Jet Propulsion System
Contents
1. the ro tary switch is located at the bottom 11 of the power supply unit Necessary supply voltage of the alignment laser 3 V T Connect the power supply unit with the alignment laser 8 Connect the power supply unit with 230 V power supply Wrong voltage adjustment can cause damage to the alignment laser 403235_RLF_Rev1 1_080714 Page 16 Repair Manual E H Jet Propulsion System Aligning the engine within the vehicle continuation 9 The laser point must hit within the reflector area 12 10 Work step 1 Align engine vertically 13 Shake engine gently 11 Work step 2 Align engine horizontally 14 Add shims 15 between engine mounts and engine brackets 13 Ifthe laser point hits within the re flector area 12 it reflects It must be hit inside the alignement laser area 16 14 Work step 3 Align the engine with shims 15 403235_RLF_Rev1 1_080714 W Weber Automotive Page 17 Repair Manual E H Jet Propulsion System 15 16 17 W Weber Automotive Aligning the engine within the vehicle continuation Disconnect power supply unit Re move alignment laser and pump reflector Assemble drive coupler driveshaft and jetpump Check axial clearance of the drive shaft See chapter checking driveshaft Too little axial clearance causes severe damage to engine and or jetpump 403235_RLF_Rev1 1_080714 Page 18 Repair Manual fs Jet Pr2. Repair Manual E F Jet Propulsion System Weber Automotive Jet Propulsion System This repair manual is valid for the following jet pump variants e 403233_Jet Propulsion System 104 V3 2007 3 1 e 403234_Jet Propulsion System 104 V4 2007 3 1 e 103820_Jet Propulsion System 143 V1 2007 3 1 e 403235 Jet Propulsion System 143 V2 2007 3 1 e 403134_Jet Propulsion System 66 V1 2008 2 1 e 403238 Jet Propulsion System 66 V2 2008 2 1 403235_RLF_Rev1 1_080714 Repair Manual ff Jet Propulsion System Table of Contents 1 Before you begin working 2 Equipment and Special Tools 3 Removing the jet pump from the vehicle 3 1 Removing Housing 3 2 Removing Rideplate Grate und Inlet Scoop 3 3 Removing Driveshaft 3 4 Removing Drive Coupler 4 Disassembling the jet pump 4 1 Removing Reverse Gate and Steering Nozzle 4 2 Removing Water Tube and Pump Wedge 4 3 Removing Stator 5 Aligning the engine within the vehicle Terminology 403235_RLF_Rev1 1_080714 Weber Automotive NOA N Repair Manual E F Jet Propulsion System Weber Automotive 1 Before you begin working Disassembly is described in the repair manual Assembly is carried out in reverse order Please observe notes following this Symbol The vehicle manufacturer s service manual may be needed as a supplement to this repair manual Rotating parts on the driveshaft and the impeller Can cause serious lacerations Before beginning work of any kind on
3. anual E H Jet Propulsion System Weber Automotive 4 3 Removing Stator The freely rotating impeller can jam or sever fingers Never hold the jet pump on the impeller or reach in 1 Remove M5 bolts 1 Tightening torque 4 5 Nm 10 3 3 ft Ib Use thread lock Loctite 243 2 Remove pump cone 2 and seal 3 Replace seal 3 Remove impeller 4 with mounting tool impeller Tightening torque 138 Nm 10 101 ft Ib Use no grease or liquid thread lock to mount the impeller Right hand thread After assembly check movement of impeller 403235_RLF_Rev1 1_080714 Page 11 Repair Manual E F Jet Propulsion System 4 5 Weber Automotive Removing Stator continuation Remove seal rings 5 6 and sleeve 7 Replace seal rings Fill seal ring 6 halfway with marine grease Mount seal rings and sleeve with marine grease Carefully mount seal rings to avoid damaging the seal Remove bearing 8 and sleeve 9 Replace bearing 8 Measure length of sleeve 9 If the sleeve measures less than the minimum size of 43 94 mm 1 730 in the sleeve must be replaced Installation of the bearing always occurs on a large area on both bearing shells Note the correct order during mount the bearings Mount bearing 8 and sleeve 9 after bearing 12 Mount bearing and sleeve with marine grease If the sleeve measures less than
4. e driveshaft and measure at point 2 with a dial gauge Maximum acceptable deviation 0 13 mm 0 005 in The driveshaft must be replaced if the deviation is greater than the maximum acceptable deviation Axial clearance 1 Check the axial clearance in the vehicle with mounted engine jet pump seal and damping bearing Move the driveshaft in the indica ted direction back and forth Required axial clearance Minimum 4 mm 0 16 in Maximum 7 mm 0 28 in If the axial clearance is outside the required axial clearance the engine must be accordingly aligned See chapter aligning the engine within the vehicle Too little axial clearance causes severe damage to engine and or jetpump 403235_RLF_Rev1 1_080714 Weber Automotive Page 6 Repair Manual E F Jet Propulsion System Weber Automotive 3 4 Removing Drive Coupler 1 Secure the flywheel 1 on the marked points and unscrew the drive coupler 2 Hand screw the drive coupler sturdily onto the stub shaft 3 Right hand thread When mounting the drive coupling is screwed onto the coupling element only hand tight When driving the drive coupling will tighten itself 403235_RLF_Rev1 1_080714 Page 7 Repair Manual E H Jet Propulsion System Weber Automotive 4 Disassembling the jet pump The freely rotating impeller can jam or sever fingers Never hold the jet pump on the impeller or reach In After re
5. moval from the vehicle the jet pump separates into the following components 1 Reverse gate and steering nozzle 2 Pump wedge 3 Stator 4 Water tube 5 Housing 4 1 Removing Reverse Gate and Steering Nozzle 1 Remove M8 bolts 1 on both sides Tightening torque 20 Nm 10 14 ft Ib Use thread lock Loctite 272 2 Remove 2 reverse gate 3 Remove M8 bolts 3 for stopper Tightening torque 20 Nm 10 14 ft Ib Use thread lock Loctite 243 403235_RLF_Rev1 1_080714 Page 8 Repair Manual E F Jet Propulsion System 4 5 6 Weber Automotive Removing Reverse Gate and Steering Nozzle continuation Remove M8 bolts 4 Tightening torque 20 Nm 10 14 ft Ib Use thread lock Loctite 243 Remove steering nozzle 5 When removing the screen the screen receiver in the jet nozzle must not be damaged Apply sealing agent 8 as shown and attach screen Observe ori entation The openings in the screen must be free and clean 403235_RLF_Rev1 1_080714 fi E parare a me Page 9 Repair Manual E F Jet Propulsion System Weber Automotive 4 2 Removing Water Tube and Pump Wedge Replace seals 1 on water pipe and lubricate with marine grease a 1 Observe orientation on pump wedge 2 The narrow side with the marking nose must face upwards 403235_RLF_Rev1 1_080714 Page 10 Repair M
6. om the vehicle See chapter removing the jetpump from the vehicle and removing driveshaft 2 Remove drive coupler 3 See chapter removing drive coup ler 403235_RLF_Rev1 1_080714 Page 14 Repair Manual Jet Propulsion System Aligning the engine within the vehicle continuation The alignment laser 4 is in accordance with class 2 international standards The ma ximum value of average radiant power is 1 mW The visible colour is red The laser beam of the alignment laser can cause eye damage Do not look into the laser beam 5 Never direct the laser beam at other people The alignment laser has no on off switch If the power supply is connected the alignment la ser is in operation Do not connect the power supply 6 until all preparaton has been done If signs of damage are shown discontinue use Do not remove the warning labels from the ali gnment laser 403235_RLF_Rev1 1_080714 Weber Automotive Page 15 Repair Manual E H Jet Propulsion System Weber Automotive Aligning the engine within the vehicle continuation 3 Screw the alignment laser 4 onto stub shaft 4 Screw the pump reflector 7 onto housing with bolts 3 8 16 UNC 2B Observe the orientation Re flector area 8 in direction of the engine 5 Unfix the bolts at the engine mounts 9 a little bit Remove exi stant shims 6 Check the voltage adjustment on the power supply unit 10
7. opulsion System Terminology A Aligning the engine within the vehicle 14 B Before you begin working 1 D Disassembling the jet pump 8 Drive Coupler removing 7 Driveshaft checking 6 Driveshaft removing 5 E Equipment 1 G Grate removing 4 H Housing removing 3 l Inlet Scoop removing 4 M Marine grease 1 P Pump Wedge removing 10 R Removing the jet pump from the vehicle 2 Reverse Gate removing 8 Rideplate removing 4 S Sealing agent 1 Special Tools 1 Steering Nozzle removing 8 W Water Tube removing 10 Manufacturer Address Internet 403235_RLF_Rev1 1_080714 Weber Automotive Weber Automotive GmbH Otto Lilienthal Str 5 88677 Markdorf Germany www weber automotive com Page 19
8. pply sealing agent 4 as shown and attach ride plate grate and Inlet Scoop See also vehicle manufacturer s service manual Apply sealing agent carefully to prevent an air gap The jet pump could take in supplementary air which would lead to power losses 403235_RLF_Rev1 1_080714 Page 4 Repair Manual E F Jet Propulsion System Weber Automotive 3 3 Removing Driveshaft 1 Remove driveshaft 1 from drive coupling 2 Carefully disassemble seal 3 to avoid damaging the seal Mount seal 3 and damping bearing 4 with marine grease Fill seal with marine grease via the lubricating nipple 5 with an grease gun Assemble the damping bearing optional 4 See the vehicle manufactur er s service manual 2 If the seals of the seal rings 6 were damaged when disassembling the seal the seal rings must be replaced Mount seal rings and sleeve with marine grease Observe the orientation of the seal rings Replace O ring 7 Mount O ring and both buffers 8 with marine grease Before installing driveshaft always check to make sure both bumpers are installed Missing bumpers lead to an unacceptably large axial clearance and can cause damage for example to the driveshaft or the drive coupler 403235_RLF_Rev1 1_080714 Page 5 Repair Manual E F Jet Propulsion System Checking Driveshaft Rotation 1 Lay the cleaned driveshaft on two V blocks 1 Rotate th
9. the jet pump remove ignition key and lanyard and detach cable on battery from negative terminal 1 Remove cable for the steering nozzle 1 and the reverse gate 2 See the vehicle manufacturer s service manual 2 Remove 5 16 18 UNC 2B bolts 3 Tightening torque 20 Nm 10 14 ft Ib Use thread lock Loctite 243 403235_RLF_Rev1 1_080714 Page 2 Repair Manual E H Jet Propulsion System Weber Automotive Removing the jet pump from the vehicle continuation The freely rotating impeller can jam or sever fingers Never hold the jet pump on the impeller or reach In 3 Remove seawater cooling tube Remove jet pump 4 from housing Lubricate surface 5 with marine grease 3 1 Removing Housing 1 Loosen the nuts 1 inside the vehicle and remove the housing Remove ride plate beforehand if necessary Replace nuts Apply sealing agent 2 as shown and attach housing See _ vehicle manufacturer s service manual for additional information When applying sealing agent ensure that it stays away from screw threads water connections or water hoses Sealing agent residue can lead to blockages in the water system 403235_RLF_Rev1 1_080714 Page 3 Repair Manual E H Jet Propulsion System Weber Automotive 3 2 Removing Rideplate Grate und Inlet Scoop 1 Remove rideplate 1 2 Remove grate 2 3 Remove inlet scoop 3 A
10. the jet pump remove ignition key and lanyard and detach cable on battery from negative terminal 2 Equipment and Special Tools SE Mounting Tool Impeller See spare parts catalogue Chapter Disassembling the jet pump Stator Alignment Laser Tool Case See spare parts catalogue Only in conjunction with an Weber Automotive GmbH engine Chapter Aligning the engine within the vehicle Marine grease Lubricating grease appropriate for Marine use x The Weber Automotive GmbH recommends a premium multipurpose lubricating grease Resistant to freshwater and saltwater Sustained operating temperature 60 C 80 F to 200 C 400 F Dropping point gt 250 C 500 F Sealing agent appropriate for Marine use The Weber Automotive GmbH recommends a one component polyurethane sealant suitable for producing elastic and vibration proof sealed joints Resistant to freshwater and saltwater Temporarily resistant to fuel and petroleum Sustained operating temperature 40 C 40 F to 90 C 195 F Loctite 272 for securing and sealing the screw coupling Chapter Reverse gate and steering nozzle Loctite 243 for securing and sealing the screw coupling 403235_RLF_Rev1 1_080714 Page 1 Repair Manual E F Jet Propulsion System Weber Automotive 3 Removing the jet pump from the vehicle Rotating parts on the driveshaft and the impeller can cause serious lacerations Before beginning work of any kind on
11. the minimum size the acceptable axial load of the bearings is exceeded This causes the bearings to wear out sooner 403235_RLF_Rev1 1_080714 Page 12 Repair Manual Jet Propulsion System 6 Removing Stator continuation Remove stub shaft Replace O rings 10 on stub shaft and lubricate with marine grease Remove O ring 11 Replace O rings 10 in stator housing and lubricate with marine grease Remove bearings 12 Replace bearing Installation of the bearing always occurs on a large area on both bearing shells Press the bearing as far as it will go in the stator Note the correct order during mount the bearings Mount bearing 12 first Mount the bearing with marine grease Weber Automotive 403235_RLF_Rev1 1_080714 Page 13 Repair Manual E F Jet Propulsion System Weber Automotive 5 Aligning the engine within the vehicle Alignment Laser Tool Case This chapter is only valid in conjunction with a Weber Automotive GmbH en gine The engine must be aligned within the vehicle if the engine was removed the engine mounts were removed or replaced Rotating parts on the driveshaft and the impeller can cause serious lacerations Before beginning work of any kind on the jet pump remove ignition key and lanyard and detach cable on battery from negative terminal 1 Remove jetpump 1 and driveshaft with seal 2 and if existant damp ing bearing fr
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