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Yanmar 6LPA-STP2, Service Manual

The Yanmar 6LPA-STP2 is a robust and high-performance marine diesel engine. Ensure optimal maintenance and service by downloading the free Service Manual from our website. This comprehensive manual provides detailed instructions, diagrams, and troubleshooting tips to keep your Yanmar engine running smoothly. Get your manual now at manualshive.com.

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TROUBLESHOOTING

12-8

6LPA Service Manual

Troubleshooting Chart

© 2007 Yanmar Marine International

Governor failure

Damaged governor bearing

Replace

Improper length of governor link

Correct

Compressed gas leak in the 
engine cylinder

Gas leak from intake / exhaust valve

Conduct fitting of the valve

Valve clearance too small

Re-adjust

Worn upper portion of cylinder bore

Lap or replace

Worn piston ring

Replace

Sticking piston ring

Overhaul or replace

Improper fuel injection timing

Injection timing too advanced

Retard the injection timing

Injection timing too retarded

Advance the injection timing

Turbocharger failure

Clogged air filter

Clean

Dirty compressor side

Clean

Clogged turbine nozzle

Clean

Damaged bearing

Replace

Other

Improper fuel

Replace with correct fuel

Clogged exhaust duct

Clean

Seized or overheated moving parts

Disassemble and conduct 
servicing

Insufficient seawater

Inspect seawater pump

Insufficient feed of lubrication oil

Disassemble and clean 
lubrication oil pump and filter

Output for each cylinder is not uniform:

Uneven fuel injection 
quantities

Air trapped in fuel injection pump

Bleed

Faulty operation of plunger

Disassemble and clean

Broken plunger spring

Replace

Faulty delivery valve

Repair or replace

Damaged delivery valve gasket

Replace

Faulty operation of regulator valve

Overhaul or replace

Faulty operation of fuel injection pump timer

Overhaul or replace

Failure of fuel injection nozzle

Oil leak from fuel injection system

Inspect and repair

Broken valve spring

Replace

Uneven injection pressures of injection valves

Re-adjust

Improper injection timing

Re-adjust

Clogged injection valve

Clean

Knocking:

Fuel injection nozzle failure

Reduction in injection pressure

Adjust for higher injection 
pressure

Broken fuel valve spring

Replace

Sticking nozzle

Disassemble and lap

Poor spray pattern

Overhaul

Fuel injection pump failure

Faulty operation of fuel injection pump timer

Repair

Faulty operation of regulator valve

Repair

Symptom

Probable Cause

Measure

Summary of Contents for 6LPA-STP2

Page 1: ...6LPA series 6LPA Service Manual SERVICE MANUAL 6LPA STP2 6LPA STZP2 P N 0B6LP G00100 MARINE ENGINES ...

Page 2: ... on the 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 tim...

Page 3: ...anual TABLE OF CONTENTS Page Table of Contents iii 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 Troubleshooting 12 1 ...

Page 4: ...TABLE OF CONTENTS 2 6LPA Service Manual 2007 Yanmar Marine International This Page Intentionally Left Blank ...

Page 5: ...ead this Service Manual completely before starting with repairs 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 a...

Page 6: ...nformation If a page or number of pages should be replaced the replacement information is sent along with a revised Revision Control Table Discard the older obsolete information At times the revision involves inserting additional pages in one or more sections Replace the Revision Control Table and insert the new pages This method of revision control represents the most cost effective solution to p...

Page 7: ...d replace them if they are lost or damaged Also if you need to replace a part that has a decal attached to it make sure you order the new part and decal at the same time Indicates a hazardous situation which if not avoided will result in death or serious injury Indicates a hazardous situation which if not avoided could result in death or serious injury Indicates a hazardous situation which if not ...

Page 8: ...re additional reminders for safe operating and maintenance techniques See your authorized Yanmar marine dealer or distributor for additional training Crush Hazard NEVER stand under a hoisted engine If the hoist mechanism fails the engine will fall on you ALWAYS secure the engine solidly to prevent the engine from falling during maintenance The safety messages that follow have WARNING level hazards...

Page 9: ... back long hair and keep your hands other body parts and clothing away from moving rotating parts Piercing 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 obtain prompt medical treatment NEVER check f...

Page 10: ...the component to be welded and as close as possible to the welding point NEVER connect the weld clamp to the engine or in a manner which would allow current to pass through a mounting bracket When welding is completed reconnect the leads to the alternator and engine control unit prior to reconnecting the batteries ALWAYS keep the electrical connectors and terminals clean Check the electrical harne...

Page 11: ...e Hazard ALWAYS wear personal protective equipment including appropriate clothing gloves work shoes eye and hearing protection as required by the task at hand Tool Hazard Always remove any tools or shop rags used during maintenance from the area before operation The safety messages that follow have CAUTION level hazards These safety messages describe a hazardous situation which if not avoided coul...

Page 12: ...or Modifications may impair the engine s safety and performance characteristics and shorten the engine s life Any alterations to this engine may void its warranty Be sure to use Yanmar genuine replacement parts 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 engin...

Page 13: ...2 3 10 Engine Sender and Switch Locations 3 12 Instrument Panel Optional 3 13 B Type Panel 119773 91131 3 13 C Type Panel 119773 91162 3 13 D Type Panel 119773 91192 3 13 Performance Curve Charts 3 14 Front Power Take Off PTO Output 3 16 Front PTO Diagram 3 16 Location of Nameplate 3 18 Engine Nameplate Typical 3 18 Diesel Fuel 3 18 Diesel Fuel Specifications 3 18 Handling Diesel Fuel 3 19 Diesel ...

Page 14: ...ations 3 27 Marine Gear Optional 3 28 Special Torque Chart 3 29 Tightening Torques for Standard Bolts and Nuts 3 30 Tightening Fasteners 3 30 Abbreviations and Symbols 3 31 Abbreviations 3 31 Symbols 3 31 Unit Conversions 3 32 Unit Prefixes 3 32 Units of Length 3 32 Units of Volume 3 32 Units of Mass 3 32 Units of Force 3 32 Units of Torque 3 32 Units of Pressure 3 32 Units of Power 3 32 Units of ...

Page 15: ...n on page 2 1 LOCATION OF SAFETY DECALS Figure 3 1 shows the location of safety decals on Yanmar 6LPA STP2 STZP2 series marine engines Figure 3 1 Figure 3 1 1 Part Number 120324 07240 2 Part Number 128296 07260 3 Part Number 119773 07280 4 Part Number 128296 07300 5 Part Number 128296 07360 Note shows an overhead view of the engine NEVER pour the engine oil across the full line 119773 07280 DANGER...

Page 16: ...ft side as viewed from propeller Figure 3 2 1 Fuel Cooler 2 Fuel Filter 3 Power Steering Oil Cooler 6LPA STZP2 Series Only 4 Engine Oil Filter 5 Intercooler 6 Mixing Elbow 7 Engine Oil Cooler 2 8 Starter 9 Engine Oil Cooler 1 10 Fuel Injection Pump 11 Seawater Pump 12 Stern Drive Note 6LPA STZP2 Series with stern drive shown 1 2 3 4 5 6 12 11 10 9 8 7 0004884 ...

Page 17: ...charger 2 Engine Nameplate on rocker arm cover 3 Freshwater Coolant Tank 4 Power Steering Oil Tank 6LPA STZP2 Series Only 5 Freshwater Filler Cap 6 Engine Oil Filler Cap 7 Power Steering Oil Pump 6LPA STZP2 Series Only 8 Alternator 9 Engine Oil Dipstick 10 Freshwater Cooler 11 V Belt Note 6LPA STZP2 Series with stern drive shown 1 2 3 4 5 6 7 8 9 10 11 0004885 ...

Page 18: ...ORMATION 3 6 6LPA Service Manual Engine Piping Diagrams 2007 Yanmar Marine International ENGINE PIPING DIAGRAMS 6LPA STP2 Figure 3 4 Figure 3 4 8 6 5 4 3 2 1 9 12 11 14 13 16 15 18 21 23 25 17 10 19 20 22 24 26 7 0004891 ...

Page 19: ...ne Oil Filter 10 Fuel Injection Pump 11 Seawater Inlet 12 Cooling Seawater Pump 13 Fuel Return Pipe To Fuel Tank 14 Diesel Fuel Cooler 15 Diesel Fuel Inlet From Fuel Tank 16 Diesel Fuel Filter 17 Water Temperature Sender Optional 18 Water Temperature Switch 19 Water Outlet to Heater 20 Engine Oil Cooler Freshwater Cooling Relief Valves 21 Safety Valve 22 Cooling Freshwater Pump 23 Engine Oil Pump ...

Page 20: ...E INFORMATION 3 8 6LPA Service Manual Engine Piping Diagrams 2007 Yanmar Marine International 6LPA STZP2 Figure 3 5 Figure 3 5 11 9 8 7 6 5 4 3 1 2 12 16 15 18 17 20 19 22 25 27 29 21 14 23 24 26 28 30 13 10 0004892 ...

Page 21: ...Engine Oil Cooler 11 Intercooler 12 Engine Oil Filter 13 Power Steering Oil Cooler 14 Fuel Injection Pump 15 Seawater Inlet 16 Cooling Seawater Pump 17 Fuel Return Pipe To Fuel Tank 18 Diesel Fuel Cooler 19 Fuel Inlet From Fuel Tank 20 Diesel Fuel Filter 21 Water Temperature Sender Optional 22 Water Temperature Switch 23 Water Outlet to Heater 24 Engine Oil Cooler Freshwater Cooling Relief Valves ...

Page 22: ...NERAL SERVICE INFORMATION 3 10 6LPA Service Manual External Views 2007 Yanmar Marine International EXTERNAL VIEWS 6LPA STP2 Figure 3 6 Figure 3 6 2 13 14 15 16 17 18 19 20 3 4 6 7 8 9 10 11 12 1 5 0005564 ...

Page 23: ...3 Rocker Arm Cover 4 Intercooler 5 Turbocharger 6 Lube Oil Cooler for Marine Gear 7 Marine Gear 8 Lube Oil Cooler 2 9 Starter 10 Lube Oil Cooler 1 11 Fuel Injection Pump 12 Seawater Pump 13 Intercooler 14 Rocker Arm Cover 15 Freshwater Tank 16 Freshwater Cooler 17 Alternator 18 Marine Gear 19 Lube Oil Cooler for Marine Gear 20 Turbocharger ...

Page 24: ...INE SENDER AND SWITCH LOCATIONS Figure 3 7 Figure 3 7 1 Freshwater Level Switch 2 Seawater Flow Switch 3 Freshwater Temperature Switch 4 Freshwater Temperature Sender 5 Fuel Filter Switch 6 Tachometer Sender 7 Engine Oil Pressure Switch 8 Engine Oil Pressure Sender 9 Boost Sender 10 Boost Switch 7 6 4 8 10 1 3 2 5 9 0005551 ...

Page 25: ...sure Meter 2 CW Temperature Meter 3 Tachometer 4 Buzzer Stop Switch 5 Panel Illumination Switch 6 Engine Stop Switch 7 Starter Key Switch 8 Alarm Buzzer 9 Hour Meter 10 Warning Lamp Unit 10 Lamp Type D Type Panel 119773 91192 Figure 3 10 Figure 3 10 1 Turbocharger Boost Pressure Meter 2 Engine Oil Pressure Meter 3 CW Temperature Meter 4 Tachometer 5 Buzzer Stop Switch 6 Panel Illumination Switch 7...

Page 26: ...ormance Curve Charts 2007 Yanmar Marine International PERFORMANCE CURVE CHARTS Figure 3 11 Figure 3 11 0005558 6LPA STP2 At Typical Propeller Load Exp 2 5 At Crankshaft Typical Propeller Load Exp 2 5 Typical Constant Rack Power With Clutchout Crankshaft Power ...

Page 27: ...3 15 Performance Curve Charts 12 05 2007 Yanmar Marine International Figure 3 12 Figure 3 12 6LPA STZP2 At Typical Propeller Load Exp 2 5 Typical Propeller Load Exp 2 5 Typical Constant Rack Power With Clutchout At Crankshaft Crankshaft Power 0005557 ...

Page 28: ... TAKE OFF PTO OUTPUT Front PTO Diagram Note Use of PTO in other than Method A is prohibited UP pull drive is not allowed even in the case of Method A Figure 3 13 Figure 3 13 1 Allowable Front PTO Output hp 2 Engine Speed rpm 12 10 8 6 4 2 0 800 1000 1200 1400 1600 1800 2000 2 1 2200 2400 2600 2800 3000 3200 3400 3600 3800 0005556 ...

Page 29: ...e overhang within 25 mm 0 98 in 5 Install the pulley to the exterior of the viscous damper and tighten the pulley and damper with the damper fixing bolts M8 x 6 Qty and the washers Torque 3 8 0 2 kg m 37 27 1 96 N m 27 4 1 4 lb ft Note The crankshaft may break if the front PTO output exceeds the allowable output Figure 3 14V Pulley Overhang Figure 3 14 1 Pulley Thickness Should be 10 mm 0 393 in 2...

Page 30: ... Fuel Requirements The fuel cetane number should be equal to 45 or higher The sulfur content must not exceed 0 5 by volume Less than 0 05 is preferred Water and sediment in the fuel should not exceed 0 05 by volume Ash content not to exceed 0 01 by volume Carbon residue content not to exceed 0 35 by volume Less than 0 1 is preferred Total aromatics content should not exceed 35 by volume Less than ...

Page 31: ...ain and dirt as water and dust mixed in with the fuel cause engine failure Keep the fuel container stationary for several hours to allow any dirt or water to settle to the bottom Use a pump to extract the clear filtered fuel from the top of the container for use Pump out only half way to avoid pumping out any contaminates or foreign matter in the bottom of the tank Figure 3 17 Figure 3 17 Figure 3...

Page 32: ...k 1 Clean the area around the fuel cap DANGER Only fill the fuel tank with diesel fuel Filling the fuel tank with gasoline may result in a fire and will damage the engine NEVER refuel with the engine running 2 Remove the fuel cap from the fuel tank WARNING Wipe up all spills immediately Keep sparks open flames or any other form of ignition match cigarette static electric source well away when refu...

Page 33: ...level in the fuel tank Refill if necessary 2 Open the fuel cock of the fuel tank WARNING ALWAYS wear safety glasses when bleeding the fuel system 3 Loosen the air bleed screw Figure 3 20 2 2 to 3 turns 4 Push up and down on the priming pump Figure 3 20 1 to release air out of the air bleed screw WARNING Ensure no fuel is leaking from the seals of the air bleed screw while pushing on the priming pu...

Page 34: ...il after the first 50 hours of operation and then every 125 hours thereafter Select the oil viscosity based on the ambient temperature where the engine is being operated See the SAE Service Grade Viscosity Chart Figure 3 21 Yanmardoesnotrecommendtheuseofengine oil additives Additional Technical Engine Oil Requirements The engine oil must be changed when the Total Base Number TBN has been reduced t...

Page 35: ...ith oil to the upper limit on the dipstick Figure 3 22 2 NOTICE NEVER mix different types of engine oil This may adversely affect the lubricating properties of the engine oil NEVER overfill Overfilling may result in white exhaust smoke engine overspeed or internal damage 3 Insert the dipstick fully to check the level NOTICE ALWAYS keep the oil level between upper and lower lines on the oil cap dip...

Page 36: ...soft water especially when operating in cold weather Without LLC cooling performance will decrease due to scale and rust in the cooling system Water alone may freeze and form ice it expands approximately 9 in volume Use the proper amount of coolant concentrate for the ambient temperature as specified by the LLC manufacturer LLC concentration should be a minimum of 30 to a maximum of 60 Too much LL...

Page 37: ...spray out if it is not closed tightly Figure 3 25 Figure 3 25 1 Hose 2 Full Mark 3 Low Mark 4 Coolant Recovery Tank Cap 5 Check the coolant level in the coolant recovery tank The level should be at the FULL mark Figure 3 25 2 Add coolant if necessary NOTICE NEVER pour cold coolant into a hot engine 6 Remove the coolant recovery tank cap Figure 3 25 4 to add coolant if necessary NEVER add water 7 R...

Page 38: ... cocks and drain the fresh water into an appropriate container 2 Close the drain cocks after draining the water 3 Dispose of waste properly Draining Seawater Cooling System NOTICE If seawater is left inside it may freeze and damage parts of the cooling system freshwater cooler seawater pump etc when ambient temperature is below 0 C 32 F 1 Close the seacock 2 Open the seawater drain cocks and drain...

Page 39: ...freshwater cooling 2 systems sea freshwater Lubrication system Forced lubrication system with Trochoid gear pump Direction of rotation Counter clockwise viewed from flywheel side Engine oil capacity Total 10 5 L 11 0 qt Oil pan 8 4 L 8 9 qt Cooling water capacity 13 5 L 14 3 qt Engine 1 6 L 1 7 qt Coolant Recovery Tank Turbocharger Model RHE62W IHI made Type Water cooled turbine housing Dimension ...

Page 40: ...40 315 299 Model HURTH KANZAKI MERCRUISER ZF063A1 KMH50A Bravo X 1 Bravo X 2 Bravo X 3 Type 8 down Hydraulic 8 down Hydraulic Stern drive Applicable engine 6LPA STP2 6LPA STP2 6LPA STZP2 Reduction ratio ZF63A1 Ahead Astern Bravo X 1 2 3 Both Ahead and Astern 1 22 1 21 1 67 1 67 1 36 1 50 1 36 1 56 1 58 2 13 2 13 1 50 1 65 1 50 2 04 2 10 2 43 2 43 1 81 1 65 2 52 2 53 2 00 1 81 See manufacturer s do...

Page 41: ... 61 N m 14 5 lb ft Camshaft bearing cap x Cylinder head 250 kgf cm2 24 52 N m 18 08 lb ft Camshaft oil seal retainer x Cylinder head 200 kgf cm2 19 61 N m 14 5 lb ft Main bearing cap x Cylinder block 12 pointed head 1050 kgf cm2 102 97 N m 75 9 lb ft 90 Retightening 6 pointed head 185 kgf cm2 18 14 N m 13 38 lb ft Crankshaft pulley x Crankshaft 4400 kgf cm2 431 50 N m 318 3 lb ft Flywheel x Cranks...

Page 42: ...se a leak or component failure NOTICE The tightening torque in the Standard Torque Chart should be applied only to the bolts with a 7 head JIS strength classification 7T Apply 60 torque to bolts that are not listed Apply 80 torque when tightened to aluminum alloy Hexagon Bolts and Nuts Torque Bolt diameter x pitch mm M6 X 1 0 M8 X 1 25 M10 X 1 5 M12 X 1 75 M14 X 1 5 M16 X 1 5 N m 11 0 1 0 26 0 3 0...

Page 43: ... gallon U S per hour gal min gallon U S per minute GL gear lubricant hp horsepower metric 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 K kelvin kg kilogram kgf cm kilogram force per square kgf m kilogram force per meter km kilometers kPa kilopascal kW kilowatt L liter L...

Page 44: ...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 0 1383 kgf m in lb x 0 0115 kgf m lb ft x 1 3558 N m lb ft x 0 1383 kgf m lb in x 0 1130 N m lb in 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 kP...

Page 45: ... crankshaft pulley Yanmar Part No 119770 0107 Toyota Part No 09213 00020 3 Remover for removing drive gear oil pump for removing Yanmar Part No 119770 01080 Toyota Part No 09213 36020 4 Tool for settling crankshaft pulley Yanmar Part No 119770 01090 Toyota Part No 09213 58012 5 Replacer for replacing the engine front oil seal Yanmar Part No 119770 01100 Toyota Part No 09223 78010 6 Tool for settli...

Page 46: ...a Part No 09202 00010 13 Crankshaft pulley holding tool Yanmar Part No 119770 01090 Toyota Part No 09213 58012 14 Washer Toyota Part No 90201 08131 15 Bolt Toyota Part No 91111 50845 16 Crankshaft pulley gear replacer for crankshaft pulley Toyota Part No 09214 60010 17 Injection pump drive gear oil seal for injection pump drive gear bearing Toyota Part No 09214 76011 18 Connecting rod bushing remo...

Page 47: ...a Part No 09223 46011 24 Crankshaft rear oil seal replacer Yanmar Part No 119770 01100 Toyota Part No 09223 56010 25 Crankshaft oil seal replacer for crankshaft front oil seal Yanmar Part No 119770 01100 Toyota Part No 09223 78010 26 Plunger stroke measuring tool Toyota Part No 09275 54011 27 Oil seal puller for crankshaft front oil seal Toyota Part No 09308 10010 28 Companion flange holding toolf...

Page 48: ...ming gear and injection pump drive gear bearing Toyota Part No 09952 04010 32 Center bolt 100 for oil pump drive shaft gear and crankshaft timing gear Toyota Part No 09953 04010 33 Center bolt 150 for No 1 camshaft timing pulley oil pump drive shaft gear crankshaft timing gear and injection pump drive gear bearing Toyota Part No 09953 04020 34 Arm 25 for No 1 camshaft timing pulley oil pump drive ...

Page 49: ... No 09951 05010 38 Slide arm for crankshaft pulley and injection pump drive gear Toyota Part No 09952 05010 39 Center bolt 100 for crankshaft pulley and injection pump drive gear Toyota Part No 09953 05010 40 Center bolt 150 for crankshaft pulley Toyota Part No 09953 05020 41 Claw No 2 for crankshaft pulley and injection pump drive gear Toyota Part No 09954 05020 42 Handle set Toyota Part No 09950...

Page 50: ...Cylinder compression check gauge set Toyota Part No 09992 00024 48 Oil pan seal cutter Yanmar Part No 119770 01060 Toyota Part No 09032 00100 49 Oil filter wrench Toyota Part No 09228 10002 50 Fuel filter wrench Toyota Part No 09228 64010 51 Water pump overhaul tool set Toyota Part No 09236 00101 52 Injection pump camshaft bearing cone replacer for rotor rear bearing cover Toyota Part No 09285 760...

Page 51: ...nator rear bearing replacer Toyota Part No 09820 00030 56 Alternator pulley nut wrench set Toyota Part No 09820 63010 57 Replacer set for rotor front bearing Toyota Part No 09950 60010 58 Replacer 26 Toyota Part No 09951 00260 59 Replacer 50 Toyota Part No 09951 00500 60 Adapter Toyota Part No 09950 06010 61 Gauge assembly Toyota Part No 09992 00211 No Tool Name and Description Tool P N Illustrati...

Page 52: ...22 65 Injection pump stand arm Toyota Part No 09245 54010 66 Injection pump tool set Toyota Part No 09260 54012 67 Distributor head plug wrench Toyota Part No 09262 54010 68 Socket 14 mm Toyota Part No 09269 54020 69 Tweezers Toyota Part No 09269 54030 70 Governor lever support bolt wrench Toyota Part No 09269 54040 71 Regulator valve wrench Toyota Part No 09262 54020 No Tool Name and Description ...

Page 53: ...ta Part No 09268 17010 73 Attachment for injection pump Toyota Part No 09957 04010 74 Toyota electrical tester set Toyota Part No 09082 00050 75 Engine adjust kit Toyota Part No 09200 00010 76 Hose plug set for plug for fuel hose Toyota Part No 09258 00030 No Tool Name and Description Tool P N Illustration 0005546 0005547 0005548 0005549 0005501 ...

Page 54: ...ine tune up tester Heater Micrometer Piston ring expander Plastigage Precision straight edge Soft brush Spring tester Valve spring Steel square Valve spring Thermometer Torque wrench Valve seat cutter V block Vernier calipers Starter Motor Dial indicator Commutator Magnetic finger Pull scale Brush spring Sandpaper Commutator Torque wrench V block Vernier calipers Commutator Brush Engine Oil Pump O...

Page 55: ... Marine International Fuel System Angle gauge Brass brush Dial indicator with magnetic base Graduated cylinder Injection nozzle tester Injection pump tester Inner pressure gauge Micrometer Steel square Timer measuring device Torque wrench Vernier caliper Wooden stick System Equipment Tool Use ...

Page 56: ...p portions that cannot be measured by dial indicator 3 Magnetic Stand For holding the dial indicator when measuring 4 Micrometer For measuring the outside diameters of crankshaft pistons piston pins etc 5 Cylinder Bore Gauge For measuring the inside diameters of cylinder liners bearing bores etc 6 Calipers For measuring outside diameters depth thickness and width 7 Depth Micrometer For measuring v...

Page 57: ...asuring valve spring inclination and straightness of parts 9 Torque Wrench For tightening nuts and bolts to the specified torque 10 Feeler Gauge For measuring piston ring gaps piston ring clearance fuel injector adjustment clearance and valve adjustment clearance No Instrument Name Application Illustration 0000838 0000840 0000841 ...

Page 58: ...FIPG formed in place gasket Timing belt cover Timing gear cover Camshaft oil seal retainer Cylinder head semi circular plug Cylinder head cover Main bearing cover Rear oil seal retainer Oil pump Oil pan 08826 00100 Seal packing 1282B Three Bond 1282B or equivalent FIPG formed in place gasket Water temperature sender gauge 08833 00070 Adhesive 1344 Three Bond 1344 Loctite 242 or equivalent Oil pres...

Page 59: ...ilm appropriate for mating surfaces of precision parts Three Bond No 4 TB1104 200 g 1 kg also available Semi drying viscoelastic material applicable for non flat surfaces have indentions or protrusions superior heat water and oil resistance Three Bond No 10 TB1211 100 g Solventless type silicone based sealant applicable for high temperature areas 50 to 250 C 122 to 482 F Three Bond TB1212 100 g Si...

Page 60: ...GENERAL SERVICE INFORMATION 3 48 6LPA Service Manual Wiring Diagrams 2007 Yanmar Marine International WIRING DIAGRAMS B Type Instrument Panel Figure 3 30 Figure 3 30 E2 19773 0020_1 ...

Page 61: ...GENERAL SERVICE INFORMATION 6LPA Service Manual 3 49 Wiring Diagrams 12 05 2007 Yanmar Marine International C D Type x B Type Instrument Panel Figure 3 31 Figure 3 31 E2 19773 0031_1 ...

Page 62: ...GENERAL SERVICE INFORMATION 3 50 6LPA Service Manual Wiring Diagrams 2007 Yanmar Marine International C D Type x C Type Instrument Panel Figure 3 32 Figure 3 32 E2 19773 0011_1 A A ...

Page 63: ...Applicable Countries 4 4 Conditions to Ensure Compliance with EPA Emission Standards 4 5 Inspection and Maintenance 4 5 Periodic Maintenance Schedule 4 6 Inspection and Maintenance of EPA Emission Related Parts 4 8 Periodic Maintenance Procedures 4 9 After Initial 50 Hours of Operation 4 9 Every 50 Hours of Operation 4 11 Every 125 Hours of Operation 4 12 After Initial 250 Hours of Operation 4 13 ...

Page 64: ...PERIODIC MAINTENANCE 4 2 6LPA Service Manual 2007 Yanmar Marine International This Page Intentionally Left Blank ...

Page 65: ...able before servicing the equipment Fire and Explosion Hazard Diesel fuel is flammable and explosive under certain conditions NEVER use a shop rag to catch the fuel Wipe up all spills immediately Piercing 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 i...

Page 66: ...at you use genuine Yanmar parts when replacement parts are needed Genuine replacement parts help ensure long engine life Tools Required Before you start any periodic maintenance procedure make sure you have the tools you need to perform all of the required tasks EPA REQUIREMENTS To maintain optimum engine performance and compliance with the Environmental Protection Agency EPA Regulations for Engin...

Page 67: ...Maintenance Procedures on page 4 9 and keep a record of the results Pay particular attention to these important points Replacing the engine oil Replacing the oil filter Replacing the fuel filter Cleaning the intake silencer air cleaner Note Inspections are divided into two sections in accordance with who is responsible for performing the inspection the user or the manufacturer Inspection and Maint...

Page 68: ...ine Note The following procedures are considered normal maintenance and are performed at the owner s expense For EPA requirements see Inspection and Maintenance of EPA Emission Related Parts on page 4 8 c Check or Clean Replace System Item Periodic Maintenance Interval Daily Every 50 hours or one month whichever comes first Every 125 hours or 6 months whichever comes first Every 250 hours or one y...

Page 69: ... elbow Check or replace the fuel line and rubber hoses c Electrical System Check the alarm indicators c Check the battery electrolyte level c Adjust the tension of the alternator V belt or replace the V belt c Remote Control Handle Check and lubricate the remote control cable operation c Adjust the remote control cable c Intake and Exhaust System Wash turbocharger blower c Clean air cleaner c Adju...

Page 70: ...Interval Clean fuel injection nozzle 1500 hours Check fuel injection nozzle adjustment 3000 hours Check fuel injection pump adjustment Check turbocharger adjustment Check electronic engine control unit ECU and its associated sensors and actuators c Check or Clean Replace System Item Periodic Maintenance Interval Daily Every 50 hours or one month whichever comes first Every 125 hours or 6 months wh...

Page 71: ...ining remove the engine oil fill cap NOTICE Prevent dirt and debris from contaminating engine oil Carefully clean the dipstick and the surrounding area before you remove the dipstick 3 Turn the engine oil filter Figure 4 1 1 counterclockwise with a wrench 4 Remove the engine oil filter 5 Apply a small amount of engine oil to the seal of the new filter 6 Install a new filter element and tighten by ...

Page 72: ...move the filter element Figure 4 3 5 with a filter wrench 7 Install the alarm switch to the new fuel filter 8 Apply a thin film of clean diesel fuel to the sealing surface of the new filter gasket 9 Install the new filter and tighten hand tight Use a filter wrench and tighten to 14 7 to 19 6 N m 130 1 to 173 5 lb in 10 Install filter and tighten hand tight 11 Connect the alarm switch harness 12 In...

Page 73: ...d also drain the fuel tank Figure 4 5 Figure 4 5 1 Close the fuel cock of the fuel tank 2 Remove the two mounting screws Figure 4 5 1 and remove the housing Figure 4 5 2 3 Loosen the drain plug of the water separator and drain off any water or dirt collected inside 4 Install housing and mounting screws 5 Bleed air from the fuel system See Bleeding the Fuel System on page 3 21 Checking the Battery ...

Page 74: ...el Figure 4 6 fill with distilled water Figure 4 6 up to the upper limit Figure 4 6 of the battery WARNING If operation continues with insufficient battery fluid the battery life is shortened and the battery may overheat and explode Figure 4 6 Figure 4 6 Perform the following maintenance every 125 hours of operation or 6 months whichever comes first Changing the Engine Oil and Replacing the Engine...

Page 75: ... page 5 90 Every 250 Hours of Operation Perform the following maintenance every 250 hours or one year of operation whichever comes first Replacing the Fuel Filter Element Changing the Coolant Checking or Replacing the Zinc Anodes Checking and Adjusting the Remote Control Cable Cleaning the Turbocharger Cleaning the Air Cleaner Replacing the Fuel Filter Element See Replacing the Fuel Filter Element...

Page 76: ... and Figure 4 12 2 Engine Oil Cooler Figure 4 11 3 4 Measure the remaining zinc in the plug Replace the zinc anode when it is less than one half its original size See chart for sizes Note Some marine drives have additional zinc anodes Check the manufacturer s documentation for location and other information 5 Install a new zinc in a new plug NOTICE NEVER use sealing tape to install the zinc anode ...

Page 77: ...emote Control Cable Refer to the manufacturer s documentation Cleaning the Turbocharger Contamination of the turbocharger causes revolutions to drop and engine output to fall If a significant drop in engine output is noted 10 or more clean the turbocharger See Inspection and Cleaning on page 9 14 Cleaning the Air Cleaner Figure 4 13 Figure 4 13 1 Slide air cleaner Figure 4 13 1 off the air inlet 2...

Page 78: ...bberized fuel hoses every two years or every 500 hours of engine operation whichever comes first even if the engine has been out of service Rubberized fuel lines tend to dry out and become brittle after two years or 500 hours of engine operation whichever comes first Checking and Adjusting the Alternator V Belt Tension Figure 4 14 Figure 4 14 NOTICE NEVER allow oil on the belt s Oil on the belt ca...

Page 79: ...urs of Operation Perform the following maintenance every 1000 hours or 4 years of operation whichever comes first Checking the Fuel Injection Timing Checking the Fuel Injector Pressure and Nozzle Spray Pattern Checking or Replacing the Seawater Pump Impeller Adjusting Intake and Exhaust Valve Clearances Lapping the Intake and Exhaust Valves Checking the Fuel Injection Timing See Injection Timing I...

Page 80: ...ce Inspection and Adjustment on page 5 90 Lapping the Intake and Exhaust Valve See Valve Seat Inspection and Servicing on page 5 24 Every 1250 Hours of Operation Perform the following maintenance procedures every 1250 hours of operation or 5 years whichever comes first Cleaning the Cooling Water System Cleaning and Checking the Seawater Cooling Passage Cleaning and Checking the Freshwater Cooling ...

Page 81: ...aning Inspection and Servicing 5 20 Camshaft Oil Seal Replacement 5 31 Cylinder Head Assembly 5 32 Cylinder Head Installation 5 33 Cylinder Block 5 40 Components 5 40 Preparation for Disassembly 5 42 Cylinder Block Disassembly 5 42 Cylinder Block Inspection 5 51 Piston and Connecting Rod Disassembly 5 53 Piston and Connecting Rod Inspection 5 54 Inspection and Servicing of Crankshaft 5 59 Cranksha...

Page 82: ... Timing Gear Removal 5 80 Timing Gear Inspection 5 82 Front Crankshaft Oil Seal Replacement 5 85 Fuel Injection Pump Drive Gear Oil Seal Replacement 5 86 Timing Gear Installation 5 87 Valve Clearance Inspection and Adjustment 5 90 Valve Clearance Inspection 5 90 Valve Clearance Adjustment 5 91 Injection Timing Inspection and Adjustment 5 93 Inspection of Injection Timing 5 93 Adjustment of Injecti...

Page 83: ...e that all connections are tightened to specifications after repair is made to the exhaust system All internal combustion engines create carbon monoxide gas during operation and special precautions are required to avoid carbon monoxide poisoning NEVER attempt to adjust the low or high idle speed limit screw This may impair the safety and performance of the engine and shorten its life If adjustment...

Page 84: ...45 000 to 45 025 mm 1 771 to 1 773 in Idler gear shaft diameter 44 950 to 44 975 mm 1 769 to 1 770 in Idler gear oil clearance Standard 0 025 to 0 075 mm 0 001 to 0 003 in Limit 0 20 mm 0 008 in Gear backlash Standard 0 05 to 0 15 mm 0 002 to 0 006 in Limit 0 30 mm 0 012 in Cylinder head Combustion surface warpage Limit 0 20 mm 0 008 in Valve seat re facing Intake 20 45 70 Exhaust 25 45 65 Valve s...

Page 85: ...008 to 0 0022 in Exhaust 0 020 to 0 055 mm 0 0008 to 0 0022 in Limit Intake 0 08 mm 0 003 in Limit Exhaust 0 10 mm 0 004 in Margin thickness Standard Intake 1 00 mm 0 040 in Exhaust 1 00 mm 0 040 in Limit Intake 0 83 mm 0 033 in Limit Exhaust 0 83 mm 0 033 in Valve spring Deviation Limit 2 0 mm 0 080 in Free Length Limit 49 6 mm 1 952 in Valve rocker arm and shaft Valve rocker arm inside diameter ...

Page 86: ...mm 0 004 in Cam lobe height Standard Intake 48 498 to 48 598 mm 1 9093 to 1 9133 in Exhaust 50 734 to 50 834 mm 1 997 to 2 0001 in Cam lobe height Limit Intake 47 998 mm 1 890 in Exhaust 50 234 mm 1 978 in Cylinder block Cylinder top surface warpage Maximum 0 20 mm 0 008 in Cylinder bore diameter Standard Mark 1 94 000 to 94 010 mm 3 7007 to 3 7011 in Standard Mark 2 94 010 to 94 020 mm 3 7011 to ...

Page 87: ... mm 0 0057 to 0 0064 in Limit 0 215 mm 0 0084 in Piston ring groove clearance Standard No 1 0 050 to 0 095 mm 0 002 to 0 004 in Standard No 2 0 060 to 0 100 mm 0 002 to 0 004 in Standard Oil 0 030 to 0 070 mm 0 001 to 0 003 in Limit 0 20 mm 0 008 in Piston ring end gap Standard No 1 0 270 to 0 470 mm 0 011 to 0 018 in Standard No 2 0 400 to 0 650 mm 0 016 to 0 025 in Standard Oil 0 200 to 0 500 mm...

Page 88: ... in Piston pin bearing inside diameter 33 008 to 33 020 mm 1 2995 to 1 2999 in Piston pin diameter 33 000 to 33 012 mm 1 2992 to 1 2996 in Piston pin bearing oil clearance Standard 0 004 to 0 012 mm 0 0001 to 0 0005 in Limit 0 03 mm 0 001 in Connecting rod bolt diameter of tension portions Standard 8 300 to 8 400 mm 0 3267 to 0 3307 in Limit 7 95 mm 0 3129 in Crankshaft Thrust clearance Standard 0...

Page 89: ...0782 in Standard Mark 5 1 988 to 1 991 mm 0 0782 to 0 0783 in Standard Mark 6 1 991 to 1 994 mm 0 0783 to 0 0785 in Crank pin diameter Standard Mark 1 58 994 to 59 000 mm 2 3225 to 2 3228 in Standard Mark 2 58 988 to 58 994 mm 2 3223 to 2 3225 in Standard Mark 3 58 982 to 58 988 mm 2 3221 to 2 3223 in Circle runout Limit 0 06 mm 0 0023 in Journal taper and out of round Limit 0 02 mm 0 0008 in Cran...

Page 90: ...0 018 to 0 020 in 5 Low idling rpm 750 25 0 6 High idling rpm 4280 25 7 Valve timing degrees Intake Open BTDC 12 Close ABDC 24 Exhaust Open BBDC 54 Close ATDC 12 8 Firing order 120 120 120 120 120 120 No 1 cylinder is located opposite the flywheel side of the engine 1 4 2 6 3 5 1 9 Oil pressure kgf cm2 4 5 At 3800 rpm MPa 0 44 psi 64 10 Oil capacity oil pan 8 4L 8 8 qt 1 4L 1 4 qt Full Effective 1...

Page 91: ...b ft Camshaft bearing cap x Cylinder head 250 kgf cm2 24 52 N m 18 08 lb ft Camshaft oil seal retainer x Cylinder head 200 kgf cm2 19 61 N m 14 5 lb ft Main bearing cap x Cylinder block 12 pointed head 1050 kgf cm2 102 97 N m 75 9 lb ft 90 Retightening 6 pointed head 185 kgf cm2 18 14 N m 13 38 lb ft Crankshaft pulley x Crankshaft 4400 kgf cm2 431 50 N m 318 3 lb ft Flywheel x Crankshaft 1300 kgf ...

Page 92: ...AVOID placing the engine block directly on the floor as the oil pan can be damaged Note Cylinder number No 1 and No 2 are located starting from the gear case side Component Views Cylinder Head and Camshaft Figure 5 1 Figure 5 1 0004923 1 13 14 15 24 3 23 2 16 19 20 17 18 25 8 7 6 5 9 21 22 11 10 4 12 ...

Page 93: ... Plate 9 Camshaft Oil Seal Retainer 10 Camshaft Oil Seal Non Reusable Part 11 Camshaft Timing Pulley 12 Fuel Return Pipe 13 Gasket Non Reusable Part 14 Gasket Non Reusable Part 15 Fuel Injection Nozzle 16 Nozzle Holder Seal Non Reusable Part 17 O Ring Non Reusable Part 18 Nozzle Seat Non Reusable Part 19 Camshaft 20 Semi Circular Plug 21 Cylinder Head 22 Cylinder Head Gasket Non Reusable Part 23 R...

Page 94: ...ead 2007 Yanmar Marine International Camshaft Bearing Cap Valve Rocker Arm Nozzle Holder Clamp and Rocker Shaft Assembly Figure 5 2 Figure 5 2 1 Camshaft Bearing Cap 2 Nozzle Holder Clamp 3 Valve Rocker Shaft 4 Valve Rocker Arm 1 2 3 4 0004924 ...

Page 95: ...der Head 12 05 2007 Yanmar Marine International Cylinder Head Assembly Figure 5 3 Figure 5 3 1 Valve Bridge 2 Cotter 3 Spring Retainer 4 Valve Spring 5 Spring Seat 6 Stem Seal Non Reusable Part 7 Valve Guide 8 Valve 1 2 3 4 5 6 7 8 0004925 ...

Page 96: ... all the cooling water and after draining close all drain cocks Figure 5 4Draining Freshwater Figure 5 4 1 Oil Filter 2 Fuel Pump 3 Freshwater Drain Cock Figure 5 5Draining Seawater Figure 5 5 1 Oil Cooler 2 Flywheel Housing 3 Seawater Drain Plug Figure 5 6Draining Fresh and Seawater Figure 5 6 1 Freshwater Cooler 2 Seawater Drain Plug 3 Freshwater Drain Plug Number of Drain Cocks Model Freshwater...

Page 97: ...d and intercooler Figure 5 8 2 Figure 5 8 Figure 5 8 1 Fuel Filter 2 Intercooler 3 Fuel Pump 8 Remove the 12 rocker cover bolts seal washers rocker cover and gasket Figure 5 9 Figure 5 9 Figure 5 9 9 Remove the semi circular plug Figure 5 1 6 10 Remove the timing belt and pulley Figure 5 10 See Timing Belt Removal on page 5 69 11 Remove the 4 bolts and the oil seal retainer Figure 5 10 Figure 5 10...

Page 98: ...mshaft thrust plate and 7 lower camshaft bearings Note Keep the bearings together and in order as disassembled to ensure reassembly in the same order 16 Loosen and remove the 26 cylinder head bolts uniformly in sequence as shown in Figure 5 12 NOTICE NEVER remove the bolts at random or the head may warp or crack Figure 5 12 Figure 5 12 17 Lift the cylinder head from the cylinder block If needed us...

Page 99: ... 2 Compress the valve spring using special tool P N 119770 02000 Figure 5 15 1 and remove 2 cotters Perform for all valves 3 Remove the spring retainer valve spring valve and spring seat Perform for all valves Note Keep the valve valve spring spring seat and spring retainer together and in the order as disassembled to ensure reassembly into their original positions Figure 5 15 Figure 5 15 4 Remove...

Page 100: ...the cylinder block deck surface during cleaning Figure 5 18 Figure 5 18 3 Using compressed air clean out all carbon deposits and oil from the bolt holes WARNING ALWAYS wear protective goggles when using compressed air 4 Remove all gasket materials from the cylinder head deck surface using a scraper Figure 5 19 NOTICE AVOID damaging the cylinder head deck surface during cleaning Figure 5 19 Figure ...

Page 101: ...re 5 22 Figure 5 22 8 Measure the flatness of the cylinder head deck surface using a straight edge and feeler gauge Figure 5 23 Maximum warpage 0 20 mm If the measured warpage exceeds the specified maximum replace the cylinder head Figure 5 23 Figure 5 23 9 Check the intake and exhaust ports and the cylinder head deck surfaces for cracks using a color check agent Figure 5 24 If any cracks are disc...

Page 102: ...re 5 25 Figure 5 25 1 Thread End 2 34 mm 1 3 in Intake and Exhaust Valve Cleaning and Inspection 1 Remove all carbon deposits from the valves using a scraper and wire brush Figure 5 26 Figure 5 26 Figure 5 26 2 Measure the inside diameter of valve guides using a caliper gauge Figure 5 27 Valve guide inside diameter 7 010 to 7 030 mm 0 276 to 0 277 in Figure 5 27 Figure 5 27 3 Measure the diameter ...

Page 103: ...ness of valve head Figure 5 29 Standard margin thickness 1 00 mm 0 014 in Minimum margin thickness 0 83 mm 0 033 in If the measured margin thickness is below the specified minimum replace the valve Figure 5 29 Figure 5 29 1 Margin Thickness 2 Valve Face 7 Check the overall length of the intake and exhaust valves Figure 5 30 Standard overall length Intake valve 126 85 to 127 45 mm 4 994 to 5 017 in...

Page 104: ...around 360 of the valve seat the valve is concentric If not concentric replace the valve If the color adheres around 360 of the valve seat the guide and face are concentric If the color fails to adhere around 360 refinish the valve seat Inspect the valve seat for proper contact width Figure 5 31 1 and proper location within the middle of valve face Figure 5 32 Figure 5 32 Contact width Intake valv...

Page 105: ... 35 5 After lapping clean the valve and valve seat Valve Spring Inspection 1 Measure the straightness of the valve spring using a square Maximum deviation 2 0 mm 0 079 in Figure 5 36 1 If the measured deviation exceeds the specified maximum replace the valve spring Figure 5 36 Figure 5 36 2 Measure the free length of the valve spring using calipers Figure 5 37 Yellow Mark 49 6 mm 1 953 in Blue Mar...

Page 106: ...5 38 Spring force 24 2 to 26 8 kgf 237 32 to 262 82 N 53 3 to 59 1 lb ft at 39 5 mm 1 555 in position If the spring force is not within the specified range replace the valve spring Figure 5 38 Figure 5 38 Valve Rocker Arm and Shaft Inspection 1 Inspect the rocker arms for smooth rotation Figure 5 39 If binding or hooking is felt repair or replace Figure 5 39 Figure 5 39 0004963 0004964 ...

Page 107: ...y in the same order Figure 5 40 Figure 5 40 1 Camshaft Bearing Caps 2 Mark 1 3 Mark 7 4 Mark 2 3 4 5 or 6 5 Valve Rocker Arms 6 Valve Rocker Arm Intake Side 7 Valve Rocker Arm Exhaust Side 8 Nozzle Holder Clamp 9 Valve Rocker Shaft 10 Camshaft Bearing Cap With Mark 1 11 Camshaft Bearing Cap With Mark 7 12 Camshaft Bearing Cap With Mark 2 3 4 5 or 6 11 6 6 10 11 12 11 11 11 12 7 7 7 8 8 7 8 7 7 6 1...

Page 108: ...exceeds the specified maximum replace the rocker arm shaft and rocker arm 6 Assemble all parts as shown in Figure 5 40 Camshaft and Bearing Inspection 1 Install the camshaft on a V block to measure camshaft runout on the center journal Use a dial indicator to measure runout while turning Figure 5 43 Maximum circle runout 0 10 mm 0 004 in If the measured runout exceeds the specified maximum replace...

Page 109: ...ce as shown in step 5 Figure 5 45 Figure 5 45 4 Check the camshaft bearings for flaking peeling or scoring scratches Figure 5 46 If the bearing is damaged replace the bearing cap and cylinder head at the same time Figure 5 46 Figure 5 46 5 Inspect the oil clearance of the camshaft journal a Remove the 7 bearing caps from the camshaft or valve rocker shaft b Clean the bearing caps and camshaft jour...

Page 110: ...move the 7 bearing caps Figure 5 49 Figure 5 49 h Measure the plastigage at the widest point Figure 5 50 If measured oil clearance is greater than the specified maximum replace the camshaft and inspect and replace the bearing caps and cylinder head as needed Standard oil clearance No 1 0 022 to 0 074 mm 0 0008 to 0 0029 in Others 0 023 to 0 075 mm 0 0009 to 0 0030 in Maximum oil clearance 0 10 mm ...

Page 111: ...e maximum replace the thrust plate Replace the camshaftorthebearingcapand cylinder headas a set as needed Figure 5 51 Figure 5 51 Camshaft Oil Seal Replacement There are two methods for replacing the oil seal Method 1 Use this procedure when the camshaft oil seal retainer has been removed from the cylinder head 1 Tap out the oil seal using a screwdriver and a hammer Figure 5 52 Figure 5 52 Figure ...

Page 112: ... tap in a new oil seal until its surface is level with the end surface of oil seal retainer Figure 5 55 Figure 5 55 Cylinder Head Assembly Note Clean all parts to be assembled Apply new engine oil to all sliding and rotating surfaces before assembling parts Replace all gaskets and seals 1 Using a suitable tool Figure 5 56 1 press new valve stem seals into the valve guides Figure 5 56 Figure 5 56 2...

Page 113: ... to the top deck surface of the cylinder block for each cylinder to determine an appropriate cylinder head gasket 1 Clean the top surface of cylinder block with solvent 2 Set the piston of the cylinder for measurement just before top dead center 3 Install a dial indicator on the cylinder block and adjust the dial indicator to zero Note Use a dial indicator measuring tip Figure 5 61 1 Always check ...

Page 114: ...nd determine the average of all Piston protrusion P Figure 5 62 2 0 175 to 0 425 mm 0 0068 to 0 0167 in If the measured value is not within the specified range remove the piston and connecting rod assembly and then reassemble and measure again See Cylinder Block Disassembly on page 5 42 Figure 5 63 Figure 5 63 7 There are three thicknesses of service gaskets Mark No 1 3 and 5 Figure 5 64 Figure 5 ...

Page 115: ...ition on the cylinder block Figure 5 66 Note Install the gasket in the correct position Figure 5 66 Figure 5 66 1 Gasket Mark Number 11 Install the cylinder head correctly on the cylinder head gasket 12 Lightly apply engine oil to the threads and cylinder head bolt seats and install the cylinder head bolts Note Uniformly tighten the cylinder head bolts in 3 steps If any bolts are damaged or deform...

Page 116: ...linder head bolts an additional 90 Figure 5 68 3 16 Retighten the cylinder head bolts again an additional 90 Figure 5 68 4 Figure 5 68 Figure 5 68 17 After tightening check that the painted marks face 180 from the starting point Camshaft Installation 1 Install the thrust plate Figure 5 69 1 Figure 5 69 Figure 5 69 2 Install the 7 lower camshaft bearings Note There are two types of camshaft bearing...

Page 117: ...ap 5 Install the bearing cap and other parts 6 Install 7 bearing caps 12 rocker arms 6 holder clamps and the rocker shaft assembly Figure 5 72 Figure 5 72 Figure 5 72 7 Uniformly tighten the 14 bearing cap bolts in steps in the order shown in Figure 5 73 Torque bearing cap others A 250 kgf cm 24 50 N m 18 07 lb ft Figure 5 73 Figure 5 73 Figure 5 73 8 Install the fuel injection nozzle See Fuel Inj...

Page 118: ...seal packing to the oil seal retainer as shown in Figure 5 74 Use a nozzle cut to a sealing width of 2 to 3 mm 0 078 to 0 118 in Figure 5 74 1 Note Parts must be assembled within 5 minutes after seal packing is applied Otherwise the packing material must be removed and reapplied Note Disconnect the nozzle from the tube immediately after use and protect it by sealing with a cap Seal packing TOYOTA ...

Page 119: ...Figure 5 76 2 to the semi circular plug Figure 5 76 1 Seal packing TOYOTA P N 08826 00080 or equivalent 3 Install the semi circular plug to the cylinder head Figure 5 76 Figure 5 76 4 Completely remove all packing material from the rocker cover sealing area 5 Apply seal packing to the cylinder head as shown in Figure 5 77 Seal packing TOYOTA P N 08826 00080 or equivalent Figure 5 77 Figure 5 77 6 ...

Page 120: ...NE 5 40 6LPA Service Manual Cylinder Block 2007 Yanmar Marine International CYLINDER BLOCK Components Figure 5 78 Figure 5 78 2 4 7 9 17 19 21 23 25 27 26 24 22 20 18 16 14 13 12 11 10 5 8 6 3 1 15 0005108 ...

Page 121: ...ring 10 Connecting Rod 11 Crank Pin Bearing 12 Connection Rod Cap 13 Rod Bolt 14 Cylinder Block 15 Rear Oil Seal Case 16 Oil Nozzle For Piston Cooling 17 Crankshaft Oil Seal Non Reusable Part 18 Check Valve 19 Crankshaft Oil Seal 20 Crankshaft 21 Crankshaft Thrust Bearing 22 Cylinder Block Oil Hole Plug Non Reusable Part 23 Upper Main Bearing 24 Main Bearing Cap 25 Lower Main Bearing 26 Main Beari...

Page 122: ...emove the oil pan and timing gear case See Oil Pump Removal on page 8 7 10 Remove the oil cooler See Oil Cooler Removal on page 8 14 11 Remove the engine mount Cylinder Block Disassembly 1 Remove the 6 rear oil seal case bolts 2 Insert a screwdriver between the oil seal case and main bearing cap and pry Figure 5 79 1 to remove the oil seal case Figure 5 79 Figure 5 79 3 To check the connecting rod...

Page 123: ... 81 Figure 5 81 5 Move the connecting rod cap transversely Figure 5 82 1 using two removed connecting rod cap bolts to remove the connecting rod cap Figure 5 82 Figure 5 82 6 Insert the lower bearing to the connecting rod cap Figure 5 83 Figure 5 83 Figure 5 83 7 Check the crank pin and bearing for corrosion and scratches If damage is present replace the bearing and grind or replace the crankshaft...

Page 124: ...1 to 0 002 in Maximum oil clearance 0 10 mm 0 004 in If the measured value exceeds the specified maximum replace the bearing and grind or replace the crankshaft as necessary Figure 5 86 Figure 5 86 Note Replace the old bearings with new bearings of the same number If the bearing number is unknown it may be determined by adding the numbers on the crankshaft with those on the connecting rod There ar...

Page 125: ...nder number for correct reassembly Crank Pin Bearing Selection Table Mark No Connecting Rod 1 2 3 Crankshaft 1 2 3 1 2 3 1 2 3 Bearing 2 3 4 3 4 5 4 5 6 Inside Diameter of Larger End of Connecting Rod Mark 1 62 014 to 62 020 mm 2 4414 to 2 4417 in Mark 2 62 020 to 62 026 mm 2 4417 to 2 4419 in Mark 3 62 026 to 62 032 mm 2 4419 to 2 4422 in Diameter of Crankshaft Crank Pin Mark 1 58 994 to 59 000 m...

Page 126: ...ure 5 90 Figure 5 90 17 Uniformly loosen and remove the 14 main bearing cap bolts 12 pointed head in the order shown in Figure 5 91 Figure 5 91 Figure 5 91 18 Insert the tip of a screwdriver Figure 5 92 1 between the main bearing cap and cylinder block and pry out the main bearing cap Insert the lower bearing into the main bearing cap in preparation for reassembly Note AVOID damaging the contact s...

Page 127: ... 12 pointed head Figure 5 95 See steps 13 to 18 starting at Cylinder Block Assembly on page 5 63 NOTICE NEVER turn the crankshaft Tightening torque First tightening 1050 kgf cm 102 90 N m 78 9 lb ft Second tightening Turn by 90 Figure 5 95 Figure 5 95 25 Remove the 14 bolts and main bearing caps 26 Measure the plastigage at the widest point Figure 5 96 a Standard clearance 0 036 to 0 054 mm 0 001 ...

Page 128: ...Crank Journal Bearing Selection Table Mark No Main bearing cap 1 2 3 Crankshaft 1 2 3 1 2 3 1 2 3 Bearing 2 3 4 3 4 5 4 5 6 Cylinder Block Journal Bore Diameter Mark 1 71 000 to 71 006 mm 2 7952 to 2 7955 in Mark 2 71 006 to 71 012 mm 2 7955 to 2 7957 in Mark 3 71 012 to 71 018 mm 2 7957 to 2 7959 in Crankshaft Journal Diameter Mark 1 66 994 to 67 000 mm 2 6375 to 2 6377 in Mark 2 66 988 to 66 994...

Page 129: ...9499 2 79503 in 4 66 993 66 994 mm 2 63751 2 63755 in 5 70 992 70 993 mm 2 79495 2 79499 in 5 66 992 66 993 mm 2 63747 2 63751 in 6 70 991 70 992 mm 2 79491 2 79495 in 6 66 991 66 992 mm 2 63743 2 63747 in 7 70 990 70 991 mm 2 79487 2 79491 in 7 66 990 66 991 mm 2 63739 2 63743 in 8 70 989 70 990 mm 2 79483 2 79487 in 8 66 989 66 990 mm 2 63735 2 63739 in 9 70 988 70 989 mm 2 79479 2 79483 in 9 66...

Page 130: ...E 3 3 4 4 4 4 4 4 5 5 5 5 5 5 6 6 6 6 H 3 4 4 4 4 4 4 5 5 5 5 5 5 6 6 6 6 6 4 4 4 4 4 4 4 5 5 5 5 5 5 6 6 6 6 6 6 5 4 4 4 4 4 5 5 5 5 5 5 6 6 6 6 6 6 7 6 4 4 4 4 5 5 5 5 5 5 6 6 6 6 6 6 7 7 7 4 4 4 5 5 5 5 5 5 6 6 6 6 6 6 7 7 7 8 4 4 5 5 5 5 5 5 6 6 6 6 6 6 7 7 7 7 9 4 5 5 5 5 5 5 6 6 6 6 6 6 7 7 7 7 7 L 5 5 5 5 5 5 6 6 6 6 6 6 7 7 7 7 7 7 M 5 5 5 5 5 6 6 6 6 6 6 7 7 7 7 7 7 8 R 5 5 5 5 6 6 6 6 6 ...

Page 131: ...der Block Inspection 1 Use a scraper to remove any remaining gasket material from the top of the cylinder block Figure 5 99 Figure 5 99 Figure 5 99 2 Thoroughly clean the cylinder block using a soft brush and solvent 3 Measure the top deck surface of the cylinder block using a precision straight edge and feeler gauge Figure 5 100 Maximum warpage is 0 20 mm 0 008 in If the measured warpage exceeds ...

Page 132: ...ial directions Figure 5 103 2 using a cylinder gauge Standard bore diameter Mark 1 94 000 to 94 010 mm 3 7007 to 3 7011 in Mark 2 94 010 to 94 020 mm 3 7011 to 3 7015 in Mark 3 94 020 to 94 030 mm 3 7015 in to 3 7019 in Maximum bore diameter 94 23 mm 3 7098 in If the measured bore diameter exceeds the specified maximum bore the cylinders or replace as needed Figure 5 103 Figure 5 103 1 Thrust Dire...

Page 133: ...s below the specified minimum replace the bolt s Figure 5 105 Figure 5 105 1 Thread End 2 40 mm 1 57 in Piston and Connecting Rod Disassembly 1 Check the piston to piston pin fit by moving the piston back and forth on the piston pin If any movement is felt replace the piston and piston pin as a set Figure 5 106 Figure 5 106 Figure 5 106 2 Remove the piston rings using the piston ring expander Figu...

Page 134: ...plastic hammer and copper bar to disconnect the connecting rod Figure 5 110 Store the piston and pin as a set Store the pistons pins rings and connecting rods together in correct order for reassembly Figure 5 110 Figure 5 110 Piston and Connecting Rod Inspection 1 Clean the carbon deposits off the piston top using a scraper Figure 5 111 Figure 5 111 Figure 5 111 2 Clean the piston ring grooves usi...

Page 135: ...r at right angle to the piston pin at the L position Figure 5 114 3 from the piston top using a micrometer Figure 5 114 Figure 5 114 1 SIze Mark 2 Front Mark Arrow 3 L Position 5 Measure the cylinder bore diameter in the thrust direction See step 5 starting in Cylinder Block Inspection on page 5 51 Figure 5 115 Figure 5 115 1 No 1 2 No 2 3 No 3 4 No 4 5 No 5 6 No 6 7 Mark 1 2 or 3 8 Front Mark Arr...

Page 136: ...ve using a thickness gauge Figure 5 116 Figure 5 116 Standard clearance 0 050 to 0 095 mm 0 002 to 0 004 in Maximum clearance 0 20 mm 0 008 in If the measured clearance exceeds the specified maximum replace the piston No 2 ring second ring and oil ring Measure the clearance between the new piston ring and ring groove using a thickness gauge Figure 5 117 Standard clearance No 2 ring 0 060 to 0 100 ...

Page 137: ...specified maximum replace the piston ring If the end gap still exceeds the maximum even when a new piston ring is used bore all six cylinders or replace the cylinder block 9 Inspect the piston pin fit to the piston If the piston pin can be pressed into the piston by hand after heating the piston to about 80 C the fit is acceptable Figure 5 120 Figure 5 120 Figure 5 120 10 Measure the bend of the c...

Page 138: ...Measure the inside diameter of the piston pin bearing using a caliper gauge Figure 5 123 Inside diameter of piston pin bearing 33 008 to 33 020 mm 1 2995 to 1 2999 in Figure 5 123 Figure 5 123 14 Measure the piston pin diameter using a micrometer Figure 5 124 Piston pin diameter 33 000 to 33 012 mm 1 2992 to 1 2996 in Figure 5 124 Figure 5 124 15 Subtract the measured piston pin diameter from the ...

Page 139: ...circle runout exceeds the specified maximum replace the crankshaft Figure 5 126 Figure 5 126 2 Inspect and measure diameters of each crank journal Figure 5 127 1 and crank pin Figure 5 127 2 using a micrometer Standard crank journal diameter 66 982 to 67 000 mm 2 6370 to 2 6377 in Standard crank pin diameter 58 982 to 59 000 mm 2 3221 to 2 3228 in If the measured diameter is out of the specified r...

Page 140: ...h that of the rear oil seal case Figure 5 129 Figure 5 129 3 Apply grease to the oil seal lip Method 2 When the rear oil seal case is installed on the cylinder block 1 Cut off the oil seal lip using a knife Figure 5 130 1 2 Pry out the oil seal using a screwdriver NOTICE AVOID damaging the crankshaft during removal Use tape on the screwdriver tip to prevent scratches Figure 5 130 Figure 5 130 3 Ap...

Page 141: ...3 Figure 5 133 3 Apply engine oil to the piston pin 4 Align the marks of the piston and connecting rod and press the piston pin in by hand Figure 5 134 Figure 5 134 Figure 5 134 1 Piston Front Mark Arrow 2 Connecting Rod Front Mark 5 Install a new snap ring into the piston pin snap ring groove on the opposite side of the piston Figure 5 135 1 Figure 5 135 Figure 5 135 6 Manually install the coil f...

Page 142: ...8 1 No 1 Piston Ring ID Mark 2 No 2 Piston Ring ID Mark 9 Install the piston rings with the ring end gaps as shown in Figure 5 139 Note NEVER allow ring end gaps to overlap at the same position Figure 5 139 Figure 5 139 1 No 1 Piston Ring End Gap 2 No 2 Piston Ring End Gap 3 Oil Piston Ring End Gap 4 Oil Piston Coil Ring End Gap 5 Piston Front Mark Arrow 10 Align the connecting rod bearing claw Fi...

Page 143: ... bearings Figure 5 141 3 Align the main bearing claws with the grooves in the main bearing caps and press in seven lower bearings Figure 5 141 Figure 5 141 4 Place the crankshaft on the cylinder block Figure 5 142 Figure 5 142 Figure 5 142 5 Push the crankshaft towards the front or rear of the cylinder block and install four thrust bearings to journal No 4 of the cylinder block with the oil groove...

Page 144: ...the main bearing cap bolts Note Replace any main bearing cap bolts that are broken damaged or deformed 13 Install the 14 main bearing cap bolts 12 pointed head and tighten them uniformly in several passes in the sequence shown in Figure 5 146 Torque 1050 kgf cm 102 90 N m 75 9 lb ft Note If any of the main bearing cap bolts fail to torque to the torque specification replace the main bearing cap bo...

Page 145: ...stall the crankshaft pulley temporarily to keep the crankshaft from rotating freely Use special tool P N 119770 01090 and 119770 01120 Figure 5 149 Figure 5 149 21 Install the connecting rod caps to each connecting rod Note Use the correct connecting rod cap corresponding to each cylinder and rod Install the connecting rod cap with the front mark Figure 5 150 1 on the connecting rod cap facing to ...

Page 146: ...ing a razor blade and gasket scraper Note Avoid contaminating the contact surface of the seal case and cylinder block with oil 2 Clean all components and remove all foreign matter 3 Clean both the sealing surfaces using solvent 4 Apply seal packing TOYOTA P N 08826 00080 or equivalent to the case as shown Figure 5 153 Apply the seal packing in a width of 2 to 3 mm 0 08 to 0 12 in Figure 5 153 1 Fi...

Page 147: ... Install the flywheel housing set bolts and torque to 185 kgf cm 18 13 N m 13 3 lb ft 7 Turn the engine upside down and mount to an engine stand 8 Install the thermostat See Thermostat Installation on page 7 11 9 Install the alternator and bracket assembly Torque bolts to 700 kgf cm 68 60 N m 50 6 lb ft 10 Install the freshwater pump See Freshwater Pump Installation on page 7 6 11 Install the cyli...

Page 148: ... Figure 5 156 1 No 1 Camshaft Timing Pulley 2 Plate Washer 3 Idler Pulley 4 Timing Belt Tensioner 5 No 2 Camshaft Timing Pulley 6 No 1 Flange 7 No 2 Flange 8 Clip 9 Timing Belt Cover 10 Seal Washer 11 Clamp 12 Timing Belt 13 Gasket 14 Insulator 15 Seal Washer 1 3 2 4 5 7 8 9 8 6 8 10 11 11 15 15 14 13 12 0005153 ...

Page 149: ...ming belt is disconnected and the crankshaft pulley is rotated engine damage will result from the piston head and intake exhaust valve heads contacting NEVER turn the crankshaft with the timing belt disconnected and always make sure to set the crankshaft pulley at the correct angle when installing the belt Figure 5 158 Figure 5 158 To remove the timing belt when the timing belt is reused Draw an a...

Page 150: ...lt 4 Remove the pivot bolt idler pulley Figure 5 161 1 and plate washer Figure 5 161 2 using an 8 mm hex allen wrench Figure 5 161 3 Figure 5 161 Figure 5 161 5 Remove the four bolts Figure 5 162 1 No 2 flange timing pulley and No 1 flange Figure 5 162 Figure 5 162 6 Remove the rocker cover See step 8 starting in Cylinder Head Removal on page 5 16 7 Slowly turn the camshaft timing pulley counter c...

Page 151: ...twist or turn the timing belt inside out NEVER contaminate the timing belt with oil water or steam Figure 5 165 Figure 5 165 Figure 5 165 Inspect the belt for the following conditions if any of the following conditions are present or the belt is damaged replace the timing belt Breaking or parting at the joints Figure 5 166 Check the timing belt cover and gasket for damage and for correct installat...

Page 152: ...mage radially and axially Figure 5 169 Figure 5 169 Figure 5 169 If the belt teeth are worn check the timing belt cover for damage and that the gasket is installed correctly Also check the pulley teeth for contamination with dust or debris Figure 5 170 Figure 5 170 Figure 5 170 Idler Pulley 1 Visually check the seal of the idler pulley If oil leakage is present replace the idler pulley Figure 5 17...

Page 153: ...4 3 Measure the push rod protrusion Figure 5 175 1 from the end of housing Protrusion 9 0 to 9 8 mm 0 354 to 0 386 in If the measured value is not within specifications replace the tensioner Figure 5 175 Figure 5 175 Timing Belt Installation 1 Install the pulley key into the key groove in the camshaft 2 Press the No 1 timing pulley onto the camshaft aligning to the key into the groove 3 Hand tight...

Page 154: ...Install the plate washer Figure 5 179 1 and idler pulley Figure 5 179 2 by the pivot bolt using an 8 mm allen hex wrench Figure 5 179 3 Torque specification 350 kgf cm 34 32 N m 25 3 lb ft Figure 5 179 Figure 5 179 12 Check the pulley bracket for smooth movement 13 Align the timing mark of the No 2 camshaft timing pulley with the bottom dead center BDC mark Figure 5 180 NOTICE NEVER turn the camsh...

Page 155: ...leys 16 Tensioner Installation a Using a press slowly press in the push rod by applying 100 to 1 000 kgf 980 67 to 9806 65 N 220 4 to 2204 6 lbf b Align the push rod to the hole in the housing and carry out positioning of the push rod by passing a 1 5 mm allen hex wrench Figure 5 182 1 through the hole Figure 5 182 Figure 5 182 c Release the force d Temporarily secure the timing belt tensioner usi...

Page 156: ...184 18 Remove all packing material from the timing cover sealing surfaces 19 Apply seal packing TOYOTA P N 08826 00080 or equivalent to the camshaft oil seal retainer and timing belt cover as shown in Figure 5 185 Figure 5 185 Figure 5 185 20 Install the insulator to the timing belt cover 21 Install the gasket to the timing belt cover 22 Install the timing belt cover Figure 5 186 1 with bolts and ...

Page 157: ...ENGINE 6LPA Service Manual 5 77 Timing Belt 12 05 2007 Yanmar Marine International This Page Intentionally Left Blank ...

Page 158: ...ENGINE 5 78 6LPA Service Manual Timing Gear 2007 Yanmar Marine International TIMING GEAR Components Figure 5 187 Figure 5 187 1 2 3 4 6 7 10 9 11 13 14 15 12 5 8 16 0005187 ...

Page 159: ...p Drive Gear 4 O Ring Non Reusable Part 5 Camshaft Timing Gear 6 Fuel Injection Pump Drive Gear Bearing 7 Oil Pump Drive Shaft Gear 8 Idler Gear 9 Idler Gear Shaft 10 Thrust Plate 11 Fuel Injection Pump Drive Gear Oil Seal Non Reusable Part 12 Timing Gear Cover 13 Crankshaft Front Oil Seal Non Reusable Part 14 Crankshaft Pulley 15 O Ring Non Reusable Part 16 Bolt 6 Used ...

Page 160: ...e 5 188 3 Remove the timing belt and pulley See Timing Belt Removal on page 5 69 4 Remove the camshaft oil seal retainer See step 11 starting in Cylinder Head Removal on page 5 16 5 Remove the viscous damper 6 Remove the freshwater pump pulley 7 Remove the pulley bolt and plate washer NOTICE NEVER rotate the crankshaft pulley If the timing belt is disconnected and the crankshaft or camshaft pulley...

Page 161: ...s the maximum specification replace the thrust plate Inspect the idler gear and idler gear shaft and replace as necessary Figure 5 192 Figure 5 192 14 Remove the 2 bolts securing the idler gear and thrust plate 15 Using a suitable tool Figure 5 193 1 turn the fuel injection pump drive gear Figure 5 193 2 in both directions to loosen and remove the idler gear Figure 5 193 3 16 Remove the idler gear...

Page 162: ... P N 119770 01080 Figure 5 196 1 Figure 5 196 Figure 5 196 Timing Gear Inspection 1 Measure the inside diameter of the idler gear using a cylinder bore gauge Figure 5 197 Inside diameter of idler gear 45 000 to 45 025 mm 1 771 to 1 773 in Figure 5 197 Figure 5 197 2 Measure the outside diameter of the idler gear shaft using a micrometer Figure 5 198 Outside diameter of idle gear shaft 44 950 to 44...

Page 163: ...ear and shaft 4 Check the fuel injection pump drive gear bearing for wear and excessive play Figure 5 199 Replace the fuel injection pump drive gear bearing as necessary Figure 5 199 Figure 5 199 5 To replace the fuel injection pump drive gear bearing remove the bearing using a suitable tool Figure 5 200 1 Use the fuel injection pump drive gear nut Figure 5 200 2 as a pressing point for the puller...

Page 164: ... 05 to 0 15 mm 0 002 to 0 006 in Maximum gear backlash 0 30 mm 0 012 in If the measured gear backlash exceeds the maximum specification replace all the gears as a set Figure 5 202 Figure 5 202 1 Crankshaft Timing Gear to Idler Gear 2 Fuel Injection Pump Drive Gear to Idler Gear 3 Oil Pump Drive Shaft Gear to Oil Pump Gear 4 Move in Both Directions 8 Remove the timing gears 0005202 2 1 3 4 4 4 ...

Page 165: ...ecial tool P N 119770 01100 Figure 5 204 1 until the surface is level with that of the timing gear cover 3 Apply grease to the oil seal lip Figure 5 204 Figure 5 204 Method 2 When the timing gear cover is installed to the cylinder block 1 Remove the oil seal using a suitable tool Figure 5 205 1 Figure 5 205 Figure 5 205 2 Apply grease to the lip of the new oil seal 3 Tap in a new oil seal to insta...

Page 166: ...he timing gear cover Figure 5 208 Figure 5 208 3 Apply grease to the oil seal lip Method 2 When the timing gear cover is installed to the cylinder block 1 Cut off the oil seal lip using a knife Figure 5 209 2 Pry the oil seal using a screwdriver Figure 5 209 1 to remove Note AVOID damaging the fuel injection pump drive gear during removal Use tape on the screwdriver tip to prevent scratches Figure...

Page 167: ...ll the gear nut 7 Tighten the gear nut and torque to 1 000 kgf cm 98 07 N m 72 3 lb ft Figure 5 212 Figure 5 212 Figure 5 212 8 Install the idler gear shaft by aligning the bolt holes of the idler gear shaft to the bolt holes of the cylinder block 9 Align timing marks 3 and 4 of the idler gear Figure 5 213 1 to the corresponding timing marks 3 Figure 5 213 2 of the crankshaft timing gear and timin...

Page 168: ... surfaces using solvent 14 Apply the seal packing TOYOTA P N 08826 00080 or equivalent to the timing gear cover as shown in Figure 5 216 Attach a nozzle cut to a sealing width of 2 to 3 mm 0 078 to 0 118 in Figure 5 216 1 Note Parts must be assembled within 5 minutes after the seal packing is applied or the seal material must be removed and reapplied Disconnect the nozzle from the tube immediately...

Page 169: ...pulley as the valve heads and piston head will contact causing engine damage Figure 5 217 Figure 5 217 21 Install the camshaft oil seal retainer See Camshaft Oil Seal Retainer Installation on page 5 38 22 Install timing pulleys and timing belt See Timing Belt Installation on page 5 73 23 Tighten crankshaft pulley bolt and torque to 44 kgf m 431 50 N m 318 2 lb ft 24 Install the freshwater pump pul...

Page 170: ...kshaft pulley is turned in the both directions about 90 If not turn the crankshaft 360 and position the mark as shown Figure 5 218 2 4 Check only the valves indicated by arrows in Figure 5 219 Measure the clearance between the adjusting screw on the valve rocker arm and valve bridge using a feeler gauge Measuring Valve Clearance at TDC of No 1 Cylinder Figure 5 219 Figure 5 219 Record the measured...

Page 171: ...auge Figure 5 222 1 between the adjusting screw Figure 5 222 2 on the valve rocker arm Figure 5 222 3 and the valve bridge for the intake size and a 0 50 mm feeler gauge Figure 5 222 1 for the exhaust side Figure 5 222 Figure 5 222 4 Turn the adjusting screw Figure 5 222 4 on the valve rocker arm slightly slide the feeler gauge and lock Figure 5 222 5 the adjusting screw by the lock nut 5 Check th...

Page 172: ...with the lock nut NEVER apply any torque to the valve bridge Figure 5 224 Figure 5 224 1 Slide Feeler Gauge 2 Valve Bridge 3 Tighten Adjusting Screw 4 Adjusting Screw 5 Tighten Nut 7 Loosen the lock nut on the valve rocker arm 8 Turn the adjusting screw on the valve rocker arm and lightly slide the feeler gauge in and lock the adjusting screw with the lock nut Figure 5 225 Figure 5 225 Figure 5 22...

Page 173: ...nuts securing the fuel injection pump to No 1 and No 5 fuel injection pipes and position them out of the way Figure 5 227 Figure 5 227 Figure 5 227 4 Remove the plug bolt Figure 5 228 1 and gasket Figure 5 228 2 from the distribution head plug of the fuel injection pump 5 Install the plunger stroke measuring tool Figure 5 228 3 and dial indicator Figure 5 228 4 into the plug bolt hole of the distr...

Page 174: ...hat the dial indicator reads the minimum NOTICE Check that the minimum reading is zero 0 mm 0 in Figure 5 229 3 Figure 5 229 Figure 5 229 8 Slowly turn the crankshaft pulley clockwise Figure 5 230 1 to align its groove to that of the timing gear cover 9 Measure the plunger stroke with the dial indicator Plunger stroke 1 48 to 1 54 mm 0 058 to 0 060 in Figure 5 230 Figure 5 230 1 2 3 0005230 1 0005...

Page 175: ...he specification incline the pump towards the engine Figure 5 232 If it is greater than the specification incline the pump away from the engine Adjust gradually by tapping the pump flange using a brass bar and plastic hammer 3 Install and torque the two nuts securing the fuel injection pump to the timing gear case to 185 kgf cm 18 14 N m 13 3 lb ft 4 Install and torque the two bolts securing the f...

Page 176: ...ENGINE 5 96 6LPA Service Manual Injection Timing Inspection and Adjustment 2007 Yanmar Marine International This Page Intentionally Left Blank ...

Page 177: ...t 6 10 Fuel Injection Nozzle 6 12 Components 6 12 Fuel Injection Nozzle Removal 6 14 Fuel Injection Nozzle Testing 6 15 Fuel Injection Nozzle Components 6 16 Fuel Injection Nozzle Disassembly and Inspection 6 17 Fuel Injection Nozzle Adjustment 6 18 Checking No 2 Opening Pressure 6 23 Adjusting No 1 Opening Pressure 6 25 Fuel Injection Nozzle Installation 6 25 Fuel Injection Pump 6 28 Components 6...

Page 178: ...FUEL SYSTEM 6 2 6LPA Service Manual 2007 Yanmar Marine International This Page Intentionally Left Blank ...

Page 179: ...f ignition out of the area ALWAYS turn off the battery switch if equipped or disconnect the negative battery cable before servicing the equipment Fire and Explosion Hazard Diesel fuel is flammable and explosive under certain conditions NEVER use a shop rag to catch the fuel Wipe up all spills immediately NEVER refuel with the engine running Store any containers containing fuel in a well ventilated...

Page 180: ...ion 2007 Yanmar Marine International INTRODUCTION This section of the Service Manual describes the procedures necessary to remove install and adjust the injectors and their associated system components as used on the Yanmar 6LPA STP2 STZP2 engines ...

Page 181: ... 0 075 to 0 079 in in 0 025 mm 0 001 in steps Pre lift 0 08 to 0 10 mm 0 003 to 0 0004 in No 2 pressure spring seat thickness 3 09 to 3 27 mm 0 122 to 0 129 in in 0 03 mm 0 001 in steps No 2 opening pressure adjusting shim thickness 0 700 mm 0 027 in 1 425 mm 0 056 in 0 850 mm 0 033 in 1 450 mm 0 057 in 1 000 mm 0 039 in 1 575 mm 0 062 in 1 025 mm 0 040 in 1 600 mm 0 063 in 1 150 mm 0 045 in 1 725...

Page 182: ...to 8 0 mm 0 30 to 0 31 in Plunger spring shim thickness 0 5 mm 0 020 in 0 8 mm 0 315 in 1 0 mm 0 04 in 1 2 mm 0 0472 in 1 5 mm 0 06 in 1 8 mm 0 71 in 2 0 mm 0 080 in Flyweight holder thrust clearance 0 15 to 0 35 mm 0 0006 to 0 0138 in Governor gear adjusting washer thickness 1 05 mm 0 041 in 1 25 mm 0 050 in 1 45 mm 0 06 in 1 65 mm 0 065 in 1 85 mm 0 073 in Governor shaft protrusion 0 5 to 2 0 mm...

Page 183: ... support x injection pump body 140 kgf cm 13 73 N m 13 7 lb ft Distribution head x injection pump body 120 kgf cm 11 77 N m 104 lb in Governor shaft x injection pump body 275 kgf cm 26 97 N m 19 9 lb ft Overflow screw x governor cover 250 kgf cm 24 52 N m 18 1 lb ft Control lever x governor cover 70 kgf cm 6 86 N m 61 lb in Governor cover x injection pump body 85 kgf cm 8 34 N m 74 lb in Idle spee...

Page 184: ...01 in Governor type AS Governor link NAR Injection order A B C D E F Direction of rotation Clockwise viewing from drive side Valve CPV Governor speed adjusting range 375 to 2140 rpm Measurement Conditions Nozzle type DN12SD12 Opening pressure 150 kgf cm2 14 71 MPa 2133 psi Injection pipe specification diameter 2 x 6 x 840 mm 0 08 x 0 23 x 269 2 in Diesel fuel feed pressure 0 2 kgf cm2 0 02 MPa 3 p...

Page 185: ... Timer Characteristics Note Values in indicate the injection timing advance cam Figure 6 2 Figure 6 2 BCS Characteristics Figure 6 3 Figure 6 3 Injection Volume Q mm3 st Pump Speed NP rpm 0005577 Injection Characteristics 0005578 Pump Speed NP rpm Timer Stroke St mm Timer Characteristics Value in parenthesis indicates the injection timing advance angle cam shaft angle BCS Characteristics Injection...

Page 186: ...rm switch and O ring from the fuel filter using pliers Figure 6 5 1 NOTICE Avoid damaging the alarm switch during removal Figure 6 5 Figure 6 5 5 Lubricate a new alarm switch O ring with clean diesel fuel and install the alarm switch and O ring to the new fuel filter 6 Inspect and clean the fuel filter mounting surface Apply clean diesel fuel to the gasket of the new fuel filter and hand tighten t...

Page 187: ...rnational 8 Open the fuel tank cock and operate the hand pump Figure 6 7 1 to fill the fuel filter with fuel and prime the fuel system Figure 6 7 Figure 6 7 9 Start the engine to check for fuel leakage Repair any leaks as necessary WARNING NEVER check for fuel leaks with your hand 0005253 1 ...

Page 188: ...FUEL SYSTEM 6 12 6LPA Service Manual Fuel Injection Nozzle 2007 Yanmar Marine International FUEL INJECTION NOZZLE Components Figure 6 8 Figure 6 8 1 2 3 4 7 12 13 14 11 10 9 8 8 6 5 1 0005254 ...

Page 189: ...r Marine International 1 Valve Cover 2 Seal Washer Non Reusable 3 Gasket 4 No 1 Fuel Return Pipe 5 No 3 Fuel Return Pipe 6 Gasket Non Reusable 7 Gasket Non Reusable 8 Clamp 9 Clamp 10 Clamp 11 Injection Pipe 12 Injection Nozzle 13 Nozzle Holder Seal 14 Nozzle Seat Non Reusable ...

Page 190: ...e manifold 3 Remove the fuel return hose 6 joint bolts nut and 7 gaskets to remove the No 1 fuel return pipe from the cylinder head Figure 6 9 Figure 6 9 Figure 6 9 4 Remove the 4 nuts and 2 clamps from the intake manifold 5 Remove the union nut of the fuel injection pipe from the fuel injection nozzle Figure 6 10 Figure 6 10 Figure 6 10 6 Remove the union nut of the fuel injection pipe from the f...

Page 191: ...le Testing Leak Test CAUTION ALWAYS wear eye protection when servicing the engine Increase the pressure to near the specified injection pressure of 10 to 20 kgf cm2 0 98 to 1 96 MPa 142 to 284 psi Check for oil leakage from the injection hole and around the retaining nut There should be no leakage Figure 6 15 1 If leakage occurs from the nozzle Figure 6 15 2 replace clean or repair the nozzle Figu...

Page 192: ... 17 1 Nozzle Holder Retaining Nut 2 Nozzle Assembly 3 Nozzle Body 4 Needle Tip 5 Adjusting Shim 6 Tip Packing 7 Straight Pins 8 No 2 Pressure Spring Seat 9 No 2 Pressure Spring 10 Adjusting Shim 11 No 1 Pressure Spring Seat 12 Pressure Pin 13 No 1 Pressure Spring 14 Adjusting Shim 15 Nozzle Holder Body 1 5 6 7 8 9 11 12 13 14 15 2 3 4 10 0005267 ...

Page 193: ...deposits from the nozzle tip Figure 6 19 1 with a wooden stick Figure 6 19 Figure 6 19 3 NOTICE Wash all parts with clean diesel fuel NEVER touch the nozzle mating surfaces with bare hands Remove carbon deposits from the outside surface of nozzle body using a soft brass brush except the lapped surface Figure 6 20 1 Figure 6 20 Figure 6 20 4 Check the nozzle body seat and needle tip for damage and ...

Page 194: ...r turning the needle tip Figure 6 23 If the needle tip fails to return smoothly replace the nozzle assembly Figure 6 23 Figure 6 23 Fuel Injection Nozzle Adjustment NOTICE High precision is required for needle lift and pre lift measurements Thoroughly clean the parts and tools before measuring Pre lift Adjustment Needle Lift Adjustment 1 Attach the special tool to the dial indicator and adjust the...

Page 195: ...re 6 26 1 using a micrometer Figure 6 26 Figure 6 26 4 Install the nozzle assembly and No 2 pressure spring seat on the special tool B Figure 6 26 2 5 Set the special tool Figure 6 27 3 on the nozzle and measure dimension A Dimension L1 t A 6 Remove the special tool and needle tip from the nozzle body Figure 6 27 Figure 6 27 3 t 2 0005286 3 3 2 L1 A 0005287 ...

Page 196: ...ol Figure 6 29 1 9 Install the straight pins into the tip packing and then into the holes in the special tool Figure 6 29 1 and then measure dimension L2 Figure 6 29 Figure 6 29 10 Measure dimension L3 Figure 6 30 of the adjusting shim using a micrometer If the measured needle lift is out of the specified range change the adjusting shim NOTICE Increasing the shim thickness reduces the needle lift ...

Page 197: ... above and No 2 pressure spring seat on the special tool B using the special tool Figure 6 31 Figure 6 31 Figure 6 31 1 No 2 Pressure Spring Seat 2 Special Tool B 3 Top 4 Bottom 2 Set the special tool on the nozzle and measure dimension B Dimension C B t Figure 6 32 Figure 6 32 1 900 mm 0 0748 in 1 925 mm 0 0757 in 1 950 mm 0 0767 in 1 975 mm 0 0797 in 2 000 mm 0 0787 in 1 3 2 4 0005291 B 1 C 1 1 ...

Page 198: ... range select a No 2 pressure spring seat from the chart Figure 6 34 NOTICE Increasing the seat thickness reduces the pre lift Dimension L5 t E Pre lift L4 L5 Pre lift standard 0 08 to 0 10 mm 0 003 to 0 004 in Figure 6 34 Figure 6 34 Thickness of No 2 Pressure Spring Seat t Figure 6 35 Figure 6 35 1 Nozzle 2 E 3 Pre lift 4 Needle lift 5 Detailed View of E L4 0005293 D t E L5 0005294 3 09 mm 0 122...

Page 199: ...ins 8 Lift Adjusting Shim 9 Nozzle Assembly 10 Nozzle Holder Retaining Nut Figure 6 37 Figure 6 37 2 Tighten the nozzle holder retaining nut using a 14 mm socket Figure 6 38 1 torque to 300 kgf cm 29 42 N m 22 lb ft NOTICE NEVER tighten excessively Otherwise deformation adhesion or other defects may occur Figure 6 38 Figure 6 38 3 Install the fuel injection valve to the nozzle tester and bleed the...

Page 200: ...sting Shim Thickness Note Changing the adjusting shim thickness by 0 025 mm changes the injection pressure by approximately 3 8 kgf cm2 0 37 MPa 54 psi Change only one adjusting shim at the upper portion of No 2 pressure spring 7 After the injection test check for leakage from from the injection hole Figure 6 41 There should be no leakage Figure 6 41 Figure 6 41 1 Normal Spray During Operation 2 U...

Page 201: ... below Adjusting Shim Thickness Note Changing the adjusting shim thickness by 0 025 mm changes the valve opening pressure by approximately 3 8 kgf cm2 0 37 MPa 54 psi Change only one adjusting shim at the upper portion of No 1 pressure spring 3 After the injection test check for leakage from from the injection hole There should be no leakage Fuel Injection Nozzle Installation 1 Install a new O rin...

Page 202: ...ump Figure 6 45 Torque to 250 kgf cm 24 52 N m 18 lb ft Figure 6 45 Figure 6 45 1 No 1 2 No 2 3 No 3 4 No 4 5 No 5 6 No 6 7 Tighten the union nut to the fuel injection nozzle and torque to 250 kgf cm 24 52 N m 18 lb ft Figure 6 46 Figure 6 46 Figure 6 46 8 Install the 2 clamps with 2 nuts and torque to 65 kgf cm 6 37 N m 56 lb in 9 Install 2 clamps with 4 nuts to the intake manifold Figure 6 47 Fi...

Page 203: ...igure 6 48 Figure 6 48 1 Joint Bolt 2 New Gasket A 3 Turbocharger Pressure Gauge Tool 4 No 1 Nozzle Fuel Return Pipe 5 New Gasket B 6 Cylinder Head 11 Use the turbocharger pressure gauge as the tool Connect the pressure gauge to the fuel return side of the No 1 fuel return pipe apply 0 5 kgf cm2 0 05 MPa 7 psi pressure continuously for 10 seconds and check for leakage 12 Connect the fuel return ho...

Page 204: ...on Pump 2007 Yanmar Marine International FUEL INJECTION PUMP Components Figure 6 49 Figure 6 49 1 Fuel Injection Pipe 2 Clamp 3 No 3 Nozzle Return Pipe 4 Clamp 5 O ring Non Reusable 6 Boost Compensator Hose 7 Injection Pump 2 4 3 4 5 5 7 6 4 1 0005312 ...

Page 205: ...other Figure 6 50 Figure 6 50 6 Remove the O ring from the fuel injection pump drive gear 7 Remove two fuel injection pump stay set bolts Figure 6 51 1 Figure 6 51 Figure 6 51 8 Check that match marks Figure 6 52 1 align before removing the fuel injection pump if they do not have match marks draw new match marks for reassembly 9 Remove the two nuts securing the fuel injection pump to the timing ge...

Page 206: ...vice Manual Fuel Injection Pump 2007 Yanmar Marine International Components Figure 6 54 Figure 6 54 16 15 14 13 12 17 18 19 11 22 23 24 25 26 27 29 30 28 31 32 35 36 37 38 39 40 42 34 33 5 41 1 2 3 4 6 7 8 9 10 21 20 43 0005317 ...

Page 207: ... Screw 20 Spring 21 Guide Bushing 22 Maximum Speed adjustment Screw 23 No 2 Fuel Return Pipe 24 Gasket Non Reusable 25 Collar Non Reusable 26 Full Load Set Screw 27 Gasket Non Reusable 28 O ring 29 Gasket Non Reusable 30 Idle Speed Adjustment Screw 31 Cap 32 Gasket Non Reusable 33 O ring Non Reusable 34 Washer 35 Control Lever 36 Support Pin 37 Gasket Non Reusable 38 Spring Seat 39 Damper Spring 4...

Page 208: ...tional COMPONENTS Continued Figure 6 55 Figure 6 55 1 3 5 6 7 9 8 10 11 15 17 34 33 32 31 30 27 28 20 21 24 26 25 23 22 19 18 16 14 13 72 50 52 55 57 78 77 76 75 74 59 70 48 49 51 53 54 56 60 61 62 63 64 73 71 36 37 38 39 40 41 42 43 44 45 46 47 2 4 12 58 69 35 29 65 66 67 68 0005318 ...

Page 209: ...lide Pin 34 Roller and Washer 35 O ring Non Reusable 36 Governor Shaft 37 Governor Gear Adjusting Washer 38 No 1 Flyweight Washer 39 Flyweight Holder 40 Flyweight 41 No 2 Flyweight Washer 42 Stop Ring 43 Bearing 44 Sleeve Plug 45 Bearing Retainer 46 E ring 47 Governor SLeeve 48 Plunger Adjusting shim 49 Pump Plunger 50 Lower Plunger Plate 51 Upper Plunger Plate 52 Lower Spring Seat 53 Spill Ring 5...

Page 210: ... 57 6 Install the fuel injection pump stay using two bolts Figure 6 58 1 and torque to 700 kgf cm 68 65 N m 50 6 lb ft NOTICE Check that the pump stay is lifted to contact with the fuel injection pump before tightening to the specified torque If there is a gap loosen the bolt securing the pump stay to the cylinder block and lift the pump stay until it comes into contact with the fuel injection pum...

Page 211: ...6 60 1 to the fuel injection pump Figure 6 60 Figure 6 60 12 Install No 2 camshaft timing pulley and the timing belt See Timing Belt Installation on page 5 73 13 Check the injection timing See Injection Timing Inspection and Adjustment on page 5 93 14 Fill the engine fresh water line with engine coolant 15 Start the engine and check for fuel leakage WARNING NEVER check for a fuel leak with your ha...

Page 212: ...FUEL SYSTEM 6 36 6LPA Service Manual Fuel Injection Pump 2007 Yanmar Marine International This Page Intentionally Left Blank ...

Page 213: ...oling System 7 4 Freshwater Pump Related Components 7 4 Freshwater Pump Removal 7 5 Freshwater Pump Installation 7 6 Seawater Pump Disassembly 7 8 Seawater Pump Reassembly 7 8 Thermostat Removal 7 10 Thermostat Installation 7 11 Components Related to Cooling System 7 12 Freshwater Tank 7 12 Freshwater Cooler 7 13 Coolant Recovery Tank 7 14 Page ...

Page 214: ...COOLING SYSTEM 7 2 6LPA Service Manual 2007 Yanmar Marine International This Page Intentionally Left Blank ...

Page 215: ...s CAUTION level hazards The safety message describes a hazardous situation which if not avoided could result in minor or moderate injury Coolant Hazard Wear eye protection and rubber gloves when you handle Long Life engine coolant If contact with the eyes or skin should occur flush eyes and wash immediately with clean water INTRODUCTION This section of the Service Manual describes the procedures n...

Page 216: ...ling System 2007 Yanmar Marine International COOLING SYSTEM Freshwater Pump Related Components Figure 7 1 Figure 7 1 1 Freshwater Pump 2 Gasket Non Reusable Part 3 Camshaft Oil Seal Non Reusable Part 4 Camshaft Oil Seal Retainer 4 3 1 2 0005329 ...

Page 217: ...belt and idler pulley and No 1 camshaft timing pulley See Timing Belt Removal on page 5 69 5 Remove the camshaft oil seal retainer See step 11 starting in Cylinder Head Removal on page 5 16 6 Remove the three bolts and alternator adjusting bar Figure 7 3 1 7 Remove the six bolts two nuts freshwater pump and gasket Figure 7 3 Figure 7 3 Figure 7 3 8 Inspect the freshwater pump by turning the pulley...

Page 218: ... kgf cm 39 23 N m 347 2 lb in Figure 7 5 Figure 7 5 3 Install the camshaft oil seal retainer Camshaft Oil Seal Retainer Installation 4 Install No 1 camshaft timing pulley idler pulley and timing belt See Timing Belt Installation on page 5 73 5 Install the freshwater pump pulley drive belt and viscous damper and torque to 65 kgf cm 6 37 N m 56 3 lb in 6 Install and adjust the drive belt Tighten fou...

Page 219: ...s 12 05 2007 Yanmar Marine International SEAWATER PUMP COMPONENTS Figure 7 7 Figure 7 7 1 End Plate 2 O ring 3 Impeller 4 Oil Seal 5 O ring 6 Spacer 7 Oil Seal 8 Bearing 9 Cam 10 Set Screw 11 Shaft 12 Retaining Ring 13 Bearing 5 4 6 7 8 9 10 11 12 13 3 2 1 0005335 ...

Page 220: ...ll out the gear the remove the retaining ring and pull out the shaft 4 Check the impeller inner sliding surface of the pump housing and the cam for excessive wear and damage Replace as necessary 5 Turn the shaft to check that it turns smoothly Check the bearing for play Replace as necessary 6 If oil or water leakage is discovered at the hole of the pump bottom replace the oil seal Seawater Pump Re...

Page 221: ...COOLING SYSTEM 6LPA Service Manual 7 9 Thermostat Components 12 05 2007 Yanmar Marine International THERMOSTAT COMPONENTS Figure 7 8 Figure 7 8 1 Thermostat Cover 2 Gasket 3 Thermostat 1 2 3 0005336 ...

Page 222: ...mostat for damage Inspect the jiggle valve Figure 7 10 1 for damage Replace as necessary Figure 7 10 Figure 7 10 6 Immerse the thermostat in water and slowly heat it Figure 7 11 The valve opening temperature is indicated on the thermostat 7 Check the valve opening temperature The valve opening temperature range is 68 to 72 C 154 to 162 F If the valve opening temperature does not satisfy the specif...

Page 223: ...place the thermostat Thermostat Installation 1 Install the thermostat on the cylinder block 2 Install a new gasket to the thermostat P N 119773 49570 ensure the jiggle valve Figure 7 13 1 faces upwards Figure 7 13 Figure 7 13 3 Install the thermostat cover Figure 7 14 Figure 7 14 Figure 7 14 4 Secure the rubber hose with the hose band 5 Fill with engine coolant fresh water 6 Start the engine and c...

Page 224: ... 15 2 Check the pressure cap NOTICE If the pressure cap Figure 7 16 1 is contaminated by foreign matter wash with water Measure the valve opening pressure by applying pressure to the tester using the pressure cap tester Figure 7 16 2 Standard valve opening pressure 0 75 to 1 05 kgf cm2 0 07 to 0 10 MPa 10 6 to 14 9 psi Minimum valve opening pressure 0 6 kgf cm2 0 06 MPa 8 5 psi Figure 7 16 Figure ...

Page 225: ... seawater flows inside the core while the fresh water flows outside the core to be cooled by the seawater 1 Disconnect the rubber hose connected to the freshwater cooler Figure 7 18 1 2 Remove the freshwater cooler carefully avoid hitting or damaging during removal Check the rubber seat Figure 7 18 2 holding the freshwater cooler for collapse and cracks Replace it before failures occur Check the h...

Page 226: ... pressure cap activates to return the water from the coolant recovery tank to the freshwater tank The water level in the coolant recovery tank rises during the operation hot state or lowers during stopping cold state Figure 7 20 Figure 7 20 Figure 7 20 1 Full Mark 2 Low Mark Coolant Recovery Tank Installation 1 Check the fresh water level on the coolant recovery tank Figure 7 21 1 daily It is not ...

Page 227: ... NOTICE The seacock should be closed after daily operation and opened before operation If the seacock is open when the boat is not operating and a leak occurs in the seawater system water will leak into the boat If the boat is operated with the seacock closed no seawater is fed to the engine and pump and will cause engine overheating or failure 2 Inspect seawater delivery periodically If the deliv...

Page 228: ...COOLING SYSTEM 7 16 6LPA Service Manual Components Related to Cooling System 2007 Yanmar Marine International This Page Intentionally Left Blank ...

Page 229: ...5 Oil Pump 8 6 Components 8 6 Oil Pump Removal 8 7 Oil Pump Disassembly and Inspection 8 8 Oil Pump Reassembly 8 9 Oil Pump Installation 8 10 Oil Cooler 8 13 Components 8 13 Oil Cooler Removal 8 14 Oil Cooler Disassembly and Inspection 8 14 Oil Cooler Installation 8 15 Piston Cooling Oil Nozzle 8 16 Components 8 16 Oil Nozzle Disassembly and Inspection 8 17 Oil Nozzle Installation 8 17 ...

Page 230: ...LUBRICATION 8 2 6LPA Service Manual 2007 Yanmar Marine International This Page Intentionally Left Blank ...

Page 231: ...R mix different types of engine oil This may adversely affect the lubricating properties of the engine oil 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 authorities or reclamation facility NEVER dispose of hazardous materials by ...

Page 232: ...0 011 to 0 035 in Maximum 0 15 mm 0 005 in Component Specification Drain Plug x Oil Pan 350 kgf m 34 32 N m 303 7 lb in Relief Valve x Timing Gear Case 425 kgf m 41 68 N m 368 8 lb in Oil Filter x Main Bearing Cap 90 kgf m 8 83 N m 78 1 lb in Timing Gear Case x Cylinder Block and Main Bearing Cap 200 kgf m 19 61 N m 173 5 lb in Injection Pump x Timing Gear Case 185 kgf m 18 14 N m 160 5 lb in Oil ...

Page 233: ...S measure oil level when the engine is positioned horizontally 2 Remove the oil pressure sender unit and attach an oil pressure gauge Figure 8 1 1 Figure 8 1 Figure 8 1 3 Start the engine and allow it to warm to normal operating temperature and read the pressure gauge 4 Remove the oil pressure gauge 5 Apply THREE BOND 1344 LOCTITE 242 or equivalent Figure 8 2 1 to the threaded portion 2 to 3 threa...

Page 234: ...e 2 Bolt 7 used 3 Taper Screw Pre coated Part 4 Oil Pump Gasket Non Reusable 5 Injection Pump O ring 6 Gasket Non Reusable 7 Oil Strainer 8 Bolt 27 used 9 Oil Pan 10 Drain Plug Gasket Non Reusable 11 Drain Plug 12 Timing Gear Case 13 Plug 14 Gasket Non Reusable 15 Spring 16 Relief Valve 17 Driven Rotor 3 4 1 13 2 5 6 9 10 11 8 17 12 16 15 14 7 0005355 ...

Page 235: ...bolts and insert an appropriate tool Figure 8 4 1 between the cylinder block and oil pan to cut off the seal and then remove the oil pan NOTICE During removal avoid damaging the oil pan flange Figure 8 4 Figure 8 4 5 Remove the 2 nuts securing the fuel injection pump to the timing gear case 6 Remove the 7 bolts securing the timing gear case to the cylinder block 7 Insert a screwdriver Figure 8 5 1...

Page 236: ...d check if the drive shaft turns smoothly and the bearing has no play If needed replace the oil pump assembly Figure 8 9 Figure 8 9 5 Check the clearance at the rotor tooth tip Measure clearance at the tips of drive and driven rotors using a feeler gauge Figure 8 10 If the measured clearance exceeds the specified maximum replace the oil pump assembly Rotor tip tooth clearance Standard 0 080 to 0 1...

Page 237: ...2 If the measured clearance exceeds the specified maximum replace the oil pump assembly Rotor side clearance Standard 0 030 to 0 090 mm 0 011 to 0 035 in Maximum 0 15 mm 0 005 in Figure 8 12 Figure 8 12 Oil Pump Reassembly 1 Install the relief valve and spring Figure 8 13 1 into the mounting holes in the timing gear case 2 Using a new gasket install the plug and torque to 425 kgf cm 41 68 N m 30 7...

Page 238: ...ng material chips and other foreign matter then wash the sealing surfaces clean with solvent 3 Apply new seal packing to the timing gear case using a 2 to 3 mm 0 078 to 0 118 in sealing width Figure 8 16 1 NOTICE All parts must be assembled within 5 minutes after the seal packing is applied otherwise the seal packing must be removed and reapplied Remove the nozzle from the tube immediately after u...

Page 239: ...igure 8 20 Figure 8 20 10 Tighten the taper screw plug using a 5 mm hexagon wrench Figure 8 20 2 NOTICE Avoid contaminating the oil pan and cylinder block mounting surfaces with oil 11 Remove all the old packing material from the oil pan gasket surface and seal groove using a gasket scraper NOTICE Use solvents that never damage painted surfaces Wash all parts and remove all old packing material ch...

Page 240: ...al torque of 100 kgf cm 9 81 N m 86 8 lb in 14 Install the timing gear See Timing Gear Installation on page 5 87 15 Fill with engine oil See Adding Engine Oil on page 3 23 16 Fill with engine coolant fresh water See Checking and Adding Engine Coolant on page 3 25 17 Start the engine and check for oil leakage 18 Check the oil level again fill to the upper limit of the oil dipstick as needed ...

Page 241: ...OOLER Components Figure 8 22 Figure 8 22 1 Oil Cooler Cover 2 Gasket Non Reusable part 3 Oil Cooler 4 Gasket Non Reusable part 5 Oil Cooler Cover Assembly 6 Relief Valve 7 Gasket Non Reusable part 8 Gasket Non Reusable part 9 Check Valve 10 Oil Filter 11 Gasket 0005374 4 1 2 11 10 9 8 7 6 5 3 ...

Page 242: ...placing the Engine Oil Filter Element on page 4 9 5 Remove the relief valve Figure 8 23 2 and gasket 6 Remove the check valve Figure 8 23 1 and gasket Figure 8 23 Figure 8 23 7 Remove 13 bolts 2 nuts oil cooler cover assembly and gasket Discard the gasket Figure 8 24 Figure 8 24 Oil Cooler Disassembly and Inspection 1 Inspect the relief valve by pressing Figure 8 25 1 the valve with a wooden stick...

Page 243: ...87 in B 40 mm 1 57 in Figure 8 29 Figure 8 29 3 Using a new gasket install the relief valve Figure 8 30 1 and torque to 400 kgf cm 39 23 N m 28 9 lb ft 4 Using a new gasket install the check valve Figure 8 30 2 and torque to 275 kgf cm 26 97 N m 19 8 lb ft Figure 8 30 Figure 8 30 5 Install the engine oil filter See Changing the Engine Oil and Replacing the Engine Oil Filter Element on page 4 9 6 i...

Page 244: ...nual Piston Cooling Oil Nozzle 2007 Yanmar Marine International PISTON COOLING OIL NOZZLE Components Figure 8 31 Figure 8 31 1 Piston Cooling Oil Nozzle 2 Check Valve 3 Oil Pan 4 Gasket Non Reusable part 5 Drain Plug 0005383 4 3 2 1 5 ...

Page 245: ...he valve for sticking If the valve sticks replace the check valve Figure 8 33 Figure 8 33 4 Inspect the oil nozzle Figure 8 34 for damage restrictions and clogs If needed replace the oil nozzle Figure 8 34 Figure 8 34 Oil Nozzle Installation 1 Align the oil nozzle pin Figure 8 34 1 with the pin hole in the cylinder block 2 Install the oil nozzle together with the check valve Figure 8 35 Install 6 ...

Page 246: ...LUBRICATION 8 18 6LPA Service Manual Piston Cooling Oil Nozzle 2007 Yanmar Marine International This Page Intentionally Left Blank ...

Page 247: ...anual Section 9 TURBOCHARGER Safety Precautions 9 3 Introduction 9 3 Turbocharger 9 4 Components and Operation 9 4 Service Specifications 9 8 Periodic Inspection 9 11 Disassembly 9 12 Inspection and Cleaning 9 14 Reassembly 9 17 Installation 9 19 Troubleshooting 9 20 Page ...

Page 248: ...TURBOCHARGER 9 2 6LPA Service Manual 2007 Yanmar Marine International This Page Intentionally Left Blank ...

Page 249: ...Yanmar Marine International SAFETY PRECAUTIONS Before you service the engine turbocharger review the Safety Section on page 2 1 INTRODUCTION This section of the Service Manual describes the procedures necessary to service the 6LPA STP2 STZP2 marine engine turbocharger ...

Page 250: ...ir intake pipe and into the engine This is called the compressor or blower Thrust Bearing Thrust force is continuously applied to the turbine shaft The thrust bearing is designed to prevent the shaft from movement due to the thrust Radial Bearing The radial bearing is a floating bearing type as it has double oil film layers on the inside and outside surfaces of the bearing This causes the bearing ...

Page 251: ...TURBOCHARGER 6LPA Service Manual 9 5 Turbocharger 12 05 2007 Yanmar Marine International This Page Intentionally Left Blank ...

Page 252: ...ne International Sectional View RHE6W Model Figure 9 1 Figure 9 1 Components RHE6W Turbocharger Figure 9 2 Figure 9 2 41 52 21 51 53 56 33 41 55 4 11 54 1 6 42 2 22 12 3 6 7 31 0005234 1 33 31 7 8 54 12 11 65 62 41 63 A 61 44 6 42 51 44 52 21 2 22 3 53 4 A 64 0005235 ...

Page 253: ...e plate 1 21 Floating bearing 2 22 Thrust bearing 1 31 Compressor housing 1 33 TORX T screw bolt Torque 230 10 kgf m 23 1 N m 17 0 7 lb ft 6 41 Turbine housing 1 42 Thermal housing plate 1 44 TORX T screw bolt Torque 285 10 kgf m 28 1 N m 20 7 0 7 lb ft 13 51 Bearing housing 1 52 Retaining ring 3 53 TORX T screw bolt Torque 38 3 kgf m 3 7 0 3 N m 32 7 3 lb in 3 54 TORX T screw bolt Torque 230 10 k...

Page 254: ...0004 in Turbine shaft play in axial direction 0 110 mm 0 004 in Service Standard 0 06 to 0 09 mm 0 002 to 0 004 in Turbine shaft play in radial direction 0 205 mm 0 008 in Service Standard 0 10 to 0 17 mm 0 004 to 0 007 in Bearing C Floating bearing inside diameter 11 460 mm 0 451 in D Floating bearing outside diameter 15 980v 0 629 in B Bearing case inside diameter 16 110 mm 0 634 in Thrust beari...

Page 255: ...1 N m 20 7 0 7 lb ft Valve case cover set bolt M8 285 10 kgf cm 28 1 N m 20 7 0 7 lb ft Tool Name Use Illustration Bar For removing thrust bearing and thrust bushing Material copper or brass Pliers For removing and installing floating bearing retaining ring Pliers For removing and installing seal ring Torque screwdriver for TORX bolt TORX TT20 or equivalent Universal Type 5 to 50 kgf cm 0 49 to 4 ...

Page 256: ...ghtening shaft end nut for M7 80 kgf cm 7 84 N m 69 3 lb in Box spanner wrench For fixing turbine shaft 14mm x 12 pointed head Box part alone may be used Probe For measuring play in axial and radial directions To be attached to a dial indicator 1 To be knurled here rolette Tool Name Use Illustration 0005243 0005244 0005245 1 ...

Page 257: ...econds abnormal operation is evident and a rotational problem may be present The bearing or rotor may be defective and cause for turbocharger replacement or overhaul Inspection of Turbine Shaft Play Remove the turbocharger from the engine and inspect the turbine shaft axial and radial play following the procedures below After removing the turbocharger from the engine always cover the oil inlet and...

Page 258: ...Disassembly NOTICE As mounting angles of the turbine housing bearing housing and compressor housing of the turbocharger are determined according to their mounting status on the engine make match marks before beginning disassembly 1 Move the hose clip Figure 9 2 64 to the center of the boost hose Figure 9 2 63 2 Disconnect the boost hose Figure 9 2 63 from the compressor housing Figure 9 2 31 and w...

Page 259: ...ation plate Figure 9 2 42 by hand and pull off turbine shaft Figure 9 2 1 Note If the turbine shaft is tight lightly tap the shaft end on the blower side with a wood or plastic hammer 13 Remove the heat insulation plate Figure 9 2 42 14 Loosen the M4 TORX T screw bolt Figure 9 2 53 securing the thrust bearing using a screwdriver TT20 15 Remove the thrust bearing Figure 9 2 22 and thrust brushing F...

Page 260: ...and turbine wheel backside 4 Inner wall of compressor housing Figure 9 2 31 5 Backside of compressor impeller Figure 9 2 8 6 Surface of seal plate Figure 9 2 11 and seal ring Figure 9 2 4 inserting area Cleaning Procedures Part Tools Detergent Procedure Notes Turbine Shaft and Housing 1 WashSolvent Tank 2 Heat Source Steam or Gas Burner 3 Plastic Brush and Scraper General carbon removing agent Ava...

Page 261: ...outside diameter Figure 9 3 A is 11 38 mm 0 448 in Wear limit of seal ring groove width Figure 9 3 E is 1 33 mm 0 052 in 3 Measure the runout of the turbine shaft Replace the turbine shaft if the measured runout exceeds 0 011 mm 0 0004 in Thermal Insulation Plate Check the thermal insulation plate Figure 9 2 42 for damage contact traces thermal deformation or corrosion Replace the thermal insulati...

Page 262: ...ace the retaining ring if necessary 3 Measure dimensions Figure 9 7 B and Figure 9 7 F of the bearing housing Replace the bearing housing if either measured value exceeds the wear limit Bearing housing inside diameter Figure 9 7 B Wear limit 16 11 mm 0 634 in Seal ring insertion hole on turbine side Figure 9 7 F Wear limit 17 03 mm 0 670 in Figure 9 7 Figure 9 7 1 Wheel Chamber 2 Turbine Side 3 Co...

Page 263: ... with new ones Turbine side seal ring Figure 9 2 6 1 pc Compressor side seal ring Figure 9 2 4 1 pc M4 pan head small screw Figure 9 2 53 3 pcs M8 pan head small screw Figure 9 2 54 4 pcs 1 Install the retaining rings Figure 9 2 52 to the bearing housing Figure 9 2 51 using retaining ring pliers 2 Install the turbine side floating bearing Figure 9 2 21 to the bearing housing Figure 9 2 51 3 Instal...

Page 264: ...t oil outlet and exhaust gas inlet locations during assembly 12 Torque the M8 TORX bolt Figure 9 2 44 to 285 10 kgf cm 27 95 1 N m 20 7 0 7 lb ft 13 Install the seal ring Figure 9 2 4 to the oil thrower Figure 9 2 3 14 Insert the oil thrower Figure 9 2 3 into seal plate Figure 9 2 11 Note Position the seal ring end on the oil inlet side 15 Apply liquid gasket Three Bond No 1207 on the flange surfa...

Page 265: ...identify the cause of the excessive movement and correct the problem Turbine shaft axial play Service standard 0 06 to 0 09 mm 0 002 to 0 004 in Turbine shaft radial play Service standard 0 10 to 0 17 mm 0 004 to 0 007 in Installation NOTICE When installing the turbocharger on the engine or handling the turbocharger after installation follow all instructions below NEVER allow debris or foreign mat...

Page 266: ...udden stop from loaded operation no load operation Turbocharger overhaul disassembly and repair Inspect the oil system of the engine and repair faulty parts and replace the engine oil Replace or wash the faulty rotating part Strictly observe instructions in the operation manual 3 Contact or breakdown of turbine wheel or compressor impeller Over speed Excessive exhaust temperature rise Foreign debr...

Page 267: ...after disassembly 2 Incomplete combustion Check the engine combustion system and take corrective action if needed to restore performance Abnormal Sound Possible Cause Corrective Action 1 Restricted exhaust gas path caused from a clogged nozzle in turbine housing or reverse flow of blower discharge during acceleration generally called surging Disassemble and wash the turbocharger 2 Rotating parts c...

Page 268: ...TURBOCHARGER 9 22 6LPA Service Manual Turbocharger 2007 Yanmar Marine International This Page Intentionally Left Blank ...

Page 269: ...6LPA Service Manual Section 10 STARTER MOTOR Page Safety Precautions 10 3 Introduction 10 3 Starter Specifications 10 4 Starter 10 5 Components 10 5 Starter Disassembly 10 6 Starter Inspection and Testing 10 8 Starter Reassembly 10 14 Performance Testing 10 17 ...

Page 270: ...STARTER MOTOR 10 2 6LPA Service Manual 2007 Yanmar Marine International This Page Intentionally Left Blank ...

Page 271: ...lt in death or serious injury ALWAYS turn off the battery switch if equipped or disconnect the negative battery cable from the battery before servicing the electrical system ALWAYS check the electrical harnesses for cracks abrasions and damaged or corroded connectors ALWAYS keep the connectors and terminals clean NEVER engage the starter motor while the engine is running Damage to the starter moto...

Page 272: ...al STARTER SPECIFICATIONS Special Torque Chart Component Specification Starter housing magnetic switch 95 kgf cm 9 32 N m 82 4 lb in End cover starter housing 95 kgf cm 9 32 N m 82 4 lb in Lead wire terminal 50 41 kgf cm 4 02 N m 35 5 lb in Lead wire terminal C 215 kgf cm 21 08 N m 186 5 lb in ...

Page 273: ... Shaft 7 Compression Spring 8 Starter Clutch 9 Plate Washer 10 Idle Gear 11 Bearing 12 Starter Housing 13 Compression Spring 14 Retainer 15 Pinion Gear 16 Stop Collar 17 Snap Ring 18 O ring Non Reusable part 19 End Cover 20 Dust Protector 21 Brush Holder 22 Field Coil Frame 23 Front Bearing 24 Armature 25 Rear Bearing 26 Felt Washer 10 11 9 13 15 17 16 14 12 8 7 6 4 5 2 1 18 18 19 20 21 22 23 24 2...

Page 274: ... 3 Figure 10 3 3 Remove the 2 through bolts Figure 10 4 1 and spring washers then pull the field coil frame from the magnetic switch together with the armature and remove the felt washer from the rear bearing Figure 10 4 Figure 10 4 4 Remove the 3 screws Figure 10 5 1 from the starter housing and then remove the starter housing and clutch assembly return spring plate washer bearing and idler gear ...

Page 275: ...le using a magnet Figure 10 7 Figure 10 7 Figure 10 7 6 Remove the 2 screws Figure 10 8 1 and end cover from the field frame Figure 10 8 Figure 10 8 7 Secure the rear of the spring tang using a screwdriver Figure 10 9 and remove the brush from the brush holder Remove the 4 brushes and then the brush holder Figure 10 9 Figure 10 9 8 Remove the armature Figure 10 1 24 from the field coil frame Figur...

Page 276: ...tator surface for damage dirt and burning If the commutator surface is lightly damaged imperfections may be corrected with 400 emery cloth or by turning on a lathe 4 Inspect the commutator for radial runout by mounting the commutator on a V block to measure runout using a dial indicator Figure 10 12 Commutator radial runout Maximum 0 05 mm 0 001 in Figure 10 12 Figure 10 12 5 If the measured value...

Page 277: ...dard 0 7 to 0 9 mm 0 027 to 0 035 in Minimum 0 2 mm 0 007 in Figure 10 14 Figure 10 14 Field Coil Frame 1 Using an ohmmeter Figure 10 15 1 check the field coil frame for continuity between the lead wire and field coil brush If the circuit is electrically open replace the field coil frame Figure 10 15 Figure 10 15 2 Using an ohmmeter Figure 10 16 1 check the field coil frame for continuity between ...

Page 278: ...h Coil Length 2 Using a scale check the brush spring load Figure 10 18 Read the scale when the brush spring just leaves the brush If the measured mounting load is out of the specified range replace the brush spring Brush spring mounting load 1 9 to 3 6 kgf 18 63 to 35 30 N 4 1 lbf to 7 9 lbf Figure 10 18 Figure 10 18 3 Using an ohmmeter Figure 10 19 1 check the brush holder insulation The circuit ...

Page 279: ...t is locked If needed replace the clutch assembly Figure 10 20 Figure 10 20 Clutch Assembly Replacement 1 Press down the pinion gear and starter housing and tap in the stop collar with a plastic hammer Figure 10 21 Figure 10 21 Figure 10 21 2 Pry the snap ring off using a screwdriver Figure 10 22 and then disassemble the starter housing and clutch assembly Figure 10 22 Figure 10 22 3 Remove the st...

Page 280: ...er pinion gear and stop collar Figure 10 25 Figure 10 25 Figure 10 25 1 Clutch Shaft and Starter Clutch 2 Starter Housing 3 Compression Spring 4 Retainer 5 Pinion Gear 6 Stop Collar 6 While pressing down the pinion gear and starter housing install the new snap ring using snap ring pliers Check that the snap ring is installed completely in position Figure 10 26 Figure 10 26 Figure 10 26 7 Tap in th...

Page 281: ...an inwards force If you feel resistance or play in the bearing replace the bearing Figure 10 28 Figure 10 28 Replacing Bearing 1 Remove the front and rear bearings using a special tool Figure 10 29 Figure 10 29 Figure 10 29 2 Press in a new front and rear bearing using the a press Figure 10 30 Figure 10 30 Figure 10 30 1 Front Bearing 2 Rear Bearing 0005416 0005417 0005418 2 1 ...

Page 282: ...ce the magnetic switch Figure 10 32 Figure 10 32 Starter Reassembly 1 Apply grease to the armature bearing and install the armature in the field frame Figure 10 33 Note Use high temperature grease for lubrication of the bearing and gear when reassembling the starter Figure 10 33 Figure 10 33 2 Install the brush holder to the armature 3 Install the brush to the brush holder while securing the rear ...

Page 283: ...nd insert the return spring Figure 10 36 1 into the magnetic switch hole 7 Install the plate washer Figure 10 36 2 to the magnetic switch Figure 10 36 Figure 10 36 8 Install the idler gear Figure 10 37 1 and bearing Figure 10 37 2 to the starter housing Figure 10 37 Figure 10 37 9 Assemble the starter housing and magnetic switch assembly using 3 screws Figure 10 38 Figure 10 38 Figure 10 38 000539...

Page 284: ...gure 10 40 12 Assemble the field coil frame and armature assembly using two through bolts Figure 10 41 1 and torque to 95 kgf cm 9 32 N m 82 4 lb in Figure 10 41 Figure 10 41 13 Connect the lead wire to terminal 50 Figure 10 42 1 using a screw and washer and torque to 41 kgf cm 4 02 N m 35 5 lb in Figure 10 42 Figure 10 42 14 Connect the lead wire to terminal C Figure 10 43 1 and install the nut a...

Page 285: ...e clutch pinion gear does not move replace the magnetic switch assembly Hold In Test Under the above condition where the clutch pinion gear is located outside and the battery is connected disconnect the negative lead Figure 10 45 1 from terminal C Figure 10 45 2 Check that the pinion gear is at the outside If it has returned to the inside replace the magnetic switch assembly Figure 10 45 Figure 10...

Page 286: ...10 47 2 to the starter 2 Check that the starter rotates smoothly and that the pinion gear moves outwards 3 Check current using ammeter If ammeter reading is not within specifications check for mechanical drag or component damage of failure Standard no load current 12V Type 180A or less at 11 0V 24V Type 90A or less at 24 0V Figure 10 47 Figure 10 47 0005435 1 2 ...

Page 287: ...ations 11 5 Components 11 6 Wiring Diagram 11 7 Test and Inspection 11 8 Drive Belt Inspection 11 8 General Inspection 11 8 Check Discharge Warning Light Circuit 11 9 Check Charging Circuit Under No Load 11 9 Check Charging Circuit Under Load 11 10 Alternator Service 11 10 Disassembly 11 10 Inspection and Testing 11 13 Bearing Service 11 15 Assembly 11 18 ...

Page 288: ...ALTERNATOR 11 2 6LPA Service Manual 2007 Yanmar Marine International This Page Intentionally Left Blank ...

Page 289: ...esses for cracks abrasions and damaged or corroded connectors ALWAYS keep the connectors and terminals clean NEVER operate the engine if the alternator is producing unusual sounds Damage to the alternator will result NEVER turn the battery switch OFF or disconnect the battery leads from the battery while the engine is operating Damage to the alternator will result NEVER reverse the positive and ne...

Page 290: ...R 11 4 6LPA Service Manual Introduction 2007 Yanmar Marine International INTRODUCTION This section of the Service Manual describes the procedures necessary to service the 6LPA STP2 STZP2 marine engine alternator ...

Page 291: ...81 3 lb ft Rectifier End Frame to Drive Shaft End Frame 46 kgf cm 4 51 N m 39 9 lb in Rectifier Holder to Coil Lead on Rectifier Frame 30 kgf cm 2 94 N m 26 0 lb in Rear End Cover to Rectifier Holder 45 kgf cm 4 41 N m 39 0 lb in 46 kgf cm 4 51 N m 40 0 lb in Plate Terminal to Rectifier Holder 39 kgf cm 3 82 N m 33 8 lb in Terminal Insulator to Rectifier Holder 41 5 kgf cm 4 07 N m 36 0 lb in 66 k...

Page 292: ...nd Frame 4 Front Bearing 5 Bearing Retainer 6 Rotor 7 Bearing Cover A 8 Rear Bearing 9 Bearing Cover B 10 Alternator Washer 11 Rectifier End Frame 12 Rubber Insulator 4 used 13 Seal Plate 14 Terminal Insulator 15 IC Regulator 16 Brush Holder 17 Brush Holder Cover 18 Rear End Cover 19 Plate Terminal 0004831 1 2 3 4 5 11 12 13 14 15 17 6 7 8 9 10 16 18 19 ...

Page 293: ...ice Manual 11 7 Wiring Diagram 12 05 2007 Yanmar Marine International WIRING DIAGRAM Figure 11 2 Figure 11 2 1 Alternator Assembly Including Regulator 2 Regulator Assembly 3 Key Switch 4 Battery 5 Load 0004872 1 2 3 4 5 5 ...

Page 294: ...1 4 with 10 kgf cm 98 N m 22 0 lbf of force to check the deflection of the drive belt Drive belt deflection New Drive Belt Belt that has less than 5 minutes of usage 6 to 8 mm 0 236 to 0 314 in Used Drive Belt Belt that has more than 5 minutes of usage 8 to 11 mm 0 314 to 0 433 in Figure 11 4 Figure 11 4 3 Adjust or replace the belt if necessary Operate the engine for 5 minutes and then re check b...

Page 295: ...f ammeter 3 Connect the positive lead of ammeter to the alternator terminal B 4 Connect the positive lead of voltmeter to the alternator terminal B 5 Connect the negative lead of voltmeter to the ground 6 Start the engine and let it run for a few minutes before carrying out the test 7 Increase the engine speed to 2000 rpm and record voltage and current output readings No load Standard Current 10A ...

Page 296: ...ir the alternator Standard current under load 12V 80A to 30A or more 12V 100A to 40A or more Note When the battery is in the fully charged state the indication is below the standard value ALTERNATOR SERVICE Disassembly 1 Remove the terminal nuts and insulator Figure 11 8 1 Figure 11 8 Figure 11 8 2 Remove the 3 nuts Figure 11 9 1 bolt Figure 11 9 2 and plate terminal Figure 11 9 3 and then remove ...

Page 297: ...egulator Figure 11 10 2 Figure 11 10 Figure 11 10 5 Remove the seal plate Figure 11 11 1 from the rectifier end frame Figure 11 11 Figure 11 11 6 Remove the 4 rectifier holder screws Figure 11 12 1 and rectifier holder Figure 11 12 2 Figure 11 12 Figure 11 12 7 Remove the 4 rubber insulators Figure 11 13 1 Figure 11 13 Figure 11 13 0004835 1 2 1 1 1 1 0004836 1 0004837 1 2 1 1 1 0004838 1 ...

Page 298: ...t over 1 4 of a turn to prevent damage to the rotor shaft 9 Remove the pulley nut and pulley Figure 11 14 Figure 11 14 10 Remove the 4 rectifier end frame nuts Figure 11 15 1 Figure 11 15 Figure 11 15 11 Using a special two jaw puller tool Figure 11 16 1 remove rectifier end frame Figure 11 16 Figure 11 16 12 Remove the alternator washer Figure 11 17 Figure 11 17 Figure 11 17 13 Remove the rotor f...

Page 299: ...ure 11 19 2 Using an ohmmeter Figure 11 20 1 check the rotor circuit for grounds The rotor circuit between the slip rings and rotor should have no electrical continuity If continuity is measured replace the rotor Figure 11 20 Figure 11 20 3 Inspect the slip rings for damage or scratches on the surface If the surface is damaged or scratched replace the rotor 4 Measure the slip ring diameter using c...

Page 300: ...gure 11 22 2 Using an ohmmeter Figure 11 23 1 check the stator for shorts to ground The stator circuit when measured between the coil leads and drive end frame should have no continuity If continuity is measured replace the drive end frame assembly Figure 11 23 Figure 11 23 Brushes 1 Check the exposed brush length using calipers Figure 11 24 If the measured length is below the specified minimum re...

Page 301: ...bove replace the rectifier 4 Check the negative rectifier Connect one of tester probes of an ohmmeter to the negative terminal Figure 11 26 1 and the other probe to the rectifier terminal Figure 11 26 2 Figure 11 26 Figure 11 26 5 Reverse polarities of the probes and repeat the procedure 6 Check that one of connections shows the continuity state while the other connection results in no continuity ...

Page 302: ...nstall the 4 bearing retainer screws Figure 11 29 Figure 11 29 5 Rotate and inspect the rear bearing for wear and damage If necessary replace the rear bearing Figure 11 30 Figure 11 30 Figure 11 30 6 Remove the rear bearing cover B and remove the bearing using a special two jaw puller tool Figure 11 31 1 NOTICE Avoid damaging the fan during bearing removal Figure 11 31 Figure 11 31 7 Remove the re...

Page 303: ...8 Install the rear bearing cover A Figure 11 32 1 Figure 11 32 Figure 11 32 9 Press in a new bearing using the special tool Figure 11 33 1 and a press Figure 11 33 Figure 11 33 10 Install bearing cover B using the special tool Figure 11 34 1 Figure 11 34 Figure 11 34 0004858 1 0004859 1 0004860 1 ...

Page 304: ... the rotor and drive end frame then install the alternator washer Figure 11 36 1 above the rotor Figure 11 36 Figure 11 36 3 Slowly press on the rectifier end frame using a 29 mm socket wrench and a press Figure 11 37 1 Figure 11 37 Figure 11 37 4 Install the 4 nuts Figure 11 38 1 and torque to 46 kgf cm 4 51 N m 39 9 lb in Figure 11 38 Figure 11 38 5 Manually tighten the pulley nut to secure the ...

Page 305: ...nsulators Figure 11 40 1 above lead wires Figure 11 40 Figure 11 40 8 Install the rectifier holder Figure 11 41 2 with 4 bolts Figure 11 41 1 while pushing it downwards Torque bolts to 30 kgf cm 2 94 N m 26 0 lb in Figure 11 41 Figure 11 41 9 Install the seal plate on the rectifier end frame and then the IC regulator and brush holder in an upward direction Figure 11 42 10 Tighten the 5 bolts and t...

Page 306: ...que the nuts to 80A Models 45 kgf cm 4 41 N m 39 0 lb in 100A Models 46 kgf cm 4 51 N m 40 0 lb in Figure 11 43 Figure 11 43 12 Install the terminal insulator and nut Figure 11 44 1 Torque the nut to 80A Models 41 5 kgf cm 4 07 N m 36 0 lb in 100A Models 66 kgf cm 6 47 N m 57 2 lb in Figure 11 44 Figure 11 44 13 After final assembly rotate the rotor pulley to ensure the rotor rotates smoothly Figu...

Page 307: ...6LPA Service Manual 12 1 2007 Yanmar Marine International 6LPA Service Manual Section 12 TROUBLESHOOTING Page Safety Precautions 12 3 Introduction 12 4 Troubleshooting Chart 12 4 ...

Page 308: ...TROUBLESHOOTING 12 2 6LPA Service Manual 2007 Yanmar Marine International This Page Intentionally Left Blank ...

Page 309: ...le before servicing the equipment Fire and Explosion Hazard Diesel fuel is flammable and explosive under certain conditions NEVER use a shop rag to catch the fuel Wipe up all spills immediately Piercing 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 inj...

Page 310: ...ng gear but does not rotate Loose battery starter terminal Tighten Poor contact of engage magnet switch Correct with sandpaper Worn brush Replace Dirty or rough surface of rectifier Correct with sandpaper 500 to 600 Open circuit of starter coil Replace Worn rectifier Replace Slippage of starter clutch Replace Excessive resistance of cable between battery and starter Increase the cable size or shor...

Page 311: ... replace Insufficient tightening of head bolt Re tighten set bolts uniformly Broken valve spring Replace Other Improper thickness of gasket packing Replace with a part of appropriate size Poor mounting of link or lever of speed control system Re adjust Location of speed control handle stopping position Move the speed control handle towards higher speed Failure of engine starting system Inspect and...

Page 312: ...filter Replace Broken fuel pipe Replace Failure of fuel feed pump Replace Faulty operation of governor Broken governor spring Replace Sticking governor sleeve Inspect and repair Actuated emergency stop system NOTE this section is not related to the engine Loose lubrication oil pressure adjusting valve Tighten valve Clogged lubrication oil filter Clean Leak from safety valve of lubrication oil pump...

Page 313: ...her Overload operation Reduce load Lubricant level too high Lower the oil level Accumulated carbon deposit at intake exhaust valve Clean Dirty air cooler Clean Poor fuel quality Replace fuel Clogged intake exhaust valve Clean Insufficient output Insufficient fuel injection by fuel injection pump Worn plunger Replace Sticking plunger Overhaul or replace Oil leak from delivery valve Lap the valve Oi...

Page 314: ...eawater pump Insufficient feed of lubrication oil Disassemble and clean lubrication oil pump and filter Output for each cylinder is not uniform Uneven fuel injection quantities Air trapped in fuel injection pump Bleed Faulty operation of plunger Disassemble and clean Broken plunger spring Replace Faulty delivery valve Repair or replace Damaged delivery valve gasket Replace Faulty operation of regu...

Page 315: ...omplete thermal insulation of exhaust pipe Ensure intake air path is unrestricted from outside air Clean air cleaner Drop in air pressure in engine room Ensure intake air path is unrestricted from outside air Broken seal ring Replace Broken turbine impeller Replace Broken nozzle ring Replace Dirty turbine impeller Clean Clogged nozzle Clean Clogged exhaust pipe Clean Incorrect reading of pressure ...

Page 316: ... in bearing housing Repair Clogged seal air path Clean Damaged seal ring Replace Clogged pressure balance path Clean Pulsation of intake air pressure Uneven cylinder combustion Adjust for uniform combustion Rapid change in load Operate correctly Excessively dirty compressor side Clean Intake temperature too high Clean cooling fin Complete thermal insulation of exhaust pipe Ensure intake air path i...

Page 317: ...he safety valve Low viscosity of engine oil used Replace the engine oil Insufficient engine oil quantity Add oil Faulty pressure gauge or sender unit Replace Engine oil temperature too high Insufficient seawater flow rate Replace seawater pump impeller Overloaded operation Decrease the load Fresh water coolant temperature too high Insufficient seawater Replace seawater pump impeller Faulty thermos...

Page 318: ...TROUBLESHOOTING 12 12 6LPA Service Manual Troubleshooting Chart 2007 Yanmar Marine International This Page Intentionally Left Blank ...

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