Westerbeke 26 G, 26 GX Technical Manual

TECHNICAL MANUAL

WESTERBEKE CORPORATION

26

GAND26

GX

MARINE

GASOLINE ENGINES

Publication # 037425

Edition Two

JANUARY, 1993

~r

....

4 MYLES STANDISH INDUSTRIAL PARK

rWESTERBEKE

WESTERBEKECORPO~TION

150

JOHN

HANCOCK ROAD, TAUNTON, MA 02780-7319

TECHNICAL MANUAL

WESTERBEKE CORPORATION

26

GAND26

GX

MARINE

GASOLINE ENGINES

Publication # 037425

Edition Two

JANUARY, 1993

~r

....

4 MYLES STANDISH INDUSTRIAL PARK

rWESTERBEKE

WESTERBEKECORPO~TION

150

JOHN

HANCOCK ROAD, TAUNTON, MA 02780-7319

TABLE

OF

CONTENTS

Section .......................................................................... page

26G

W

and W 26GX

ENGINES

W

26G

and W 26GX

GENERAL

MARINE

GASOLINE

SPECiFiCATIONS

SYSTEM

SPECIFICATIONS

.........................

...........

31
32

W

26G

and W 26GX

ENGINES
ENGINE
TIGHTENING
TABLE

TIGHTENING

ENGINE

SERVICE

TUNE-UP

TORQUES

OF

STANDARD

TORQUES

OVERHAUL
PREPARATIONS
ENGINE

.

REMOVING
FROM

CYLINDER

CYLINDER

SPECIAL

DISASSEMBLY

THE

THE

CYLINDER
HEAD
BLOCK

SERVICE

MARINE

SPECIFICATIONS

SPECIFICATIONS

GASOLINE

..........................

............................

REQUIREMENTS

...................

HARDWARE

.................................................

........•.........................••....................

.•....••......................................................

..................................................

CYLINDER

DISASSEMBLY

DiSASSEMBLy

TOOLS

HEAD

BLOCK

.......................................

...................................

................................

.............................................

36

42
43

45
46
47
48

52
53
56
62

CYLINDER

HEAD

INSPECTION

AND

AND

ENGINE

REPAIR

BLOCK

.............................................

1

65

Westerbeke Engines

TABLE

OF CONTENTS

(CONTINUED)

Section

.........................................................................

SUBASSEMBLY
AND

ASSEMBLY

ENGINE

CYLINDER

CYLINDER

BOLTING

TO
TIMING

ADJUSTING

LUBRICATING

COOLING

CARBURETOR

ASSEMBLy ....................................................... 112

BLOCK

HEAD

THE

CYLINDER

THE

CYLINDER

BELT

ASSEMBLy ..............................................

VALVE

SYSTEM

SYSTEM

AND

page

INSPECTION,

REPAIR,

............................................................... 88

ASSEMBLY

ASSEMBLY

..................................... 113

....................................... 120

HEAD

BLOCK

........................................... 124

125

CLEARANCES ............................... 129

................................................. 133

........................................................ 137

FUEL

SYSTEM ..............................

14D

DC

ELECTRICAL

DC

WIRING

HBW

TRANSMiSSiONS ..................................................

BW-7TRANSMISSION

LAY-UP
SPARE

INDEX

AND

PARTS

.............................................................................. 168

SYSTEM

DIAGRAM

............................................. 144

#36037

....................... 145

................................................... 160

RECOMMISSIONING

LiST ........................................................ 167

............................... 163

and

146

151

Westerbeke Engines

2

Top Engine Oil Fill

W

200 and W 26GX Marine Gasoline Engines

Sea

Water

Pump

Ignition

45

Coil

0

Exhaust Elbow

DC
Connection

Battery Ground

Transmission
Dipstick and Fill

Please note that the W
except for its engine mounts. The installation mounts for the W
insulated, whereas the W
is that the W 26GX engine was designed
Atomic Four

Gasoline Engine. Please keep in mind as you read this manual that the
specifications for the W
for the engine mounts. Also note that the length
ing upon the type

of

your engine.

Special Note:

26GX

Gasoline Engine is exactly like the W

26GX

engine has solid mounts. The reason for

to

be a replacement engine for the Universal

26G

engine are exactly the same for the W 26GX engine except

of

each engine will be different depend-

26G

Gasoline Engine

26G

engine are rubber

this

difference

transmission the engine comes with. Find out the exact length of

3

Westerbeke Engines

Fuel lift: Pump

W

Distributor

26G

and W 26GX Marine Gasoline Engines

Electric Choke

Air Intake
Flame Arrestor

Zinc Anode

Heat Exchanger

Water Temperature Alarm Switch

Transmission

Lube

Oil Filter

Throttle
Connection

DC

Alternator

Oil Pressure

Sender

Oil Pressure

Alarm Switch

Lube Oil Drain Hose

Cable

Please note that the W 26GX

for

except
insulated, whereas
is

that the W 26GX engine was designed

its engine mounts. The installation mounts for the W 26G engine are rubber

the

W 26GX engine has solid mounts. The reason for this difference

Atomic Four Gasoline Engine. Please keep in mind as you read
specifications for the W

26G

for the engine mounts. Also note that the

the

type

of

ing upon

transmission the engine comes with. Find out the exact length

your engine.

Westerbeke Engines

Special

Note:

Gasoline Engine is exactly like the W 26G Gasoline Engine

to

be a replacement engine for the Universal

this

manual that the

engine are exactly the same

length

of

each engine will be different depend-

for

the W 26GX engine except

of

4

IMPORTANT

PRODUCT SOFTWARE DISCLAIMER

Product software

of

all kinds, such

as

brochures, drawings, technical data, operator's and workshop manuals,
parts lists and parts price lists, and other information, instructions and specifications provided from sources
other than Westerbeke, is not within Westerbeke's control and, accordingly, is provided to Westerbeke
customers only as a courtesy and service. Westerbeke cannot be responsible
software, makes
timeliness

or

incurred in connection with,

example, components and subassemblies incorporated in Westerbeke's products and supplied by others

For

no

warranties

or

representations with respect thereto,

completeness thereof, and will in

or

arising

out

of,

the

no

event be liable

furnishing

or

use

for

of

any

such

for

the

including

type

of

software.

content

the

damages

of

such

accuracy,

or

injury

(such as engine blocks, fuel systems and components, transmissions, electrical components, pumps and
other products) are generally supported by their manufacturers with their own software, and Westerbeke
must depend on such software for the design of Westerbeke's own product software.

Such software may
be outdated and no longer accurate. Routine changes made by Westerbeke's suppliers, of which Westerbeke
rarely has notice in advance, are frequently not reflected in the supplier's software until after such changes
take place.

Westerbeke customers should also keep in mind the time span between printings of Westerbeke product
software, and the unavoidable existence of earlier, non-current Westerbeke software editions in the field.

do

Additionally, most Westerbeke products include customer-requested special features that frequently

not

include complete documentation. .

In summation, product software provided with Westerbeke products, whether from Westerbeke

or

other
suppliers, must not and cannot be relied upon exclusively as the definitive authority on the respective product.
It not only makes good sense but is imperative that appropriate representatives of Westerbeke
in question be consulted to determine the accuracy and currency

of

the product software being consulted

or

the supplier

by the customer.

Please note
except
insulated, whereas

is

that
Atomic
specifications
for

the engine mounts. Also note

depending

length

that

the

W 26GX Gasoline Engine is exactly like the W 26G Gasoline Engine

for

its engine mounts. The installation

the

W 26GX engine has solid mounts. The reason

the

W 26GX engine was deSigned

Four

Gasoline Engine. Please keep

for

the W 26G engine are exactly

upon

the

type

of

of

your

engine.

Special Note:

mounts

for

the W 26G engine are rubber

for

to

that

be a replacement engine

in

mind

as

you read

the

same

for

the

the length

of

each engine

for

this

manual

W 26GX engine except

will

transmission the engine comes with. Find

5

this

difference

the

Universal

that

the

be different

out

the exact

Westerbeke Engines

Introduction

GENERAL

This manual is a general guide
marine
term operation.

gasoline engine. The information contained

A.

Read

it.

B.

Keep it in a safe,

C.

Keep it handy for reference at all times.

to

the installation, start-up, operation and maintenance

in

dry

this manual is vital

place.

to

your engine's dependable, long

of

your Westerbeke

Understanding the Gasoline Propulsion Engine

The marine gasoline propulsion engine is
cylinders are vertical
The engine utilizes a solid-state distributor which
incorporates a pressure type lubrication system, and a fresh water-cooled engine block which is thermostat

-controlled. To a large degree, the marine gasoline engine requires the same preventive maintenance that
of

is required
ventilation, maintenance

a gasoline automobile engine. The most important factors

in-line, and the engine's cylinder head has an overhead camshaft which is chain-driven.

of

the fuel system, ignition system, and the fresh water cooling system.

in

many ways similar

is

horizontally mounted and camshaft-driven. The engine

to

a gasoline automobile engine. The

to

the engine's longevity are proper

Ordering Parts

Whenever replacement parts are needed, always provide the engine's model and serial number, and
transmission number as they appear on the black and silver name plate located on the engine's exhaust

we

manifold. You must provide us with this information so
include a complete part description and part number for each part needed (see the separately furnished

to

Parts List). Also, be sure
are frequently not made

insist upon Westerbeke factory packaged parts, because "will

to

the same specifications as original equipment.

may properly identify your engine. In addition,

fit"

or

generic parts

Note that component locations
pulley/drive belt end. (The flywheel/transmission end
the engine; imagine straddling the engine and facing
side is at your left, the right side at your right.

Westerbeke engines are thoroughly checked and given a final run under various load conditions before
leaving the factory. Test running the engine ensures dependable operation, long service, and a satisfied
owner.

Care at the factory during assembly and thorough testing have resulted in a Westerbeke gasoline engine

of

capable
is the treatment the engine receives

many thousands of hours of dependable service. However, what the manufacturer cannot control

Westerbeke Engines

in

the manual are referenced from the front

is

the rear end.) Left and right sides are determined

in

the same direction as the front

in

the field. That part is up

to

the owner/operator.

6

of

the engine which is the

of

the engine: the left

by

W 26G

and

W 26GX MARINE

GENERAl

GASOUNE

SPECIFICATIONS

ENGINES

Engine Type

Combustion Chamber

Bore

& Stroke

Piston Displacement

Order

Firing

Direction

Maximum Torque (at 2500 rpm)

Compression Ratio

Compression Pressure

(Umit

Valve Timing

of

Rotation

of

difference between cylinders)

Gasoline, four-cycle, three-cylinder, fresh water-cooled
Vertical, in-line overhead valve mechanism

(30

hp

at 3200 rpm maximum).

Multi-sphere

2.99 x 2.87 inches (76 x 73 mm)

60.6 cubic inches

1-2-3

Oockwise, when viewed from the front

Ib-ft (6.5 kg-m)

47

9.5:1

n psi (12.5

1
(28 psi

Intake Opens 19° BTDC
Intake Closes 51°

type

kg/cm

[2.0 kg/cm

(0.993 liters)

2

)

at 350 rpm

2

])

ABDC

Seat Angle

Valve

Oearance

Valve

(engine cold)

Engine

Dimensions

Weight

Fuel Consumption

Inclination

Speed

Exhaust

Exhaust

Intake

Exhaust 45°

Intake 0.0098

Exhaust

Idle Speed 700 - 900 rpm
CruiSing rpm 2500 - 3000
Maximum

Height: (total) 22.88 inches (581.15 mm)
Height: (from base mount) 18.75 inches (476.25 mm)

Width: 18.69 inches (474.73 mm)

*Length: 27.75 inches (704.85 mm)
*(Length can vary depending upon transmission length)

2751bs (124.74 kgs)

1.5

Continuous

Temporary 20° (not

Opens 51° BBDC
Ooses

45°

0.0098 inches (0.25 mm)

gph

(5.68 Iph) running at 3200 rpm (approximate)

1

go

ATDC

inches (0.25 mm)

No

Load (Neutral) rpm 4000

15°

to

exceed 20 min.)

31

Westerbeke

Engines

INTAKE SYSTEM

W 26G

and

W 26GX SYSTEM SPECIFICATIONS

Carburetor (STD type)

IGNITION SYSTEM

General

Distributor

Spark Plug Thread Size

Spark Plug

FUEL

General

SYSTEM

Type

Down draft type, single barrel with U.S.C.G.

approved flame arrester.

Battery ignition, 12-Volts, negative ground,
distributor with points, ignition coil and spark
plugs.

Solid state type with signal generator and igniter

14 mm x 1.25 pitch

Westerbeke part Number
33805
(f.Jways identify the engine model when ordering parts.)

Conventional carburetor type with fuel

lift

pump

Fuel

Uft

Pump

Fuel

Screens (on engine)

Air cleaner

Air Flow (engine combustion)

COOLING SYSTEM

General

Operating Temperature

Fresh Water Pump

Sea

Water Pump

Regular
of

12-Volt DC; lift capacity 5 ft (1.5

Reusable screen type (one
in electric fuel pump).

Metal screen type - cleanable
64 cfm (0.906 cmm) at 3200 rpm

Fresh water-cooled block,
thermostatically-controlled
with heat exchanger.

170

Centrifugal type, metal impeller, belt-driven

Positive displacement, rubber impeller, belt-driven.

or

unleaded gasoline with an octane rating

89

or

better.

-1900 F (78 -

880 C)

m)

in

Carburetor and one

Westerbeke

Engines

32

W 26G

Water Flow, at 3200 rpm

Sea
(measured before discharging
into exhaust

elbow)

and

W 26GX SYSTEM SPECIFICATIONS

gpm

6.5 - 6.6

(24.6 - 24.9 Ipm)

System

Capacity (fresh water)

LUBRICATION SYSTEM

General

Oil Filter

Capacity (not including filter)

Sump

Operating Oil Pressure (engine hot)

Oil Grade

ELECTRICAL SYSTEM

Starting

Battery

Battery Capacity

5.7 qts (5.39 liters)

Pressure type
chain-ciriven through

by

Trochoid pump,

balance shaft.

Full flow, paper element, spin-on type

3.0 U.S. qts (2.9 liters)

50

- 75 psi (3.5 - 5.2 kg/cm

API

specification of SC, SD,

12-Volt,

26 A-H, (-) negative ground

(recommended) (35 A-H in

-125

90

(Ampere-Hours)

2

)

SE,

or

cold areas)

SF

Alternator

Starter

DC

No-Load Current

DC Cranking Current

Belt driven, 12 Volt, 50 Amps.

12-Volt, 1.2KW, reduction type,

solenoid-mounted

90 Amp (max.) at 11.5

Volts.

175 - 200 Amps (engine cold)

33

Westerbeke

Engines

W

26G

and W 26GX

TRANSMISSION SPECIFICATIONS

HBW 100

SYSTEM

SPECIFICA

nONS

Standard Gear Ratio

Direction of Rotation
Lubricant

Sump Capacity

HBW

100-2

(W

26G

1.79:1

Ratio)

Propeller Recommendations

(approximate)

HBW

100-2

(using

HBW

100-1.5

transmission)

(W

26GX

1.48:1
Propeller Recommendations
(approximate)

HBW

(using

100-1.5 transmission)

Ratio)

W26G
W26GX

Right

handed - standard transmission

Automatic Transmission Auid
Type A or Dexron

0.3.7

U.S.

qts

15

0 x 9 P

-2

1.79:1

1.48:1

II

(0.35

liters) approximate

blade or

15

(ATF)

D x 7 P -3 blade

Propeller should allow the engine
its

full rated

RPM

(3200 + 000 -100)

throttle while underway.

13

D x

10

P -2 blade or

13

D x 8 P -3 blade

Propeller should allow the engine

full

rated

RPM

its

(3200 + 000 -100)

throttle while underway.

to

reach

at full open

to

reach

at full open

BW-7

Standard Gear Ratio
Direction of Rotation

Lubricant

Sump Capacity

Propeller Recommendations
(approximate)

BW-7

(using

transmission)

2.05:1
Right handed - standard transmission

SAE

20W/20

DO

NOT MIX SAE GRADES I

DO

NOT

1

U.S.

16

D x
Propeller should allow the engine
its full rated

or

SAE

USE

MULTI-GRADE OILS I

qt

(1

liter) approximate

10 P -2

blade or

RPM

(3200 + 000 -100)

30

16

D x 8 P - 3 blade

to

throttle while underway.

reach

at full open

Westerbeke Engines

34

W 26G

TUNE-UP SPECIFICATIONS

and

W 26GX SYSTEM SPECIFICATIONS

Spark Plug

Timing

Gap

0.028 - 0.036 inches (0.7 - 0.9 mm)

10° ± 2°

BTDC at idle (900 rpm)

35

Westerbeke Engines

W 26G

and

W 26GX

ENGINE SERVICE SPECIFICATIONS

Cylinder

Head

Lower gasket surface distortion - inches (mm)

Grinding tolerance - inches (mm)

Manifold gasket surface distortion - inches (mm)

Valve seat width

(Intake and Exhaust)

Valve seat angle

Valve seat recession allowable limit - inches (mm)

Valve

Guide

Bushing

Valve stem-to-bushing clearance - inches (mm)
Intake

Specified

VaJue

0.0118 (0.3 mm)

0.039 -

(1.0

-1.8

0.071
mm)

0.0016 - 0.0028

(0.040 - 0.070 mm)

Allowable

Umit

0.0039 (0.10 mm)

4.949 (total height)
(125.50 mm)

0.0039 (0.10 mm)

0.020 (0.5 mm)

0.0035 (0.09 mm)

Exhaust

Valves

Valve seat width (Intake and Exhaust) - inches (mm)

Valve head

stock

thickness - inches (mm)

Intake

Exhaust

Valve stem outer diameter - inches (mm)

Intake

Exhaust

0.0018 - 0.0030

(0.045 - 0.075 mm)

0.039 -

(1.0

-1.8

0.071
mm)

0.035 - 0.059

(0.9 - 1.5 mm)

0.047 -

(1.2

-1.8

0.071
mm)

0.2734 - 0.2740

(6.945 - 6.960 mm)

0.2732 - 0.2738

(6.940 - 6.955 mm)

0.0039

(0.10

mm)

0.031

(0.8 mm)

0.039 (1.0 mm)

0.2724 (6.920 mm)

0.2720 (6.910 mm)

Westerbeke

Engines

36

Valve

Spring

Free length - inches (mm)

Length as installed - inches (mm)

Out-of-squareness -inches (mm)

Valve

Rocker

Shaft

and

Rocker

Arm

Rocker shaft-to-rocker arm clearance -inches (mm)

Cylinder

Block

Top

gasket surface distortion - inches (mm)

bore

Cylinder

Cylinder

wear - inches (mm)

bore

out-of-roundness, taper

1.7047 (43.3 mm)

1.3740 (34.9 mm)

0.0006 - 0.0024

(0.16

- 0.060 mm)

1.6535

(42.0 mm)

0.059 (1.5 mm)

0.0035 (0.09 mm)

0.0020 (0.05 mm)

0.0039 (0.10 mm)

0.0031 (0.08 mm)

Piston,

Piston

Pin,

and

Piston

Ring

Piston-to-cylinder clearance - inches (mm)

gap

Piston ring end

Compression

- inches (mm)
No.1

and No.2

Oil

Piston ring side clearance -inches (mm)

Compression

NO.1

Compression No.2

Piston outer diameter - inches (mm)

Piston-to-piston pin clearance - inches (mm)

0.0014 - 0.0022

(0.035

- 0.055 mm)

0.0079 - 0.0157
(0.2

- 0.4 mm)

0.0079 - 0.0315
(0.2

- 0.8 mm)

0.0012 - 0.0026

(0.03

- 0.07 mm)

0.0008 - 0.0024

(0.02

- 0.06 mm)

2.9903 - 2.9915

(75.955 - 75.985 mm)

0.0002 - 0.0004

(0.005

- 0.011 mm)

0.0039 (0.10 mm)

0.0276 (0.70 mm)

0.0433 (1.10 mm)

0.0047 (0.12 mm)

0.0047 (0.12 mm)

0.0008 (0.02 mm)

37

Westerbeke

Engines

Connecting

Rod

Specified

Value

Allowable

Limit

Bend of rod per 3.94 inches (100 mm)

Twist

of

rod per 3.94 inches (100 mm)

Connecting rod bearing

Big end thrust

Crankshaft

Crankshaft run-out - inches (mm)

Uneven wear

Crankshaft bearing

Side

clearance - inches (mm)

clearance - inches (mm) 0.0059 - 0.0087 0.0118 (0.30 mm)

of

journal section - inches (mm) 0.0008 (0.02 mm)

oil clearance - inches (mm)

oil clearance - inches (mm)

0.0020 (0.05 mm)

0.0020 (0.05 mm)

0.0008 - 0.0017 0.0028 (0.07 mm)

(0.020 - 0.044 mm)

(0.150 - 0.220 mm)

0.0012 (0.03 mm)

0.0008 - 0.0017 0.0028 (0.07 mm)

(0.020 - 0.044 mm)

0.0004 - 0.0063 0.0118 (0.30 mm)

(0.010 - 0.160 mm)

Balance

Camshaft

Shaft

Thrust clearance - inches (mm)

Balance shaft bearing oil clearance - inches (mm) 0.0010 - 0.0026 0.0039 (0.10 mm)

Thrust clearance - inches (mm)

Cam lobe height - inches (mm)

Camshaft

Camshaft bearing oil

journal uneven

clearance - inches (mm)

wear

- inches (mm)

(front)

(center)

(rear)

0.0012 - 0.0051 0.0039 (0.10 mm)

(0.03 - 0.13 mm)

(0.025 - 0.066 mm)

0.0402 - 0.0496 0.0551 (1.40 mm)

(1.020 - 1.260 mm)

1.5743 - 1.5822

(39.987 - 40.187 mm)

0.0016 - 0.0035 0.0055 (0.14 mm)

(0.04 - 0.09 mm)

0.0035 - 0.0055

(0.09 - 0.14 mm)

0.0024 - 0.0043

(0.06 -

0.11

mm)

1.5630 (39.70 mm)

0.0016 (0.04 mm)

0.0075 (0.19

0.0063 (0.16

mm)

mm)

Westerbeke

Engines

38

Timing Belt Pulley

Pulley outer diameter - inches (mm)

Camshaft pulley

Crankshaft

pulley

Manifold

I ntake manifold gasket surface

distortion - inches (mm)

Exhaust manifold gasket surface
distortion - inches (mm)

Flywheel

Specified Value

4.7189 - 4.7260

(119.86 -

(59.26 - 59.36 mm)

2.3331 -

120.40 mm)

2.3370

Allowable

4.7165 (119.80 mm)

2.3307 (59.20 mm)

0.0039 (0.10 mm)

0.0039 (0.10 mm)

Limit

Flywheel run-out - inches (mm)

Electrical System

Starting battery (recommended)

Starter

No-load performance

Alternator

No-load performance
(Engine speed at

Current

Load performance
(Engine speed at 2000 rpm)

2000 rpm)

Regulated voltage

Regulated voltage

12-Volt,

12-Volt,
solenoid-mounted.

Less than

1.2'r<'N,

13.9 -

Less than

30 A-H

reduction type,

50 Amp at

15.1

10 Amps

13.9 -15.1'r<'N

11

Volts

0.0039 (0.10 mm)

(45 A-H in cold areas)

Volts

Brush length - inches (mm)

Stator resistance - 0 (Ohms)

Rotor resistance - 0 (Ohms)

39

Less than

2.90

10

Westerbeke Engines

Ignition

Distributor

System

Condenser capacity - uF (microfarads)

Specified Value

0.27

Allowable

Limit

Contact point clearance - inch (mm)

Dwell angle - degrees

Ignition coil

Primary coil resistance
Secondary coil resistance
Resistor resistance

Lubricating

System

General

Oil filter

Oil sump capacity (filter not included) - qts

Oil pressure at 1800 rpm engine speed

(engine hot)

Oil

pump

Oil

pump

chain

deflection - inches (mm)

0.016 - 0.020

(0.4 - 0.5 mm)

-66

58

Ohms 0.98 ±

0.1
Ohms 17.5 ± 2.6
Ohms 1.92 ± 0.2

Pressure type with Trochoid pump,

chain-driven through balance shaft.

Full flow, paper element, spin-cartridge.

Oiters)

3.0 (2.9 liters)

50

- 70 psi

3.5 - 4.9 kg/cm

2

0.275

(7

mm)

Westerbeke

Shaft-to-body clearance - inches (mm)

Tip clearance (inner

to

outer

rotor) - inches (mm)

Side clearance (rotor end float)

Body

clearance (outer rotor-

to-body) - inches (mm)

Engines

0.008 - 0.0033

(0.045

0.0059 (0.15 mm)

0.0012 - 0.0035

(0.03 - 0.09 mm)

0.0039 - 0.0063

(0.10 - 0.16 mm)

40

0.0039 (0.10 mm)

- 0.085 mm)

0.0098 (0.25 mm)

0.0079 (0.20 mm)

0.0118 (0.30 mm)

Lubricant:

API

specification

of

SC

or

SD,

grade

in

accordance with thermal environment

(see

table).

Temperature

Engine oil

Ie')

IF' )

-30

-20

:}::::})(:.::::i::iSW:,;;30:? :::::::::",:):::::::.,.

::,sw"',,<at

-20

o

')l>

<:(?:<

:'·',

..

·,i<):i:.}·,·/'·':

<!

:,

..

~:SS::}",7·;pc]Tillfr77

-10

<Z/}()

:,·"·"·,·:·",,,:·,·:,:·:,,,,':::«.:::'tOW:':;:':'30t\::)::{:':

o

20

?':i'\::ZOW,;",20\::Y

10

40 60

·,:::}tU}J{((?n:

,.""."

::::))::t30t/':::::t

\\2>

:,:,::':'}:.':"::::.}:':.:':',:,:.:,:)){:">

20

30

80

":,:"",,,

'::"::)i?::(:.:>

"'<"'!22":"':':':'2':"22"'El2!!tl2i£I2~

Specified Value

Cooling System

General Fresh water-cooled block, thermostatically-controlled,

with

sea

water heat exchanger system

Operating Temperature 0 F e

C)

130 -150

(55 -66)

Fresh water pump Centrifugal type, metal impeller, belt-driven
Sea

water pump Positive displacement, rubber impeller, belt-driven

Sea water flow at

1800

rpm
(measured at discharge point
from heat exchanger) 4.75 - 5.0 gpm

40

100 120

50

Allowable Limit

System capacity (fresh water) -qts (liters)

Fuel System

Fuel

Carburetor
Governor
Lift pump
Air cleaner
Fuel

filter

Engine fuel consumption at
rpm (approximat)e

U.S

3200

gph (lph)

5.7 (5.39 liters)

Unleaded

or

leaded gasoline

(minimum octane rating of

Single-barrel, down-draft

Mechanical, belt-driven

12-Volt electric; lift capacity 6 feet

Metal screen type, cleanable

Reusable metal screen

1.5

(5.68)

89)

(1.8

meters)

41

Westerbeke Engines

Spark

Plug

Gap

- inches (mm)

ENGINE TUNE-UP SPECIFICATIONS

0.028 - 0.036 (0.7 - 0.9 mm)

Contact

Dwell

Condenser

Point

Angle

Clearance

- degrees

Capacity

- inches (mm)

- microfarads

Valve Clearance (engine cold) - inches (mm)

Timing

900 rpm (at idle)

0.016 - 0.020 (0.4 - 0.5 mm)

-66

58

0.270

Intake

0.0071 (0.18 mm)

0

± 2

0

BTDC

10

Exhaust

0.0071 (0.18 mm)

Westerbeke

Engines

42

TIGHTENING TORQUE REQUIREMENTS

Cylinder head

Crankshaft pulley

Manifold

Main bearing caps

Connecting rod bearing caps to connecting rod

Balance shaft thrust plate

Spark plug

Rocker cover

Flywheel

Timing

Timing

beH

beH

to

cylinder block

to

crankshaft

to

cylinder head

to

cylinder block

to

cylinder head

to

cylinder head

to

crankshaft

cover to cylinder head

cover to cylinder block

Lb-ft

36.2 - 43.4

65.2

-72.4

7.2

-11.6

39.1 - 47.7

15.2 - 21.0

7.2 - 10.8

10.8

-15.9

5.8 - 8.7

28.9 -36.2

1.4 - 2.9

7.2

-11.6

Kg-m

5.0 - 6.0

9.0 - 10.0

1.0

-1.6

5.4 - 6.6

2.1

- 2.9

1.0

-1.5

1.5 - 2.2

0.8

-1.2

4.0 - 5.0

0.2 - 0.4

1.0 - 1.6

Valve adjusting screw locknut

beH

Camshaft timing

Fuel pump drive cam to camshaft

Timing beH tensioner to cylinder block

Oil pan

Oil pan drain plug

Oil

Oil pump drive shaft sprocket to oil pump rotor

Balance shaft gear cover to cylinder block

Distributor housing

Oil seal retainer

Flywheel

to

pump

cylinder block

to

cylinder block

housing

pulley to camshaft

10

cylinder block

to

cylinder block

to

cylinder block (Backplate)

9.4

-13.0

21.7 - 32.5

7.2 - 10.8

21.7 - 32.5

2.9 -

5.1

18.1 - 25.3

10.8

-15.9

7.2 - 11.6

7.2

-11.6

10.8

-15.9

7.2 - 11.6

7.2

-11.6

1.3 - 1.8

3.0 - 4.5

1.0 - 1.5

3.0 - 4.5

0.4 - 0.7

2.5 - 3.5

1.5 - 2.2

1.0 - 1.6

1.0 - 1.6

1.5 - 2.2

1.0 - 1.6

1.0 - 1.6

Fuel line

to

pump

43

10.8 - 14.5

1.5 - 2.0

Westerbeke Engines

Fuel line to carburetor

M10

indicates Metric thread diameter; (17), if given, indicates 17 mm across the flats

bolt head.

TIGHTENING TORQUE REQUIREMENTS

(continued)

10.8

-14.5

1.5 - 2.0

ofthe

Westerbeke

Engines

44

Unless

Grade

6mm

8mm
10mm
10mm
12mm
12mm
12mm
13mm
14mm
14mm
16mm
16mm

stated

for

4T

bolt head/nut
bolt head/nut
bolt head/nut
bolt head/nut
bolt head/nut
bolt head/nut
bolt head/nut
bolt head/nut
bolt head/nut
bolt head/nut
bolt head/nut
bolt head/nut

TABLE

a specific assembly, use the following

OF

STANDARD

Pitch

HARDWARE TIGHTENING TORQUES

1

1.25

1.25

1.5

1.25

(ISO)

1.5

1.75

1.5

1.5

2

1.5

2

torque

2.9 -

7.2 - 11.6

13.7 - 22.4

13.0 - 21.7

25.3 - 39.8

25.3 - 39.8

21.7 - 36.2

32.5 -

36.2 - 57.9

34.0 - 55.7

54.2 - 79.6

51.4 - 76.7

values when tightening standard hardware.

Ib-ft kg-m

5.1

50.6

0.4 - 0.7

- 1.6

1.0

1.9 -

3.1

1.8 - 3.0

3.5 - 5.5

3.5 - 5.5

3.0 - 5.0

4.5 - 7.0

5.0

- 8.0

4.7 - 7.7

7.5-11.0

7.1

-10.6

Grade

Grade

Grade 5

6T

6mm

bolt head/nut

8mm

bolt head/nut

10mm

bolt head/nut
10mm bolt head/nut
12mm bolt head/nut
12mm
12mm bolt head/nut

bolt head/nut

?T. 8T and 8.8

6mm

bolt head/nut

8mm

bolt
10mm
10mm bolt head/nut
12mm bolt head/nut
12mm
12mm bolt head/nut
13mm
14mm bolt head/nut
14mm bolt head/nut
16mm bolt head/nut
16mm

bolt

bolt head/nut

bolt

bolt head/nut

capscrew

1/4

UNC

1/4

UNF

5/16

UNC

5/16

UNF

3/8

UNC
3/8 UNF
7/16

UNC

7/16

UNF

1/2

UNC
1/2 UNF

head/nut
head/nut

head/nut

1.25

1.25

1.5

1.25

1.5

1.75

1.25

1.25

1.5

1.25

1.5

1.75

1.5

1.5

2

1.5

2

(ISO)

(ISO)

4.3 -

6.5

10.8 - 15.9

21.7 - 32.5

19.5 -

30.4

36.2 - 57.9

36.2 -

50.6

34.7 - 49.2

5.8 - 8.7

14.5 - 21.7

28.9 - 39.8

26.8 - 37.6

54.2 - 75.9

50.6 -

65.1

43.4 - 61.5

57.9 - 86.8

72.3

-108.5

68.7 -101.3

108.5

- 166.4

101.3 -159.1

9 -

11

11

- 13

18 -

20

21

- 23

28 -

33

30 -

35

44-

49

50 -

55
68 - 73
73 -

80

0.6

- 0.9

1.5-2.2

3.0 - 4.5

2.7 - 4.2

5.0 - 8.0

5.0

- 7.0

4.8 - 6.8

0.8 - 1.2

2.0 - 3.0

4.0

- 5.5

3.7 - 5.2

7.5

-10.5

7.0

- 9.0

6.0

- 8.5

8.0 -12.0

10.0 -15.0

9.5 - 14.0

15.0

- 23.0

14.0

- 22.0

1.2 - 1.5

1.5 - 1.8

2.5 - 2.8

2.9 - 3.2

3.7 - 4.6

4.1

- 4.8

6.1

- 6.8

6.9 - 7.6

9.4-10.1

10.1

-11.1

45

Westerbeke Engines

ENGINE OVERHAUL

Section .........................................................................

PREPARATIONS
ENGINE

DiSASSEMBLy .................................................. .48

Removal

Timing

REMOVING
FROM

THE
CYLINDER
CYLINDER

Camshaft
Camshaft

SPECIAL

SERVICE

...............................................................

of External

Belt

Removal

THE

CYLINDER

CYLINDER
HEAD
BLOCK

Oil

Seal

Oil

Seallnstallation ......................................

Parts

and

Subassembiies .........

.................................................. .49

HEAD

BLOCK

DISASSEMBLY

DISASSEMBLY

Removal

TOOLS

........................................ 52

................................... 53

................................. 56

......................................... 60

.............................................. 62

Page

47

48

61

NOTE:
removal
this

Special

Service Tools

or installation of engine parts.

manual,

page 62, for illustrations

Westerbeke Engines

are

available through Westerbeke Corporation to help

Refer

to the

and

part numbers for

"SPECIAL

each

SERVICE

tool.

TOOLS"

46

in

the

section of

1.

Remove

all wire connections running to the
gine from the control panel and battery.
sure

that the wire ends

2.

Shut off

3.

Unbolt the engine from its

all

fuel

and

are

sea

water lines,

properly marked.

bed

and

PREPARATIONS

en-

Make

and

disconnect the exhaust

carefully move

it

to the overhaul

system.

shop.

I

I

I

•.

I

t·

I I

'f

I,

" I /

----

"

."

...

.:::

.~

...

\.

\1

~J

\:~.:~~'https://manualmachine.com/L,

..,,'

.~»J

I " .-

.""

/

..

'.

I

'.

I

' I

I

I

I

4.

Once

at

the overhaul shop, drain

5.

Clean

all

oil

and dirt from the engine's exterior.

~liilIrlll

.':

, :I:!;'::

.'

..

~~

!\l\I\'II!!!l!\!il!!\!Pjji:l\?H'

11,:1:

'

,

..

Oil

Sump Drain

all

lubricating

oil

and

coolant from the engine and

Heat Exchanger Drains

heat

exchanger.

47

Westerbeke Engines

ENGINE DISASSEMBLY

This section describes the disassembly

procedures which
repair

or

replacement

Removal

1.

Remove

2.

Remove

of

the

the

follow include the disassembly

of

these parts

External

Parts

and

exhaust manifold and related hoses as a unit Disassemble and inspect these parts.

heat exchanger and its related hoses and mounts

of

the

engine when performing a complete overhaul of the unit. The

of

subassemblies, inspection of their components parts,

(If

necessary), and the reassembly of the subassemblies.

Subassemblies

from

exchanger cleaned and tested at a local automotive radiator repair shop,

3. Remove

the

starter

motor

and circuit breaker assembly. Examine the starter and have it repaired

replaced if necessary.

4.

Remove

5. Remove

6.

Remove

7.

Remove

8.

Remove

the

sea water pump,

the

alternator,

the

fresh water circulating

the

fresh water circulating pump.

the

fuel line,

the

the

the

fresh water

carburetor,

drive belt, and

pump's

pump's

pulley.

the

fuel pump, and

the

sea water

pump's

drive belt, and the alternator's mounting bracket.

the

intake manifold.

the

front

of

the engine. Have the heat

or

replace it if necessary.

mounting brackets.

or

9.

Remove the ignition coil and its mounting bracket.

10. Remove the engine's transmission.

11

. Remove the water temperature switch and the water temperature sender.

the

12. Remove the oil pressure switch, the oil pressure sender,

the

13. Remove the thermostat housing and

thermostat.

oil filter, and

the

oil filter bracket.

14. Remove the crankshaft pulley from the crankshaft.

the

15. Remove the spark plugs from

the

16. Remove

The basic engine assembly is

Since the W 26G
may

be laid on a sturdy bench while they are disassembled and repaired. However, special service tools

distributor from the right rear

now

or

W 26GX engines are

are available through Westerbeke that will help
overhaul attachment (service tool
tachment can then be attached
available

through

the

Westerbeke Corporation).

cylinder head.

of

the

engine.

ready

for

disassembly, cleaning, inspection, and repair if necessary.

not

as bulky nor as heavy

to

make the overhaul

#09219 - 87701) can be attached

to

the overhaul stand (special service tool #09219 - 87202, which is also

as

an automobile engine, the engines

of

the

engine easier.

to

the cylinder block. This overhaul at-

For

example, and

Westerbeke

Engines

48

Timing

1.

2.

6.

Belt

Removal

Remove the sea water pump, the drive belt, and the sea water pump's mounting bracket.

Remove the alternator, the fresh water

inspect the belt

Remove the fresh

for

wear.

water

circulating

pump

pump

drive belt, and the alternator's mounting bracket. At this time,

pulley.

7.

Remove the fresh

8.

Remove the crankshaft pulley from the

water

circulating pump.

crankshaft.

9.

Remove the rocker cover and gasket

cylinder head. Inspect the gasket

10.

breaks.

keep it

Remove

covers

Replace

for

reinstallation.

the

along

the

upper

with

gasket if necessary,

and

lower

their

associated

covers.

from

for

cuts and

timing

the

or

belt

dust

~---)

TIMING

BELT

COVER

49

Westerbeke

Engines

11.

Remove the tension spring from the timing belt tensioner and the tension spring bracket, and remove
the timing

belt tensioner.

i~

"'"

~

~~

,

CAUTION

When removing the timing belt, be sure NOT
belt into a small radius). The cablecord contained in the timing belt is extremely durable
against tensile forces. However, the cablecord is susceptible
sharply bent. Bending reduces the belt's overall strength.

Carefully remove the timing belt from its pulleys.

12.

CAUTION

The timing belt must be kept free

belt

to

the

13.

Inspect the timing belt

belt if it

deteriorate

is

found

to

be

faulty. Refer

or

swell.

for

deterioration, swelling, cracking, and peeling

of

oil, grease, water

to

the picture below.

~

to

bend the belt sharply (that is,

to

breakage when the belt is

or

other substances which may cause

do

or

deformed teeth; replace the

not

bend the

Westerbeke Engines

50

14. I nspect the timing belt tensioner for abnormal noise and/or damage at the belt contact point. If the timing
belt tensioner is excessively worn, replace

it.

Checking the Belt Tensioner

15. Remove the camshaft timing belt pulley.

NOTE: When removing the camshaft timing belt pulley, insert a screwdriver between the
spokes

of

the pulley

to

prevent the camshaft rotating while loosening the pulley's screw.

51

Westerbeke Engines

REMOVING THE

CYliNDER

HEAD FROM THE CYLINDER BLOCK

To avoid the possibility of distorting the cylinder head, loosen each
time,

in

the sequence shown below. Repeat this sequence several times until the bolts are unfastened.

Remove the

cylinder head and cylinder head's gasket.

NOTE: Discard the cylinder head gasket when it is removed. When reassembling the cylinder

to

head

the cylinder block, install a new cylinder head gasket.

of

the cylinder head bolts, a little at a

W 266

HEAD

LOOSENING

BOLT

SEQUENCE

Westerbeke Engines

52

CYLINDER

HEAD

DISASSEMBLY

The figure
the W 26G and W 26GX engines'

below

presents the relationship

~

\}

~

Q

e

,

,

po.,

of

parts (and the

cylinder heads.

order

in

which

those parts are disassembled) for

2

*1. Valves

2. Distributor Housing

*3.

*4. Camshaft

* Denotes

CYLINDER HEAD DISASSEMBLY ORDER

Rocker

that

Arms

disassembly instructions

for

these parts

53

(page

54, step 2)

(page 55, step 3)
(page 55, step 4)

follow

on

the indicated pages.

Westerbeke

Engines

1.

Mount the cylinder head on the cylinder head holder using special service tool [SST] # 09219-87702.
This tool is available through the Westerbeke Corporation. Clamp the special tool in a bench vise and

remove the designated parts as follows.

2.

Remove the valves and their associated parts using the valve spring replacer (special service tool [SST]

#

09202-8n01).

This tool is available from the Westerbeke Corporation.

NOTE:
correct order with respect
replaced, they must be returned

2.

Remove the distributor housing.

As

the valves and their associated parts are removed, keep valve sets together and in

to

their placement in the cylinder head. Unless any of the parts are

to

the same locations from which they were removed.

Westerbeke

Engines

54

3.

Loosen the

lock

nuts and back the adjusting screws

off the valve rocker arms.

4.

Remove the rocker shaft plug from the rear end of the

the

to

No.2

puller (spe-

extract the

rocker

No. 1 rocker shaft and use the valve shaft
cial service tool

[SST] # 09204-87701 which is avail­able from the Westerbeke Corporation)
rocker shaft; repeat this process

for

shaft.

NOTE: At the same time the rocker shaft

the

tracted, remove

valve rocker arms and com-

is

ex-

pression springs associated with the shaft.

5.

Extract the camshaft from the rear end of the cylinder head.

Exercise care when removing the camshaft

of

lobe surfaces

the camshaft.

CAUTION

to

avoid damaging the bearing journals

55

or

cam

Westerbeke Engines

CYLINDER

The figure below presents the relationship of parts (and the order in which those parts are disassembled) for
the W 26G and W 26GX engines' cylinder blocks.

BLOCK

DISASSEMBLY

CYUNDER

1.

Crankshaft Timing Belt Pulley

*

2. Fresh Water Pump

3.

Oil Pan and Gasket

4.

Balance Shaft Gear Cover

5.

Rear Oil Seal Retainer

6.

Oil Pump Drive Sprocket and Chain

7.

Oil Pump

8.

Balance Shaft Weight

*

9.

Balance Shaft and Pulley

*10.

Pistons and Connecting Rod Assembly

*11.Crankshaft and Bearings

BLOCK DISASSEMBLY ORDER

(page 57, step

(page 57, step
(page 58, step 9-10)
(page 59, step 12-15)

1)

8)

2

* Denotes that disassembly instructions

Westerbeke

Engines

for

these parts follow on the indicated pages.

56

1.

Remove the crankshaft's timing belt pulley and the crankshaft timing belt pulley's flanges.

NOTE: If the crankshaft's timing belt pulley is difficult
threaded
ley with the

2. Remove the fresh water

3.

Remove

4.

Remove the balance shaft's gear cover, gasket, and dust seals.

5.

Remove the rear oil seal retainer.

holes in the face

two

bolts.

the

oil pan and gasket.

of

the pulley as shown

pump

assembly and gasket.

to

in

the illustration below. Withdraw the pul-

remove, screw a pair

of

bolts into the

6.

Remove the oil

sprocket and

7.

Remove the oil

NOTE: The oil
Use a 6-mm hexagon wrench (which is commercially

8.

Remove the balance shaft as follows.

A.

Align the stamped mark on the balance shaft's drive gear. This aligns the holes in

pump's

oil

pump

pump

pump

drive sprocket from the right side balance gear; remove

drive chain from

together with

is fastened

the

oil

pump's

the

oil

pump

to

the cylinder block with hexagon socket head

drive shaft.

outlet pipe.

available)

to

remove the oil pump.

the

oil

pump's

cap

the

face of the balance
shaft's gear with the hexagon socket head cap screws which fasten the balance shaft's thrust plate
the cylinder block.

drive shaft

screws.

to

57

Westerbeke Engines

B.

Remove the hexagon socket head cap screws from the cylinder block using a 6-mm hexagon wrench;

extract the balance shaft and balance shaft gear toward the front

of

the cylinder block taking care

avoid damaging the bearing journals.

9.

Remove the connecting rod cap screws and detach the connecting rod cap. Push the connecting rod
and piston assembly upward, out

of

the

top

of

the cylinder block, using the handle of a hammer (or similar

nonmetallic tool).

to

NOTE: Temporarily reassemble the connecting rod and cap

to

keep the parts together
later reassembly of the cylinder block components in the same locations from which they were
removed.

Repeat this procedure

10.

Remove the piston rings from each piston as follows.

A.

Remove the No. 1 and

to

the illustration shown

B.

Remove the combination-type oil ring

for

each cylinder.

No.2

to

the right.

piston rings using a commercially-available piston ring expander. Refer

by

hand.

for

Westerbeke

Engines

58

11.

Remove the piston pin from each piston and connecting rod assembly using the piston pin removal tools

(special service tools #

09221-8n02

and # 09221-25018).

@)Long

A. Attach the fitting piece

B. Place the spring

c.

Position the piston/rod assembly on the main body (1).

D.

Insert the large bar

E.

Use a soft-metal pin punch

NOTE: Take care
replaced in the same pistons from which they were removed, and the pistons replaced
same cylinders from which they were removed.

12. Remove the crankshaft's bearing caps.

13. Remove the crankshaft.

14. Remove the crankshaft's bearing sets and the
thrust bearing.

(2)

into the main

(3)

and the small bar

(4)

into the piston over the piston pin.

or

a bearing press

to

keep the related pins and pistons in their proper order so that the pins are

body

(1).

(5)

into the main body

to

drive the piston pin from the piston.

No.3

(1).

in

the

NOTE: the crankshaft's bearing sets must be kept
in proper order
same locations from which

15. Remove the studs and other small parts as required.

so

they can be reassembled

they

were removed.

in

the

59

Westerbeke

Engines

Camshaft

Oil Seal Removal

Remove the camshaft's oil seal from the cylinder head using either a large screwdriver,
and replacer (special service tool

A.

For

removing

the

# 09223-87701). This tool is available from the Westerbeke Corporation.

camshaft's

oil

seal

with

a

screwdriver, insert the screwdriver in the inner grove

pry

of the seal and gently
the seal with the screwdriver. Refer
to

the right.

the seal out while turning

to

the illustration

NOTE: Be extremely careful not to damage the oil

sea journal's surface. Damaging this surface could

cause excessive oil leaks even when a new oil seal

has been installed.

For removing the camshaft's oil

seal with the special

service tool, punch a hole in the camshaft's oil seal

with the oil seal remover tool

002.

[SST] # 09223-87701-

or

the oil seal remover

B. Screw the oil seal remover [SST] # 09233-87701-004

into the hole punched

C.

Remove the oil seal

remover that was

Westerbeke

Engines

in

step

A.

by

prying against the oil seal

installed in step

B.

60

SST

---...,,~'""--

D.

Align the oil remover tool in the punched hole

(aligning

tapping screws

it with the punch) and screw in the

to

hold the oil seal remover

tool.

E.

Remove the oil seal by extracting the oil seal

remover tool with the puller

(4).

SST

Tapping

screw

Balance

shaft

Camshaft Oil Seal Installation

Install a

new

oil seal using special service tool # 09515-87202.

61

Westerbeke

Engines

SPECIAL

SERVICE TOOLS

NOTE: Special Service Tools

Illustration

are listed in

the

same order as

Tool

No. Tool Name

09219-87701 Engine overhaul attachment

09219-87202 Engine overhaul stand

09219-87702

they

appear in the manual.

Cylinder head holder

11

Westerbeke Engines

09204-87701

09202-87701 Valve spring replacer

62

Valve rocker shaft puller

Illustration

Tool No. Tool Name

09221-25014

09223-sn01

Piston pin remover and replacer

Oil seal remover and replacer

63

Westerbeke

Engines

YOUR NOTES

Westerbeke Engines

64

CYUNDER

INSPECTION

HEAD

AND

AND

ENGINE

REPAIR

BLOCK

Section ..........................................................................

Checking the Cylinder
Checking

Replacing the
Checking
Valve
Refacing the

Valve

Valve

Valves

Seats .......................................................................

Valve
Checking Rocker
Checking

Valve

Head

............................................

Guides

....................................................

Guides .............................................

...............................................................

and

Valve

Seat

..................................

Arms

and

the Rocker Shaft ................

Springs ...................................................

Page

Checking the Cylinder Block ...........................................

Checking the Pistons .......................................................

Checking

Piston

Rings

.....................................................

66
67
67
68
69

70
70
71
72
73

73
Checking the Connecting
Checking the Piston
Checking the Connecting

Rods

.......................................

Pins

.................................................

Rod

Bearings .........................

74

75

76

Checking the Crankshaft ................................................. n

Checking the Camshaft ....................................................

Checking the Balance Shaft Thrust Bearing ...................

Replacing the Balance Shaft Bearing ..............................

Checking the Crankshaft Timing Belt
Replacing Front
Checking the

and

Rear

Flywheel

Crankshaft

and

Ring

Pulleys

Oil

Seals

Gear

............................

.................

.............

79

82

83

84

84

86

65

Westerbeke Engines

ENGINE INSPECTION AND

REPAIR

NOTE:

Before washing the cylinder

head

and block, check them for indications of water leaks,

gas leaks, damage or cracks. After checking these components, wash each part to remove

as

any adhered matter such
head,

cylinder head cover, timing chain cover and other engine parts are made of aluminum,

handle them carefully to ensure against damage. Do not

pieces of gasket, dust, oil, carbon, and scale. Since the cylinder

use

cleaning solutions that will be

harmful to the aluminum.

Checking the

1.

Replace the cylinder head if it shows signs of water leaks, gas leaks or cracks.

2.

Measure the extent of warping (flatness) on the lower surface that mates with the cylinder block. If the

warping exceeds the allowable

tolerance.

Cylinder Head

limit of distortion, grind the surface

to

within the specified grinding

If the warping exceeds the allowable grinding tolerance, then replace the cylinder head.

draigne-dgs

~~~~--~~~~---~~~

co

Specified Cylinder Head Height:

Allowable Limit of Distortion:

Grinding Tolerance:

Westerbeke Engines

4.953

inches

0.0039 inches

0.0118

66

inches

(125.8

(0.10

(0.30

mm)

mm)

mm)

Checking

Measure the clearance between the valve and guide bushing. If the clearance exceeds the specified limit,
replace those parts that have worn beyond the allowable limit.

Valve

Guides

Specified Limit:

Allowable Limit:

Measuring Method
between the inner diameter

ing and the diameter

#1:

Check the difference

of the valve stem.

of

the guide bush-

Intake 0.0016
Exhaust

Intake
Exhaust

0.0018 - 0.0030 inches (0.045 - 0.075 mm)

0.0031

0.0039 (0.100 mm)

- 0.0028 inches (0.040 - 0.070 mm)

(0.080 mm)

#2:

Measuring Method
deflection with a mounted dial indicator

moving the valve stem from side

NOTE: Separate the valve from the
valve seat before measuring. Measure
at

a position closest

bushing.

Replacing

1.

Remove the valve seal from the valve guide.

2.

Knock the guide out toward the opposite
side

valve guide installer. (Special Service Tool

the

Valve

of

the combustion chamber with a

Check each valve's

to

side.

to

the valve guide

Guides

# 09201-87201-000)

by

67

Westerbeke Engines

3.

Place a clip on the new valve guide and drive it in from the opposite side

the valve guide installer.

of

the combustion chamber with

NOTE: The shape
side.

4. Install the valve seal on the valve guide with a

valve seal pusher.

5.

Check the clearance

bushing.

Projection Height (Dimension A):

0.598 - 0.622 inches (15.2 - 15.8 mm)

Checking

1. Check the contact surface

repaired with a valve grinder.

Valves

of

the

intake valve guides differs from that of the guides on the exhaust

for

each new valve guide

of

the valve face and valve seat

for

damage. Minor

or

rough surface may be

2.

If the valve stem is worn, damaged, bent

of

end surface
valve.

·3.

Check

micrometer; if the stem is worn beyond the

lowable limit, replace the valve.

Valve stem diameter limit:

Specified Limit

the stem is dented, replace the

the

valve

Intake: 0.2734 - 0.2740 inches

stem's

diameter

(6.945 - 6.960 mm)

Exhaust: 0.2732 - 0.2738 inches

6.940 - 6.955 mm)

Allowable Limit

Intake: 0.2724 inches

(6.920mm)

Exhaust:

0.2720 inches
(6.910 mm)

or

with

the

a

al-

\~

--if--

..

f\

____

v

Valve head

stock

+---_~

/

Valve

stem

thickness

outer

ill

diameter

Westerbeke

Engines

68

4.

Check of each valve's head stock thickness.
Replace

limit.

Valve Head
Specified Limit

the valve if it is beyond the allowable

Stock Thickness Limit

Intake: 0.35 - 0.59 inches

(0.9 - 1.5 mm)

Exhaust: 0.047 -0.071 inches

(1.2

-1.8

mm)

I"

If

--I~

Valve head

stock

/1

Valve stem

thickness

I

I

outer

nl

diameter

5. Check

valve stem.

Valve

1 . Inspect the valve's contact surface

damage.

for

excessive grooves

Seats

at

the end

for

2. Measure each valve's contact width.

Contact Width (Both

Intake and Exhaust)

0.039 - 0.071 inches

(1.0

-1.8

mm)

NOTE: Check
position
Blue

or

red lead

the valve upward into cylinder head's seat

(apply only enough pressure
press fit). Under its own weight, let the valve
drop

away from the cylinder head. Perform
this operation
valve's contact surface can be accurately
measured.

the

valve's contact area and

by

applying a this coat

to

the valve's seat and push

two

or

three times until the

to

of

pitting and

of

Prussian

assure a

the

Check

.-

for

excessive grooves

//

--_/

Contact Width

Check
tacts the center position
tact face. DO

if the valve seat's contact face con-

NOT

rotate the valve.

of

the valve's con-

69

Westerbeke

Engines

Refacing the Valve and Valve Seat

To reface the valve and cylinder head valve seats,
follow the steps below.

1.

For the intake port in the cylinder head, use a

cutter

to

bring back the valve seat's shoulder.

Then use a 45° cutter

to

recondition the valve seat

30°

contact face.

30· !

(20-

<15'

/

,

,

2. For the exhaust port in the cylinder head, use a

( ) are

Exhaust

Side

20° cutter to bring back the valve seat's shoulder.
Then use a 45° cutter

3. Grind each valve's contact face to 45°. Match each valve

to

ensure that both the cylinder's contact face and the valve's contact face are perfectly matched.

4. After each valve is reconditioned, hand lap each valve with a good brand

to

recondition the valve seat contact face.

to

its respective cylinder head port and check

of

lapping compound.

5. Remeasure the contact width of both the valves

and each cylinder head valve seat and ensure that

to

they conform

Contact Width (Both

Checking Rocker Arms and

the following specification.

I ntake and Exhaust)

0.039 ­(1.0

0.071

-1.8

mm)

the

Rocker Shaft

inches

Contact

width

1.

Check each component

of

the rocker arm assembly

a new one.

2. Check

them

to

see that the oil passages of the rocker arm and shaft are open. If any clogs are found, remove

or

replace the unit.

3. Measure the clearance between each rocker arm's

bore and the shaft. If this measurement exceeds

the

allowable limit, replace the worn rocker arm

bushings and shaft.

Arm Inner Diameter: 0.6300 - 0.6307 inches

(16.000 -16.018 mm)

Shaft Outer Diameter: 0.6283 - 0.6293 inches

(15.958 - 15.984 mm)

(See next page)

Westerbeke Engines

70

for

damage

or

cracks. If necessary, replace it with

Clearance

Specified Limit: 0.0006 - 0.060 inches

(0.016 - 0.060 mm)

Allowable Limit:

Checking

Valve

Springs

All models covered

by

0.003 inches (0.08 mm)

this manual have

two
springs for each valve, an inner spring and an
outer spring.

1.

Check

the

valve spring

for

corrosion

or

damage and replace, if necessary.

2.

Check each spring

for

free length and square­ness; replace the spring if the free length is
less than the free length limit specified below.

Free Length

Standard
Outer: 1.646 inches (41.8 mm)
Inner: 1.614 inches (41.0 mm)

Free Length Limit

Outer: 1.594 inches (40.5 mm)
Inner: 1.567 inches (39.8 mm)

3.

Check the squareness

of

the valve spring. If

it exceeds the limit, replace with a new one.

Squareness

- i

Squareness limit

Outer: 0.059 inches (1.5 mm)
Inner: 0.059 inches (1.5 mm)

4.

Using a spring tester, measure each spring's tension at the specified installed length. Replace the springs

if they prove

to

be weakened.

Free

length

-1_

Installed Length: 1.374 inches (34.9 mm)

valve

spring tester

Installed Load

Standard: 62.8 - 69.0 Ibs

(28.5 - 31.3 kgs)

Allowable Limit: 56.71bs

(25.7 kgs)

71

Westerbeke

Engines

Checking

1.

Check

sary, repair

2.

Check

of
compressed air

3.

Check

allowable limit
block.

4.

Check

the cylinder block.

5.

Measure the
the six positions
right with an inside micrometer. (The
is
minimum diameters.)
have
the cylinder
each cylinder's

the

Cylinder

the

cylinder

or

replace

to

see that

the cylinder

the

Allowable Limit

(0.05 mm)

for

the

difference between

worn

block

or a wire

cylinder

of

scratches

wear

beyond

block

true

Block

block

for

damage

the

cylinder block.

the

oil passages and coolant passages

are

open. If clogged, remove with

probe.

block

for

distortion. If it exceeds the

distortion, repair

of

Distortion: 0.002 inches

or

bums

on the cylinder walls. If necessary, repair

on

the

cylinder bores

shown

in

the

the

maximum

If

the

cylinder bores

the

specified

requires boring

wall surface.

or

cracks.

or

replace the cylinder

at

figure

to

the

wear

and

wear

limit,

to

restore

If

neces-

~~~~~~~~~~~~3

1

by

boring each cylinder

-

r---------1r----r

'lOrnm

35mm

1.3779

35mm

1.3779

0.393

(i

nch)

(inch)

(inch)

or

replace

2

6

z

Standard Bore Diameter:
inches

Out-of-Roundness,
ches

(0.08

Wear limit: 0.0039 inches (0.10

6.

Check

has a
ridge
exists, have
these ridges. Leaving these ridges in the
cylinder can break piston rings when
pistons
tion, if
have the cylinder walls de-glazed (roughed

up)

so

(76.00

mm)

the

ridge in

number

most

new

the

of

likely will

the

are

installed in

piston rings are

rings

- 76.03 mm)

Taper

the

cylinder. If

hours on it, a large cylinder

be

cylinders reamed

may

seat properly.

2.9921 - 2.9933

Limit: 0.0031 in-

mm)

the

engine

present. If a ridge

to

remove

the

engine. In

to

be

installed,

the

addi-

~O

Ie)

~l

/

.'

~/

-

CD

@

Thrust
Axial

direction

direction

Westerbeke

Engines

72

Checking

1.

Check

cumference

2.

Measure each piston's diameter 0.7087 inches (18 mm) under the oil ring groove,

the

Pistons

all pistons carefully, and replace those that exhibit severe burns

of

the

piston are found.

or

scratches on the external cir-

piston pin's location (that is, in the thrust direction) without the pin in place.

3.

Check

the clearance between the piston and the cylinder wall.

at

right angles

to

the

Piston Diameter (Dimension

A):

Standard Cylinder-to-Piston Clearance:

Allowable Cylinder-to-Piston Umit:

18

mm

(0.7087111)

2.9903 - 2.9915 inches
(75.955 - 75.985 mm)

0.0014 - 0.0022 inches
(0.035 - 0.055 mm)

0.0039 inches (0.10 mm)

Checking

1.

Check

2.

Measure each piston ring's end gap. Replace

the

gap

Piston

the piston rings

ring if the

gap

limit.

Rings

for

exceeds the allowable end

NOTE: Push a ring into the cylinder with a
piston until it is
block's

top

about

surface.

cracks, burning

2 inches

from

or

wear and replace, if necessary.

the

73

Westerbeke

Engines

Standard End Gap Clearance

Compression ring No.1:

Compression ring No.2:

Oil ring: 0.0079 - 0.0315 inches

3.

Measure the side clearance between the

piston ring and ring groove.

NOTE:

Measure

the

clearance

around the total circumference of the

ring groove.

Standard

Side Clearance

Compression Ring No.1:

0.0012 - 0.0028 inches
(0.03 - 0.07 mm)

Compression Ring No.2:

0.0008 - 0.0014 inches
(0.02 - 0.06 mm)

0.0079 - 0.0157 inches (0.20 - 0.40 mm)

0.0079 - 0.0157 inches (0.20 - 0.40 mm)

(0.20

- 0.80 mm)

Allowable Side Oearance Limit:

0.0047 inches (0.12 mm)

Checking

1.

Check the side

the

Connecting

Rods

of

each connecting rod's small end and large end for cracks

replace damaged connecting rods.

2.

Check the connecting rod for bends
with a suitable alignment fixture.
is

necessary, place the connecting rod in a

press and apply a gradual pressure

replace the connecting rod.

or

or

If realignment

to

Allowable Limit per 3.937 inches (100 mm)

Bend:

Twist:

0.0020 inches (0.05 mm)

0.0020 inches (0.05 mm)

twists

the rod

or

damage. If necessary,

twist

cheaJ:

Westerbeke Engines

74

3.

Check
dial indicator
the
connecting

figure.

End

the

connecting

or

a feeler

If

it

exceeds

rod

or

crankshaft.

play

limit: 0.012 inches

(0.30

rod's

mm)

Checking the Piston Pins

1.

Check

A.

each piston pin's oil clearance.

Measure

each

piston pin's bore diameter.

side play with a

gauge

the

as

shown in

limit, replace the

Standard

B. Measure each piston

Standard Pin Diameter: 0.7083 - 0.7087
inches (17.991 -18.000 mm)

Standard
inches (0.005 - 0.011

2. Replace

oil clearance exceeds
specified below.

Allowable Umit:

(0.011 - 0.020

the

Bore

Diameter: 0.7086 - 0.7089 inches (17.999 -18.008 mm)

pin's

diameter.

Oil

Clearance: 0.0002 - 0.0004

mm)

piston

and

piston pin if

the

allowable limit

0.0004 - 0.0008 inches

mm)

the

pin's

75

Westerbeke Engines

Checking

1.

Check each connecting rod bearing careful-

Iyand

2.

Check each connecting rod bearing's oil

clearance

the

Connecting

replace it if it

is

worn, scored or flaked.

with a "plastigauge."

Rod Bearings

clearance for these bearings exceed the al­lowable limit, replace all
bearings.
scored
necting rod

If the connecting rod journals are

or

flaked, grind the crankshaft's con-

journals and install an under-

the connecting rod

sized bearing.

If

the

Bearing

Oil Clearance:

Specified Limit:

0.0008 - 0.0016 inches

(0.020 -0.044 mm)

Allowable Limit:

Kinds of Connecting

0.0031

Rod

inches (0.08 mm)

Bearings:

Standard Repair

Undersize

Undersize

Check

3.

0.0098 inches (0.25 mm)

0.0196 inches (0.50 mm)

each

connecting

rod's

clearance.

Specified Limit: 0.0059 - 0.0098 inches

(0.150 - 0.250 mm)

Allowable Limit; 0.0012 inches (0.03 mm)

1.5739 -1.5748 inches (39.976 - 40.000 mm)

1.5642 -1.5646 inches (39.732 - 39.742 mm)

1.5544 - 1.5548 inches (39.482 - 39.492 mm)

thrust

4.

Check each connecting rod's journal width.

Journal Width:

0.8661 -0.8681

inches

(22.00 - 22.05 mm)

Westerbeke

Engines

76

5.

Measure the connecting rod width.

Standard Rod Width: 0.8583 - 0.8602 inches

(21.80 - 21.85 mm)

Checking

1.

Check the crankshaft

necessary, replace the crankshaft.

2.

Check

are open.
compressed air

3.

Check the crankshaft

the journals have
ceeds the
grinding the bearing journals and replace the bearings
with undersized bearings.

the

Crankshaft

for

cracks

to

see that the oil passages

If

any

clogs are found, remove them with

or

a suitable wire.

for

eccentric wear; that

become

allowable limit, compensate

NOTE: Measure
crankpins and main journals
and rear portions)
axis, as shown in the figure.

Allowable

Specified
Allowable Umit:

elliptical

Oil Clearance: 0.008 - 0.0017 inches (0.020 - 0.044 mm)

elliptical

the

at

90 degrees

or

tapered Umit: 0.0008 inches (0.02 mm)

or

other damage. If

of

the crankshaft

is,

or

tapered. If it ex-

for

this

wear

diameter

0.0028 inches (0.07 mm)

of

at

two

points (the front

to

the

each

crankshaft

see if

of

by

the

LI3/

Q7

$

Two
directions

4.

If the journals must be ground because

crankshaft bearings with undersized bearings.

Standard Repair limit 1.6526 - 1.6535 inches 1.5739 - 1.5748 inches

Undersize

Undersize

0.0098 inches 1.6430 - 1.6434 inches 1.5642 - 1.5646 inches

(0.25 mm) (41.732 - 41.742 mm) (39.732 - 39.742 mm)

0.0196 inches 1.6331 - 1.6335 inches 1.5544 - 1.5548 inches

(0.50 mm) (41.482 - 41.492 mm) (39.482 - 39.492 mm)

of

severe burning

Main Journal

Outer Diameter

(41.976 -

42.000 mm) (39.976 - 40.000 mm)

77

or

scoring, grind the crankshaft and replace the

Crankpin Journal

Outer Diameter

Westerbeke

Engines

NOTE: When grinding the crankshaft, the

of

corner sections
pin journals

0.0098 inches (0.25 mm)
crankshaft grinding
qualified machine shop.

NOTE: The Main and Crankpin Journals must

be accurately ground

(0.25 mm)

ches

5.

Measure the crankshaft's runout.

the main journals and crank

must be ground to a radius of

(R1

and

should be done by a

to

a radius of 0.0098 in-

R2).

Any

Runout Limit:

6.

Measure the crankshaft
gauge at the center bearing journal and turning the
crankshaft, as shown in the illustration to the right.

Bend Limit:

0.0012 inches (0.03 mm)

for

bend

by

0.0012 inches (0.03 mm)

placing a dial

Westerbeke

Engines

78

7.

Check the crankshaft's thrust clearance with a
feeler gauge, as shown in the figure.

allowable limit, replace the thrust washer.

the

If it exceeds

Specified

Allowable Umit

Kinds

of

Thrust Washers:

Umit

0.0004 - 0.0063 inches
(0.010 - 0.160 mm)

0.0118 inches (0.30 mm)

Standard Repair

Over size 0.0049 inches (0.125 mm)

Oversize

0.0098 inches (0.250 mm)

0.0764 - 0.0783 inches (1.940 - 1.990 mm)

0.0813 - 0.0833 inches (2.065 - 2.115 mm)

0.0862 - 0.0882 inches (2.190 - 2.240 mm)

Checking

1. Check the camshaft

damage and replace it

2.

Measure the runout. If it exceeds the allow­able

the

Camshaft

for

if

limit, replace the camshaft.

Umit

of

Allowable

Runout: 0.0012 (0.03

mm)

cracks, wear

necessary.

or

79

Westerbeke Engines

3.

Measure the camshaft's lobe height. Replace the

camshaft if the wear limit is exceeded.

Cam Height (Both Intake and Exhaust)

Specified Limit

1.5743 - 1.5822 inches

(39.987 - 40.187 mm)

Allowable Limit

1.563 inches

(39.7mm)

Westerbeke

Engines

80

4. Measure the camshaft journal-to-cylinder head
journal clearance. Replace the part that exhibits
the

most wear.

Camshaft Diameter (Specified Limit)

1.2583 - 1.2591 inches

Front:

(31.96 - 31.98 mm)

Center:

1.8655 - 1.8665 inches
(47.385 - 47.410 mm)

1.9061· - 1.9071 inches

Rear:

(48.415 - 48.440 mm)

Cylinder Head Bearing Diameter (Specified Limit)

Front:

1.2606 - 1.2616 inches
(32.020 - 32045 mm)

Center:

1.8701 - 1.711 inches
(47.500 - 47.525 mm)

1.9094 - 1.9104 inches

Rear.

(48.500 - 48.525 mm)

Oil Clearance between Camshaft Journals and Cylinder Head Journals

Specified Limit:

Front:

0.0016 - 0.0035 inches (0.04 - 0.09 mm)

Center.

Rear:

0.0035 - 0.0055 inches (0.09 - 0.14 mm)

0.0024 - 0.0043 inches (0.06 - 0.11 mm)

81

Allowable Limit

0.0055 inches (0.14 mm)

0.0075 inches (0.19 mm)

0.0063 inches (0.16 mm)

Westerbeke

Engines

Checking the Balance Shaft Thrust Bearing

1.

Tighten the thrust plate

to

3.6 - 7.2 Ib-ft (0.5 -

1.0 kg-m) and measure the clearance.

Thrust Bearing Clearance

Specified Limit: 0.0012 - 0.0051 inches

(0.15 - 0.25 mm)

Allowable Limit:

2.

Measure the balance shaft's oil clearance.

0.0118 inches 90.30 mm)

Oil Clearance

Inner Bearing Diameter

Block

Front

1.7717 -1.7726 inches
(45.000 - 45.025 mm)

Rear: 1.3386 - 1.3396 inches
(34.000 - 34.025 mm)

Balance

Shaft Outer Diameter

1.7700 -1.7707 inches

Front:
(44.959 - 44.975 mm)

1.3370 - 1.3376 inches

Rear:
(33.959 - 33.975 mm)

If

the oil clearance is not within the allowable limit, replace the bearings

Bearing

Size (Undersize 0.0196 inches [0.5 mm])

Front Bearing

Rear Bearing

Westerbeke Engines

Block's inner diameter

1.7530 - 1.7542 inches
(44.526 - 44.556 mm)

1.3199 - 1.3211 inches
(33.526 - 33.556 mm)

82

or

refinish the balance shaft.

Balance Shaft's outer
diameter

1.7516 - 1.7520 inches
(44.490 - 44.500 mm)

1.3185 - 1.3189 inches
(33.490 - 33.500 mm)

Replacing the Balance Shaft Bearing

1.

Remove the balance shaft's bearing with special

#

service tool

through the Westerbeke Corporation).

2.

Install a new,

the journal conditions, with the same special ser-

vice tool used

09215-sn01

or

undersized bearing depending on

to

remove the bearing.

(This tool is available

09215-87701-000

NOTE:
ing aligns with its corresponding oil passage in
the block.

3.

In order

shaft's gear must be pressed off the shaft with spe­cial service tools

Makesurethattheoil

to

refinish the balance shaft, the balance

# 09253-87201-000 and 09214-

hole

of

each bear-

Sn01-000.

4. Replace the shaft's gear after the shaft has been
refinished. Use special service tools

S7201, 09506-S7303,

and

09214-sn01.

# 09253-

83

U

I

09506-87303-000

Westerbeke Engines

Checking

the

Crankshaft

TIming Belt Pulleys

Measure

crankshaft and camshaft pulleys. Replace those

pulleys that have worn beyond the allowable limit.

Crankshaft Pulley

Allowable Limit:

Camshaft

the

outside

Specified

Specified

Allowable Limit: 4.7165 inches (119.80 mm)

Limit:

Pulley

Limit: 4.7189 - 4.7260 inches

diameter

2.3331

(59.26 - 59.36 mm)

2.3307 inches (59.20 mm)

(119.86 -

- 2.3370 inches

120.04 mm)

of

both

the

Replacing

1.

Remove both front and rear oil seals with a

screwdriver. Be

nal

Front

and

Rear

careful not

that holds the seal.

Crankshaft

to

scratch the jour-

Front Oil

Rear Oil Seal

Seal

Oil Seals

Westerbeke

Engines

84

2.

Install a new front oil seal using the special service

tool # 09515-87202

Oil seal

Front

Rear Oil Seal

3.

After installing

new

front and rear

them with MP grease.

oH

seals, coat

85

Westerbeke Engines

Checking

1.

Check the flywheel

the

Flywheel

for

and

Ring Gear

damage

or

wear. Check the

ring gear's teeth for wear. Replace the ring gear

if it is badly worn.

2.

Check the runout limit on the flywheel.

Runout Umit:

2.

Replace the ring gear

A.

Heat the ring with a torch.

B.

Remove the ring gear by striking its circum-

0.0079 inches (0.20 mm)

by

the following procedure:

ference.

C.

Heat the new ring gear

to

250 - 3000 C

(480

- 5700 F)

on a hot plate

or

in an oven. Before slipping it

onto the flywheel, make sure that the chamfered side of the ring gear is directed toward the engine.

NOTE: Excessive heat
of

the ring gear.

may

destroy the original heat treatment and cause premature failure

Westerbeke

Engines

86

YOUR NOTES

87

Westerbeke Engines

SUBASSEMBLY INSPECTION, REPAIR, AND ASSEMBLY

Section ......................................................................... Page

Disassembling and

Inspecting the Oil Pump ...................

Assembling the Oil Pump .................................................

89

91

Disassembling and Inspecting

the Fresh Water Pump ......................................................

93

Assembling the Fresh Water Pump .................................. 94

Thermostat

Removal and Inspection ............................... 96

Disassembling and Inspecting the

Sea Water Pump ............................................................... 97

Testing and Disassembling the

Electric Fuel Pump ............................................................ 98

Disassembling and Rebuilding the Carburetor ................ 99

Inspecting the Distributor and

its Components ............................................................... 1

Testing

the

Ignition Coil .................................................. 1 07

06

Inspecting the Spark Plugs ............................................ 107

Testing the Alternator ..................................................... 1 08

Testing the Starter

(fest

procedures for the starter are not

available at this time.)

Westerbeke Engines

88

Disassembling and Inspecting the Oil Pump

1.

Disassemble the parts according

order presented in the illustration

2.

Inspect the oil pump's drive shaft sprocket. Check

for

cracks, worn teeth,

or

any damage.

to

the numerical

to

the right.

3.

Check the oil pump's drive chain for wear.

When the oil pump is installed, check the deflection

of

the oil pump's chain. Measure the chain's deflec-

at

tion

the center

between the

two

sprockets.

of

the chain along the widest span

89

Westerbeke Engines

4.

Measure the rotor shaft's clearance.

beyond the allowable limit, replace the rotor and
the rotor housing.

Specified Limit: 0.0018 -0.0033 inches

If

it has

(0.045 - 0.085 mm)

Allowable Limit: 0.0039 inches (0.10 mm)

wom

5. Measure the

Specified Limit: 0.0059 inches (0.15 mm)

Allowable Limit: 0.0079 inches (0.20 mm)

tip

dearance.

6. Measure side clearance.

Specified Limit: 0.0012 - 0.0035 inches

(0.03 - 0.09 mm)

Allowable Limit: 0.0079 inches (0.20 mm)

or

less

Westerbeke

Engines

90

7.

Measure the

body

clearance.

Specified

limit: 0.0039 - 0.0063 inches

(0.10 - 0.16 mm)

Allowable Limit:

8.

Check the relief valve's oil passage and sliding sur-

face

for

damage.

Assembling

the

0.0118 inches (0.30 mm)

Oil

Pump

NOTE: Coat each sliding part with engine oil
before

1.

Assemble the relief valve in the numerical order
shown in the illustration

2.

Assemble the rotor and rotor housing, aligning the

punched marks
also face toward you. Refer
right.

it

is assembled with its mating part.

to

the right.

so

that they face each other and

to

the illustration

to

the

91

Westerbeke Engines

3.

Assemble the pump cover and body. Tighten the

bolts between 2.9

4.

Attach the oil pump pickup strainer. Tighten the

bolts between 2.9 to

to

5.1

Ib-ft

(0.4

5.1

Ib-ft (0.4 - 0.7 kg-m)

- 0.7 kg-m).

NOTE: Replace the gasket with a new

5.

Check the oil pump's operation.

A.

After assembling the oil pump, immerse the
pump's strainer into a
and

hand

turn

pail of clean engine oil,

the

pump's

counterclockwise.

Oil

should be discharged from the oil pump's

outlet port.

one.

sprocket

6.

Block the outlet port with your finger and perform

as

the same test
that the

oil pump's shaft becomes harder

described in step #5. Confirm

until it cannot be turned any more.

Westerbeke Engines

to

turn

92

Disassembling
Pump

and

Inspecting the Fresh Water

Disassemble the

water

pump according

numerical order presented in the illustration.

Disassemble

CD

Water

pump

cover and gasket

®

Water

pump

pulley

seat

@

Water

pump

bearing, seal set and

rotor

1.

Using special service tool # 09253-87201 and
09238-87201, press off the water pump's
seat.

to

the

pulley

2.

Using the same special service tools as in step

press off the water pump's bearing and

seal

#1

set.

,

93

Westerbeke Engines

3.

Using the same special service tools, press off the

rotor from the water pump's bearing.

4.

Inspect the water pump's rotor and seal set
wear

or

damage. Replace any part that shows

signs

of

excessive wear

5.

Inspect the water pump's bearing

normal sound,

or

bearing if it shows any

or

damage.

for

damage, ab-

improper rotation. Replace the

of

these symptoms.

for

6.

Inspect the water inlet's O-ring

for

damage. Replace the O-ring if it shows
of

deterioration

Assembling

or

the

Fresh Water

damage.

Pump

1.

Press the water pump's seal set
into position after applying
bond sealer

to

the seal set's press-

the

fitting section. Use special service
tool # 09237-87201.

deterioration

any

signs

09237-87201-000

\

or

-+--SST

~-+--

Water
seal

Bearing

pump

Westerbeke

Engines

94

2.

Press the rotor into position. Make sure that dimen-

sion A equals 0.008 inches (0.2 mm)

3. Press the water pump assembly into the water

pump's pulley seat. Make sure that dimension H

is maintained between 3.78 to 3.80 inches (96 - 97

mm)

4.

After the water pump has been assembled, make

sure that the rotor rotates smoothly.

NOTE: When installing the water
engine, use new gaskets.

pump

on the

11

~

09238-87

201 -000

95

Westerbeke Engines

Thermostat Removal and Inspection

The thermostat is
take manifold within

1.

Remove

2.

To test

gradually heat
start
176
open

water temperature reaches

the

the

to

open

to

1830 F (80 -840 C).

by

located

the

thermostat

thermostat, immerse it in water and

the

water. The thermostat should

when

the

more

than

0.31

toward

thermostat housing.

from

water

the

rear

of

its housing.

temperature reaches

The thermostat should

inches (8 mm) when the

2030 F (950 C).

the in-

the

3. Replace
at normal temperatures
the valve is

When replacing
Westerbeke thermostats. These thermostats
are

covered

thermostats will

may
be installed.

thermostat

fully closed.

designed

in

seriously

this

if

the valve remains open

or

if the valve is lose when

CAUTION

the

thermostat, use genuine

specifically

manual.

not

work

damage

for

in the engine, and

the engine should

Westerbeke Engines 96

the

Other,

engines

generic

they

Disassembling and Inspecting the Sea Water Pump

When disassembling the sea water pump for inspection, an impeller kit (part # 032620) should be purchased
so

the impeller can be replaced along with a new gasket at the time of inspection. Although the impeller

a small part, it plays an important role in the proper operation of the engine. Replacing the impeller at the

of

time
tion, a new impeller is accompanied with a new gasket, an item that is needed

pump. See the note below.

the sea water pump's inspection can only improve the sea water pump's pumping ability.

to

assemble the sea water

In

is

addi-

SCREW

WASHER

1.

To disassemble the sea water pump, remove the four cover screws.

2.

Remove the cover and the gasket.

3. Remove the rubber impeller and the wear plate.

4.

Remove the rubber a-ring.

5. Remove the cam screw and washer and the cam.

GASKET

IMPELLER

COVER

Now

the sea water

Inspect the sea water pump

or

rough

Since rebuilding a damaged
of

a new pump, we recommend that an new pump be purchased instead of rebuilding one.

is frozen, replace the entire pump.

NOTE: When reassembling the sea water pump with a new impeller kit, wipe a little petroleum
jelly around the impeller. This ensures that when the engine is started the
dry

until sea water reaches the pump.

pump

is stripped far enough to be inspected.

by

rotating the pump's drive shaft. If it excessive play exists

or

worn pump from individually purchased pieces would almost match the price

pump

97

in

it,

or

if it sound

will not run

Westerbeke Engines

Testing

and

Disassembling

the

Electric

Fuel

Pump

To test

1.

2.

3.

4.

Electric

The electric choke uses a

starts and is running.

the

electric lift pump, follow

Working from a workbench, place

line

into a clean

Place

the

outlet fuel line into a measuring container

such as a beaker.

Using a fully-charged 12-Volt battery, connect a
negative

the

( + ) lead

the illustration

When

imum of 2 quarts
per
adequate. If
rating, perform

(-)

fuel

pump

to

the

21

minutes). A pumping rate below this is

Choke

tank

of gasoline.

wire

to

the

fuel

by

connecting the

the battery's positive terminal. Refer

to

the

right

pump

is energized, it should

per

21

minutes at 2 psi (1.89 liters

the

pump's

the

pumping rate is below this

following steps.

12

the

steps below.

the

pump's

pump's

volt heating element which opens the choke automatically once the engine

bocIy. Energize

pump's

positive

pump

inlet

to

a min-

not

POSITIVE

(+)

CONNECTION

NOTE: Some hunting will be present when the generator is first started, when the choke is
on, and when the generator has

The choke is adjusted with the engine off and cooled. Adjust the
choke

by

loosening the three cover-securing screws and rotating
the cover clockwise
to

RICH the choke. The choke is initially set at the factory

average of

The choke
the ambient temperature of the area the engine is operating in.

The choke index mark is
inboard side.

70°

may

The choke housing will normally get hot during engine operation.

NOTE: When initially starting the engine (commissioning)
prime the engine's
by

depressing the control panel's ON switch.
carburetor's electric choke,
operation and reconnect it after priming

to

LEAN the choke and counterclockwise

F

(210

C) room temperature. C H 0 K E

need readjustment at engine commissioning

located on the choke cover lower right

fuel system

no-load on

by

using the engine mounted fuel pump. Prime the fuel system

unplug the

it.

IWARNINGI

12

volt ( + ) lead

to

start the engine.

for

an E

for

To

prevent the unwanted activation

at

lEe

T R I

(:

or

after servicing the fuel system,

the electric choke during this priming

of

the

Westerbeke

Engines

98

Disassembling and Rebuilding the Carburetor

To rebuild the carburetor, first purchase a carburetor rebuilding kit. Make sure that the rebuild kit contains

to

all of the following rebuild parts. Refer

Two

(2)

copper accelerator

pump

gaskets

One

(1)

throttle shaft valve spring

One

(1)

idle mixture screw O-ring

One

(1)

choke lever spring

One

(1)

rotary throttle shaft valve

One

(1)

fuel filter element

the illustration below the list.

One

(1)

needle valve and seat

(two pieces

One

(1)

aluminum seat gasket

One

(1)

accelerator pump diaphram/gasket

One

(1)

main body gasket

One

(1)

manifold gasket

to

the set)

00

COPPER

PUMP

ACCELERATOR

GASKETS

NEEDLE

VALVE

•••

THROTTLE
VALVE

SPRING

o

IDLE

MIXTURE

SCREW

CHOKE

ROTARY
SHAFT

FUEL

O-RING

LEVER

FILTER

SHAFT

THROTTLE

VALVE

SPRING

ELEMENT

VALVE

ALUMINUM
SEAT

GASKET

o

e.-

·8·

•

ACCELERATOR
DIAPHRAM/GASKET

SEAT

PUMP

VALVE

• •

.

ft·

•

MAIN

BODY

•

•

•

MANIFOLD

GASKET

GASKET

Westerbeke Generators

CARBURETOR

AND

FUEL SYSTEM

Carburetor

The carburetor is a single barrel down draft type with a metal screened air intake filter which is cleanable.
The carburetor has
jet is set at the factory and will accept no adjustment. Any adjustment

two

metering jets, one of which

is

adjustable (the idle mixture). The other fast running

to

the idle mixture jet should be

done

with the engine warmed up and without any load on the generator.

Carburetor

1.

Idle Mixture Jet

Disconnect the
the idle stop screw. Turn the idle mixture screw clockwise

Adjustment

Lhrottle linkage arm from the governor control arm and reduce the engine's speed with

(in)

until the engine skips; back the screw

out (counterclockwise), slowly, until the engine smooths then skips again; then turn the screw clockwise

(in) one-quarter to one-half of a turn. The idle mixture should be satisfactory at this setting.

2.

Run Mixture Jet

This mixture jet

made in the
section

of

is

presized at the factory and is not adjustable. The idle mixture jet adjustment can be

1800 rpm range to improve engine performance. Refer

this manual for instructions on how

Electrio

to

adjust the engine's speed, page 106.

Choke

'Wire

.·l.:m.e

Cl

....

up

to

the "Governor Adjustments"

Arreater

Carburetor with flame arrester removed.

Westerbeke Generators

100

1.

Loosen the flame arrester clamp
and remove the flame arrester (not
shown). Disconnect the electric
choke wire, the vacuum hose at­tached

to

the manifold, the fuel
supply line, and the throttle control
linkage (see bottom drawing).

2.

Remove the two nuts holding the
carburetor to the manifold and

the carburetor from the manifold.

lift

Electric

Choke

lUre

Flame

Arrester

3.

Disconnect the vacuum hose at one

end. Remove the cotter pin from

the electric choke to

control lever
rod and disconnect the electric
choke to control lever rod from the
electric choke assembly.

4.

Remove the two choke assembly
retaining screws and their washers.
Disconnect the electric choke as­sembly from the carburetor.

Choke

ScreW'

Throttle

VaCUUIIl

Hos.,

(to

manifold)

Choke

Ley

~

r

®

.. r Sprlni

__

Choke
Reta.lnlni

Choke

AlJlJembly

Ground

Electric

Screw

Choke

Westerbeke Generators

to

Control

LeTer

Vacuum

lor

Rod

5.

Remove

washers.

straight
carburetor's

the four cover screws

and

Lift the carburetor's top cover

up

and

base.

away

Take

from

off the four
screws holding the accellerator housing
cover to the side of the carburetor body.
Remove

the

cover,

accellerator
diaphram and spring. Inspect the
diaphram

replace

it

if

cracked or

and

pourous.

their

the

6.ln the carburetor top cover, gently punch
in

out the float retaining pin

the opposite

direction of the split side of the pivot

and

bracket

remove the float. Make
sure you catch the needle valve that
hangs from the float retaining hook
under the float's pivot arm and

it aside.

7.

Remove

8.

Shake

the old cover gasket.

the float. If you

can

place

hear any
sand-like particles moving inside the
float, replace

it.

Float

Retaininc

Hook

102..

Westerbeke Generators

9.

Remove the needle valve's seat with a

millimeter wrench. Make sure that the

is

seat's aluminum gasket

this time.

Screw

in

the new seat along

removed at

with a new gasket.

10.

Place a new carburetor cover gasket

the carburetor top cover. Do not
any gasket sealer on this gasket.

11.

Gently place the needle valve

::

needle valve

Jat. Replace the float

and float retaining pin so that the

needle valve's wire retaining loop
hooks onto the float's retaining hook.
Now check the float level distance from

the housing mating surface with the

housing

held vertically.

in

10

on

use

the

Wire

Floa.t

Relll.lnlnll:

Retaininll:

Hook

or

Top

COTer

Distance
inches

(4.76

Needle V ...

"A"

from mating surface: 3/16

mm).

lve

Seal

1'lo"l

Hook

Wlr
Loop

1"10"

Rcl"ininll:

..

Retaining

t

Pin.

Westerbeke Generators

103

12.

On

the carburetor
the retaining screw to the ac­celerator pump
and

the

two

placed above

zle.

13.

Replace
and
nozzle. Snug down the nozzle's
retaining screw. Do
tighten the screw.
cellerator pump diaphram, spring
and
retaining screws.

the two copper washers

reinstall the accelerator pump

housing. Snug down the four

base,

nozzle, the nozzle,
copper

and

washers

below the noz-

not

Reinstall the ac-

remove

over-

.....---

I

C.pp

••

/:

W~b"'~~

/

Nozzle

.=

.....

.

Retll.ininc

,

..

Pu=p N ...

Screw

I.

14.

Place the carburetor top cover

on

straight down
base.
and
screws
shown
Snug down each screw. Over
tightening these screws
the threads

Replace the four washers

hand

tighten the four cover

in

the indicated order

in

the drawing to the right.

in

the carburetor

the carburetor.

can

as

strip

Carbure

COTer

Base

Westerbeke Generators

15.

Reconnect

the

electric choke
assembly to the carburetor
and

replace

the

two choke

assembly retaining screws

and

their washers. Reattach

the electric choke to

lever rod to the electric choke

and

assembly
ter pin. Reattach

insert the cot-

the

hose.

16. Replace the

idle mixture
screw's O-ring, the rotary
throttle shaft

valve
rotary throttle shaft valve
spring.

Remove

ter element

pI

ug

the

and

the fuel filter element.

control

vacuum

and

the

fuel

fil-

replace

to

Control

Choice
Retaining

Assem

bly

Sere,..

Choke

Vacuum

Lever

Spring

, .....

Cotter

Pin~

Hose

Choke

Assembly

n'n.

Electric
Choke

S<<<w

is

Now the carburetor
Make

sure

all

the screws

carburetor

are

rebuilt.

on

the

properly

tightened and replace the car-

on

buretor

the intake manifold
using a new manifold gasket
along with a gasket sealant.

and

Replace the two nuts
the

carburetor to the manifold.

tighten

Reconnect the throttle control

fuel

linkage, the
vacuum hose,

supply

and

choke wire. Replace

the

line,

electric

the

the

flame
arrester on the carburetor and
tighten the flame arrester clamp.

Westerbeke Generators

Idle

Rotary
Shalt

Mixture

Screw

Throttle

Valve

Element

Plug

)o·uel
Element

)O·ilter

Inspecting the Distributor and its Components

1.

Inspect the rotor and cap for cracks, wear, rust, dirt or salt deposits.

2.

Check the cap with an electronic tester, as il­lustrated in the diagram

Prior

to

testing the distributor cap, apply

breath inside of the cap

of the cap.

Set the range of the ohm tester
INSULATION M Ohm. If the cap's resistance is
less that

neutral

20M ohms, clean the cap using a

detergent.
remeasure the insulation resistance. If the in­sulation resistance is

replace the cap.

3.

Check the distributor shaft for wear

to

the right.

your

to

damped the interior

to

After

drying

the

cap,

still less than 20M ohms,

or

damage. Replace all damaged parts.

f-

~

'"

::

0-

0.0.

o

>-

0.

~

o

,:"

',',---'-

Measuring

G)Between

No.1

®Between

No.3

,

,

,

,

:

1'-

rJ._

(;;

L,

.

c;::

0

()

.,'

t ' ,

--

L..

______________

___

mn

points

center

through

electrode

No.3

each segment

,.

u I : :

::

: :

J I

___

n

__

J_u

-J.)_n~

and segments

of

No.1

through

,

,

4.

Measure the condenser capacity with a circuit tester. If the reading does not fall within the specified range,

replace the condenser.

Specified range:

0.225 - 0.275 microfarads (uF)

(Condenser Capacity)

5.

Test each spark plug wire and the coil wire. Con-

nect the

leads of a circuit tester

to

each end

of
the spark plug wire. Check the continuity. of the
spark plug wire while gently waving the center

of

portion

the tester deflects

the spark plug wire. If the pointer on

while the wires are waved,

then the wires are satisfactory.

Specified resistance:
Allowable limit:

16KOhm/m
25KOhm/m

Westerbeke Engines

106

Testing the Ignition Coil

PN#035667

Measure the Ignition coil's primary and secondary resistance and capacitance

if any test fails

Primary Coil Resistance:

Secondary

Resistor Resistance:
(Replace

fails. this test.)

IGNITlONCOIL

to

meet the resistance value given.

Coil Resistance:

only

the resistor if it

(LATE

MOVELS

0.98

17.5

1 .92

:!::0.1

:!::

2.6 ohm

:!::

0.2 ohm

ohm

F

PN#036-16?

S peci fications

Primary

resiSlanc~

Secondary

EXlernal

3. Ignition coil

resislan.;~

r~siSlaIlCC:

Primary coil resistance Measurement. Be­tween positive B and negative C terminal.

Resistance: 1.08 - 1.32

Secondary coil resistance measuremem_

Between positive C terminal and high

tension terminal

. Resistance:

(O)p"."

(kO)

(0)

21i

:!:

3.9

i

1.7

£0.

Ff

!l

F,

22.1 - 29.9

k!l

A

(bic

as

follows. Replace the coil

D

Ignition Coil

D

\

i--~--/;

A

~

\:

\:

.•

E

IC

/1'"

:

I

I
I

Resister resistance measurement. V .to E

Resistailcc:

1.53 -

1.8:

f!

Inspecting the Spark Plugs PLUG

Inspect each spark plug
Clean

of

replace the spark plugs if necessary. Make sure

or

that new

installed in

Spark Plug Gap: 0.028 - 0.036 inches (0.7 - 0.9 mm)

used spark plugs are gapped before

the

engine. D [T

NOTE: Make sure
removing and specting the spark plugs.

for

cracks, chips,

that

the engine is cold before in-

or

for

fouling.

they

are

107

GAP

WEAR

AND

ADHESION

OF

CARBON

DAMAGE

ER I ORAT

DAMAGE

Westerbeke Engines

AND

ION

Testing

1.

the

Alternator

For the No Load performance inspection, start
the engine and test the alternator's regulated
voltage.

Regulated voltage: 13.9 -

15.1

Current: Less than

2.

To test the stator, use

an

ohm meter

resistance between each terminal.

Resistance: Less than 1 ohm

Volts

10

Amps

to

check the

3.

To test the rotor, use an ohm meter

resistance between the slip rings.

Resistance: 2.9 ohms

Westerbeke Engines

to

check the

108

Testing the Starter

(Left blank

for

starter test procedures)

109

Westerbeke

Engines

(Left blank for starter test procedures)

Westerbeke

Engines

110

YOUR NOTES

111

Westerbeke Engines

ENGINE ASSEMBLY

Take the following precautions when assembling

A.

Make sure that all parts

B.

Be careful

C.

During

and face

bearing caps.

D.

Apply lubricating oil

on the engine, rotate

E.

If there are mating marks scribed during disassembly, reference them correctly for assembly.

F.

Use

G.

Tighten the bolts and nuts on important parts

wrench.

H.

Use liquid sealants when required

not

to

the

assembly, recheck clearances and ensure that all parts are assembled in their proper order

the

correct direction in relation

new

gaskets, lockwashers, and a-rings.

to

be assembled are thoroughly cleaned.

mix

nuts and bolts. Metric and SAE bolts are used on various engine assemblies.

to

moving parts during the assembly. Ensure that moving parts, when assembled

or

slide and are not subject

on

Section

'"

...................................................................... Page

the

engine:

to

the engine block; that is, pistons, piston rings, bearings and

to

binding

of

the engine

nuts, bolts and gaskets. Refrain

or

excessive tension.

to

specified torques using a reliable torque

from

using tape sealants.

CYLINDER

(Illustration

Assembling the Crankshaft ............................................. 114

Piston and Connecting Rod Assembly .......................... 115

Piston Ring

Installing the Crankshaft Timing Belt Pulley ................... 119

CYLINDER HEAD
(Illustration

BOLTING

TO THE CYLINDER BLOCK ........................................... 124

TIMING BELT ASSEMBLY .............................................. 125

ADJUSTING VALVE CLEARANCES ............................... 129

I nstalling the Distributor .................................................. 130

Installing

BLOCK ASSEMBLY

and Numerical Order) ................................. 113

Installation ................................................... 116

ASSEMBLY

and Numerical Order) ................................. 120

THE CYLINDER HEAD

External Parts and Subassemblies .................

131

Westerbeke

Engines

112

CYLINDER

For

the W 26G and the W 26GX engines, assemble the components in the order indicated below.

BLOCK

ASSEMBLY

*

1.

Crankshaft and Bearings

*

2.

Piston and Connecting Rod Assembly

*

3.

Balance Shaft

4.

Balance Weight

5.

Oil Pump

*

6.

Oil Pump Drive Sprocket and Chain

7.

Rear Oil Seal Retainer

*

8.

Balance Shaft Gear Cover

*

9.

Oil Pan

10. Water Pump

*11. Crankshaft Timing Belt

* Denotes that assembly instructions

CYUNDER BLOCK ASSEMBLY ORDER

(page 114)
(page 115)
(page 117, step

(page 117, step

(page 118, step
(page 118, step 1

Pulley

for

these parts follow

(page 119)

on

the indicated pages.

113

# 7-8)

#

8)

9)
0-11

)

Westerbeke

Engines

Assembling

1.

Before each bearing cap

the

Crankshaft

is

installed, coat the
crankshaft's bearing cap bolts (threaded portion)
with engine

oil.

NOTE:

Do not allow any oil

to

get on the back-

side of the bearing inserts.

2.

Attach the thrust washers on the cylinder block at

the front and rear sides of the

3.

When installing the bearing caps,

No.3

be

bearing

certain that
their arrowheads face toward the front of the
cylinder block, respectively. After the bearing
cap bolts have been torqued

to

the proper

specification, ensure that the crankshaft can

lightly.

rotate

4.

Tighten the bearing caps.

40

- 47 Ib-ft (5.4 - 6.6 kg-m)

Westerbeke Engines

114

Piston and Connecting Rod Assembly

1.

Assemble the pistons and connecting rods so that

of

the front mark tocated at the side
rod and the front mark provided on the

the connecting

top

of the pis-

ton come on the same side.

Front

mark

2. Using the special service tool
body) and

onto

09221-87702. attach the fitting piece

the stand

(1).

and place the long bar

# 09221-25014 (Main

position.

3.

Place the small bar

(5)

into the piston pin. Then press

the piston pin into position using a press.

NOTE: After the connecting rod has been as-

sembled in the piston. ensure that the piston can

move lightly back and forth.

(4)

(2)

into

115

Westerbeke Engines

Piston Ring Installation

1.

When installing the piston rings, make sure that

by

the marks stamped on the rings
turer face upward.

the manufac-

2.

Make sure that the ring openings DO NOT align

when they are on the piston. Position the ring

gaps in the direction shown in the figure.

3.

Apply engine oil

piston pin.

4.

Insert the connecting rod and piston assembly
into the cylinder block with a piston ring com-

pressor attached.

to

the external circumference

of

Compression

No.2

ring

Thrust side

..

Compression
ring No.1

5.

Install the cap on the connecting rod, making
sure that the front mark (projected) on the bear­ing caps are

the connecting rod.

Westerbeke Engines

aligned with the mark provided on

116

6. Tighten the connecting rod caps between 15.2 - 21.0
Ib-ft

(2.1

- 2.9 kg-m).

7.

Install the balance shaft. Align the stamped mark

balance shaft's drive gear with the stamped mark

on

the

on

the balance gear.

a.lnstall the oil pump's drive chain.

NOTE: The sprocket that attaches
shaft must
CB-OUTSIDE faces away

be attached so that the stamped mark

from

to

the balance

the engine.

Stamped marks

117

Westerbeke Engines

9.

Install the balance shaft's gear cover.

10. Replace the old oil pan gasket with a new one.

to

Prior
sealer

installing the oil pan, apply silicon bond

to

the gasket.

11

. Place the gasket on the cylinder block and attach

the oil pan. Tighten the oil pan

5.1

Ib-ft (0.4 - 0.7 kg-m).

-

Westerbeke

Engines

bolts between 2.9

118

Installing

the

Crankshaft Timing Belt Pulley

After the balance shaft drive gear has been installed
on the crankshaft, place the two crankshaft timing
belt

pulley
crankshaft) on both sides
pulley. Refer

flanges

to

the illustration

(convex

side

toward

of

the crankshaft timing belt

to

the right.

the

Convex side

119

Westerbeke Engines

CYLINDER HEAD

ASSEMBLY

For the W 26G and the W 26GX cylinder heads, assemble the components in the order indicated below.

CYLINDER HEAD

*1. Valve Guide Bushings
*2. Valves
*3. Camshaft
*4. Timing

Belt Pulley
*5. Rocker Arm Shafts
*6. Wave Washer (not shown)
*7. Distributor Housing

*Denotes that assembly instructions

ASSEMBLY ORDER

(page 121, step
(page 121, step 2)
(page 121, step 3)
(page 121, step 3)
(page 122, step 4)

(page 122, step 5)
(page 122, step 6)

for

these parts follow on

1)

the

indicated pages.

Westerbeke

Engines

120

1.

If

the

cylinder head had its valve guide bushings

removed, insert new valve guide bushings using

the special service tool

Replace the plate washer.

2.

NOTE: For this step, temporarily insert the rocker

arm shafts (see
press the valve springs, using special service
tools

# 09202-87001 and 09219-87702, and in-

stall the spring retainer locks. Repeat this process
for

each valve.

step#

[SST] # 09201-87702.

4).

Insert a valve,

com-

3.

Install the camshaft and timing belt pulley. During

the

installation, the camshaft can

from

rotating

the opening

pulley

bolt between 21.7

m).

by

inserting a screw driver through

of

the pulley. Tighten

be

prevented

the

timing belt

to

32.5Ib-ft (3.0 -4.5 kg-

121

Westerbeke

Engines