Westerbeke 55B-FOUR User manual

SERVICE MANUAL
55B-FOUR and 55e-FOUR
MARINE DIESEL ENGINE
PUBLICATION NO. 049970
2ND EDITION
SEPTEMBER 2006
~ WESTERBEKE CORPORA TION. 150 JOHNHANCOCKROAD
I MYLES STANDISHINDUSTRIAL PARK' TAUNTON MA 02780
WEBSITE: WWW.W£ST£RB£KE.COM
----
AlMM'" Metn«f National Marin~ Manufacturers Association
-~

CALIFORNIA PROPOSITION 65
WARNING
Exhaust gas from diesel and
gasoline engines (and some of
its constituents) are known to
the State of California to cause
cancer, birth defects, and other
reproductive harm.
AWARNING:
Exhaust gasses contain Carbon Monoxide, an odorless and
colorless gas. Carbon Monoxide is poisonous and can cause
unconsciousness and death. Symptoms of Carbon Monoxide
exposure can include:
-Dizziness
-Nausea
-Headache
- Weakness and Sleepiness
• Throbbing in Temples
• Muscular Twitching
• Vomiting
• Inability to Think Coherently
IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,
GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist,
seek medical attention. Shut down the unit and do not restart
until it has been inspected and repaired.
A WARNING DECAL is provided by WESTERBEKE and
should be fixed to a bulkhead near your engine or
generator.
WESTERBEKE also recommends installing CARBON
MONOXIDE DETECTORS in the /iving/sleeping quarters
of your vessel. They are inexpensive and easily
obtainable at your local marine store.
Engines & Generators

SAFETY INSTRUCTIONS
INTRODUCTION
Read this safety 11Ul1Iual carefully. Most accidents are
! caused by failure tofollow fundamental rules and
precautiJJns. Know when dangerous conditions existand
toke the necessary precautiJJns toprotect yourse1/, your
personnel, andyour
machinery.
The following safety instructions are in comp1iance with
the American Boatand Yacht Council (ABYC) stondards.
PREVENT ELECTRIC SHOCK
A WARNING: Do nut touch AC electrical connections
while engine is running, or when connected to shore
power. Lethal voltage is present at these connections!
• Do not operate this machinery without electrical
enclosures and covers
in place.
• Shut offelectrical power before accessing electrical
equipment
• Use insulated mats whenever working on electrical
equipment.
• Make sure your clothing and skin are dry, not damp
(particularly shoes) when handling electrical equipment
• Remove wristwatch and all jewelry when working on
electrical equipment.
• Do not connect utility shore power to vessels AC
circuits, except through a shiJ>-to-shore double throw
transfer switch. Damage to vessels AC generator may
result if this procedure is not followed.
• Electrical shock results from handling a charged capaci-
tor. Discharge capacitor by shorting terminals together.
PREVENT BURNS - HOT ENGINE
A WARNING: Do not touch hot engine parts or
exhaust system components. A running engine gets
reryhot!
• Always check the engine coolant level at the coolant
recovery
tank.
A WARNING: Steam can cause injury or death!
• In case of an engine overheat, allow the engine to cool
before touching the engine or checking the coolant.
PREVENT BURNS - FIRE
A WARNING: Fire can cause injury or death!
• Prevent flash fires. Do not smoke or permit flames or
sparks to occur near the 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 not operate with a Coast Guard Approved flame
arrester removed. Backfire can cause severe injury or
death.
• Do not operate with the air cleaner/silencer removed.
Backfire can cause severe injury or death.
• Do not smoke or permit flames or sparks to occur near
the fuel system. Keep the compartment and the
engine/generator clean and free of debris to minimize the
chances of
fire. Wipe up all spilled fuel and engine oil.
• Be aware -diesel fuel will burn.
PREVENT BURNS - EXPLOSION
A WARNING: Explosions from fuel vapOIS can cause
injury or death!
• Follow re-fueling safety instructions. Keep the vessels
hatches closed when fueling. Open and ventilate cabin
after fueling. Check below for fumes/vapor before
running the blower. Run the blower for four minutes
before starting your engine.
• All fuel vapors are highly explosive. Use extreme care
when handling and storing fuels. Store fuel in a well-
ventilated area away from spark-producing equipment
and out of the reach of children.
• Do not fill the fuel tank(s) while the engine is running.
• Shut off the fuel service valve at the engine when servicing
the fuel system. Take care in catching any fuel that might
spill. DO NOT allow any smoking, open flames, or other
sources of fire near the fuel system or engine when servic-
ing. Ensure proper ventilation exists when servicing the
fuel system.
• Do not alter or modify the fuel system.
• Be sure all fuel supplies have a positive shutoff valve.
• Be certain fuel line fittings are adequately tightened and
free of leaks.
• Make sure a fire extinguisher is installed nearby and is
properly maintained. Be familiar with its proper use.
Extinguishers rated ABC by the NFPA are appropriate
for
all applications encountered in this environment.
Engines & Generators
i

SAFETY INSTRUCTIONS
ACCIDENTAl STARTING
A WARNING: Accidental starting can cause injury
Dr death!
• Disconnect the battery cables before servicing the engine!
generator. Remove the negative lead first and reconnect
it last.
• Make certain all personnel are clear of the engine before
starting.
• Make certain
all covers, guards, and hatches are
re-installed before starting the engine.
BATTERY EXPLOSION
A WARNING: Battery explosion can cause injury
ordeath!
• Do not smoke or allow an open flame near the battery
being serviced.
Lead acid batteries emit hydrogen, a
highly explosive
gas, which can be ignited by electrical
arcing or
by lit tobacco products. Shut off all electrical
equipment
in the vicinity to prevent electrical arcing
during servicing.
• Never connect the negative (-) battery cable to the
positive (+) connection terminal of the starter solenoid.
Do not test the battery condition by shorting the terminals
together. Sparks could ignite battery gases or fuel vapors.
Ventilate any compartment containing batteries to prevent
accumulation ofexplosive
gases. To avoid sparks, do not
disturb
the battery charger connections while the battery
is being charged.
• Avoid contacting the terminals with tools, etc., to prevent
bums or sparks that could cause
an explosion. Remove
wristwatch, rings, and any otherjewelry before handling
the battery.
• Always tum the battery charger offbefore disconnecting
the battery connections. Remove the negative lead first
and reconnect it last when disconnecting the battery.
BATTERY ACID
A WARNING: Sulfuric acid in batteries can cause
severe injury Dr death!
• When servicing the battery or checking the electrolyte
level, wear rubber gloves, a rubber apron, and eye
protection. Batteries contain sulfuric acid which is
destructive. If it comes in contact 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: Carbon monoxide (CO) is a deadly gas!
• Ensure that the exhaust system is adequate to expel gases
discharged from the' engine. Check the exhaust system
regularly for leaks and make sure the exhaust
manifolds/water-injected elbow is securely attached.
• Be sure the unit and its surroundings are well ventilated.
Run blowers when running the generator set or engine.
• Do not run the generator set or engine unless the boat is
equipped with a functioning marine carbon monoxide
detector that complies with ABYCA-24. Consult your
boat builder or dealer for installation of approved
detectors.
• For additional information refer to ABYC T-22
(educational information on Carbon Monoxide).
A WARNING: Carbon monoxide (CO) is an invisible
odorless gas. Inhalation produces "u·like symptoms,
nausea or death!
• Do not use copper tubing in diesel exhaust systems. Diesel
fumes can rapidly destroy copper tubing in exhaust
systems. Exhaust sulfur causes rapid deterioration of
copper
tubing resulting in exhaust/water leakage.
• Do not install exhaust outlet where exhaust can be drawn
through portholes, vents, or air conditioners. If the engine
exhaust discharge outlet is near the waterline, water could
enter the exhaust discharge outlet and close or restrict the
flow of exhaust. Avoid overloading the craft.
• Although diesel engine exhaust gases are not as toxic as
exhaust fumes from gasoline engines, carbon monoxide
gas is present in diesel exhaust fumes. Some of the
symptoms or sigus of carbon monoxide inhalation or
poisoning are:
Vomiting Inability to think coherently
Dizziness
Headache
Nausea
Throbbing in
temples
Muscular twitching
Weakness and sleepiness
AVOID MOVING PARTS
A WARNING: Rotating parts can cause injury
or death!
• Do not service the engine while it is running. If a
situation
arises in which it is absolutely necessary to
make operating adjustments, use extreme care to avoid
touching moving parts and hot exhaust system
components.
Engines & Generators
ii

SAFETY INSTRUCTIONS
• Do not wear loose clothing orjewelry when servicing
equipment; tie back longhair and avoid wearing loose
jackets, shirts, sleeves, rings, necklaces or bracelets that
could be caught in moving parts.
• Make sure all attaching hardware is properly tightened.
Keep protective shields and guards in their respective
places at all times.
• Do not check fluid levels or the drive belts tension while
the engine is operating.
• Stay clear of the drive shaft and the transmission coupling
when the engine is runuing; hair and clothing can easily
be caught in these rotating parts.
HAZARDOUS NOISE
I ~WARNING: High noise levels can C81/S8 hearing
• Never operate an engine without its muffler installed.
• Do not run an engine with the air intake (silencer)
removed.
• Donot run engines for long periods with their enclosures
open.
A WARNING: Do not nt lin macIJinlll1 when ytlU are
,.",." fIT p/JysIt:al" Incapacifatetl by fatigue!
ABYC, NFPA AND USCG PUBLICATIONS FOR
INSTALLING DIESEL ENGINES
Read the following ABYC, NfPA and USCG publications
for safety codes and standards. Follow their
recommendations when installing your engine.
ABYC (American Boat and Yacht Council)
"Safety Standards for S!1IaU Craft"
Order from:
ABYC
3069 Solomon's Island Rd.
Edgewater, MD 21037
NFPA (National Fire Protection Association)
"Fire Protection Standard for Motor Craft"
Order from:
NfPA
II Tracy Drive
Avon Industrial Park
Avon, MA 02322
USCG (United Slates Coast Guard)
"USCG 33CFR183"
Order from:
U.S. Government Printing Office
Washington, D.C. 20404
) OPERATORS MANUAL
)
Many of the preceding safety tips and warnings are repeated
in your ()peratOIs Manual along with other cautions and
notes to highlight critical information. Read your manual
carefully, maintain your equipment, and follow all safety
procedures.
GASOUNE ENGINE AND GENERATOR INSTAllATIONS
Preparations to instaII an engine should begin with a
thorough examination ofthe American Boat and Yacht
Council's (ABYC) standards. These standards are a
combination of sources including the USCG and the NfPA.
Sections of the ABYC standards ofparticular interest are:
H-2 Ventilation
P-l Exhaust Systems
P-4 InboanI Engines
E-9 DC Electrical Systems
All installations must comply with the Federal Code of
Regulations (FCR).
Engines & Generators
iii

INSTALLATION
Wheninstalling WESTERBEKE engines and generators it is important that strict
attention be paid to the following infonnation:
CODES AND REGlIATIONS
Strict federal regulations, ABYC guidelines, and safety codes must be complied with
when installing engines and generators in a marine environment.
SlPHON-BREAK
For installations where the exhaust manifold/water injected exhaust elbow is close to
orwillbe below the vessel's waterline, provisions must be made to install a siphon-
break in the raw water supply hose to the exhaust elbow. This hose must be looped a
minimum of 20" above the vessel's waterline. Failare to use a siphon-breok when
the exhaust manifoldinjection port is ator below the load waterline will result in
mw water dDmoge tothe engine and possible flooding of the boat.
If you have any doubt about the position of the water-injected exhaust elbow relative
to the vessel's waterline under the vessel's various operating conditions, install a
siphon-breok.
JIOIE: A siphon-break requires periodic inspection and cleaning to ensure proper
operation. Failure to properly maintain a siphon-break can result in catastrophic
engine damage. Consult the siphon-break manufacturer for proper maintenance.
EXHAUST SYSTEM
The exhaust hose must be certified for marine use. The system must be designed to
prevent water from entering the exhaust under any sea conditions and at any angle
of the vessels hull.
A detailed 40 page Marine Installation Manual covering gasoline and
diesel, engines and generators, is available from your WESTERBEKE
dealer.
,.~/WESIJ:RBEKE
I Engines & Generators
iv
AVAILABLE FROM
YOUR WESTERBEKE
OEALER

TABLE OF CONTENTS
Parts Identification ............................................. 2
Introduction . ....................................................... .3
Engine Specifications ....................................... ..4
Testing for Overhaul ............................................ 5
Alternator Inspection........................................5
Engine Troubleshooting ....................................... 6
Engine Disassembly ........................................... 10
Engine Measurements ...................................... 11
(Prior to Disassembly)
Transmission ..................................................... 11
Injection Pump .................................................. 11
Engine Disassembly (Exploded View) .................. 12
Engine Inspection and Repair ........................... 15
Engine Assembly ............................................... 25
Sealants and Lubricants..................................25
Bolts and Fasteners.........................................25
Engine Assembly (Exploded View) ...•................... 28
Engine Assembly (External Parts) ....................... .34
Engine Assembly ............................................... 38
Engine Tuning ................................................38
Lubrication Diagram .......................................... 39
Cooling System ................................................. .40
Fuel System ...................................................... .43
Governor Drawing..........................................46
Engine Adjustments ..•........................................ 50
Testing Compression ......................................50
Oil Pressure .................................................... 50
Valve Clearance.............................................. 51
Injection TIming .............................................52
Warning Lights, Alarms, & Circuit Breakers .... 53
Starter Motor .... , ................................................ 54
Dual Output Alternators .................................... 58
Wiring Schematic ............................................. 60
Wiring Diagram .................................................. 61
Tachometer ....................................................... 62
Alternator Testing ............................................. 63
Torque Data ....................................................... 70
Nut and Bolt Tightening Method ....................... 73
Tightening Torque Standard ..................... ......... 74
Metric Conversion Formulas ............................... 76
~ WESTERBEKE
Engines & Generators
1

PARTS IDENTIFICATION
INTAKE/AIR AlTER
OIL
~UUI"'~' PRESSURE CAP
CONNECTION
THERMOSTAT
ASSEMBLY
RAW WATER D"'.D-----
REAR
FRONT
PREHEAT "u,.<NU"U,
AIR INTAKE/AIR rlLltH,~
FUEL UFT PUIRP-~
2DACIRCUIT
BREAKER
Fua AlTER ----~
HaTEXCHIANGJ:R-------~~
SHIFT lEVER
Oll .. 'T1'· .....
WATER INJECTED
EXHAUST
OIL COOLER
Oll.~~~SSURE
SENOOR
RIGHT SIDE
Engines & Generators
2
1c~~~, ~~ ___ EWXiATERir.U:iliNJECTED
ElBOW
1.0. PLATE
:\.......:.Jf---HI:AT EXCHANGER
REAR
ANODE
COOlER
LEFT SIDE
All
THERMOSTAT
::'\...-_". AlTERNATOR
fRONT
PUllEY
OIL All
MOUNT

INTRODUCTION
PRODUCT SOFTWARE
Product software, (technical data, parts lists, manuals,
. brochures and catalogs), provided from sources other than
WESTERBEKE are not within WESTERBEKE'S control.
WESTERBEKE CANNOT BE RESPONSIBLE FOR mE
CONTENT OF SUCH SOF1WARE, MAKES NO WAR-
RANl1ES OR REPRESENTATIONS WITH RESPECT
THERETO, INCLUDING ACCURACY, TIMEliNESS OR
COMPLETENESS mEREOF AND WIUIN NO EVENT
BE liABLE FOR ANY TYPE OF DAMAGE OR INJURY
INCURRED IN CONNECTION WIm OR ARISING OUT
OF THE FURNISHING OR USE OF SUCH SOF1WARE.
WESTERBEKE customers should keep in mind the time
span between printings of WESTERBEKE product software
and the unavoidable existence ofearlier WESTERBEKE
product software. The product software provided with
WESTERBEKE products, whether from WESTERBEKE or
other suppliers,
must not and cannot be relied upon exclu-
sively as the definitive authority on the respective product It
not only makes good sense but is imperative that appropriate
representatives ofWESTERBEKE or the supplier in question
be consulted to determine the accuracy and currentness of the
_product software being consulted by the customer.
SERIAL NUMBER LOCATION
The engine's model number and serial number are located on
a nameplate mounted on the side of the engine's manifold.
The engine's serial number can also be found stamped into
I the engine blOck on the flat surface of the block just forward
ofthe number one cylinders injection pump. Take the time to
enter this information on the illustration of the nameplate
shown below, as this will provide-a quick reference when
seeking technical information and/or ordering repair parts.
ORDERING PARTS
Whenever replacement parts are needed, always provide the
engine model.number and serial number as they appear on
the silver and black nameplate located on the manifold. You
must provide us with this information so we may properly
identify your engine. In addition, include a complete part
description
and part number for each part needed (see the
separately furnished Parts List). Insist upon WESTERBEKE
packaged parts because willfit or generic parts are frequently
not made to the same specifications as original equipment.
RAW WATER CODLING SYSTEM
Siphon-Break
For installations where the water injected exhaust elbow is
close to or will be below the vessels waterline, provisions
must be made to install a siphon-break in the raw water
supply hose to the water injected exhaust elbow. The siphon-
break provides an air vent in the raw water cooling system to
prevent raw water from filling the exhaust system and the
engine's cylinders when the engine is shutdown.
A CAUTION: Failure to use a siphon-break when
the exhaust manifold injection port is at or below the
load waterline will result in raw water damage to the
engine and possible flooding of the boat.
If you have any doubt about the position of the water-
injected exhaust elbow relative to the vessels waterline under
the vessels various operating conditions, installa siphon-
break. This precaution is necessary to protect your engine.
The siphon-break must be installed in the highest point ofa
hose that is looped a minimum of 20 inches (51cm) above
the vessels waterline. This siphon-break must always be
above the waterline during all angles of vessel operation to
prevent siphoning.
NOTE: A siphon-break requires periodic inspection and
cleaning to ensure proper operation. Failure to properly
maintain a siphon-break can result in catastrophic engine
damage. Consult the siphon-break manufacturer for proper
maintenance.
SIPHON-BREAK WITH STAINLESS
LOOP FOR 3/4" HOSE
PART NO.045368
SIPHON·BREAK
PART NO. 033327
"flY' WESTERBEKE
Engines & Generators
3

SPECIFICATIONS 558 ENGINE
SPECIFICATIONS
Engine Type
Displacement
Combustion Type
Combustion System
Bore & Stroke
Max. Angle of Installa~on
Max. Angle of Rota~on
Rring Order
Direction of Ro~on
Propeller Shaft
Compression Ra~o
Aspimtion
Engine Speed
Fuel Consump~on
Dimensions - inches (mm)
Engine Only
Weight
Air Row
Diesel, water cooled, four cycle, four cylinder,
in-line overhead valve type
133 cubic inches (2.179 liter)
In-direct injection
Swirl chamber
3.35 x 3.78 incheS'(85 x 96 mm)
Notto exceed 14'
Not to exceed 30' for 30 minutes
1-3-4-2
Counterclockwise, when viewed from flywheel
Right hand direction of rotation
21:5:1
Naturally Aspirated'
Idle speed: 850-1000 RPM
CruiSing Speed: 2000-2500 RPM
No load speed: 3200 RPM (neutral)
1.5 U.S. gph running at 2500 RPM (approx.)
when the propeller used allows the engine to
tum at 3000 RPM at full open throttle underway
in forwam
H~ght 23.3 inches
Width: 18.6 inches
Length: 27.0 inches
448 Ibs (203.2 kgs)
(592 mm)
(472 mm)
(687 mm)
Engine Combu~on: 116 cfm (3.3 cmn)
Engine Cooling: 200 cfm (5.6cmm)
TUNE-UP SPECIFICATIONS
Compression Pressure
Valve Timing
Intake Opens
Intake Closes
Injection Timing
Nozzle Injector Pressure
Valve Clearance
(engine cold)
441 psi (3.04 MPa)
Open at 15' BTDC - Close 29' ABDC
Open at 40' BTDC - Close 16' ATDC
16" BTDC
1920 psi (13.2 MPa)
0.0157 inches (0.4 mm)
ELECTRICAL SYSTEM
Starting Battery
Battery Capacily
DC Charging Altemator
Starting Aid
Starter
Cold Cranking Amps
Altemator Regulator
Exhaust Elbow
Exhaust Hose Size
Exhaust Gas Flow
Muffler Size (min.)
12 Vott, (-) negative ground
400 - 600 CCA (min.)
50 Amp rated, bett-driven -12V
Glow plugs, 12V sheathed
12 von, 1.8 KW w~h solenoid
175 - 200 Amps
Intema! regulator, buitt into altemator
EXHAUST SYSTEM
45' elbow
3.0" 1.0. hose
265 cfm at 3000 RPM
14" x 14"
Fuel
Fuel Injection Pump
Injectors
Fuel Rner
Air cleaner
Fuel Uft Pump
General
Operating Temperature
Fresh Water Pump
Raw Water Pump
System Capaclly
Sea Water Row
at 3000 rpm
Diesel fuel I? (catane rating of 45 or higher).
BOSCH, PFR type
Throttle type
Primary, full flow, spin-on element
Replaceable paper carlridge.
Solid atate with extemal fitter
COOLING SYSTEM
Fresh water-cooled with tube and shell type
heat exchanger.
170 -190'F (77 -88' C)
Centrifugal matal impeller type belt-driven.
Positive displacemen~ rubber impeller,
ben-driven.
7.25 US qts (6.861~ers)
8.0 - 8.5 gpm (30.2 - 32.1Ipm)
(measured before discharging into water
injected exhaust elbow)
LUBRICATION SYSTEM
General
Oil Rtter
Sump Capeclly
(not including fitter)
Opemting Oil Pressu re
(engine hot)
Oil Grade
Oil Cooler
General
clutch
Gear Ratio (atandam)
Forced lubri~on bY Trochoid type pump
Full flow spin-on
8 U.S. qts (7.61~ers)
43 - 85 psi (290 - 590 KPa)
API Specifi~on CF or CG-4, SAE 30, 15W-30
Fresh water cooled
TRANSMISSION
ZF Marine Transmission, case hamened, helical
gears, with a servo-operated multiple disc
1:88:1 (ZF25M)
Propeller Recommenda~ons 18 x 13P-2blade (RH) or 18 x l1P 3 blade (RH)
(Propeller used should allow the engine to
reach its full rated RPM (3000 + 000 -100) at
full open throttle while underway in forwarc
gear)
Lubri~ng Ruid
Transmission Sump
Capacity
Automatic transmission fluid, type Dexron II
or III
0.75 U.S. qts. (0.79 liters)
~ WESTERBEKE
Engines & Generators
4

)
)
TESTING FOR OVERHAUL
HOW TO DETERMINE ENGINE OVERHAUL PERIOD
Cause of Low Compression
Genenilly, the time at which an engine should be overhauled
is determined by various conditions such as lowered engine
poweroutput, decreased compression pressure, and increased
fuel and oil consumption. The lowered engine power output
is not
neoessarily due to trouble with the engine itself, but is
sometimes caused by injector nozzle wear or injection pump
wear. The decrease in compression pressure is caused by
many factors. It is, therefore, necessary to determine a cause
or
causes on the basis of data produced by periodic
inspection and maintenance. Oil analysis on a seasonal basis
is a good means of monitoring engine internal wear. When
caused by worn cylinders orpiston rings, the following
symptoms will occur:
1 Low engine poweroutput
2 Increased fuel consumption
3 Increased oil consumption
4
Hard enginestarting
5 Noisy engineoperation
These symptoms often appear together. Symptoms 2 and 4
can result also from excessive fuel injection, improper injec-
tion timing, and wear of the injectors. They are caused also
by defective electrical devices such as the battery, alternator,
starter and glow plugs. Therefore it is desirable to judge the
optimum engine overhaul time by the lowered compression
pressure caused by worn cylinders and pistons plus increased
oil consumption. Satisfactory combustion is obtained only
under sufficientcompression pressure. If an engine lacks
compression pressure, incomplete combustion of fuel will
take place even if other parts of the engine are operating
properly. 1b detennine the period of engine overhaul, it is
important to measure the engine compression pressure regu-
larly. Atthe same time, the engine speed at which the mea-
surement of compression pressure is made should be checked
because the compression pressure varies with engine rpm.
The engine rpm can be measured at the front end of the
crankshaft.
NDlE: To test engine compression see the ENGINE
ADJUSTMENT section of this manual.
ASSEMBLY
1. Wash all parts, except for oil seals, O-rings, rubber sheets,
etc., with cleaning solvent and dry them with pressure air.
2. Always use tools that are in good condition and be sure
you understand how to use them before perfonning any
job.
3.
Use only good quality lubricants. Be sure to apply a coat
of oil, grease orsealant to parts as specified ..
4. Be sure to use a torque wrench to tighten parts for which
torques are specified.
5_ Ant time the engine is assembled, new gaskets and
O-rings must be installed.
OVERHAUL CONDITIONS
Compression pressure tends to increase a little in a new
engine until piston rings and valve seats have been broken in.
Thereafter, it decreases gradually with the progress of wear
of these parts.
When decrease of compression pressure reaches the repair
limit, the engine must be overhauled.
The engine requires
overhaul when oil consumption is high,
blowby evident, and compression values are at minimum or
below. 558 FOUR COMPRESSION PRESSURE
DISASSEMBLY
441 PSI (3.04 MPa) NORMAL AT CRANKING
SPEED OF 250 RPM.
44.1 PSI BETWEEN CYLINDERS
1. Before disassembly and cleaning, carefully check for
defects which cannot be found after disassembly and
cleaning.
2.
Drain water, fuel and oil before disassembly.
3. Clean or wash the engine exterior.
4. Do not remove or disassemble the parts that require no
disassembly.
5. Perform disassembly in a proper order using proper tools.
Keep disassembled parts in order. Apply oil when neces-
sary. Take special care to keep the fuel systern parts from
intrusion ofdust and dirt.
6. Parts must be restored to their respective·components from
which they were removed at disassembly. This means that all
parts must be set aside separately in groups, each marl<ed for
its component, so that the same combination or set can be
reproduced at assembly.
7. Pay attention to marks on assemblies, components and
parts for their positions
or directions. Put on marks, if
necessary, to aid assembly ..
S. Carefully check each part or component fore any sign of
faulty condition during removal or cleaning. The part will
tell you how it acted or what was abnormal about it more
accurately during removal or cleaning.
ALTERNATOR INSPECTION
When rebuilding the engine, the alternator should be cleaned
and inspected. The housing can be wiped off with asolvent
and
the alternator terminal studs should be cleaned with a
wire
brush. Make certain the studs are tight and clean the
wiring connections that connect to the wiring harness.
Thm the rotor pulley by hand. It should tum smoothly.
Depending on when the alternator was last serviced, the
brushes may need replacing. If the alternator is at all suspect,
send it to a service shop for testing and overhaul.
For additional information on alternators refer to the
ALTERNATOR TROUBLESHOOTING and MANDO
SERVICE in this manual.
... WESTERBEKE
Engines & Generators
5

ENGINE TROUBLESHOOTING
The following troubleshooting chart describes certain
problems relating to engine service, the probable causes of
these problems, and the recommendations to overcome
these problems. This chart may be of assistance in determining
the need for an engine oveIhaui.
PROBLEM
PROBABLE CAUSE
lIARD STARTING
lOW CRANKING SPEED
1. Engine oil viscosity too high.
2. Run-down battery.
3. Worn battery.
4. Battery terminals loosely connected.
5. Defective slarter.
DEFECTIVE INJECTION SYSTEM
1. Airtrapped in fuel passage.
2. Clogged fuel fmer.
3. low injection pressure.
4. Inadequate spray.
5. Injection pump delivering insufficient fuel.
6. Injection too earty.
MAIN ENGINE TROUBLES
1. low compression.
a. Incorrect valve clearance.
b. Inadequate conlact of valve seat.
c. Valve stem seized.
d. Broken valve spring.
NOTE: The engine's electricol system is protected by a 20-
ampere 1IIl11IJJo1 reset circuit breaker. The preheat solenoid is
mounted on the same bracket.
VERIFICATION/REMEOY
1. Replace engine oil w~h less viscous oil.
2. Recharge battery.
3. Replace battery.
4. Clean terminals and correct cables.
5. Repair or replace slarter.
1. Bleed air from fuel system.
2. Clean or replace filler.
3. Adjust injection pressure.
4. Clean or replace nozzle.
5. Repair or replace injection pump.
6. Adjust injection timing.
a. Adjust valve clearance.
b. lap valve.
c. Replace valve and valve guide.
d. Replace valve spring.
e. Compression leaks through cylinder head gasket.
e. Repl~ce gasket
I. Piston ring seized.
I. Replace piston and piston ring.
g. Worn piston ring and cylinder. g. Overhaul engine.
2. Burnt glow plug. 2. Replace glow plug.
3. Faulty glow plug operation.
3. Correct lead wire connection.
4. Incorrect governor lever position. 4. Set lever to slarting position.
LOW OUTPUT
LOW COMPRESSION
See HARD STARTING
INJECTION SYSTEM OUT OF ADJUSTMENT
1. Incorrect injection timing. 1. Adjust injection timing.
2. Insufficient injection. 2. Repair or replace injection pump.
3. low injection pressure.
3. Check injection nozzle and adjusl pressure.
INSUffiCIENT FUEL
1. Airtrapped in fuel system.
1. Check and retighten connector.
2. Clogged fitter.
2. Clean or replace filter.
3. Contaminated fuel tank.
3. Clean lank.
INSUffiCIENT INTAKE AIR
1. Clogged air cleaner. 1. Clean or replace air cleaner.
(continued)
~ WESTERBEKE
Engines & Generators
6

ENGINE TROUBLESHOOTING
PROBLEM
PROBABLE CAUSE
VERIFICATION/REMEDY
LOW OUTPUT (ooM.)
OVERHEATING
1. Low coolantlevel.
1. Add coolant.
2. Loose V-be~.
2. Adjust or replace V-belt
3. Incorrect injection timing.
3. Adjust injection timing.
4. Low engine·oillevel. 6. Add engine oil.
EXCESSIVE OIL OIL
LEAKAGE
CONSUMPTION
1. Defective oil seals. 1. Replace oil seals.
2. Broken gear case gasket. 2. Replace gasket.
3. Loose gear case attaching bolts. 3. Retighten bolts.
4. Loose drain hose.
4. Retighten hose.
5. Loose oil pipe connector. 5. Retighten oil connections.
6. Broken rocker cover gasket.
6. Replace gasket.
7. Loose rocker cover attaching bolts. 7. Retighten attaching bolts.
OIL LEVEL RISING
1. Incorrectly positioned piston ring gaps. 1. Correct ring gap positions.
2. Displaced or twisted connecting rod. 2. Replace connecting rod.
3. Worn piston ring.
3. Replace ring.
4. Worn piston or cylinder. 4. Replace piston and rebore cylinder.
OIL LEVEL FALLING
1. Defective stem seal. 1. Replace stem seal.
2. Worn valve and valve guide. 4. Replace a valve and valve guide.
EXCESSIVE FUEL
ENGINE BODY mOUBLES
CONSUMPTION 1. Noisy knocking. 1. See KNOCKING.
2. SmokY exhaust
2. See SMOKY EXHAUST.
3. Moving parts nearly seized or excessively worn. 3. Repair or replace.
4. Poor compression.
4. See LOW COMPRESSION; HARD STARTING.
5. Improper valve timing. 5. Adjust.
6. Improper valve clearance.
6. Adjust.
INSUFFICIENT INTAKE AIR
1. Air intake obstructed.
1. Remove obstruction.
NOZZLE mOUBLES
1. Seized nozzle.
1. Replace.
2. Worn nozzle.
2. Replace.
IMPROPER FUEL
Replace with proper fuel.
FUEL LEAKS
Find fuel leaks.
SMOKY EXHAUST WHmSH OR PURPLISH
1. Excessive engine oil.
1. Correct oil level.
2. Excessive rise of oil into combustion chamber.
a. Poor piston contact.
a. Check.
b. Seized piston ring.
b. Replace or clean.
c. Excessive piston-to-cylinder clearance.
c. Replace or correct.
(continued)
~ WESTERBEKE
Engines & Generators
7

ENGINE TROUBLESHOOTING
PROBLEM
PROBABLE CAUSE
VERIFICATIONJREMEDY
SMOKY EXHAUST (em.)
WHmSH OR PURPUSH (conI •• )
d. Worn valve stem and valve guide.
d. Replace.
e. Low engine oil viscosity.
e. Replace.
f. Excessive oil pressure.
f. Correct.
3. Injection timing is too late. 3. Adjust.
4. Insufficient compression.
4. See LOW COMPRESSION; HARD STARTING.
BLACKISH OR DARK GRAYISH
1. Engine body troubles.
a. Poor compression.
a. See LOW COMPRESSION; HARD STARTING.
b. Improper valve clearance. b. Adjust.
2. Insufficient intake air (air cleaner clogged).
2. Clean air cleaner.
3. Improper fuel.
3. Replace with proper fuel.
ABNORMAL SOUND CRANKSHAFT AND MAIN BEARING
OR NOISE
1. Badly worn bearing.
1. Replace bearing and grind crankshaft.
2. Badly worn crankshaft. 2. Grind crankshaft.
3. Melled bearing. 3. Replace bearing and check lubrication system.
CONNECTING ROD AND CONNECTING ROD BEARING
1. Worn connecting rod big end bearing. 1. Replace bearing.
2. Worn crankpin.
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 pin. 2. Replace piston.
3. Piston seized. 3. Replace piston and rebore cylinder.
4. Piston seized and ring worn or damaged. 4. Replace piston and rings.
VALVE MECHANISM
1. Worn camshaft. 1. Replace.
2. Excessive valve clearance.
2. Adjust.
3. Worn timing gear. 3. Replace.
4. Worn fan pulley bearing. 4. Replace.
ROUGH OPERATION INJECTION PUMP SYSTEM
1. Uneven injection. 1. Adjust injection or replace paris.
2. Control rack manunctioning. 2. Disassemble, check and correct injection pump.
3. Worn delivery valve. 3. Replace.
4. Inadequate injection nozzle spray. 4. Replace injection nozzle.
GOVERNING SYSTEM
1. Governor lever manunctioning. 1. Check governor shaft and correct operation.
2. Fatigued governor spring. 2. Replace.
(continued)
-..v: WESTERBEKE
Engines & Generators
8

ENGINE TROUBLESHOOTING
PROBLEM PROBABLE CAUSE VERIFICATION/REMEOY
--
KNOCKING ENGINE KNOCKS WITHOUT MUCH SMOKE
1. Main engine troubles.
a. Overheated cylinder.
a. See OVERHEATING; LOW OUTPUT.
b. Carbon deposits in cylinder.
b. Clean.
2. Too early injection timing.
2. Correct.
3. Too high injection pressure.
3. Correct
4. Improper fuel.
4. Replace wnh proper fuel.
KNOCKING WITH DARK SMOKE
1. Poor compression.
1. See LOW COMPRESSION; HARD STARTING.
2. Injection pump malfunctioning.
2. Adjust/Repair
3. Improper nozzle.
a. Poor spray.
a. Clean or replace nozzle.
b. Poor chattering. b. Repair or replace nozzle.
c. After·injection drip.
c. Repair or replace nozzle.
d. Nozzle needle valve seized.
d. Replace.
INTERMITTENT 1. Fuel fi~er clogged. 1. Clean or replace.
EXHAUST SOUND 2. Water mixed in fuel 2. Replace fuel.
OVERHEATING 1. V-belt slackening or slippery wnh oil.
1. Adjust, replace or clean.
2. Damaged water pump.
2. Replace.
3. Lack of coolant 3. Add.
4. Low oil level or poor oil quality. 4. Add or change.
5. KnOCking.
5. See KNOCKING.
6. Moving parts seized or damaged.
6. Replace.
7. Defective thermostat.
7. Replace.
LOW OIL PRESSURE
1. Wom Bearings.
1. Engine overhaul replace bearings.
2. Relief valve malfunction.
2. Overhaul oil pump.
3. Clogged oil cooler.
3. Repair.
4. Diesel dilution of the oil.
4. Injection pump repair.
"~/WESIERBEKE
I engines & Generators
9

ENGINE DISASSEMBLY
PROPll.SION ENGINE
Switch offthe batteries and disconnect the battery cables
from the engine and tape over the tenninals.
Drain
or pump out all the engine oil and drain the coolant
from the engine
and engine hoses.
Unplug the instnnnent panel wiring harness. Drain the
ttansmission fluid and the ttansmission oil cooler hoses.
Detach the oil coolerhoses and unbolt the ttansmission from
the engine.
NOTE: Lobel any lines. hoses orcables as you separate them
TRANSMISSION .
If the ttansmission is not being rebuilt it should be visually
inspected Flusb out and pressure test the oil cooler and
replace thecoolant hoses. Inspect and lubricate the gear shift
linkage andthe propeller shaft coupling. Clean and repaint
the IIlInsmission and cbange theIIlInsmission fluid.
For transmissi 9n service and maintenance refer to your
transmission manual To rebuild a transmission contact
your WES1ERBEKE dealer or an authorized
transmisdoD service center.
DAMPER
PlATE
COOLANT DRAIN
OAMPER PLATE
BOLTS
INSPECT THE DAMPER
PLATE FOR WEAR AND
BROKEN SPRINGS
ENGINE DISASSEMBLY
Take the following precautions:
• Clean the exterior of the engine of any deposits of
dirt and oil.
• Be careful not to damage the disassembled parts.
• Arrange parts in the order of disassembly. Mark or
label parts as needed to insure proper mating and
reassembly. Keep parts clean.
• Mount the engine on a suitable engine stand for
disassembly.
With the ttansmission separated from the engine. begin the
following step by step procedure to disassemble the engine.
I.Remove the transmission damper plate from the
engine flywheeL
2. Remove
the engine oil cooler and oil hoses. Note oil
hose connections from the oil cooler to the engine.
3.Remove
the engine heat exchanger. If possible. leave
one end of each hose connected to the part being removed.
4. Remove
the bell housing and the circuit breaker!
preheat solenoid mounting bracket.
5. Remove the engine back plate.
6. Remove the start motor, drive belt and the alternator.
Label the wires and cables.
7. Remove the engine mounted raw water pump,
complete with its adapter mounting plate. See RAW
WA:rnR PUMP for parts breakdown.
.8. With the hoses disconnected, remove the thermostat
housing and housing gasket, leaving the temperature
sender in place.
9. Remove the coolant circulating pump. Refer to
COOLANT CIRCULATING PUMP ASSEMBLY.
10.Remove the air intake silencer and the intake manifold.
1l.Remove the oil filter and the mounting bracket from the
engine block.
12.Unbolt the elbows and remove the exhaust manifold in
its entirety.
13.
Remove the fuel injection pumps. Disconnect the fuel
injection pipes and fuelleak-offpipe from the fuel
injection pumps and nozzles.
14.
Fuel pipe, injection pipe, and leak offpipe.
a. Loosen the sleeve nuts on the nozzle holder side and
on the injection pump side, and then disconnect the
injection pipes.
b. Disconnect theleak offpipe together with gaskets.
c. Remove the eye bolt, and then disconnect the fuel
pipe. Injection
pipe
\ Leak off pipe
~~~ /
\..:J~. 0 .
~~ O. /' Fuel pipe
\
.... ~...-- Nozzle holder
Engines & Generators
~r~
~.- Injection pump
10

ENGINE DISASSEMBLY
Injection pump
MEASUREMENTS
. 1. Align the hole of the fuel cut lever with the hole of
the governor cover, and then insert a pin (6!!) into
tliis hole to hold the fuel cut lever. PRIOR TO
MAIN ENGINE DISASSEMBLY
2. Check to see if the pin groove of the control link is at
the center of the injection pump.
3 .. Remove the injection pump, and then take out the
shim.
NOTE:
Fuel cut lever --,..~
Pin(6 ~)
Governor cover
Control link
\ IInjection pump
1/ center position
"
(n,ection pump rack
pm
1. Mark each injection pump as to which cylinder it
was removed from.
2. Do not reuse the shim, replace it with the same
thickness
that was removed.
___ Injection pump ASM
Shim
Cylinder block
Backlash
oftiming gear
STANDARD
CRANK GEAR! 0.04
IDLER GEAR (0.0017)
CAM GEAR! 0.03
IDLER GEAR (0.0012)
IDLER GEAR END PLAY
STANDARD
0.058 -0.115 (0.0023 -0.0045)
CRANKSHAFT END PLAY
STANDARD
0.058 -0.208 (0.0023 -0.0082)
""'" WESTERBEKE
Enginds & Generators
11
mm (in.)
LIMIT
0.2
(0.0079)
0.2
(0.0079)
mm (in)
LIMIT
0.2 (0.0079)
mm (in)
LIMIT
0.3 (0.0118)

INTERNAL PARTS
DiSassembly Steps
(11 Rocker BracketAssembly
(21 Push Rods
(31 Rear Hanger
(41 Front Hanger
(51 Cylinder Head Assembly
(61 CylinderHead Gasket
(71 Tappets
(81 Oil Pan
(91 Oil Strainer
(101 Oil Pipe
(111 Crank Pulley
(12) Flywheel
(131 Flywheel Housing
(14111ming Gear
Case
(15) Oil PumpAssembly
(16) IdlerGear and Shaft
(171 Cam Gear
(181 Camshaft
(19) Rear Seal Retainer
(20) Piston Assemblies
(211 Crankshaft
00 nat pull out -"'=,""
thisbolt. \t
191
ENGINE DISASSEMBLY
111
~
Rocker bracket
Push rod
1. Remove the rocker bracket assembly.
(M6 x 1 ..... 5 bolts and 6 nuts)
2. Pull out the push rods (8 pes.).
nuts
(6)
"' ..
{
Cylinder head
1. Remove the rear and front hangers.
2. When removing the cylinder head bolts, loosen
them slowly, a little at a time, starting with the
outside, working in acircular pattern inward.
3. Remove the cylinder head assembly and the head
gasket.
4. Pull out the tappet from the cylinder body.
E!19ines & Generators
12

ENGINE DISASSEMBLY
5 4 3 2 1 Timing gear
1. Remove the idle gearand the idle gearshaft.
2. Pull out the sleeve from the tip end
of the cam shaft.
Rear
hanger--,
Cylinder head
ASM ~
Valve mechanism
"Head bolt
(M12)
3.
1. Before disassembling the valve mechanism, remove
the connector, glow plug and nozzle holder as-
sembly.
2. Compressing the valve spring, remove the split col-
lar, spring seat, valve spring and valve.
connecto~r ..,lll="'"A ...
G
....
lo
..
w
,r ;1 ~:~~, :::~
~ ~udsare appHed wfih
\
sealing agent.
Do not pull them out.
Nozzle holder (3)---.. (5 locations)
e~
t
Hot plug
F1I ~...:::.. Split collar (4)
'10"' ~
; 11\ Spring seat 151
~lveSprlng lSI
@@
\
Seat; valve insert
® '.
~~'J
.!:t:-,
Remove the lock nut of the cam shaft gear, and then
remove the
flyweight assembly and the cam gear.
Camshaft
1. Remove the snap ring which holds down the front
bearing of the cam shaft from the ring groove of the
cylinder block.
2. Pull out the cam shaft from the cylinder block.
together with the bearing.
Snap ring
Engines & GelJerstors
13

ENGINE DISASSEMBLY
Piston and Connecting Rod
(\ _ Connecting rod
~ap
Piston and connecting rod
1. Turning the crankshaft, position the piston to be
removed
at the bottom dead center.
2. Loosen the cap nut of the connecting rod, and then
remove it.
3. Give another rotation to the crankshaft to position
the piston at the top dead center.
4. With the handle of a hammer placed at the bottom
of the connecting rod, push the piston assembly
upward out of the cylinderblock.
Notes:
1. Before removing the piston, scrape the carbon
deposit
off the cylinder wall.
2. When pushing out the piston assembly, care should
be taken not to damage the cylinder wall.
3. Attach a tag with a cylinder number to the removed
caps and bearings to keep them in order.
Piston ring (4)
r.. :"1
ri
~
~ ~
'--'
""
~
Piston -- ...... _1'<;'"
Con'rod bolt
(The drawing·out ofthe con'rod bolt
mustbe limited to only when replaced.)
Connecting rod (7) -- ...... "i~~\,c.k
~ Snap r;n9 (5)
Bearing (3)
Piston ring
Remove the piston ring
with a ring pliers.
Brass bar
Piston pin
1. Remove the snap rings with a commercially avail·
able tool.
2. With a brass bar attached to the piston pin, push it
out by hammering it lightly.
Note:
Keep
the pistons, piston pins and connecting rods in
order
for each cylinder.
Engines & Generators
14