Page 4 - Technical data; Specifications
iii Technical data Capacity 280cc / 17.1 cu.in. Bore x stroke 73 mm x 67 mm / 2.87 in x 2.64 in Max. power 4.5 kw / 6 bhp @ 3600 rpm Compression ratio 22 : 1 Dry weight with gearbox 68 kg / 150 lbs Gearbox reduction forward 2.7:1, reverse 1.9:1 Max. installation angle 15 o Specifications Fuel Diesel...
Page 5 - List of Special Tools D7; Description
iv List of Special Tools D7 BMW Part No. Description 74 64 1 333 525 To refit ball hub 74 64 1 333 526 To refit crankshaft gear 74 64 1 333 513 Crankshaft installation tool 74 64 1 333 514 Puller for valve lifter shaft 74 64 1 333 515 Tool for crankshaft removal 74 64 1 333 516 Tool for camshaft nee...
Page 6 - BMW Marine Diesel Engine D7; head
Summary General 1 BMW Marine Diesel Engine D7 Description: Water cooled single cylinder four stroke producing 4.5 kW (DIN) (6 Hp) 1. Cylinder head cover 2. Decompression lever 3. Throttle cable mount 4. Hand crank attachment 5. Cover 6. Sea water pump 7. Fitting 8. Hose clips 9. Sea water hose 10. E...
Page 8 - Removing cylinder head and cylinder; CAUTION; Cover all openings in the fuel system
Cylinder Head Detach Air filter, seawater hose, fuel overflow hose, cylinder head vent hose clip, Disassemble cylinder head cover with gasket, rocker shaft with rockers, pushrods Remove 3 Removing cylinder head and cylinder - Remove air filter (1) - Loosen sea water pipe from exhaust manifold and wa...
Page 9 - Cylinder Head Repair Data
Cylinder Head Detach Rocker shaft with rockers, pushrods Disassemble Remove 4 - Remove rocker shaft with bushing and retainer yoke and remove rockers (8) and (9) - Pull out both pushrods Cylinder Head Repair Data Dimension D7 nominal values Max. allowable wear (mm) Remarks Rocker arms shaft dia. Roc...
Page 13 - Bearing cover
Bearing cover Remove bearing cover Detach 8 Remove starter (13) - Remove attaching clamp of the cable to the stator and remove starter - Remove the four cyclinder screws M 10 and remove the flywheel (15) and (16) Remove gearbox (14) complete with flywheel cover.
Page 15 - Cover to timing gear cover / timing gear cover / hand cranking device
Cover to timing gear cover / timing gear cover / hand cranking device Detach Cover of timing gear cover, hand crank device, dipstick, cover on engine bottom, Remove connecting rod 10 - Remove screws from cover of timing gear cover and take off the cover (18) - Remove hand crank mechanism (19) with e...
Page 16 - Dipstick / cover on engine bottom / connecting rod
Dipstick / cover on engine bottom / connecting rod Detach Dipstick / cover on engine bottom / connecting rod Remove 11 - Turn the engine on to the flywheel side (23) and remove dipstick (24) - Remove cover and O-ring from crankcase on the engine bottom (25). - Unscrew the two connecting rod screws (...
Page 19 - Fuel pump / timing gear cover
Fuel pump / timing gear cover Detach Fuel pump, pump plunger, timing gear cover Remove 14 - Remove fuel pump (29a) - Remove pump plunger (29b) - Unscrew the three M16 hex nuts and remove timing gear cover (29c)
Page 21 - Turn the engine block into the horizontal position.; NOTE; Press off the roller bearing on timing side (33a)
Ball sleeve / Crankshaft Remove Ball sleeve, crankshaft 16 - Remove ball sleeve with sliding disc taking care that no balls fall out (30) Ball hub and spacer washer (31) remain on crankshaft. Detach these parts only when removing the crankshaft. - Turn the engine block into the horizontal position. ...
Page 22 - mm
Crankshaft Remove Crankshaft 17 The outer race of the straight roller bearing on the timing gear side remains in the crankcase and can be removed with the aid of a press In order to remove the bearing rings which have been shrunk on to the crankshaft (35) heat the crankshaft on a heating plate or wi...
Page 24 - Replace valve rockers if worn.
Valve lifters and camshaft Remove Valve lifter shaft, valve lifters, camshaft, roller bearing 19 - Remove the plastic plug from the side of the engine block (37) - Unscrew the M8 set screw (38) with a 4 mm Allen key and remove together with plug CAUTION When removing the camshaft, lift off both rock...
Page 25 - Camshaft Crankshaft; C and mount on the
Camshaft Crankshaft Install Camshaft, Valve lifter shaft, valve lifters Crankshaft, ball sleeve 20 Reassembly of the engine parts is carried out in the reverse order. NOTE The tooth gear on the camshaft is marked with the letter “L”. This indicates the direction of rotation of the engine as viewed f...
Page 30 - Decompression lever adjustment; Turn the decompression lever to Position “1”; Installing the automatic decompression system
Decompression lever adjustment Adjust Automatic decompression 25 If the engine is not decompressed in Position “1” of the decompression lever, adjust the decompression screw as follows: - Crank the engine to the same position as in the valve adjustment - Turn the decompression lever to Position “1” ...
Page 31 - Timing gear adjustment; Correction is required in the following cases:
Timing gear adjustment Adjust Decompression lever 26 Correction is required in the following cases: - If the collar pan constantly engages the cog lightly, in the case of running the engine and zero position of the decompression lever (Shaft moves back and forth) In this case, shorten the tappet som...
Page 32 - Function; Remarks
Injector Remove Injector Check Injection system 27 Injector check CAUTION Check injection valve for: - Function - Injection pressure (ref figure with pintle type nozzle) Be sure to observe a maximum of cleanliness when working on the fuel system - Remove injection pipe and leak-off-line - Loosen M6 ...
Page 33 - Jet needle H is damaged or eroded
Injection pump Remove Injector nozzle 28 Injector overhaul Extreme cleanliness is necessary during work on injector. - Unscrew sleeve nut F (22 mm) and withdraw injector jet G - Clean jet with correct apparatus, not with sharp tool, wire brush or similar. All traces of carbon should be removed. Inje...
Page 34 - Injection pump; Remove the injection pipe; Set regulator lever with the aid of the throttle; The bolt must be exactly in the
Injection pump Remove Injection pump 29 Preliminary tasks before removing the injection pump: The injection pump has two hose connectors and a pipe connection. The lower connection is for the fuel supply, the upper connection is designed for the fuel return hose. - Remove the injection pipe - Clamp ...
Page 35 - Clamp off the fuel supply line; Adjust injection pump; Injection Pump Adjustment
Injection pump Adjust Injection pump 30 NOTE Slide the pump in to about the last 4 mm without overcoming any resistance. Only then may resistance occur due to the tension of the tappet spring - This tension can be overcome by a small pressure and the pump pushed in completely by hand. Preliminary wo...
Page 36 - Subsequently tighten the locknut again
Injection pump Adjust Injection pump Adjust Engine speed 31 Adjustment of the delivery end: - Crank the engine in the direction of rotation until the fuel stops to flow from the adjustment device - Slowly crank further, until the fuel just begins to flow again NOTE The number of degrees indicated on...
Page 37 - Fuel must pulse from the fuel line
Injection pump / Injector Venting Injection pump Fuel pump Check Injection pump, injector Check Fuel jet, venting Clean Fuel pump 32 NOTE Carry out the check with the throttle in the fully open position and with the starting filling not pulled. - After installing the testing device No 74 64 1 333 54...
Page 38 - Cleaning the air filter; Install new sealing ring and filter element.; Never use an old filter element
Air filter Clean Air filter 33 Cleaning the air filter - Loosen clips. Remove filter element. - Remove sealing ring from cover and clean groove - Install new sealing ring and filter element. NOTE Never use an old filter element - Clean air intake openings and pipe in the filter NOTE Premature engine...
Page 39 - Wiring diagram
Page 40 - Remove starter motor; Rotor Removal; Stator Removal
Generator and generating equipment 35 Preparation - Remove starter motor - Detach gearbox/clutch cover assembly - Remove clutch - Remove flywheel Rotor Removal - Extract spring clip A from flywheel magnet by inserting snip-nosed pliers into cut-outs provided Generating Equipment Removal - Disconnect...
Page 41 - Generator and generating equipment; Remove bolts G (7 mm) and lift off stator
Generator and generating equipment 36 - Flatten lockwasher/cable clip F (renew on assembly), securing stator cable to bearing housing (SW 13) - Remove bolts G (7 mm) and lift off stator Notes on Assembly - Grip magnet (rotor) firmly by hand and carefully place in flywheel, taking care to avoid jammi...
Page 42 - Repeat test with second lead; Checking Procedure 2 – Charge Current
Generator and generating equipment 37 - When no or insufficient charge are shown, control unit and/or generator are defective - For further fault location, voltage between each of the 2 black leads, red lead and generator should be checked. Checking Procedure 1 – Impulse Transmitter Thin red lead of...
Page 44 - Lift off starter motor
Starter Motor 39 Starter Motor Removal - Disconnect cables A from solenoid (connector 19mm) and remove insulation B - Remove fixing nuts C (19mm) and detach earth strap D from upper stud - Lift off starter motor When faulty renew.
Page 46 - pin
Water pump 41 Waterpump 1. Sea water pump 2. Cheese head screw M4 x 8 3. Cover 4. Seal 5. Impeller 6. Cheese head screw 7. Washer 8. Cam 9. Straight pin 10. Sealing plate 11. Sealing ring 12. O-ring 13. Deep groove ball bearing 14. Snap ring 15. Shaft 16. Clamping sleeve 17. Stop screw 18. Hex head ...
