Usage:
Reference: 3208 Marine Engine Service Manual (SEBR0542-01)
Parts are now available for converting 3208TA Marine Engines from 355 BHP to 375 BHP. There are three different conversion groups available, one for each specific serial number range. Basic Conversion Group 7C0378 converts engines with S/N's 1Z4501 and up. The 7C0379 Conversion Group includes the basic conversion group plus new flow-thru water cooled manifold elbows (page 6), to convert engines with S/N's 1Z4227 thru 1Z4500. The 7C0380 Conversion Group includes the basic group plus water cooled manifold elbows and a new larger capacity heat exchanger bundle assembly (page 7), to convert engines with S/N's 1Z4042 thru 1Z4226.
NOTE: Group numbers will not be serviced. Separate parts must be ordered. (See necessary parts list on pages 8 and 9).
Basic Conversion Group 7C0378 Procedure
Modification of Fuel Injection Pump Assemblies.
1. Remove the fuel injection pump assemblies (See the Service Manual for the correct procedure).
2. Remove ring (1) and separate bonnet (2) from the barrel assembly (3). Install a new 7W8039 Bonnet (4) with a 7W8038 Insert (5). Again, install ring (1). NOTE: Make sure insert (5) is positioned properly in the bonnet for correct pump operation. Normal precautions should be taken to ensure cleanliness. Install the fuel injection pump assemblies with new 7W8120 Bushings (6). Tighten bushings (6) to a torque of 82 ± 7 N·m (61 ± 5 lb ft).
Modification of Sea Water Pump Assembly.
3. Remove the sea water pump from the engine (see the Service Manual).
4. Remove screws (7), cover (8) and the gasket. Remove spacer (9) and impeller assembly (10) from the pump. Remove screw (11) and cam (12) from body assembly (13).
5. Put 3S6252 RTV Silicone Sealant on the top of new cam (14) and on the threads of the screw that holds the cam. Put cam (14) in position and install the screw to hold the cam in body assembly (13). Put a small amount of 5P0960 Multipurpose Type Grease on the end surface of impeller (10) and on the impeller bore. Push down and turn to install impeller (10) in body assembly (13). Install spacer (9). Install a 5L9566 Gasket with cover (8) and screws.
6. Install sea water pump on the engine (see the Service Manual).
Modification of Water Lines.
7. Drain the coolant from the engine cooling system.
8. Remove clamp (17), hose (18), clip (19), tube (20), plug (21) and a bolt at location (A).
10. Install 7W6255 Support Bracket (25) and 2W9754 Bracket (26) onto the marine gear oil cooler bracket with a 0S0509 Bolt and a 5M2894 Washer.
NOTE: Use the threaded 9.52 mmØ (.375"Ø) hole on the marine gear oil cooler bracket.
11. Install 7W3633 Hose (27) and 7W3641 Adapter Assembly (28) with an existing 2S3440 Clamp (29), and new 9M2904 Clamp (30) and 5P7854 Clip (31).
12. Connect adapter assembly (28) to existing hose (32) with existing clamp (33).
13. Install a 8F4994 O-Ring Seal on 7W3626 Tube (34). Lubricate seal and seal bore lightly with engine oil or glycerin. Install tube (34) onto 4W7081 Hose (23) with an 8T1117 Clamp (35).
14. Clamp tube (34) in position with a 4S1962 Clip (36) and connect the clip to 1W6255 Support Bracket (25) with 0S0509 Bolt and 5M2894 Washers. Install 5B4274 Bolt (37), 4L3641 Clip (38), 5M2894 Washer (39) and 9S8752 Nut (40).
15. Clamp tube (28) in position with a 5P7854 Clip (41) and connect it to 2W9754 Bracket (26) with a 0S0509 Bolt and two 5M2894 Washers.
NOTE: Make sure 7W3626 Tube (34) and 7W3641 Adapter Assembly (28) are firmly secured with the clips to prevent separation due to coolant pressure.
16. Fill the cooling system with the correct coolant mixture. Do not fill over 12 liters (3 gallons) per minute, or it can cause air pockets in the cooling system. After filling the cooling system, operate the engine with the filler cap removed, and the small vent line at the turbocharger disconnected, until all air is completely vented and the coolant level has stabilized. Again, check the coolant level while the engine is operating and add coolant as necessary to fill the system to within 13 mm (.50") of bottom of fill pipe.
17. Change the full load static fuel setting.
18. Increase high idle 20 rpm, greater than measured high idle. This will allow engine to maintain proper 2820 set point rpm. (Existing rpm may be slightly lower than plate specification due to the parasitic load of the alternator, sea water pump and other driven accessories.) Existing high idle should not be greater than the high idle specified on the Engine Information Plate.
19. Install 4W5140 Engine Information Plate over existing information plate. Stamp the following information in 3 mm (.1") high maximum figures on the plate.
AR. NO.: ... 7W7500
PERF. SPEC.: ... 0T5875
MAX. ALT.: ... 900 m (3000 ft)
OEM NO.: ... Same as recorded on existing plate.
FULL LOAD
STATIC FUEL: ... As given in Step 17.
FULL TORQUE
STATIC FUEL: ... .1 mm greater than above.
POWER: ... 375 BHP
A/F RATIO DYNAMIC: ... Same as recorded on existing plate.
BARE ENGINE
HIGH IDLE RPM: ... 20 rpm greater than recorded on existing plate.
FULL LOAD RPM: ... 2800 rpm
FUEL TIMING: ... 18° BTC
Flow-Thru Water Cooled Manifold Elbow Conversion Procedure (Part of 7C0379 and 7C0380 Conversion Groups)
1. Drain the coolant from the cooling system.
2. Remove water cooled exhaust elbow (1) [both sides] and all elbow hardware. Remove connectors (2) [each manifold] and install a 1B5174 Plug. Loosen sixteen bolts (3) and two bolts (4) that hold rear manifold (5).
3. Install new 4W7610 and 4W7611 Exhaust Elbows (6) with 7W1642 Gaskets (8), four 0L1143 Bolts (9) and 5M2894 Washers. Install 7W1641 Gaskets (10) and four 3B1915 Bolts (11), 9S8752 Nuts and 5M2894 Washers.
* Manifold bolt torque and tightening sequence order:
1) Tighten bolts (A) through (D) by alphabetical order to finger tight.
2) Tighten bolts (A) and ((B) by alphabetical order to a torque of 14 ± 7 N·m (10 ± 5 lb ft).
3) Tighten bolts (A), (B) and (C) by alphabetical order to a torque of 43 ± 7 N·m (32 ± 5 lb ft).
4) Tighten bolts (D) to a torque of 100 ± 14 N·m (74 ± 10 lb ft).
4. Refill cooling system with correct coolant mixture as given earlier in Step 16.
Modification of Heat Exchanger (Part of 7C0380 Conversion Group)
1. Drain the coolant from the cooling system.
2. Remove the existing bundle assembly from the heat exchanger housing.
3. Install a new 1W3421 Bundle Assembly (1) with a new 1S1225 Seal (2) [lubricate seal lightly with engine oil or glycerin], 4N6187 Gaskets (3) and one 4N9220 Gasket (4). Fill the cooling system with correct coolant and mixture as described earlier in Step 16.
Necessary Parts
7C0378 Conversion Group - S/N's 1Z4501-Up (Basic)
7C0379 Conversion Group - Engine S/N's 1Z4227 Through 1Z4500
7C0380 Conversion Group - Engine S/N's Through 1Z4226
NOTE: 1W9350 Engine Arrangement (355 BHP) with S/N's prior to 1Z4042 are not recommended for this conversion because of extensive changes required to the front gear train and fuel injection pump group.