Engine Disassembly - Westerbeke 8.0KW-60Hz Service Manual

ENGINE DISASSEMBLY
GENERATOR
Disconnect the AC wiring and unplug the engine's DC
wiring harness at the generator control paneL Remove the
battery cables from the engine and tape over the tenninals.
NOTE:
Label any lines, hoses or cables as you separate them.
Separate the exhaust hose at the water injected elbow and
disconnect the fuel supply and return lines.
Drain the engine oil and the coolant from the engine.
Carefully support and then unbolt the generator backend
from the engine. See SPECIAL TOOLS in this manual.
Additional generator information
wi11
be found in the
GENERATOR section of this manual.
PROPULSION ENGINE
Switch off the batteries and disconnect the battery cables
from the engine and tape over the tenninals.
Drain or pump out all the engine oil and drain the coolant
from the engine and engine hoses.
Unplug the instrument panel wiring harness. Drain the
transmission fluid and the transmission oil cooler hoses,
Detach the oil cooler hoses and unbolt the transmission from
the engine.
NOTE:
Label any lines, hoses or cables as you separate them.
OIL DRAIN PLUG
TRANSMISSION
If the transmission is not being rebuilt it should be visually
inspected. Flush out and pressure test the oil cooler and
replace the coolant hoses. Inspect and lubricate the gear shift
linkage and the propeller shaft coupling. Clean and repaint
the transmission and change the transmission fluid.
For transmission service and maintenance refer to your
transmission manual. To rebuild a transmission contact your
\VESTERBEKE dealer or an authorized transmission service
center.
DAMPER
PLATE
DAMPER PLATE
BOLTS
ENGINE DISASSEMBLY
Take the following precautions:
• Clean the exterior of the engine of any deposits of
dirt and oil.
• Be careful not to damage the disassembled parts.
• Arrange parts in the order of disassembly. Mark or
label parts as needed to insure proper mating and
reassembly. Keep parts clean.
• Mount the engine on a suitable engine stand for
disassembly.
With the transmission separated from the engine, begin the
following step by step procedure to disassemble the engine.
l.Remove the transmission damper plate from the
engine flywheel.
2. Remove the engine oil cooler and oil hoses. Note oil
hose connections from the oil cooler to the engine.
3. Remove the engine heat exchanger.
If
possible. leave
one end of each hose connected to the
part
being removed.
4. Remove the bell housing and the circuit breaker/
preheat solenoid mounting bracket.
5. Remove the engine back plate.
6. Remove the start motor, drive belt and the alternator.
Label the wires and cables.
7. Remove the engine mounted raw water pump,
complete with its adapter mounting plate. See RAW
WATER PUMP for parts breakdown.
S. With the hoses disconnected, remove the thermostat
housing and housing gasket, leaving the temperature
sender in place.
9. Remove the coolant circulating pump. Refer to
COOlANT CIRCULATING PUMP ASSEMBLY.
10.Remove the air intake silencer and the intake manifold.
1l.Remove the oil filter and the mounting bracket from the
engine block.
12.UnboIt the elbows and remove the exhaust manifold in
its entirety.
13.Remove the fuel injection pump. Disconnect the fuel
injection pipes and fuelleak·off pipe from the fuel injection
pump and nozzles.
NOTE:
Put plugs or caps on the openings of the injection pump
and
n012ie
connectors. Golf tees work well as plugs.
14.Remove the fuel injection nozzle .. Loosen the fuel
injection nozzles with a wrench. Remove the nozzles and
gaskets from the cylinder head.
NOTE:
Remove the gaskets from the cylinder head with a
gasket scraper. Discard the gaskets.
Engines & Generators
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