Hyundai CM4.80 Engine

⚠ Only check the V-belt when the engine is not running

Tools: Spanner 13

1. Loosen both bolts of the alternator.
2. Tension the belt by pushing the alternator outward.
3. Tighten the upper bolt of the alternator first.
4. Thereafter tighten the support and the lower bolt of the alternator.

⚠ Do not spill oil over the engine

⚠ Make sure that no oil is added above the upper mark of the dipstick

Tools: Funnel

1. Fill the engine through the filling opening on top of the engine with lubrication oil of specifications on page 11.
2. Use a funnel in order to avoid spilling oil over the engine.
3. Close the filler opening and have the engine idling for a few moments and check for leaks.
4. Stop the engine and check the oil level by means of the dipstick after about 5 minutes.

⚠ Replace the oil when the engine has its operating temperature (but is stopped); oil temperature about 80 degrees Celsius - risk of burning the skin

Tools: Special sump pump

1. Remove the dipstick.
2. Insert the hose of the special sump pump into the pipe of the dipstick.
3. Extract the oil by quickly pushing down the grip of the sump pump and then pulling it slowly upwards.
4. Collect the used oil and bring it to the service station in accordance with environmental directives.

⚠ Do not smoke when draining liquids from engine or filters; keep open fire away

1. Open the drain plug at the bottom of the filter housing.
2. Drain the water and collect it in a bowl; close the drain plug.
3. Bleed the fuel system: turn the key in the start switch to the 'ON' position.
4. After about 1 minute the fuel lift pump operates and bleeds the system automatically.

⚠ The rubber impeller should never run dry

⚠ Always carry a spare impeller on board (AA.480.90021)

Tools: Impeller removal tool

1. Close the seawater inlet cock.
2. Loosen the screws of the cover.
3. Remove the cover and use an impeller removal tool to remove the impeller.
4. Inspect the impeller blades for cracks and replace if necessary.
5. Remove any rubber residues from the pump housing and water pipes.

1. Use a silicone spray to lubricate the impeller before fitting.
2. Fit the impeller to the pump shaft.
3. Fit the cover while placing a new gasket.
4. Open the seawater inlet cock.

⚠ Open the filler cap on top of the heat exchanger housing only when the engine is cold

⚠ Never add sea (or salt) water into the inner cooling circuit

1. Remove the hose from the heat exchanger to drain the heat exchanger.
2. Open the drain cock to drain the engine block.
3. Remove the filler cap from the expansion tank and/or heat exchanger housing to drain the internal cooling circuit completely.
4. After draining reconnect the hose but leave the drain cock open.
5. Fill the system with a mixture of 40% anti-freeze and 60% clean tap water to about 1 cm below the bottom of the filler pipe.
6. Put the filler cap back in place and close the drain cock in the engine block.

⚠ Do not smoke when working at or around the fuel system and avoid open fire

Tools: Special filter tool

1. Close off the fuel supply to the engine.
2. Remove the entire filter with a special tool; collect residual fuel and dispose of it per environmental directives.
3. Clean the surface to touch the engine before fitting the filter; grease the rubber ring with clean engine oil.
4. Fill the filter with clean diesel fuel.
5. Position the filter against the filter housing and tighten it with one half to three quarters of a turn.
6. Bleed the fuel system afterwards.

1. Clean the surface of the rubber ring in the rim of the new oil filter and grease it with fresh engine lubrication oil.
2. Turn the new oil filter onto the engine, following the instructions given on the filter housing.

⚠ Do not load the engine with this mixture; idle speed only

⚠ Anti-freeze liquid is very poisonous; dispose of it correctly

1. Run the engine about 10 minutes with a protective mixture of 10% lubrication oil and 90% clean diesel fuel (idle speed only).
2. Replace the oil filter and change the engine lubrication oil with a good quality protective oil.
3. Close the raw water seacock, open the water strainer cover and run the engine while adding antifreeze until the seawater circuit is completely filled.
4. Remove the impeller during winter storage.
5. Make sure the inner cooling system contains sufficient anti-freeze.
6. Disconnect the battery cables and charge the batteries from time to time.
7. Drain water from the fuel filter/water separator and fit a new fuel filter.

⚠ Place a bucket underneath the exhaust exit to catch excessive antifreeze while starting; anti-freeze is poisonous

1. Open the fuel supply cock.
2. Charge the battery(ies) if necessary.
3. Connect the battery cables.
4. Verify that the cover of the raw water cooling strainer is tightened well.
5. Insert the impeller removed during winter preparation; verify tightness of the raw water pump cover and all drain plugs.
6. Reconnect and tighten well any hoses disconnected before winter storage.
7. Open the seacock of the raw water entry.
8. Check the level of the cooling liquid.
9. Make sure the engine has sufficient lubrication oil.
10. Start the engine and make sure there are no leaks in the fuel system, cooling system and exhaust assembly.
11. Verify the proper functioning of all electronic parts, engine instruments and the mechanical remote control of throttle and gearbox.
12. Check the exhaust for cooling water.

⚠ Stop the starting procedure if the engine does not come to life within 10 seconds

⚠ Do not run the starter motor more than 30 seconds continuously

1. Position the throttle lever at half of its travel, without engaging the gearbox.
2. Turn the key to the 'on' position; monitoring lights for oil pressure, charging current and pre-heating light up and the buzzer sounds.
3. Turn the key to the 'pre-heating' position; keep the key about 6 seconds at ambient temperature of 15 C or more.
4. Turn the starter key to 'start' and release as soon as the engine starts; the key returns to 'on'.
5. Let the engine idle for a short period to warm up.