Engine Assembly - Westerbeke 12C-TWO Operator's Manual

ENGINE ASSEMBLY
Install the raw water pump and drive belt. Insure it is in
proper alignment with the crankshaft pulley. Check tension.
Refer to RAW WATER PUMP.
Install the oil and water sender and switch.
Install the starter motor.
Install the breaker panel and the preheat solenoid.
Reinstall the engine electrical harness.
Mount the complete exhaust manifold and the expansion
tank
to the cylinder head.
Manifold Mounting Bolts Torque Values 20 - 24 H-lb (2. 7 - 3.3 m-kg)
See EXHAUST MANIFOLD/HEAT EXCHANGER for ser-
vice and inspection.
Install new hose connections and clamps for the cooling
system.
A
CAUTION:
Check all AC and DC wiring connections
to WESTERBEKE's wiring schematics and diagrams.
ENGINE TUNING OPERATION
After re-assembly, the unit must be test run. This will ensure
that the engine/generator operates to its specifications. Fill
the engine cooling system with an antifreeze mixture and
the engine oil sump with lube oil API specifications of CI-4
CG-4, CH-4 or C-14 SAE 15-40.
1. Mount the engine on a test bench and cm;mect the fuel
lines.
2. Connect the electrical wiring. Refer to the
WIRING DIAGRAM.
3. Connect the air intake line to the air cleaner.
4. Connect the exhaust pipe.
5. Crank the engine with the starter (non-ignition
operation) for about twenty seconds. This will
pre-lubricate the engines internal components and fill
the fuel lines.
6. Start the engine and allow it to run at 1000 to 1200 rpm
for five minutes.
7. Remove the cylinder head cover while the engine is
running.
8. Check that the engine oil continuously circulating
from the oil pump to the valve rockers through the
cylinder head.
If there is no oil circulation or if the oil circulation is
sluggish, stop the engine and make the appropriate repairs
or adjustment.
Re-install the cylinder head cover.
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9. Mount the engine on a test bench and connect the fuel
lines.
10.Check the engine for oil, fuel, coolant and air intake
leakage.
11.Check for abnormal noise and odor.
12.Check for abnormal electrical charging.
13.Check the engine fastening parts for looseness.
14.When the engine coolant temperature reaches
75°C (167°F) or more, increase the engine speed to
2000 rpm and allow it to run for twenty seconds.
This will give the engine the essential run-in operating
time.
15.Adjust the engine operation speed to the specific
value.
16.Stop the engine to complete the tuning procedure.
Refer to the following pages for details of sub-assemblies.
These sections also include: Wiring Diagrams, Engine
Specifications, Torque Diagrams, Starter Motor, Alternator
and Raw Water Pump.
Be aware of these common problems that can occur during
assembly.
Insufficient Lubrication. Heavily oil sliding and
reciprocating parts, lightly oil head bolts and other fasteners,
except those that penetrate into the water jacket. These
fasteners should be sealed with Permatex No. 2 or the
high-tech equivalent.
Reversed orientation. Most gaskets, many bolt washers, and
all thermostats are asymmetrical.
Mechanical damage. Run fasteners down in approved
torque sequences and in three steps-1/2, 2/3, and 1/1 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 also be damaged during
assembly, they should be positioned with great care.