Installation manual
ENGINE
ADJUSTMENTS
VALVE
CLEARANCE
ADJUSTMENT
NOTE:
Retorque
the
cylinder head bolts
before
adjusting
the
engine's
valves.
See
TORQUING THE CYLINDER HEAD
BOLTS.
A
WARNING:
Adjust
the
valve
clearance
when
the
engine
Is
cold.
Valves
are
adjusted
by
cylinder
In
the
tir-
ing
Drder
Df
the
engine.
Tighten
the
cylinder
head
bolts
to
the
specified
torque
betore
adjusting
the
valves.
Pull
off the
air
breather pipe from the rocker cover and take
off the rocker cover bolts and the rocker cover
to
expose the
rocker shaft and valve assembly.
Remove the
glow
plugs from each of the cylinders
to
enable
the crankshaft
to
be easily rotated by hand
to
position each
cylinder for valve adjustment.
Valves·are adjusted with the cylinder in the piston being
adjusted at
Top
Dead Center (TDC)
of
its
compression
stroke. Each cylinder
is
adjusted following the engine's firing
order (1-3-2
for
WESTERBEKE three cylinder engines).
Valve adjustment beginning with cylinder #1. Rotate the
crankshaft slowly and observe the operation of the valves for
cylinder
#1.
Watch
for the intake valve
to
open indicating the
piston is
on
it's intake stroke (the piston
is
moving down in
the cylinder). Continue to rotate the crankshaft slowly and
look for the intake valve
to
close. This indicates the piston is
now
starting it's compression stroke (the piston is moving
up
in
the cylinder towards IDC).
Align the
IDC
mark on the crankshaft front pulley with the
timing marker
on
the front gear case cover when positioning
the
#1
Piston at
IDC
of it's compression stroke. Confirm this
by
rotating the crankshaft approximately 20 degrees before
and after this point and the two valves for the
#1
cylinder
should not
move.
VALVE
CLEARANCE
~
.
~
0.25
mm
(0.010
in)
~
I
COLD
ENGINE
~~
Adjust the
valves
in
#1
cylinder for both intake and exhaust.
Proceed
to
the next cylinder in the firing order.
Rotate the crankshaft 240 degrees in the normal direction of
rotation
.and
adjust the next cylinder's valves in the firing
order. Rotate the cranKshaft another 240 degrees and adjust
the valves of the next cylinder in the firing
order.
Adjust each valve's ciearance by inserting a
O.01Oin
(0.25mm) feeler gauge between the rocker arm and the valve
stem. Make sure
to
adjust all valves while the engine is cold.
Re-install the glow plugs (use anti-seize compound
on
the
tIn'eads)
and
assemble the rocker cover and rocker cover
bolts. See TIGHTENJNG TORQUE SCHEDULE
in
this
manual.
ENGINE
COMPRESSION
Check the compression pressure.
To
do
this warm the engine,
remove
all
fuel
injectors, or glow plugs, disconnect the
fueJ
shut-off solenoid wire,
and
install a compression adapter
in
the injector hole or
glow
plug hole. Connect a compression
tester
on
the adapter and crank the engine with the starter
motor until the pressure reaches a maximum
value.
Repeat
this process for each cylinder. Look for cylinders with
dra-
matically (at least
20%)
lower compression than the average
of the others. Compression pressure should not differ
by
more
than
35.5 psi (2.5
kg/cm2)
at
280 rpm.
Standard
compression
pressure
398
Ib/in'
at
280
rpm
'(28.0
kg/em')
If
a weak cylinder
is
flanked by healthy cylinder,
the
problem
is
either valve or piston related. Check the
valve
clearances
for the weak cylinder, adjust
as
needed and test again.
If
the
cylinder
is
still
low,
apply a small amount of
oil
into the
cylinder
to
seal the rings and repeat the test.
If
compression
comes up - the rings are
faulty.
Abnormally high readings
on
all cylinders indicates heavy
carbon accumulations, a condition that might be
accompani'ed
by
high pressures and noise.
NOTE:
In
case
of
severe
vibrations and detonation
noise,
the
cause
may
be
fuel injector
problems,
see
FUEL INJEC-
TORS.
Poor
fuel
quality,
contaminates and
loss
of
positive
fuel
pressure
to
the
injection pump will result
in
injector
faults.
When re-installing the glow plugs use anti-seize compound.
COMPRESSION
TESTER
ADAPTER~
:'~~~·.;;,..:r"'':
....
~
-,~r-
~
INJECTOR
OR
~---
GLOW
PLUG
HOLE
Engines & Generators
25