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COOLING SYSTEM

7-4

BY Service Manual

Before You Begin Servicing

A

WARNING

FUME / BURN HAZARD!

• Always read and follow safety related

precautions found on containers of
hazardous substances like parts
cleaners, primers, sealants and
sealant removers.

• Failure to comply could result in death

or serious injury.

0000014en

A

CAUTION

FLYING OBJECT HAZARD!

• ALWAYS wear eye protection when

servicing the engine and when using
compressed air or high-pressure
water. Dust, flying debris, compressed
air, pressurized water or steam may
injure your eyes.

• Failure to comply may result in minor

or moderate injury.

0000003en

A

CAUTION

PINCH HAZARD!

Use care not to catch finger between
belt and pulley while installing belt.
Failure to comply may result in minor or
moderate injury.

0000034en

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Summary of Contents for BY series

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

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

Page 3: ...atest 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 p...

Page 4: ...CONTENTS Page Introduction 1 1 Safety 2 1 General Service Information 3 1 Periodic Maintenance 4 1 Engine 5 1 Fuel System 6 1 Cooling System 7 1 Lubrication 8 1 Turbocharger 9 1 Starter Motor 10 1 Al...

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

Page 6: ...h repairs as some of the procedures described are rather complex Along with standard tools Yanmar recommends the use of special tools necessary to perform repairs correctly Yanmar products are continu...

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

Page 8: ...ome alert your safety is involved Please read and abide by the message that follows the safety alert symbol A DANGER Danger the word DANGER is in white letters with a red rectangle behind it indicates...

Page 9: ...her form of ignition away while the engine is running or battery is charging Failure to comply will result in death or serious injury 0000003en A DANGER CRUSH HAZARD ALWAYS use the engine lifting eyes...

Page 10: ...flammable and explosive under certain conditions NEVER remove the fuel cap with the engine running Failure to comply will result in death or serious injury 0000011en A DANGER FIRE AND EXPLOSION HAZARD...

Page 11: ...ry out and become brittle after two years or 500 hours of engine operation whichever comes first Failure to comply will result in death or serious injury 0000015enBY A DANGER NEVER start the engine un...

Page 12: ...ing before installing ALWAYS install new gaskets and seals for the turbocharger lubrication lines and check after installation for leaks NEVER install a heat shield that is oily ALWAYS replace it with...

Page 13: ...hat any tools or shop rags used during maintenance have been removed from the area Failure to comply could result in death or serious injury 0000002enMarine A WARNING EXPOSURE HAZARD Wear personal pro...

Page 14: ...k the electrical harnesses for cracks abrasions and damaged or corroded connectors ALWAYS keep the connectors and terminals clean Failure to comply could result in death or serious injury 0000009en A...

Page 15: ...hortly after you shut the engine down These surfaces are extremely hot while the engine is operating and could seriously burn you Failure to comply could result in death or serious injury 0000015enBY...

Page 16: ...o comply could result in death or serious injury 0000003en A WARNING BURN HAZARD Batteries contain sulfuric acid NEVER allow battery fluid to come in contact with clothing skin or eyes Severe burns co...

Page 17: ...task at hand Use the correct size tool for loosening or tightening machine parts Failure to comply may result in minor or moderate injury 0000024en A CAUTION Be sure to secure the engine solidly to p...

Page 18: ...ine coolants This may adversely affect the properties of the engine coolant 0000006enMarine CAUTION NEVER engage the starter motor while the engine is running This may damage the starter motor pinion...

Page 19: ...high pressure wash directly on the alternator Water will damage the alternator and result in inadequate charging 0000049en CAUTION Do not reverse the positive and negative ends of the battery cable T...

Page 20: ...0185en CAUTION Any part which is found defective as a result of inspection or any part whose measured value does not satisfy the standard or limit must be replaced 0000119en CAUTION Immediately cap or...

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

Page 22: ...uel 3 10 Diesel Fuel Specifications 3 10 Bleeding the Fuel System 3 11 Engine Oil 3 11 Engine Oil Specifications 3 11 Recommended Engine Oil 3 12 Recommended Marine Gear or Stern Drive Oil 3 14 Recomm...

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

Page 24: ...DRAWINGS Note All dimensions are metric Contact Yanmar Marine for the most current drawings 4BY Inboard Version Borg Warner Flange Figure 3 1 0003569 VIEW S SECTION A A A A 209 55 0 02 0 06 50 356 5 2...

Page 25: ...Outline Drawings 4BY Stern Drive Version Note All dimensions are metric Contact Yanmar Marine for the most current drawings Figure 3 2 0003570 SECTION A A A A 737 94 2 284 54 861 S 149 1 760 373 240...

Page 26: ...rner Flange Note All dimensions are metric Contact Yanmar Marine for the most current drawings Figure 3 3 0003571 SECTION A A 538 5 A S 50 209 55 G7 21 5 7 0 03 0 0 061 0 015 A 145 240 700 669 373 759...

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

Page 28: ...Sensor 6 High Pressure Fuel Pump 7 High Pressure Fuel Supply Line 8 Common Fuel Rail 9 Fuel Injection Line 1 each injector 10 Fuel Injector 1 each cylinder 11 Fuel Injector Return Fuel Hose 12 Common...

Page 29: ...engine shown 6BY is similar 1 Seawater Supply 2 Seawater Pump 3 Hydraulic Oil Cooler 4 Charge Air Cooler 5 Engine Heat Exchanger 6 Exhaust Elbow 7 Exhaust Seawater Exit 8 Engine Coolant Pump 9 Thermo...

Page 30: ...lock Serial Label Figure 3 8 The engine block information label is affixed to the cylinder block and is located behind the engine oil cooler near the end of the starting motor 0003636 YANMAR DIESEL EN...

Page 31: ...and or cause engine damage Fuel additives are not recommended Some fuel additives may cause poor engine performance Diesel Fuel Lines Figure 3 9 1 Optional Boatbuilder Installed Fuel Filter Water Sepa...

Page 32: ...and engine oil filling equipment are free of sediment and water Change the engine oil after the first 50 hours of operation and then at every 250 hours or annually thereafter Choose engine oil from t...

Page 33: ...Formula RS Power and Protection Castrol Limited Castrol Formula SLX Castrol Limited Castrol Formula SLX LL01 Castrol Limited Castrol Formula SLX Long Tex Castrol Limited Castrol Formula SLX Turbodies...

Page 34: ...ate Ravenol HCL Ravensburger Schmierstoffvertrieb GmbH Repsol Elite Common Rail Repsol YPF Shell Helix Ultra AB Shell International Petroleum Company Shell Helix Ultra AL Shell International Petroleum...

Page 35: ...imited Castrol Edge Turbo Diesel Castrol Limited Castrol Formula RS Castrol Limited Castrol GTX Magnatec Castrol Limited Castrol SLX LL 04 Castrol Limited Castrol TXT LL 04 Castrol Limited Elf Excelli...

Page 36: ...e engine is hot Steam and hot engine coolant will escape and seriously burn you Allow the engine to cool before attempting to remove the filler cap Securely tighten the filler cap after checking the c...

Page 37: ...per Addinol Lube Oil GmbH Aral Antifreeze Extra Aral AG AVIA Antifreeze APN AVIA Mineral l AG BMW Coolant BMW AG BP anti frost X 2270A BP Schmierstoff GMBH Hamburg Caltex CX Engine Coolant Caltex Cast...

Page 38: ...278 47 psi Torque 317 N m 234 ft lb 355 N m 262 ft lb 487 N m 359 ft lb 545 N m 402 ft lb High Idle Speed 4600 rpm Low Idle Speed Warm Engine 88 C 190 F 750 rpm ECU controlled 670 rpm ECU controlled C...

Page 39: ...ern Drive front to middle of engine mount 760 mm 29 9 in 942 mm 37 1 in Marine Gear front to marine gear mounting face 644 mm 25 4 in 825 5 mm 32 5 in Overall Length 861 mm 33 9 in 1001 mm 39 4 in Wid...

Page 40: ...rade Lubricated 8 8 or 8 10 9 or 10 12 9 or 12 M4 2 7 N m 24 in lb 3 88 N m 34 3 in lb 4 6 N m 41 in lb M5 5 5 N m 48 6 in lb 8 N m 71 in lb 9 5 N m 84 in lb M6 9 5 N m 84 in lb 13 N m 115 in lb 16 N...

Page 41: ...und force per minute g gram gal gallon U S gal hr gallon U S per hour gal min gallon U S per minute GL gear lubricant hp horsepower U S hr hour I D inside diameter ID identification IDI indirect injec...

Page 42: ...0 g kg x 2 20500 lb g x 0 03527 oz lbf x 4 4480 N lbf x 0 4536 kgf N x 0 2248 lbf N x 0 1020 kgf kgf x 2 2050 lbf kgf x 9 8070 N ft lb x 1 3558 N m ft lb x 0 1383 kgf m in lb x 0 1130 N m in lb x 0 01...

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

Page 44: ...s 4 6 Required EPA Maintenance 4 6 EPA Requirements 4 6 Conditions to Ensure Compliance with EPA Emission Standards 4 6 Inspection and Maintenance 4 7 Periodic Maintenance Schedule 4 8 Inspection and...

Page 45: ...mply will result in death or serious injury 0000007en A DANGER SCALD HAZARD NEVER remove the coolant filler cap if the engine is hot Steam and hot engine coolant will escape and seriously burn you All...

Page 46: ...009en A DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions NEVER use diesel fuel as a cleaning agent Failure to comply will result in death or serious inj...

Page 47: ...uch as the flywheel or PTO shaft Wear tight fitting clothing and keep your hair short or tie it back while the engine is running Remove all jewelry before you operate or service the engine NEVER start...

Page 48: ...tion of this gas within an enclosure could cause illness or even death Make sure that all connections are tightened to specifications after repair is made to the exhaust system Failure to comply could...

Page 49: ...nly in USA Conditions to Ensure Compliance with EPA Emission Standards This product is an EPA approved engine The following are the conditions that must be met in order to ensure that the emissions du...

Page 50: ...n the user or the maker Inspection and Maintenance See Inspection and Maintenance of EPA Emission Related Parts on page 4 10 Inspection and maintenance procedures not shown in the Inspection and Maint...

Page 51: ...irst Every 250 hoursorone year whichever comes first Every 500 hours or 2 years whichever comes first Whole Visual inspection of engine exterior c Before starting Fuel System Check for fuel leakage c...

Page 52: ...m Visual inspection c Before starting Replace turbocharger heat shield Check the exhaust pipe c Check the air intake pipes c Check the exhaust water mixing elbow c Clean or replace the air filter elem...

Page 53: ...0 c Adjust the propeller shaft alignment if equipped with marine gear c Initial 50 c Check hydraulic oil cooler c Replace rubberized hoses fuel and water Check zinc anodes periodically Any anode havin...

Page 54: ...ment from Fuel Tank Replace the Fuel Pre Filter Replace the Fuel Fine Filter Replace the Fuel Filter Water Separator Element Change the Engine Oil and Replace the Engine Oil Filter Element Check Repla...

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

Page 56: ...17 Testing Compression 5 17 Repair 5 18 Cylinder Head 5 19 Cylinder Head Components 5 19 General Guidelines 5 20 Remove and Install Cylinder Head Cover 5 20 Remove and Install Glow Plugs 5 22 Removal...

Page 57: ...Adjusting Camshaft Timing 5 48 Removing and Installing Vibration Damper 4BY 5 50 Removing and Installing Vibration Damper 6BY 5 51 Removing Timing Case Cover 5 52 Removing and Installing Timing Chain...

Page 58: ...DANGER CRUSH HAZARD NEVER stand under hoisted engine If the hoist mechanism fails the engine will fall on you causing death or serious injury Failure to comply will result in death or serious injury 0...

Page 59: ...n A WARNING BURN HAZARD Handle hot components with heat resistant gloves Failure to comply could result in death or serious injury 0000110en A WARNING FUME BURN HAZARD Always read and follow safety re...

Page 60: ...EVER overfill Overfilling may result in white exhaust smoke engine overspeed or internal damage 0000005enBY CAUTION Only use the engine coolant specified Other engine coolants may affect warranty cove...

Page 61: ...the air cleaner turbocharger if equipped and electric components from damage when you use steam or high pressure water to clean the engine 0000014en CAUTION NEVER hold the key in the START position f...

Page 62: ...gines SPECIFICATIONS General Information Test and Adjustment Specifications Engine Model 4BY 6BY Number of Cylinders In Line 4 In Line 6 Bore 84 mm 84 mm Stroke 90 mm 90 mm Effective Displacement 1995...

Page 63: ...18 85 0 08 mm 0 742 0 003 in Valve Seat Angle 45 Outer Correction Angle 15 Inner Correction Angle 60 Valve Seat Width Intake 1 0 0 1 mm 0 039 0 004 in Valve Seat Width Exhaust 1 2 0 1 mm 0 047 0 004 i...

Page 64: ...50 White 59 464 59 469 mm 2 3411 2 3413 in Crankshaft Bearing Clearance Radial 0 019 0 052 mm 0 0007 0 0020 in Crankshaft Thrust Bearings Standard 25 00 0 020 0 066 mm 0 9842 0 0008 0 0026 in Size 1...

Page 65: ...Cylinder Block Bore Diameter stage 0 84 007 0 007 mm 3 3074 0 0003 in Bore Diameter stage 1 84 257 0 007 mm 3 3172 0 0003 in Permitted out of round of cylinder bore 0 005 mm 0 0002 in Permitted conic...

Page 66: ...Assembly Torque Initial Torque Torque angle 5 N m 44 in lb 20 N m 177 in lb 70 Cylinder Head with Cover Cylinder Head Bolts Replace wash and oil 4BY 6BY M12x1 5 Initial Torque then Loosen all bolts 1...

Page 67: ...ling Rings 22 N m 195 in lb Turbocharger Oil Return to Crankcase 4BY 6BY Hose Clamp 3 N m 27 in lb Exhaust Manifold to Cylinder Head 4BY Apply Copper Anti seize to Threads 19 N m 168 in lb 6BY 13 N m...

Page 68: ...uel Rail 4BY 6BY 70 N m 52 ft lb Pressure Regulator to Fuel Rail 4BY 6BY 80 N m 59 ft lb Fuel Return to Rail 4BY 6BY Banjo Bolt 25 N m 221 in lb Poly V Belt Drive Idler Pulley to Alternator Bracket 4B...

Page 69: ...having part numbers must be obtained locally No Tool Name Applicable Model and Tool Size Illustration 1 Valve Spring Compressor Obtain Locally 2 Valve Stem Seal Installer OEM Part No 11 6 370 Remover...

Page 70: ...ide diameters of crankshaft pistons piston pins etc 4 Cylinder Bore Gauge For measuring the inside diameters of cylinder bores bearing bores etc 5 Calipers For measuring outside diameters depth thickn...

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

Page 72: ...Turn engine over several times using the starter motor to remove any loose debris in the cylinders Figure 5 1 4 Assemble special tools OEM No 11 0 222 and 11 0 236 and install in glow plug port Figure...

Page 73: ...gine repair stand having adequate weight capacity 6 Cap or plug all openings to prevent contamination 7 Remove starter motor and alternator 8 Clean engine by washing with solvent air or steam cleaning...

Page 74: ...ft 3 Hydraulic Rocker Arm Pivot 4 Valve Keeper 2 used each valve 5 Cam Follower 6 Valve Spring Retainer 7 Valve Spring 8 Valve Stem Seal 9 Coolant Temperature Sensor 10 Valve 11 Cylinder Head Gasket 1...

Page 75: ...ber Gasket 3 Oil Fill Cap 4 Seal 5 Crankcase Ventilation Diaphragm Housing 6 Seal 7 Double Ended Bolt 8 Bolt 9 Profile Gasket IMPORTANT When working on the oil coolant or fuel circuits you must protec...

Page 76: ...om breather 6 Remove oil fill cap Figure 5 4 4 and lift rubber gasket Figure 5 4 5 to access bolt located below 7 Remove cylinder head cover bolts in sequence working from the outer bolts toward the c...

Page 77: ...shaft sensor intake air pressure sensor and intake air temperature sensor 10 Install engine cover Remove and Install Glow Plugs 1 Disconnect battery negative terminal 2 Remove intake manifold See Inta...

Page 78: ...ve heat exchanger See Remove and Install Heat Exchanger on page 7 16 6 Remove front and rear heat exchanger mounting brackets Figure 5 9 3 7 Remove exhaust manifold See Exhaust Manifold on page 5 72 8...

Page 79: ...itting Figure 5 12 1 15 Disconnect electrical connector from coolant temperature sensor Figure 5 12 2 Figure 5 13 16 Remove high pressure fuel rail See Removing and Installing Fuel Rail on page 6 27 1...

Page 80: ...gure 5 15 1 Figure 5 16 20 4BY Engines Remove cylinder head bolts in reverse sequence beginning with number 10 Figure 5 16 Figure 5 17 21 6BY Engines Remove cylinder head bolts in reverse sequence beg...

Page 81: ...ace special tool OEM No 11 9 008 with straight surface on combustion chamber side of cylinder head Figure 5 19 Figure 5 20 3 Insert special tool OEM No 11 9 006 and lock with special tool OEM No 11 9...

Page 82: ...ss down to compress valve spring and lock in place with special tool OEM No 11 9 011 Figure 5 23 8 Remove valve keepers Figure 5 23 Figure 5 24 1 Valve 2 Valve Stem Seal 3 Valve Spring 4 Valve Spring...

Page 83: ...6 Note Reduce surface tension of water used for test with a few drops of detergent 3 Connect air source to cylinder head and immerse in water bath Apply pressure and adjust to 4 5 bar 65 psi Figure 5...

Page 84: ...r head and valves must be replaced Specifications Replacing Valve Stem Seals 1 Remove the valve spring It is not necessary to remove valve Figure 5 28 2 Press special tool OEM No 11 6 370 onto valve s...

Page 85: ...linder head 3 Install new valve stem seals See Replacing Valve Stem Seals on page 5 29 Figure 5 31 4 Secure cylinder head to special tool OEM No 11 9 001 Figure 5 31 5 Install spring compressor OEM No...

Page 86: ...de fixture and indicator over cleaned area of piston Figure 5 34 1 Rotate the crankshaft to determine the highest point of piston travel and record the measurement Repeat the procedure in a second are...

Page 87: ...Check condition and placement of alignment dowel sleeves Figure 5 36 1 3 Ensure the gasket surfaces of the cylinder head and cylinder block are clean and dry Transition areas Figure 5 36 2 must be ab...

Page 88: ...and tighten Figure 5 40 8 Install high pressure pump to fuel rail line Figure 5 40 1 4BY Engines Install rubber mount Figure 5 40 3 9 Install glow plugs Figure 5 40 2 10 Install high pressure fuel rai...

Page 89: ...43 16 Rotate crankshaft using the crankshaft dampener bolt until No 1 cylinder is at TDC Secure flywheel using flywheel holding tool IMPORTANT NEVER mix used valve train components Whenever installing...

Page 90: ...askets Tighten securely 23 Connect wires Figure 5 44 2 to oil pressure sender 24 Install heat exchanger See Remove and Install Heat Exchanger on page 7 16 25 Install turbocharger See Turbocharger Inst...

Page 91: ...make it impossible to remove the pistons Use a suitable ridge reamer to remove ridges and carbon prior to removing pistons 5 Remove the ridge at the top of the cylinder if necessary 6 Mark each piston...

Page 92: ...ng care not to scratch the surface of the piston Inspection of Pistons and Piston Rings Figure 5 49 Note Measure cylinder bore to ensure it is within specifications before measuring piston ring end ga...

Page 93: ...with the second ring Note The oil ring third groove cannot be measured 6 Repeat steps for each of the cylinders and the piston rings for that specific cylinder Assembling Piston and Connecting Rod 1 C...

Page 94: ...g Figure 5 54 3 has an expander spring underneath it Figure 5 54 4 Install the expander end gap and oil ring end gap 180 apart Stagger all exposed ring gaps 120 from each other with none in line with...

Page 95: ...Lubricate the piston piston rings cylinder bore and piston ring compressor with clean engine oil Figure 5 58 7 Position the piston rings so that the ring gaps are distributed evenly approximately 120...

Page 96: ...isely If it does not the piston will become too warm resulting in engine breakdown Do not straighten damaged nozzles They must be replaced 14 Check that the piston cooling nozzles are in perfect condi...

Page 97: ...leeves Figure 5 63 5 and dowel Figure 5 63 6 6 Clean mating surfaces Install alignment sleeves and dowel in flywheel housing 7 Install flywheel housing 8 Install washers on the M10 x 130 M8 x 130 and...

Page 98: ...Install flywheel holding tool to prevent flywheel rotation IMPORTANT Ensure all mating surfaces are clean and dry 2 Stern drive engines Install coupler adapter and tighten eight bolts to specification...

Page 99: ...engage properly Replacement of Rear Crankshaft Seal 1 Drain engine oil 2 Remove flywheel See Removal of Flywheel on page 5 44 3 Remove oil sump See Remove and Install Oil Sump on page 8 16 Figure 5 66...

Page 100: ...orque plate Figure 5 65 2 IMPORTANT Never reuse flywheel bolts Always install new flywheel bolts 3 Install the flywheel on the crankshaft Note Flywheel bolts are T 60 Torx head 4 Apply medium strength...

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

Page 102: ...de Rail Pin 6 Upper Timing Chain 7 Sprocket 8 Timing Case Cover Gasket 9 Timing Case Cover 10 O Ring 11 Access Plug 12 Plug 13 Seal 14 Guide Rail 15 Sprocket to High Pressure Pump Nut 16 Lower Timing...

Page 103: ...5 71 IMPORTANT DO NOT rotate the crankshaft backward If the crankshaft is turned past TDC rotate two more turns 720 to bring No 1 piston back to TDC 4 Secure crankshaft in TDC position with flywheel h...

Page 104: ...er stroke The front lobe of each camshaft Figure 5 74 1 will be facing toward the exhaust side and the timing marks Figure 5 74 2 will meet 4 Verify position by checking the camshaft timing marks Figu...

Page 105: ...stall cylinder head cover See Remove and Install Cylinder Head Cover on page 5 20 Removing and Installing Vibration Damper 4BY 1 Disconnect battery negative cable 2 Remove alternator and seawater pump...

Page 106: ...ive belts See Remove and Install Alternator on page 11 7 and Replace Seawater Pump Belt on page 7 21 Figure 5 81 3 Remove bolts Figure 5 78 1 4 Remove the vibration damper 5 Place vibration damper on...

Page 107: ...move vibration dampener See Removing and Installing Vibration Damper 4BY on page 5 50 or Removing and Installing Vibration Damper 6BY on page 5 51 7 Remove front crankshaft seal See Replacing Front Cr...

Page 108: ...Install gasket Figure 5 85 and apply a thin coat of Three Bond 1207F Yanmar part No 977770 1207F sealing agent to gasket at ends arrow on both sides 4 Install timing case cover 5 Install all bolts an...

Page 109: ...ve bolts Figure 5 86 3 4 Remove chain tensioner Figure 5 86 2 5 Installation is in the reverse of removal Removal of Camshafts 1 Remove cylinder head cover See Remove and Install Cylinder Head Cover o...

Page 110: ...ure 5 89 7 Remove plug Figure 5 89 from timing case cover 8 Rotate crankshaft counterclockwise 45 Figure 5 90 9 Use a wrench Figure 5 90 2 to turn exhaust camshaft Figure 5 90 1 in direction of arrow...

Page 111: ...ween the two marks on the exhaust camshaft gear Figure 5 93 IMPORTANT DO NOT rotate the crankshaft backward If the crankshaft is turned past TDC rotate two more turns 720 to bring No 1 piston back to...

Page 112: ...ds the center IMPORTANT Camshaft bearing caps are numbered and must be installed in their original locations 20 Remove all bearing caps 21 Remove the intake Figure 5 97 2 and exhaust Figure 5 97 3 cam...

Page 113: ...t bearing caps are marked A1 A7 5 Lightly oil the threads of all bolts and install finger tight 6 Tighten all bearing caps evenly in 1 2 turn increments starting at the center and working toward each...

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

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

Page 116: ...Seal Assembly 9 Lower Main Bearing Inserts 10 Lower Main Thrust Bearing Insert 11 Oil Deflector 12 Upper Main Bearing Inserts 13 Upper Main Thrust Bearing Insert 14 Main Bearing Cap Bolt 15 Dowel Sle...

Page 117: ...stalling Timing Chain on page 5 52 7 Remove oil sump oil suction pipe and strainer and the oil pump See Oil Pump on page 8 17 Figure 5 103 8 Remove oil deflector Figure 5 103 1 9 Remove pistons and co...

Page 118: ...Clearance Oil clearance should be checked during disassembly to determine the extent of wear and during reassembly to ensure long engine life The same procedure is done for both connecting rods and m...

Page 119: ...il Clearance 3 Bearing Inserts red or blue 4 Bearing Cap Rt Red Bl Blue 7 Figure 5 109 and Figure 5 110 show the relationship of each color coding compared to diameter If necessary install bearing ins...

Page 120: ...mm 2 3416 2 3418 in Undersize 2 U 0 50 Green 59 470 59 476 mm 2 3413 2 3416 in Undersize 2 U 0 50 White 59 464 59 469 mm 2 3411 2 3413 in Crankshaft Bearing Clearance Radial 0 019 0 052 mm 0 0007 0 00...

Page 121: ...measurements are not within specification 5 Take measurements at three places a b c and in two directions d and e in each cylinder Cylinder Bore Specifications Crankshaft Installation 1 Select the cor...

Page 122: ...ellow painted main bearing inserts in the cylinder block and main bearing caps Apply a generous amount of clean engine oil to the bearing inserts Ensure all oil holes are properly aligned Do not lubri...

Page 123: ...page 5 44 15 Install timing case cover using a new gasket See Installing Timing Case Cover on page 5 53 16 Install vibration damper See Removing and Installing Vibration Damper 4BY on page 5 50 or Re...

Page 124: ...housing 5 Turn center screw in to remove seal 6 Wipe the sealing surface in the cover clean 4BY Engines 6BY Engines Figure 5 120 7 Install seal protector tool OEM No 11 7 400 4BY or 11 6 470 6BY on en...

Page 125: ...Damper 4BY on page 5 50 13 Install belts See Remove and Install Alternator on page 11 7 and Replace Seawater Pump Belt on page 7 21 INTAKE MANIFOLD Removal Figure 5 122 1 Remove injector harness conn...

Page 126: ...s Figure 5 125 1 9 Remove nuts Figure 5 125 2 10 Remove intake manifold Installation 1 Clean all sealing surfaces Figure 5 126 2 Install new sealing rings Figure 5 126 1 3 Check condition of rubber mo...

Page 127: ...Exchanger on page 7 16 2 Remove turbocharger See Turbocharger Removal on page 9 9 6BY Engine Shown Figure 5 129 3 Remove nuts Figure 5 129 1 4 6BY Engines Remove plates Figure 5 129 2 5 Remove manifo...

Page 128: ...e to use a stand of adequate capacity to safely support the engine to be repaired and that it is securely attached to the engine A DANGER CRUSH HAZARD NEVER stand under hoisted engine If the hoist mec...

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

Page 130: ...Diagram 6 10 Tests and Adjustments 6 11 Measuring Fuel Feed Pump Pressure 6 11 Testing Return Fuel Pressure 6 12 Repair 6 13 Removal of Fuel Injector 6 13 Cleaning Fuel Injector Cavities 6 14 Install...

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

Page 132: ...Failure to comply will result in death or serious injury 0000009en A WARNING ENTANGLEMENT HAZARD Stop the engine before you begin to service it NEVER leave the key in the key switch when you are servi...

Page 133: ...zardous substances like parts cleaners primers sealants and sealant removers Failure to comply could result in death or serious injury 0000014en A CAUTION FLYING OBJECT HAZARD ALWAYS wear eye protecti...

Page 134: ...lting in engine damage 0000182en CAUTION NEVER hold the key in the START position for longer than 10 seconds or the starter motor will overheat 0000201en CAUTION Identify all parts and their location...

Page 135: ...Reference Page High Pressure Fuel Pump Pressure Minimum at cranking 250 bar 3625 psi Minimum at low idle 400 bar 5800 psi Maximum at 4000 rpm 1600 bar 23 200 psi Fuel Feed Pump Pressure Minimum All s...

Page 136: ...re Fuel Control Valve on page 12 27 High Pressure Fuel Sensor Retaining Nut 70 N m 52 ft lb Replacing High Pressure Fuel Sensor on page 12 28 High Pressure Pump Sprocket Nut Access Plug M30 x 1 0 70 N...

Page 137: ...t having part numbers must be acquired locally No Tool Name Applicable Model and Tool Size Illustration 1 Diagnostic Tool Obtain Locally 2 Union Nut Wrench For Removing and Installing High Pressure Fu...

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

Page 139: ...Temperature Sensor 6 High Pressure Fuel Pump 7 High Pressure Fuel Supply Line 8 High Pressure Fuel Rail 9 Fuel Injection Line 10 Fuel Injector 11 Fuel Injector Return Hose 12 Common Rail Return Line 1...

Page 140: ...re 6 4 1 Figure 6 5 2 Disconnect the fuel hose from the fuel fine filter inlet Figure 6 5 1 3 Connect test gauge assembly between disconnected ends Install and tighten hose clamps 4 Start engine and s...

Page 141: ...nd tighten hose clamps 4 Start engine and allow speed to stabilize at normal low idle 5 Read and record pressure Specification Results If test pressure reading is not within specifications find and co...

Page 142: ...page 5 70 4 Remove return fuel line from fuel injector See Replacing Injector Return Fuel Line on page 6 28 Figure 6 7 5 If removing only one fuel injector remove the clamp Figure 6 7 1 joining the fu...

Page 143: ...the bottom of the injector seat Cleaning Fuel Injector Cavities 1 Remove fuel injector See Removal of Fuel Injector on page 6 13 Figure 6 10 2 Ensure the injector seal has been removed from the bottom...

Page 144: ...hile covering cavity with cloth to catch debris 11 Inspect to ensure sealing surface is clean Repeat cleaning if necessary 12 Use special tool OEM No 13 5 214 to remove tip special tool OEM No 13 5 21...

Page 145: ...If installing used fuel injectors clean the stem and nozzle prior to installation Figure 6 16 5 Install the injector and retainer as an assembly 6 Install two nuts Figure 6 16 1 and tighten to 8 N m 7...

Page 146: ...el supply system 3 Remove intake manifold and cover intake ports to prevent foreign objects from entering engine See Intake Manifold on page 5 70 4 If removing only one line remove the clamp joining t...

Page 147: ...ines Injection lines having an even numbered last digit are used on even numbered cylinders Injection lines having an odd numbered last digit are used on odd numbered cylinders Start both union nuts o...

Page 148: ...connector 10 Open fuel supply valve 11 Bleed fuel system See Bleeding the Fuel System on page 6 29 12 Start the engine and check for leaks 13 Check and delete any trouble codes that are registered in...

Page 149: ...emove banjo bolt Figure 6 20 3 and disconnect fuel return line 8 Remove high pressure line Figure 6 20 4 between pump and fuel rail using special tool OEM No 13 5 020 Figure 6 21 9 Remove plug Figure...

Page 150: ...ad special tool OEM No 13 5 192 into timing case cover Figure 6 23 Figure 6 24 12 Thread special tool OEM No 13 5 191 without jack screw Figure 6 24 1 into sprocket by hand until firmly seated 13 Thre...

Page 151: ...Figure 6 28 2 Ensure gasket surfaces of the engine block and high pressure pump are clean Install new gasket Figure 6 28 1 Figure 6 29 Note The pump shaft may have a keyway cut into it but no key is...

Page 152: ...y a light coat of oil to O ring and install plug Tighten to M30 x 1 0 70 N m 52 ft lb M40 x 1 5 30 N m 22 ft lb Figure 6 33 IMPORTANT Start both union nuts on high pressure line before tightening eith...

Page 153: ...ure fuel can penetrate your skin and result in serious injury If you are exposed to high pressure fuel spray obtain prompt medical treatment NEVER check for a fuel leak with your hands ALWAYS use a pi...

Page 154: ...and tighten screws securely 7 Install hoses and tighten new clamps to specification See Hose Clamps on page 3 19 8 Connect battery negative cable 9 Bleed the fuel system and check for leaks See Bleed...

Page 155: ...filter bowl Inspect the water sensor probe Figure 6 36 1 for damage Inspect the bowl seal Figure 6 36 2 IMPORTANT When replacing fuel filters always pre fill them with fresh clean fuel to improve the...

Page 156: ...ose and tighten clamp using special socket 11 Connect electrical connectors to fuel pressure sensor and fuel pressure regulator 12 Install high pressure lines See Removing and Installing High Pressure...

Page 157: ...epeat with all fuel injectors IMPORTANT NEVER disassemble fuel return line assembly No individual parts are available and it must be replaced as a complete assembly A DANGER FIRE AND EXPLOSION HAZARD...

Page 158: ...k After fuel system maintenance such as changing a fuel filter draining the fuel filter water separator or replacing a fuel system component The fuel feed pump is ECU controlled and will operate for o...

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

Page 160: ...hermostat 7 9 Repair 7 10 Prepare Engine for Long Term Storage 7 10 Drain Seawater Cooling System 7 10 Check and Replace Zinc Anodes 7 11 Draining and Filling Closed Cooling System 7 12 Disconnect and...

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

Page 162: ...he key in the key switch when you are servicing the engine Someone may accidentally start the engine and not realize you are servicing it This could result in a serious injury If you must service the...

Page 163: ...h or serious injury 0000014en A CAUTION FLYING OBJECT HAZARD ALWAYS wear eye protection when servicing the engine and when using compressed air or high pressure water Dust flying debris compressed air...

Page 164: ...Reference Page Cooling System Test Pressure All 1 4 bar 20 psi See Pressure Testing Cooling System and Filler Cap on page 7 8 Filler Cap Test Pressure All 1 4 bar 20 psi Thermostat Marking Begins Ope...

Page 165: ...eferred to as OEM Part No Tools not having part numbers must be obtained locally MEASURING INSTRUMENTS No Tool Name Applicable Model and Tool Size Illustration 1 Cooling System Tester For pressure tes...

Page 166: ...gine shown 6BY is similar 1 Seawater Supply 2 Seawater Pump 3 Hydraulic Oil Cooler 4 Charge Air Cooler 5 Engine Heat Exchanger 6 Exhaust Elbow 7 Exhaust Seawater Exit 8 Engine Coolant Pump 9 Thermosta...

Page 167: ...ter and adapter in place of the filler cap 4 Pump until pressure is 1 45 bar 21 psi Figure 7 2 5 Pressure should hold steady If the pressure drops there is leakage in the system Start by checking all...

Page 168: ...nd record this number 2 Immerse the thermostat into a container of water Suspend it so that it does not come into contact with the walls or bottom of the container 3 Slowly heat the water and monitor...

Page 169: ...prevent rain or seawater from entering 9 Charge the battery once a month to compensate for battery s self discharge 10 Remove key from key switch and cover key switch with moisture cap if equipped Dr...

Page 170: ...er cooling system and they should be inspected and replaced periodically See Periodic Maintenance Schedule on page 4 8 for the recommended frequency Figure 7 6 Zinc anodes are located in the heat exch...

Page 171: ...ain plug with a new gasket Figure 7 8 5 Install heat exchanger See Remove and Install Heat Exchanger on page 7 16 Ensure the drain cock Figure 7 8 1 on the heat exchanger is closed 6 If not already do...

Page 172: ...position shown 2 Disconnect fitting joint Connect 1 Push metal clip against the fitting into the latched position 2 Ensure the O ring is in place and in good condition 3 Align the two fittings and pu...

Page 173: ...Figure 7 12 1 Drain seawater system See Drain Seawater Cooling System on page 7 10 2 Disconnect seawater pipe between hydraulic oil cooler and charge air cooler Figure 7 12 1 3 Disconnect seawater pip...

Page 174: ...MPORTANT Under no circumstances should caustic soda be used to clean the components 7 Use paraffin based engine detergent to clean the cooler element Thoroughly flush and rinse all components 8 If any...

Page 175: ...7 Remove the heat exchanger 8 Disassemble inspect and clean heat exchanger as necessary See Disassemble and Assemble Heat Exchanger on page 7 16 9 Install the heat exchanger assembly on the engine In...

Page 176: ...16 3 and outlet cover Figure 7 16 1 13 Install new zinc anode Figure 7 16 7 and washer Figure 7 16 6 See Check and Replace Zinc Anodes on page 7 11 14 Install heat exchanger See Remove and Install He...

Page 177: ...ure 7 18 3 7 Remove the old gasket and clean any material off engine block Figure 7 19 8 Cut tabs Figure 7 19 1 of new gasket at locations shown Check gasket fit on engine before proceeding 9 Hold new...

Page 178: ...tat on page 7 9 Installation 1 Clean the thermostat housing and mounting surface of the coolant pump Figure 7 21 2 Ensure the O ring type seal Figure 7 21 1 is in place in the thermostat housing 3 Ins...

Page 179: ...acks broken vanes or excessive wear Replace as necessary 6 Inspect the housing and cover for excessive wear Figure 7 24 Note When installing the new impeller rotate the impeller clockwise to bend the...

Page 180: ...e it must be replaced 4 Cut seawater belt to remove 5 Install new belt on crankshaft pulley and around seawater pump pulley as far as possible Figure 7 26 6 Install special tool Figure 7 26 1 between...

Page 181: ...COOLING SYSTEM 7 22 BY Service Manual Repair This Page Intentionally Left Blank...

Page 182: ...Torque Chart 8 6 Special Service Tools 8 7 Measuring instruments 8 7 Tests and Adjustments 8 8 Engine Oil Flow 8 8 Checking Engine Oil Pressure 8 9 Repair 8 11 Engine Lubrication System Components 8 1...

Page 183: ...LUBRICATION 8 2 BY Service Manual This Page Intentionally Left Blank...

Page 184: ...y clear of the hot engine oil to avoid being burned ALWAYS wear eye protection Failure to comply could result in death or serious injury 0000011en A WARNING ENTANGLEMENT HAZARD Stop the engine before...

Page 185: ...y responsible Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as engine oil diesel fuel and engine coolant Consult the local authori...

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

Page 187: ...Test RPM Specification Oil Pressure 4BY Idle 0 8 bar 12 psi 4000 rpm 3 8 6 0 bar 58 87 psi 6BY Idle 0 7 bar 10psi 4000 rpm 3 8 6 0 bar 55 87 psi Component Tightening Torque Lubricating Oil Applicatio...

Page 188: ...to as Yanmar Part No and BMW part numbers are referred to as OEM Part No Tools not having part numbers must be obtained locally MEASURING INSTRUMENTS No Tool Name Part Number Illustration 1 Oil Pressu...

Page 189: ...ve Adjuster 3 Oil Galleries 4 Piston Cooling Jet 5 Crankshaft Bearings 6 Oil Gallery for Pressure Regulator Valve 7 Oil Pump 8 Oil Return 9 Oil Filter 10 Timing Chain Lubrication Nozzle 11 Port to Tur...

Page 190: ...pressure sensor Figure 8 2 2 Figure 8 3 5 Install special tool OEM No 11 4 050 with O ring Figure 8 3 1 in oil pressure sensor port A WARNING BURN HAZARD Keep your hands and other body parts away from...

Page 191: ...ine speeds Results If the mechanical oil pressure test gauge indicates good oil pressure replace the faulty oil pressure sensor or faulty oil pressure gauge If the mechanical oil pressure test gauge i...

Page 192: ...stem Components Figure 8 5 1 Engine Oil Cooler 2 Oil Filter Housing 3 Oil Pressure Sensor 4 Oil Pressure Sensor Line 5 Turbocharger Lubrication Supply Line 6 Turbocharger 7 Turbocharger Lubrication Re...

Page 193: ...lter cap Figure 8 6 2 1 2 turns with a socket wrench A WARNING BURN HAZARD If you must drain the engine oil while it is still hot stay clear of the hot engine oil to avoid being burned ALWAYS wear eye...

Page 194: ...Approximately 10 minutes after stopping the engine remove the oil dipstick and check the oil level Add oil if the level is too low CAUTION Only use the engine oil specified Other engine oils may affec...

Page 195: ...7 12 2 Remove oil filter element See Replace Engine Oil and Engine Oil Filter Element on page 8 12 Figure 8 8 3 Remove coolant pipe retaining bolt Figure 8 8 1 4 Disconnect coolant pipe Figure 8 8 2 f...

Page 196: ...th coolant 14 Run engine and check for oil or water leaks Remove and Install Oil Filter Housing 1 Drain engine coolant See Draining and Filling Closed Cooling System on page 7 12 2 Remove oil filter c...

Page 197: ...Start the engine and inspect for leaks Remove and Install Oil Sump 1 Remove bolt securing oil dipstick tube to oil filter housing Remove oil dipstick tube from oil pan Figure 8 15 2 Remove bolts Figu...

Page 198: ...oil sump 2 Remove oil sump See Remove and Install Oil Sump on page 8 16 Figure 8 17 3 Remove bolts Figure 8 17 1 2 Remove oil strainer assembly and suction pipe 4 Remove bolts securing oil pump Figure...

Page 199: ...LUBRICATION 8 18 BY Service Manual Repair This Page Intentionally Left Blank...

Page 200: ...ing 9 3 Introduction 9 5 Specifications 9 5 Test and Adjustment Specifications 9 5 Special Torque Chart 9 5 Special Service Tools 9 6 Tests and Adjustments 9 7 Measuring Charge Pressure 9 7 Adjusting...

Page 201: ...TURBOCHARGER 9 2 BY Service Manual This Page Intentionally Left Blank...

Page 202: ...injury 0000034en A WARNING To prevent possible eye injury always wear SAFETY GLASSES while servicing the engine 0000013en A WARNING ENTANGLEMENT HAZARD Stop the engine before you begin to service it...

Page 203: ...ld seriously burn you Failure to comply could result in death or serious injury 0000015enBY A CAUTION FLYING OBJECT HAZARD ALWAYS wear eye protection when servicing the engine and when using compresse...

Page 204: ...23 2 psi Maximum 1750 mbar 25 4 psi See Measuring Charge Pressure on page 9 7 4BY180 Minimum 1650 mbar 23 9 psi Maximum 1800 mbar 26 1 psi 6BY220 Minimum 1900 mbar 27 6 psi Maximum 2020 mbar 29 3 psi...

Page 205: ...are either Yanmar or BMW part numbers Yanmar part numbers are referred to as Yanmar Part No and BMW part numbers are referred to as OEM Part No Tools not having part numbers must be obtained locally...

Page 206: ...uge to the charge air temperature sensor port 3 Operate the engine under normal load conditions at WOT 4000 rpm and take a reading after at least 30 seconds of constant operation Results If the readin...

Page 207: ...warranty Figure 9 2 1 Remove retainer Figure 9 2 1 2 Loosen jam nut Figure 9 2 2 3 Turn wastegate control rod connector Figure 9 2 3 to shorten or lengthen rod Lengthen the rod to reduce charge pressu...

Page 208: ...n page 9 7 Doing so will cause incorrect boost pressure resulting in poor performance or engine damage and can void all warranty 1 Disconnect wastegate control rod Figure 9 3 1 2 Remove the insulating...

Page 209: ...tighten clamps securely 0003787 2 1 3 A DANGER FIRE HAZARD Hot engine surfaces such as the exhaust pipe and turbocharger can cause material such as oil and grease to ignite ALWAYS ensure the exhaust p...

Page 210: ...change the length of the wastegate control rod without doing it in coordination with a charge pressure test See Measuring Charge Pressure on page 9 7 Doing so will cause incorrect boost pressure resu...

Page 211: ...TURBOCHARGER 9 12 BY Service Manual Repair This Page Intentionally Left Blank...

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

Page 213: ...STARTER MOTOR 10 2 BY Service Manual This Page Intentionally Left Blank...

Page 214: ...ng away from moving rotating parts Failure to comply could result in death or serious injury 0000010en A WARNING SHOCK HAZARD Turn off the battery switch if equipped or disconnect the negative battery...

Page 215: ...g the engine and when using compressed air or high pressure water Dust flying debris compressed air pressurized water or steam may injure your eyes Failure to comply may result in minor or moderate in...

Page 216: ...ICATIONS General Specifications Special Torque Chart Item Bosch 4BY Denso 6BY Nominal Power 2 0 kW 2 0 kW Nominal Voltage 12V 12V Test Voltage 13 0 26V 13 0 26V Maximum Operating Temperature 120 C 248...

Page 217: ...projection length Inspect shift lever for deformation return spring for fatigue and pinion for sliding Repair meshing between pinion and ring gear or replace as needed Replace engine oil Repair or re...

Page 218: ...or to the flywheel housing 5 Carefully remove the starter motor IMPORTANT Check the starter pinion for damage If the starter pinion is damaged the flywheel ring gear must also be checked for damage 6...

Page 219: ...STARTER MOTOR 10 8 BY Service Manual Remove and Install Starter Motor This Page Intentionally Left Blank...

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

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

Page 222: ...g away from moving rotating parts Failure to comply could result in death or serious injury 0000010en A WARNING SHOCK HAZARD Turn off the battery switch if equipped or disconnect the negative battery...

Page 223: ...alternator is producing unusual sounds Damage to the alternator will result 0000039en CAUTION Do not remove the positive battery cable from alternator terminal B while the engine is operating Damage t...

Page 224: ...servicing of the 4BY and 6BY charging systems SPECIFICATIONS General Specifications Special Torque Chart Item Specification Manufacturer Valeo Model TG15 150A KSR DF Nominal Voltage 12V Nominal Outpu...

Page 225: ...models Figure 11 1 B shows belt routing for marine gear standard models 4 Use a socket and breaker bar to rotate the belt tensioner and relieve belt tension Remove belt IMPORTANT If belt is to be reus...

Page 226: ...d tighten mounting bolts to 38 N m 28 ft lb 9 Connect cables to alternator Tighten positive cable nut to 13 N m 115 in lb 10 Install idler pulley and install protective cap 11 Install alternator belt...

Page 227: ...ly 7 Loosen bolt Figure 11 4 3 securing tensioning pulley and arm to belt tensioner spring assembly 8 Remove arm and pulley Figure 11 4 4 in direction of arrow Figure 11 5 9 Remove bolts Remove tensio...

Page 228: ...e Control Unit ECU Assignments 12 12 Component Tests 12 14 Relays 12 14 Oil Pressure Sensor 12 15 Fuel Injector 12 16 Engine Coolant Temperature Sensor 12 16 Fuel Rail Pressure Control Valve 12 17 Wat...

Page 229: ...Air Pressure Sensor 12 25 Replacing Charge Air Temperature Sensor 12 25 Replacing Crankshaft Sensor 12 26 Replacing Camshaft Sensor 12 26 Replacing High Pressure Fuel Control Valve 12 27 Replacing Hi...

Page 230: ...d other obstructions before increasing rpm Failure to comply could result in death or serious injury 0000006enMarine A WARNING FUME BURN HAZARD Always read and follow safety related precautions found...

Page 231: ...t Consult the local authorities or reclamation facility NEVER dispose of hazardous materials irresponsibly by dumping them into a sewer on the ground or into ground water or waterways Failure to follo...

Page 232: ...t and replace the components of the electrical system and engine control unit ECU as used on the Yanmar 4BY and 6BY marine engines SPECIFICATIONS Special Torque Chart Item Specification High Pressure...

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

Page 234: ...nnector 8 Instrument Panel 9 Electrical Panel Fuses Relays ECU 10 Starter Motor 11 Crankshaft Speed Sensor 12 Glow Plug Harness Connector 13 Circuit Breaker Boatbuilder Installed Option 14 Battery 15...

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

Page 236: ...nnector 8 Instrument Panel 9 Electrical Panel Fuses Relays ECU 10 Starter Motor 11 Crankshaft Speed Sensor 12 Glow Plug Harness Connector 13 Circuit Breaker Boatbuilder Installed Option 14 Battery 15...

Page 237: ...wer 7 Jumper Fuse F7 3 A Single Starboard Selection 8 Jumper Fuse F8 3 A CAN Analog Throttle Selection 9 K1 Starter Relay 10 K3 Fuel Supply Pump Relay 11 K2 Main Power Relay 12 ECU 13 Connector X1 Com...

Page 238: ...l I O 0 1 A X1 F Error Indicator Check Engine Indicator Input signal for CAN hub 0 5 A X1 G Instrument Power Fused Battery Power Power for accessories 5 A X1 H Warning Indicator 0 5 A X1 J GEAR Switch...

Page 239: ...X1 D KL15 KL87 KL31 F6 182 157 132 154 107 106 180 139 187 115 162 114 243 252 256 239 229 230 250 238 183 111 130 156 178 208 202 204 206 233 246 173 149 151 175 103 127 150 174 102 126 101 125 171...

Page 240: ...ge Air Pressure Sensor 43 Charge Air Temperature Sensor 44 Engine Coolant Temperature Sensor 45 Ignition Power Input from Key Switch terminal X1 D 46 Auxiliary Power Output terminal X1 G 47 CAN to War...

Page 241: ...starter fuel feed pump and main system power The winding ground circuit terminal 85 of all relays is controlled by the ECU Start Relay K1 12 V is supplied by fuse F5 to winding terminal 86 When the s...

Page 242: ...minal 87 2 Pin 4 terminal 85 3 Pin 5 terminal 87 4 Pin 6 terminal 30 Fuel Pump Relay K3 12 V is supplied by fuse F3 to terminal 30 An internal connection connects one end of the winding to terminal 30...

Page 243: ...harness 2 Engine harness Note Polarity in not important Fuel Injector The fuel injectors are continuously supplied with high pressure fuel and are electronically triggered by the ECU The ECU controls...

Page 244: ...Pin 1 Out ECU pin 1 82 2 Pin 2 Ground ECU pin 1 7 Fuel Rail Pressure Control Valve This valve controls the fuel pressure in the fuel rail The ECU uses values supplied by several sensors and sends cor...

Page 245: ...ue is compared with the camshaft speed by the ECU It is mounted on the rear crankshaft seal housing at the rear of the engine The ECU supplies 5V and ground The sensor signal is used by the ECU for Th...

Page 246: ...that the glow plugs are switched on and off Preheating When the coolant temperature is above 25 C 77 F the unit will operate for 0 5 second As temperatures decrease below 25 C 77 F the on time will in...

Page 247: ...ype sensor It is mounted in the fuel line just upstream from the high pressure fuel pump The sensor output is used by the ECU for Protecting the engine from overheating Calculation of the injection ra...

Page 248: ...ure out of range P0087 fuel rail pressure out of range P0089 fuel rail pressure out of range P0090 fuel rail pressure out of range Test Values Resistance at 20 C 68 F 3 0 ohm Figure 12 17 1 Pin 1 12V...

Page 249: ...12 19 1 Pin 1 5V ECU pin 1 39 2 Pin 2 Ground ECU pin 1 80 3 Pin 3 Out ECU pin 1 54 Fuel Rail Pressure Sensor This sensor measures the fuel pressure in the fuel rail The values are used by the ECU for...

Page 250: ...th the ECU with varying signals based on throttle position The ECU then calculates the position of the throttle lever in percent and adjusts fuel injection to adjust engine speed The ECU supplies 5V a...

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

Page 252: ...the lower attaching screws Figure 12 23 3 and remove the ECU 6 Install the new control unit and tighten the screws 7 Connect the electrical connectors to the ECU 8 Connect the electrical panel power...

Page 253: ...ctor 6 Check and delete any trouble codes that are registered in the ECU after the work has been completed Replacing Charge Air Temperature Sensor 1 Disconnect battery negative cable Figure 12 27 2 Di...

Page 254: ...N m 84 in lb 7 Install connector in bracket and connect engine harness 8 Install starter motor See Remove and Install Starter Motor on page 10 7 9 Check and delete any trouble codes that are register...

Page 255: ...Disconnect electrical connector Figure 12 31 1 5 Hold sensor hex Figure 12 31 2 with wrench and loosen retaining nut Figure 12 31 3 6 Remove regulator from fuel rail CAUTION ALWAYS be environmentally...

Page 256: ...y 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...

Page 257: ...led 9 Install sensor in fuel rail Ensure orientation is correct 10 Hold hex of sensor and tighten retaining nut to 70 N m 52 ft lb 11 Connect battery negative cable 12 Bleed fuel system See Bleeding t...

Page 258: ...ge 5 70 8 Bleed fuel system See Bleeding the Fuel System on page 6 29 9 Start engine and check for fuel leaks 0003688A 1 2 A WARNING HIGH PRESSURE HAZARD Avoid skin contact with high pressure diesel f...

Page 259: ...ws Figure 12 34 2 7 Remove fuel volume regulator 8 Installation is done in the reverse of removal Tighten screws to 6 6 N m 58 in lb 9 Connect battery negative cable 10 Open fuel supply valve 11 Bleed...

Page 260: ...e sensor to 23 N m 204 in lb Note Polarity of wire connections is not important Either wire can be connected to either terminal 5 Connect wires A WARNING HIGH PRESSURE HAZARD Avoid skin contact with h...

Page 261: ...ELECTRICAL AND ECU 12 34 BY Service Manual Repair This Page Intentionally Left Blank...

Page 262: ...3 Torque Limitation for Overheat Protection 13 5 Troubleshooting Chart 13 6 Starting Trouble 13 6 Exhaust Color 13 6 Vibration Drive Disengaged 13 7 Vibration Drive Engaged 13 7 Engine Knocks 13 8 Low...

Page 263: ...TROUBLESHOOTING 13 2 BY Service Manual This Page Intentionally Left Blank...

Page 264: ...t temperature sensor Camshaft sensor Boost pressure sensor Rail pressure system Throttle signal missing Sensor supply voltage Metering unit failure Fuel injector failure Rail pressure governor deviati...

Page 265: ...N m Boost pressure abs bar Torque N m Boost pressure abs bar Engine 4BY150 100 normal operation 265 1600 295 700 90 240 700 265 400 80 215 600 240 250 70 185 300 205 100 60 160 150 180 0 50 135 0 150...

Page 266: ...stitute value of the fuel temperature is fixed at 90 C and that sets a limitation of approximately 75 from the maximum torque Figure 13 1 If the coolant temperature is over 108 C an audible alarm soun...

Page 267: ...clogged fine filter Bleed fuel system Blown fuse F3 F4 F5 ECU software problem Low ambient temperature Install optional glow plug control Install block heater Oil viscosity too high Replace with corre...

Page 268: ...m Bleed fuel system Faulty fuel injector Replace as necessary Leaking cylinder head gasket Replace Damaged intake or exhaust valves Repair as necessary Incorrect injection pressure Check replace fuel...

Page 269: ...y Faulty fuel supply pump Replace Low Fuel Injection Pressure Defective fuel pressure regulator sensor Check replace Worn high pressure fuel pump Check replace Injection timing is incorrect ECU softwa...

Page 270: ...ernal leakage Repair as necessary External leakage at connection Repair as necessary Coolant Forced Out of Coolant Recovery Tank Turbocharging pressure enters cooling system via leaking charge air coo...

Page 271: ...sor or other component sending and out of normal range signal to the ECU An example is a disconnected intake air pressure sensor which would set a P0237 code Code Fail Mode Run or Condition Engine Can...

Page 272: ...122 Throttle Signal Both throttle signals are missing short circuit to Ground 1600 yes alarm Throttle Signal Throttle signal 1 is missing short circuit to Ground reduce yes alarm P0123 Throttle Signal...

Page 273: ...hort circuit to B reduce yes alarm P0264 Injector No 2 Short circuit to B reduce yes alarm P0267 Injector No 3 Short circuit to B reduce yes alarm P0270 Injector No 4 Short circuit to B reduce yes ala...

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

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

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