BMW D7 Workshop Manual
BMW D7 is a marine diesel engine designed for use in boats and other watercraft. It is a four-stroke, single-cylinder engine with direct injection and an open-circuit cooling system. The engine has a maximum power output of 4.5 kW (6 horsepower) at 3600 rpm and a dry weight of 68 kg (150 lbs). It is equipped with an electric starter and a flywheel alternator, and features automatic bleeding in the injection system. The BMW D7 is known for its reliability, fuel efficiency, and ease of maintenance. It is a popular choice for powering small boats, sailboats, and other marine vessels.
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Workshop Manual
BMW D7
BMW Marine
This copy of the BMW D7 Workshop Manual has been re-created using images computer scanned from a manual rather than original artwork.
BMW D7 Marine Engine
A four-stroke diesel engine with direct injection and open-circuit cooling system. The
Neoprene impeller of the coolant pump is driven directly from the crankshaft. Electric starter and flywheel alternator are standard equipment. The injection system is fitted with automatic bleeding.
Notes on Use
This workshop manual describes complete procedures for dismantling, overhaul and assembly of the BMW D7 marine engine.
If only part of the procedure is to be carried out (e.g. small repairs or replacement of gaskets, oilseals) the remainder can be ignored.
The relevant technical data is provided with each section. General specifications are found on page iii.
Assembly is generally a reversal of removal procedure. Special attention, however, should be paid to "notes on assembly".
Checking and adjustment procedures, where applicable, are to be found at the end of the relevant section. i
Contents
Page
Introduction i Fuel System
Remove, adjust:
Summary 1
Removing cylinder head
- Valve mechanism
- Cylinder head
3
- Preparations 3
4
- Valves 5
7
- Cylinder 7
- Injection valve
- Injection pump
- Engine speed
Check:
- Injection pump
- Injection valve
- Fuel pump
Air filter
Removing gearbox 8
- Starter 8
- Reversing gear 8
- Bearing cover
- Hand crank mechanism
9
10
- Connecting rod 11
- Piston 13
- Fuel pump 14
Electrical system
- Wiring diagram
Water Pump
Page
27
27
29
31
32
32
32
33
34
34
- Generator 35
- Starter motor 39
40
- Timing gear cover
- Fuel regulator
14
15
- Crankshaft 16
- Valve lifters 19
- Camshaft 20
Assemble crankshaft 20
- Camshaft 20
- Crankshaft 20
- Fuel regulator
- Timing gear cover
- Fuel pump
21
21
21
- Piston 21
- Connecting rod
- Hand crank mechanism
21
21
- Bearing cover
- Reversing gear
- Starter
22
22
Assemble cylinder head 22
- Cylinder 22
- Cylinder head 23
- Valves 23
- Valve mechanism 23
- Hoses & pipes 23
Adjust: 24
- Valve clearance - valve timing 24
- Decompression lever
- Automatic decompression
25
26
General ii
Technical data
Capacity
Bore x stroke
Max. power
Compression ratio
Dry weight with gearbox
Gearbox reduction
Max. installation angle
280cc / 17.1 cu.in.
73 mm x 67 mm / 2.87 in x 2.64 in
4.5 kw / 6 bhp @ 3600 rpm
22 : 1
68 kg / 150 lbs forward 2.7:1, reverse 1.9:1
15 o
Specifications
Fuel
Lubricating oil, engine gearbox
Oil capacity, engine
Diesel oil, DIN 51601/USA #2
HD-API CC/CD
Hurth ATF Dexron - ZF SAE 20 W 20
2 litres / 3.5 pints UK / 4.4 pints US
Fuel filter gearbox 0.4 litres / 0.7 pints UK / 0.85 pints US
BMW 13 32 1 328 270
Air filter BMW 13 71 1 329 269
Injector Bosch
Injection pressure
Injection pump
135 + 8 bar
Bosch PFR 1 K 70 A 343/II
Starter motor Bosch 0.8 kw
Generator 14V
Battery
Gearbox
Adjustment data
Injection ends
Valve clearances, cold
Torque settings
12V 60 Ah
Hurth HBW5 - ZF Bw 3
11.5
o
- 12.5
o
BTDC
0.15 mm / .006 in.
Cylinder head nuts M 8
Connecting rod screws
Counter weight screws
M 6 hex nut for the mounting of the injector
Flywheel bolts M 10
Injection pump delivery valve
M 6 hex head screw for fastening bearing cover retaining yoke on the flywheel side
Nozzle nut
Nm kpm Remarks
40 4.0 Use permanently elastic
40 4.0 sealing compound (e.g.
Atmosit) on the stud screws in the oil space!
Oil threads and screw head
22 2.2 insert lightly
Oil threads and screw head insert lightly
10
70
1.0
7.0
40 4.0
10 1.0
85 8 - 9 iii
List of Special Tools D7
BMW Part No.
74 64 1 333 525
74 64 1 333 526
74 64 1 333 513
74 64 1 333 514
74 64 1 333 515
74 64 1 333 516
74 64 1 333 517
74 64 1 333 527
74 64 1 333 535
74 64 1 333 528
74 64 1 333 536
74 64 1 333 529
74 64 1 333 530
74 64 1 333 531
74 64 1 333 537
74 64 1 333 538
74 64 1 333 539
74 64 1 333 540
74 64 1 333 518
74 64 1 333 519
74 64 1 333 520
74 64 1 333 541
74 64 1 333 521
74 64 1 333 542
74 64 1 333 532
74 64 1 333 543
74 64 1 333 522
74 64 1 333 523
74 64 1 333 524
74 64 1 333 544
74 64 1 333 545
74 64 1 333 546
74 64 1 333 547
74 64 1 333 534
74 64 1 333 548
74 64 1 333 549
74 64 1 333 550
74 64 1 333 551
74 64 1 333 552
Description
To refit ball hub
To refit crankshaft gear
Crankshaft installation tool
Puller for valve lifter shaft
Tool for crankshaft removal
Tool for camshaft needle bearing installation
Wrench for injection adjuster
Crankshaft gear puller
Tool for adjustment of injection pump
Tool for injection adjuster
Multi purpose extractor
Auxiliary wrench for cable connector
Sleeve 27 - 36 mm internal extractor
Counter support-internal extractor
Allen socket with center pin 8 mm
Allen socket with center pin 10 mm
Clamping holder to grind valve-valveseat
Allen wrench 6 mm elongated
Auxillary bush-oil seal
Punch - needle bearing camshaft
Socket 13 mm (long size)
Allen socket 6 mm
Retaining bracket for cylinder
Press-in mandrel-valve guide 7 mm Ø
Hand reamer 7 mm Ø H 7 for valve guide
Flare nut wrench 17/19 mm
Special tool for governor spring
Box wrench 10mm
Piston ring clamp
Measuring device for bumping clearance
Testing device for injection equipment
Dial gauge 1/100 mm
Torque wrench 1 - 140 NM
Guiding pin 7 mm Ø (valve reseating tool)
Handle for valve reseating tool
Piston ring pliers
Allen socket 8 mm
Valve reseating tool 42.5 mm Ø
Gudgeon pin extractor iv
Summary
BMW Marine Diesel Engine D7
Description:
Water cooled single cylinder four stroke producing 4.5 kW (DIN) (6 Hp) lever
3. Throttle cable mount
4. Hand crank attachment
5. Cover
6. Sea water pump
7. Fitting clips
9. Sea water hose
10. Engine mounts
11. Cylinder head
12. Metering device
13. Fuel return hose
14. Injector
15. Air filter
16. Fuel injection pipe
17. Injection pump
18. Throttle
19. Dipstick
20. Oil filler screw
General
1
Summary
21. Exhaust
22. Starter
23. Retainer yoke
24. Gear box
25. Crankcase
26. Fuel pump
27. Fitting
28. Sea water pipe
General
CAUTION
To avoid damage to engine parts, always use special tools as shown in the illustrations.
The tools to be used fit only in the position shown.
2
Cylinder Head
Removing cylinder head and cylinder
Remove air filter (1)
Loosen sea water pipe from exhaust manifold and water pump and remove (2) + (3)
CAUTION
Cover all openings in the fuel system
Disconnect fuel return hose from injector and remove (4)
Disconnect fuel injection pipe from injector and injection pump and remove (5)
Remove clip of crankcase vent hose (6), unscrew both nuts of the rocker cover and remove the rocker cover with gasket (7)
Detach
Disassemble
Remove
Air filter, seawater hose, fuel overflow hose, cylinder head vent hose clip, cylinder head cover with gasket, rocker shaft with rockers, pushrods
3
Cylinder Head
Remove rocker shaft with bushing and retainer yoke and remove rockers (8) and (9)
Pull out both pushrods
Rocker arms shaft dia.
Rocker arm internal dia.
Rockaer arm radius
Valve seat angle
Dimension mm mm mm o
Cylinder Head Repair Data
D7 nominal values
18
-0.027
Max. allowable wear (mm)
0.05
18
+0.024
+0.006 0.05
8 No flats
45
Remarks
After press fitting
Detach
Disassemble
Remove
Rocker shaft with rockers, pushrods
4
Cylinder Head, Timing Gear
Remove decompression lever from the underside of the cylinder head (10)
Unscrew the M10 nut and unscrew stud bolt.
Remove the spring
Remove retaining pin with pointed pliers
Unscrew inner clamping sleeve on gear segment and remove shaft and gear segment.
Remove valves & valve springs (11)
Press down the spring retainers
WARNING
Danger of injury due to spring retainers and valve keys popping out.
Loosen both key halves while applying pressure from below and remove with pointed pliers.
Remove cap and washer from under the valve spring
Remove valve
Press out the valve guides from below
NOTE
When pressing in the new valve guides, when parts are cold note minimum force of 1000 N (approx 100 kp)
Ream the valve guides
Rework leaky valve seats with a 45 o valve seat cutter. Mill only enough to remove spots from valve seats.
Reseat valves using auxiliary tool
No 74 64 1 333 539
Detach Decompression lever handle, clamping sleeve on handle, spring shaft,
Remove valve poppets, spring plate with valve spring, cone halves, valve guides
Rework
5
Cylinder Head
The valves should sit back as measured from the seating surface of the cylinder head, according to the following table:
Cylinder Head
Valve clearance cold
Intake valve stem dia
Exhaust valve stem dia
Intake valve disc dia
Exhaust valve disc dia
Valve sit back max
Valve sit back min
Valve guide bore
Outer diameter
Valve guide bore in cylinder head
Valve guide press in force
Dimension mm mm mm mm mm mm mm mm mm mm kp
Repair Data Valves
D7 nominal values
Max. allowable wear (mm)
0.15
7
7
30.5
30.5
7
0.70
0.45
10
10
100
-0.04
-0.05
-0.05
-0.04
+0.09
0
+0.023
+0.029
+0.0011
0.05
0.05
0.05
Remarks
CAUTION!
Valve sit back may not be less than 0.45 mm as otherwise the danger exists that the valve disc hits the piston.
The sealing surface of the cylinder head can be reworked to a maximum of 0.5 mm if the sit back of
0.7 mm is exceeded due to valve seat milling.
With the cylinder head cold.
Table: Valve sit back
6
Cylinder Head / Cylinder
Remove cylinder head and pull off cylinder (12) The cylinder head is unusable in the following cases:
Sealing surface fouled or damaged i.e. uneven
Clean the sealing surface and re-grind, observing the tolerances
Valve seats worn out or no longer suitable for re-facing.
Cracks in the valve seats in the cylinder head
NOTE
Measure cylinder bore with a cylinder indicator
In the following cases, the cylinder is unusable:
Seize marks are found in the bore
Scratches are present
Wear exceeds 0.15 mm
Cylinder
Bore dia
Roughness Ra
Oversizes
Dimension mm mm
Repair Data Cylinder
D7 nominal values
Max. allowable wear (mm)
73 + 0.01
1.0 – 1.2
+ 1
0.15
Remarks
Remove Unusability of cylinder head/cylinder
Detach Cylinder head, cylinder
7
Bearing cover
Remove starter (13) Remove attaching clamp of the cable to the stator and remove starter
Remove the four cyclinder screws M 10 and remove the flywheel (15) and (16)
Remove gearbox (14) complete with flywheel cover.
Remove bearing cover
Detach
8
Bearing cover
After loosening the four M6 hex screws, remove the bearing cover with locking plate and the sealing ring located on the inner face (17)
NOTE
Bearing cover can be replaced when the engine is cold
Remove bearing cover
Detach
9
Cover to timing gear cover / timing gear cover / hand cranking device
Remove screws from cover of timing gear cover and take off the cover (18)
Remove hand crank mechanism (19) with extractor tool No 666 332 00
Detach Cover of timing gear cover, hand crank device, dipstick, cover on engine bottom,
Remove connecting rod
10
Dipstick / cover on engine bottom / connecting rod
Turn the engine on to the flywheel side (23) and remove dipstick (24)
Remove cover and O-ring from crankcase on the engine bottom (25).
Unscrew the two connecting rod screws (26).
Take out connecting rod cap with oil pick-up
(27) from below and piston and connecting rod
(28) from top.
Detach Dipstick / cover on engine bottom / connecting rod
Remove
11
Table: Repair data for connecting rod and connecting rod bearing
Con-rod bearing
Outer dia
Inner dia
Width
Undersize
Repair Data for con-rod bearing and con-rod
Dimension
D7 nominal values
Remarks
Max. allowable wear (mm) mm mm
46
42
+0.016
-0.026
Minimum bearing play =
0.040-0.076mm when new max wear to 0.15mm see table on page
17 mm mm
26.5
41.5 see table on page
17 mm 1.998 +0.02 mm 2.248 +0.02
Total play after wear: max 0.15mm
Con-rod bearing wall thickness normal(W)
Con-rod bearing wall thickness oversize(WU)
Con-rod
Gudgeon pin bushing bore dia
Con-rod bearing bore dia
Gudgeon pin bushing: outer dia inner dia – loose
- installed mm mm mm mm mm
28
46
28
25
25
+0.013
0
+0.010
-0.006
+0.048
+0.035
+0.082
+0.068
+0.020
+0.007
Thread con-rod bolts
M8
0.20
12
Piston
Note
Heat piston to remove piston pin
Remove the gudgeon pin snap rings and press out the gudgeon pin by hand while the parts are still warm (29).
In the following cases, the piston is unusable:
ring land between the rings broken
piston scuffed
ring groove worn out
and cracked
Piston rings are unusable when the gap is too big
Piston dia
Oversize
Overall length
Piston ring gap
(new condition) mm mm mm mm
Repair Data
Max. allowable wear (mm)
72.96
+1.00
0.25 – 0.4 Up to 2.00
Remarks
82mm
Unscrew Piston
Detach
13
Fuel pump / timing gear cover
Remove fuel pump (29a)
Remove pump plunger (29b)
Unscrew the three M16 hex nuts and remove timing gear cover (29c)
Detach Fuel pump, pump plunger, timing gear cover
Remove
14
Fuel regulator, gear on crankshaft
Bring engine into the horizontal position, as shown in Fig (29d)
Remove gear from crankshaft using extractor tool (29k)
Loosen M6 hex nut (29f) on the regulator lever and pull out locking pin with pointed pliers
Unscrew both M10 hex nuts (29e) from regulator shaft.
Remove regulator shaft together with round nut, spring washer, sealing ring and friction disc.
Unscrew M8 hex nut. Withdraw eccentric bolt with cap plate and sealing ring
Loosen M20 hex nut. Remove start filling (29h) with sealing ring.
Pull out clamping sleeve, using pointed pliers.
Withdraw regulator lever with regulator spring
(29i)
Turn engine on flywheel side.
Maximum rpm
3600/160
Repair Data for Regulator Spring Washers
No of balls Regulator Spring BMW Part No
4 13 41 1 329 652
Remove Regulator lever with regulator spring
Wire Dia
2.6
15
Ball sleeve / Crankshaft
Remove ball sleeve with sliding disc taking care that no balls fall out (30)
Ball hub and spacer washer (31) remain on crankshaft. Detach these parts only when removing the crankshaft.
Turn the engine block into the horizontal position.
Removing the crankshaft
NOTE
It is essential that all plastic parts such as oil filler cover and cold start cover are removed
Heat the crankcase on a heating plate to between
80 and 100 o
C (32)
Press out the crankshaft with extractor tool (33)
74 64 1 333 515
Press off the roller bearing on timing side (33a)
Press off straight roller bearing together with spacer washer and drive dog hub (34)
Remove Ball sleeve, crankshaft
16
Crankshaft
The outer race of the straight roller bearing on the timing gear side remains in the crankcase and can be removed with the aid of a press
In order to remove the bearing rings which have been shrunk on to the crankshaft (35) heat the crankshaft on a heating plate or with a sufficiently large gas burner rapidly to about 70 to 80 o
C
After removal of the M8 cylinder head screws, remove the counterweights (36).
Set the crankshaft on a solid support and loosen bearing race by a blow to the crankshaft.
Repair Data for Crankshaft Crank Pins
Crank pins must not become convex upon regrinding. A concave shape of from 0.01 to 0.02 mm in diameter in the mid portion of length is allowable.
Crank pin nominal diameter (D)
Crank pin diameter undersize (DU)
42
41.5
-0.060
+0.074
-0.060
-0.074 mm mm
Total play when worn out max
0.15mm
Remove Crankshaft
17
Crank pin dia
End float
Crankshaft crank pin width
Radii on crank pin
Hardness of crank pin
Depth of hardening of crank pin
Diameter of ball hub (regulator)
Diameter of ball sleeve
Diameter of gear on crankshaft
Regrinding of crankpin
Axial play
Table: Repair data for crankshaft mm mm mm mm mm mm mm
RC mm mm
42.0
0.3
33.0
Repair Data for Crankshaft
Max. allowable wear (mm)
Remarks
-0.060
-0.070
Total play 0.15 max Max allowable crank pin out-of-round 0.05mm
+0.068
0
3.0
50-55
1.1-1.5
29.0 +0.021
0
28.0
22.0
0.5
0.3-0.4
-0.020
-0.041
+0.048
+0.035
Grinding finish see page 17
Hardness at least
48 RC
18
Valve lifters and camshaft
Remove the plastic plug from the side of the engine block (37)
Unscrew the M8 set screw (38) with a 4 mm Allen key and remove together with plug
CAUTION
When removing the camshaft, lift off both rockers from the camshaft to prevent damage by the cam lobes
Pull out valve rocker shaft with the aid of extractor tool No 74 64 1 333 514 (39)
Remove valve rockers together with washer (39b, 39c)
Replace valve rockers if worn.
Withdraw camshaft
Press roller bearing off the camshaft
Rotate crankshaft so that the needle bearing becomes accessible.
A damaged camshaft needle bearing can be removed from the crankcase with drift punch No 74 64 1 333 519.
Remove Valve lifter shaft, valve lifters, camshaft, roller bearing
19
Camshaft Crankshaft
Reassembly of the engine parts is carried out in the reverse order.
Installing the crankshaft
NOTE
The tooth gear on the camshaft is marked with the letter “L”. This indicates the direction of rotation of the engine as viewed from the front.
-
Attach the counterweights, tightening the bolts to a torque of 2.2 kg/m (16 lb/ft)
Heat the inner race of the roller bearing to between 70 and 80 o
C and mount on the crankshaft.
Place the retainer ring on the outer bearing race.
Push inner straight roller bearing onto the crankshaft together with spacer washer and drive dog hub.
Heat the crankcase to between 100 and 150 o on a heating plate.
C
Push the outer race of the bearing on the flywheel side onto the crankshaft and screw it on using special tool No 74 64 1 333 513
Drive in the rear camshaft bearing using the assembly punch No 74 64 1 333 516.
Install the camshaft.
Screw in the set screw and replace the plastic plug.
Insert the valve lifter shaft and tighten, so that the valve lifters show a minimum of axial play but are still free to move on the valve lifter shaft.
NOTE
Take care that the thrust washer is placed between the valve lifters and the crankcase to prevent the valve lifters from wearing into the aluminium case.
CAUTION
The crankshaft bearing is asymmetrical.
The correct position is that shown in the illustration (41). The large rounding must be placed towards the outside, to ensure sufficient lubrication.
Push the crankshaft with bearing into the heated crankcase from the flywheel side, until it reaches the stop of the special tool.
CAUTION
When installing the crankshaft, make sure that the axial play between the crankshaft and crankcase is between about 0.2 and 0.4 mm.
Replace all plastic parts such as oil filter cover and cold start cover
Turn the engine back onto flywheel side and place ball sleeve with sliding disc into position.
Take care that the balls are inserted correctly.
Install Camshaft, Valve lifter shaft, valve lifters Crankshaft, ball sleeve
20
Fuel Regulator / Gear on the Crankshaft Connecting Rod
Timing gear cover / Fuel pump Crankcase cover / dipstick / bearing cover
Set the engine block into the horizontal position
Insert regulator lever and regulator spring
Insert clamping sleeve into the regulating spring with pointed pliers
Install start filling sealing ring and tighten M20 hex nut
Install eccentric bolt with cap, plate and sealing ring.
Insert regulator shaft and tighten both M10 hex nuts.
Insert stop pin into the regulator lever and tighten hex nut.
Install gear on the crankshaft
Before assembly, heat the cog for the crankshaft on a heating plate or in an oil bath to approx 80 o C and assemble with tool No 74 64 1
333 526
When mounting the cog onto the crankshaft, take care that the marking on the cog opposite the key groove points to the outside
Turn engine block onto flywheel side.
When mounting the timing gear cover, adjust the cog on the camshaft and the cog on the crankshaft so that their markings are opposite each other.
Check upper dead center and overlapping.
Mount the timing gear gear cover with light taps of a hammer and tighten both M16 hex nuts
NOTE
It is imperative that copper washers be used for the timing cover screws
Insert pump tappet and mount fuel feed pump
Before assembling the pistons, heat them on a hot plate. Insert gudgeon pin and the gudgeon circlips.
Turn the piston ring gaps of the two piston rings and of the oil scavenge ring 120 o to each other
Lightly oil the threads and the screw head inserts of the connecting rod parts
Insert the connecting rod bearing half with the hole into the connecting rod cap
Insert the connecting rod bearing half without the hole into the connecting rod
Assemble the connecting rod. Tighten the connecting rod screws with torque wrench and
6mm socket No 74 64 1 333 541 to torque of 40
Nm (4 kpm)
Install connecting rod in such a manner that the scoop is filled through the scoop opening when dipping into the lubricating oil. Scoop opening must point in running direction. The lubricating system is based on the centrifugal principle.
CAUTION
Set the cylinder slowly with great care onto the piston so that no piston ring is broken or damaged.
Observe that the opening in the combustion chamber located in the piston crown points towards the flywheel side.
Install crankcase cover with seal into the underside of the engine block
Insert dipstick
Turn engine block to the horizontal
Assemble starting crank mechanism with extractor tool No 666 332 00
Screw on the cover to the timing gear cover
Mount bearing cover
CAUTION
In order to avoid damage to the bearing cover during assembly, use auxiliary bushing No 74 64 1 333 518
Fill the groove in the bearing cover between packing washer and dust lip with ball bearing grease
Mount the sealing ring on the inside of the holder, onto the holder with grease in order to prevent slipping during assembly.
Insert the thrust ring into the dry bushing with the graphite coated side towards the outside.
Mount the cog onto the camshaft without
Woodruff key and tighten
NOTE
The marking of the cog on the camshaft must align with the Woodruff key groove.
Coat the sliding surface of the dry bushing with molykote grease
Insert the cog with needle bearing into the dry bushing
Fill the housing with approx 100g of hot bearing grease e.g. “Calypsol WDT” or equivalent quality and assemble with gasket.
Install Regulator lever, regulator spring
Mount Regulator shaft, cog on crankshaft
Timing gear cover, connecting rod
Cover on crankcase, starting crank device, cog on camshaft
21
Flywheel / Stator / Reversing Gear / Starter / Cylinder head
Fasten the stator in the crankcase and screw on the attaching clamp
Install the flywheel. Tightening torque of the flywheel screws is 7.0 kpm
Attach the reversing gear
Attach the starter
NOTE
When installing the cylinder head pay close attention to the following points. It is imperative that a new cylinder head gasket be used and pay close attention to valve sit back and tightness
Tightness is checked by filling fuel into the intake or exhaust channel. If nothing leaks through, the valve seat is tight.
Adjust the gap with a corresponding cylinder foot gasket
The gasket set contains gaskets of various thicknesses.
CAUTION
Do not damage the rubber sealing rings for the decompression lever, resp. decompression shaft and stop pin
After replacing cylinder, piston, connecting rod, crankshaft or crankcase, measure the gap between cylinder and piston upper surface at
TDC (42).
Use the measuring bridge No 74 64 1 333 544 and clamping piece No 74 64 1 333 546 with
measuring gauge, for measuring the gap.
Mount the completely assembled cylinder head onto the cylinder
Fasten the cylinder head with the aid of socket wrench No 6425 evenly and crosswise with the required tightening torque.
Tightening torque of the M8 hex nut on studs
(tension rod) for the fastening of cylinder and cylinder head – 35 Nm (3.5 kpm)
NOTE
Oil threads lightly. However, do not use molykote.
Seal locking screws in the oil space of the cylinder head with a permanently elastic sealing compound
(e.g. Atmosit or similar)
CAUTION
If the gap is too small piston, cylinder head and valves may be damaged. If the gap is too large, the engine loses performance.
Cylinder Head
Piston gap (A)
Cylinder head (b) gasket
Cylinder shim
Repair Data
Dimension D7 nominal values mm mm
0.55 – 0.65
1.50 mm 0.1/0.2
Assemble Flywheel
Test Valve seat tightness, piston gap
Cylinder head
22
Cylinder head / Injection pipe / Leak-off-line / Water pump / Water hose / Air filter
Press in valve guides from underneath
Insert valves
Insert valve springs with cap and washer
Insert spring plate
Insert both valve keys, while applying counter pressure to the valve
Insert shaft with gear segment and screw in internal clamping sleeve.
Slide handle with ring onto the shaft and screw in external clamping sleeve.
Insert push rods
Insert rocker arms and assemble rocker shaft with bushing and retaining plate (43)
NOTE
Check that the rocker arms are free to move
Adjust valve clearance
Fasten cylinder head cover and vent hose clamp with both nuts
Fasten injection pipe to the injection pump and to the injector
Attach leak-off-line hose to the injector
Install water pump
Fasten water hose to the water pump and to the
exhaust manifold
Attach air filter
Assemble Valves, push rods, rocker arms, cylinder head cover.
Install Injection pipe, leak-off-line, water hose, air filter
23
Timing gear adjustment
Adjust valve clearance and timing
NOTE
Carry out the testing and adjusting when the engine is cold.
The following must be carried out:
Set the decompression lever to “0”
Remove cylinder head cover
Crank the engine in rotation direction until the compression resistance can be felt
Check valve clearance between rocker arm and valve shaft with a feeler gauge
In the case of incorrect valve clearance, loosen the lock nut and adjust the set screw with a screwdriver so that the feeler gauge can be pulled through between the rocker arm and the valve shaft with noticeable resistance after the nut is re-tightened
Cylinder Head
Valve clearance cold
Intake valve stem dia
Exhaust valve stem dia
Intake valve disc dia
Exhaust valve disc dia
Valve sit back max
Valve sit back min
Valve guide bore
Outer diameter
Valve guide bore in cylinder head
Valve guide press in force
Dimension mm mm mm mm mm mm mm mm mm mm kp
10
10
100
0.70
0.45
7
Repair Data Valves
D7 nominal values
Max. allowable wear (mm)
0.15
7
7
0.05
0.05
30.5
30.5
0.05
Remarks
CAUTION!
Valve sit back may not be less than 0.45 mm as otherwise the danger exists that the valve disc hits the piston.
The sealing surface of the cylinder head can be reworked to a maximum of 0.5 mm if the sit back of
0.7 mm is exceeded due to valve seat milling.
With the cylinder head cold.
Adjust Valve clearance
24
Decompression lever adjustment
If the engine is not decompressed in Position “1” of the decompression lever, adjust the decompression screw as follows:
Crank the engine to the same position as in the valve adjustment
Turn the decompression lever to Position “1”
After loosening the hex nut, turn the adjusting screw to the right until the rocker arm touches the valve shaft
From this position, turn the adjusting nut another quarter (¼) revolution to the right and secure by tightening the nut.
The engine is equipped with automatic decompression.
Function:
If the handle is set to Position “2”, cranking the motor automatically turns the handle further to
Position “0” (compression)
A specially designed tappet turns the decompression shaft further with every raising of its valve.
Extract the clamping sleeve of the gear segment on the valve shaft with pointed pliers and dismantle the decompression shaft with gear segment.
Installing the automatic decompression system
NOTE
The hole for the clamping sleeve in the gear segment, viewed from the flattened side of the shaft, lies towards the outside of the engine.
In this arrangement, the automatic decompression is operated by the left tappet (when looking towards the timing gear side). The decompression handle turns clockwise.
The length of the tappet (with collar) is adjustable.
The standard length is
147.8 – 148 mm
Adjust Automatic decompression
25
Timing gear adjustment
Correction is required in the following cases:
If the collar pan constantly engages the cog lightly, in the case of running the engine and zero position of the decompression lever (Shaft moves back and forth)
In this case, shorten the tappet somewhat and dimension “A” will become larger (see figure)
The decompression shaft is not rotated further properly from position “2” of the handle
In this case, lengthen the tappet somewhat and dimension “A” will become smaller (see figure)
Correct the position of the collar pan to the cog
(lateral distance) by a small movement of the rocker arm shaft on the cylinder head plane.
NOTE
Choose distance “B” so that certain functioning of the automatic system is ensured. In the running position of the engine (lever position “0”) the collar pan may not touch the cog.
Fix the cog segment on to the shaft so that the cogged area is on the upper side when the flattened part of the shaft points upward.
Adjust Decompression lever
26
Injector
Injector check
CAUTION
Be sure to observe a maximum of cleanliness when working on the fuel system
Remove injection pipe and leak-off-line
Loosen M6 hex nut and remove injector from the cylinder head together with holding bracket
NOTE
During removal and installation of the injector, pay attention to the sealing washer in the cylinder head
Check injection valve for:
Function
Injection pressure (ref figure with pintle type nozzle)
Position of the sealing disc: the side with a recess towards the injection nozzle. The sealing washer must seal properly.
Injection Pump
Bosch type code
Bosch No
BMW Part No
Injector Assy
Bosch type code
Bosch No
BMW Part No
Nozzle
Bosch type code
Bosch No
BMW Part No
Injection pressure
Remove Injector
Fuel Injection Equipment
PFE 1Q 55/19
0 414 050 996
1351 1329 656
Remarks
With second hole in housing
(for automatic venting)
-
0432 297 022
1351 1329 667
DNO SD 21
0434 250 001
1353 1329 669
135 bar
Check Injection system
27
Injection pump
Adjust the injection pressure by inserting or removing shims at the injector spring
NOTE
A shim with a thickness of 0.1 mm changes the pressure by approx.
15 bar
Unscrew the screw cap and remove the injector nozzle
CAUTION
Clean the nozzle only with a
Bosch nozzle cleaning device.
Do not use hard objects as steel brushes, wire or similar.
Carry out the cleaning and testing of the nozzle with a maximum of cleanliness, rinse injector parts in clean fuel only.
Microscopically small particles can lead to wear and malfunction.
NOTE
A malfunctioning nozzle leads to, amongst other things, poor combustion
(black exhaust smoke), poor performance and overheating of the cylinder head, piston and cylinder.
Injector overhaul
Extreme cleanliness is necessary during work on injector.
Unscrew sleeve nut F (22 mm) and withdraw injector jet G
Clean jet with correct apparatus, not with sharp tool, wire brush or similar. All traces of carbon should be removed.
Injector should be replaced as a complete unit if:
Jet needle H is damaged or eroded
Overheating of the needle and jet has occurred
(blueing)
Taper of jet needle does not seal
Remove Injector nozzle
Injector operation check and adjustment
This should be carried out as completion of checking operation of injector pump.
With special tool 74 64 1 333 545 fitted to injector pump. See page 32
28
Injection pump
Preliminary tasks before removing the injection pump:
The injection pump has two hose connectors and a pipe connection. The lower connection is for the fuel supply, the upper connection is designed for the fuel return hose.
Remove the injection pipe
Clamp off the fuel supply line
Pull off fuel return hose and fuel supply line from the injection pump
Set the engine throttle to the full position without pulling the start filling lever when removing the injection pump.
Remove the injection pump hex nuts and pull out the pump
The start maximum fuel eccenter must be turned in such a manner that the eccentric arm points vertically upward before installing the injection pump.
Bring the regulator lever into the center position by slightly adjusting the position of the eccentric shaft.
Rotate the plunger on the injection pump
NOTE middle of the groove in the pump housing.
The bolt must be exactly in the
Insert the shims and carefully slide injection pump in without shifting the regulating bushing
NOTE
Pay attention to the shims between the pump and crankcase and the washer in the pump tappet.
First install the fuel supply line, then fasten the valve.
When installing the injection pump, rotate the camshaft so that the injection pump tappet lies on the camshaft basic radius (lowest position).
Set regulator lever with the aid of the throttle
Remove Injection pump
29
Injection pump
NOTE
Slide the pump in to about the last 4 mm without overcoming any resistance. Only then may resistance occur due to the tension of the tappet spring
This tension can be overcome by a small pressure and the pump pushed in completely by hand.
Preliminary work:
Clamp off the fuel supply line
Unscrew injection pump pressure valve holder.
Remove spring, sealing ring, valve cone and pressure valve (see figure)
Screw in adjusting device No 74 64 1 333 535 with sealing ring and pressure valve body
If this is not possible, the plunger pin is interfering with the regulator lever.
CAUTION
A fastening of the pump in this position would cause serious damage to the pump, regulator lever and, in some cases, to the engine (during start, because of a blocked regulator)
Determine the correct position of the injection pump:
(1) Move the throttle in both directions. The regulator lever must audibly reach its stops.
(2) Remove the injection pipe together with delivery valve holder
NOTE
When moving the throttle and the start filling button, the pump plunger must rotate
Screw down the injection pump after the completed check
Connect the fuel supply line and fuel return hose
Adjust injection pump before TDC
Injection Pump Adjustment
Injection timing – delivery end in degrees
Delivery stroke in mm
11.5 – 12.5
1.40
-
-
-
Set throttle into position “START”. Do not pull cold start filler.
Set flywheel to approx 2.00 mm before top dead center (observe direction of rotation)
The marking for tope dead center (OT) as well as the degrees for the injection pump timing are located on the flywheel
The countermarking on the crankcase is located on the flange thread hole on the upper right
(when looking at the flywheel)
Insert dial indicator with extension pin with the zero setting at 1.00 mm and clamp (45)
Open the fuel supply line. Fuel free from air must flow from the adjustment device.
NOTE
The injection pump of this engine has the helical groove on top of the plunger. The adjustment of the injection timing and delivery stroke is therefore done at the injection end.
Adjust Injection pump
30
Injection pump
Adjustment of the delivery end:
Crank the engine in the direction of rotation until the fuel stops to flow from the adjustment device
Slowly crank further, until the fuel just begins to flow again
NOTE
The number of degrees indicated on the flywheel must correspond with the nominal values (11.5 – 12.5
o
BTDC). If the values do not correspond, correct with the shims inserted under the pump.
Basic rule:
More shims = delivery ends later (lower number of degrees)
Less shims = delivery ends earlier (higher number of degrees)
In order to determine which thickness of shims must be removed or added, rotate the flywheel to the required number of degrees from the delivery end already determined (dial indicator set at zero)
The value shown on the dial indicator corresponds to the thickness of the shims which must be added or removed in order to compensate for the difference.
NOTE
Repeat the procedure after the adjustment as a double-check
Set the delivery stroke at the correctly set delivery stop.
Set the dial to zero.
Rotate the flywheel against the direction of rotation until the dial indicator indicates the delivery stroke value.
Hold the flywheel at this position.
At this point fuel must just start flowing out of the leak-off-line. If this does not occur, loosen the start filling lock nut with wrench No 74 64 1 333 517 and carefully turn the eccentric shaft with wrench No 74
64 1 333 528 until the fuel begins to flow.
Subsequently tighten the locknut again
NOTE
After the adjustment is completed remove the dial indicator and install the completely assembled delivery valve with injection pipe in the correct sequence.
NOTE
Pressure valve body with the exterior truned groove lies in the direction of the pump tappet.
When screwing in the injection pipe, replace the internal copper sealing ring and the external O-ring.
Observe tightening torque.
NOTE
The camshaft is geared down in a ratio of 1:2. The rpm measured there must therefore be multiplied by 2 in order to arrive at the nominal rpm
In order to adjust the rpm, remove the plastic plug and loosen the retaining nut
Turn the eccentric shaft, recognisable from the outside only as a set screw, with the aid of a screwdriver, until the desired rpm is reached
Move the throttle in the direction of STOP briefly after each adjustment of the eccentric shaft and then bring the throttle to the full throttle stop position
Check injection pump and injection valve for correct function (46)
After having correctly adjusted the rpm, fasten the retaining nut again and insert the plastic plug
Preliminary work for the functional check of the injection pump and injection valve
Remove injection pipe
Vent the engine correctly
As a check, also repeat this adjustment.
CAUTION
When adjusting rpm it is imperative that a tachometer is used
Adjust Injection pump Adjust Engine speed
31
Injection pump / Injector Venting Injection pump
-
NOTE
Carry out the check with the throttle in the fully open position and with the starting filling not pulled.
After installing the testing device No
74 64 1 333 545 of which the connections at the sides must be closed off, crank the engine by hand until the pressure gauge shows a pressure of 300-350 bar
WARNING
Danger of Injury
Stop cranking and watch whether the pressure is maintained. If the pointer falls back, and if the pump does not maintain a pressure of 250 bar either, the injection pump is defective
NOTE
During the testing, the injection valve can be connected to the testing device in place of a blind plug.
WARNING
Danger of Injury
When cranking the engine by hand, watch the injection pressure on the pressure gauge and the function of the injector
In the case of possible service interferences and after longer periods of engine standstill check the functioning of the vent valve.
WARNING
Danger of injury due to the fuel jet
As the engine has automatic fuel system venting, the necessity for a manual venting does not apply, as the trapped air in the injection pump escapes through the return line during the filling of the pump with fuel.
Due to the pulsating of the feed pump, the restrictor causes a constant flow of fuel in the injection pump.
Possible gas bubbles are automatically drawn off, thereby service interruptions resp. interferences are prevented.
NOTE
Crank the engine with the handcrank resp. starter and remove the vent valve at entry to the fuel tank
Fuel must pulse from the fuel line
If this is not the case, stop the engine and unscrew the vent valve
Clean the valve with fuel and compressed air, resp. replace the valve
When cleaning the fuel supply pump, unscrew cover and remove filter.
Clean the fuel filter, especially under protruding corners of the cover
Insert the filter again, fasten cover.
Correct function “a”
Incorrect function “b”
Check Injection pump, injector Check Fuel jet, venting
Clean Fuel pump
32
Air filter
Cleaning the air filter
Loosen clips. Remove filter element.
Remove sealing ring from cover and clean groove
Install new sealing ring and filter element.
NOTE
Never use an old filter element
Clean air intake openings and pipe in the filter
NOTE
Premature engine wear occurs if unfiltered or badly filtered air is drawn in through a badly maintained air filter
Clean Air filter
33
Wiring diagram
34
Generator and generating equipment
Preparation
Remove starter motor
Detach gearbox/clutch cover assembly
Remove clutch
Remove flywheel
Rotor Removal
Extract spring clip A from flywheel magnet by inserting snip-nosed pliers into cut-outs provided
Generating Equipment Removal
Disconnect leads from temperature sensor and remove stator cable plug C from socket on equipment carrier
Remove bolts D (13 & 19 mm), noting position of spacers, washers and injector pipe clip (if fitted) and remove carrier and equipment complete from engine.
Pull magnet B from flywheel with even movement, if necessary with suitable puller
Stator Removal
Detach plug E from stator cables with fine implement, first marking their positions.
35
Generator and generating equipment
Flatten lockwasher/cable clip F (renew on assembly), securing stator cable to bearing housing (SW 13)
Remove bolts G (7 mm) and lift off stator
-
Notes on Assembly
Grip magnet (rotor) firmly by hand and carefully place in flywheel, taking care to avoid jamming by lowering unevenly. If necessary, tap magnet with judicious use of soft-faced hammer
CAUTION
Do not hit magnet directly with a metal tool, or heat flywheel (loss of magnetism can result)
Lay stator harness close to bearing housing, to avoid contact with flywheel
Bend tags of stator cable end slightly to ensure firm fit before fitting to plug. Note fitted positions of cables.
Operation check and fault-finding
Check that cable insulation is in order
Examine stator windings for possible damage
Check all connections for corrosion and ensure that connections are firm
The generator generates current without mechanical contacts and has no bearings.
Faults, therefore, generally arise from shortcircuits, loose or wrong connections in electrical circuit of boat.
When faults occur, first check circuit, then operation of generator in situ (see wiring diagram)
Required for testing are:
Voltmeters 0-15 DC, 0-250 AC
Ammeter 0-40
Test/amp 12V
Control lamp remains lit after starting engine
No charge
Faulty impulse transmitter. Faukts in boat circuit (e.g. short circuits)
No charge
Check impulse transmitter (see section checking procedure 1)
Check charge (see checking procedure 2)
Defective control unit Check voltage (see checking procedure 3)
Faulty generator (control unit is usually also defective)
Check voltage (see checking procedure 3)
Check boat circuit for faults.
Renew impulse transmitter
See 2 (this table)
Depending on result renew control unit and/or generator
Renew generator rotor and/or stator. Possibly renew control unit.
36
Generator and generating equipment
Checking Procedure 1 – Impulse Transmitter
Thin red lead of impulse transmitter earths control lamp when engine is stationery. When charge from control unit passes through transmitter, this earth is interrupted.
To check:
Disconnect thin red lead from boat circuit and connect 12V testlamp connected to B+ (charge lead)
With the engine stationary, testlamp should light, and at 1150 rpm extinguish
If the lamp does not extinguish, impulse transmitter is defective and should be renewed, or generator is not charging.
When no or insufficient charge are shown, control unit and/or generator are defective
For further fault location, voltage between each of the 2 black leads, red lead and generator should be checked.
Checking Procedure 2 – Charge Current
Charge current passes from control unit (white lead) through implulse transmitter (black lead – thick red lead) to B+ (connection 30)
To check:
With engine stationary, disconnect thick red cable from boat circuit and interpose 0-40 Amp ammeter
Start engine, switch one or two items of electrical equipment on (to load battery)
Checking Procedure 3 – Voltage Check
(without load)
This check enables generator to be checked independently of control unit and battery
With the engine stationery, disconnect control unit from generator (2 black, red lead from 4 pole plug)
Connect one black lead and red lead to 250V voltmeter, ensuring remaining black lead cannot earth
Start engine, set to maximum speed and compare reading with that specified (see diagram)
-
Repeat test with second lead
If reading is correct, generator is in order and charging fault lies with control unit or boat circuit.
37
Generator and generating equipment
If reading is not adequate, whereby reading of leads 1 and 2 are different, there are 2 possibilities:
- when both leads lie below the correct reading, rotor magnetism is inadequate and rotor should be replaced
- when only one lead shows a low reading, a fault in the stator windings is indicated and the stator should be renewed.
38
Starter Motor
Starter Motor Removal
Disconnect cables A from solenoid
(connector 19mm) and remove insulation B
Remove fixing nuts C (19mm) and detach earth strap D from upper stud
Lift off starter motor
When faulty renew.
39
Water pump
Service Instructions
A. Disassembly
Remove cover screws, cover and gasket
Press out impeller with 2 screwdrivers
After removing the cam, remove residual traces of sealing compound from cam and pump housing
Remove lip seal and O-ring
Remove bearing assembly circlip
Remove the shaft with ball bearing by pressing in the impeller side of the shaft
Press off the ball bearings from the shaft. Do not press the ball bearings over the sealing surface of the shaft
Weight and Dimensions
B. Assembly
Press the ball bearings on to the shaft. Do NOT press the ball bearings over the sealing surface of the shaft
Press the shaft with ball bearings into the pump housing and fit the circlip and sealing plates (11)
Assemble O-ring and sealing plate with the opening towards the impeller
Fasten the cam, before doing so, apply sealing compound to cam and screw to prevent leakage
Lubricate the impeller and fit it with a rotating movement in the intended direction of impeller rotation
Fit a new gasket before mounting the cover
Type:
Dimension B
Weight
Kp/cm
0.3
0.6
1.0
2
F35B-8
12.5
0.5kg
500 rpm kW l/min
0.06
0.06
0.06
3.6
3.4
2.7
Performance Table F35B-8 Impeller Neoprene
700 rpm kW l/min
0.06
0.09
0.09
5.2
4.6
4.0
900 rpm kW l/min
0.09
0.09
0.09
6.8
6.2
5.6
1400 rpm kW l/min
0.13
0.13
0.13
11.2
10.6
9.2
2000 rpm kW l/min
0.18
0.18
0.18
16.0
15.8
13.6
2500 rpm kW l/min
0.18
0.18
0.18
20.5
19.6
17.0
Performance stated is for new pumps and water at room temperature
40
Water pump
Waterpump
1. Sea water pump
2. Cheese head screw M4 x 8
3. Cover
4. Seal
5. Impeller
6. Cheese head screw
7. Washer
8. Cam pin
10. Sealing plate
11. Sealing ring
12. O-ring
13. Deep groove ball bearing
14. Snap ring
15. Shaft
16. Clamping sleeve
17. Stop screw
18. Hex head nut M6
19. Washer
20. Stop screw M6 x 16
21. O-ring
41
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