403235_RLF_Rev1.1_080714

Jet Propulsion System

Jet Propulsion System

• 403233_JetPropulsionSystem104V320073.1• 403234_JetPropulsionSystem104V420073.1• 103820_JetPropulsionSystem143V120073.1• 403235_JetPropulsionSystem143V220073.1• 403134_JetPropulsionSystem66V120082.1• 403238_JetPropulsionSystem66V220082.1

Repair Manual

Thisrepairmanualisvalidforthefollowingjetpumpvariants:

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Jet Propulsion SystemRepair Manual

Table of Contents

1 Beforeyoubeginworking 1

2 EquipmentandSpecialTools 1

3 Removingthejetpumpfromthevehicle 2

3.1 RemovingHousing 33.2 RemovingRideplate,GrateundInletScoop 43.3 RemovingDriveshaft 53.4 RemovingDriveCoupler 7

4 Disassemblingthejetpump 8

4.1 RemovingReverseGateandSteeringNozzle 84.2 RemovingWaterTubeandPumpWedge 104.3 RemovingStator 11

5 Aligningtheenginewithinthevehicle 14

Terminology 19

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1 Before you begin working

2 Equipment and Special Tools

- MountingTool Impeller.Seesparepartscatalogue.Chapter:Disassembling the jetpump,Stator.

- AlignmentLaserToolCase.Seesparepartscatalogue.OnlyinconjunctionwithanWeberAutomotiveGmbHengine.Chapter:Aligningtheenginewithinthevehicle.

- Marinegrease.LubricatinggreaseappropriateforMarineuse. The Weber Automotive GmbH recommends a premium multipurpose lubricating grease.

Resistant to freshwaterandsaltwater.Sustainedoperating temperature: -60°C[-80°F] to+200°C[+400°F].Droppingpoint>250°C[500°F].

- SealingagentappropriateforMarineuse TheWeberAutomotiveGmbHrecommendsaone-componentpolyurethanesealantsuitable

forproducingelasticandvibration-proofsealedjoints.Resistanttofreshwaterandsaltwater.Temporarilyresistanttofuelandpetroleum.Sustainedoperatingtemperature:-40°C[-40°F]to+90°C[+195°F]

- Loctite272forsecuringandsealingthescrewcoupling.Chapter:Reversegateandsteeringnozzle.

- Loctite243forsecuringandsealingthescrewcoupling.

Rotatingpartsonthedriveshaftandtheimpellercancauseseriouslacerations.

Beforebeginningworkofanykindonthejetpump,removeignitionkeyandlanyardanddetachcableonbatteryfromnegativeterminal.

WARNING

Disassemblyisdescribedintherepairmanual.Assemblyiscarriedoutinreverseorder.PleaseobservenotesfollowingthisSymbol.

Thevehiclemanufacturer’sservicemanualmaybeneededasasupplementtothisrepairmanual.

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3 Removing the jet pump from the vehicle

Tighteningtorque:

20Nm±10%[14ft.lb.]

UsethreadlockLoctite243.

1) Remove cable for the steeringnozzle (1) and the reverse gate(2).

See the vehicle manufacturer‘sservicemanual.

2) Remove5/16-18UNC-2Bbolts(3).

Rotatingpartsonthedriveshaftandtheimpellercancauseseriouslacerations.

Beforebeginningworkofanykindonthejetpump,removeignitionkeyandlanyardanddetachcableonbatteryfromnegativeterminal.

WARNING

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1) Loosen the nuts (1) inside thevehicle and remove the housing.Remove ride plate beforehand ifnecessary.

3.1 Removing Housing

Replacenuts.

Applysealingagent(2)asshownandattachhousing.

See vehicle manufacturer’sservice manual for additionalinformation.

Removingthejetpumpfromthevehicle(continuation)

3) Remove seawater cooling tube.Remove jet pump (4) fromhousing.

Lubricatesurface(5)withmarinegrease.

The freely rotating impeller can jam or severfingers.

Neverholdthejetpumpontheimpellerorreachin.

WARNING

Whenapplyingsealingagent,ensurethatitstaysawayfromscrewthreads,water connections, or water hoses. Sealing agent residue can lead toblockagesinthewatersystem.

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3.2 Removing Rideplate, Grate und Inlet Scoop

1) Removerideplate(1).

2) Removegrate(2).

3) Removeinletscoop(3).

Applysealingagent(4)asshownandattach rideplate,grate,andinletscoop.

See also vehicle manufacturer’sservicemanual.

Applysealingagentcarefullytopreventanairgap.Thejetpumpcouldtakeinsupplementaryair,whichwouldleadtopowerlosses.

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3.3 Removing Driveshaft

1) Remove driveshaft (1) from drivecoupling(2).Carefullydisassembleseal (3) to avoid damaging theseal.

Mountseal(3)anddampingbearing(4)withmarinegrease.

Fill seal with marine grease viathe lubricatingnipple (5)withangreasegun.

Assemble the damping bearing(4).See thevehiclemanufactur-er’sservicemanual.

ReplaceO-ring(7).

MountO-ringandbothbuffers(8)withmarinegrease.

Before installing driveshaft, always check to make sure both bumpers areinstalled.Missingbumpersleadtoanunacceptablylargeaxialclearanceandcancausedamage,forexample,tothedriveshaftorthedrivecoupler.

2) Ifthesealsofthesealrings(6)weredamaged when disassemblingthe seal, the seal rings must bereplaced.

Mountsealringsandsleevewithmarinegrease.

Observe the orientation of thesealrings.

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Checking Driveshaft

Rotation:

1) LaythecleaneddriveshaftontwoV-blocks(1).Rotatethedriveshaftandmeasureatpoint(2)withadialgauge.

Maximum acceptable deviation:

0,13 mm [0.005 in.]

2) The driveshaft must be replacedif thedeviationisgreaterthanthemaximumacceptabledeviation.

Axialclearance:

1) Check the axial clearance in thevehicle with mounted engine, jetpump,sealanddampingbearing.

Move thedriveshaft in the indica-teddirectionbackandforth.

Required axial clearance:

Minimum 4 mm [0.16 in.]

Maximum 7 mm [0.28 in.]

2) Iftheaxialclearanceisoutsidetherequiredaxialclearancetheenginemustbeaccordinglyaligned.

See chapter aligning the enginewithinthevehicle.

Toolittleaxialclearancecausesseveredamagetoengineand/orjetpump.

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3.4 Removing Drive Coupler

1) Secure the flywheel (1) on the marked points and unscrew thedrivecoupler(2).

Hand-screw the drive couplersturdilyontothestubshaft(3).

Right-handthread.

Whenmounting,thedrivecouplingisscrewedontothecouplingelementonlyhand-tight.Whendriving,thedrivecouplingwilltightenitself.

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After removal from the vehicle, thejet pump separates into the followingcomponents:

(1)Reversegateandsteeringnozzle

(2)Pumpwedge

(3)Stator

(4)Watertube

(5)Housing

4 Disassembling the jet pump

Tighteningtorque:

20Nm±10%[14ft.lb.]

UsethreadlockLoctite272

Tighteningtorque:

20Nm±10%[14ft.lb.]

UsethreadlockLoctite243.

4.1 Removing Reverse Gate and Steering Nozzle

The freely rotating impeller can jam or severfingers.

Neverholdthejetpumpontheimpellerorreachin.

WARNING

1) Remove M8 bolts (1) on bothsides.

2) Remove(2)reversegate.

3) RemoveM8bolts(3)forstopper.

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Tighteningtorque:

20Nm±10%[14ft.lb.]

UsethreadlockLoctite243.

Applysealingagent(8)asshownand attach screen. Observe ori-entation.

Theopeningsinthescreenmustbefreeandclean.

RemovingReverseGateandSteeringNozzle(continuation)

4) RemoveM8bolts(4).

5) Removesteeringnozzle(5).

6) When removing the screen, thescreen receiver in the jet nozzlemustnotbedamaged.

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4.2 Removing Water Tube and Pump Wedge

Replace seals (1) on waterpipe and lubricate with marinegrease.

Observeorientationonpumpwedge(2).

Thenarrowsidewiththemarkingnosemustfaceupwards.

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4.3 Removing Stator

Tighteningtorque:

4.5Nm±10%[3.3ft.lb.]

UsethreadlockLoctite243.

Replaceseal.

Tighteningtorque:

138Nm±10%[101ft.lb.]

Usenogreaseorliquidthreadlocktomounttheimpeller.

Right-handthread.

Afterassembly,checkmovementofimpeller.

The freely rotating impeller can jam or severfingers.

Neverholdthejetpumpontheimpellerorreachin.

WARNING

1) RemoveM5bolts(1).

2) Remove pump cone (2) and seal(3).

3) Removeimpeller(4)withmountingtoolimpeller.

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Replacebearing(8).

Measure length of sleeve (9). Ifthe sleeve measures less thanthe minimum size of 43.94 mm[1.730 in.], the sleeve must bereplaced.

Installationofthebearingalwaysoccurs on a large-area on bothbearingshells.

Note the correct order duringmount the bearings. Mountbearing (8) and sleeve (9) afterbearing(12).

Mount bearing and sleeve withmarinegrease.

Replacesealrings.

Fill seal ring (6) halfway withmarinegrease.

Mountsealringsandsleevewithmarinegrease.

Carefully mount seal rings toavoiddamagingtheseal.

RemovingStator(continuation)

5) Remove bearing (8) and sleeve(9).

Ifthesleevemeasureslessthantheminimumsize,theacceptableaxialloadofthebearingsisexceeded.Thiscausesthebearingstowearoutsooner.

4) Remove seal rings (5) (6) andsleeve(7).

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Replace O-rings (10) on stubshaft and lubricate with marinegrease.

Replacebearing.

Installationofthebearingalwaysoccurs on a large-area on bothbearingshells.

Pressthebearingasfarasitwillgointhestator.

Note the correct order duringmount the bearings. Mountbearing(12)first.

Mount the bearing with marinegrease.

ReplaceO-rings(10)instatorhousingandlubricatewithmarinegrease.

RemovingStator(continuation)

6) Removestubshaft.

8) Removebearings(12).

7) RemoveO-ring(11).

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Rotatingpartsonthedriveshaftandtheimpellercancauseseriouslacerations.

Beforebeginningworkofanykindonthejetpump,removeignitionkeyandlanyardanddetachcableonbatteryfromnegativeterminal.

WARNING

5 Aligning the engine within the vehicle

Theenginemustbealignedwithinthevehicle,if...

... theenginewasremoved.

... theenginemountswereremovedorreplaced.

ThischapterisonlyvalidinconjunctionwithaWeberAutomotiveGmbHen-gine.

- AlignmentLaserToolCase

1) Removejetpump(1)anddriveshaftwithseal(2)andifexistant,damp-ingbearingfromthevehicle.

Seechapterremovingthejetpumpfrom the vehicle and removingdriveshaft.

2) Removedrivecoupler(3).

Seechapterremovingdrivecoup-ler.

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Aligning the engine within the vehicle (continuation)

WARNING

The alignment laser (4) is in accordancewith class 2 international standards. The ma-ximum value of average radiant power is1mW.Thevisiblecolourisred.

Thelaserbeamofthealignmentlasercancauseeyedamage.

- Donotlookintothelaserbeam(5).

- Neverdirectthelaserbeamatotherpeople.

- Thealignmentlaserhasnoon/offswitch.Ifthepowersupply isconnected, thealignment la-serisinoperation.Donotconnectthepowersupply(6)untilallpreparatonhasbeendone.

- If signs of damage are shown discontinueuse.

- Donotremovethewarninglabelsfromtheali-gnmentlaser.

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Aligning the engine within the vehicle (continuation)

3) Screwthealignmentlaser(4)ontostubshaft.

4) Screw the pump reflector (7) onto housing with bolts 3/8 - 16 UNC-2B.Observetheorientation.Re-flector area (8) in direction of the engine.

5) Unfix the bolts at the engine mounts(9)alittlebit.Removeexi-stantshims.

6) Check the voltage adjustment onthepowersupplyunit(10);thero-taryswitchislocatedatthebottom(11)ofthepowersupplyunit.

Necessary supply voltage of thealignmentlaser:3V

7) Connectthepowersupplyunitwiththealignmentlaser.

8) Connectthepowersupplyunitwith230V~powersupply.

Wrongvoltageadjustmentcancausedamagetothealignmentlaser.

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Aligning the engine within the vehicle (continuation)

9) Thelaserpointmusthitwithinthereflector area (12).

10) Workstep1

Alignenginevertically(13):

Shakeenginegently.

11) Workstep2

Alignenginehorizontally(14):

Add shims (15) between enginemountsandenginebrackets.

13) Ifthelaserpointhitswithinthere-flector area (12) it reflects.

Itmustbehitinsidethealignementlaserarea(16).

14) Workstep3

Aligntheenginewithshims(15).

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Aligning the engine within the vehicle (continuation)

15) Disconnectpowersupplyunit.Re-move alignment laser and pumpreflector.

16) Assembledrivecoupler,driveshaftandjetpump.

17) Checkaxialclearanceofthedrive-shaft.

Seechaptercheckingdriveshaft.

Toolittleaxialclearancecausesseveredamagetoengineand/orjetpump.

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Terminology

A

Aligningtheenginewithinthevehicle14

B

Beforeyoubeginworking1

D

Disassemblingthejetpump8DriveCoupler,removing7Driveshaft,checking6Driveshaft,removing5

E

Equipment1

G

Grate,removing4

H

Housing,removing3

I

InletScoop,removing4

M

Marinegrease1

P

PumpWedge,removing10

R

Removingthejetpumpfromthevehicle2ReverseGate,removing8Rideplate,removing4

S

Sealingagent1SpecialTools1SteeringNozzle,removing8

W

WaterTube,removing10

Manufacturer: WeberAutomotiveGmbH

Address: Otto-Lilienthal-Str.5 88677Markdorf Germany

Internet: www.weber-automotive.com