BMW D12 Diesel Engine Workshop Manual

Workshop BMWD Manual 12 BMW .Marine Engines (1~ a;

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BMW Dl 2 Marine engine DESCRIPTION The D 12 marine engine is a single-cylinder, four-stroke Diesel engine with direct injection. It features a single-circuit cooling system. The coolant pump with Neoprene impeller is driven directly from the crankshaft. The A.C. generator is located in the flywheel and, like the electric starter, is standard epuipment. The injection pump is driven from the camshaft. The injection system bleeds itself automatically. GENERAL This manual describes the overhaul of the BMW D 12 marine engine when not installed. All removal, installation and overhaul jobs on a specific assembly (component) are always combined into one section and named after the assembly. The sequence of the sections corresponds to the job sequence in stripping the engine. Additionally, at the beginning of each section the jobs are listed which are required to remove (overhaul) the assembly (component) in each case, if the engine is not being completely stripped. The job sequence for assembling the complete engine is given as a list of key words with the title “Job sequence in assembling the engine” follçwing the overhaul sections. The terms “top, bottom, front, rear, left, right” invariably are related, unless otherwise defined in the text, to the installed position of the engine as viewed in the direction of travel. C Figures in the manual are numbered consecutively throughout. When cross references are made to Figures in the text, the Figure No. is given first, followed by the item No. in the Figure, e.g., (25/1) is a reference to Fig. 25, item 1. 1

BMW Dl 2 Marine engine Contents Page C Checking the functioning of injection pump and injector Checking the generator 11 Cooling system (schematic) 4 D Description 1 F Fuel system (schematic) G General 1 Installing the cylinder head 19 Installing the valves 26 J Job sequence in assembling the engine 50 M Measuring the valve projection 27 Q 0 Overhauling the injector nozzle 37 R Removing and installing retaining plate with engine electricals 6 Removing and installing the air filter 15 Removing and installing the bearing flange 14 Removing and installing the camshaft assembly 38 Removing and installing the connecting rod 47 Removing and installing the crankshaft Removing and installing the cylinder 28 Removing and installing the decompression lever 22 Removing and installing the engine stop magnet 32 Removing and installing the exhaust manifold 16 Removing and installing the fuel control system 41 Removing and installing the fuel pump 32 Removing and installing the gearbox Removing and installing the generator 8 Removing and installing the injection pump Removing and installing the piston 46 Removing and installing the rocker arms 21 Removing and installing the rocker levers 40 Removing and installing the starter 7 Removing and installing the timing cover 33 Removing and installing the water pump 30 Removing the cylinder head 17 Removing the valves 25 S Service and maintenance Setting the decompression device 23 Setting the engine speed Setting the injection pump Setting the valves 28 Special tools Stripping and assembling the water pump 31 T Technical data and specifications 51 Tightening torques w 0 Winter lay-up and lengthy operating breaks 55 Wiring diagram 5 2

BMW Dl 2 Marine engine SERVICE UND MAINTENANCE Daily Every After every Every 100 Every 150 14 days 50 op. hrs or once op. hrs or once op. hrs or peryear per year ev. 2 years Check engine oil Fuel filter (drain condensate ancidirt) Engine oil change (first time after 10 hrs.) Check/set valves Change fuel filter Clean fuel pump screen Exchangeairfilterelement Check gearbox oil level Change gearbox oil Clean injector Check hoses and lines Clean injection pump When necessary Exchange zinc anodes Check/exchange impeller (water pump) Set decompression device (always after valves have been set) 3

BMW Dl 2 Marine engine 1) Water pump 2) Cylinder 3) Cylinder head 4) Thermostat 5) Exhaust pipe 1) Tank vent 2) Filler neck 3) Fuel tank 4) Fuel filter 5) Hand pump 6) Fuel pump 7) Injection pump 8) Injector COOLING SYSTEM 4 3 1 FUEL SYSTEM C C C C 4

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BMW Dl 2 Marine engine REMOVING AND INSTALLING RETAINING PLATE WITH ENGINE ELECTRICALS Removing retaining plate with engine electricals Fig. 4 Sever the cable clamp. Pull back the rubber protective cap (4/1) on the starter and screw off the electrical lead (4/2). Disconnect the plug-in connector (4/3) from the starter. Disconnect the electrical leads from the temperature pick-up (4/4) and, where an automatic engine shut-off device is fitted as special equipment, from the magnet (4/5) as well. Fig. 5 Disconnect the four plug-in connectors (5/1) of the stator leads. Unscrew the two hex. nuts, remove the grounding cable (5/2) and take the retaining plate (5/3) off the flywheel housing. Installation takes place in the removal. Caution: reverse sequence to Pay attention to polarity when the electrical leads are connected up. 0 0 0 C Installing retaining plate with engine electricals. 6

BMW Dl 2 Marine engine REMOVING AND INSTALLING THE STARTER Removing the starter — Disconnect the electrical leads from the starter Fig. 6 Loosen the two hex. nuts (6/1) and screw them back as far as they will go, pull back the starter and again unscrew the nuts as far as they will go. Repeat the process until the nuts are fully unscrewed. Remove the washers (6/2) from the threaded bolts and take the starter off the flywheel housing. Installing the starter Installation takes place in the reverse sequence to removal. REMOVING AND INSTALLING THE GEARBOX Removing the gearbox — Remove the retaining plate with engine electricals — Remove the starter Fig. 7 Unscrew the four hex. nuts (7/1) and take them off together with the washers. Remove the flywheel housing cover (7/2) complete with gearbox from the engine. 7

Installing the gearbox Installation of the gearbox takes place in the reverse sequence to removal. — Install the starter — Install the retaining plate with engine electricals Fig. 8 Screw out the six hex.-head screws (8/1) and remove them together with the washers. Take the gearbox off the flywheel housing cover. BMW Dl 2 Marine engine F 0 0 0 REMOVING AND INSTALLING THE GENERATOR — Remove the retaining plate with engine electricals — Remove the starter — Remove the gearbox Removing the generator Fig. 9 Screw out the four socket-head screws (9/1) and take the clutch disc (9/2) off the flywheel. 8

BMW D12 Diesel Engine Workshop Manual

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