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Yanmar 4BY Service Manual Download Page 57

ENGINE

5-2

BY Service Manual

Pistons and Cylinders .................................................................... 5-36

Removal and Disassembly of Piston and Connecting Rod ...... 5-36
Inspection of Pistons and Piston Rings .................................... 5-37
Assembling Piston and Connecting Rod .................................. 5-38
Installation of Piston and Connecting Rod ............................... 5-39

Flywheel and Flywheel Housing..................................................... 5-42

Remove and Install Flywheel Housing  .................................... 5-42
Remove and Install Drive Coupling .......................................... 5-42
Removal of Flywheel ................................................................ 5-44
Replacement of Rear Crankshaft Seal..................................... 5-44
Installation of Flywheel ............................................................. 5-45

Camshaft and Timing Gear Train ................................................... 5-46

Components ............................................................................. 5-46
Checking and Adjusting Camshaft Timing ............................... 5-48
Removing and Installing Vibration Damper - 4BY .................... 5-50
Removing and Installing Vibration Damper - 6BY .................... 5-51
Removing Timing Case Cover ................................................. 5-52
Removing and Installing Timing Chain..................................... 5-52
Installing Timing Case Cover ................................................... 5-53
Removing and Installing Timing Chain Tensioner.................... 5-54
Removal of Camshafts ............................................................. 5-54
Installation of Camshafts .......................................................... 5-57

Cylinder Block and Crankshaft ....................................................... 5-60

Components ............................................................................. 5-60
Removal of Crankshaft............................................................. 5-62
Measuring Oil Clearance.......................................................... 5-63
Inspection of Crankshaft........................................................... 5-64
Inspection of Cylinder Block ..................................................... 5-66
Crankshaft Installation.............................................................. 5-66
Replacing Front Crankshaft Seal ............................................. 5-68

Intake Manifold ............................................................................... 5-70

Removal ................................................................................... 5-70
Installation ................................................................................ 5-71

Exhaust Manifold............................................................................ 5-72

Remove .................................................................................... 5-72
Install ........................................................................................ 5-72

Attaching Engine to Repair Stand .................................................. 5-73

Summary of Contents for 4BY

Page 1: ...BY series 4BY 6BY SERVICE MANUAL ...

Page 2: ...BY Service Manual BY series SERVICE MANUAL 4BY 6BY P N 0BBY0 G00100 MARINE ENGINES ...

Page 3: ...latest information available at the time of publishing The illustrations used in this manual are intended as representative reference views only Moreover because of our continuous product improvement policy we may modify information illustrations and or specifications to explain and or exemplify a product service or maintenance improvement We reserve the right to make any change at any time Yanmar...

Page 4: ...F CONTENTS Page Introduction 1 1 Safety 2 1 General Service Information 3 1 Periodic Maintenance 4 1 Engine 5 1 Fuel System 6 1 Cooling System 7 1 Lubrication 8 1 Turbocharger 9 1 Starter Motor 10 1 Alternator 11 1 Electrical and ECU 12 1 Troubleshooting 13 1 ...

Page 5: ...TABLE OF CONTENTS iv 4BY 6BY Service Manual This Page Intentionally Left Blank ...

Page 6: ...th repairs as some of the procedures described are rather complex Along with standard tools Yanmar recommends the use of special tools necessary to perform repairs correctly Yanmar products are continuously undergoing improvement This Service Manual has been checked carefully in order to avoid errors However Yanmar is not liable for any misrepresentations errors of description or omissions Contact...

Page 7: ...INTRODUCTION 1 2 BY Service Manual This Page Intentionally Left Blank ...

Page 8: ...come alert your safety is involved Please read and abide by the message that follows the safety alert symbol A DANGER Danger the word DANGER is in white letters with a red rectangle behind it indicates an imminently hazardous situation which if not avoided will result in death or serious injury Danger is limited to the most extreme situations 0000001en A WARNING Warning the word WARNING is in blac...

Page 9: ...ther form of ignition away while the engine is running or battery is charging Failure to comply will result in death or serious injury 0000003en A DANGER CRUSH HAZARD ALWAYS use the engine lifting eyes when lifting the marine engine The lifting eyes are engineered to lift the weight of the marine engine only ALWAYS use lifting equipment with sufficient capacity to lift the marine engine Additional...

Page 10: ... flammable and explosive under certain conditions NEVER remove the fuel cap with the engine running Failure to comply will result in death or serious injury 0000011en A DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions When you remove any fuel system component to perform maintenance such as changing the fuel filter place an approved container under th...

Page 11: ...dry out and become brittle after two years or 500 hours of engine operation whichever comes first Failure to comply will result in death or serious injury 0000015enBY A DANGER NEVER start the engine unless the air filter is installed Failure to comply will result in death or serious injury 0000025en A DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions ...

Page 12: ...sing before installing ALWAYS install new gaskets and seals for the turbocharger lubrication lines and check after installation for leaks NEVER install a heat shield that is oily ALWAYS replace it with a new one Failure to comply will result in death or serious injury 0000034en A DANGER CRUSH HAZARD When you need to transport an engine for repair have a helper assist you to attach it to a hoist an...

Page 13: ...that any tools or shop rags used during maintenance have been removed from the area Failure to comply could result in death or serious injury 0000002enMarine A WARNING EXPOSURE HAZARD Wear personal protective equipment such as gloves work shoes eye and hearing protection as required by the task at hand NEVER wear jewelry unbuttoned cuffs ties or loose fitting clothing when you are working near mov...

Page 14: ...ck the electrical harnesses for cracks abrasions and damaged or corroded connectors ALWAYS keep the connectors and terminals clean Failure to comply could result in death or serious injury 0000009en A WARNING ENTANGLEMENT HAZARD Stop the engine before you begin to service it NEVER leave the key in the key switch when you are servicing the engine Someone may accidentally start the engine and not re...

Page 15: ...shortly after you shut the engine down These surfaces are extremely hot while the engine is operating and could seriously burn you Failure to comply could result in death or serious injury 0000015enBY A WARNING FUME BURN HAZARD Always read and follow safety related precautions found on containers of hazardous substances like parts cleaners primers sealants and sealant removers Failure to comply co...

Page 16: ...to comply could result in death or serious injury 0000003en A WARNING BURN HAZARD Batteries contain sulfuric acid NEVER allow battery fluid to come in contact with clothing skin or eyes Severe burns could result ALWAYS wear safety goggles and protective clothing when servicing the battery If battery fluid contacts the eyes and or skin immediately flush the affected area with a large amount of clea...

Page 17: ...e task at hand Use the correct size tool for loosening or tightening machine parts Failure to comply may result in minor or moderate injury 0000024en A CAUTION Be sure to secure the engine solidly to prevent injury or damage to parts due to the engine falling during work on the engine 0000009en A CAUTION RISK OF CRUSH INJURY The starter motor is very heavy Use care when removing the starter motor ...

Page 18: ...gine coolants This may adversely affect the properties of the engine coolant 0000006enMarine CAUTION NEVER engage the starter motor while the engine is running This may damage the starter motor pinion and or ring gear 0000012en CAUTION Keep the piston pin parts piston assemblies and connecting rod assemblies together to be returned to the same position during the reassembly process Label the parts...

Page 19: ...a high pressure wash directly on the alternator Water will damage the alternator and result in inadequate charging 0000049en CAUTION Do not reverse the positive and negative ends of the battery cable The alternator diode and stator coil will be damaged 0000050en CAUTION Identify all parts and their location using an appropriate method It is important that all parts are returned to the same positio...

Page 20: ...00185en CAUTION Any part which is found defective as a result of inspection or any part whose measured value does not satisfy the standard or limit must be replaced 0000119en CAUTION Immediately cap or plug all openings to prevent contamination of system 0000199en CAUTION NEVER use an engine starting aid such as ether Engine damage will result 0000009en ...

Page 21: ...SAFETY 2 14 BY Service Manual Safety Precautions This Page Intentionally Left Blank ...

Page 22: ...Fuel 3 10 Diesel Fuel Specifications 3 10 Bleeding the Fuel System 3 11 Engine Oil 3 11 Engine Oil Specifications 3 11 Recommended Engine Oil 3 12 Recommended Marine Gear or Stern Drive Oil 3 14 Recommended Power Steering Fluid 3 14 Engine Coolant 3 15 Engine Coolant Specifications 3 15 Recommended Engine Coolant 3 16 Principal Engine Specifications 3 17 Tightening Torques for Standard Bolts and N...

Page 23: ...2 BY Service Manual Unit Conversions 3 21 Unit Prefixes 3 21 Units of Length 3 21 Units of Volume 3 21 Units of Mass 3 21 Units of Force 3 21 Units of Torque 3 21 Units of Pressure 3 21 Units of Power 3 21 Units of Temperature 3 21 ...

Page 24: ... DRAWINGS Note All dimensions are metric Contact Yanmar Marine for the most current drawings 4BY Inboard Version Borg Warner Flange Figure 3 1 0003569 VIEW S SECTION A A A A Ø209 55 0 02 0 06 50 356 5 21 5 373 669 286 356 5 54 ENGINE MIDDLE 456 5 572 240 700 SAE 20 40 26 7 S 760 54 287 861 ...

Page 25: ...e Outline Drawings 4BY Stern Drive Version Note All dimensions are metric Contact Yanmar Marine for the most current drawings Figure 3 2 0003570 SECTION A A A A 737 94 2 284 54 861 S 149 1 760 373 240 700 669 71 1 120 65 572 54 457 5 ENGINE MIDDLE 286 241 3 ...

Page 26: ...rner Flange Note All dimensions are metric Contact Yanmar Marine for the most current drawings Figure 3 3 0003571 SECTION A A 538 5 A S 50 Ø209 55 G7 21 5 7 0 03 0 0 061 0 015 A 145 240 700 669 373 759 287 1001 572 145 538 5 30 5 30 5 ORIGINAL GEAR BRACKETS ZF45 444 5 ENGINE MIDDLE 286 608 5 21 222 25 ...

Page 27: ...GENERAL SERVICE INFORMATION 3 6 BY Service Manual Engine Outline Drawings 6BY Stern Drive Version Note All dimensions are metric Contact Yanmar Marine for the most current drawings Figure 3 4 ...

Page 28: ... Sensor 6 High Pressure Fuel Pump 7 High Pressure Fuel Supply Line 8 Common Fuel Rail 9 Fuel Injection Line 1 each injector 10 Fuel Injector 1 each cylinder 11 Fuel Injector Return Fuel Hose 12 Common Rail Return Fuel Line 13 Tee 14 Fuel Return from High Pressure Pump 15 Return Fuel to Fuel Tank 16 Fuel Pressure Sensor 17 Fuel Pressure Regulator ECU Controlled 18 High Pressure Fuel Flow Regulator ...

Page 29: ...Y engine shown 6BY is similar 1 Seawater Supply 2 Seawater Pump 3 Hydraulic Oil Cooler 4 Charge Air Cooler 5 Engine Heat Exchanger 6 Exhaust Elbow 7 Exhaust Seawater Exit 8 Engine Coolant Pump 9 Thermostat 10 Engine Oil Cooler 11 Engine Coolant Passages 12 Coolant Recovery Tank 0003635 12 10 8 9 3 2 4 5 1 11 6 7 ...

Page 30: ...Block Serial Label Figure 3 8 The engine block information label is affixed to the cylinder block and is located behind the engine oil cooler near the end of the starting motor 0003636 YANMAR DIESEL ENGINE YANMAR CO LTD MADE IN AUSTRIA M o d e l G e a r M o d e l ContinuousPowerKW SpeedofPropShaft FuelStopPowerKW min 1 min 1 min 1 D ENG No SERIAL NUMBERS ENGINE TRANSOM DRIVE MERCRUISER MODEL TRANS...

Page 31: ... and or cause engine damage Fuel additives are not recommended Some fuel additives may cause poor engine performance Diesel Fuel Lines Figure 3 9 1 Optional Boatbuilder Installed Fuel Filter Water Separator 30 Micron Pre Filter 2 Fuel to Fuel Feed Pump 3 Less than 500 mm 19 68 in 4 Fuel Return Line 5 Fuel Tank 6 Fuel Tank Drain Cock 7 Approximately 20 30 mm 0 75 1 125 in 8 Fuel Shutoff Valve IMPOR...

Page 32: ...s and engine oil filling equipment are free of sediment and water Change the engine oil after the first 50 hours of operation and then at every 250 hours or annually thereafter Choose engine oil from the table Recommended Engine Oil on page 3 12 Yanmar does not recommend the use of engine oil additives Engine Oil Viscosity Select the appropriate engine oil viscosity based on the ambient temperatur...

Page 33: ...l Formula RS Power and Protection Castrol Limited Castrol Formula SLX Castrol Limited Castrol Formula SLX LL01 Castrol Limited Castrol Formula SLX Long Tex Castrol Limited Castrol Formula SLX Turbodiesel Castrol Limited Castrol Syntec Castrol Limited Castrol Syntec 0W 30 European Formula Castrol Limited Castrol Super Racing 0W 40 Castrol Limited Castrol TXT Softec LL01 Castrol Limited Cepsa Star M...

Page 34: ...tate Ravenol HCL Ravensburger Schmierstoffvertrieb GmbH Repsol Elite Common Rail Repsol YPF Shell Helix Ultra AB Shell International Petroleum Company Shell Helix Ultra AL Shell International Petroleum Company Statoli LazerWay B Statoil Lubricants Tecar Motorenöl Supersyn Techno Einkauf GmbH Titan Supersyn SL Fuchs Petrolub AG Titan Supersyn SL Longlife Fuchs Petrolub AG Tor Synthetic LL De Oliebr...

Page 35: ...Limited Castrol Edge Turbo Diesel Castrol Limited Castrol Formula RS Castrol Limited Castrol GTX Magnatec Castrol Limited Castrol SLX LL 04 Castrol Limited Castrol TXT LL 04 Castrol Limited Elf Excellium LSX Total Galp Energy Ultra LS Petrogal SA Liqui Moly TopTec 4100 Liqui Moly Midland Synova Oel Brack AG Midland Synova Oel Brack AG Mobil 1 ESP Formula ExxonMobil Motorenöl Low Emission Meguin Gm...

Page 36: ...he engine is hot Steam and hot engine coolant will escape and seriously burn you Allow the engine to cool before attempting to remove the filler cap Securely tighten the filler cap after checking the coolant level Steam can escape during engine operation if the cap is loose Failure to comply will result in death or serious injury 0000002enMarine A CAUTION COOLANT HAZARD Wear eye protection and rub...

Page 37: ...uper Addinol Lube Oil GmbH Aral Antifreeze Extra Aral AG AVIA Antifreeze APN AVIA Mineralöl AG BMW Coolant BMW AG BP anti frost X 2270A BP Schmierstoff GMBH Hamburg Caltex CX Engine Coolant Caltex Castrol ANTI FREEZE NF Castrol International Fridex G48 Velena s a Glacelf Plus Total GlycoShell Shell International Glyco star Bremin Mineralöl GmbH Co Glysantin G48 24 Engine Coolant UNICO Ltd Glysanti...

Page 38: ... 278 47 psi Torque 317 N m 234 ft lb 355 N m 262 ft lb 487 N m 359 ft lb 545 N m 402 ft lb High Idle Speed 4600 rpm Low Idle Speed Warm Engine 88 C 190 F 750 rpm ECU controlled 670 rpm ECU controlled Cold Start Speed 20 C 68 F 1200 rpm gradually decreasing to warm engine idle 88 C 190 F ECU controlled Rev Limit fuel cut off 4600 rpm ECU controlled 4600 rpm ECU controlled Prop rpm Wide Open Throttl...

Page 39: ...tern Drive front to middle of engine mount 760 mm 29 9 in 942 mm 37 1 in Marine Gear front to marine gear mounting face 644 mm 25 4 in 825 5 mm 32 5 in Overall Length 861 mm 33 9 in 1001 mm 39 4 in Width 670 mm 26 4 in local exceeding Weight without marine gear Dry without mixing elbow 250 kg 551 lb 310 kg 683 lb Wet with mixing elbow 270 kg 595 lb 340 kg 750 lb Cylinder numbering starts at the co...

Page 40: ...Grade Lubricated 8 8 or 8 10 9 or 10 12 9 or 12 M4 2 7 N m 24 in lb 3 88 N m 34 3 in lb 4 6 N m 41 in lb M5 5 5 N m 48 6 in lb 8 N m 71 in lb 9 5 N m 84 in lb M6 9 5 N m 84 in lb 13 N m 115 in lb 16 N m 142 in lb M7 15 N m 133 in lb 22 N m 195 in lb 26 N m 230 in lb M8 23 N m 204 in lb 32 N m 24 ft lb 39 N m 29 ft lb M8 x 1 25 N m 221 in lb 35 N m 26 ft lb 42 N m 31 ft lb M10 46 N m 34 ft lb 64 N ...

Page 41: ...nd force per minute g gram gal gallon U S gal hr gallon U S per hour gal min gallon U S per minute GL gear lubricant hp horsepower U S hr hour I D inside diameter ID identification IDI indirect injection in inch in Aq inches Aqueous water in Hg inches Mercury in lb inch pound j joule JASO Japanese Automobile Standards Organization k kelvin kg kilogram kgf cm kilogram force per square centimeter kg...

Page 42: ...000 g kg x 2 20500 lb g x 0 03527 oz lbf x 4 4480 N lbf x 0 4536 kgf N x 0 2248 lbf N x 0 1020 kgf kgf x 2 2050 lbf kgf x 9 8070 N ft lb x 1 3558 N m ft lb x 0 1383 kgf m in lb x 0 1130 N m in lb x 0 0115 kgf m kgf m x 7 2330 ft lb kgf m x 86 8000 in lb kgf m x 9 8070 N m N m x 0 7376 ft lb N m x 8 8510 in lb N m x 0 1020 kgf m psi x 0 0689 bar psi x 6 8950 kPa psi x 0 0703 kg cm bar x 14 5030 psi...

Page 43: ...GENERAL SERVICE INFORMATION 3 22 BY Service Manual Unit Conversions This Page Intentionally Left Blank ...

Page 44: ...ts 4 6 Required EPA Maintenance 4 6 EPA Requirements 4 6 Conditions to Ensure Compliance with EPA Emission Standards 4 6 Inspection and Maintenance 4 7 Periodic Maintenance Schedule 4 8 Inspection and Maintenance of EPA Emission Related Parts 4 10 Periodic Maintenance Procedures 4 11 After Initial 50 Hours of Operation 4 11 Every 50 Hours of Operation 4 11 Every 250 Hours of Operation 4 11 Every 5...

Page 45: ...omply will result in death or serious injury 0000007en A DANGER SCALD HAZARD NEVER remove the coolant filler cap if the engine is hot Steam and hot engine coolant will escape and seriously burn you Allow the engine to cool before attempting to remove the filler cap Securely tighten the filler cap after checking the coolant level Steam can escape during engine operation if the cap is loose Failure ...

Page 46: ...0009en A DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions NEVER use diesel fuel as a cleaning agent Failure to comply will result in death or serious injury 0000012en A DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions NEVER remove the fuel cap with the engine running Failure to comply will result in dea...

Page 47: ...such as the flywheel or PTO shaft Wear tight fitting clothing and keep your hair short or tie it back while the engine is running Remove all jewelry before you operate or service the engine NEVER start the engine in gear Sudden movement of the engine and or vessel could cause death or serious personal injury NEVER operate the engine without the guards in place Before you start the engine make sure...

Page 48: ...ation of this gas within an enclosure could cause illness or even death Make sure that all connections are tightened to specifications after repair is made to the exhaust system Failure to comply could result in death or serious injury 0000003en A WARNING BURN HAZARD Keep your hands and other body parts away from hot engine surfaces such as the muffler exhaust pipe turbocharger and engine block du...

Page 49: ...only in USA Conditions to Ensure Compliance with EPA Emission Standards This product is an EPA approved engine The following are the conditions that must be met in order to ensure that the emissions during operation meet the EPA standards Be sure to follow these The operating conditions should be as follows Ambient temperature 16 to 40 C 3 to 104 F Relative humidity 80 or lower 4BY Maximum exhaust...

Page 50: ...on the user or the maker Inspection and Maintenance See Inspection and Maintenance of EPA Emission Related Parts on page 4 10 Inspection and maintenance procedures not shown in the Inspection and Maintenance of EPA Emission Related Parts section are covered in See Periodic Maintenance Schedule on page 4 8 This maintenance must be performed to keep the emission values of your engine in the standard...

Page 51: ...first Every 250 hoursorone year whichever comes first Every 500 hours or 2 years whichever comes first Whole Visual inspection of engine exterior c Before starting Fuel System Check for fuel leakage c Before starting Check the fuel level and refill if necessary c Before starting Drain water and sediment from fuel tank c Drain the fuel filter water separator c Replace the fuel pre filter Replace th...

Page 52: ...em Visual inspection c Before starting Replace turbocharger heat shield Check the exhaust pipe c Check the air intake pipes c Check the exhaust water mixing elbow c Clean or replace the air filter element c Electrical System Check the electrolyte level in the battery serviceable batteries only c Check the wiring connectors c Before starting Check alternator belt for wear c Check Replace System Ite...

Page 53: ...50 c Adjust the propeller shaft alignment if equipped with marine gear c Initial 50 c Check hydraulic oil cooler c Replace rubberized hoses fuel and water Check zinc anodes periodically Any anode having less than 1 2 its original size remaining should be replaced use this to establish a regular replacement interval Recommendation Use washing kit BMC WA250 355 c Check Replace System Item Periodic M...

Page 54: ...iment from Fuel Tank Replace the Fuel Pre Filter Replace the Fuel Fine Filter Replace the Fuel Filter Water Separator Element Change the Engine Oil and Replace the Engine Oil Filter Element Check Replace the Seawater Pump Belt Replace the Zinc Anodes Check or Replace the Seawater Pump Impeller Replace the Turbocharger Heat Shield Check the Exhaust Water Mixing Elbow Clean or Replace the Air Filter...

Page 55: ...PERIODIC MAINTENANCE 4 12 BY Service Manual Periodic Maintenance Procedures This Page Intentionally Left Blank ...

Page 56: ...5 17 Testing Compression 5 17 Repair 5 18 Cylinder Head 5 19 Cylinder Head Components 5 19 General Guidelines 5 20 Remove and Install Cylinder Head Cover 5 20 Remove and Install Glow Plugs 5 22 Removal of Cylinder Head 5 23 Disassembly of Cylinder Head 5 26 Cleaning Cylinder Head Components 5 28 Pressure Testing Cylinder Head 5 28 Inspection of Cylinder Head Components 5 28 Replacing Valve Stem Se...

Page 57: ...d Adjusting Camshaft Timing 5 48 Removing and Installing Vibration Damper 4BY 5 50 Removing and Installing Vibration Damper 6BY 5 51 Removing Timing Case Cover 5 52 Removing and Installing Timing Chain 5 52 Installing Timing Case Cover 5 53 Removing and Installing Timing Chain Tensioner 5 54 Removal of Camshafts 5 54 Installation of Camshafts 5 57 Cylinder Block and Crankshaft 5 60 Components 5 60...

Page 58: ... DANGER CRUSH HAZARD NEVER stand under hoisted engine If the hoist mechanism fails the engine will fall on you causing death or serious injury Failure to comply will result in death or serious injury 0000033enMarine A DANGER CRUSH HAZARD ALWAYS use the engine lifting eyes when lifting the marine engine The lifting eyes are engineered to lift the weight of the marine engine only ALWAYS use lifting ...

Page 59: ...en A WARNING BURN HAZARD Handle hot components with heat resistant gloves Failure to comply could result in death or serious injury 0000110en A WARNING FUME BURN HAZARD Always read and follow safety related precautions found on containers of hazardous substances like parts cleaners primers sealants and sealant removers Failure to comply could result in death or serious injury 0000014en A WARNING B...

Page 60: ...NEVER overfill Overfilling may result in white exhaust smoke engine overspeed or internal damage 0000005enBY CAUTION Only use the engine coolant specified Other engine coolants may affect warranty coverage cause an internal buildup of rust and scale and or shorten engine life Prevent dirt and debris from contaminating engine coolant Carefully clean the filler cap and the surrounding area before yo...

Page 61: ...t the air cleaner turbocharger if equipped and electric components from damage when you use steam or high pressure water to clean the engine 0000014en CAUTION NEVER hold the key in the START position for longer than 10 seconds or the starter motor will overheat 0000201en ...

Page 62: ...ngines SPECIFICATIONS General Information Test and Adjustment Specifications Engine Model 4BY 6BY Number of Cylinders In Line 4 In Line 6 Bore 84 mm 84 mm Stroke 90 mm 90 mm Effective Displacement 1995 cc 122 cu in 2993 cc 183 cu in Compression Ratio 16 5 1 16 5 1 Test Item Remarks Specification Cylinder Compression Test Compression Pressure 28 2 bar 406 29 psi ...

Page 63: ... 18 85 0 08 mm 0 742 0 003 in Valve Seat Angle 45 Outer Correction Angle 15 Inner Correction Angle 60 Valve Seat Width Intake 1 0 0 1 mm 0 039 0 004 in Valve Seat Width Exhaust 1 2 0 1 mm 0 047 0 004 in Valve Seat Surface Outside Diameter Intake 24 5 0 1 mm 0 965 0 004 in Valve Seat Surface Outside Diameter Exhaust 24 4 0 1 mm 0 961 0 004 in Camshaft Thrust Bearing Width 19 000 0 01 mm 0 748 0 004...

Page 64: ...0 50 White 59 464 59 469 mm 2 3411 2 3413 in Crankshaft Bearing Clearance Radial 0 019 0 052 mm 0 0007 0 0020 in Crankshaft Thrust Bearings Standard 25 00 0 020 0 066 mm 0 9842 0 0008 0 0026 in Size 1 25 2 0 020 0 066 mm 0 9921 0 0008 0 0026 in Size 2 25 4 0 020 0 066 mm 1 000 0 0008 0 0026 in Crankshaft Axial Play 0 06 0 25 mm 0 0024 0 0098 in Connecting Rod Journals Standard 45 00 0 009 0 025 mm...

Page 65: ...e Cylinder Block Bore Diameter stage 0 84 007 0 007 mm 3 3074 0 0003 in Bore Diameter stage 1 84 257 0 007 mm 3 3172 0 0003 in Permitted out of round of cylinder bore 0 005 mm 0 0002 in Permitted conicity of cylinder bore 0 01 mm 0 0004 in Permitted total wear tolerance piston to cylinder 0 15 mm 0 006 in Oil Change Volume Includes Oil Filters 4BY 8 0 L 8 5 qt 6BY 11 0 L 11 5 qt Values are for new...

Page 66: ...9 Assembly Torque Initial Torque Torque angle 5 N m 44 in lb 20 N m 177 in lb 70 Cylinder Head with Cover Cylinder Head Bolts Replace wash and oil 4BY 6BY M12x1 5 Initial Torque then Loosen all bolts 180 2nd Torque 1st Torque Angle 2nd Torque Angle 80 N m 59 ft lb 50 N m 37 ft lb 90 90 Seal Plug Replace screws 4BY 6BY M14x1 5 30 N m 22 ft lb Camshaft Sprocket to Camshaft 4BY 6BY M7x19 15 N m 133 i...

Page 67: ...aling Rings 22 N m 195 in lb Turbocharger Oil Return to Crankcase 4BY 6BY Hose Clamp 3 N m 27 in lb Exhaust Manifold to Cylinder Head 4BY Apply Copper Anti seize to Threads 19 N m 168 in lb 6BY 13 N m 115 in lb Alternator Wires to Alternator 4BY M8 13 N m 115 in lb Alternator to Crankcase 4BY M10 38 N m 28 ft lb Belt Pulley with Free Wheel 4BY 80 N m 59 ft lb Electrical System Engine Wiring Harnes...

Page 68: ...Fuel Rail 4BY 6BY 70 N m 52 ft lb Pressure Regulator to Fuel Rail 4BY 6BY 80 N m 59 ft lb Fuel Return to Rail 4BY 6BY Banjo Bolt 25 N m 221 in lb Poly V Belt Drive Idler Pulley to Alternator Bracket 4BY M8x35 10 9 28 N m 21 ft lb Thermostat and Coolant Pipes Coolant Return Pipe to Crankcase and Oil Filter Housing 4BY M8x18 11 N m 97 in lb Glow Plugs Glow Plugs 4BY 6BY 17 5 N m 154 in lb System Com...

Page 69: ... having part numbers must be obtained locally No Tool Name Applicable Model and Tool Size Illustration 1 Valve Spring Compressor Obtain Locally 2 Valve Stem Seal Installer OEM Part No 11 6 370 Remover 11 1 960 Protector and 11 6 380 Installer 3 Cylinder Compression Tester OEM Part No 11 0 222 and 11 0 236 4 Piston Ring Compressor For Installing Piston Obtain Locally 5 Piston Ring Tool For Removing...

Page 70: ...side diameters of crankshaft pistons piston pins etc 4 Cylinder Bore Gauge For measuring the inside diameters of cylinder bores bearing bores etc 5 Calipers For measuring outside diameters depth thickness and width 6 Depth Micrometer For measuring valve recession 7 Square For measuring valve spring inclination and straightness of parts 8 Torque Wrench For tightening nuts and bolts to the specified...

Page 71: ...ENGINE 5 16 BY Service Manual Measuring Instruments 9 Feeler Gauge For measuring piston ring gaps and piston ring side clearance No Instrument Name Application Illustration 0000841 ...

Page 72: ... Turn engine over several times using the starter motor to remove any loose debris in the cylinders Figure 5 1 4 Assemble special tools OEM No 11 0 222 and 11 0 236 and install in glow plug port Figure 5 1 5 Turn engine with the starter motor until reading on gauge stabilizes Note reading on the gauge 6 Reset gauge and repeat procedure with the remaining cylinders 7 Connect fuel injector electrica...

Page 73: ...ngine repair stand having adequate weight capacity 6 Cap or plug all openings to prevent contamination 7 Remove starter motor and alternator 8 Clean engine by washing with solvent air or steam cleaning Carefully operate cleaning equipment so as to prevent any foreign matter or fluids from entering engine or any fuel system or electrical components remaining on the engine 9 Remove cooling system co...

Page 74: ...aft 3 Hydraulic Rocker Arm Pivot 4 Valve Keeper 2 used each valve 5 Cam Follower 6 Valve Spring Retainer 7 Valve Spring 8 Valve Stem Seal 9 Coolant Temperature Sensor 10 Valve 11 Cylinder Head Gasket 12 Head Gasket Identification Holes 13 Cylinder Head 14 Cylinder Head Bolt 15 Bolt 10 15 14 1 2 3 4 5 4 11 13 6 7 8 9 0003654 12 ...

Page 75: ...bber Gasket 3 Oil Fill Cap 4 Seal 5 Crankcase Ventilation Diaphragm Housing 6 Seal 7 Double Ended Bolt 8 Bolt 9 Profile Gasket IMPORTANT When working on the oil coolant or fuel circuits you must protect the alternator from contamination Cover alternator with suitable materials Failure to comply may result in an alternator failure CAUTION Identify all parts and their location using an appropriate m...

Page 76: ...rom breather 6 Remove oil fill cap Figure 5 4 4 and lift rubber gasket Figure 5 4 5 to access bolt located below 7 Remove cylinder head cover bolts in sequence working from the outer bolts toward the center 8 Remove cylinder head cover Installation 1 Thoroughly clean all gasket residue from the mating surfaces Figure 5 5 2 Apply a thin uniform bead of Three Bond 1207F Yanmar part No 977770 1207F a...

Page 77: ...mshaft sensor intake air pressure sensor and intake air temperature sensor 10 Install engine cover Remove and Install Glow Plugs 1 Disconnect battery negative terminal 2 Remove intake manifold See Intake Manifold on page 5 70 Figure 5 7 3 Release locks and remove connector Figure 5 7 1 from glow plug Figure 5 8 4 Use special tool OEM No 11 6 050 to remove glow plug Figure 5 8 1 from cylinder head ...

Page 78: ...ove heat exchanger See Remove and Install Heat Exchanger on page 7 16 6 Remove front and rear heat exchanger mounting brackets Figure 5 9 3 7 Remove exhaust manifold See Exhaust Manifold on page 5 72 8 Remove cylinder head cover See Remove and Install Cylinder Head Cover on page 5 20 Figure 5 10 9 Rotate crankshaft using the crankshaft dampener bolt until No 1 cylinder is at TDC Secure flywheel us...

Page 79: ...fitting Figure 5 12 1 15 Disconnect electrical connector from coolant temperature sensor Figure 5 12 2 Figure 5 13 16 Remove high pressure fuel rail See Removing and Installing Fuel Rail on page 6 27 17 Remove pump to fuel rail high pressure line Figure 5 13 1 Note 4BY Engines Make note of position of the rubber mount Figure 5 13 3 for reassembly 18 Remove glow plugs Figure 5 13 2 See Remove and I...

Page 80: ...igure 5 15 1 Figure 5 16 20 4BY Engines Remove cylinder head bolts in reverse sequence beginning with number 10 Figure 5 16 Figure 5 17 21 6BY Engines Remove cylinder head bolts in reverse sequence beginning with number 14 Figure 5 17 22 Remove cylinder head 23 Remove the cylinder head gasket ...

Page 81: ...lace special tool OEM No 11 9 008 with straight surface on combustion chamber side of cylinder head Figure 5 19 Figure 5 20 3 Insert special tool OEM No 11 9 006 and lock with special tool OEM No 11 9 005 in direction of arrows Figure 5 20 Figure 5 21 4 Lock special tool OEM No 11 9 005 in direction of arrows Figure 5 21 Rotate cylinder head 180 into service position ...

Page 82: ...ess down to compress valve spring and lock in place with special tool OEM No 11 9 011 Figure 5 23 8 Remove valve keepers Figure 5 23 Figure 5 24 1 Valve 2 Valve Stem Seal 3 Valve Spring 4 Valve Spring Retainer 5 Valve Keeper 2 used each valve 9 Release tension on valve spring and remove valve spring retainer and valve spring 10 Remove valve stem seals See Replacing Valve Stem Seals on page 5 29 ...

Page 83: ...26 Note Reduce surface tension of water used for test with a few drops of detergent 3 Connect air source to cylinder head and immerse in water bath Apply pressure and adjust to 4 5 bar 65 psi Figure 5 26 4 Inspect cylinder head for discharge of bubbles indicating a crack in the casting Inspection of Cylinder Head Components Clean all gasket material sealant and carbon from components Use a suitabl...

Page 84: ...er head and valves must be replaced Specifications Replacing Valve Stem Seals 1 Remove the valve spring It is not necessary to remove valve Figure 5 28 2 Press special tool OEM No 11 6 370 onto valve stem seal and turn Figure 5 28 3 Remove special tool together with valve stem seal Figure 5 29 4 Lubricate valve stem and install special tool OEM No 11 1 960 5 Coat new valve stem seal Figure 5 29 1 ...

Page 85: ...ylinder head 3 Install new valve stem seals See Replacing Valve Stem Seals on page 5 29 Figure 5 31 4 Secure cylinder head to special tool OEM No 11 9 001 Figure 5 31 5 Install spring compressor OEM No 11 9 015 on lever OEM No 11 9 009 Figure 5 31 6 Install valve spring and retainer Figure 5 32 7 Press down to compress valve spring and lock in place with special tool OEM No 11 9 011 Figure 5 32 8 ...

Page 86: ...ide fixture and indicator over cleaned area of piston Figure 5 34 1 Rotate the crankshaft to determine the highest point of piston travel and record the measurement Repeat the procedure in a second area Figure 5 34 2 6 Measure all pistons in the same manner Figure 5 35 7 Select the lesser measurement for all pistons and use the following chart to choose the correct gasket Gasket thickness is ident...

Page 87: ...2 Check condition and placement of alignment dowel sleeves Figure 5 36 1 3 Ensure the gasket surfaces of the cylinder head and cylinder block are clean and dry Transition areas Figure 5 36 2 must be absolutely clean of grease and oil IMPORTANT Ensure the threaded bolt holes are clean and dry If coolant or oil remains in the holes there is a risk of cracking the cylinder block when the bolts are in...

Page 88: ... and tighten Figure 5 40 8 Install high pressure pump to fuel rail line Figure 5 40 1 4BY Engines Install rubber mount Figure 5 40 3 9 Install glow plugs Figure 5 40 2 10 Install high pressure fuel rail See Removing and Installing Fuel Rail on page 6 27 Figure 5 41 11 Connect harness connector to temperature sensor Figure 5 41 2 12 Install coolant branch fitting with a new seal and tighten bolts F...

Page 89: ... 43 16 Rotate crankshaft using the crankshaft dampener bolt until No 1 cylinder is at TDC Secure flywheel using flywheel holding tool IMPORTANT NEVER mix used valve train components Whenever installing valve train components be sure to install them in their original positions 17 Install all hydraulic rocker arm pivots and cam followers 18 Install both camshafts See Installation of Camshafts on pag...

Page 90: ...gaskets Tighten securely 23 Connect wires Figure 5 44 2 to oil pressure sender 24 Install heat exchanger See Remove and Install Heat Exchanger on page 7 16 25 Install turbocharger See Turbocharger Installation on page 9 10 26 Fill engine with coolant 27 Connect negative battery cable 28 Bleed fuel system See Bleeding the Fuel System on page 6 29 29 Start engine and check for leaks 0003765 1 3 2 ...

Page 91: ... make it impossible to remove the pistons Use a suitable ridge reamer to remove ridges and carbon prior to removing pistons 5 Remove the ridge at the top of the cylinder if necessary 6 Mark each piston and connecting rod before removing them They must be installed in the same location and orientation as they were removed Figure 5 46 IMPORTANT Pistons can fall from cylinder block if engine is inver...

Page 92: ...ing care not to scratch the surface of the piston Inspection of Pistons and Piston Rings Figure 5 49 Note Measure cylinder bore to ensure it is within specifications before measuring piston ring end gap See Inspection of Cylinder Block on page 5 66 1 Insert each piston ring one at a time into the cylinder Use a piston with the piston rings removed to slide the ring squarely into the cylinder bore ...

Page 93: ... with the second ring Note The oil ring third groove cannot be measured 6 Repeat steps for each of the cylinders and the piston rings for that specific cylinder Assembling Piston and Connecting Rod 1 Clean the piston and rings thoroughly without damaging the ring grooves 2 Oil the wrist pin bore and wrist pin before assembling Figure 5 51 3 Check the fit of the wrist pin in the connecting rod The ...

Page 94: ...ng Figure 5 54 3 has an expander spring underneath it Figure 5 54 4 Install the expander end gap and oil ring end gap 180 apart Stagger all exposed ring gaps 120 from each other with none in line with the wrist pin Installation of Piston and Connecting Rod IMPORTANT ALL parts that are being reused MUST be installed in their original location and orientation Figure 5 55 Figure 5 56 1 Bearing insert...

Page 95: ...6 Lubricate the piston piston rings cylinder bore and piston ring compressor with clean engine oil Figure 5 58 7 Position the piston rings so that the ring gaps are distributed evenly approximately 120 apart around the piston and not in line with the wrist pin Install piston ring compressor Figure 5 58 Figure 5 59 IMPORTANT NEVER force piston or drive piston into cylinder bore Install using only f...

Page 96: ...cisely If it does not the piston will become too warm resulting in engine breakdown Do not straighten damaged nozzles They must be replaced 14 Check that the piston cooling nozzles are in perfect condition and fully open If necessary clean with compressed air 15 Install the piston cooling nozzles and tighten the banjo bolts to 23 N m 17 ft lb 16 Install oil deflector and tighten bolts to 10 N m 89...

Page 97: ...sleeves Figure 5 63 5 and dowel Figure 5 63 6 6 Clean mating surfaces Install alignment sleeves and dowel in flywheel housing 7 Install flywheel housing 8 Install washers on the M10 x 130 M8 x 130 and M8 x 40 bolts 9 Install 11 bolts and washers Tighten in two stages to specifications Flywheel Housing Torque 10 Install starter See Remove and Install Starter Motor on page 10 7 11 Connect battery ne...

Page 98: ... Install flywheel holding tool to prevent flywheel rotation IMPORTANT Ensure all mating surfaces are clean and dry 2 Stern drive engines Install coupler adapter and tighten eight bolts to specification 3 Install coupler Install bolts and washers washers used on stern drive engines only Tighten to specification Drive Coupling Torque 4 Remove flywheel holding tool 5 Install flywheel housing See Remo...

Page 99: ... engage properly Replacement of Rear Crankshaft Seal 1 Drain engine oil 2 Remove flywheel See Removal of Flywheel on page 5 44 3 Remove oil sump See Remove and Install Oil Sump on page 8 16 Figure 5 66 4 Remove bolt Figure 5 66 2 and crankshaft sensor Figure 5 66 3 See Replacing Crankshaft Sensor on page 12 26 5 Remove bolts Figure 5 66 1 and remove rear crankshaft seal and housing as an assembly ...

Page 100: ...torque plate Figure 5 65 2 IMPORTANT Never reuse flywheel bolts Always install new flywheel bolts 3 Install the flywheel on the crankshaft Note Flywheel bolts are T 60 Torx head 4 Apply medium strength thread lock and sealer to the threads of the flywheel bolts Figure 5 65 1 Install bolts and tighten to initial torque specification Flywheel Bolt Torque 5 Tighten flywheel bolts to final torque spec...

Page 101: ...ENGINE 5 46 BY Service Manual Camshaft and Timing Gear Train CAMSHAFT AND TIMING GEAR TRAIN Components Figure 5 69 0004027 19 20 21 5 22 1 2 3 4 5 6 7 8 9 14 16 15 5 13 12 10 11 18 17 ...

Page 102: ...ide Rail Pin 6 Upper Timing Chain 7 Sprocket 8 Timing Case Cover Gasket 9 Timing Case Cover 10 O Ring 11 Access Plug 12 Plug 13 Seal 14 Guide Rail 15 Sprocket to High Pressure Pump Nut 16 Lower Timing Chain 17 Crankshaft Sprocket 18 Lower Chain Tensioner 19 Hydraulic Tensioner 20 Pivot Pin 21 Upper Chain Tensioner 22 Sprocket Retaining Screw ...

Page 103: ... 5 71 IMPORTANT DO NOT rotate the crankshaft backward If the crankshaft is turned past TDC rotate two more turns 720 to bring No 1 piston back to TDC 4 Secure crankshaft in TDC position with flywheel holding tool OEM No 11 5 180 Figure 5 71 Figure 5 72 Note Special tool shown on intake camshaft Exhaust camshaft is checked in the same manner but has no adjustment If camshaft gears are properly alig...

Page 104: ...wer stroke The front lobe of each camshaft Figure 5 74 1 will be facing toward the exhaust side and the timing marks Figure 5 74 2 will meet 4 Verify position by checking the camshaft timing marks Figure 5 74 2 on gears are aligned The single mark on intake camshaft gear must fall between the two marks on the exhaust camshaft gear Figure 5 75 IMPORTANT DO NOT rotate the crankshaft backward If the ...

Page 105: ...nstall cylinder head cover See Remove and Install Cylinder Head Cover on page 5 20 Removing and Installing Vibration Damper 4BY 1 Disconnect battery negative cable 2 Remove alternator and seawater pump drive belts See Remove and Install Alternator on page 11 7 and Replace Seawater Pump Belt on page 7 21 Figure 5 78 Note A shop made flywheel holder can be fabricated using a piece of an old ring gea...

Page 106: ...rive belts See Remove and Install Alternator on page 11 7 and Replace Seawater Pump Belt on page 7 21 Figure 5 81 3 Remove bolts Figure 5 78 1 4 Remove the vibration damper 5 Place vibration damper on crankshaft and install new bolts 6 Torque turn tighten bolts diagonally to specification Specifications 7 Install alternator and seawater pump belts See Remove and Install Alternator on page 11 7 and...

Page 107: ...emove vibration dampener See Removing and Installing Vibration Damper 4BY on page 5 50 or Removing and Installing Vibration Damper 6BY on page 5 51 7 Remove front crankshaft seal See Replacing Front Crankshaft Seal on page 5 68 8 Remove alternator belt tensioner 9 4BY Remove alternator See Remove and Install Alternator on page 11 7 Figure 5 82 10 Remove bolts securing cover and remove timing case ...

Page 108: ...1 Install gasket Figure 5 85 and apply a thin coat of Three Bond 1207F Yanmar part No 977770 1207F sealing agent to gasket at ends arrow on both sides 4 Install timing case cover 5 Install all bolts and tighten to an initial torque of 5 N m 44 in lb then tighten in an alternating sequence to final torque specification of 14 N m 124 in lb 6 After all bolts have been tightened to final specification...

Page 109: ...ove bolts Figure 5 86 3 4 Remove chain tensioner Figure 5 86 2 5 Installation is in the reverse of removal Removal of Camshafts 1 Remove cylinder head cover See Remove and Install Cylinder Head Cover on page 5 20 2 Drain engine coolant 3 Remove alternator drive belt See Remove and Install Alternator on page 11 7 Figure 5 87 4 Remove cover Figure 5 87 1 and bracket Figure 5 87 2 5 Rotate the cranks...

Page 110: ...gure 5 89 7 Remove plug Figure 5 89 from timing case cover 8 Rotate crankshaft counterclockwise 45 Figure 5 90 9 Use a wrench Figure 5 90 2 to turn exhaust camshaft Figure 5 90 1 in direction of arrow to compress the timing chain tensioner Figure 5 91 10 While holding the exhaust camshaft rotated secure the tensioner in place using special tool OEM No 11 3 340 Figure 5 91 0003774 1 ...

Page 111: ...tween the two marks on the exhaust camshaft gear Figure 5 93 IMPORTANT DO NOT rotate the crankshaft backward If the crankshaft is turned past TDC rotate two more turns 720 to bring No 1 piston back to TDC 13 Secure crankshaft in TDC position with flywheel holding tool Figure 5 93 Figure 5 94 IMPORTANT Do not remove the camshaft sprocket screws without first locking the chain tensioner in the relea...

Page 112: ...rds the center IMPORTANT Camshaft bearing caps are numbered and must be installed in their original locations 20 Remove all bearing caps 21 Remove the intake Figure 5 97 2 and exhaust Figure 5 97 3 camshafts Figure 5 98 IMPORTANT NEVER remove bolts retaining loop casting Figure 5 98 Installation of Camshafts 1 Lubricate all camshaft bearings caps and journals with clean engine oil Figure 5 99 2 Id...

Page 113: ...ft bearing caps are marked A1 A7 5 Lightly oil the threads of all bolts and install finger tight 6 Tighten all bearing caps evenly in 1 2 turn increments starting at the center and working toward each end until all bearing caps are seated 7 Tighten all bearing cap bolts to 10 N m 89 in lb 8 Install chain on sprocket and install sprocket on intake camshaft Tighten bolts until snug 9 Install guide r...

Page 114: ...ENGINE BY Service Manual 5 59 Camshaft and Timing Gear Train This Page Intentionally Left Blank ...

Page 115: ...ENGINE 5 60 BY Service Manual Cylinder Block and Crankshaft CYLINDER BLOCK AND CRANKSHAFT Components Figure 5 102 0004029 1 2 3 4 5 5 6 13 12 12 14 15 16 17 7 8 9 10 11 9 9 18 ...

Page 116: ...t Seal Assembly 9 Lower Main Bearing Inserts 10 Lower Main Thrust Bearing Insert 11 Oil Deflector 12 Upper Main Bearing Inserts 13 Upper Main Thrust Bearing Insert 14 Main Bearing Cap Bolt 15 Dowel Sleeve 16 Timing Chain Oiler 17 Seal 18 Main Bearing Cap Note Service procedures for 4BY and 6BY engines are similar therefore graphics shown will be representative and might not match the engine being ...

Page 117: ...nstalling Timing Chain on page 5 52 7 Remove oil sump oil suction pipe and strainer and the oil pump See Oil Pump on page 8 17 Figure 5 103 8 Remove oil deflector Figure 5 103 1 9 Remove pistons and connecting rods See Removal and Disassembly of Piston and Connecting Rod on page 5 36 10 Before removing main bearing caps measure crankshaft end play Figure 5 104 Mount a dial indicator on the cylinde...

Page 118: ...l Clearance Oil clearance should be checked during disassembly to determine the extent of wear and during reassembly to ensure long engine life The same procedure is done for both connecting rods and main bearings 1 Remove the bearing cap Do not remove the bearing inserts at this time 2 Wipe oil from the bearing insert and crankshaft journal surfaces Figure 5 107 3 Place a piece of PLASTIGAGE Figu...

Page 119: ...Oil Clearance 3 Bearing Inserts red or blue 4 Bearing Cap Rt Red Bl Blue 7 Figure 5 109 and Figure 5 110 show the relationship of each color coding compared to diameter If necessary install bearing inserts having a different color coding 8 Repeat with the remaining bearings Inspection of Crankshaft 1 Use the color check method or MAGNAFLUX to inspect the crankshaft for cracks Replace the crankshaf...

Page 120: ... mm 2 3416 2 3418 in Undersize 2 U 0 50 Green 59 470 59 476 mm 2 3413 2 3416 in Undersize 2 U 0 50 White 59 464 59 469 mm 2 3411 2 3413 in Crankshaft Bearing Clearance Radial 0 019 0 052 mm 0 0007 0 0020 in Connecting Rod Journals Specification Standard 45 00 0 009 0 025 mm 1 7716 0 0004 0 0010 in Size 1 44 75 0 009 0 025 mm 1 7618 0 0004 0 0010 in Size 2 44 50 0 009 0 025 mm 1 7520 0 0004 0 0010 ...

Page 121: ... measurements are not within specification 5 Take measurements at three places a b c and in two directions d and e in each cylinder Cylinder Bore Specifications Crankshaft Installation 1 Select the correct bearing as follows Figure 5 112 a Locate and record the grinding size of crankshaft Figure 5 112 Figure 5 113 b The crankshaft will be marked with yellow green or white paint to determine the co...

Page 122: ...yellow painted main bearing inserts in the cylinder block and main bearing caps Apply a generous amount of clean engine oil to the bearing inserts Ensure all oil holes are properly aligned Do not lubricate the crankshaft journals at this time 3 Carefully lower the crankshaft into place Do not rotate crankshaft 4 Check bearing oil clearance before proceeding See Measuring Oil Clearance on page 5 63...

Page 123: ...n page 5 44 15 Install timing case cover using a new gasket See Installing Timing Case Cover on page 5 53 16 Install vibration damper See Removing and Installing Vibration Damper 4BY on page 5 50 or Removing and Installing Vibration Damper 6BY on page 5 51 17 Install flywheel See Installation of Flywheel on page 5 45 18 Install flywheel housing See Remove and Install Flywheel Housing on page 5 42 ...

Page 124: ... housing 5 Turn center screw in to remove seal 6 Wipe the sealing surface in the cover clean 4BY Engines 6BY Engines Figure 5 120 7 Install seal protector tool OEM No 11 7 400 4BY or 11 6 470 6BY on end of crankshaft Lubricate surface of tool with clean engine oil IMPORTANT NEVER touch the sealing lip of the new seal with your fingers 8 Slip seal over seal protector until it contacts case cover Re...

Page 125: ...n Damper 4BY on page 5 50 13 Install belts See Remove and Install Alternator on page 11 7 and Replace Seawater Pump Belt on page 7 21 INTAKE MANIFOLD Removal Figure 5 122 1 Remove injector harness connectors Figure 5 122 1 from all fuel injectors 2 Remove screws Figure 5 122 2 and move injector harness out of the way Figure 5 123 3 Disconnect electrical connectors from charge air pressure sensor F...

Page 126: ...ts Figure 5 125 1 9 Remove nuts Figure 5 125 2 10 Remove intake manifold Installation 1 Clean all sealing surfaces Figure 5 126 2 Install new sealing rings Figure 5 126 1 3 Check condition of rubber mounts Figure 5 126 2 and replace if damaged 4 Install manifold on engine 5 Install bolts and nuts Tighten to 15 N m 133 in lb Figure 5 127 6 Install fuel fine filter Connect inlet Figure 5 127 1 and o...

Page 127: ...t Exchanger on page 7 16 2 Remove turbocharger See Turbocharger Removal on page 9 9 6BY Engine Shown Figure 5 129 3 Remove nuts Figure 5 129 1 4 6BY Engines Remove plates Figure 5 129 2 5 Remove manifold from engine Install 1 Clean mounting surfaces of all gasket material 2 Apply a light coating of copper anti seize to mounting studs 3 Install new gaskets 4 Install manifold with new nuts 6BY Engin...

Page 128: ...re to use a stand of adequate capacity to safely support the engine to be repaired and that it is securely attached to the engine A DANGER CRUSH HAZARD NEVER stand under hoisted engine If the hoist mechanism fails the engine will fall on you causing death or serious injury Failure to comply will result in death or serious injury 0000033enMarine ...

Page 129: ...ENGINE 5 74 BY Service Manual Attaching Engine to Repair Stand This Page Intentionally Left Blank ...

Page 130: ...w Diagram 6 10 Tests and Adjustments 6 11 Measuring Fuel Feed Pump Pressure 6 11 Testing Return Fuel Pressure 6 12 Repair 6 13 Removal of Fuel Injector 6 13 Cleaning Fuel Injector Cavities 6 14 Installation of Fuel Injector 6 16 Removing and Installing High Pressure Fuel Lines 6 17 Replacing the Fuel Feed Pump 6 19 Replacing High Pressure Fuel Pump 6 20 Replacing Fuel Filters 6 24 Removing and Ins...

Page 131: ...FUEL SYSTEM 6 2 BY Service Manual This Page Intentionally Left Blank ...

Page 132: ... Failure to comply will result in death or serious injury 0000009en A WARNING ENTANGLEMENT HAZARD Stop the engine before you begin to service it NEVER leave the key in the key switch when you are servicing the engine Someone may accidentally start the engine and not realize you are servicing it This could result in a serious injury If you must service the engine while it is operating remove all je...

Page 133: ...azardous substances like parts cleaners primers sealants and sealant removers Failure to comply could result in death or serious injury 0000014en A CAUTION FLYING OBJECT HAZARD ALWAYS wear eye protection when servicing the engine and when using compressed air or high pressure water Dust flying debris compressed air pressurized water or steam may injure your eyes Failure to comply may result in min...

Page 134: ...ulting in engine damage 0000182en CAUTION NEVER hold the key in the START position for longer than 10 seconds or the starter motor will overheat 0000201en CAUTION Identify all parts and their location using an appropriate method It is important that all parts are returned to the same position during the reassembly process 0000080en CAUTION Immediately cap or plug all openings to prevent contaminat...

Page 135: ...n Reference Page High Pressure Fuel Pump Pressure Minimum at cranking 250 bar 3625 psi Minimum at low idle 400 bar 5800 psi Maximum at 4000 rpm 1600 bar 23 200 psi Fuel Feed Pump Pressure Minimum All speeds 5 0 bar 73 psi See Measuring Fuel Feed Pump Pressure on page 6 11 Return Fuel Pressure Maximum All speeds 200 mmAq 7 87 in Aq See Testing Return Fuel Pressure on page 6 12 Fuel Supply Restricti...

Page 136: ...ure Fuel Control Valve on page 12 27 High Pressure Fuel Sensor Retaining Nut 70 N m 52 ft lb Replacing High Pressure Fuel Sensor on page 12 28 High Pressure Pump Sprocket Nut Access Plug M30 x 1 0 70 N m 52 ft lb Replacing High Pressure Fuel Pump on page 6 20 M40 x 1 5 30 N m 22 ft lb High Pressure Pump Drive Sprocket Nut 65 N m 48 ft lb High Pressure Fuel Line Union Nut 23 N m 204 in lb Removing ...

Page 137: ...ot having part numbers must be acquired locally No Tool Name Applicable Model and Tool Size Illustration 1 Diagnostic Tool Obtain Locally 2 Union Nut Wrench For Removing and Installing High Pressure Fuel Lines OEM Part No 13 5 020 3 Injector Removal Adapter For Removing Fuel Injectors OEM Part No 13 5 231 13 5 232 and 13 5 233 3 Slide Hammer For Removing Fuel Injectors OEM Part No 13 5 250 4 Fuel ...

Page 138: ...h Pressure Line from Pump 7 Rubber Insulator 8 High Pressure Pump with Fuel Measuring Unit 9 High Pressure Fuel Regulator 6BY Engines Figure 6 2 1 High Pressure Line Cylinders No 1 3 and 5 2 High Pressure Line Cylinders No 2 4 and 6 3 Fuel Injectors 4 High Pressure Fuel Rail 5 High Pressure Fuel Regulator 6 High Pressure Line from Pump 7 High Pressure Pump with Fuel Measuring Unit 8 Rubber Insulat...

Page 139: ... Temperature Sensor 6 High Pressure Fuel Pump 7 High Pressure Fuel Supply Line 8 High Pressure Fuel Rail 9 Fuel Injection Line 10 Fuel Injector 11 Fuel Injector Return Hose 12 Common Rail Return Line 13 Return Fuel Tee 14 High Pressure Pump Return Hose 15 Return Fuel to Fuel Tank 16 Fuel Pressure Sensor 17 Fuel Pressure Regulator ECU Controlled 18 Fuel Measuring Unit ECU Controlled 0003634 3 2 14 ...

Page 140: ...ure 6 4 1 Figure 6 5 2 Disconnect the fuel hose from the fuel fine filter inlet Figure 6 5 1 3 Connect test gauge assembly between disconnected ends Install and tighten hose clamps 4 Start engine and set speed to low idle Read and record pressure 5 Operate engine at full load Read and record pressure CAUTION ALWAYS be environmentally responsible Follow the guidelines of the EPA or other government...

Page 141: ...and tighten hose clamps 4 Start engine and allow speed to stabilize at normal low idle 5 Read and record pressure Specification Results If test pressure reading is not within specifications find and correct the return fuel restriction Inspection Item RPM Specification Fuel Feed Pump Pressure Minimum All 5 bar 73 psi CAUTION ALWAYS be environmentally responsible Follow the guidelines of the EPA or ...

Page 142: ... page 5 70 4 Remove return fuel line from fuel injector See Replacing Injector Return Fuel Line on page 6 28 Figure 6 7 5 If removing only one fuel injector remove the clamp Figure 6 7 1 joining the fuel injector lines to each other 6 Remove high pressure fuel line Figure 6 7 2 from injector and fuel rail See Removing and Installing High Pressure Fuel Lines on page 6 17 CAUTION ALWAYS be environme...

Page 143: ... the bottom of the injector seat Cleaning Fuel Injector Cavities 1 Remove fuel injector See Removal of Fuel Injector on page 6 13 Figure 6 10 2 Ensure the injector seal has been removed from the bottom of the injector cavity Figure 6 10 1 Figure 6 11 3 Thread the tip special tool OEM No 13 5 215 Figure 6 11 1 onto the end of special tool OEM No 13 5 214 Figure 6 11 2 4 Ensure O ring Figure 6 11 3 ...

Page 144: ...while covering cavity with cloth to catch debris 11 Inspect to ensure sealing surface is clean Repeat cleaning if necessary 12 Use special tool OEM No 13 5 214 to remove tip special tool OEM No 13 5 215 from bottom of injector cavity See Installation of Fuel Injector on page 6 16 A CAUTION FLYING OBJECT HAZARD ALWAYS wear eye protection when servicing the engine and when using compressed air or hi...

Page 145: ... If installing used fuel injectors clean the stem and nozzle prior to installation Figure 6 16 5 Install the injector and retainer as an assembly 6 Install two nuts Figure 6 16 1 and tighten to 8 N m 71 in lb 7 Install the high pressure fuel line Figure 6 16 2 See Removing and Installing High Pressure Fuel Lines on page 6 17 8 If removed install clamp Figure 6 16 3 A WARNING HIGH PRESSURE HAZARD A...

Page 146: ...uel supply system 3 Remove intake manifold and cover intake ports to prevent foreign objects from entering engine See Intake Manifold on page 5 70 4 If removing only one line remove the clamp joining the fuel injector lines to each other A WARNING HIGH PRESSURE HAZARD Avoid skin contact with high pressure diesel fuel spray caused by a fuel system leak such as a broken fuel injection line High pres...

Page 147: ...lines Injection lines having an even numbered last digit are used on even numbered cylinders Injection lines having an odd numbered last digit are used on odd numbered cylinders Start both union nuts on high pressure line before tightening either one 8 Install line s and start all union nuts before tightening any Hand tighten all union nuts Note Always use special tool OEM No 13 5 020 or similar w...

Page 148: ...g connector 10 Open fuel supply valve 11 Bleed fuel system See Bleeding the Fuel System on page 6 29 12 Start the engine and check for leaks 13 Check and delete any trouble codes that are registered in the ECU after the work has been completed See Fault Codes on page 13 20 A WARNING HIGH PRESSURE HAZARD Avoid skin contact with high pressure diesel fuel spray caused by a fuel system leak such as a ...

Page 149: ...Remove banjo bolt Figure 6 20 3 and disconnect fuel return line 8 Remove high pressure line Figure 6 20 4 between pump and fuel rail using special tool OEM No 13 5 020 Figure 6 21 9 Remove plug Figure 6 21 1 A DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions When you remove any fuel system component to perform maintenance such as changing the fuel fi...

Page 150: ...ead special tool OEM No 13 5 192 into timing case cover Figure 6 23 Figure 6 24 12 Thread special tool OEM No 13 5 191 without jack screw Figure 6 24 1 into sprocket by hand until firmly seated 13 Thread jack screw Figure 6 24 1 into special tool until firmly in contact with end of pump shaft Figure 6 25 14 Remove three nuts Figure 6 25 1 ...

Page 151: ...d Figure 6 28 2 Ensure gasket surfaces of the engine block and high pressure pump are clean Install new gasket Figure 6 28 1 Figure 6 29 Note The pump shaft may have a keyway cut into it but no key is used in this application 3 Install high pressure fuel pump and install three nuts Figure 6 29 1 CAUTION DO NOT remove special tools until high pressure pump is installed If the special tools are remo...

Page 152: ...ly a light coat of oil to O ring and install plug Tighten to M30 x 1 0 70 N m 52 ft lb M40 x 1 5 30 N m 22 ft lb Figure 6 33 IMPORTANT Start both union nuts on high pressure line before tightening either one 7 Install high pressure line and tighten union nuts Figure 6 33 4 using special tool OEM No 13 5 020 to 23 N m 204 in lb See Removing and Installing High Pressure Fuel Lines on page 6 17 8 Con...

Page 153: ...sure fuel can penetrate your skin and result in serious injury If you are exposed to high pressure fuel spray obtain prompt medical treatment NEVER check for a fuel leak with your hands ALWAYS use a piece of wood or cardboard Have your authorized Yanmar marine dealer or distributor repair the damage Failure to comply could result in death or serious injury 0000008enMarine A DANGER FIRE AND EXPLOSI...

Page 154: ...t and tighten screws securely 7 Install hoses and tighten new clamps to specification See Hose Clamps on page 3 19 8 Connect battery negative cable 9 Bleed the fuel system and check for leaks See Bleeding the Fuel System on page 6 29 CAUTION ALWAYS be environmentally responsible Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as e...

Page 155: ...e filter bowl Inspect the water sensor probe Figure 6 36 1 for damage Inspect the bowl seal Figure 6 36 2 IMPORTANT When replacing fuel filters always pre fill them with fresh clean fuel to improve the system ability to be bled 8 Lubricate the seal at the top of the new filter element and install Figure 6 36 3 9 Lubricate the filter bowl seal and install the filter bowl Turn clockwise by hand to t...

Page 156: ...hose and tighten clamp using special socket 11 Connect electrical connectors to fuel pressure sensor and fuel pressure regulator 12 Install high pressure lines See Removing and Installing High Pressure Fuel Lines on page 6 17 13 Install intake manifold See Intake Manifold on page 5 70 14 Open fuel supply valve 15 Bleed fuel system See Bleeding the Fuel System on page 6 29 16 Start engine and check...

Page 157: ...Repeat with all fuel injectors IMPORTANT NEVER disassemble fuel return line assembly No individual parts are available and it must be replaced as a complete assembly A DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions When you remove any fuel system component to perform maintenance such as changing the fuel filter place an approved container under the...

Page 158: ...nk After fuel system maintenance such as changing a fuel filter draining the fuel filter water separator or replacing a fuel system component The fuel feed pump is ECU controlled and will operate for only 10 seconds when the key switch is turned ON and the engine is not running or being started For this reason the key switch must be repeatedly turned ON then OFF to sufficiently bleed the fuel syst...

Page 159: ...FUEL SYSTEM 6 30 BY Service Manual Repair This Page Intentionally Left Blank ...

Page 160: ...Thermostat 7 9 Repair 7 10 Prepare Engine for Long Term Storage 7 10 Drain Seawater Cooling System 7 10 Check and Replace Zinc Anodes 7 11 Draining and Filling Closed Cooling System 7 12 Disconnect and Connect Quick Connect Fittings 7 13 Remove and Install Hydraulic Oil Cooler 7 13 Inspect and Clean Hydraulic Oil Cooler 7 14 Remove and Install Charge Air Cooler 7 14 Disassemble and Assemble Charge...

Page 161: ...COOLING SYSTEM 7 2 BY Service Manual This Page Intentionally Left Blank ...

Page 162: ...the key in the key switch when you are servicing the engine Someone may accidentally start the engine and not realize you are servicing it This could result in a serious injury If you must service the engine while it is operating remove all jewelry tie back long hair and keep your hands other body parts and clothing away from moving rotating parts Failure to comply could result in death or serious...

Page 163: ...th or serious injury 0000014en A CAUTION FLYING OBJECT HAZARD ALWAYS wear eye protection when servicing the engine and when using compressed air or high pressure water Dust flying debris compressed air pressurized water or steam may injure your eyes Failure to comply may result in minor or moderate injury 0000003en A CAUTION PINCH HAZARD Use care not to catch finger between belt and pulley while i...

Page 164: ...n Reference Page Cooling System Test Pressure All 1 4 bar 20 psi See Pressure Testing Cooling System and Filler Cap on page 7 8 Filler Cap Test Pressure All 1 4 bar 20 psi Thermostat Marking Begins Opening Fully Open See Testing Thermostat on page 7 9 All 88 C 88 C 190 F 96 C 205 F Coolant Capacity Approximate 4BY 10 0 L 10 6 qt 6BY 13 5 L 14 3 qt Component Torque Lubricating Oil Application Refer...

Page 165: ...referred to as OEM Part No Tools not having part numbers must be obtained locally MEASURING INSTRUMENTS No Tool Name Applicable Model and Tool Size Illustration 1 Cooling System Tester For pressure testing the cooling system and filler cap Obtain locally 2 Belt Tool For removing and installing seawater pump belt 0003828 No Instrument Name Application Illustration 1 Torque Wrench For tightening nut...

Page 166: ...ngine shown 6BY is similar 1 Seawater Supply 2 Seawater Pump 3 Hydraulic Oil Cooler 4 Charge Air Cooler 5 Engine Heat Exchanger 6 Exhaust Elbow 7 Exhaust Seawater Exit 8 Engine Coolant Pump 9 Thermostat 10 Engine Oil Cooler 11 Engine Coolant Passages 12 Coolant Recovery Tank 0003635 12 10 8 9 3 2 4 5 1 11 6 7 ...

Page 167: ...ster and adapter in place of the filler cap 4 Pump until pressure is 1 45 bar 21 psi Figure 7 2 5 Pressure should hold steady If the pressure drops there is leakage in the system Start by checking all hoses and pipe connections A DANGER SCALD HAZARD NEVER remove the coolant filler cap if the engine is hot Steam and hot engine coolant will escape and seriously burn you Allow the engine to cool befo...

Page 168: ...and record this number 2 Immerse the thermostat into a container of water Suspend it so that it does not come into contact with the walls or bottom of the container 3 Slowly heat the water and monitor the temperature with a thermometer Stir the water 4 Check that the thermostat begins to open at the specified temperature and that it is fully open at the temperature given in the specifications If t...

Page 169: ...o prevent rain or seawater from entering 9 Charge the battery once a month to compensate for battery s self discharge 10 Remove key from key switch and cover key switch with moisture cap if equipped Drain Seawater Cooling System IMPORTANT If water fails to drain from any open drain cock or port remove the cock completely and probe the opening with a small piece of wire to loosen debris Figure 7 4 ...

Page 170: ...ter cooling system and they should be inspected and replaced periodically See Periodic Maintenance Schedule on page 4 8 for the recommended frequency Figure 7 6 Zinc anodes are located in the heat exchanger Figure 7 6 1 and the charge air cooler Figure 7 6 2 A zinc anode is also located in the optional high rise elbow Figure 7 6 3 1 Remove each anode and inspect for corrosion Any anode having less...

Page 171: ...rain plug with a new gasket Figure 7 8 5 Install heat exchanger See Remove and Install Heat Exchanger on page 7 16 Ensure the drain cock Figure 7 8 1 on the heat exchanger is closed 6 If not already done remove the filler cap Figure 7 8 2 from the heat exchanger A DANGER SCALD HAZARD NEVER remove the coolant filler cap if the engine is hot Steam and hot engine coolant will escape and seriously bur...

Page 172: ...o position shown 2 Disconnect fitting joint Connect 1 Push metal clip against the fitting into the latched position 2 Ensure the O ring is in place and in good condition 3 Align the two fittings and push together until the clip makes an audible click 4 Check to be sure the connection is securely latched by attempting to pull apart Remove and Install Hydraulic Oil Cooler Figure 7 10 1 Loosen clamps...

Page 173: ... Figure 7 12 1 Drain seawater system See Drain Seawater Cooling System on page 7 10 2 Disconnect seawater pipe between hydraulic oil cooler and charge air cooler Figure 7 12 1 3 Disconnect seawater pipe between charge air cooler and heat exchanger Figure 7 12 2 4 Disconnect pipe between charge air cooler and turbocharger Figure 7 12 3 5 Remove pipe between charge air cooler and intake manifold Fig...

Page 174: ...IMPORTANT Under no circumstances should caustic soda be used to clean the components 7 Use paraffin based engine detergent to clean the cooler element Thoroughly flush and rinse all components 8 If any internal deposits remain in the tubes consult a local radiator repair shop Note Always install new O rings 9 Install new O rings Figure 7 13 2 on cooler core 10 Install cooler core and inlet cover F...

Page 175: ...7 7 Remove the heat exchanger 8 Disassemble inspect and clean heat exchanger as necessary See Disassemble and Assemble Heat Exchanger on page 7 16 9 Install the heat exchanger assembly on the engine Install and tighten bolts Figure 7 14 5 6 7 Figure 7 15 10 Install two new O rings on coolant pipe Figure 7 15 1 and connect to heat exchanger 11 Connect remaining seawater and coolant hoses to heat ex...

Page 176: ...7 16 3 and outlet cover Figure 7 16 1 13 Install new zinc anode Figure 7 16 7 and washer Figure 7 16 6 See Check and Replace Zinc Anodes on page 7 11 14 Install heat exchanger See Remove and Install Heat Exchanger on page 7 16 Remove and Install Coolant Pump 1 Drain coolant from engine See Draining and Filling Closed Cooling System on page 7 12 2 Remove belt guard 3 Remove seawater pump belt and a...

Page 177: ...gure 7 18 3 7 Remove the old gasket and clean any material off engine block Figure 7 19 8 Cut tabs Figure 7 19 1 of new gasket at locations shown Check gasket fit on engine before proceeding 9 Hold new gasket in place and install coolant pump 10 Install thermostat assembly See Remove and Install Thermostat on page 7 19 11 Fill engine block with coolant See Draining and Filling Closed Cooling Syste...

Page 178: ...stat on page 7 9 Installation 1 Clean the thermostat housing and mounting surface of the coolant pump Figure 7 21 2 Ensure the O ring type seal Figure 7 21 1 is in place in the thermostat housing 3 Install thermostat assembly and tighten bolts 4 Ensure O rings are in good shape and in place in quick connectors 5 Install coolant pipes and secure with clips See Disconnect and Connect Quick Connect F...

Page 179: ...racks broken vanes or excessive wear Replace as necessary 6 Inspect the housing and cover for excessive wear Figure 7 24 Note When installing the new impeller rotate the impeller clockwise to bend the vanes in the direction of rotation Figure 7 24 7 Install a new O ring Figure 7 24 1 and hold it in the groove using petroleum jelly 8 Install the shaft cover and pulley assembly Install and tighten f...

Page 180: ...se it must be replaced 4 Cut seawater belt to remove 5 Install new belt on crankshaft pulley and around seawater pump pulley as far as possible Figure 7 26 6 Install special tool Figure 7 26 1 between seawater pump pulley and belt 7 Roll the belt onto the pulley by rotating crankshaft using a socket and breaker bar on the crankshaft pulley bolt Figure 7 26 2 Lift end of tool while rotating IMPORTA...

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Page 182: ... Torque Chart 8 6 Special Service Tools 8 7 Measuring instruments 8 7 Tests and Adjustments 8 8 Engine Oil Flow 8 8 Checking Engine Oil Pressure 8 9 Repair 8 11 Engine Lubrication System Components 8 11 Replace Engine Oil and Engine Oil Filter Element 8 12 Remove and Install Oil Cooler 8 14 Remove and Install Oil Filter Housing 8 15 Remove and Install Oil Sump 8 16 Oil Pump 8 17 ...

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Page 184: ...ay clear of the hot engine oil to avoid being burned ALWAYS wear eye protection Failure to comply could result in death or serious injury 0000011en A WARNING ENTANGLEMENT HAZARD Stop the engine before you begin to service it NEVER leave the key in the key switch when you are servicing the engine Someone may accidentally start the engine and not realize you are servicing it This could result in a s...

Page 185: ...ly responsible Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as engine oil diesel fuel and engine coolant Consult the local authorities or reclamation facility NEVER dispose of hazardous materials irresponsibly by dumping them into a sewer on the ground or into ground water or waterways Failure to follow these procedures may ser...

Page 186: ...LUBRICATION BY Service Manual 8 5 Before You Begin Servicing CAUTION If the oil pump must be replaced replace it as an assembly only Do not replace individual components 0000030en ...

Page 187: ...l Test RPM Specification Oil Pressure 4BY Idle 0 8 bar 12 psi 4000 rpm 3 8 6 0 bar 58 87 psi 6BY Idle 0 7 bar 10psi 4000 rpm 3 8 6 0 bar 55 87 psi Component Tightening Torque Lubricating Oil Application Reference Page Oil Filter Cap 25 N m 225 in lb Not Applied See Replace Engine Oil and Engine Oil Filter Element on page 8 12 Oil Sump Bolt 20 N m 177 in lb Not Applied See Remove and Install Oil Su...

Page 188: ... to as Yanmar Part No and BMW part numbers are referred to as OEM Part No Tools not having part numbers must be obtained locally MEASURING INSTRUMENTS No Tool Name Part Number Illustration 1 Oil Pressure Test Gauge Kit OEM Part No 13 6 054 13 6 051 13 3 063 and 13 3 061 No Instrument Name Application Illustration 1 Torque Wrench For tightening nuts and bolts to the specified torque 0000840 ...

Page 189: ...lve Adjuster 3 Oil Galleries 4 Piston Cooling Jet 5 Crankshaft Bearings 6 Oil Gallery for Pressure Regulator Valve 7 Oil Pump 8 Oil Return 9 Oil Filter 10 Timing Chain Lubrication Nozzle 11 Port to Turbocharger Lubrication Line and Oil Pressure Sensor Line 12 Piston Cooling Oil Pressure Regulator 0003789 1 2 3 9 4 5 12 6 5 4 3 8 7 9 10 11 ...

Page 190: ... pressure sensor Figure 8 2 2 Figure 8 3 5 Install special tool OEM No 11 4 050 with O ring Figure 8 3 1 in oil pressure sensor port A WARNING BURN HAZARD Keep your hands and other body parts away from hot engine surfaces such as the muffler exhaust pipe turbocharger and engine block during operation and shortly after you shut the engine down These surfaces are extremely hot while the engine is op...

Page 191: ...gine speeds Results If the mechanical oil pressure test gauge indicates good oil pressure replace the faulty oil pressure sensor or faulty oil pressure gauge If the mechanical oil pressure test gauge indicates low oil pressure troubleshoot the lubrication system to locate the cause of the low oil pressure Repair as necessary Specifications Inspection Item Test RPM Specification Engine Oil Pressure...

Page 192: ...ystem Components Figure 8 5 1 Engine Oil Cooler 2 Oil Filter Housing 3 Oil Pressure Sensor 4 Oil Pressure Sensor Line 5 Turbocharger Lubrication Supply Line 6 Turbocharger 7 Turbocharger Lubrication Return Line 8 Oil Pump 9 Oil Pickup and Screen 0003788 3 4 5 7 6 8 9 1 2 ...

Page 193: ...ilter cap Figure 8 6 2 1 2 turns with a socket wrench A WARNING BURN HAZARD If you must drain the engine oil while it is still hot stay clear of the hot engine oil to avoid being burned ALWAYS wear eye protection Failure to comply could result in death or serious injury 0000011en CAUTION ALWAYS be environmentally responsible Follow the guidelines of the EPA or other governmental agencies for the p...

Page 194: ... Approximately 10 minutes after stopping the engine remove the oil dipstick and check the oil level Add oil if the level is too low CAUTION Only use the engine oil specified Other engine oils may affect warranty coverage cause internal engine components to seize and or shorten engine life Prevent dirt and debris from contaminating the engine oil Carefully clean the dipstick and the surrounding are...

Page 195: ... 7 12 2 Remove oil filter element See Replace Engine Oil and Engine Oil Filter Element on page 8 12 Figure 8 8 3 Remove coolant pipe retaining bolt Figure 8 8 1 4 Disconnect coolant pipe Figure 8 8 2 from thermostat housing Figure 8 9 5 Disconnect coolant pipe hose Figure 8 9 1 from oil cooler 6 Remove three screws Figure 8 9 2 and remove oil cooler Figure 8 9 3 Figure 8 10 7 Inspect ports for evi...

Page 196: ...ith coolant 14 Run engine and check for oil or water leaks Remove and Install Oil Filter Housing 1 Drain engine coolant See Draining and Filling Closed Cooling System on page 7 12 2 Remove oil filter cartridge See Replace Engine Oil and Engine Oil Filter Element on page 8 12 Figure 8 12 3 Remove coolant pipe retaining bolt Figure 8 12 1 4 Disconnect coolant pipe Figure 8 12 2 from thermostat housi...

Page 197: ...2 Start the engine and inspect for leaks Remove and Install Oil Sump 1 Remove bolt securing oil dipstick tube to oil filter housing Remove oil dipstick tube from oil pan Figure 8 15 2 Remove bolts Figure 8 15 1 that secure oil sump to flywheel housing Figure 8 16 3 Remove bolts Figure 8 16 1 securing oil sump to cylinder block 4 Remove oil sump Figure 8 16 2 and gasket Figure 8 16 3 5 Clean gasket...

Page 198: ... oil sump 2 Remove oil sump See Remove and Install Oil Sump on page 8 16 Figure 8 17 3 Remove bolts Figure 8 17 1 2 Remove oil strainer assembly and suction pipe 4 Remove bolts securing oil pump Figure 8 17 3 Remove oil pump from engine Installation of Oil Pump 1 Install oil pump assembly Ensure drive chain is properly engaged on sprocket 2 Secure oil pickup to oil deflector and oil pump with new ...

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Page 200: ...cing 9 3 Introduction 9 5 Specifications 9 5 Test and Adjustment Specifications 9 5 Special Torque Chart 9 5 Special Service Tools 9 6 Tests and Adjustments 9 7 Measuring Charge Pressure 9 7 Adjusting Charge Pressure 4BY 9 8 Repair 9 9 Turbocharger Removal 9 9 Turbocharger Installation 9 10 ...

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Page 202: ...s injury 0000034en A WARNING To prevent possible eye injury always wear SAFETY GLASSES while servicing the engine 0000013en A WARNING ENTANGLEMENT HAZARD Stop the engine before you begin to service it NEVER leave the key in the key switch when you are servicing the engine Someone may accidentally start the engine and not realize you are servicing it This could result in a serious injury If you mus...

Page 203: ...uld seriously burn you Failure to comply could result in death or serious injury 0000015enBY A CAUTION FLYING OBJECT HAZARD ALWAYS wear eye protection when servicing the engine and when using compressed air or high pressure water Dust flying debris compressed air pressurized water or steam may injure your eyes Failure to comply may result in minor or moderate injury 0000003en CAUTION Any part whic...

Page 204: ...r 23 2 psi Maximum 1750 mbar 25 4 psi See Measuring Charge Pressure on page 9 7 4BY180 Minimum 1650 mbar 23 9 psi Maximum 1800 mbar 26 1 psi 6BY220 Minimum 1900 mbar 27 6 psi Maximum 2020 mbar 29 3 psi 6BY260 Minimum 2000 mbar 29 0 psi Maximum 2120 mbar 30 7 psi Component Size Comments Specification Turbocharger to Exhaust Manifold 4BY 6BY Apply copper anti seize to threads 23 N m 204 in lb Turboc...

Page 205: ...n are either Yanmar or BMW part numbers Yanmar part numbers are referred to as Yanmar Part No and BMW part numbers are referred to as OEM Part No Tools not having part numbers must be obtained locally No Instrument Name Application Illustration 1 Torque Wrench For tightening nuts and bolts to the specified torque 0000840 ...

Page 206: ...auge to the charge air temperature sensor port 3 Operate the engine under normal load conditions at WOT 4000 rpm and take a reading after at least 30 seconds of constant operation Results If the reading is not within specification adjust the control rod 4BY or replace the turbocharger See Adjusting Charge Pressure 4BY on page 9 8 Specifications 1 0003769B Inspection Item Engine Limit Turbocharger ...

Page 207: ... warranty Figure 9 2 1 Remove retainer Figure 9 2 1 2 Loosen jam nut Figure 9 2 2 3 Turn wastegate control rod connector Figure 9 2 3 to shorten or lengthen rod Lengthen the rod to reduce charge pressure Shorten the rod to increase charge pressure One half turn will result in a change of approximately 25 bar 0 4 psi One turn will result in a change of approximately 50 60 bar 0 70 0 8 psi 4 Install...

Page 208: ...on page 9 7 Doing so will cause incorrect boost pressure resulting in poor performance or engine damage and can void all warranty 1 Disconnect wastegate control rod Figure 9 3 1 2 Remove the insulating cover Figure 9 3 2 3 Disconnect the lubrication supply line Figure 9 3 3 and return line Figure 9 3 4 from the turbocharger 4 Remove air filter Figure 9 3 5 5 Loosen turbocharger to mixing elbow cla...

Page 209: ... tighten clamps securely 0003787 2 1 3 A DANGER FIRE HAZARD Hot engine surfaces such as the exhaust pipe and turbocharger can cause material such as oil and grease to ignite ALWAYS ensure the exhaust pipe turbocharger and heat shields are absolutely free of oil and grease Clean all grease and oil from the exterior surfaces of the exhaust pipe and turbocharger housing before installing ALWAYS insta...

Page 210: ...R change the length of the wastegate control rod without doing it in coordination with a charge pressure test See Measuring Charge Pressure on page 9 7 Doing so will cause incorrect boost pressure resulting in poor performance or engine damage and can void all warranty 7 Install insulating cover Figure 9 6 2 and connect wastegate control rod Figure 9 6 1 8 Install air filter Figure 9 6 5 9 Start e...

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Page 212: ... Section 10 STARTER MOTOR Page Before You Begin Servicing 10 3 Introduction 10 5 Starter Motor Specifications 10 5 General Specifications 10 5 Special Torque Chart 10 5 Starter Motor Troubleshooting 10 6 Remove and Install Starter Motor 10 7 ...

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Page 214: ...ing away from moving rotating parts Failure to comply could result in death or serious injury 0000010en A WARNING SHOCK HAZARD Turn off the battery switch if equipped or disconnect the negative battery cable before servicing the electrical system Check the electrical harnesses for cracks abrasions and damaged or corroded connectors ALWAYS keep the connectors and terminals clean Failure to comply c...

Page 215: ...ng the engine and when using compressed air or high pressure water Dust flying debris compressed air pressurized water or steam may injure your eyes Failure to comply may result in minor or moderate injury 0000003en CAUTION NEVER hold the key in the START position for longer than 10 seconds or the starter motor will overheat 0000201en ...

Page 216: ...FICATIONS General Specifications Special Torque Chart Item Bosch 4BY Denso 6BY Nominal Power 2 0 kW 2 0 kW Nominal Voltage 12V 12V Test Voltage 13 0 26V 13 0 26V Maximum Operating Temperature 120 C 248 F 120 C 248 F Rotation Clockwise Clockwise Weight 3 5 kg 7 7 lb 3 5 kg 7 7 lb Item Specification Battery Positive Cable 15 N m 133 in lb Solenoid Primary Wire 8 N m 71 in lb ...

Page 217: ...n projection length Inspect shift lever for deformation return spring for fatigue and pinion for sliding Repair meshing between pinion and ring gear or replace as needed Replace engine oil Repair or replace starter motor Solenoid switch assembly contact defective Repair or replace Repair or replace key switch starting motor relay or magnetic switch assembly If a problem occurs Immediately disconne...

Page 218: ...tor to the flywheel housing 5 Carefully remove the starter motor IMPORTANT Check the starter pinion for damage If the starter pinion is damaged the flywheel ring gear must also be checked for damage 6 Clean the starter mounting area of the flywheel housing 7 Install the starter motor 8 Clean the cable connections 9 Connect the cable and primary wire to the appropriate terminals of the starter 10 C...

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Page 220: ...ATOR Page Before You Begin Servicing 11 3 Introduction 11 5 Specifications 11 5 General Specifications 11 5 Special Torque Chart 11 5 Repair 11 6 Replace Alternator Belt 11 6 Remove and Install Alternator 11 7 Remove and Install Alternator Belt Tensioner 11 7 ...

Page 221: ...ALTERNATOR 11 2 BY Service Manual This Page Intentionally Left Blank ...

Page 222: ...ng away from moving rotating parts Failure to comply could result in death or serious injury 0000010en A WARNING SHOCK HAZARD Turn off the battery switch if equipped or disconnect the negative battery cable before servicing the electrical system Check the electrical harnesses for cracks abrasions and damaged or corroded connectors ALWAYS keep the connectors and terminals clean Failure to comply co...

Page 223: ... alternator is producing unusual sounds Damage to the alternator will result 0000039en CAUTION Do not remove the positive battery cable from alternator terminal B while the engine is operating Damage to the alternator will result 0000037en CAUTION NEVER operate the engine with the batteries disconnected Damage to the alternator will result 0000185en CAUTION Do not turn the battery switch OFF while...

Page 224: ...s servicing of the 4BY and 6BY charging systems SPECIFICATIONS General Specifications Special Torque Chart Item Specification Manufacturer Valeo Model TG15 150A KSR DF Nominal Voltage 12V Nominal Output 150A Item Specification Alternator Mounting Bolts 38 N m 28 ft lb Positive Cable Nut 13 N m 115 in lb ...

Page 225: ... models Figure 11 1 B shows belt routing for marine gear standard models 4 Use a socket and breaker bar to rotate the belt tensioner and relieve belt tension Remove belt IMPORTANT If belt is to be reused note direction of travel and install in same direction of travel 5 Installation is the reverse of removal IMPORTANT Ensure belt correctly engages all grooves of each pulley Failure to do so will l...

Page 226: ...nd tighten mounting bolts to 38 N m 28 ft lb 9 Connect cables to alternator Tighten positive cable nut to 13 N m 115 in lb 10 Install idler pulley and install protective cap 11 Install alternator belt See Replace Alternator Belt on page 11 6 12 Install belt guard 13 Connect battery negative cable to the battery Remove and Install Alternator Belt Tensioner 1 Disconnect battery negative cable from t...

Page 227: ...bly 7 Loosen bolt Figure 11 4 3 securing tensioning pulley and arm to belt tensioner spring assembly 8 Remove arm and pulley Figure 11 4 4 in direction of arrow Figure 11 5 9 Remove bolts Remove tensioner spring assembly Figure 11 5 1 in direction of arrow 10 Installation is done in reverse of removal Install new seal Figure 11 5 2 ...

Page 228: ...ne Control Unit ECU Assignments 12 12 Component Tests 12 14 Relays 12 14 Oil Pressure Sensor 12 15 Fuel Injector 12 16 Engine Coolant Temperature Sensor 12 16 Fuel Rail Pressure Control Valve 12 17 Water in Fuel Sensor 12 17 Crankshaft Speed Sensor 12 18 Glow Plug Control Unit 12 18 Fuel Temperature Sensor 12 20 Fuel Volume Regulator 12 20 Charge Air Temperature Sensor 12 21 Charge Air Pressure Se...

Page 229: ...e Air Pressure Sensor 12 25 Replacing Charge Air Temperature Sensor 12 25 Replacing Crankshaft Sensor 12 26 Replacing Camshaft Sensor 12 26 Replacing High Pressure Fuel Control Valve 12 27 Replacing High Pressure Fuel Sensor 12 28 Replacing Fuel Temperature Sensor 12 30 Replacing Fuel Volume Regulator 12 31 Remove and Install Oil Pressure Sensor 12 32 ...

Page 230: ...nd other obstructions before increasing rpm Failure to comply could result in death or serious injury 0000006enMarine A WARNING FUME BURN HAZARD Always read and follow safety related precautions found on containers of hazardous substances like parts cleaners primers sealants and sealant removers Failure to comply could result in death or serious injury 0000014en A WARNING HIGH PRESSURE HAZARD Avoi...

Page 231: ...nt Consult the local authorities or reclamation facility NEVER dispose of hazardous materials irresponsibly by dumping them into a sewer on the ground or into ground water or waterways Failure to follow these procedures may seriously harm the environment 0000013en CAUTION NEVER hold the key in the START position for longer than 10 seconds or the starter motor will overheat 0000201en CAUTION Immedi...

Page 232: ...st and replace the components of the electrical system and engine control unit ECU as used on the Yanmar 4BY and 6BY marine engines SPECIFICATIONS Special Torque Chart Item Specification High Pressure Fuel Control Valve Retaining Nut 80 N m 59 ft lb High Pressure Fuel Sensor Retaining Nut 70 N m 52 ft lb Fuel Volume Regulator Screws 6 6 N m 58 in lb ...

Page 233: ...12 6 BY Service Manual Function Description Engine Management System FUNCTION DESCRIPTION ENGINE MANAGEMENT SYSTEM Component Locations 4BY Figure 12 1 0004119 3 4 2 1 5 6 7 9 8 10 11 13 12 15 14 16 17 18 19 20 21 22 23 24 ...

Page 234: ...onnector 8 Instrument Panel 9 Electrical Panel Fuses Relays ECU 10 Starter Motor 11 Crankshaft Speed Sensor 12 Glow Plug Harness Connector 13 Circuit Breaker Boatbuilder Installed Option 14 Battery 15 Battery Negative Cable Black 16 Battery Positive Cable Red 17 Battery Ground Connection 18 Alternator 19 Fuel Temperature Sensor 20 Fuel Volume Regulator 21 Charge Air Temperature Sensor 22 Charge Ai...

Page 235: ...ELECTRICAL AND ECU 12 8 BY Service Manual Function Description Engine Management System 6BY Figure 12 2 1 2 10 11 9 3 4 5 6 7 8 12 13 15 16 17 18 19 20 21 22 23 24 14 0004120 ...

Page 236: ...onnector 8 Instrument Panel 9 Electrical Panel Fuses Relays ECU 10 Starter Motor 11 Crankshaft Speed Sensor 12 Glow Plug Harness Connector 13 Circuit Breaker Boatbuilder Installed Option 14 Battery 15 Battery Negative Cable Black 16 Battery Positive Cable Red 17 Battery Ground Connection 18 Alternator 19 Fuel Temperature Sensor 20 Fuel Volume Regulator 21 Charge Air Temperature Sensor 22 Charge Ai...

Page 237: ...ower 7 Jumper Fuse F7 3 A Single Starboard Selection 8 Jumper Fuse F8 3 A CAN Analog Throttle Selection 9 K1 Starter Relay 10 K3 Fuel Supply Pump Relay 11 K2 Main Power Relay 12 ECU 13 Connector X1 Communication to Helm Display 14 Connector X21 1 Engine Wiring Harness 15 Connector X22 1 Fuel Injector Wiring Harness 16 Blocking Diode V1 IMPORTANT The electrical panel cables must be connected direct...

Page 238: ...al I O 0 1 A X1 F Error Indicator Check Engine Indicator Input signal for CAN hub 0 5 A X1 G Instrument Power Fused Battery Power Power for accessories 5 A X1 H Warning Indicator 0 5 A X1 J GEAR Switch to Ground Start in gear protection 50 mA X1 K FWG2 Throttle Position Second Channel Analog throttle safety channel 5 mA X1 L FWG1 5V Throttle Supply f Main Channel 5 mA X1 M FWG1 GND Throttle Return...

Page 239: ...X1 E X1 D KL15 KL87 KL31 F6 182 157 132 154 107 106 180 139 187 115 162 114 243 252 256 239 229 230 250 238 183 111 130 156 178 208 202 204 206 233 246 173 149 151 175 103 127 150 174 102 126 101 125 171 172 245 220 232 234 207 201 203 205 KL50 X1 C 211 224 DRV 124 X1 H X1 U X1 G 251 211 KL87 X1 H F7 F8 0003303 2 3 5 4 6 44 43 42 7 8 9 11 15 13 14 16 12 1 48 46 45 16 41 47 40 37 36 39 38 35 33 32 ...

Page 240: ...rge Air Pressure Sensor 43 Charge Air Temperature Sensor 44 Engine Coolant Temperature Sensor 45 Ignition Power Input from Key Switch terminal X1 D 46 Auxiliary Power Output terminal X1 G 47 CAN to Warning Indicator terminal X1 H 48 Battery Power to Key Switch terminal X1 B 49 CAN Signal Blocking Diode 50 High Bench 1 51 High Bench 2 Figure 12 5 shows a general schematic diagram of all ECU input a...

Page 241: ...e starter fuel feed pump and main system power The winding ground circuit terminal 85 of all relays is controlled by the ECU Start Relay K1 12 V is supplied by fuse F5 to winding terminal 86 When the start signal from the key switch is seen at ECU terminal 2 24 the winding ground circuit terminal 85 is completed at ECU terminal 2 34 assuming neutral is sensed at ECU terminal 2 50 and current passe...

Page 242: ...rminal 87 2 Pin 4 terminal 85 3 Pin 5 terminal 87 4 Pin 6 terminal 30 Fuel Pump Relay K3 12 V is supplied by fuse F3 to terminal 30 An internal connection connects one end of the winding to terminal 30 When the key switch is turned ON a 12 V signal is sent to ECU terminal 2 7 The ECU then completes the winding ground circuit terminal 85 through ECU terminal 2 32 Results of Failed Relay Failure of ...

Page 243: ... harness 2 Engine harness Note Polarity in not important Fuel Injector The fuel injectors are continuously supplied with high pressure fuel and are electronically triggered by the ECU The ECU controls the frequency duration and timing of injection Results of Failed Injector If an injector related failure occurs the following P codes may be generated P2049 Short circuit on high side to ground or B ...

Page 244: ...1 Pin 1 Out ECU pin 1 82 2 Pin 2 Ground ECU pin 1 7 Fuel Rail Pressure Control Valve This valve controls the fuel pressure in the fuel rail The ECU uses values supplied by several sensors and sends corresponding signals to control fuel pressure It is mounted on the rear of the fuel rail Results of Failed Valve Failure of the valve results in Limitation of the injection rate See Engine Faults and T...

Page 245: ...lue is compared with the camshaft speed by the ECU It is mounted on the rear crankshaft seal housing at the rear of the engine The ECU supplies 5V and ground The sensor signal is used by the ECU for The calculation of the actual rotations of the engine The check of the starting conditions The calculation of the injection rate at the starting procedure The control of the injection start The calcula...

Page 246: ... that the glow plugs are switched on and off Preheating When the coolant temperature is above 25 C 77 F the unit will operate for 0 5 second As temperatures decrease below 25 C 77 F the on time will increase up to a maximum of 2 7 seconds depending on temperature If the key switch is turned ON but the engine is not started immediately the controller will continue to implement the glowing process f...

Page 247: ...type sensor It is mounted in the fuel line just upstream from the high pressure fuel pump The sensor output is used by the ECU for Protecting the engine from overheating Calculation of the injection rate Calculation of the rate of the fuel pump Results of Failed Sensor Failure of the sensor results in Limitation of the injection rate See Engine Faults and Torque Limitations on page 13 3 Destructio...

Page 248: ...sure out of range P0087 fuel rail pressure out of range P0089 fuel rail pressure out of range P0090 fuel rail pressure out of range Test Values Resistance at 20 C 68 F 3 0 ohm Figure 12 17 1 Pin 1 12V Fuse F5 2 Pin 2 Out ECU pin 1 71 Charge Air Temperature Sensor This sensor measures the temperature of the compressed air coming from the turbocharger It is mounted on the charge air pipe Results of ...

Page 249: ...e 12 19 1 Pin 1 5V ECU pin 1 39 2 Pin 2 Ground ECU pin 1 80 3 Pin 3 Out ECU pin 1 54 Fuel Rail Pressure Sensor This sensor measures the fuel pressure in the fuel rail The values are used by the ECU for fuel quantity regulation and fuel pressure regulation It is mounted on the front of the fuel rail The ECU supplies 5V and ground Results of Failed Sensor Failure of the sensor results in Default val...

Page 250: ...ith the ECU with varying signals based on throttle position The ECU then calculates the position of the throttle lever in percent and adjusts fuel injection to adjust engine speed The ECU supplies 5V and ground connections Results of Failed Sensor Failure of the sensor results in One failed sensor limitation of the injection rate See Engine Faults and Torque Limitations on page 13 3 Two failed sen...

Page 251: ...ervice Manual Component Tests Figure 12 22 1 Pin 1 Ground ECU pin 1 78 2 Pin 2 Out ECU pin 1 56 3 Pin 3 5V ECU pin 1 30 Voltage Set Point Values Sensor Low Idle High Idle PWG 1 0 70 0 80 3 65 4 10 PWG 2 0 31 0 43 1 83 2 04 0004167 ...

Page 252: ...n the lower attaching screws Figure 12 23 3 and remove the ECU 6 Install the new control unit and tighten the screws 7 Connect the electrical connectors to the ECU 8 Connect the electrical panel power cables to the battery 9 Check and delete any trouble codes that are registered in the ECU after the work has been completed Replacing Coolant Temperature Sensor 1 Drain engine coolant 2 Remove intake...

Page 253: ...ector 6 Check and delete any trouble codes that are registered in the ECU after the work has been completed Replacing Charge Air Temperature Sensor 1 Disconnect battery negative cable Figure 12 27 2 Disconnect electrical connector Figure 12 27 1 3 Remove sensor from charge air pipe 4 Replace sealing ring before installing sensor 5 Install sensor and tighten to 7 N m 62 in lb Connect electrical con...

Page 254: ...5 N m 84 in lb 7 Install connector in bracket and connect engine harness 8 Install starter motor See Remove and Install Starter Motor on page 10 7 9 Check and delete any trouble codes that are registered in the ECU after the work has been completed Replacing Camshaft Sensor Figure 12 29 1 Disconnect harness connector Figure 12 29 1 2 Remove screw Figure 12 29 2 and remove camshaft sensor Figure 12...

Page 255: ...4 Disconnect electrical connector Figure 12 31 1 5 Hold sensor hex Figure 12 31 2 with wrench and loosen retaining nut Figure 12 31 3 6 Remove regulator from fuel rail CAUTION ALWAYS be environmentally responsible Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as engine oil diesel fuel and engine coolant Consult the local authori...

Page 256: ...ay caused by a fuel system leak such as a broken fuel injection line High pressure fuel can penetrate your skin and result in serious injury If you are exposed to high pressure fuel spray obtain prompt medical treatment NEVER check for a fuel leak with your hands ALWAYS use a piece of wood or cardboard Have your authorized Yanmar marine dealer or distributor repair the damage Failure to comply cou...

Page 257: ...lled 9 Install sensor in fuel rail Ensure orientation is correct 10 Hold hex of sensor and tighten retaining nut to 70 N m 52 ft lb 11 Connect battery negative cable 12 Bleed fuel system See Bleeding the Fuel System on page 6 29 13 Start engine and check for fuel leaks 14 Check and delete any trouble codes that are registered in the ECU after the work has been completed CAUTION Immediately cap or ...

Page 258: ...age 5 70 8 Bleed fuel system See Bleeding the Fuel System on page 6 29 9 Start engine and check for fuel leaks 0003688A 1 2 A WARNING HIGH PRESSURE HAZARD Avoid skin contact with high pressure diesel fuel spray caused by a fuel system leak such as a broken fuel injection line High pressure fuel can penetrate your skin and result in serious injury If you are exposed to high pressure fuel spray obta...

Page 259: ...ews Figure 12 34 2 7 Remove fuel volume regulator 8 Installation is done in the reverse of removal Tighten screws to 6 6 N m 58 in lb 9 Connect battery negative cable 10 Open fuel supply valve 11 Bleed fuel system See Bleeding the Fuel System on page 6 29 CAUTION ALWAYS be environmentally responsible Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardo...

Page 260: ...re sensor to 23 N m 204 in lb Note Polarity of wire connections is not important Either wire can be connected to either terminal 5 Connect wires A WARNING HIGH PRESSURE HAZARD Avoid skin contact with high pressure diesel fuel spray caused by a fuel system leak such as a broken fuel injection line High pressure fuel can penetrate your skin and result in serious injury If you are exposed to high pre...

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Page 262: ... 3 Torque Limitation for Overheat Protection 13 5 Troubleshooting Chart 13 6 Starting Trouble 13 6 Exhaust Color 13 6 Vibration Drive Disengaged 13 7 Vibration Drive Engaged 13 7 Engine Knocks 13 8 Low Power Output 13 8 Engine Overheat 13 8 Engine Runs Cold 13 9 Coolant Loss 13 9 Helm Panel Display 13 9 Trouble Codes 13 10 Working Procedure 13 10 Diagnostic Trouble Codes 13 10 After Troubleshootin...

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Page 264: ...nt temperature sensor Camshaft sensor Boost pressure sensor Rail pressure system Throttle signal missing Sensor supply voltage Metering unit failure Fuel injector failure Rail pressure governor deviation Torque Limitation for Smoke Limitation In the case of this limitation there are two possible situations If an electronic fault occurs it will be displayed on the display alarm and a P Code is save...

Page 265: ... N m Boost pressure abs bar Torque N m Boost pressure abs bar Engine 4BY150 100 normal operation 265 1600 295 700 90 240 700 265 400 80 215 600 240 250 70 185 300 205 100 60 160 150 180 0 50 135 0 150 0 Engine 4BY180 100 normal operation 315 1700 315 900 90 285 1050 285 500 80 250 900 250 350 70 220 600 220 200 60 190 300 190 50 50 160 100 160 0 Engine 6BY220 100 normal operation 390 2000 450 1100...

Page 266: ...bstitute value of the fuel temperature is fixed at 90 C and that sets a limitation of approximately 75 from the maximum torque Figure 13 1 If the coolant temperature is over 108 C an audible alarm sounds and engine overheat is displayed on the instrument panel display At 120 C the torque limitation is 30 Figure 13 2 If the fuel temperature is too high over 90 C this limitation is also active for t...

Page 267: ... clogged fine filter Bleed fuel system Blown fuse F3 F4 F5 ECU software problem Low ambient temperature Install optional glow plug control Install block heater Oil viscosity too high Replace with correct viscosity oil for operating conditions Problem Symptom Cause Action White Smoke Cold engine Allow engine to warm to operating temperature Defective thermostat Incorrect fuel Replace fuel with corr...

Page 268: ...em Bleed fuel system Faulty fuel injector Replace as necessary Leaking cylinder head gasket Replace Damaged intake or exhaust valves Repair as necessary Incorrect injection pressure Check replace fuel pressure regulator Check replace high pressure fuel pump Vibration Increases with Engine Speed Stern Drive Models Worn or damaged universal joints Replace universal joints Problem Symptom Cause Actio...

Page 269: ...ry Faulty fuel supply pump Replace Low Fuel Injection Pressure Defective fuel pressure regulator sensor Check replace Worn high pressure fuel pump Check replace Injection timing is incorrect ECU software problem Low RPM at Wide Open Throttle Propeller pitch too great Replace Engine overheated Reduce load repair cooling system Damaged turbocharger Replace Problem Symptom Cause Action Instrument Sho...

Page 270: ...ternal leakage Repair as necessary External leakage at connection Repair as necessary Coolant Forced Out of Coolant Recovery Tank Turbocharging pressure enters cooling system via leaking charge air cooler Repair replace as necessary Defective cylinder head gasket internal leakage Replace White Smoke when Engine is Hot Indicates Water Vapor Crack in cylinder head not cracks between valve seats Repa...

Page 271: ...nsor or other component sending and out of normal range signal to the ECU An example is a disconnected intake air pressure sensor which would set a P0237 code Code Fail Mode Run or Condition Engine Can Start Check Engine Alarm No Code Coolant Temp Under 0 C 32 F 1000 rpm yes no No Code Coolant Temp Over 108 C 226 F reduce yes alarm No Code Charge Air Temp Over 110 C 230 F reduce yes no No Code Boo...

Page 272: ...0122 Throttle Signal Both throttle signals are missing short circuit to Ground 1600 yes alarm Throttle Signal Throttle signal 1 is missing short circuit to Ground reduce yes alarm P0123 Throttle Signal Both throttle signals are short circuited to B 1600 yes alarm Throttle Signal Throttle signal 1 short circuit to B reduce yes alarm P0182 Fuel Temperature Sensor Short circuit to B reduce yes alarm ...

Page 273: ...Short circuit to B reduce yes alarm P0264 Injector No 2 Short circuit to B reduce yes alarm P0267 Injector No 3 Short circuit to B reduce yes alarm P0270 Injector No 4 Short circuit to B reduce yes alarm P0273 Injector No 5 Short circuit to B reduce yes alarm P0276 Injector No 6 Short circuit to B reduce yes alarm P0344 Camshaft or Crankshaft Speed Sensor Disagreement between camshaft speed sensor...

Page 274: ...ay Power relay sense short circuit low no no alarm P0690 Main Relay Power relay sense short circuit high no no alarm P2049 4BY Injector Bank 1 6BY Injector Bank 1 Short circuit on high side to Ground B Short circuit on high side to Ground B no reduce no no alarm P2052 4BY Injector Bank 2 6BY Injector Bank 2 Short circuit on high side to Ground B Short circuit on high side to Ground B reduce reduce...

Page 275: ...TROUBLESHOOTING 13 14 BY Service Manual After Troubleshooting or Repair This Page Intentionally Left Blank ...

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