Section 2.1 - Basic Engine Mechanical 2.4.1. Tightening Cylinder Head Bolts 24.2. Tightening Manifold, Exhaust Tube ‘and Carburetor Fasteners, 2.41.3- Adjusting Valve Clearance 2.1.4 Checking Orive Bolts 2.1. Measuring Compression Pressure Section 2.2 - Timing Belt Removal, Inspec- tion & Installation 2.2.1. Timing Belt Precautions 2.22. Timing Belt Removal 2.23 Timing Bett inspection 2.2. Timing Bott installation Section 2. Cylinder Head 2.31. Oylinder Head Removal 2.2 Disassembly 2.33. Check Cylinder Head Distortion 2.34. Valve Guide Clearance 2.35: Valve Gulde Replacement 2.36 Valve inserts 2.7. Camshatt Bearing Clearance 2.38- Camshat Runout 2.9. Valve Dimensions 2.10- Valve Spring Squereness, Free Length and Tension 2.9.11- Cylinder Head Assembly 23:12-Instaliation Crd ENGINE MECHANICAL Section 2.4- Ol Pan and Ol! Pump 2.4:1- Removal 2.4.2-Inspection Section 2.5 - Oil Seal Replacement 2.5: Replacoment of Camshait Oll Ses! 2.5.2- Replacement of Crankshalt Front Olt Seal Section 2.6- Engine Overhaul 26:1- Disassembly 26.2-Inspection 263- AssemblySECTION 2.1 - BASIC ENGINE MECHANICAL 2.1.1- Tightening Cylinder Head Bolts Rotighten cylinder head bolts who ongine ts ool (ap- proximately 68°F, (20°C.), as follows: A__ Remove all spark plugs, oll pump drive gears, tetainer ane bot. A B._otighten bots in the sequence shown. Tighten to {47-51 foot pounds (64-59 Ne). i a 8 3 8 8 U4 2.4.2. Tightening Manifold, Exhaust Tube and Carburetor Fastenets Intake Manifold Nuts 12-15 foot pounds (16-21 Nn) Exhaust Tube Nuts: 22-26 foot pounds (29-35 Nem) Carburetor Bots: 43-5 8 footpounds (6-8 Ne) 2.1.3- Adjusting Valve Clearance ‘Aust valves while engine is warm but not running, 28 follows: C__ sot No. 1 cylinder at top dead center (TDC) of Its ‘compression soko ané adj! valve darance 1, 2. 3 ‘and, Then, set No.4 cyndor a ep dead center (TOC) ‘ofits compression siroke and adjust valve dlearance 4, 5,7 and 8, Set valve learance a flows: Cleararce HOT INTAKE - 0.010 inch (0.28mm) EXHAUST -0.012 Inch (0.30%mm) D winen valve clearance is properly set, tighten the ad- Justing sore locket to 8-11 foot pounds (11-15 Nem). D2.4.4- Checking Drive Belts E_ inspect tor cracks, traying, wear or olliness. Replace, if necessary. The belts should not touch bottom ot pulley groove. Beltlensioniscorrectwhan foree of about 22 pounds, (10 kg) applied migway betwen pulleys, results in a belt deflection of about 2-3/8 neh (12.7-49.0me). 2.1.5- Measuring Compression Pressure F warm up engine. Then, shut down and romove all spark plugs. Use astandara automotive type ange cor pression fester. Hold thre and choke valves on ear- orator hilly open, then erank engine and read the com pression pressure. Compression pressure should be a5 follows: STANDARD - 192>psi(19.5 kgiem*) at 350 pm MINIMUM. - 164 psi (11.5kg/om?) at 350 pst DIFFERENCE BETWEEN CYLINDERS SHOULD NOT EXCEED 14 PSI (1.0 kgicm?) 4 compression is tow in any cyindr(s). pour a smal amount of clean engine al nto cinders through the Spark plug opening. Then, retest compression ‘and valle a8 tows! * If compression pressure increased ater adding ol, check for wom or damaged piston rings. “Hf pressure dl NOT increase ator adcing ol, valve(s) ‘may be sticking or seating improper. “It compression in any two adjacent cylinders stow and adding oll didnot increase the compression, check for a foaking head gasketSECTION 2.2 - TIMING BELT REMOVAL, INSPECTION & INSTALLATION 2.2.1- Timing Belt Precautions 2.2.2- Timing Belt Removal ‘Comply with the following precautions when removing, n- | AL Remove BELT GUARD. specting or instaling the ting belt * Check that the timing belt, pullies and tensioner || AL are tree rom oll ana water. «Prior to Installing the timing belt, make sure that ||| No. 1 eylindar Is set at top dead center (TOC) of ts compression stroke. { + al row on the timing belt inthe dection of engine rotation. * Flemove all spark plugs before adjusting timing bett tension, When timing belt is removed, nkshaft and camshaft separate ‘strike the piston heads). * DO NOT bend or twist the timing belt too tightly. NOT rotate (valves wil TIMING BELT AND RELATED COMPONENTS: Timing oat 2 Mattes 7B Loosen tension on drive bet by loosening sea water pump tensioning bol. Remove Dive Gel. D_ set no. 1 oyiner at top dead center (TDO) of ts ‘compression stroke, Then, remove upper and lower Cust ‘gaskets, Loosen ting bell tensioner and return spring, then remove ining bel 2.2.3- Timing Belt Inspection E pattie Broken: Caused y improper hencing, poor belt cover sealing, coolant loakage at water pump. F Tooth Broken or Tooth Root Cracked: Caused by camshatt jamming, distbutor jamming, damaged ‘rarkstat or camshaft of sea G_ ack Surtace Is CrackearWom: Caused by ten- sioner jamming, overnested engin, interterence wh G H. side surtace Worn: Caused by improper bat lation, detective crank pulley andlor ting bel plat. —SUJ Belt Teeth are Worn: Caused by poorbelt cover seal ing, coolant leakage at water pump, detecve camhat, dalectve distributor, excessive el tension, J 2.2.4- Timing Belt installation K check hat No. 1 cyinderis at top dead center (TOC) ‘tls compression stoke, Algn camshatt and eankshat pulley mars. (ores L._ Install tensioner and rebum spring. Hook the return | shrng toils stopper. temporary. IN chockthat ne waterpurnp and tensioner pulleys can be tated smoobiy. ith no evidence of binding. ns ‘ening bot IMPORTANT: Make sure timing bellis clean and free of oll and water. Do not bend the alt. Arrow on Belt ‘must palnt In normal rection of rotation. Loosen tensioner lock nut With all spark pluge cemoved, rotate camshaft pulley two fl ume counterclockwise, ‘Tighten the tensioner lock. Fnaly, check bl inion. ‘with force of 1.06-1.28 pounds applied, belt should erect about 0.08 inch (2m).Tighten tensioner lock nut to 11-12 foot-pounds (15- vNa.SECTION 2.3 - CYLINDER HEAD 2.3.1- Cylinder Head Removal 2.3.2- Disassembly Remove timing belt (Section 2.2). Then, remove O1L | Remove bolt lock tabs and rocker shaft with rocker PUMP IDLER GEAR. farms, KEEP THEM IN PROPER ORDER,‘+ When isang sing pars suc a ‘earns, Be ute 0 apply engine i ENGINE CYLINDER HEAD.G_ Remove valve oll seals, using suitable puller. 2.3.3. Check Cylinder Head Distortion H. uses thickness gauge and straightadge to moasure ‘ftder oad distortion. Lay the straightedge acres the Gytinder head surtace as sown. Surtace Warpago Ms ot exceed 0.004 ine (tr). I surtace warpage (eds the stated value, cylinder head maybe resuaced Fsurfacing Limit:- The amount of reeurtacing that can be dene onthe ytnder head depends onthe amount of resuracing onthe cyinder block H te amount of HEAD resurfacing fs A" and he amount of BLOCK resurfacing 15°" the maximum bts a ollows + 8 = 0.008 inch (0.2mm) FE wssuing gine 2.3.4- Valve Guide Clearance -J_Use a suitable dial insicator to measure valve stem {e guida clearance. Valve should be rove paral othe {ocker arm, since most of the wear cocurs inthis doo tion. See blustaton for maximum Srna. J ¥ i 2.3.5- Valve Guide Replacement K. Heat cyfinder head to 302-320" F. (180°-160" C.). aa =“ L {ress wate guide ou wih a ras, using 82.2 US. {on 20KN) fore. If presss not avalabe, use a hammer And suitable deving Yoo t 10IM. Ream cylinder head valve guide hole. IN Heat cylinder head to 302'-320" F, (150"-160" C.), then pass Service valve guide onto cyinder bead O Ream valve guide to finished size of 0.2788-0.2764 ten (7.005-7.020mm). 2.3.6- Valve Inserts P check valve inserts for evisence of piting at valve contact surface. Resoat or replace I wom excessively. “The following rues apply: * when repairing valve inserts, frst chock valvo and valve gulde fer wear. Hern, replace them. Thon, comect vate Soat, * Cutting should be done wih both hands, for more Uniorm cing, necessary, replace valve insets as flows: ‘a Roam the onder head recess. 'b, Heat cylinder head fo 302320" F.(160'-160" C), «install insert. Make aur it bonds at bottom fao0 of fs ‘reoeee and caulk at more than 4 places. Nowy fee val 8 Le ba ground with 2 ‘Suitable fal, to the sted in the apphcable SPECIFIGRTIONS chart ‘Apply @ small amount of vahe grinding compound to ‘valve contacting face and place valve Into guid. 2.3.7- Camshaft Bearing Clearance Q chock camshatt bearing clearance as shown. Max mum clearance between bearag and ts bores 0.0089 Inch (0.5mm) check bore and check bearing outside diameter. Dit- {erence between them is bearing clearance. ain nctnes) be a] ‘men vaive head is worn to 0.020 inch (0.5mm) mar- ginthickness, replace the valve. Grinding allowance for valve stem end surface is 0.008 inch (0.2mm) of less. 2.3.10. Valve Spring Squé Length and Tension 108s, Free U_Vaive spring out-of squareness must not exceed 9.079 inch (20mm). Rotor to applbable SPECIFICA. ‘TIONS chat fr sprng free loagih and tension, U 2.3.8- Camshaft Runout 'S Use a sultable measuring device to check camshaft nou 2.3.11- Cylinder Head Assembly V. nstl valve ol sea. Thon nstallvalve components gars App engine oo cama ase anata he W install camshatt assembly. Note positioning of cam: -shattfonttaoe when No.1 cylinder set attop dead cen: {er (TDC) of ts compression stoke, 2.3.9- Valve Dimensions T check dimensions of al valves. Retor to applicable SPECIFICATIONS char. RX Measure camshatt end play with thermostat hous- ing and gastet nsaled -Y install Rocker Shatt with Rocker Arms. Z__ attach boit stoppers, ALWAYS USE NEW BOLT ‘STOPPERS. AA. naa ci pump tar gear and ot pun rgustor $n, Make cure ping lace the proper aector.2.3.12- Installation BB sero. t cylinder at 106 ofits compression stroke by frst aligning the CRANKSHAFT TIMING PULLEY MAF wit mark on main bearing cap. [uloe” (CC Align CAMSHAFT TIMING PULLEY MARK with ‘ark on cyinder head. IMPORTANT: DO NOT ROTATE CRANKSHAFT AND (CAMSHAFT SEPARATELY, BECAUSE VALVES WILL HIT PISTON HEADS. EE cylinder Head Botts Tightening Procedure: * Fist, Tighton al bois o 22 foot peunes (29 N-m) * Thon, tighien al bolts o 47 foot peunds (64 N-) * Loosen albttscomplotly. * Tighten all bok 0 22 foot pounds (29 Nem * Tighten allbots to 47-51 foot pounds (64-69 Nm) EE a ® © DD instatt cytinder head with new gaskot, * Always use anow cylinder head gasket * Belore tightening cylinder head bolts, check that the pump dive gear can be tured freely by and. * Aways insall washers between bolts and head * "Tighton cylinder head bolts ia the sequence shown in iMustation "DD" “ IMPORTANT: When retorquing cylinder head bolts for normal periodic maintenance, frst loosen all cylinder head bots sight. Then (wih engine COLD), lighten al bolts in the correct sequence to 47-51 foot pounds (64-69 Nim). FF instattiming bet. install ot pump idler and oll pump ‘regulator spring. Make eure spring iecction score. n- Stal UPPER DUST COVER, making sure le gasket ‘ates wih oyinder heas properyGG ZTgon upper dust cover bots 23.6 ook | sal Spek plugs and taht tc 14-22 fot pounds (20- pounds (45 2am)SECTION 2.4 - OIL PAN AND OIL PUMP. 2.4.1- Removal A. Drain engine of, Thon, remove oll pump assembly with of strainer BE CAREFUL NOT TO DROP OIL PUMP DRIVE SHAFT. 2.4.2- Inspection Foterto Part 3, ENGINE LUBRICATION AND COOLING SYSTEM, 2.4.3- Installation Insta of pump assombly and tighton to 13:46 foot- pounds (18-22 Nm), IMPORTANT: Before tightening oll pump sssembly. rotate oilpump drive geartomake sure that pump drive ‘shalt does not interfore with inner wall of cylinder block. B Apply RTV gasket seatant to oll pan as shown, 16 C instailotiseals. Apply ATV sealartto upper andlower surfaces of gackeis as Mustated c Install gaskets andot pan Tightento2.9-3.6foot pounds (hone),SECTION 2.5 - OIL SEAL REPLACEMENT 2.5.1- Replacement of Camshatt Oil Seal [A emove ting bet pug idler goa. Remove bot Slopper and rocker shat i roster arma. Remove ‘ara ernve cams ol seal Apay engine of 0 raw cashat ot sal and neta 5.2» Replacement of Crankshaft Front Oi! Seal | B__ Remove timing belt and 20ver. Remove oll pan. ‘Remove main bearag caps. Remove erankahatt ol tea ‘Apply engine oll to new ol soa and italSECTION 2.6 - ENGINE OVERHAUL 2.6.1- Disassembly ‘A. rac engine on wasted. Remove ining bt over and trang ben Remove oe head and Opn Remove pore ‘bearing caps. Finally, remave crankshaft. 2.6.2- Inspection C-_Shie piston pin into piston pin tore. Pin must side smoothly info bre at reantternperat', without si play ‘an that binding, Piston Pin to Piston Clearance: ¢.0002-0.0008 inch {(0:008-0.012mm) D. check side clearance as shown Clearance shoulé at excaed the masirsam ini tated Top Ring 9 9016-9.0029 inches 0.040-0.73mm) Sebond fing "0.0012-0.0008 Inches (0.090-0.053mm Maximum ‘Tolerance .....0.008 inch (0.2mm) 8ENGINE OVERHAUL- CYLINDER BLOCK, CRANKSHAFT & PISTONE cheek piston ring gap as shown, Top Ring No.1 Grade... 0.0089-0.0118 inch (.21-0:20mm) No.2 Grade. 0.007%-0.0118 neh (0.18-0.20mm) No.3 Grade.” 0.0071-0.0118 inch (0.18-0.90mm) ‘Second Ring ..0.0059-0.0154 inch (0.18-0.30mm) OH Ring... 0:0078-0.0311 inch (0.20-0.79mm) G inspect crankshatt journals for scoring, bias, wear or cracks. Minor detects may be correctod using tne crocus ‘oth. Use a icrometer to eieck joumals fr taper and outoteound our Round (2-¥)...0.0004 inch (0.01mn) ‘Taper (A-B)..-Less tnan 0.0008 inch (0.02mnm) G F Uso "Plastigaga™ to check beering clearance. Com: ly th ho folowing: * DO.NOT tur crankshalt or connecting rod when pas: ‘igage i beng sorted, *Whon bearing clearance exceeds the spectod ln ceckthat the corset bearing has boon intalleg. excos” ‘sho Goarance stlexts, use thicker main beeing or un ‘ersizo boating o obtain specttieg clearance. Bearing Clearance Main Bearing .0.0012-0.0020 inch (0.09-0.05mn) Limi. 0.0030 inch (0.075mm) ‘Connecting od Bearing... 0.0008-0.0024 inch (0.02-0.06mm) Cmte (0.0047 inch (0.t2mm) ‘ton regrinding crank pin joural, measure tho “L" Install piston sings as shown in lusratio, Vv (:)W insta main bearing caps and tighten bolts to 34-98 {ect pounds (45.2 Nm} Always ighton in 2 3 stages Botore Ughtening bearing cap bots place cap in proper postion by shifting orakshatt axial. Aer tgmtering ts bearing cap bots, make sure crankshaft tue smoothly YY Measure connecting rod end pay. Ed Play... 0.0088-0.0946 inch (0.10-0:57mm)Section 3.1 - Engine Lubrication System 2.1.1- Oll Pressure Check 3.12- Oi! Pump Disassombly 3.13-OllPump Inspection 3.14- Low Oil Pressure Shutdown Section 3.2- Cooling System Water Pump ‘and Thermostat 3.2.1 Water Pump 322. Thermostat ‘Section 3.3 - Heat Exchanger and Exhaust Outlet 2.:1- General 3.32: Radiator Cap 3.33-Zine Anode 3.34- High Exhaust Temperature Switch Section 3.4 - Automatic Protective Shut- down Switches 3.4.1- High Coolant Temperature Switch 3.42: High Exhaust Temperature Switch 3.43 Testing the High Coolant Temperature Switeh 3.4.4. Testing High Exhaust Temperature Switch 3.45 Operational Tests Cur ENGINE LUBRICATION & COOLING SYSTEM ‘Section 3.5- Sea Water System 35.1. The Sea Water System Section 3.6 - Cooling System Periodic Maintenance 36.1- Sea Water Pump Operation 3.62. Freezing Temperature Operation 263. Checking Captive Coolant LevelSECTION 3.1 - ENGINE LUBRICATION SYSTEM. 3.1.1- Oll Pressure Check ‘A._ worm up cngine. Then, shut down and romeve of esse swith hl a ec ead pete Bran angina ana check of pressure wth engine nny site loacndin sear wae corratadt 2 mo) Ol prpaure shoud be approsmately 40-8 pel (2033 kg a 1860 rpm. Engine Luibrication Circuit Seon3.1.2- Oil Pump Disassembly 3.1.3- Oll Pump Inspection B Wnen removing ol pump assembly, be carstulnotto | C° visually inspect pars for wear and damage. Check ‘top the ol pump dive shaft When isialing the pump, | ol pressure regulator valve shising surfaoes and valve ‘’ppiy engine cil to drive gear and shaft. The inner rtor | spring. Replace valve seat, If damaged. Using a feler nee ae —— ie | =e [7 nef mr, RS) Se ee+ (1)Rotor Tp (Clearance... Less than 0.008 inch (0.2mm) * (2) Outer Rotor to Body, (Clearance... Less than 0,008 inch (9.2mm) *G) Rote te Straight Eg ‘Less than 0.008 Inch (0-2mrm) 9.1.4- Low Oil Pressure Shutdown D should engine oll pressure during operation drop below approsimaly 15 pl, an autematic engine shut | down wil accu. The low ol pressure switch sensing port | Senses oll pressure in the engine main ol galery. The Switchis nonmaly-closed (N.C. held open by of pres ure dring startup and operation. To tes the low ol proscure shutdown feature, start on gine and ran at no-load (all electra! loads deconnectes from gonerate). Remove wire fom of pressure switch ‘and eas forminal end against a clean tame ground. ‘Affe short delay, engine should shut down D,COOLING CIRCUIT 1 ENGINE WATER PUMP. THERMOSTAT FRE To SEA _—WiATER OUTLET 7 EiChncen -—) SotSECTION 3.2 - COOLING SYSTEM WATER PUMP AND THERMOSTAT ‘3.2.1- Water Pump: ‘A. Tow engine water pump cannot be csassembied and ‘nuat be epiacea sat. Chnes pump for exceacve “napa anamantnecsot tation Bothols we dtod thowgh water act te yn tock. Use a eaten hu tpien heb fotne oconmend tq. Aor instataton operat gine and check for taks 9.2.2. Thermostat B & C check thermostat for proper seating at am- bent temperature. It should seat tightly Check opening temperate and valve It Valve Opening “Tomperature 190° F.(88° C) Maximum Vaive (0.31 inch at 212° F. (8mm at 100°C.) un ‘Aloo check that valve closes at (5° C.) below valve ‘opening temperature. Following instalation, un engine and check for leaks,SECTION 3.3 - HEAT EXCHANGER AND EXHAUST OUTLET 3.3.1- General ‘When working onthe heat exchanger assembly, comply wh to fang * Tighten al M65 fasteners on Heat Exchanger o 7 oot pounce * spply LOCTITE 21210 al stds batorenstating them Ino Hoal Exchanger exhaust maniol * Apply LOCTITE™ ppo stant all 12 and 5/8 inch pe tngs on Hoat Exchanger * “Apply ANTESEIZE COMPOUND fo EXHAUST OUT- LET PIPE NIPPLE betore rstallng i + Apply PLIOBOND" gasket sealant to all gasket sur- faces betore instalation ~ apply PETROLEUM JELLY to exhaust mani ong before te tubo bund is sted + Pressure fest captive water coolant chamber in Heat Exchangor at 90 pal engine colant chamber * Prose tat eea wale and exhaust outlet chamber 130 pal 3.9.2- Radiator Cap A. Use an automotive type cooling system pressure {stor to test radiator cap opening pressure. Opening ‘pressure should be approximately 12°-19.5psl. The cap [ealco equipped witha vacuum rail valve. Proper opera tion of bath prescure and vacuum root valves fs neces: ary for poration oft caclamt racouary Systm A PRESSURE RELIEF LNAWE vacuum POOF VALVE 3.3.3-Zine Anode B this sacrincial anode will erode to protect other cool. {ng system parts against corrosion. Replace the anede ‘eroded 80% or greater i“ ZINC {LAN 6 3.3.4 High Exhaust Tempereture Switch CT thwator tomporature in exhaust cutittiting exceeds: eppronmateyy 246-266" F. (119°-100" C.) engine wil shutdown automaticaly. The switch frotocts he exhaust System hoses against heat domago tat might recut leakage of exhaust fumes nto arses hnabtadby people. See Section 3.4 HIGH TEMPER) [EXHAUST SVCHEAT EXCHANGER & EXHAUST OUTLET EXCHANGERSECTION 3.4 - AUTOMATIC PROTECTIVE SHUTDOWN SWITCHES 3.4.1- High Coolant Temperature Switch A. 4 normaly-open (N.0,)thoemostatc swatch has @ ‘Sensing tip, which i Immersed In captive (engine water FRcket) coolant. Should captive coolant exceed ap. Proximetely 230° F. (110°C), the switch contacts wil ‘ose and (alte a short delay the engine wil shat down, 3.4.4. Testing High Exhaust Temperature Switeh C_Use an ohmmeter to check dosing temperatur of ‘witch contacts Contacts should cose et 246256" F. (119-130°0) A 3.4.2- High Exhaust Temperature Switch ‘See Paragraph $3.4 0n Page 6 3.4.3- Testing the High Coolant Tempera- ture Switch B_Romove switch and check awitch contacts closing temporature wit an ohmmeter. Contacts should ose al bout 225298" F711 C) _O. 3.4.5- Operational Tests IMPORTANT: Operational tosts of automatic shut- ddown systems must be done withthe engine at no- {oad (na electrical loads connected to generator). D. remove wire #85 rom yt tina. Star ong, lethctantce an wart op etn oad Fad erin end {Wee #05 kno frm cont wna doa rao pound ‘era shor day, engine shou st down. D foie = bro HIGH aust ENGINE Le: CONTROL Sh ciRCUT 8s $p BOARD,SECTION 3.5-SEA WATER SYSTEM 3.5.1- The Sea Water System A Sea seater (aw water), rather than ars used to ox tracthet rom the captive Slant during operation, TRS ea wateris pmpedintothe heal hanger and exhaust filet by a goa water pump. The folowing rus apply to this system: IMPORTANT: Only tush type (through the ul) cae ‘water ine iting should be used on a vesel. DO NOT USE “SCOOP TYPE" FITTING. A forward facing scoopcantorce seawater past the seawelerpump and Into the engine. * Sea water system suction tinge MUST be AIR TIGHT ‘oF fie pump wil net sll prime. The pump depends on ‘ea mator for is hibcation. NEVER RUN THE PUMP DAY FOR LONGER THAN 30 SECONDS. Lack of wator ‘willeeut in damage tothe pump Inpolir * Sea water pump maximum it (wen dy) Is ap proximately 10 feet (3.0m). When wel the pump wil rociee a Suction it of about 22 fet (6.7m). Vater MUST be avaliable 0 the soa wator pump btore tne engine is startad Without an adequate fow of ‘water trough the 8ea water sysee, pump damage and ‘Snginelexnaust system overhoaing wil occur * Seawater pump tow rate is approximately 6 U.S. ga fons per minute, ‘An engine water pp (Section 3.2 forces captive water ‘througntne engine cya bloc, evinder head and heat ‘oxcnanger, Sea (ew) wet f= pienped tough the heat ‘exchanger to cod the captive water. Afler being cooled, the capve wate Is retuned tothe engine water pump fn reciedated trough the sytem. The sea water pumped into the excuadst out fing and overboard {vou the exhaust system. A FWaHL Tyre Abt Fir)EXPLODED VIEW OF SEA WATER PUMP DESCRIPTION ‘SCREW M0500 LOCKWASHER: M5 BACK PLATE GASKET IMPELLER WATER SEAL BALL BEARING SHAFT PUMP HOUSING PUMP PULLEY PUMP BEARING INTERNAL SNAP FING O-RING PUMP CAM 15 ELBOW. 2/8" NPT x 56°10 16 SPRING CLIP 10‘SECTIONAL VIEW OF SEA WATER PUMP REFNO. DESCRIPTION 7 PUMP HOUSING 2 SHAFT 3 PUMP PULLEY 4 BACK PLATE 5 GASKET 8 ‘IMPELLER, 7 WATER SEAL a O-RING 3 BEARING 10 BEARING " PUMP CAM 2 INTERNAL SNAP RING 8 ‘SCREW. N5-0.80%8mn 4 LOCKWASHER: M5 7 PACK AREA WITH GREASE 18 SCREW: M5-0.80 x8mmSECTION 3.6 - COOLING SYSTEM PERIODIC MAINTENANCE. 3.6.1- Sea Water Pump Operation ‘The onnerioperator of the vessel in which tho marine generator Is installed Is responsible for the folowing ‘Sporatonal and maintenance requirements: ‘Sea water pump operation must checked dally. This ccan be done by observing the sea water flow from the Vetea's exhaust ote, * The vessel's sea water cock must be opened before ‘operating the marine generar. * ithe sea water systom includes a sea water fer, that fiter MUST be checked periodicaly. Evan a partially clogged ter mey result in engine and exhaust systom overheating, * Clamps and ftings on sea water suction hoses must betightand the systemmustbe ree offeaks. Ary oakage inthe suction sie ofthe system can result in las ofthe pumps self priming capabiiy, loss of sea water fom, and ‘Snginhe/eshaus system overhoating. AWARNING ‘without adequate sea water, engine andior exhaust system damage may result. Damage to the exhaust System can result In serious Injury oF death To oc- Cupants of the vessel caused by carbon monoxide poisoning, 3,6.2- Freezing Temperature Operation The engine captive watet system was latory servi wih & 30-50 misture of etiylne glycol base ant-reeze and soft water. When adaing coolant, ony the recom: ended 50-50 midure should be used. I the rocom: ‘mended 50-50 mixture is added consistent, the marine {enoraor wil be adequately protected against keazing fomporatures, ] ACAUTION When adding coolant or when refilling the cooling system after flushing, use only a LOW SILICATE, ethylene glycol base anittreeze formula and use SOFT WATER only. If rust Innbilor Ie used, do not Use any chromate base Inhibitor wih ethylene glyco! base ntr(reezo of the formation of "green slime’ (chromfum hydroxide) wil result. radon, the for mation of "green slime” may be caused by (2) use of high slicate antl-treeze boosters oraddltves,(b)use of hard water, of (c) use of a high rallo of atitreeze ‘to water. Donat exceed 69% ant-reeze nthe coolant misture. Formation of "green slime” wil lower the heat transfer rate and cause overheating, 3.6.3- Checking Captive Coolant Level Daily, checks of captive coolant Isvel may be ac- ‘complished by checking the coolant recovery bate. Ad ‘terecommendeds0-50 mintureo the recovery bot as soquired, Periodically, remove the pressure cap from the heat ‘exchanger to ensure the coolant recovery system it {unetioning property. Coolant level must be at lop of heat exchanger filer neck. It coolant level is low, inepect gasket in pressure cap for damage of wear, Replace cap, i! necessary. Cap may be tested as out lined in Paragraph 3.3.2. Also inapest cooling system and coolant recovery system fr leaksSection 4.1- Fuel System 4.1.4-Fuel Recommendations 44.2. Fuol System Components Section 4.2- Fuel Pump 44.24- General 4.22. Testing ana Section 4,3- Carburetor 43:1- Disassembly 43.2. Reassembiy 4.3.3-Instaliaion 434. Section 4.4 - Engine Governor Assembly 44.41- General Description 442. Governor Maintenance 4.43- Removal of d-c Atternator Assombly 4.44. Oi Servicing 4.45. Governor Lever, Links and Spring ue ENGINE FUEL AND) SPEED CONTROL SYSTE!CARBURETOR AIR INTAKE COMPONENTS (Continued) REF.NO. DESCRIPTION REFNO. DESCRIPTION T ‘AIR CHAMBER BASE 2 PIPE PLUG: VE NPT 2 {AIR CHAMBER COVER, a (CHOKE CONTROL LEVER, 3 STUD: No, 1032 2-3/0" ca SCREW: No. 1024 x 3/8" 4 FLAME ARRESTOR 2 COTTER PIN 5 FLANGED LOCK NUT a NUT-5116"24 6 CRANKCASE VENTHOSE = 28 ‘SCREW. No. 4-40 7 ‘SLOTTED HEX SCREW 2 (CHOKE BLMETAL ASSY 8 ‘SCREW. M8-1 25 x 60mm 20 (CHOKE SOLENOID 2 LOCKWASHER- 5/16" a CHOKE BRACKET 10 ‘CARBURETOR AIR BOX GASKET 32 LOCKWASHER-No, 4 1" SSTUD-M6-1.00 x 114mm 33 FLATWASHER: No, 4 2 INTAKE MANIFOLD GASKET KIT 34 ELBOW. 1/8" 18" NPT 8 FUELFILTER 35 ‘TEMPERATURE SWITCH 14 ‘CARBURETOR Assy 38 DASHPOT 15 CARB.ADAPTERGASKET 37 DASH POT BRACKET 16 CARBURETOR ADAPTER 38. DASH POT CAM. ia ‘SOCKET HEAD SCREW. 1/4°20. 39 LOCKWASHER- No, 10 8 INT. MAN. ADAPOTER GASKET 49 FLATWASHER- M5 18 NUT-MB-1.25 a2 WASHER. M6 2 INTAKE MANIFOLD “a NUT M6-1.00| at ‘SCREW. MB-1 25 x 40mm “4 PAN HEAD SCREW- No. 10:32 2 LOCKWASHER: MSSECTION 4.2 - FUEL PUMP 4.2.1- General A. The tue! pump is energized on by ENGINE CON- {TROL cir board action during ranking, startup and operon, via Wire #14. Wo 814 Is elocoaly hot only {bring cranking and operation. Circuit board and Wire ‘#14 action also energizes (a) a fuel ook solenoid, (©) ' choke heater (c) an optional hourmeter, (a) igalton al and (e) an optional remote panel generator un amp {is0-equppes) 4.2.2. Testing and Maintenance B Anohmmeter may be usedt9 test continty of pump ‘windings. To pororm operational tes, disconnect out Sideline om purnp and eonnectinlt side to a fuel Supp iy. Separate pump wre luge and connect a.+12 volis ower source (euch at a batty) to the pump WHITE {nre, negative (+) d'0 POWER source to the BLACK (grouna) wire. Pump should operate and pump fuel. 1 otoctve, replace pump.CARBURETOR ASSEMBLY LamsSECTION 4.3 4.3.1- Disassembly Remove carburetor alr intake components (Page 2) as ‘nocestary fo gan access fo carbuTelor. Disconnect car boretorgoveror ink, Disconnect uel tne. Remove car butelor, carburetor adapter and gaskets Thon, dias: Semble carburetor as folows a. Remove two SCREWS and LOCKWASHERS, then femove INLET PLATE and GASKET , Remove two SCREWS and WASHERS and remove ‘ulomaie CHOKE. «, Remove four SCREWS and WASHERS, then remove FLOAT BOWL COVER along with GASKET, FLOAT, FLOAT SHAFT, FLOAT SPRING, FUEL VALVE and SEAT. 4 Remove FLOAT SHAFT, SPRING, FUEL VALVE and Fioar. 2, Remove GASKET. {, Remove SEAT ASSEMBLY. 19. Remove twa SCREWS, then remove CHOKE PLATE. hh, Remove two SCREWS, then remove THROTTLE PLATE. {, i necessary for replacement, remove SOLENOID VALVE end SEA j. Romove IDLE ADJUSTING NEEDLE and SPRING, Clean all parts in clean gasoline 4.3.2- Reassembly FRascemblo all parte inthe rovereeondor of deasserb- ly, During the rasseomly prooass Install new pat rom Kit and pay dose alnton tothe folowing * Open thot pate light fr late spece. + Sotidia adjust eccow 24 tam open. A. wits oat Bont Cover inverted and body gasket in Stalled, sot lat level 0.125 inch (2.1 75mm) ror body gasket CARBURETOR BB Tighten air intake mountingscrows in the correct so ‘quence, as shown. [es * Check that throttle chat rotates freely. * Tighten solenoid valve to 70 ht pounds. C insert short ag of choke spring in smait hole in lever, 8 shown, D_wind choke spsing 1-12 tums courterlocwiee {Cow and anchor on eaning sew ose4.3.3- Installation Install GASKET, ADAPTER, GASKET and CAR- BURETOR. Retain with flat socket head machine screws | E Loosen choke brackel adjusting screws and adjust (420) choke patio shat wth solenoid plledin, choke plate ISelosea. Tignten choke bracket acjusting screws. Then, ‘with solenoid extended, bend tip of mets un choke 4.3.4- Adjustment Plate about 1/8 Inch trom Vert and towards the Roles to Section 1.5 (ADJUSTMENTS). To adjust | 92864 poston ‘lama choke, prooaed as flows Cc iD 5hSECTION 4.4 4,4.1- General Description A__The mechanical, contrfugal type engine governor Utizesepring tnslon versus centtugal freeto maintain 8 steady silo engine speed regards of load. When Contigal ywoight lorce exceeds governor spring te. Sion, firweight action againel a yoko rotates rocker Shaft io decrease corburetor tate sting and reduce fengine speed. Should engine speed decrease below a pectic geting, governor spring teneion sil become the honor toroo, Carburetor fotte eating wi then ba I= ‘roased to Increase angina speed. Governor action vl ‘ease when fiyweight foro and spring tension are equal ‘and cancel each otha. f\ INC ou nna \ = Res “The governor tyweights are diven by an engine drive bat The governor also supports and divos a do ator halor essembly, which deivers charging curent oe {generator battery duing engine operation. See Par 7, ENGINE ELECTRICAL SYSTEM. 4.4.2- Governor Maintenance Maintenance and repair ofthe engine governor linited {o a} removal and replacement of he de lero as- ‘emby, (0) famoval and replacement of governor lever, Spring an tins, (6) removal and roplacement of gover” nor fo carburetatinkage, and (d)agustment of governed speed. 4.4.3- Removal of d-c Alternator Assembly See EXPLODED VIEW OF ENGINE GOVERNOR, Flomove HEX JAM NUT (hom 43), WAVE WASHER ENGINE GOVERNOR ASSEMBLY {tem 48), and PULLEY HALE (tem 44). Then, remove {alterator ROTOR (item 44) Femove SOCKET HEAD 'SCREWS (Hem35) and LOGKWASHERS (tlem 22}, ten emave STATOR (tom 47), Inotal the d- alrnator assomby inthe reverse ordor of omovalTightan aockst head screws thal rtain the ‘tort § foot pounes (7 Nem). Tghon the hex am nut {tem 43) 1 95 foot pounds (47 Nem) 4.4.4 Oil Servicing B Remove OL FILLER PLUG and OlL LEVEL CHECK PLUG. Aad engine of trough FLLER PLUG untill just Stars to ovorlow CHECK PLUG opening. Pour slow). Wino oi tovel i correct, instal OIL FILLER and OC LEVEL CHECK PLUGS {Sef 4.4.5- Governor Lever, Links and Spring C the GOVERNOR LEVER (tem 52) is retained tothe GOVERNOR SHAFT (Hom 25)9y A ROLL PIN (Rem 17). ‘men instaling governor lever to carburetor nkage, sot lang of inka 43/ inches (measured between ballot ccenterinas) I o 14 dinesEXPLODED VIEW OF GOVERNOR ASSEMBLY REFNO. DESCRIPTION REFNO. _DESCRPTION 2 rine 3 LOcKWaSHER. Ms, 5 OVERNOR FLANGE 31 TENSION BRACKET ‘ DRIVE SHAFT ASSY 32 TENSION BRACKET BUSHING 5 BALL BEARING 33 HEXSCREW-MeH.00 é on seal, 36 SEALING WASHER 7 BALL BEARING 35 SOCKET HEAD SCREW: M-c70 8 TRUSSHEAD SCREW 96. —CHEXSCREW- 6-100, 8 EXT RETANINGRING = 3 NUT Me-.00 to FLYWeIGHT 38 BUMPERSCnEW " DOWELPR 33 COMPRESSION SPRING 2 EXTAETANNGAING — 40 PIPE PLUG We NPT 8 ‘unust SLEEVE ‘1 SPACER’ “ NEEDLEBEARING 2 PULLEYHALE 15 “THRUST WASHER 4 HEXJAMNUT 6 THRUST WASHER 4% BeALTeRNATOR v ROLLIN 4 CABLE CLAMP ® EXT. AETANINGRING 4 PANHEAD SCREW. 64.070 18 INNERAINGBUSHING —47,—=‘D.C STATOR ASS 2 BEARINGDRAW CUP 42 WAVE WASHER a NEXSCREW.MG070 49,«——_TENSIONSPRING 2 LOCRWASHER Ma 0 Hexnuteneton 2 yore St SRE m6-1.00. 2 ROCKER SHAFT 2 GOVERNORLEVER 2 OL SEAL 53 GOVERNOAICARB. LINK z BALL BEARING St BALLJONT 2 EXTAETAINNGRING 55 FLANGED LOCKNUT- No. 1032Section 5.1 - Ignition System General 5.1.1-Components 5.12: Operation 5.1.8- Service Data and Specifications Section 5.2- Tests, Checks and Adjust- ments 5.2.1 Ignition Coll Resistance 5.2.2- Checking the Condensor 5.23: Inspect Distributor Cap and Rotor Head 45.24. Contact Pointe 152.5. Check Governor Advance 9.26. Checking and Replacing Spark Plugs | 5.27. Checking ignition Wires 5.28- Ignition TimingSECTION 5.1 - IGNITION SYSTEM GENERAL Components he ignton systom consists of (a) an ignition col. (8) a | dstrior. (6) sparkplug wiros, (2) spark plugs, and (0) 5.1.2- Operation Fused bottery voltage Is avaliable to Terminal tof an ENGINE CONTROL circu board, via Wire #13, a 10, lamp circuit breaker, Wire #154, a 20 amp fuse, and Wire #15. During engine cranking and operation, ENGINE CONTROL circuit board action delivers that battery voltage (112 volls de) tothe ignition col, la Wire #18 and a resistor wire. The V12volts dc current Hows though the ignition col primary winding an to the distributor contact points. During contact points lapses to Induce a high voltage into the ignition coll, secondary coll which is distributed to the correct spark plug by distributor rotor action 5.1.3- Service Data and Specifications | Firing order... nes £882 | Distributor Rotation Counterciockwise Point Gap. (0.018-0.022 inch Cap insulation Resistance...” More than 80 meg-onms otor Head Insulation Resistance so. More than 50 megonms (Cap Carbon Point Length More than 0.012 {neh (3mm) protruded tengih Ignition Goll Resistance | Primary Col eons 134.5 0S ‘Secondary Cail SN TLT ohms: Spark Pugs Nok. ne BPRGES Champion. NOYE, ae" R2XLS Spark Piug Gap. Condenor Capacity '0.034-0.035inch 0.2:0.24micro-orads IGNITION SYSTEM WIRING DIAGRAM pistRieuTOR ENGRE CONT! okculr Cewe. DoF DC VOLT TGNITION con,DISTRIBUTOR COMPONENTS eTSECTION 5.2 - TESTS, CHI 5.2.1- Ignition Coll Resistance A. connectteatprobest an ohmmeter across the pos tive andnegative primary windng terminals of tergniion ‘col and measure ine sistance Primary Winding Resistance at68°F.(20°C.)- 1.34.5, ohms Ing terminal and to prmavy winding negative (-) torminal, ‘and maaaure the resistance Secondary Winding Resistance at 68°F. (20° C= 8700-11,700 hme B B Connect ohmmeter test probes to secondary wind | |ECKS AND ADJUSTMENTS 5.2.2 Checking the Condensor Use acapactytesterte chock he condenser. acapacty testers hot avalabe, the condensor may also be tested ‘sing a vol-ahenliammeter wh Hs range soto high Fesistance reading, When ihe tester noodlo swings ‘olny and then raves back olin gradually, the Condensor ls good. I Testor needle indicates a stoady reading or # reads zero, the condensor should be repiaced. 5,2.3- Inspect Distributor Cap and Rotor Head Inspect cap and rotor head for dst, carbon doposits and case. 5.2.4- Contact Points C inspect surtaces of contact points. inegulartties may tbe removed with No. 500 0° 600 sanpaper oF with Gistone, Logson breaker pont set scrow and adjust gap wna feser gauge. Points Gap:- 0,016-0,022 Inch (0.45.0.55mm) 5.2.5- Check Governor Advance D Tumnrotor shatt counterclockwise, then release itand | enecktnatit tums tothe clockwise decton. Also check {hat he rotor shaft isnot excessively lose.[DO 5.2.6- Checking and Replacing Spark Plugs E Disconnect sparkplug wies at toot. Do not pull on thewires, G _Ciean spark plugs in a sand blest cleaner. Inspact Iouiators fr cracks, chipping, Inspec gasket for damage ‘oF deterioration. inspect elecrode fo wear, buring, pit ting. Roplace plug if dalocive. Check sparkplug gap. G \ Install spark plugs and tighon to 14-22 foot pounds torque (20-28 Nim). Reconnect sparkplug wires. 5.2.7- Checking Ignition Wires check high tension wires for damage, cracks, burned terminals, proper. Measure resistance of each ‘iro. Shake wires during the resistance test. Fesistanoa ‘shouldbe less than 30,000 of. H E 5.2.8- Ignition Timing J _Use an automotive ting light to check and adjust timing. timing mark's provided on be erarksht pul ley anda degre nears ls proved. Sel tring as folows= Ignition Timing at 1860 rpm and at No-Load: 21° Broc’“ignition Timing Adjustment‘Section 6.1 - Engine Exhaust System 6.1.1-Eshaust System installation 6:1 2- Typical Exhaust Systom Intalations 8.1.2. Tho Siphon Break 6.1.4- Operating an Uninstaled Engine ENGINE EXHAUS SYSTEMSECTION 6.1 - ENGINE EXHAUST SYSTEM. DANGER Exhaust gases contain DEADLY carbon monoxide (905, an odorless and colorless gas formed during the Combustion of hystocarbon fuels. D0 NOT operate the marine generator engine the exhaust system is leaking or as been damaged. Carbon monoxide gas can cause unconsciousness or even death. ‘Symptoms of carbon monoxide poteoning are) I. ‘pity (o tink coherently, o) voriting, () twitching ‘muscles, (2) throbbing in temples, (0) dizziness, () headache, (g) weakness or sleopinoss. Hany ofthese symptoms are exporionced, move into fresh ait im- mediately. symptoms persist, get medical ate tlon. Never operate the marine generator engine un. leas exhaust gasos are piped safely away and to an area not innabites by people 6.1.1- Exhaust System Installation * vinen the marine generators install in a vessel. the ‘exhaust system must comply fully with US, Coast Guard (USC), National Fire Protection Association (NFPA, lana Amertoan Boat and Yacht Councl (ABYC) requie- ‘oni. you ae servicing ar repaing an installed ge ‘rater set, never do anything that might fond to place the Instaiaton te non-compliance with such requrements * tn an installed systom, soa water must not be able to ‘ontarthe engine exhaust manifold and oyinders whe the ‘esse is undarvay, heollng, backing down, oF ay other Underway conaivons potely FREE OF LEAKS. " * Exhaust piping and hoses must be of adequats sizo (dlameter to proven! excessive backpressure on Ho tga. The number of exhaust fitings and elbows must bo Kept ta minimum, sine they wil tend to ceale back pressure * Exhaust piping betwoen the engine exhaust out ft- ting and the exhaust muflor must Be a fact as large as ‘he exhaust oul iting, Fo every 10 running fet of ex tnaust pipe, an increase In dlamater of one standard pipe size ls racommanded, * thexhaust piping rune ina vessel aro excossively fg, back pressure shouldbe checked. Back prsure should not exceed 1.2 inees af mercury (Hg) (30m oF 4 KPa) * Never combine the generators exhaust system withthe foxhaust rom another engine * tnatal an appxoved, tobe length of exhaust pipe be twean tha generator ang any rig exhaust piping. This will permit engine vibration and movement without Dreakage, + emnaustoutots in any vessel should be placed aft of sink, shower, and oer gabin dans, o prevent backiow fof exnaust gases though such epenings. * When nstaling or replacing exhaust systemnoses, use piping and noses recommended by the ABYC: (Safety ‘Slandaras tor Smal Cra. 6.1.2 Typical Exhaust System Installations ‘wo typoaloxtaust system insaaions are showin the tnustaions on next page. A. Exhaust Outlot Fiting an Engine is Above the Water tine’ BB exnaust Out Fting on Engine is Below he Water ne’ 6.1.3- The Siphon Break CC whon aninsttied gnerator’s exhaust outit ting f= below ha vasse's water ne, a siphon break valve ‘Shoulde Installed. The valve fsa vam operates. ant Siphon vahe tat opens the exaust Ine 1 atmesphoro ‘nhen the engine fe shut Gown. The valve prevents Sea ‘Wate rom being siphoned into he engine, c > 6.1.4- Operating an Uninstalled Engine \Whon operating an uninstalled engine, connectasuitabio txhaust hose or piping fo the engine exhaust out Route tha hoes or piping fo a eae area, whore exhaust ‘gates cannot accumulate ang endanger people‘Ay Typical installation with Exhaust Outlet Above the Water Line “Typical installation with Exhaust Outlet Below the Watar LineSection 7.1- Battery Charging System 7.4.1- Components TA. The dc Akernator 7.4.3: Voltage Re yator Section 7.2 - Engine Cranking System 72.4- Operation 7.2.2. Starter Motor Servicing Instrvetions 72.3. State Performance Test Section 7.3 - Engine Control Circuit 73.1- Engine Control Grout Board 7.3.2 Ckeut Operation Section 7.4 - Engine Electrical System Troubleshooting Guide ENGINE ELECTRICAL} SYSTEMSECTION 7.1 - BATTERY CHARGING SYSTEM 7.1.4- Components A. Ade ALTERNATOR supptos charging vata © ines dogma oporn sepotodty a CNOLIRGE REGULATOR thw cat's poteed by {0am FUSE The reguetes charging caret dnivere ote unt 12 wet baer, ite #134, he fine, Wire #19, the STARTER CONTACTOR termina See and be post 1) baton cabo. 7.4.2 The dec Alternator ‘Tho belt even, permanent magnet ype d-< alternator ic attached fa he angine speed governor (Section & 4). Maintenance on the alfornator I imted fo replacement of detectve pars. Removal of atemater parts from te {governors coveredin Paragraph 4.4.3, 7.1.8: Voltage Regulator ‘Tho solid stato d-c voRage regulators housed in an sumioum neat sink with all components covered wih ‘Spoxy fesin The regulator isnot reparable, Regulator bantcter ping are numbered tom ft tonghtas allows Pin 1- Charging output to battey (12.5-145 volts dc) Pin 2 Charging input rom de alternator Pin 3 Charging input fom dc alternator Fin 4- Not Used (Charge indccting lamp connection) Pin 5 - Sensing veltage rom battery (Wire #15) IMPORTANT: The de alternaior delivers alternating current (a-c) to the vollage regulator. Rectification {conversion oalrectcurrent}is done within the vot ‘90 regulator, A ee 2] [Bevogwer BATTERY vorTAG= ft pects“ Came EOS comets BOGS Ldhesadl] f Cc fuse 13A- : ° 30AMP 48 — A) | De R " peer L499} Jf fastenerSECTION 7.2- ENGINE CRANKING SYSTEM 7.2.4- Operation ‘The battery posive (+) cable is connected to one of tho large torn studs onthe staner contactor, During én gine startup, the sianor contacior (SC) 1s energized by ENGINE CONTROL creuitboard action, Le. 12 vols is applied tothe stator contactor va Wire #56. Batery Sulpulis ten devered tote startr assembly an othe ulomatic coke cvoul via Wire #16, The engine cranks, ‘Wen the StartStop switchs released by the operator, ENGINE CONTROL crcul board action opens the Wire 456 clu 10 the starter contactor and cranking te nats ENGINE CRANKING SYSTEM ‘56: STARTER CONTACTOR 78 S10 ENGINE CONT, CKT BOARD 3 123456 rl ok 7 1 laa T STARTISTOP Switch 15 ZL 20 AMP the FUSE iRCUIT [BREAKER BAT-ERYSTARTER ASSEMBLY EXPLODED VIEW \ | “ \ \ ope Kir poe] ks i a ; tt SAVER ION ~_ Seeecr) =. = Arn \a BRUSH & SPRING KIT , it PARTSIN z COMMUTATOR CAP THRU BOLTS: v ‘COMMUTATOR, ‘CAP, ARMATURE ASSEMBLY7.2.2- Starter Motor Servicing Instructions Rated Voltage:- Starter motor i raled 12 vols -¢. The ‘rotage applied tote starter motor should never exceed the rated votage, or magnets Inthe motor may become ‘demagnetized Inspection: Check for adverse wear on all bealogs (oars, shafts, ete. Check spring washer fr woar, convex Bice next to Bearing. Add a drop of lo ace of bearing Thru-Bolts:-Tightonthu-bolts to 78 inc-pounds. Drive Cap:- Apply afm of SAE #10 oll tothe bearings Inthedtive cap Duringroassembly. he ineulating washer must be placed against tho crive cap. Brush Assembiy:- Brushes andbrush springs shouldbe ‘replaced at each overhaul. Any rush thats wom i 5/16 ineh (or ass), measured on the short sido of the brush, ‘oF that has been in contact with grease, olor cleaning Tuid most be replaced. Assemble brushes wth thot ‘chamfored sie away from the springs. Torque the Brush ‘Sere to 30-95 Ine pounds. Tigton the het std ut fo 45 50inety pounds, Armature:- Check the armature fora ground, open ot ‘hut, wii a grower. Hold armature in avise when sta ing removing te dvs ase Aply an ir ot ‘Guicksver non-conducting grease to the commutator ‘nd ofthe armature shaft and tothe portions ofthe shalt ‘hat contact the bearings 7.2.3- Starter Performance Test CAUTION Do not operate the starter motor continuously for longer than 30 seconds when testing Uso atu charged, 12,vots battery comected as follow: 1. Postive +) tamil to the starter motor Input stud 2. Negative (terminal tothe starter motor housing Use a No. 10 cable (r lagen), not over 6 fest in length Maximum current draw and starter speed should be as {allows 17 amps at 6000-7200 rpmSECTION 7.3.1- Engine Control Circuit Board A. Asolid state circuit board controls all engine staring, running and stoping lnetons. The board recives as ‘als ¢-¢ input for con! of those funcions (Wire #15). Circuit board terminals and connecting wires are sted the CHART on tis page, NOTE: A complete WIRING DIAGRAM may be found fon Page 19 of Part f ENGINE CONTROL CIRCUIT 7.9.2- Clreult Operation B Engine Shut Down: Battery vattage s avatlable to Terminal #1 ofthe Engine Cons cou board, via the postive (4) batery cable, Wire #13, a 10.amp Circ Breaker, Wir #154, a 20 amp Fuse, and Wie #15. In shutdown condion, "eeu board action holds te crcut ‘open (simiar oan automotive igniten seth) tsimpor- {ant to note that, without battery voltage at circuit beard Terminal, cranking and strap cannek occur. A CMOMmods) 7 89100 12 ENGINE CONT. CKT. BOARD 123456 PSS sone] Senees | ENGINE CONTROL CIRCUIT BOARD TERMINAL IDENTIFICATION feRMNal Wine [DESCRIPTION OR FUNCTION 1 15 Fused battery voliage (+12 vols <) 2 o Common Ground 3 7 Engine crank & start (Ground! to crank engine) 4 2% Engine stop (Ground to shut dawn engine) Bas m2 Generator 120 volts a-2 (frequency) sensing for automatic overspeed shutdown 7 ey 12 volts eto starter contactor (crank signal) wen Stan’Stop ‘Suiten at START only 8 ° Engine ignition grourd- terminates ignition when StartiStop switch Issel to STOP. ° 4 ‘512 Volts che (o carburetor Fuel Solenoid during e-anking and unning only (opens Fue! Solenolg)- Also +12 vols de to automatic ‘Choke Heater during cranking and running only 10 “ “512 volls sto Fue! Bump, Hourmeter and "Gene‘ator Run” ‘amp on optional remote siart panel when running only 1“ “4 +12 voTts dc to engine ignition circuit when eranking and funning only 2 8 Automatic protective shutdown circuit to High Exheust Temperature, {Cow Olt Pressure and righ Cootamt Temperature switehos - ground ‘ite #250 stop engine [NOTE:- Wire #14 Is electrically hot (+12 volts ¢-c) with engine running only© _tntiat cranking Seting the Engine Stanstop vith fon gaertor Pana oon reso Pane) StARt poston connect he We 817 ort tare ground faire 20, Engine Cl Boat actor sen Givers ss age 1 seal terminal of he Staror Contato via Wrens, The Sater Contactor energies to ater batey vaio tote Sher and fhe aie Cranes On dose oe Stonar Contactor ora ouput s aio deters o'a Cote Module (CM). vn Ws #16 and 190. The Choke Mode houses a St State cult wien operand cases he We #0 oat taro copordenton antlenierperre, te Cots Sclooid (68) then opora and nose the carvrtor ‘chokes cytes (bout every 2105 Secon) IMPORTANT: The Choke Module (CM) algo houses 2 Field Boost Diode ana Resistor wll deliver areduces battery vollage to the generator olor windings during cranking only. See Section 1.1 startup ane punning: with engine cranking, En dine Col crcut board Scion wi datver sd okage {Blak ures #14 The carrer Fool Soon (5) val Spe Fuel mp ©) pert: gon ocr ‘engine wt tow sa, Won he Stavtop swt ‘aoaul cian board acon wll open fs era ore £50. Tho Strer Contactor) when de aneraee ans ring wt mint. n on, some nee ane i bot aparatons wl cbse IMPORTANT: On some instaations, Wire #14 dec ‘output may also turn on an optional Hourmeter anda remote panel mounted "Generator Run” lamp. E Normal Shutdown: Setting the Stat/Stop switch to ‘STOP results connection of Wie #18 to framo ground Circuit board action then opens al Wie FI chews 1 torminat anton fuel pump operation, ste. Engine shut ‘own wil thon occur F engine Fat shutdown: Wr 45 rom the Engine Son exe board connocs (aa Low OV ressre Sc, ).a High Water Temperature St, an (6) Eiht Tampere Ses Those engi sey Rees have neal open contact eich se on ‘Stzuroos of the aphid engine fut Gn contacts ‘Soere Wore 405 wh connect ota ground sn an Stone eng shaonn wl Sonar IMPORTANT: Generator ac frequency (speed) sia- nals are delivered (othe clcult oar via Wires #11 ‘and #22. Should a-c frequency exceed approximate ly 70 Hz (60 He units) oF 60 He (30 Hz units), an ‘automatic overspeed shutdown will occur. =. ‘one ENGRE CONTROL incur Bans 123456 posSECTION 7.4 - TROUBLESHOOTING GUIDE 7.4.1- General “The folowing quid s provided to assist the technician in locating ana erecting causes ofaprobimin the engine ‘ecricl eystom. Folew the procedure carey areper formeacnstepin te exact order given is assumed nat the troubleshooting technician nasa working knowledge of e-c electrical crete and now fo est Pom, 7.4.2-If the Engine Won't Crank 1 tho engine won't crank whan the StariStap switch is heldat START, proceedas follows ntho.exactorder each tests given A. Check the 10 amp Circut Breaker:-Try resetting the ‘pushto-raeet ype oak. breaker Is reset and ar {do sill won't crank, fst check for +12 volts dat the Erosker'a Wire 12 erminal, Then, check fr &c vos at the breakers Wie 154 termina RESULTS: 1, Voltage present at Wire 13 terminal, but not at Wire {5A formal of breaker... Replace Cicul Broaker 2, Valiage is present at both terminal... Goto Stop B 28, Novattage at ether terminal Goto step c B. Check the 20 Amp Fuse:- Remove fuse, inspoct ‘nd tet with an ohmmater fuse elmant has mated ‘pen, repiace wn aniaennical 20 amp ruse RESULTS: 1. Engine cranks normally. ‘Tests complote 2. Engine sil doosntt crank Goto Step ¢ . Check Battery and Battery Cables:-Use an autome- tive ypebatory hydrometertotestbatey sttectcharge and Condon. Follow the hyrometer manufacturers i Suction caretly. spect gravy roading is ess than 41.230, recharge the battery. afer recharging bar, the aiference in specie gray reading between the lowest and highest oot great than 0.050 (50 poms), tha battary shouldbe roplaced ‘Check all battry cables for ighiness and corasion (Gisan or tighten ae race 0. Check StartStop Switch: Disconnect Wie 17 tm tho San/Stop swleh. Hold the terminal end ofthat wo Into fm contact wih @ clean frame ground. The engine should eran. RESULTS: 1. Engine Cranks normaly wah Wie 17 grounded, but notin Stat/Stop Swit... Feplace Star’Siop Switch 2. Engine dows not ark Goto step E Check Engine Control Circuit Board Power Supp- ly Use a cee votimetey fo tos! volage at Pin #1 of keut board (Wire #15. conrection}. Battery vollage ‘Should be present at his pln RESULTS: 1. Vollage checks 990d. Goto Sepa 2. Noveltage indication Goto Step F F. Check Circult Board Power Circuit: Check the ci: ‘ult which inludestire 18 tha 20 amp Fuse, Wire 154 SOlamp Creut Breaker, and Weo 13 back To the Starter Contactor connection. Any open condo inthis ecu wll resut In loss oe power othe circu board RESULTS: 1. Grout is open, Fepair or replace detective vig oF components) 2. Chou checks Good. Goto Step G. Check Crank Signal trom Circult Board:- Hold the Star’Stop switch at START nila checking for +d-c vale lage al Engine Cont! cut beard Pin #7 (We 56 con ‘etion) edo vokage was avatableatPin 3 (Stop €) bul ISnotavalabie at Pin 7 inthis et. the Engine Conte ‘cll board has probably falled RESULTS: 1. 46 voltage I naloated. Goto Stop H 2. No voltage Indicated, but good voliags in Stop E was ‘ead place Engine Contrel circuit board H. Check Wire 56:- Hold the Star/Stop switch at START ‘wile shocking for +d-0 vos st the Wire 56 terminal of the Starter Contactor large tenina sic), RESULTS: 1. No votage indicated. 2. Voliage checks good. Fepaicropiace Wire 56 Goto siep JJ. Check Starter Contactor:- Chock for battoryvatage al he Wire 13 terminal arge stud) of the Starter Contac tor. This isthe battery sido of te Contactor. Then, nals the StarvStop amten at START while checkingtor batlery votage at tho Wiro 18 terminal stud (arge std). RESULTS: 1. No battery votts at Wire 13 terminal tery and batory cable (Step C) 2 Voltage incloale at Wie 13 stud, but not at Wire 16 ‘stud with svtch actuated... Replace Starter Con- ‘actor 3, Voltage good at both terminal studs Recheck bat- Goto Step K K. check ing Cir tarter:- Refer te Section 7.2 (Engine Crank 7.4.3- Engine Cranks But Won't Start the engine cranks but won't sta, procaed as follows: A. Check Fue Supply: On some instalation, the gen- ‘orator fuel pickup tube may be shorter than the propul Sion engine pickup tube. Thus, he gonerator wil "tun out of gas" wile adequate foal romaine inthe tare for the propulsion engine. hack fuel supply tothe gonerator on ‘ne fuel tter, any hota valves, ote 'B. Check Fuel Pump: Disconnect ful pump outlet in, rank engine and check fuel ow fom pump, Ago $09 Secon 42 ©. Check Fuet Solengd.-Resnowe Sunenutronrongies Carburetor Hold the Solenoid housing eto fm Sonat ‘witha clean frame ground and set the StaStop such AOSTART. The Sotonokd Valve ip should pullin. Hit does ot operate, replace the Solenold. the Solenoid works, ‘stall and tighten before proceeding . Check Automatle Choke Operation:- Wale cranking the Choke Solenoid should pull in about every 2 t0 5 ‘seconds, See Section 4.3. E. Check ignition Power Supply:- Locate the Wire 14 terminal atthe ignition Call. Check ioe a vee voliage at that terminal whi cranking engine. ttre vellage In ‘ated, check Wire 14 between igelion Col and cut Bard for open sondion. Repair or replace wie. a8 ecdled. F. Check Engine Ignition System: Reler to Part § of, Manual . Check Engine Control Circult Berd: While crank: Ing engine, chock for +d-c voltage at Fine 8,10 an 11 of ‘he oreutboad. no voltages incicaled, eplace te ci- ‘ut boar, H. Check Engine Compression: Se2 Part 2of Manual 7.4.4- Engine Starts Hard, Runs Rough H engine stars hard and runs rough, refer to the ap- propriate pars of this manual and check the flowing 1. Chock ar intake eystem 2. Check automatic choke operation 8. Cheok carburetor adjustments 4, Check engine govern adjustment 5. Check engine ignition system 6. Check engine 7.4.5- Engine Starts But Shuts Down When Start/Stop Switch is Released W engine cranks and starts, but shuts down as S000 a8 the Start shat is released, the problem is probably In fone ofthe engine protective devices. chock engine level, chock ongine of pressure. Then checkthe Low OM ressure, High Coolam Temperature, and High Eshaust ‘Temmperaire sutches for proper operation, Rater te applicable sections fr tet procedures‘Marine Generator Specifications Model 25-4.06. Model 06-856. Model as-8.06. Genocal Engine Spesiaiiane Engine Service Data Valve Timing. Compression Pressure (Gylnder Hoad Flas, Vaivo Data Valve Soring, Valve Guise Valo Seat, Camenat and Camshalt Bearing Gpinder Block Picton Piston ings Piston Pin ‘Crankshati Bearing Clearance: ‘Avaiable Main Beings Main Bearing Undorsie. Connecting Rod Bearing Undorsize Flyweight Runout Engine Lubrication Sysiam Tightaning Torques of Standard Met Bole Tightening Torque of Standard Non Mate Botts Tightening Terques for Engine Bal. Page | 4 12MARINE GENERATOR SPECIFICATIONS Model QS-4.06 (At 120/240 Volts, 60 Hz) “Type of Equipment Revolving Fioiéa.¢ Generator Fated Maximum Continuous a © Power Out 4000 watts (4.0 KW) Rated vols 120 andlor 240 volts -¢ Rated Maximum Continuous Load Curran ‘A 120vols 2, 33.3 ac amperes A240 vote a6, 16.7 acampores Rated ac Frequency {50 Hz at 1860 rpm Phase ‘Single Phase Power Factor. 10 "Number of Revolving Field (Rotor) Poles. 4 Diiven Spaed of Revolving ila 1960 rpm atNo-Loac* ‘Stator Exctation Winding Resistance (plus or minus 10%) 1.65 ohms ‘Stator arc Power Windings Resistance (plus or minus 10%) Wires 1110 22. 10.43 ohms Wires 23 10 44 10.49 ohms Rotor Winding Resistance (pus © minus 10%). 86 ohms * Rated votage and frequency are obtained at 1800 rpm. The sightyhighor “no-load” rpm setting helps prevent excessive rpm, voltage and frequency droop under heavy elecical loading Model QS-4.0G (At 110/220 Volts, 50 Hz) “Type of Equipment Fevalving Field a-¢ Generator Rated Maximum Continuous ac Power Output 3300 watts (3.3 kW) Rated Vote. 110 andlor 220 vols a-0 Rated Maximum Continuous Load Curent ALTO vols a 20a-c amperes ‘A120 ols @e 1Sa-camperos Fated ac Frequency. “50 He at 1820 rpm Phase: “Single Phase Power Factor 10 Number of Revolving Feld Poles... a} Driven Speed of Revolving Field 1550 rpm atNo-Loac” Stator Exetaion Winding Resistance (Plus of minus 10%) 1.65 0hme ‘Stator Power Windlngs Resistance (plus or minus 1034) ‘Wires 11 22 10.49 ohme Wires 33 to 48 vont 8 08 Rotor Winding Resistance (plus or minus 10%), 85 ohms * Rated votago and traquency are obtained at 1500 rpm. The slightly bigher no-load" speed helps prevent excessive rpm, vllage anc frequency droop under heavy electcal ladingMARINE GENERATOR SPECIFICATIONS (Continued Model QS-6.5G (At 120/240 Volts, 60 Hz) “Type of Equipment Revolving Field 2-3 Generator Rated Maximum Continuous a-¢ Power Output 5500 watts (6.5 KW) Fated Vots 120 andlor 240 vols Fated Maximum Continuous Load Current ‘AL 120 volts. 542 acampores ‘A240 vols. (27.4 acampares Rated ac Frequency {50 Hz at 1800 rp Phase: Single Phase Power Facer. 10 Number of Revolving Feld Polos 4 Driven Speed of Revolving ita. 4860 rpm at No-Load ‘Stator Excitation Winding Resistance (Pius of minus 10%) 1.300hms Stator ac Power Windings Resistance (Plus or minus 10%) ‘Across Leads 11 and 22 0.28 ohms Across Leads 33 and 44 (0.26 ohms Rotor Winding Resistance (Plus or minus 10%) 74oNms * Rated ac voltage and requency are obtained at 1800 rpm. Taye slighty high "no toad” setting hops provont excassive rpm, frequency an voltage dracp under heavy elecca leading Model @5-6.5G (At 110/220 Volts, 50 Hz) “Type of Equipment Revolving Field a2 Generator Rated Maximum Continuous a-¢ Power Outpt 5200 watts (5.2 kw) Fated Vols 190 andlor 220 vats 0 Rated Maximum Gontinuous Load Current ‘AL 110 volt, 47.3 a-camperes ‘At 220 volts. 23.8. a-c amperes Rated ac Frequency SSO eat 1500 7pm Phase ‘Single Phase Power Factor 10 [Number of evolving Field Poles. ' 4 Driven Speed of Revolving Feld 1550 rpm at no-losd Stator Exoation Windinge Resistance (plus or minus 10%)... 1.300hms Stator a-c Power Windings Resistance (Plus or minus 10%) ‘Acroes Leads 11 and 22 0.28 ohms ‘Acroes Loads 39 and 44 0.26 ohms Rotor Winding Resistance (Pius or minus 10%). 7.4 ohms + Rated ac voltage and frequency are obtained at 1500 rpm. The sight high “no-load” setting helps prevent excessive rim, frequency and voltage dreap uder heavy electrical leadingMARINE GENERATOR SPECIFICATIONS (Continued) Model Q5-8.06 (At 120/240 Volts, 60 Hz) “Type of Equipment Revolving Fst a-c Generator Rated Maximum Continuous ae Power Output 3000 watts (3.0 KW) Fated Vots, 120 andlor 240 vots a6 Rated Maximum Continuous Load Currant ‘A120 volt se 86.7 ac amperes 'A1240 vols. ‘38.3 8c amperes Phase: ‘Single Phase Power Factor. 19 Number of Revolving Field Poles 4 Driven Spoed of Revolving Fil. 1850 rpm atNo-Load” Stator Exctation Winding Resistance (plus or minus 10%) (0.88 ohm Stator ae Power Winging Resistance (lus o minus 10%) ‘Across Leads 14 and 22 9.16 ohm ‘Across Leads 33 and ad, 1.16 ohm Rotor Winding Resiatance (plus or minus 10%). 7.4 ohm + Rated voltage and requency are obtained at 1800 rpm. The sighty high “no-load” speed setting helps prevent excessive rpm, frequency and voltage droop under heavy soctialloadng ‘Mode! Q5-8.06 (at 110/220 Volts, 50 Hz) “Type of Equipment Revolving Fs a-c Generator Rated Maximum Continuous ac Power Output (5400 watts (5:4 KN) Rated Vols {10 andlor 220 vots 2-6 Fated Maximum Continuous Load Current ‘ALTO volts 58.2.acampores ‘81220 vot [29.1 acamperes nase “single Pnase Power Factor. 40 Number of Revolving Field Polos. 4 Driven Speed of Revolving Fil 1550 rpm atNo-Load" Stator Exctation Winding Resistance (plus oF MUS 1036) ras 0.88 Oh Stator arc Power Wingings Resistance (plus or minus 19%) ‘Across Load 11 and 22 2.16 ohm ‘Across Leads 33 and a, 1.16 ohm Foter Winging Resiatance (pus o minus 10%). 7.40hme + Rated votiage and irequency are obtained at 1500 rpm. The sigty high "ntoas speed setting helps prevent excessive pm, Fequency and voltage droop under heavy electrical load,GENERAL ENGINE SPECIFICATIONS Engine Displacement senna sonen6O CU. (88860) No.of Cylinders “4, n-ne Bore ad Stoke 12.68 x 2.68 inches (68 x 68mm) Vale Arrangement. “non Ovethoad Cam Fling Order : 13-42 Compression Ratio, 95t0t “Type ot Engine Speed Governor : Fed Speed, Mechanical Fiyweight Govemed Speed Seting ‘Units Rated 1207280 volts, 60 He. 1860 rpm at No-Lead Unis Rated 110220 wots, 50 Hz 1560 rpm at No-Load Engine Cooling System Type. : : Meat Exchanger Captiva Water Systom Cookant Capacity = conn.BUS. quans Flecommended Coolant 50-50 midure of ew scate ‘etyione glycol base ant-reeze and sot water Ignition System Timing. 21° BTDC at 62 He (No-Load) Distibutor Point Gap... . 0.018-0.022 neh (0.45-0.55m) wal ANGIE se 49°55) ‘Condenser Capacity... a :0.20-0.24 microterad Recommended Spark Plugs ‘Champion LRNOYE AG sonsssnnnnn ne ven RAQXLS Nok "BPRES ‘spark Plug Gap “9.nat-0.995 inch (2.8-0.9m) Lubrication System Oa Prossize. 25.50 pal (1.64. 0kg/em?) Crankease Oil Gapacty (with Fat change). ‘3.0US. quarts (28 liters)ENGINE SERVICE DATA. T Compression Pressure (at 350 rpm) Standard 192 pai (125 kotem*) inion 164 pai (11.5kglom) Ditoronce Umit Between Cylinders 14 0psi (0 kgiom Cylinder Head Flatness, Standard Less than 0.0020 inch (0.05en) mit 0.004 inch (0.1m) Valve Data | atv Hoad Damete"0° ‘Ince exhaust Vat Length ite. Exhaust ‘Valve Stern Diametor "at Intake. Exhaust Valve Seat Angle "a Intake & Exhaust Valve Margin "T* Lit Valve Stem End Suda ringing Limit Valve Clearance (Hot) Intake. Exhaust. Valve Clearance (Cold) Intake Valve Spring Free Height. Prossure Height Assomblod Height ‘Outof Square “S* Valve Guide Standard OD Service init OD Valve Guido 10. (Finished Size) 1.988 nch(94.5mm) 1.18 inch (20mm) 4.2796-4.2854inch (108.55-108.85mn) .2539-4.2857 inch (108.05-108.35mr) 0.2744-0.2750INch (6970-6.9850) 02734-02740 ach (6:945-6.960mm) AS 15'-45'48 (0,020 inh (05m) 0.008 inch (02m) 0.0088 inch (0.2mm) 0.0118 inch (0.200) 0.009 nen (022mm) (9.009 Ih (972m) 1.8986 inh (48.70%) 1.4221. at 1226 tbe (2.5mm st $5.8ka) 1.457 in, at 964 fos (7.0mm at 16.5kg) 0.078 inch (2.0m) (0.4340-0.4344 inch (11.028-11 034mm) (0.4418-0.4423 inch (11.228-11.284mm) sn 2759-0.2766inch (7.008-7.020mm)Valve Guide (Continued) finder Head Valve Guide Hole Diameter SHANE nnn 4818-0.4822 NC (10.960-10.978mm) ‘Service Limit 0.4394-0.4401 inch (11.160-11.178mm) Imterterance Fit ot Valve Guide + 0,0018-0 0029 neh (0045-0074) Valve Stom o Valve Guide Clearance Intake (Standara) 0.0006-0,0018 inch (0.018.0.045m) Exhaust (Standara 0.0018-0.0030 inch (0.0480.075mm) 0.004 it (0. tr) 0.008 inch (02m) Maximum Tolerance Valve Deflection Lit Valve Seat Camshaft and Camshaft Bearing ‘Camshaft Journal te Bearing Ceararce ‘Standard 0.0512-0,0028 neh (003-007) Maximum Tolerance. nn 0059 eh (015mm) ‘Camshatt Bearing 1D. 1.5748-1,5760 Inch (4000-40.03mm) ‘Carnshatt Journal 0. 115728-1.6736 inch (6995.39.97mm) ‘Camshatt Bend (Toa Indicated Reading) ‘Standard {Less than 0.0008 neh (oem) Max, Tolerance .004 inch (0, tern) Camshaft End Play, o.ont20.0122ineh (0.08-0:31me) ‘Gam Height Intake. 1.9295-1:2994 inch (2977-24.02mm) Exhaust 1.3280-1.9978 inch 3878-8898) ‘Wear Lins of Gam Height...0.008 ne (0:2) Cylinder Block Surtace Flatness ‘Standaré. ---Lessthan 0.920 inch (0.05) Lum. 0.0039 inch (010mm)Cylinder Block (Continued) ylnder Breiner Diameter Standard 2677228783inch (68.0068.03nm) Wear Lina sv 9099 ne (010m) Oyler Bore Out ot Round x. Less than 0.0008 ch (002mm) cytindr Bore Taper ABs Legs an 0.0008 neh (0.02n) Diternce in 0 Between Cylinders standard Less than 0.0020 ch (0.05) Wear Lint 10.0078 nen (020mm) Wain Jounal 1 rade No.0 19201-19203 (49.000-49.004nen) (rade No.1 4.92901 8294 en {$9.004-49.008n=n) ade No.2 1.9204-19296!0ch (49,008 49.0121) rade No.3 1.8296-1 8208 inch (99.01249.016m) otf &Ty Y Piston Piston Shirt Diameter "A" Standard. 1» 2.6759-2.6770inch (67.957-67.997mm) “L Dimension £0.25 neh (re) Piston Pin Hole Dlamoter....0.6694-0,6898inch (17.008-17.012mm) Piston Clearance to Cylinder Block. .0.0008-0.0017 inc (0.028-0.043m) Piston Rings ‘Sido Clearance (Standard) Top. -£.0018-0.0029 inch {(0.040-0.073mm) 2nd snnnen, 012-0,0025ingh (0.030.083) Of rene, 0069 i (0.178) ‘Side Clearance Limi (Al)...-0.008 inch (0.2m) Piston Ring Gap (Standard) Top (NO. 1 GE) nnn 0. 0088-0.0118 inch (021-0.30mm) Top (No. 28 3 Grade).....~.0.0071-0.0118 inch (0:18-090mm) 2a. son 0,0058-0.0184 inch (0:18-0:39mm) on Ring (0.0079-0.0811 inch (0200.78) Piston Fling Gap Lint (Al)....0.084 Inch (0.8mm)