Service Data/Standards And Limits - Westerbeke BCGA-60HZ Service Manual

SERVICE DATA
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STANDARDS AND LIMITS .• BCG ENGINEiGENEIU\TOR
Component Specified Value
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Standard Repair Limit
inches(mm) inches(mm)
FRONT CASE/COUNTERBALANCE SHAFT
Oil Pump Side Clearance
Driven Gear .......................... 0.0024-0.0047 (0.06-0.12)
Drive Gear ............................ 0.0027 -0.0051 (0.07 -0.13)
Counterbalance Shaft Front Journal Diameter
. . .. ............................ 0.7869-0. 787 4 (19.987-20.000)
Counterbalance Shaft Rear Journal Diameter
. . . ............................. 1. 7317-1.7322 (43.984-44.000)
Counterbalance Shaft Front Journal Oil Clearance
................................ 0.0014 - 0.0027 (0.035 - 0.068)
Counterbalance Shaft Rear Journal Oil Clearance
................................ 0.0014 - 0.0028 (0.035 - 0.071)
CYLINDER BLOCK
cxlinder Bore 2.5591-2.5602 (65.00-65.03)
Out-of-Roundness and
Taper of Cylinder Bore 0.0004 (less than 0.01)
Gasket Surface Flatness 0.0020 (less than 0.05)
CYLINDER HEAD
0:0039 (0.1)
Aatness of Gasket Surface . ..less
t~n
0.0019 (0.05) ........ ,0.0079 (0.2)
Overall Height... ................... 4.287 -4.295 (1 08.9-109.1)
Cylinder Head oversize rework dimension of valve seat hole
Intake 0.3 O.S ...... 1.2323 -1.2333 (31.300 -31.325)
Intake 0.6 O.S ..... 1.2441 -1.2451 (31.600- 31.625)
Exhaust 0.3 O.S .... 1.1535 - 1.1544 (29.300 - 29.321)
Exhaust 0.6 O.S .... 1.1653 - 1.1662 (29.600 - 29.621)
Cylinder Head rework of valve guide hole (both intake and exhaust)
0.05
o.s ..................
0.4744- 0.4751 (12.050 -12.068)
0.25
o.s ......... · .........
0.4823 - 0.4830 (12.250 - 12.268)
0.50
o.s ..................
0.4921 - 0.4928 (12.500 -12.518)
Intake Valve Seat Angle ........................ .45"
Exhaust Valve Seat Angle ...................... 30"
Intake Valve Seat Width ...........•.•.... O.D79 (2.0) ...•.........•.......... 0.004 (0.1)
Exhaust Valve Seat Width ............... 0.079 (?.0) ........................ 0.004 (0.1)
Valve Clearance ........................................ .
Exhaust... ................................... O.D12 (0.30)
lntake ..................................... : ... 0.008 (0.20)
Valve Head Thickness (margin)
(Intake) ......................................... 039 (1.0) ........................... 020 (.5)
(Exhaust) ...................................... 051 (1.3) ............................. 031 (8)
Valve Length
(Intake) ..................................... 3.960 (100.6)
(Exhaust) .................................. 3.968 (100.8)
Valve Stem O.D.
Intake ......... : ............. :0.2585 - 0.2591 (6.565 - 6.580)
Exhaust.. .................... 0.2571 - 0.2579 (6.530 - 6.550)
Stem to Guide Clearance
Intake ......................... 0.0008 - 0.0020 (0.02 - 0.05) ...... 0.0039 (0.1 0)
Exhaust ................... 0.0020 - 0.0033 (0.0050 - 0.0085) .. 0.0059 (0.15)
Valve Guide Length
(lntake) ......................................... 1.73 (44)
(Exhaust) ................................... 1.949 (49.5)
Component
VALVES
Specified Value
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Standard
inches(mm)
Valve Guide Service Size 0.05, 0.25, 0.50 oversize
Valve Seat Width of
Seat Contact ............................... 035-.051 (0.9-1.3)
Valve Seat Angle .............................. 30°/44°/65°
Repair Limit
inches(mm)
Valve Seat Sink ............................................................................ 0.008 (0.2)
Valve Spring Free Length ................ 1.823 (46.3) ...................... 1.783 (45.3)
Valve Spring
Load/Installed Height
lbslin (N!mm) .......................... .46/1.48 (21 0/37.7)
Squareness ...... .,. ............................. .less than 2° ............................. .4
o
TIMING BELT
Seal Line Clearance ............................. 47 (12)
ROCKER ARM/CAMSHAFT
Camshaft Height
No.1 (lntake) .......................... 1.3815 (35.09) .................. 1.3618 (34.59)
No.2 (lntake) .......................... 1.3807 (35.07) .................. 1.3610 (34.57)
No.3 (lntake) .......................... 1.3803 (35.06) .................. 1.3606 (34.56)
No. 1 (Exhaust) ....................... 1.3839 (35.15) .................. 1.3642 (34.65)
No. 2 (Exhaust) ....................... 1.3831 (35.13) .................. 1.3634 (34.63)
No.3 (Exhaust) ...................... 1.3854 (35.190) ................ 1.3657 (34.69)
Camshaft Journal
Diameter .......................... 1.6118-1.6124(40.940-40.955)
Bearing Oil Clearance .......... 0.0018-0.0033 (0.045-Q.085
End Play .................................... 0024-.0055 (.06-.14) ................. 118 (.03)
Rocker Shaft Length ........................ 9.134 (232)
Rocker Arm Shaft
Outer Diameter .....
~.0.6687
- 0.6692 (16.985 - 16.998)
Clearance ................... 0.0005 - 0.0017 (0.012 - 0.043) ...... 0.004 (0.1)
PISTON AND CONNECTING ROD
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Piston Outer Diameter ...... 2.5579-2.5591 (64.97 -65.00)
Piston to Cylinder Clearance
.................................. 0.0008- 0.0016 (0.02- 0.04)
Pistan Ring Grove Width
No.1 ............................. 0.0480- 0.0488 (1.22 -1.24)
No.2 ............................. 0.0476- 0.0484 (1.21 - 1.23)
011 .............................. 0.1108- 0.1116 (2.815- 2.835
Piston Service Size ............... 0.25, 0.50, 0.75, 1.00 OS
Piston Ring End Gap
No.1 ............................. 0.0059- 0.0118 (0.15- 0.30) ........ 0.0315 (0.8)
No.2 ............................. 0.0138 - 0.0197 (0.35 - 0.50) ........ 0.0315 (0.8)
Oil .................................... 0.008 - 0.028 (0.2 - 0.7) ............ 0.0394 (1.0)
Piston Side Clearance
No.1 ............................. 0.0012 - 0.0028 (0.03- 0.07) ...... 0.0047 (0.12)
No.2 ............................. 0.0008- 0.0024 (0.02- 0.06) ...... 0.0039 (0.1Q)
Piston Pin O.D .............. 0.6300- 0.6302 (16.001 -16.007)
Piston Pin Press-in Load lbs(N)
................................... 1102- 3307 (5000 -15000)