FOREWORD This workshop manual contains repair instructions for the 2001, 2002 and 2003 engines. The instructions concerning overhauling describe the most suitable working method using the special tools listed under the heading "Special tools" . Both the engine designation and its serial number must be clearly stated in all correspondence concerning the engine and when ordering parts.
INDEX Components guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 DISASSEMBLY . . . . . . . . . . . . . . . . . . Disassembling the cylinder head Valve guides . . . . . . . . . . . . . . . . . . . Valve seats . . . . . . . . . . . . . . . . . . . . Valves . . . . . . . . . . . . . . . . . . . . . . . . . Valve springs . . . . . . . . . . . . . . . . . . Rocker arm mechanism . . . . . . . . Injector sleeve . . . . . . . . . . . . . . . . . Injectors . . . . . . . . . . . . . .
COMPONENTS GUIDE 8 1. 2. 3. 4. 5. 6. 7. 8. 9. 10 . 11 . 12 . 13. 14 . 15 . Exhaust elbow Injectors Temperature sender Electrical distribution box Fuel filter Alternator Starter motor Drainage, cooling water Feed-pump Engine serial number Decompression device Inlet air silencer Fuel injection pumps Oil dipstick Sea-water pump Halpert@Optonline.
DISASSEMBLY Drain off the cooling water and the lubricating oil from the on engine cradle p/n 9992520 and fixture p/n 884837 . If the engine is fresh water cooled, see page 21 . 3 . Remove the fuel filter, the oil filter, the feed-pump, the thermostat housing and the exhaust elbow . Also remove the sea-water pump with its attachment tubes . 1 . Remove the alternator, the tensioner bracket and the starter motor .
5 . Remove the fuel injection pumps . Mark the pumps to ensure installation in the same cylinders from which they were removed . Take care of the shims . Remove the screws on the side of the engine block and lift out the pump . lifters 7 . Remove the transmission cover : Start by removing the throttle control cover . Use a suitable type of pliers to the spring (1) . Then remove the end-nipple (2) and remov the spring (3) .
10 . Pull out the camshaft . 12 . Turn the engine upside down and remove the oil pan . Be careful as the pan is glued . NOTE! The oil pan ends also function as main bearings . 11 . Remove the outer flywheel housing, the flywheel and the inner flywheel housing . 13 . Remove the connecting rod bolts and remove the rods and the pistons . The connecting rod andconetig the connecting rod cap are marked with figures .
14 . Remove the main bearing caps . The main bearing caps are marked with a figure . The corresponding figure is into the block . Lift out the crankshaft . On later engine punched versions an arrow is cast in the separate main bearing caps (2002, 2003) . The arrow is to point towards the dipstick.
3 . Use mandrel p/n 5218 to press out the valve guides . Oil the new valve guides externally and use mandrel p/n 884559 to install them . Press down the mandrel all the way down to the cylinder head . Ream the valve guides if . necsary THE CYLINDER HEAD 1 . Remove the "collets" and valve springs using a valve bow . Remove the valves . Remove the valve stem seals . Place the valves in the proper sequence in a valve stand . Valve guides 2 .
Replacing the valve seat exhaust port 2003T Grind down the valve disc of a discarded valve to just below 27 mm (1 .063 in) diameter . Push the valve stem through the guide . NOTE! Do not push in too far- the valve disc should be just below the edge of the seat . Spot weld the disc in place at three points using a electric welder . Knockout the seat by the valve guide with a plastic-headed hammer . hitng Cool the new seat to approx .
Injector-sleeve 8 . Insert the expanding screw on the special tool p/n 884811 into the copper sleeve and turn the screw anti-clockwiseuntilshecrwshatucktinhe.slv Tighten the screw hard to allow the threads to work themselves into the copper material . Then install the yoke (1) on the stud bolt of the injector . Put a cylinder head screw in the cylinder head as a supportforthe leg of the yoke . Install the nut (2) and tighten it until the sleeve is removed . 9 .
Reduction valve 12 . Remove the cover of the reduction valve and check to make sure that the spring and the piston are faultless . If there are reasons to suspect a fault in the opening pressure of the reduction valve, then check the data of the spring . See under "Technical Data" - reduction valve . Feed-pump 13 . Depress the pump lever. if the diaphragm of the pump sounds squeaky, the diaphragm is faultless . Changing the diaphragm 14 .
16 . Clean the pump housing carefully and replace worn parts . Install the diaphragm and the lever on the shaft . Then insert the shaft and tighten it with diaphrgm the screw. Assemble the two housing halves and install the attachment plate (1) . Then install the spring (2) and the O-ring (3). 19 . Place a support under the camshaft gear and use a hydraulic press to remove the gear . Valve lifters 17. Check the valve lifters for wear . Replace them if neces sary . Camshaft 18 .
Pistons, cylinders 21 . Check the wear on pistons, piston rings and gudgeon pins . Replace these if necessary . Use a cylinder indicator gauge to measure the cylinder bores . The measurement of the biggest wear is made immediately beneath the edge of the upper dead center and crosswise the engine . The mea surement of the smallest wear is made at the lower dead center . As to the cylinder diameter, see "Technical Data" . Use a micrometer to measure the pistons . Piston diameter, see under "Technical Data" .
26 . Check the connecting rod bushings by using the pin as a gauge . There must be no play. If the bushings gudeon must be replaced, use a suitable mandrel for the removal and installation . Make sure to install the bushing with the oil hole coinciding with that of the connecting rod . Ream the new bushings . The fit is correct when an oiled gudgeon pin by its own weight can slowly slide through the . bushing Sea-water pump 27 . The pump is equipped with two ball-bearings (1) .
ASSEMBLY Always use new gaskets, sealing rings, sealing washers and lock-washers . Coat the sealings with grease or oil them and also oil all moving parts prior to installing them . If the engine is fresh-water cooled, see page 21 . 1 . Heat the crankshaft gearwheel to approx . 150°C (302 ° F) prior to the installation . Place the key in the key-way of the crankshaft and press on the gear wheel . Oil the new main bearing halves (with oil hole) and install them in the block . Put in the crankshaft.
5 . Replace the flywheel housing sealing (1). Smear sealing compound (p/n 840879) on the edge between the flywheel housing and the sealing . NOTE! The sealing lip with a spring shall be turned towards the engine . Make sure that the sealing is installed in accordance with the picture . 7A . Heat the camshaft gear wheel to a temperature of approx . 150°C (302°F) and use a suitable sleeve to install it . Check to make sure that the gear wheel "bottoms" on the camshaft .
8 . Insert the control rod through the black and into the timing gear casing . Install the bearing ball (1) into the control rod and push the control rod through the hole in the control lever (2) . Fit the spring (3) and screw on the end nipple (4) until it botms (Note! Do not use any tools) . Screw in the upper bolts (with copper sealing washers) that guide the control rod . Then, screw the lower bolts that hold the control rod in place in the engine block .
14 . Valve clearance cold/warm engine 0 .30 mm (.01181 in .) . Turn the engine in the direction of rotation until the valves in one cylinder are "rocking" . Then turn the engine the valves for this cylinder . one turn more and the procedure adjust for the remaining cylinders . Repat 2003 12 . Tighten the two guide screws p/n 884840 in the block and install the cylinder head gasket with the marking "Top" facing upwards . Install the cylinder head .
On later version engines an O-ring has been introduced as a seal between the injection pump and the block . Only so-called hard shims may be used on these engines when shimming . Hard shims are available in thicknesses of 0 .2 mm (0 .0079 in), 0 .3 mm (0 .0118 in), 0 .6 mm (0 .0024 in) and 0.9 mm (0 .0354 in) . 16. New block or camshaft setting-disc If the block or the camshaft are replaced the block must be measured and marked, using the setting-disc p/n 884787 and a sliding caliper . A .
C . Turn cylinder no . 1 to it's injection. position . Place the guide pin (2) in the setting-disc's hole marked cyl . 1 . Turn the crankshaft a little against the normal direction of and thereafter in the normal rotation direction untilrotain the setting-disc's guide pin (2) goes in the timing cover's hole . Measure using a caliper the distance between the cylinder block and the roller lifter's edge (do not measure on the roller) . The distance should be : 2001 : 55 .8 mm (2.
21 . Fit the valve cover using a new gasket . Make sure that the round hole for the crankcase ventilation is in the right position . Fit the decompression device lever . Fit the pipes between the injectors and the injection pumps presu . Also refit the inlet air silencer . 19 . Install the sea-water pump and the cooling water . pies 20 . Install the injectors and the return fuel pipe . Tightening torque for the injectors 20 Nm (2,0 kpm) (14.7 ft .lbs .) .
2003T Turbo-Compressor Where there is an excessive amount of smoke in the exhaustftorumesheiosuntgp ilptoawrcuy ma be that the turbo-compressor is not functioning properly . If the boat's speed through the water is gradually decrasing, the boat's bottom should also be inspected, and cleaned where necessary . Check that the air intake has not become clogged, and clean the intake silender .
RECONDITIONING Make line-up marks between the turbine housing, the bearing housing and the compressor housing . Dismantle the compressor housing (1) . Unscrew the left-hand threaded nut which holds the compressor wheel, using dollies on the turbine shaft . Remove the compressor wheel (2) and dismantle the turbine housing (3) . Dismantle the turbine shaft (4) and the heat shield . If the turbine shaft sticks, tap the end gently with a wooden .
Compressor Housing, Turbine Housing Check that the housings are free from cracks or other caused by excessive wear and tear . Damaged damge parts should be replaced . Heat Shield Check that the heat shield is free from damage caused by wear and tear, heat or corrosion, and replace it if necsary . Unfasten the four screws which hold the compression bearing (8) . Using a small copper mandrel, tap out the compression bearing and the bushing (9) .
Reassembly Grease all removable parts when reassembling them . the circlips in the bearing housing so that the Positn in them are facing towards the oil outlet . openigs Mount the packing ring shaft . Turn the openig in the ring so that iton isthe facing turbine towards the oil intake . Position the heat shield on the bearing casing, and then place the turbine axle in the bearing housing . Mount the bushing on the turbine shaft .
FRESHWATER COOLING 2002, 2003 1. 2. 3. 4. 5. 6. 7. 8. 9. 10 . 11 . 12 . 13 . Fit the circulation pump (complete with tensioner bracket and spacer sleeve, position 4). Tighten the bolts (M8x75) to 20 Nm (2,0 kpm) (14.7 ft .lbs), position 1 . Suspend the heat exchanger loosely by the rear bolt (M8x16 and spring washer .), position 5 .
Wiring diagram, alternative A (Standard) INSTRUMENTPANEL 1. 2. 3. 4. 5. 6. Printed circuit card Rev counter (accessory) Start button Switch for instrument panel Alarm test button Alarm Max output from the panel = 5 A Cable colour R PU BN OR GR SB W Y GN BL = -= = = = = = = = Red Purple Brown Orange Grey Black White Yellow Green Blue Z ENGINE 1. 2. 3. 4. Relay Fuse Temp .
Wiring diagram, alternative B (De Luxe) INSTRUMENT PANEL 1. Voltmeter 2. Oil pressure gauge 3. Coolant temperature gauge 4. Printed circuit card 5. Alarm test Switch for instrument lighting 6. 7. Rev. counter 8. Key switch 9. Alarm Max output from the panel : 5 A Cable colour GR SB BN LBN R P GN Y W BL LBL = = = = = = = = = = = Grey Black Brown Light brown Red Purple Green Yellow White Blue Light blue ENGINE 1. 2. 3. 4. 5. 6.
FAULT TRACING Engine does not start Engine stops Engine not reaching correct temp at full rpm Engine runs roughly or vibrates abnormly Engine becomes abnormal y hot Fault Stop control not fully pushed back . Main switch: not switched on . Flat battery . Broken electric wires . Main fuse blown . " " Empty fuel tank, closed fuel cock or clogged fuel filter. " " Water or impurities in the fuel . Faulty injectors or air in the fuel system .
1 9992265-0 Pulley puller 884813-7 Installation ring for piston 9995218-6 Mandrel for valve guide removal 884557-0 Mandrel for installation of injector sleeve 884559-6 Mandrel for installation of valve guide 884787-3 Setting-disc for injection pump setting 884811-1 Puller for injector sleeve 884823-6 Flaring tool for injector sleeve 884837-6 Flange for engine cradle 884838-4 Mandrel for installation of sealing ring in transmission cover 884839-2 884840-0 Assembly and disassembly tool
TECHNICAL DATA General Type designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . .. . 2001 Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . Cylinder bore Stroke . . . . . . . Compression Compression .. . . . .. . . . ratio ratio . . . . . . at .. .. .. . . . .. .. . . . .. .. . starter . . . . . .. . . . .. . . .. . .. . . . .. . . . . . ..
Main bearing journals Diameter, standard 0,250 m m under-size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,500 mm under-size- . . . . . . . . . . . . . . . . 59,987-60,000 (2,36169-2,36220 in .) 59,737-59,750 (2,35185-2,35236 in .) 59,487-59,500 (2,34200-2,34252 in .) Main bearing shells Thickness, standard - - . .. .. . .. . . . . . . .. .. . . .. .. . . .. 0,250 mm over-size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,500 mm over-size - - . - . . . . . . . .
Lubricating system ENGINE Oil quantity model 2001 . . . . . . Oil quantity model 2002 . . . . . . . . . Oil quantity model 2003 . . . . . . . . . . . . . . . . Oil quality according to the API-system .. . . . Viscosity . . . . . . . . . . . . . . .. .. .. . . Oil pressure, warm engine, idling speed . Oil pressure, warm engine, full rpm . . . . . . .. . . . . . ... .. . . .. ... . . . .. . .. . . .. ... . . . .. . .. . . Lubricating oil pump Type . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft Bearing journals, permitted out-of-round . . . . . . . . . . . . . . . Max . clearance between camshaft and bushings . . . . . . . . 0,03 mm (0,00118 in .) 0,15 mm (0,00590 in .) Valves Max . clearance between valve stem and valve guide . . . . The valve disc edge must be at least 0,15 mm (0,00590 in .) 1,5 mm (0,05906 in .) Tightening torques Main bearing bolts, 1st tightening . . 2nd tightening . . Big-end bearing bolts . . . . . . . . . . . . . Flywheel housing bolts . . . . . . . . . . . .
