Westerbeke Universal M-50 User manual

SERVICE MANUAL
M- 30
MODELS
M- 40
PIN 200154
M- 50

CONTENTS
NOTE: Refer to the beginning ofthe individual sections for a cqrnplete table of contents forthat section.
SECTION I - SPECIFICATIONS .................................................... 1-18
SECTION II -PREVENTIVE MAINTENANCE ........................................ 19-24
SECTION III -CONSTRUCTION AND FUNCTION .................................... 25-30
SECTION IV -LUBRICATION, COOLING, AND FUEL
SySTEMS ....................... 31-49
SECTION V - ELECTRICAL SYSTEM .............................................. 51-82
SECTION VI -DISASSEMBLY AND REASSEMBLY ................................. 83-130
SECTION VII -DYNAMO AND REGULATOR ...................................... 132-147
TROUBLESHOOTING ......................................................... 148-157

NOTES
ii
I
a
I
~
~
--- --------- -_i----~-,J

SECTION 1- SPECIFICATIONS
Model M-30 ...................................................................... 2,3
Model M-40 ..................................................................... 4,5
Model .M-50 .................................................. , .................. ,. 6,7
Parts Specifications . ............................................................. 8-15
Bolt Torques. ................................................................. .16-18
1

UNIVERSAL MODEL M-30 SPECIFICATIONS
Horsepower
No. of Cylinders
Bore x Stroke
Cubic Inch
Maximum R.P.M.
Cruising Range (Approx.)
Compression Ratio
Electrical Equipment
Lubrication (Eng. Approx. Qts)
24 @ 2800
3
3.00 x 3.23
68
2800
2000-2400 R.P.M.
21:1
12 Volt - 51 Amp W/Glow Plugs
5.0 to 5.5
(SAE 30 HD. (CD) or 10W40) CAUTION: FILL ONLY TO FULL MARK ON DIPSTICK
Lubrication (Trans.) FILL TO FULL RING ON DIPSTICK
(Type AFT. "/1\' or GM-DEXRON - II Do not mix different oils)
Transmission Reduction
Coolant FWC (50/50 Solution Approx.)
Exhaust Flange
Fuel
Type
Fuel Filter
Oil Filter
Eng. Operating
Temp. Degrees F.
Propeller Rotation
We.ight (Ibs.)
Injection Nozzle
2:1
6 qts.
1 V4" N.P.T.
#2 Diesel
PIN 298854
PIN 300209
Right Hand
4251bs.
PIN 298787 & 298788
Engine is governorcontrolled to prevent overspeed. It is recommended to carry the following extra parts should
the need arise: V-Belt, Sea Water Pump Impeller, Fuel & Lube Oil Filters, 1 Qt. of Trans. Oil, 2 Qts. Lub. Oil
and 1 Gal. 50/50 Coolant.
All pictorial views and specifications subject to change without notice.
2

GLOW PLUG~- ____ __
SEA WATER OVERBOARD
HEAT EX. DRAIN & ZINC_
TRANS. DIP STICK
OIL FILL HOLE ---
SHIFT LEVER
ENGINE COUPLIN
UNIVERSAL MODEL M-30
FUEL LINES
TIMING PORT
AIR BREATHER
FUEL AIR
LEED VALVE
c---_ STOP LEVER
'----OIL FILTER
BLOCK COOLANT DRAIN
COOLANT AIR BLEED VALVE COOLANT FILL CAP
THERMOSTAT HSG.
F.W. CIRCULATING
PUMP ---,
ALTERNATOR
SEA WATER PUMP
V·BELT
DIP STICK OIL PAN
"3
MANIFOLD
AUST FLANGE
MANIFOLD DRAIN
HEAT EXCHANGER
HEAT EX. CLEAN·OUT
COVERS
----DRAIN AND ZINC
TRANSMISSION
n_'I"~_ DRAIN PLUG

UNIVERSAL MODEL M-40 SPECIFICATIONS
Horsepower
No.
of Cylinders
Bore x Stroke
Cubic Inch
Maximum R.P.M.
Cruising Range (Approx.)
Compression Ratio
Electrical Equipment
Lubrication (Eng. Approx. ats.)
32 @ 2800
4
3.00 x 3.23
91
2800
2000/2500 R. P.M.
21:1
12 Volt - 51 Amp WIGlow Plugs
8.0 to 8.5
(SAE 30 HD. (CD) or 10W40) CAUTION: FILL ONLY TO FULL MARK ON DIPSTICK
.
Lubrication (Trans.) FILL
TO FULL RING ON DIPSTICK
(Type AFT. "1\' or GM-DEXRON - II Do not mix different oils)
Transmission Reduction
Coolant FWC (50/50 Solution Approx.)
Exhaust Flange
Fuel Type
Fuel Filter
Oil Filter
Eng. Operating
Temp. Degrees F.
Propeller Rotation
Weight (Ibs.)
Injection Nozzle (Prior to
Ser. #315023)
(After
Ser. #315023)
2:1
8 qts.
1 V4" N.P.T.
#2 Diesel
PIN 298854
PIN 299927
Right Hand
5451bs.
PIN 299517 &299518
PIN 299567
Engine is governorcontrolled to prevent overspeed. It is recommended to carry the following extra parts should
the need arise: V-belt, Sea Water Pump Impeller, Fuel & Lube Oil Filters, 1 at. of Trans. Oil, 2 Ots. Lub. Oil
and 1 Gal. 50/50 Coolant.
All pictorial views and specifications subject to change without notice.
4

FUEL RETURN
GLOW PLUGS- ____ _
SEA WATER OVERBOARD
HEAT EX. DRAIN & ZIN
TRANS. DIP STICK
OIL FILL HOLE ---
ENGINE COUPLING/
UNIVERSAL MODEL M-40
FUEL LINES
TIMING PORT
AIR BREATHER
FUEL AIR
BLEED VALVE
---THROTTLE
-- STOP LEVER
--OIL FILTER
BLOCK COOLANT DRAIN
EX MOUNTS
COOLANT AIR BLEED VALVE COOLANT FILL CAP
THERMOSTAT HSG
F.W. CIRCULATING
PUMP ---'
ALTERNATOR
SEA WATER PUMP
V·BELT
DIP STICK OIL PAN
5
MANIFOLD
MANIFOLD DRAIN
HEAT EXCHANGER
HEAT EX. CLEAN·OUT
COVERS
---- DRAIN AND ZINC
TRANSMISSION
RANS. DRAIN PLUG

UNIVERSAL MODEL M-50 SPECIFICATIONS
Horsepower 44 @ 3000
No. of Cylinders 4
Bore x Stroke
3.35 x 3.23
Cubic Inch 115
Maximum R.P.M. 3000
Cruising Range (Approx.) 2000/2500 R.P.M.
Compression Ratio 21:1
Electrical Equipment 12 Volt - 51 Amp WIGlow Plugs
Lubrication (Eng. Approx. Ots.) 8.5
(SAE 30 HD. (CD) or 10W40) CAUTION: FILL ONLY TO FULL MARK ON DIPSTICK
Lubrication (Trans.) FILL TO FULL RING ON DIPSTICK
Transmission Reduction 1.9:1
Coolant FWC (50/50 Solution Approx.) 8 qts.
Exhaust Flange 1
1/4" N.P.T.
Fuel Type #2 Diesel
Fuel Filter
PIN 298854
Oil Filter PIN 299927
Eng. Operating
Temp. Degrees F. 165
0 to
195
0
Propeller Rotation Right Hand
Weight
(Ibs.) 545 Ibs.
Injection Nozzle PIN 299567
Engine
is governor controlled to prevent overspeed. It is recommended to carry the following extra parts should
the need arise: V-Belt, Sea Water Pump Impeller, Fuel & Lube Oil Filters, 1 at. of Trans. Oil, 2 Ots. Lub. Oil
and 1 Gal. of 50/50 Coolant.
All pictorial views and specifications subject
to change without notice.
6

UNIVERSAL MODEL M-50
FUEL LINES
FUEL RETURN
GLOW PLUGS- ____ _
SEA WATER OVERBOARD
HEAT EX. DRAIN & ZINC_
TRANS. DIP STICK
OIL FILL HOLE --
SHIFT LEVER
ENGINE COUPLING/
TIMING PORT
COOLANT AIR BLEED VALVE
THERMOSTAT HSG.
F.W. CIRCULATING
PUMP ---
ALTERNATOR
SEA WATER PUMP
V·BELT
DIP STICK
AIR BREATHER
INJECTOR PUMP
FUEL AIR
--, ... , EED VALVE
------ TH ROTTLE
,..--- STOP LEVER
~-OIL FILTER
BLOCK COOLANT DRAIN
LEX MOUNTS
COOLANT FILL CAP
MANIFOLD
EXHAUST FLANGE
/ LD DRAIN
HEAT EX. CLEAN·OUT
COVERS
. DRAIN AND ZINC
NS. DRAIN PLUG
STARTER
OIL PAN
7

ENGINE SPECIFICATIONS
ENGINE BODY
Cylinder Head
Item M-30 M-40
Cylinder head surface 0.05 mm 0.05 mm
flatness (0.002 in.) (0.002 in.)
Top clearance 0.7 to
0.9 mm 0.7 to
0.9 mm
(0.028 to 0.035 in.) (0.028 to 0.035 in.)
Free
1.30 to 1.60 mm 1.30 to 1.60 mm
Gasket
(0.051 to 0.063 in.) (0.051 to 0.063 in.)
thickness Tightened 1.05 to
1.15 mm 1.05 to 1.15 mm
(0.041 to 0.045 in.) (0.041 to 0.045 in.)
Gasket shim thickness 0.2 mm 0.2 mm
(0.008 in.) (0.008 in.)
Compression pressure 448 psi 448 psi
Variance among cylinders - -
Valves (IN., EX.)
Valve clearance (cold)
0.18 to 0.22 mm
0.18 to 0.22 mm
(0.007 to 0.008 in.) (0.007 to 0.008 in.)
Valve seat width
2.1 mm
2.1 mm
(0.083 in.) (0.083 in.)
Valve seat angle 450 450
Valve face angle 450 450
Valve recessing
1.1 to 1.3 mm
1.1 to 1.3 mm
(0.043 to 0.051 in.) (0.043 to
0.051 in.)
Clearance between valve 0.04 to 0.07 mm 0.04 to
0.07 mm
stem and guide
(0.001 to 0.003 in.) (0.001 to 0.003 in.)
Valve stem O. D.
7.960 to 7.975 mm 7.960 to
7.975 mm
(0.313 to 0.314 in.)
(0.313 to 0.314 in.)
Valve guide 1.0.
8.015 to 8.030 mm
8.015 to 8.030 mm
(0.315 to 0.316 in.)
(0.315 to 0.316 in.)
Valve Timing
Open 0.35 rad. 0.35 rad.
Inlet valve (200 before TDC (200 before TDC)
Close
0.79 rad. 0.79 rad.
(450 after TDC (450 after TDC
Open
0.87 rad.
0.87 rad.
(500 before TDC (500 before TDC
Exhaust valve Close 0.26 rad. 0.26 rad.
(15
0 after TDC
(15
0 after TDC)
Valve Springs
Free length
41.7 to 42.2 mm
41.7 to 42.2 mm
(1.642 to
1.661 in.) (1.642 to
1.661 in.
Tilt
1.0 mm
1.0 mm
(0.039 in.) (0.039 in.)
Tension
1.117 N.
1.117 N
(12 kgf, 26.5 Ibs.)
(12 kgf, 26.5 Ibs.)
8

ENGINE SPECIFICATIONS
M-50 Allowable
Limit
0.05 mm
-
(0.002 in.)
0.7 to 0.9 mm -
(0.028 to 0.035 in.)
1.30 to 1.60 mm
-
(0.051 to 0.063 in.
1.05 to 1.15 mm
-
(0.041 to 0.045 in.)
0.2 mm
-
(0.008 in.)
448 psi 350 psi
-10%
0.18 to 0.22 mm -
(0.007 to 0.008 in.)
2.1 mm
-
(0.083 in.
450 -
45
0 -
1.1 to 1.3 mm
1.6 mm
(0.043 to 0.051 in.) (0.063 in.)
0.04 to 0.07 mm
0.1 mm
(0.001 to 0.003 in.) (0.004 in.
7.960 to 7.975 mm -
(0.313 to 0.314 in.)
8.015 to 8.030 mm
-
(0.315 to 0.316 in.)
0.35 rad -
(200 before TDC)
0.79 rad. -
(450 after TDC)
0.87 rad. -
(500 before TDC
0.26 rad. -
(15
0 After TDC
41.7 to 42.2 mm 41.2 mm
(1.642 to 1.661 in. (1.622 in.)
1.0 mm
1.00 N
(0.039 in. (10.2 kgf, 22.5 Ibs.)
1.117 N
(12 kgf, 26.5 Ibs.) -
9

ENGINE SPECIFICATIONS
Rocker Arm
Item M-30 M-40
Clearance between rocker 0.Q18 to 0.070 mm
0.Q18 to 0.070 mm
arm and bushing (0.0007 to 0.003 in.) (0.0007 to 0.003 in.)
Rocker arm shaft
0.0.
13.973 to 13.984 mm
13.973 to 13.984 mm
(0.550 to 0.551 in.) (0.550 to
0.551 in.)
Rocker arm bushing
1.0.
14.002 to 14.043 mm 14.002 to 14.043 mm
(0.551 to 0.553 in.)
(0.551 to 0.553 in.)
Camshaft
Camshaft alignment 0.05 mm 0.05 mm
(0.002 in.) (0.002 in.)
Cam height (IN., EX.) 33.36 mm 33.36 mm
(1.313 in.)
(1.313 in.)
Oil clearance of camshaft 0.050 to
0.091 mm 0.050 to
0.091 mm
(0.002 to 0.004 in.) (0.002 to 0.004 in.)
Camshaft journal
0.0.
39.934 to 39.950 mm 39.934 to 39.950 mm
(1.572 to 1.573 in.)
(1.572 to 1.573 in.)
Camshaft bearing
1.0.
40.000 to 40.025 mm 40.000 to 40.025 mm
(1.575 to 1.576 in.) (1.575 to 1.576 in.)
Timing Gear
Timing gear backlash 0.042 to
0.115 mm 0.042 to
0.115 mm
(0.002 to 0.005 il).) (0.002 to 0.005 in.)
Idle gear side clearance 0.20 to
0.51 mm 0.20 to
0.51 mm
(0.008 to 0.020 in.) (0.008 to 0.020 in.)
Clearance between idle gear 0.Q16 to 0.045 mm
0.Q16 to 0.045 mm
shaft and idle gear bushing (0.0006 to
0.001 in.) (0.0006 to
0.001 in.)
Idle gear shaft 0.0.
15.973 to 15.984 mm 15.973 to 15.984 mm
(0.628 to 0.629 in.) (0.628 to 0.629 in.)
Idle gear bushing 1.0.
16.000 to 16.018 mm 16.000 to 16.018 mm
(0.621 to 0.630 in.) (0.621 to 0.630 in.)
Cylinder (Liner)
Cylinder (Liner) 1.0.
76.000 to 76.019 mm 76.000 to
76.019 mm
(2.992 to 2.993 in.) (2.992 to 2.993 in.)
Oversize of cylinder liner +0.5 mm +0.5 mm
(+0.020 in.) (+0.020 in.)
Piston/Piston Ring
Piston pin hole 1.0.
23.000 to 23.013 mm 23.000 to 23.013 mm
(2.905 to 0.906 in.) (0.905 to 0.906 in.)
Compression 0.093 to 0.120 mm 0.093 to 0.120 mm
Piston ring ring 2 (0.004 to 0.005 in.) (0.004 to 0.005 in.)
clearance 0.020 to 0.052 mm 0.020 to 0.052 mm
Oil ring (0.0008 to 0.002 in.) (0.0008 to 0.002 in.)
Compression 0.30 to 0.45 mm 0.30 to 0.45 mm
Ring gap ring
1, 2
(0.012 to 0.Q18 in.) (0.012 to 0.Q18 in.)
Oil ring 0.25 to 0.45 mm 0.25 to 0.45 mm
(0.010 to 0.Q18 in.)
(0.010 to 0.Q18 in.)
Oversize of piston rings +0.5 mm +0.5 mm
(+0.020 in.) (+0.020 in.)
10

ENGINE SPECIFICATIONS
M-50 Allowable
Limit
0.Q18 to 0.070 mm
0.15 mm
(0.0007 to 0.003 in.) (0.006 in.)
13.973 to 13.984 mm
-
(0.550 to 0.551 in.)
14.002 to 14.043 mm
-
(0.551 to 0.553 in.
0.05 mm
(0.002 in.) -
33.36 mm
33.31 mm
(1.313 in.)
(1.315 in.)
0.050 to 0.091 mm
0.15
(0.002 to 0.004 in.) (0.006 in.)
39.934 to 39.950
mm
(1.572 to 1.573 in.) -
40.000 to 40.025 mm
(1.575 to 1.576 in.) -
0.042 to 0.115 mm
0.15 mm
(0.002 to 0.005 in.) (0.006 in.)
0.20 to 0.51 mm
0.6mm
(0.008 to 0.020 in.) (0.024 in.)
0.Q16 to 0.045 mm
0.10mm
(0.0006 to
0.001 in.) (0.004 in.)
15.973 to 15.984
mm
(0.628 to 0.629 in.) -
16.000 to 16.018 mm
-
(0.621 to 0.630 in.)
--
85.000 to 85.022 mm
+0.15 mm
(3.346 to 3.347 in.) (+0.006 in.)
+0.5 mm
(+0.020 in.) -
23.000 to 23.013 mm
23.053 mm
(0.905 to 0.906 in.) (0.907 in.)
0.093 to 0.120 mm
(0.004 to 0.005 in.) -
0.020 to 0.052 mm
(0.0008 to 0.002 in.) -
0.30 to 0.45 mm
1.25 mm
(0.012 to 0.Q18 in) (0.049 in.)
0.25 to 0.45 mm
1.25 mm
(0.010 to 0.Q18 in.) (0.049 in.)
+0.5 mm
(+0.020 in.) -
11

Item
Crankshaft alignment
Oil clearance between crank-
shaft journal and bearing
Front and
intermediate
Journal
0.0.
Rear
Front and
Bearing
1.0.
intermediate
Rear
Oil clearance between crank
pin and bearing
Crank pin
0.0.
Crank pin bearing 1.0.
Crank shaft side clearance
Under sizes of crankshaft
bearing and crank pin bearing
Oversizes of thrust bearing
Connecting Rod
Connecting rod alignment
Oil clearance between piston
pin and small end bushing
Piston
0.0.
Small end bushing 1.0.
(fitting)
WBRICATING SYSTEM
At idle
Oil pressure speed
At rated
speed
Oil Pump
Rotor lobe clearance
Radial clearance between
outer rotor and pump body
End clearance between rotor
and cover
Oil Filter
Opening pressure of bypass
valve
ENGINE SPECIFICATIONS
M-30
0.02 mm
(0.0008 in.)
0.040 to 0.118 mm
(0.002 to 0.004 in.)
51.921 to 51.940 mm
(2.044 to 2.045 in.)
51.921 to 51.940 mm
(2.044 to 2.045 in.)
51.980 to 52.039 mm
(2.046 to 2.049 in.)
51.980 to 52.025 mm
(2.046 to 2.048 in.)
0.035 to 0.093 mm
(0.002 to 0.004 in.)
43.959 to
43.975 mm
(1.731 to 1.732 in.)
44.010 to 44.052 mm
(1.733 to 1.734 in.)
0.15 to 0.31 mm
(0.006 to 0.012 in.)
-0.02 mm, -0.04 mm
(-0.008 in., -0.016 in.)
+0.2mm, +0.4 mm
(+0.008 in., +0.016 in.)
0.02 mm
(0.0008 in.)
0.014 to 0.038 mm
(0.0006 to 0.001 in.)
23.002 to 23.011 mm
(0.905 to 0.906 in.)
23.000 to 23.013 mm
(0.905 to 0.906 in.)
1.0 kgf/cm2
(14.2 Dsi)
3.0 to 4.5 kgf/cm2
(43 to 64 psi)
0.10 to 0.16 mm
(0.004 to 0.006 in.)
0.11 to 0.19 mm
(0.004 to 0.007)
0.105 to 0.150 mm
(0.004 to 0.006 in.)
98 KPa
1.0 kgf/cm2 (14.2 psi)
12
M-40
0.02 mm
(0.0008 in.)
0.040 to 0.118 mm
(0.002 to 0.004 in.)
51.921 to 51.940 mm
(2.044 to 2.045 in.)
51.921 to 51.940 mm
(2.044 to 2.045 in.)
51.980 to 52.039 mm
(2.046 to 2.049 in.)
51.980 to 52.025 mm
(2.046 to 2.048 in.)
0.035 to 0.093 mm
(0.002 to 0.004 in.)
43.959 to
43.975 mm
(1.731 to 1.732 in.)
44.010 to 44.052 mm
(1.733 to 1.734 in.)
0.15 to 0.31 mm
(0.006 to 0.012 in.)
-0.02 mm, -0.04 mm
(-0.008 in, -0.Q16 in.)
+0.02 mm, +0.04 mm
(+0.008 in., +0.016 in.)
0.02 mm
(0.0008 in.,
0.014 to 0.038 mm
(0.0006 to 0.001 in.)
23.002 to 23.011 mm
(0.905 to 0.906 in.)
23.000 to 23.013 mm
(0.905 to 0.906 in.)
1.0 kgf/cm2
(14.2 DSi)
3.0 to 4.5 kgf/cm2
(43 to 64 psi)
0.04 to 0.13 mm
(0.002 to 0.005 in.)
0.11 to 0.19 mm
(0.004 to 0.007 in.)
0.105 to 0.150 mm
(0.004 to 0.006 in.)
98 KPa
1.0 kgf/cm2 (14.2 psi)

ENGINE SPECIFICATIONS
M-50 Allowable
Limit
0.02 mm 0.08 mm
(0.0008 in.) (0.003 in.)
0.040 to 0.118 mm 0.20 mm
(0.002 to 0.004 in.) (0.008 in.)
51.921 to 51.940 mm -
(2.044 to 2.045 in.)
51.921 to 51.940 mm -
(2.044 to 2.045 in.)
51.980 to 52.039 mm -
(2.046 to 2.049 in.)
51,980 to 52,025 mm -
(2,046 to 2.048 in.)
0.035 to 0.093 mm 0.20 mm
(0.002 to 0.004 in) (0.008 in.)
43.959 to 43.975 mm -
(1.731 to 1.732 in.)
44.010 to 44.052 mm -
(1.733 to 1.734 in.)
0.15 to 0.31 mm 0.5mm
(0.006 in. to
0.012 in.) (0.020 in.
-0.02 mm, -0.04 mm -
(-0.008 mm, -0.016 mm
+0.02 mm, +0.04 mm -
(+0.008 in., +0.016 in.)
0.02 mm 0.05 mm
(0.0008 in.) (0.002 in.)
0.014 to 0.038 mm
0.15 mm
(0.0006 to 0.001 in.) (0.006 in.)
23.002 to 23.011 mm -
(0.905 to 0.906 in.)
23.000 to 23.013 mm 23.053 mm
(0.905 to 0.906 in.)
(0.907 in.)
1.0 kgf/cm2 or more
(14.2 psi)
3.0 to 4.5 kgf/cm2 2.5 kgf/cm2
(43 to 64 psi) (35 psi)
0.04 to 0.13 mm 0.20 mm
(0.002 to 0.005 in.) (0.008 in.)
0.11 to 0.19 mm 0.25 mm
(0.004 to 0.007 in.)
(0.010 in.)
0.105 to 0.150 mm 0.2 mm
(0.004 to 0.006 in.) (0.008 in.)
98 KPa
1.0 kgf/cm2 (14.2 psi)
13

COOLING SYSTEM
Fan Belt
Item
Belt deflection under load of
98 N (10 kgf, 21 Ibs.)
Heat Exchanger
Exchanger water tightness
Radiator cap opening
pressure
Thermostat
Thermostat's valve opening
temperature
Temperature at which
thermostat completely opens
FUEL SYSTEM
Injection Pump
Injection timing (static)
Fuel tightness of pump
element
Fuel tightness of delivery
valve
Injection Nozzle
Fuel injection pressure
Fuel tightness of nozzle valve
seat
ELECTRICAL SYSTEM
Starter
Commutator 0.0.
Variance
Mica undercut
Brush length
Glow Plug
IResistance
AC dynamo
INo-load output
Regulator
IRegulating voltage
ENGINE SPECIFICATIONS
M-30
7 to 9 mm
(0.275 to 0.355 in.)
1.2 kgf/cm2
(14 to 15 psi)
0.9 to 0.6 kgf/cm2
(15 to 9 psi)
60 C
(140°) F
73.9 C
(165°) F
23° to 25° before TOC
600 to 500 kgf/cm2
(8532 to 7110 Ibs.)
100 to 5 kgf/cm2
(1422 to 71.1 Ibs.)
140 to 150 kgf/cm2
(1990 to 2133 Ibs.)
130 to 140 kgf/cm2
(1848 to 1991 Ibs.)
32.7 mm
(1.287 in.)
45 A or less
0.5 to 0.8 mm
(0.092 to 0.032 in.)
19 mm
(0.748 in.)
Approx. 1.5 ohm
AC 20 volts or more 5200 RPM
13.8 to 14.8 volts
14
M-40
7 to 9 mm
(0.275 to 0.355 in.)
1.2 kgf/cm2
(14 to 15 psi)
0.9 to 0.6 kgf/cm2
(15 to 9 psi)
60 C
(140°) F
73.9 C
(1650) F
23° to 25° before TOC
600 to 500 kgf/cm2
(8532 to 7110 Ibs.)
100 to 5 kgf/cm2
(1422 to 71.1 Ibs.)
140 to 150 kgf/cm2
(1990 to 2133 Ibs.)
130 to 140 kgf/cm2
(1848 to 1991 Ibs.)
30.0 mm
(1.181 in.)
90 A or less
0.5 to 0.9 mm
(0.020 to 0.035 in.)
19 mm
(0.748 in.)
Approx. 1.5 ohm
AC 20 volts or more 5200 RPM
13.8 to 14.8 volts

M-50
7 to 9 mm
(0.275 to 0.355 in.)
1.2 kgf/cm2
(14 to 15 psi)
0.9 to 0.6 kgf/cm2
(15 to 9 psi)
73.9 C
(165<» F
23° to 25° before TOC
600 to 500 kgf/cm2
(8532 to
7110 Ibs.)
100 to 5 kgf/cm2
(1422 to
71.1 Ibs.)
140 to 150 kgf/cm2
(1990 to 2133 Ibs.)
130 to 140 kgf/cm2
(1848 to
1991 Ibs.)
30.0 mm
(1.181 in.)
90 A or less
0.5 to 0.9 mm
(0.020 to 0.035 in.)
19 mm
(0.748 in.)
Approx.
1.5 ohm
IAC 20 bolts or more 5200 RPM
13.8 to 14.8 volts
ENGINE SPECIFICATIONS
Allowable
Limit
-
-
-
-
-
-
-
-
-
0.2 mm
(0.008 in.)
-
12.7 mm
(0.500 in.
. 15

BOLT TORQUES
As a lot of bolts and nuts in the engine are of special shape, be careful to tighten them correctly using a torque wrench.
When tightening, follow this method: First tighten all the bolts 50% of the regular torque, then tighten them fully.
TIGHTENING BOLTS OF IMPORTANT PARTS
Marked bolts must be tightened after applying oil.
MODEL M-30 M-40
Head bolts and nuts
7.5 to 8.0 kgf/m
7.5 to 8.0 kgf/m
(54.2 to 57.9 ftllbs.) (54.2 to 57.9 ftllbs.)
Bearing case bolts 1
3.0 to 3.5 kgf/m
3.0 to 3.5 kgflm
(21.7 to 25.3 ftllbs.) (21.7 to 25.3 ftllbs.)
Bearing case bolts 2
3.0 to 3.5 kgf/m
3.0 to 3.5 kgflm
(21.7 to 25.3 ftllbs.)
(21.7 to 25.3 ftllbs.)
Flywheel bolts
10 to 11 kgf/m
10 to 11 kgf/m
(72.3 to 79.6 ft.llbs.) (72.3 to
79.6 ftllbs.)
Connecting rod bolts 3.7 to 4.2 kgflm 3.7 to 4.2
kgf/m
(26.8 to 30.4 ftllbs.)
(26.8 to 30.4 ftllbs.)
Rocker arm bracket studs
1.7 to 2.1 kgf/m
1.7 to 2.1 kgf/m
(12.3 to 15.2 ftllbs.)
(12.3 to 15.2 ftllbs.)
Idle gear shaft bolts
1.0 to 1.15 kgf/m
1.0 to 1.15 kgf/m
(7.23 to 8.31 ftllbs.) (7.23 to
8.31 ftllbs.)
Glow plugs 2.0 to 2.5 kgflm 2.0 to 2.5
kgf/m
(No neea to apply oil)
(14.5 to 18.1 ftllbs.)
(14.5 to 18.1 ftllbs.)
Drain plugs
4.0 to 4.5 kgf/m 4.0 to 4.5 kgf/m
(28.9 to 36.2 ftllbs.) (28.9 to 36.2 ftllbs.)
Nozzle holders 3 to 5 kgf/m 3 to 5
kgf/m
(21.7 to 36.2 ftllbs.)
(21.7 to 36.2 ftllbs.)
Bis
0.14 to 0.2 kgf/m
0.14 to 0.2 kgf/m
Oil
(10.1 to 14.5 ftllbs.)
(10.1 to 14.5 ftllbs.)
Switch Taper screw
1.5 to 2.0 kgf/m 1.5 to 2.0 kgf/m
(10.8 to 14.5 ftllbs.)
(10.8 to 14.5 ftllbs.)
Fuel limit lock nut 2.8 to
3.5 kgf/m 2.8 to 3.5 kgf/m
(20.3 to 25.3 ftllbs.)
(20.3 to 25.3 ftllbs.)
Fuel limit cap nut 2.5 to
3.0 kgf/m 2.5 to 3.0 kgf/m
(18.1 to 21.7 ftllbs.) (18.1 to 21.7 ftllbs.)
Injection pipes
1.5 to 2.6 kgf/m 1.5 to 2.6 kgflm
(10.8 to 18.8 ftllbs.) (10.8 to 18.8 ftllbs.)
Crankshaft nut
14 to 16 kgf/m
14 to 16 kgf/m
(101 to 116 ftllbs.) (100 to 116 ftllbs.)
Air vent screw
1.4 to 1.8 kgf/m
1.4 to 1.8 kgflm
(on injection pump)
(10.1 to 13.0 ftllbs.) (10.1 to 13.0 ftllbs.)
. 16

M-50
7.5 to 8.0 kgf/m
(54.2 to 57.9 ftllbs.)
3.0 to 3.5 kgf/m
(21.7 to 25.3 ftllbs.)
3.0 to
3.5 kgf/m
(21.7 to 25.3 ftllbs.)
10 to 11 kgf/m
(72.3 to 79.6 ftllbs.)
3.7 to 4.2 kgflm
(26.8 to 30.4 ftllbs.)
1.7 to 2.1 kgf/m
(12.3 to 15.2 ftllbs.)
1.0 to 1.15 kgf/m
(7.23 to
8.31 ftllbs.)
2.0 to 2.5 kgf/m
(14.5 to 18.1 ftllbs.)
4.0 to
4.5 kgf/m
(28.9 to 36.2 ftllbs.)
3 to 5 kgf/m
(21.7 to 36.2 ftllbs.)
0.14 to 0.2 kgf/m
(10.1 to 14.5 ftllbs.)
1.5 to 2.0 kgf/m
(10.8 to 14.5 ftllbs.)
2.8 3.5 kgf/m
(20.3 to 25.3 ftllbs.)
2.5 to 3.0 kgf/m
(18.1 to 21.7 ftllbs.)
1.5 to 2.6 kgf/m
(10.8 to 18.8 ftllbs.)
14 to 16 kgf/m
(101 to 116 ftllbs.)
1.4 to 1.8 kgf/m
(10.1 to 13.0 ftllbs.)
17