Westerbeke 6.5 MCG 60HZ User manual

SERVICE MANUAL
6.5 MCG 60HZ .5.2 MCG 50HZ
5.0 MCG 60HZ 4.2 MCG 50HZ
/tlu/ti-port ELECTRONIC FUEL INJECTION
MARINE GASOLINE GENERATOR
Single Phase
PUBLICATION. NO: 055743!
REVISION 1 .
NOVEMBER. 2017.

CALIFORNIA PROPOSITION 65
WARNING
Exhaust gas from diesel and
gasoline engines (and some of
its constituentsr are known to
the State of California to cause
cancer, birth defects, and other
reproductive harm.
A WARNING:
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 living/sleeping
quarters of your vessel. They are cost affective and
easily obtainable at your local marine store.

TABLE OF CONTENTS
COMPONENT STATIC TESTING .............................. 53
MAP SENSOR•STEPPER MOTOR............................ 53
TESTING FOR ENGINE OVERHAUL ............................. 2 Oll. PRESSURE SENSOR•OXYGEN SENSOR........
54
TESTING ENGINE COMPRESSION ............................... 3
ENGINE TROUBLESHOOTING ...................................... 4
DISASSEMBLY/ASSEMBLY PROCEDURES .................. 6
DC CIRCUIT BREAKER•WB OXYGEN SENSOR .. 54
HIGH/LOW RPM SHUTDOWN..................................54
EXHAUST TEMPERATURE SWITCH....................... 54
MAGNETIC PICK-UP COIL ...................................... 55
REMOVING THE GENERATOR ..................................... 8 FUEL PRESSURE PUMP..........................................
.-.55
DISASS'EMBLY OF EXTERIOR ENGINE COMPONENT .9
REMOVING FUEL SYSTEM ........................................ lO
FUEL INJECTOR .........................,.............................. 56
AIR AND COOLANT TEMPERATURE SENSORS .56
FUEL PRESSURE SYSTEM ...................................... 56
REMOVING THE TIMING BELT .................................. 11
ENGINE TROUBLESHOOTING AND
DISASSEMBLY, INSPECTION AND REASSEMBLY
SOFTWARE DIAGNOSTICS ........................ : ............... 57
CONTROL BOX COMPONENTS...............................57
OF THE MAIN ENGINE ....................................... 15·33
SOFIWARE DIAGNOSTICS (CHART) .................... 58
ON-BOARD DIAGNOSTICS ..................................... 62
COOLANT CIRCULATING PUMP ................................ 34
EXHAUST MANIFOLD/HEAT EXCHANGER ................ .35
BC GENERATOR ....................................................... 67
DISTRIBUTER ....................................................... : .... 36
AC TERMINAL CONNECTIONS...............................67
RAW WATER PUMP ................................................... 37· GENERATOR OUTPUT...............................................
68
TIGHTENING TORQUES (ENGIN£)........................... 35
SPECIAL TOOLS (ENGINE ....................................... 39
ROTATING AUXILLARY WINDING ......................... 68
EXPLODED VIEW ...................................................... 69
CON'l'ROL BOX .......................................................... 69
SERVICE STANDARDS AND LIMITS ....................... 40
BC GENERATOR TROUBLESHOOTING ...................... 70
EXCITING THE GENERATOR................................... 70
MAIN STATOR RESIDUAL VOLTAGE ..................... 70
ENGINE ADJUSTMENTS .................... : ...................... .42 TESTING
THE DIODES............................... .-~ .............71
SPEED SENSOR .......................................................... 42
NO-LOAD VOLTAGE ADJUSTMENT.......................71
IGNITION TIMING...................................................... 42
AC HERTZ CONVERSION.........................................71
VALVE CLEARANCE ................................................. 42
BC GENERATOR TROUBLESHOOTING (CHART) ....... 72
CAM SENSOR.............................................................. 42
SPA.RK PLUGS............................................................. 43
DRIVE BELTS .............................................................. 43
IGNITION WIRES.,...................................................... 43
INTERNAL WIRING SCHEMATIC............................ 72
TESTJNG THE EXCITER WINDINGS ...................... 73
TESTING CONTINUITY............................................. 74
TESTING CAPACITORS ............................................. 74
BLEEDING THE FUEL SYSTEM .................................. 44
BC ROTOR • TESTING ............................................... 75
OIL PRESSURE .......................................................... 45
TESTINGWINDINGS .................................................75
MEASURING EXHAUST PRESSURE ......................... .45 TESTING CONTINUITY..............................................75
IGNITION COIL· TESTING ........................................... 46
NOTE: Page 76 has been removed from this manual
POINT GAP·TESTING ................................................. 46
SHORE POWER TRANSFER SWITCH ......................... 77
IGNITER-TESTING ..................................................... 46
PICK-UP COIL-TESTING ........................................... .46
WIRING DIAGRAMS (#55536) ............................. 18:82
BATTERY CHARGER· TESTING .................................. .47
DC AUXILLIARY POWER ADAPTER ........................... 83
STARTER MOTOR ....... : .............................................. 48
REMOTE PANEL WIRING ........................................... 83
EXPLODED VIEW....................................................... 49
REMOTE OIL FILTER ................................................. 84
SERVICING.................................................................. 50
ENGINE/GENERATOR SPECIFICATIONS .................... 85
ECU-ELECTRONIC CONTROL UNIT ........................... 52
HARDWARE TORQUES (CHART) .......................... , .... 86
SETTING/CHANGING ENGINE SPEED ................... 52
DECIMAUMETRIC CHART ......................................... 87
1

TESTING FOR OVERHAUL
HOW TO DETERMINE ENGINE OVERHAUL PERIOD
Cause of Low Compression
Generally, the time at which an engine should be overhauled
is detennined by various conditions such as lowered engine
power output, decreased compression pressure, and increased
fuel and oil consumption. The lowered engine power output
is not necessarily due to trouble with the engine itself, but is
sometimes caused by improper oil, clogged filters or a faulty
carburetor.
The decrease in compression pressure is caused by many fac-
tors. It is, therefore, necessary to detennine 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 or piston rings, the following symptoms will
occur:
1 Low engine power output
2 Increased fuel consumption
3 Increased
oU consumption ·
4 Hardengine starting
5 Noisy engine operation
These symptoms often appear together. Symptoms 2 and 4
can result also from improper fuel regulation or a faulty car-
buretor. They are caused also by defective electrical devices
such as the battery, starter or spark 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 combus-
tion is obtained only under sufficient compression pressure.
·If an engine lacks compression pressure, incomplete combus-
tion of fuel will take place even if other parts of the engine
are operating properly. To detennine the period of engine
overhaul, it is important to measure the engine compression
pressure regularly. At the same time, the engine speed at
which the measurement 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. ·
NOTE: To test engine co~ression see the ENGINE
ADJUSTMENTsection of this manual.
OVERHAUL CONDITIONS
Compression pressure tends to increase alittle 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 ofcompression pressure reaches the repair
limit, the engine must be overhauled.
The engine requires overhaul when oil consumption is high,
blow by evident,. and comp~ssion val~es are at n:Unimurn or
below. Refer to the following page for testing engine compression.
2
ENGINE OVERHAUL
The following sections contain detailed information
relating to the major components and systems of the engine.
Included are disassembly and inspection instructions for the
guidance of suitable equipped and staffed marine engine ser-
vice and rebuilding facilities. The necessary procedures
should be undertaken only .by such facilities.
Additional detailed information and specifications are
provided in other sections of this manual, covering the
generator, alternator, starter motor, engine adjustments,
cooling pumps, etc.
DISASSEMBLY
1. Before disassembly and cleaning, carefully check for
defects which eannot be found after disassembly and
cleaning. '
2. Clean the engine exterior. ·
3. Perform disassembly in aproper order using proper tools.
Keep disassembled parts in order. Apply oil when neces-
sary. Take special care to keep the fuel system parts from ·
intrusion ofdust and dirt
The generator serial
number is stamped
· on the top the
generator nu1~;su1g ••
PCINTERFACESOFnNARE
The engine serial
number is stamped
\ into the engine block.
.~
'
Prior to overhaul, it is advised to operate the unit with PC
Interface Software connected to the ECU. This will help
determine system operation and whether system components
may need ~placement during overhaul. .

TESTING THE ENGINE COMPRESSION
BY-PASSING THE ECU
DESCRIPTION
The ECU is by-passed·by attaching an electrical jumper
dirnctly to the starter motor solenoid as illustrated below.
The electrical jumper can easily be assembled using a push
button and connecting wires as shown.
COMPRESSION TEST PROCEDURES
NOTE: The activation of the starter motor is afunction of
the ECU (Electronic Control Unit). To by-pass the ECU, a
simple electrical jumper arrangement can befabricated to
connect between the battery B+ cable connection on the
starter solenoid and the spade type activation connection on
the starter solenoid with a push button in this jumper to make
a circuit between these two connections andactivate the
starter solenoid.
1. Start the engine and allow it to warm up to its normal
operating temperature. Then shut itdown.
2. Open the DC breaker on the unit's control box to disable
the ECU. Connect the jumper arrangement on the starter
solenoid connections.
3. Close the unit's raw water thru-hull opening. This is to
prevent the raw water pump from pumping water into the
unit's exhaust system during the test as no or very little
exhaust pressure will
be present during the test to help
expel water
from the unit's exhaust system during engine
cranking.
4. Remove the high tension leds from the spark plugs and
remove all spark plugs.
5. Thread the compression gauge adapter into the spark
plug opening of cylinder #1. Connect the compression
gauge to the adapter.
ATTACHING THE ELECTRICAL JUMPER
6. Activate the starter motor using the push button on the
electrical jumper arrangement for the starter. Allow the
engine to crank, observing the compression gauge. Allow
the engine to crank until the gauge reaches a maximum
reading where further cranking does not produce a higher
reading on the compression gauge. Stop cranking
and
record the pressure.
7. Remove the compression gauge and adapter from the #1
spark plug opening and install it in the #2 cylinder spark
plug opening and repeat step -.·6.
8. Proceed to the next cylinder and repeat step #6 until all
cylinders have been tested and there p~sures recorded.
STANDARD COMPRESSION PRESSURE AT 400 RPM
178 PSI (12.5 KG/CM'
LOWER LIMIT· 137 PSI (9.6 KG/CM')
NOTE: A wet test can be pelformedon cylinders with "zow
compression figures. This will help determine if the iow ·
compression is the result of worn cylinders/rings or worn
valve seats/valves or both. Place afew squirts of oil into
the cylinder and the peiform the compression test on that
cylinder.
a. Adramatic rise in recorded compression value would
iridicate worn cylinder/rings.
b.Aminimal rise in recorded compression value
would indicate both cylinder/ring and valve wear.
c. No appreciable rise in recorded compression would
indicate valve/valve seat wear.
Engines & Generators
3

·ENGINE TROUBLESHOOJINQ: ..
The following troubleshooting chart describes certain problems
and causes relating to engine service. Also note there is a
Diagnostic Troubleshooting section.
Problem
Engine does not crank.
Engine cr'anks, does not start
(engine will crank 8 seconds)
(3 crank cycles before underspeed fault occurs)
Engine starts, runs and the shuts down.
Engine hunts.
Engine ll)isfires/back firing.
Engine overheats/engine temp LED is illuminated.
Exhaust temp LEO is illuminated.
Low oil pressure/oil pressure LEO is illuminated.
Note: When servicing the engine/generator, the main circuit
breaker (control panel) disconnects all AC power and can be
switched off and reset manually.
. Possible Cause
1. DC panel breaker OFF.
2.0C battery OFF-
3.1<2 relay faulty.
4·.Starter solenoid faulty .
. 5.0C_battery low/dead Of? LOOSEBIUTERYCABLE.
6: Wiring harness disconnected
7. Water filled cylinder.
8.DC panelS amp buss fuse is faulty.
1.Fuel starVation.
2.Air in fuel system.
3.Fouled spark plugs.
4.Faulty ignition coil.
1.Fuel starvation.
2.Air in fuel system.
3.F,aulty shutdown switch/sensor.
4.Faulty fuel pump.
1.Air in fuel system.
2.Faulty fuel pump.
3.Low octane fuel (lower than 89).
4.Faulty spe~d sensor (crankshaft).
1.Low octane fuel (lower than 89}.
2.Dirty air intake screen.
3.High tension ignition wires.
4.Exha:ust restriction.
5.Wom/fouled spark plug.
&.Faulty ignition coil.
7.low or no .fuel pressure. Poor quality fuel.
1.Raw water coolant flow obstruction.
2.Coolant level iow.
3.Faulty impeller.
4.Pump belt loose/broken.
5.Stuck thermostat.
&.Air in cooling system (fresh water).
1.Loss of coolant flow/faulty pump.
2.Faulty exhaust temperature switch.
3.Faulty fire shutdown
-.
.1.0illevellow.
2.Faulty oil pressure sendor.
3.0il viscosity incorrect.
Engines & Generators
4

ENGINE TROUBLESHOOTING
Problem Possible CaiiSe
No DC charge to starting battery.
1.Circuit fuse faulty/blown (two fuses).
2.Faulty circuit connection.
3.Faulty regulator/battery charger.
4.Bridge rectifier.
5.Charge AC winding.
High DC Charge to batterY.
· 1.Battery chargltt misad]usted.
2.Faulty starter solenoid.
Starter stays energiZed after sfilit:
1. Faulty K1 relay.
2.Faulty starter solenoid.
Poor performance at generator speed.
1.Low octane fuel.
2.1ncorrect ignition timing.
3.Fuel supply issue.
4.High engine compartmenttemperature (122" F max}.
Black exhaust smoke.
1. Dirty air screen.
2.Faulty injector.
Blue exhaust smoke.
1.Lube oil is diluted.
2.Crankcase breather tube is clogged.
3.High lube oil level.
White exhaust smoke. (Check engine fault)
1.Faulty oxygen sensor ..
2.Poor connection at sensor.
Check engine LED's are illuminated.
1.Diagnostic software required.
2. . .
(0 Sensor I Low Battery )
Speed LED's are illuminated-no flashing.
1. Throttle shaft sticking.
2.lntake manifold vacuum leak.
Pair of Speed LED's are illuminated"flashing.
1 ~AC generator overload.
2.Fuel starvation.
External alarnt LED is illuminated.
1.Loose connection.
2.Faulty fire suppression shutdown devise.
3.1ncorrect setting on shutdown device (contacts should n/c)
Engine runs for 15 +I· seconds, then shuts
1. Oil Pressure Switch (#037323)
down. The SPEED LED illuminates AFfER
2. T~Relay (053555)
the engine shuts down.
----·· , ..
Engine starts, runs for 20-30 seconds then
1. Air in Friel System.
Overspeeds. Shuts down with Overspeed
LEOs ON.
Engines & Generators
5

DISASSEMBLY ·PROCEDURES ..
PREPARATION FOR DISASSEMBLY
• Clean or wash the engine exterior.
• Do not remove or disassemble the parts that require no
disassembly.
• When disconnecting sensor wires, label and tape the ends.
• Perform disassembly in a proper order using proper tools.
Keep disassembled parts in order. Apply oil when
necessary. Take special care to keep the fuel system parts
from intrusion of dust and dirt.
• Pans 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 marked for
its component, so that the same combination or set can be
reproduced at assembly.
• Pay attention to marks on assemblies, components and
parts for their positions or directions. Put on marks, if
necessary, t6 aid assembly.
• Carefully check each part or component for any sign of
faulty condition during removal or cleaning. The part will
tell you how it acted orwhat was abnormal about it more
accurately during removal and cleaning.
6
REMOVE EXTERIOR COMPONENTS
Wi~ the generator separated from the engine,
begm the following. step by step procedure to
disassemble the exterior parts.
NOTE: Mount the engine securely on a suitable engine stand.
1. Remove the start n:t()t~r and drive belt.
Label the wires and cables.
2. With thehoses disconneeted, removethethermostat
housing and housing gasket, leaving thetemperature
sender in place.
3. Remove the magnetic pick-up from the bell housing.
4. Remove thebell housing and the circuit breaker/
pre-heatsolenoid mounting bracket
Remove the engine back plate.
5. Remove the oil filter, oil cooler, oil hoses and mounting
bracket.Make note of the hose arrangements.
6. Remove the engine tncmilted raw water pump~
complete with its adaptermounting plate. See RAW
WATER PUMP for parts breakdown.
8. Remove the engine beatexchanger and exhaust elbow.
Refer to HEAT EXCHANGER ExHAUST MANIFOLD
in this manual.
9. Remove the fresh water cooling pump. Refer
to
COOLANT CmCUIATING PUMP in this'manual.

ENGINE ASSEMBLY
GENERAL INFORMATION
• Be careful not to mix bolts and nuts. Metric and S.A.E.
bolts are used on various engine assemblies.
• During assembly, recheck clearances and insure that parts
are being assembled in their proper order and facing in the
correct direction in relation to the engine block, such as,
pistons, piston rings, bearings and bearing caps.
• Apply lubricating oil to moving parts during assembly.
Insure that moving parts, when assembled on the engine,
rotate or slide and are not subject to binding or
excessive tension.
• If there are mating marks scribed during disassembly,
reference them correctly for assembly.
• Use new gaskets, lockwashers, 0-rings, packings and seals.
• Tighten the bolts and nuts on important parts of the engine
to specified torques using a reliable torque wrench.
• When required, use liquid sealants when required on nuts,
bolts and gaskets. Refrain from using tape sealants.
• Most gaskets and many bolt washers are asymmetrical,
make certain they are positioned properly.
Torquing Hardware
Prevent mechanical damage by running fasteners dowri in
three steps-1/2, 2/3, and 111 torque. Exceptions are torque-to-
yield bolts and rocker arm shaft fasteners. The former are
torqued as indicated. The latter-rocker shaft fasteners-should be
brought down in very small increments, working from the
center bolts out. Gaskets, especially head gaskets, might be
damaged during assembly, they should be positioned with great
care. See TORQUE SPECIFICATIONS thru out this manual.
Sealants and Lubricants
Oil based PERMA'IEX #2 and its HIGH TACK equivalent are
excellent
all purpose sealers. They are effective in just about
any joint in contact with coolant, raw water, oil, or fuel. Alight
coating of oil or LIQUID TEFLON can be used on rubber
gaskets and o-rings.
LOCTITE hydraulic red sealant should be used on oil adapter
hoses and the oil filter assembly.
Coat both surfaces of the oil pan gasket with high temp RED
SILICONE SEALER.
When installing gaskets that seal around water (coolant)
passages, coat both sides with WHITE SILICONE GREASE.
Do not use sealant when installing a new gasket.
HIGH-COPPER ADHESIVE SPRAYS are useful for hold-
ing a gasket in position during assembly.
Specialized gasket sealers such as HYLOMAR work well in
applications requiring non-hardening properties. HYLO~
is particularly effective on copper cylinder-head gaskets and
resists fuel, oil , and water.
NOTE: TAPE SEALANTS should be used on pipe plugs and
fitting that connect water coolant passages.
Bolts and Fasteners
Lightly oil head bolts and other fasteners as you assemble
them. Bolts and other plugs that penetrate the water jacket
should be
sealed with PERMATEX #2 or HIGH TACK.
When assembling the flywheel, coat the bolt threads with
LOCTI1E blue.
LITIIIUM based grease is waterproof, ideal for water pump
bearings and stuffing boxes.
Antiseize compounds and thread locking adhesives such as
LOCTI'IE protect threaded components yet allow them to
come apart when necessary. LOCKTI'IE offers levels of
locking
according to the job.
Heavily oil all sliding and reciprocating components, always
use clean engine oil.
7

GENERATOR/ENGINE DISASSEMB.LY_
DESCRIPTION
The MCG generator models are not bulky ot_ extremely
heavy (330~3701bs. With reasonable e:ffott, itcan be
removed from its location in the vessel.
Thm OFF the DC_ batterypowerfor the generator.
Disconnect the DC battery cables, Disconnect theACoutput
connectiOn from the genertitor'sACbreaker: Uripl'ug any
remote Starl!Stop panel connection;
Close OFF the raw· watersea:.;cock and disconnect ibe ra\v
water supply at the rawwaterpunip. Separate 'tt¢ eXhaust at
the water injected eXhaust elbow. Shtit OFF the fuel supply
and disconneCt the supply at the inlet connection at the ·
engine. Be consCious of fuel spillage.
COOLANT DRAIN • REMOVE USING AN BMM (11/16'7 SOCKET
LOCATED JUST BELOW TO DRAIN THE OIL OR PUMP THE WARMED ·
THE INTAKE MANIFOLD OIL UP THRU THE HOSE.
BC GENERATOR
-COMPONENTS
TYPICAL BC GENERATOR
BACK-END ASSEMBLY
NOTE: For serviCing and testing of the back~ehd (generator),
refer to the GENERATOR section in this ttu:cn:tt4l.
NOTE: There is a re~con ACgenerator exchange program.
Contact your WESTERiJEKE Dealer.
tJmastenthe·genetator from'its mouritingnn1s ot the .
mount:fug raiis from the platform and remove the generator
from the ·bOat.
Once the generator is securely mounted on the work bench,
drain the engine oil and coolarit. .
Disconnectand remove the eontrolpanel With wiring
harness .. Label an connections· S() they·ciin be properly
reconnected. Take·digital photos ifneedoo.
SEP.ERATiNGTHE·GENERATOR•FROM'·THE·ENGINE
1. Reri:IOve the Lou~ered COvet.
2. Remove the nuts/washets from the three securing Studs.
(On sOme uni~s, the hex nut is part ofthe stud).
3. Carefuily workthe Bearing·Support Housing off the
R<)tor earner Beating~.
4. Slide the Generators Housing away from the Adapter
Pla~e and RotOr.
5. Unbolt the RotorAssembly from the Flywheel.
6. Unbolt the Adapter Plate froni the Back Plate.
7. Unbolt.theFlywhed.
Set all generator components aside for cleaning, inspection,
testing and painting as tnay be needed and cover!
GENERATOR BAGK·END
SEE SPECIAL TOOLS FOR
DISASSEMBLING THE
GENERATOR COMPONENTS
Engines & Generators
8

ENGINE DISASSEMBLY
GASK.ET
TO COOLANT
RECOVERY TANK
-1'<1/'
BRACKET
THERMOSTAT
ASSEMBLY
THERMOSTAT.
Remove thethermostat assembly and cleanthe interior
chambers. Inspect
the seal in the pressure cap. Properly
alignthe gasket andbleedhole inthe thermostat with
notch_in housing when reassembling.
RAW WATER eUMP
·· ·....; '_ '·':.'. __ ,,, •i .:,:' ··.· · · r'''·· ~,·--. :'. ·.; •• ' ..
Loose~ fu~ taW Water pump, re!l10Ve the drive beit and then
removetheraw water pump. _Refer to theTable of CoritentS
for the ·exploded Parts Drawing.
RAW WATER
PUMP
9
OIL FILTER ASSEMBLY
~
OIL.FILTER ASSEMBLY
Remove and properly dispose ofthe oil filter. Disassemble
the oil ~allecy casting from the engine being careful to dean
up !lilY spilled oil. Clean the interior pl!Ssage"in the casting,
cove:r an!f.s~t aside,
EXHAUST ELBOW
NOtE: Refe; to the Table of Contents for the dis£L$sembly and
servicing. of the engine's Coolant Circulating Pump andthe
removal of the ~haust Manifold and Elbow Casting.·
DisTRIBUTER ....
Detl.Ch and remove the ignition wires,. the distrl.butor and .
spark plugs. Refer to DISTRIBUToR DISASSEMBLYin the
manual. See ENGINEADJUSTMENTS for infomiation on
ignition wires_~d spark plllgs. ·-

DISASSEMBLY OF FUEL SYSTEM COMPONENTS
REMOVING ASSEMBUES
The fuel system components can be removed as assemblies
by simply unbolting their brackets from the engine. Unplug
the
fuel injectors and wiring harness connections and discon-
nect the
fuel lines and coolant hoses.
Mark and label the connections for re-assembly.
NOTE: Coolant hoses and fuel lines may need·to be drained
off as they are disconnected.
A CAUTION: Clean up spilled fllel immediately and
dispose of rags properly.
Remove all the bolts and nuts that fasten the brackets to the
engine. The components can then
be removed as complete
assemblies, covered over
and set aside. This allows full
. ~
access to the engine block. ~
1
I
'I
FUEL PUMP:
AND FUEL
MODULE
ASSEMBLY
THE FUEL PUMP AND FUEL MODULE
CAN BE DISASSEMBLED FROM THE
ENGINE AS AN ASSEMBLY BY
REMOVING THE BRACKET.
Engines & Generators
10
THE FUEL RAIL AND INTAKE MANIFOLD
INJECTORS CAN BE REMOvt:D AS AN
ASSEMBLY BY REMOVING THIS BRACKET. ;
THE TIMER IS MOUNTED ON A
BRACKET JUST ABOVE THE FUEL
CELL THE TIMER FUNCTION IS TO
TERMINATE DC VOLTAGE TO THE
FUEL PUMP AT ENGINE SHUTDOWN.
FUEL FILTER ASSEMBLY
FUEL SYSTEM COMPONENTS
Incoming fuel (from the owner installed Gasoline Water
Separator/Filter) is pumped thru the Inlet Fuel Filter into the
Fuel Module by the Electric Fuel Pump. The fuel is cooled
as it circulates thru the Fuel Module and then is pumped by
the Elf!ctric Fuel Pump to the High Pressure Pump Modide
and to the Secondary Fuel Filter. The fuel passes to the Fuel
Rail and is delivered (utider pressure) to the Fuel Injectors.

12BOLT
NUMBERS INDICATE THE
SUGG!STED ORDER OF
DISASSEMBLY
1 TIMING
COVER A
TORDiJE 98 • 105 FT-LBS
135·145Nm
TIMING BELT DISASSEMBLY
INSTRUCTIONS FOR INSPECTING AND REPLACING
THE nMING BELT
WESTERBEKE requires as normal mafutenance, replacing
the timing belt after 1000 engine operating hours. The timing
belt should always bereplaced during an engine overhaul.
The adjustments, inspection, and replacement procedures
may be perfoxmed without removing the generator from the
boat THE TIMING BaT PART NUMBER IS #043036
TIMING BELT ADJUSTMENT;
INSPECTION AND REPLACEMENT
CAN BE PERFORMED WITH
ENGINE IN THE BOAT
OD 0.311n [8 mml
Timing Belt Removal
1. Thm the crankshaft clockwise to align the timing mark on
the camshaft sprocket and timing belt rear cover.
3. Loosen the timing belt tensioner nut
NOTE: Always tum the crankshaft clockwise.
2. Remove the plug on the left surface of the cylinder block
and insert arod with a diameter of0.31 in (8 p'Ull) to lock
the counterbalance'shaft ·
NOTE: Be sure to use an inserting rod with a diameter of
0.31 in (8 mm).
4.
Engin!!_s ~-Generators
11
CRANKSHAFT
SPROCKET

TIMING BELT DISASSEMBLY
5. Remove the timing belt.
NOTE: If the timing belt is to be reused, draw an anvw on
the belt to indicate the direction of rotation (clockwise).
Cams~aft Sprocket Removal
1. Remove the camshaft sprocket bolt without turning the
camshaft.
Oil Pump SprockJtt Flange Nut Removal
1. Remove the oil pump sprocket flange nut
Crankshaft Bolt Removal
1. Lock the crankshaft in position.
NOTE: Do not tum the crankshaft
2. Remove the crankshaft bolt.
nmlng BeH Inspection
Replace the belt if any of the following conditions exist:
• Hardening of the back rubber, leaves no indent when
pressed with fingernail (back side is glossy).
• Cracks on rubber back.
• Cracks or peeling of canvas.
• Cracks on tooth bottom.
• Craeks on belt
• Abnormal wear ofbelt sides. The sides are normal if they
are sharp as if cutby a knife.
• Abnormal wear on teeth.
• Tooth missing and canvas fiber exposed.
RUBBER
EXPOSED---boo
5.
7.
Tensioner Inspection
6.
8.
TOOTH MISSING
AND CANVAS
FIBER EXPOSED
L Replace the tensioner if the pulley binds, rattles or is noisy
when turned.
Engines &_Jienerators
·12

ENGINE TIMING BELT
Flange Installation
1. Mount the flange so that its side shown by the heavy
arrow in the illustration faces toward the sprocket.
FLANGE
A-rriKSHAFT
-~
WASHER
Crankshaft Bolt Installation
1. Lock the crankshaft
NOTE: Do not tum the crankshaft,
2. Tighten the crankshaft bolt to the specified torque.
Oil Pump Sprocket Flange Nut Installation
1. Insert the round .bar into the plug hole in the left side of
the cylinder block to keep the counterbalance shaft from
turning.
.
2. Install the oil pump sprocket.
3. Tighten the nut to the specified torque.
D
d
Camshaft Sprocket Bolt Installation
1. Tighten the bolt to the specified torque.
CAMSHAFT BOLT TORQUE 58 ·72fl·lbs (SO ·100 Nm)
SPROCKET BOLT
Tensioner Spring/Timing Tensioner Installation
1. Install the tensioner spring and timing belt tensioner.
2. Hook the tensioner spring onto the bend of the timing belt
tensioner bracket and the stopper pin on the cylinder block.
3. Move the timing belt tensioner as close as possible to the
water pump; temporarily tighten the tensioner nut.
Timing Belt Installation
1. Align the triangular marking on the camshaft sprocket
with a marking on the timing belt rear cover.
2. Align the notch in the crankshaft sprocket flange with the
marking on the front case.
3. Align the triangular marking on the oil pump sprocket
with the marlcing on the front case, and then insert a 2.56 in.
(65 mm.) or longer, 0.31 in (8mm.) diameter round bar into
the plug hole in the left side of the cylinder block.
NOTCH IN CRANKSHAFT
SPROCKET
MARK ON FRONT CASE
Engines &Generators
13

ENGINE TIMING BELT
At this time, check that the moveable range of teeth on the
oil pump sprocket is according to specifications.
STANDARD VALUE: 4 to 5 teelh in forward direction.
1 to 2 teelh in reverse direction.
4. If the movable range of the teeth on the oil pump sprocket
exceeds the specified range, correct as follows:
a. Pull outthe round bar from the plug hole in the left
side
of the cylinder block.
b. Thm the oil pump sprocket one turn at a time until the
round bar can again be inserted.
c. Check that the movable range ofthe oil pump sprocket
is in the specified value. ·
5. Set the timing belt over the crankshaft sprocket and then
over the oil pump sprocket and camshaft sprocket, in that
order.
NOTE: Ensure that the tension side of the timing belt is not
slack. Keep the round barinserted until the timing belthas
been placed. After this step, be sure to remove the round bar.
6. Apply counterclockwise force to the camshaft sprocket to
make the belt taut on the tension side, and make sure that
all timing marks are lined up.
CAMSHAFT SPROC
TENSION SIDE
7. Loosen the temperorarily tightened tensioner nut on the
water pump
side 1 or 2 turns, and tension the belt making
use of the spring force.
8. Thrn the crankshaft clockwise by nine camshaft sprocket
teeth (81 j to align the timing mark on the camshaft
sprocket
with the tensioner set mark on the timing belt
rear cover.
A CAUTION: This operation Is pedonned to give a
pmper tension to the timing belt, so do not tum the
crankshaft COIInterclockwise and push the belt to
check the tensiDn.
9. Make sure that th~ timing belt teeth are engaged with the
camshaft sprocket teeth along the portion of the sprocket
shown by the curved arrow in the illustration below. Then
tighten the tensioner nut.
lO.Pull the timing belt in the center of the tension side
toward the sealing gasket line for the belt cover, as illus-
trated. Make sure that the clearance between the back of
the belt and the sealing line is the standard vaJ.ue.
STANDARD VALUE: 0.4Ttn. (12mm)
D.471n [12 mmJ
ll.Pull out the rod from the plug hole on the left surface of
the cylinder block and apply the specified sealant. Then
tighten the plug to the specified torque.
14
Specified sealant value: 3M A1D Part No. 8660 or
equivalent.
TIGHTENING TORQUE: 11·16 ft.lbs. (15·22 Nm)

CYLINDER HEAD AND VALVES
4 CYLINDER HEAD
TORDU£43- 51 FT-LIJS
60-lONm
REMOVING THE CYLINDER HEAD
FROM THE CYLINDER BLOCK
Disassemble the cover bolts as shown above, taking care not
to lose the washer and insert. Remove the rocker cover and
rocker cover gasket.
Loosen each of the cylinder head bolts, a little at a time so
as to avoid the possibility ofdistorting the cylinder. Repeat
several times until the bolts are unfastened. Follow the
sequence shown in the diagram. ,
Remove the cylinder head and the cylinder head gasket.
NUMBERS INDICATE THE
SUGGESTED ORDER OF
DISASSEMBLY
CYLINDER HEAD BOLTS
LOOSENINf.! SEQUENCE
Remove the valve retainers, valve springs and valves from
the cylinder head. When removing each valve retainer,
depressing the retainer againstthe valve spring and remove
the retainer lock. Identify each valve by putting a mark
indicating the number ofthe cylinder from which the valve
was removed.
~
~
KEEP THE PARTS'
IN ORDER ACCORDING )..6)
NUMBER- EXHAUST
AND INTAKE
TO THE CYLINDER ~\
~ WESTERBEKE
Engines &Generators
15

CYLINDER HEAD AND VALVES
Use pliers to remove the valve stem seals. Do not reuse the
stem seals.
CYLINDER HEAD INSPECTION
Before cleaning check the cylinder head for water leaks,
cracks and other possible damage.
Clean by completely removing the oil, scaling, carbon and
sealant After flushing the oil passage, blow air thru to ensure
that no portion of the oil passage is clogged.
To check the cylinder head bottom surface for flatness and
distortion, as indicated in the diagram, use a straight edge
and a feeler gauge. If distortion exceeds the limit correct
by grinding.
CHECKING CYUNDER HEAD FLATNESS
I
CYLINDER HEAD flAlNESS
Standard O.OD191n (0.06mm) Limit O.DD791n (0.2mm)
CYLINDER HEAD GRINDING UMIT .
D.0079in (D.2mm}
Total resurfacing_ depth of cylinder head and block
CYLINDER HEAD HEIGHT (NEW)
4.287- 4.2961n (108.9 -109.1mm)
A CAUTION: No more than 0.079Jn (0.2mm) of
stock may be removed from the cylinder head and
cylinder block mating surfaces In total.
See the STANDARDS AND UMll'S CHART for cylinder
head rework dimensions of the valve seat hole.
VALVE ASSEMBLY INSPECTION
Valve StemNalve Seat
If the valve stem is bent or worn, replace the valve. Check
contact between the valve and valve seat by applying a thin
coat ofPrussion Blue (or Redhead) on the valve seat contact
face, then insert the valve into the valve guide and press-fit
the valve on the valve seat. Do not rotate the valve.
Check if the valve seat contact face contacts the center posi-
tion ef the valve contact face. If it is not correct concentric,
correct the valve seat. If the margin is out of the limit, replace
the valve.
THICKNESS OF VALVE HEAD MARGIN
standard
Intake D.0391n (1.Dmm)
Exhaust D:D51in (1.3mm)
CONTACT WllH
VALVE SEAT
!It be at center
of seat)
VALVE LENGTH: Intake 3.961ln (100.6mm)
'Exhaust 3.968in (1 oo.amm)
VALVE SEAT WIDTH OF CONTACT·
Standard 0.0361n- 0.051 (0.9 -1.3mm)
Valve Spring
Umit
0.0201n (r0.5mm)
O.D311n (O.Bmm)
---r
• VALVE
LENGTH
Measure the free height of the valve spring and replace the
spring if it is out of limit.
VALVE SPRING FREE LENGTH
standard 1.8231n (46.3mm)• ____ Limlt 1.783in (45.3 mm)
Also check the spring for squareness and if it exceeds the
limit replace the spring.
'VALVE SPRING SQUARENESS
Engines & Generators
16

CYLINDER HEAD AND VALVES
Valve Stem and Guides
Measure the clearance between the valve guide, ana the valve
stem and , if the clearance exceeds the limit, replace the
valve guide or valve, or replace both.
MEASURING VALVE
STEM DIAMETER
VAlVE STEM TO VAlVE GUIDE CLEARANCE
Standard Intake 0.0008· O.OOZOin (0.02- 0.05mm)
EX!Iau:st 0.0026- 0.0033in{0.0050 - tUIOSSmm}
Umlt Intake 0.0039in (0.10mm)
Extlau:st 0.0059ln (0.15mm)
VALVE STEM OUTER DIAMETER
Staridani lnta.ke
Exhaust
0.2585 ·.0.25911n (6.565 • 6;58Dmm)
0.2571 • 0.2579in (6;530-· 6.55Dmm)
Valve Seat Reconditioning
Before correcting the valve seat, check for clearance
be~een the valve guide an(l the valve. replace the valve
gUide if necessary. ·
To recondition, use a valve and seat cutter and apilot or a
seat
grinder, repair so that the seat width and seat angle are
the specified configuration.
After correction~ the valve and the valve seat should be
lapped with lapping COJilpound.
INSTALLATION
Valve Stem Seal
VALVE SEAT CONTACT WIDTH
.035 • .051 In [0.9 • 1.3 mmJ
Install the valve spring seat, then using the valve stem seal
installer, install a new stem seal to the valve guide.
Do not use the old valve stem seal.
NOTE: Use the installertool to insertthe stem seal,' improper
installation can cause oil to leak into the cylinder.
17
VALVE STEM
SEAL INSTALLER
Valve .Springs
~
Install the valve spring with it's enamel coated side toward
the rocker ann side.
ENAMEL
COAT EO
· SIDE
REMOVING
RETAINER
LOCKS
Cylinder Head Gasket
Clean the residue of gasket and oil from the gasket mounting
surface of the cylinder block and the cylinder head.
Place a new cylinder head gasket on the cylinder block
faCing its identification mark upward.
·J.D.
MARK
CYliNDER HEAD GASKET

CYLINDER HEAD
Cylinder Head Bolts
Tighten the cylinder head bolts in the order shown in the dia-
gram using a stepped-up tightening torque.
1. Temporarily tighten the bolts in numerical order to 14-
. 22ft-lbs (20 - 30 Nm).
2. Tighten the bolts again in numerical order to 29 -36ft-lbs
(40- 50Nm).
3. Tighten the bolts in numerical order to the specified
torque.
CYLINDER HEAD TORQUE 43 -51ft-lbs (60- 70Nm)
Rocker Cover
Install the rocker cover using a new gasket (slightly coat both
sides with clean oil). Gradually tighten the cover bolts to the
specified torque making certain the cover gasket is positioned
properly.
ROCKER COVER BOLT TORQUE (&mm BOLT)
2.9- 5.2 ft-lbs (4- 7Nm)
¢::J
ENGINE FRONT
Engines & Generators
18
INTAKE SlOE
2
EXHAUST SlOE
CYUNDER HEAD BOLTS
TIGHTENING SEQUENCE