INJECTION M1 PUMP BRACKET Fuel Injection Lines 1 Install the high pressure fuel injection lines from the injection pump to the injectors Fuel injection line tig...
Page 42: ...ing torque 1 6 2 3 kg m 12 17 ft lb 3 Install the temperature switch and sender and reconnect their wires 4 Check the thermostat for proper operation by placing it in a pan of cold water and then rais...
Page 43: ...lleys are aligned with the timing marks on the seal plate 7 N TIMING MARKS J TIMING MARKS 2 Install the timing belt tensioner locking bolt and spring 3 Push the timing belt tensioner to the left towar...
Page 44: ...ecification repeat theprocedure from Step 1 9 Install the left timing belt cover with its rubber seal 10 Install the right timing belt cover with its rubber seal TIming belt cover bolts tightening tor...
Page 45: ...the oil cooler free of oil and apply a thin coat of clean engine oil to the rubber gasket on the new oil filter 4 Screw the oil filter onto the threaded stub and tighten firmly by hand COOLANT RECOVER...
Page 46: ...nt tightening torque 3 2 4 7 kg m 23 34 ft Ib J Fuel Filter Mount the fuel filter assembly then connect the fuel supply line to the filter Bellhousing Heat Exchanger Damper Plate 1 Install the bellhou...
Page 47: ...also be inspected refer to HEATEXCHANGERS Fluids TYPICAL TRANSMISSION OIL COOLERS I Fill the engine cooling system with antifreeze mixture 2 Fill the engine oil sump with lube oil Lubrication system o...
Page 48: ...idle then shut down and recheck the belt tension A CAUTION Use onlygenuine WESTERBEKE drive belts poor quality belts will lead to premature wear andbelt elongation resulting in alternator damage 1 2 D...
Page 49: ...in 9 Measure anda just as needed the valves in cylinders 3 4 and 2 following the instructions above CAM INTAKE VALVE CLEARANCE ADJUSTlNGrt tJ DISC l r f TIMING BELT NOTE WESTERBEKE recommends replaci...
Page 50: ...over gaskets for damage and installation PREMATURE SEVERANCE 2 Check the teeth for damage cracks peeling and harden ing and check for any missing teeth MISSING TOOTH CRACKED TOOTH _Y f CRACKED TOOTH 3...
Page 51: ...HEAD SOCKET 6 Recheck the timing mark positions between the three pul leys and the seal plate Check the timing belt deflection with a pushing force of 10 kg 221b at the point on the belt shown in the...
Page 52: ...ylinder is flanked by healthy cylinders the problem is either valve or head gasket related Very low compression in an adjacent cylinder indi cates gasketfailure Abnormally high readings on all cylin d...
Page 53: ...on starting pressure 5 If the diesel fuel of the nozzle tester is stained replace the fuel At the same time clean or replace the fuel filter A CAUTION The spray injected from the nozzle is ofsuch velo...
Page 54: ...urrounding area of the nozzle orifice to avoidpossible damage to the orifice Iron dust on the magnetic filter top must be completely removed 2 After cleaning set the nozzle body in an upright position...
Page 55: ...ed if the engine speed is not within the specified value Normal Idle Speed 750 1000 rpm Adjusting the Idle Speed 1 Loosen the locknut on the idle adjustment bolt on the fuel injection pump 2 Tum the i...
Page 56: ...BIDe 3 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 feeler needle of the measuring...
Page 57: ...he glow plug s wire connection and the other to the body of the glow plug as shown in the illustra tion A good glow plug will have a 1 0 1 5 ohm resistance This method can be used with the plug in or...
Page 58: ...the following conditions and repair or replace the oil pan if necessary 1 Cracks deformation damage at bolt locations 2 Damaged drain plug threads DRAIN PLUG Reassembly 1 After cleaning the surfaces...
Page 59: ...OUTER GEAR OIL PUMP DISASSEMBLY SEQUENCE 2 Loosen the screws by an impact driver or similar tool so that the oil pump body is not damaged Inspection LOOSENING THE SCREWS 1 Check for the following con...
Page 60: ...ar with the mark indicated by the punch holes facing toward the oil pump cover 2 Apply a thin coating of grease to the O ring and position it at the location shown in the illustration 3 Apply a coat o...
Page 61: ...pressure rises to 5 10 psi OIL PRESSURE OIL PRESSURE SWITCH 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 dow...
Page 62: ...arm up 3 Check for oil leaks at the filter and pump assembly 4 Maintain the engine rpm at 3 000 and note the gauge reading S If the pressure does not come up to the specified pres sure check the lubri...
Page 63: ...IONAL 3 4 TURN AFTER THE O RING CONTACTS THE BASE To install simply remove the engine oil filter and thread on WESTERBEKE s remote oil filter kit as shown Always install this kit with the oil filter f...
Page 64: ...and alternator strap DISASSEMBLY Remove the pump cover and the gasket A CAUTION I o not disassemble the coolant pump body Replace it as an assembly if necessary INSPECTION Replace the cover gasket RE...
Page 65: ...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 arborpress to press the...
Page 66: ...ssembling install new gaskets and O rings Apply some lubricant to the new gaskets and to the pet cock and fittings as you install them 2 Install a new zinc anode NOTE All ofthe above service can be ac...
Page 67: ...tain the upper and lower seals are in good condition If in any doubt replace the cap PRESSURE CAP PLUG EXHAUST ELBOW AIR FILTER ___ ELEMENT S Clean the passage that connects to the coolant recovery ta...
Page 68: ...t attempt adjusting the meter through the calibration access hole If no results repair or replace the meter 2 AC voltage not present check for proper alternator DC output voltage 3 Check for AC voltag...
Page 69: ...return stroke called pinion gap 3 If the pinion gap is not within the standard range 0 5 to 2 0 mm adjust it by increasing or decreasing the number of shims on the solenoid The gap is decreased as the...
Page 70: ...enter bracket At the same time the washers for tpe pinion shaft end play adjustment will come off PINION STARTER MOTOR INSPECTFOR WEAR CHIPPING 4 Return test With a battery connected to the solenoid t...
Page 71: ...if the service limit is exceeded Also check the commutator outside surface for dirtiness and roughness If rough polish the commutator with fine crocus cloth Brush and Brush Holder Inspection 1 Check t...
Page 72: ...shaft end play adjustment Set the end play thrust gap to between 0 5 to 2 mm by inserting an adjusting washer between the center bracket and the reduction gear a Fit the pinion shaft reduction gear w...
Page 73: ...s clear ofmovingparis Keep away from sheaves andbelts during testprocedures NOTE Multimeters and DC Circuits DC andAC circuits are often mixed together in marine appli cations Always disconnect shore...
Page 74: ...minal trace the wiring look for breaks and poor connections Alternator is Working 5 Check the voltage of the service battery This battery should have a voltage between 13 and 14 voltswhen the engine i...
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Page 76: ...H A CONTINUOUS RATING OF 175 AMPS AT 12 VDC WILL SERVE THIS FUNCTION THIS SWITCH SHOULD NOT BE USED TO MAKE OR BREAK THE CIRCUIT NOTE 2 I 1 J 1 1 12 VDC lWliB l DC ELECTRICAL SYSTEM WIRING DIAGRAM 391...
Page 77: ...LAN TEST OW 1 1 I I I I I 2 BO iiP mIQNL T I L __________ I ADM I RAL PANEL CAPTAIN PANEL 51 AMP ALTERNATOR Q9PRESTOl TE 72 AMP STANDARD ALTERNATOR ON THE AIT mB C I C ii n 82e n 1 ___________________...
Page 78: ...on manufacturer directly for information on the locations of authorized service facilities The addresses of two of these manufacturers are given below HURTH Marine Gear ZF Industries 1018 Carolina Dri...
Page 79: ...4 508 in VALVE CLEARANCE Intake 0 20 0 30 mm 0 008 Q 012 in Exhaust 0 30 0 40 mm 0 012 0 016 in VALVE TIMING Intake open BTDC 13 Intake closed ABDC 39 Exhaust open BBDC 600 Exhaust closed ATDC 8 VALV...
Page 80: ...n CONNECTING ROD Bending or torsion 0 16 mm 0 006 in per 100 mm 3 94 in Bushing inner diameter 25 01 25 03 mm 0 9846 0 9854 in End play 0 11 0 26 mm 0 0043 0 0102 in 0 35 mm 0 014 in Sideplay clearanc...
Page 81: ...0 mm 1 783 in 44 90 mm 1 768 in End play 0 02 0 15 mm 0 00079 0 00591 in 0 2 mm 0 0079 in Journal elliptical 0 05 mm 0 002 in Journal diameters 31 96 31 98 mm 1 258 1 259 in 31 86 mm 1 254 in Deflecti...
Page 82: ...mm 0 008 in Oil bypass filter Type Full flow type paper element Oil cooler Type Water cooled Oil pressure control valve opening pressure 4 5 kg cm2 64 IbM Oil filter body Oil filter relief valve open...
Page 83: ...168 2 1 82880 7 6 40080 2 2 18723 7 7 65529 3 2 74320 8 7 31520 3 3 28084 8 8 74891 4 3 65760 9 8 22960 4 4 37445 9 9 84252 5 4 57200 10 9 14400 5 5 46807 10 10 93614 I MOVE DECIMAL POINT FOR HIGHER V...
Page 84: ...Rear oil seal housing 0 7 1 0 5 7 Oil pump assembly M10 bolt 3 2 4 7 23 34 M8 bolt 1 6 2 3 12 17 Oil cooler assembly M10 bolt 3 2 4 7 23 34 M6 bolt 0 7 1 0 5 7 Oil filter Tighten firmly by hand Block...
Page 85: ...3 159 1 14 0 22 0 Grade 6T Grade 5Cap Screw 6mm bolt head nut 1 4 3 6 5 0 6 0 9 1 4 UNC 9 11 1 2 1 5 Smm bolt head nut 1 25 10 S 15 9 1 5 2 2 1 4 UNF 11 13 1 5 1 S 10mm bolt head nut 1 25 21 7 32 5 3...
Page 86: ...jection Nozzles 34 Fuel Injection Pump Removal 12 Reassembly 35 Fuel Injection Pump Pulley Removal 13 Inspection 25 Reassembly 37 Fuel Injection Pump Timing Adjustment 50 Fuel Injectors Testing 47 Glo...
Page 87: ...ng Belt Pulley Removal 14 Reassembly 32 Timing Belt Tensioner Removal 13 Inspection 25 Reassembly 37 Torques 55A FOUR 78 Torques Standard Hardware 79 Torsional Damper 38 Transmission Removal ll Reasse...
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