Exhaust Manifold/Heat Exchanger - Westerbeke 8.0KW-60Hz Service Manual

EXHAUST MANIFOLD / HEAT EXCHANGER
EXHAUST MANIFOLD
The exhaust manifold, which was disassembled from the
cylinder head, should be inspected before reassembly.
1. Remove the exhaust elbows from the lower surface of the
manifold. Clean and inspect for cracks and defects.
Replace as needed.
2. Remove the exhaust nipples, elbows and plugs from the
manifold.
3. Remove water connectors from the ends of the manifold.
Be sure to note the proper location and arrangement of
each for proper alignment.
4, Examine all parts for defects, corrosion and wear and
replace as needed.
5. Flush out the manifolds interior with a liquid cleaner and
rinse thoroughly with fresh water.
6. Use a pipe cleaner to clear the passage that connects the
coolant recovery tank tubing.
7. Flush out the coolant recovery tank and it's connecting
tube.
ASSEMBLY
1. If
the manifold was removed as an assembly and left
intact, it can be replaced on the cylinder head in the
reverse order of removal. Do not reuse the gaskets; install
new ones.
Manifold Mounting
Bolts Torque Values 20 - 24 ft-Ib (2.7 - 3.3 m-kg)
2.
If
the manifold has been disassembled, follow the steps
below.
a. Loosely attach the elbows to the cylinder head and the
manifold using new gaskets. Do not use any gasket
sealant
b. Gradually tighten each fitting to make sure of proper
alignment of all the parts. This should be done in three
steps.
Manifold Mounting
Bolls Torque Values
20 - 24 ft-Ib (2.7 - 3.3 m-kg)
c. Reinstall the exhaust connections and plugs into the
manifold using Loctite-Anti-Seize on the threads.
Check the manifold pressure cap. Open the valve by pulling
it and make sure it closes when released. Make certain the
upper and lower seals are in good condition.
If
any doubt,
replace the cap.
CHECKING THE PRESSURE CAP
HEAT EXCHANGER
The heat exchanger should be inspected and serviced during
an engine overhauL
1.
Disconnect the hoses and remove the hose fittings,
petcock, drain plugs and zinc anode. Also, remove the
end fittings and gaskets.
2. Inspect the tube (casing) for wear and dents, if at all
suspect replace the heat exchanger.
3. Clean out any zinc debris and pressure test the coolant
and raw water passages.
4. When reassembling, install new gaskets and O-rings.
Apply some lubricant to the new gaskets and to the
petcocks and fittings as you install them.
5. Install a new zinc anode.
NOTE:
All of the above can be accomplished by sending the
heat exchanger to a heat exchanger service shop. They will
also service transmission and engine oil coolers.
6. Repaint the assembled heat exchanger with Westerbeke
resistant spray enamel.
HEAT EXCHANGER
CLEAN OUT
DEBRIS
ANODE
AFTER COMPLETED ENGINE ASSEMBLY
7. Reconnect all hoses, replacing them as needed.
8. Refill the system with coolant as detailed above.
9. Pressure test system and check for leaks.
HEAT EXCHANGER
Engines
&
Generators
35