Yanmar BY Series Service Manual
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Yanmar BY Series Service Manual

Yanmar BY Series Service Manual

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BY series
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6BY

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Summary of Contents for Yanmar BY Series

  • Page 1 SERVICE MANUAL BY series...
  • Page 2 BY Service Manual series SERVICE MANUAL P/N:0BBY0-G00100 MARINE ENGINES...
  • Page 3 / or safely. Please contact an authorized Yanmar repair or service professional before working on your Yanmar product.
  • Page 4 TABLE OF 4BY / 6BY Service Manual CONTENTS Page Introduction ..................1-1 Safety....................2-1 General Service Information .............. 3-1 Periodic Maintenance ................. 4-1 Engine ....................5-1 Fuel System ..................6-1 Cooling System ................... 7-1 Lubrication................... 8-1 Turbocharger ..................9-1 Starter Motor..................10-1 Alternator ...................
  • Page 5 TABLE OF CONTENTS This Page Intentionally Left Blank 4BY / 6BY Service Manual...
  • Page 6 BY Service Manual INTRODUCTION This manual gives specific instructions for the proper repair of Yanmar BY series marine engines. Please follow the procedures carefully to ensure quality service. Yanmar recommends that you read this Service Manual completely before starting with repairs, as some of the procedures described are rather complex.
  • Page 7 INTRODUCTION This Page Intentionally Left Blank BY Service Manual...
  • Page 8 Section 2 BY Service Manual SAFETY Yanmar is concerned for your safety and the WARNING condition of your marine engine. Safety statements are one of the primary ways to call your attention to Warning (the word “WARNING” is in the potential hazards associated with Yanmar black letters with an orange rectangle marine engines.
  • Page 9 SAFETY Safety Precautions SAFETY PRECAUTIONS DANGER DANGER CRUSH HAZARD! • ALWAYS use the engine lifting eyes SCALD HAZARD! when lifting the marine engine. The • NEVER remove the coolant filler cap if lifting eyes are engineered to lift the the engine is hot. Steam and hot weight of the marine engine only.
  • Page 10 Safety Precautions SAFETY DANGER DANGER FIRE HAZARD! FIRE AND EXPLOSION HAZARD! • Keep fire extinguishers handy in case • Diesel fuel is flammable and explosive of fire. Clearly indicate the location of under certain conditions. the fire extinguishers with a safety •...
  • Page 11 SAFETY Safety Precautions DANGER DANGER NEVER start the engine unless the air filter is installed. Failure to comply will result in death or serious injury. 0000025en EXPLOSION HAZARD! • NEVER check the remaining battery DANGER charge by shorting out the terminals. This will result in a spark and may cause an explosion or fire.
  • Page 12 Safety Precautions SAFETY DANGER DANGER FIRE AND EXPLOSION HAZARD! CRUSH HAZARD! • Only use the key switch to start the engine. • When you need to transport an engine for repair, have a helper assist you to • NEVER jump-start the engine. Sparks attach it to a hoist and load it on a caused by shorting the battery to the truck.
  • Page 13 SAFETY Safety Precautions WARNING WARNING SEVER HAZARD! EXPOSURE HAZARD! • Keep hands and other body parts away from moving / rotating parts • Wear personal protective equipment such as the flywheel or PTO shaft. such as gloves, work shoes, eye and hearing protection as required by the •...
  • Page 14 ALWAYS use a piece of wood is operating, remove all jewelry, tie or cardboard. Have your authorized back long hair, and keep your hands, Yanmar marine dealer or distributor other body parts and clothing away repair the damage. from moving / rotating parts.
  • Page 15 SAFETY Safety Precautions WARNING WARNING BURN HAZARD! FUME / BURN HAZARD! • Wait until the engine cools before you • Always read and follow safety related drain the engine coolant. Hot engine precautions found on containers of coolant may splash and burn you. hazardous substances like parts cleaners, primers, sealants and •...
  • Page 16 Safety Precautions SAFETY WARNING WARNING EXHAUST HAZARD! BURN HAZARD! • NEVER operate the engine in an • Batteries contain sulfuric acid. NEVER enclosed area such as a garage, allow battery fluid to come in contact tunnel, underground room, manhole or with clothing, skin or eyes.
  • Page 17 SAFETY Safety Precautions CAUTION CAUTION Be sure to secure the engine solidly to prevent injury or damage to parts due to the engine falling during work on the engine. 0000009en FLYING OBJECT HAZARD! CAUTION • ALWAYS wear eye protection when RISK OF CRUSH INJURY servicing the engine and when using The starter motor is very heavy.
  • Page 18 Safety Precautions SAFETY CAUTION CAUTION • Only use the engine oil specified. Keep the piston pin parts, piston Other engine oils may affect warranty assemblies, and connecting rod coverage, cause internal engine assemblies together to be returned to components to seize and / or shorten the same position during the engine life.
  • Page 19 SAFETY Safety Precautions CAUTION CAUTION Protect the air cleaner, turbocharger (if Do not reverse the positive (+) and equipped) and electric components negative (-) ends of the battery cable. from damage when you use steam or The alternator diode and stator coil will high-pressure water to clean the engine.
  • Page 20 Safety Precautions SAFETY CAUTION NEVER operate the engine with the batteries disconnected. Damage to the alternator will result. 0000185en 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.
  • Page 21 SAFETY Safety Precautions This Page Intentionally Left Blank 2-14 BY Service Manual...

  • Page 22: Table Of Contents

    Section 3 BY Service Manual GENERAL SERVICE INFORMATION Page Engine Outline Drawings..............3-3 4BY - Inboard Version (Borg Warner Flange) ......3-3 4BY - Stern Drive Version ............3-4 6BY - Inboard Version (Borg Warner Flange) ......3-5 6BY - Stern Drive Version ............3-6 Engine Piping Diagrams..............
  • Page 23 GENERAL SERVICE INFORMATION Unit Conversions ................3-21 Unit Prefixes ................3-21 Units of Length ................. 3-21 Units of Volume ................ 3-21 Units of Mass................3-21 Units of Force ................3-21 Units of Torque................. 3-21 Units of Pressure..............3-21 Units of Power ................3-21 Units of Temperature..............

  • Page 24: Engine Outline Drawings

    Engine Outline Drawings GENERAL SERVICE INFORMATION ENGINE OUTLINE DRAWINGS Note: All dimensions are metric. Contact Yanmar Marine for the most current drawings. 4BY - Inboard Version (Borg Warner Flange) +0.06 Ø209.55 +0.02 SECTION A-A VIEW S ENGINE MIDDLE 0003569 Figure 3-1...

  • Page 25: 4By - Stern Drive Version

    GENERAL SERVICE INFORMATION Engine Outline Drawings 4BY - Stern Drive Version Note: All dimensions are metric. Contact Yanmar Marine for the most current drawings. SECTION A-A ENGINE MIDDLE 120.65 241.3 0003570 Figure 3-2 BY Service Manual...

  • Page 26: 6By - Inboard Version (Borg Warner Flange)

    Engine Outline Drawings GENERAL SERVICE INFORMATION 6BY - Inboard Version (Borg Warner Flange) Note: All dimensions are metric. Contact Yanmar Marine for the most current drawings. +0.061 Ø209.55 G7 0.015 SECTION A-A ENGINE MIDDLE 222.25 ORIGINAL GEAR 444.5 30.5 30.5...

  • Page 27: 6By - Stern Drive Version

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

  • Page 28: Engine Piping Diagrams

    Engine Piping Diagrams GENERAL SERVICE INFORMATION ENGINE PIPING DIAGRAMS Fuel Flow (10) (11) (17) (15) (12) (16) (11) (18) (13) 0003634 (14) Figure 3-5 Note: Typical 4BY engine shown. 6BY is similar. 1 – Fuel from Tank 14 – Fuel Return from High-Pressure Pump 2 –...
  • Page 29 GENERAL SERVICE INFORMATION Engine Piping Diagrams Cooling Flow (11) (12) 0003635 (10) Figure 3-6 Note: Typical 4BY engine shown. 6BY is similar. 1 – Seawater Supply 2 – Seawater Pump 3 – Hydraulic Oil Cooler 4 – Charge Air Cooler 5 –...

  • Page 30: Location Of Labels

    The following figures show the location of 4 B Y 1 0 8 5 0 7 5 informational labels on Yanmar BY marine engines. 1 1 0 0 7 8 2 4 9 5 1 Engine Nameplates (Typical) Engine Data and Drive Information Labels...

  • Page 31: Diesel Fuel

    • NEVER use Biocide or mix winter and summer fuels. Yanmar recommends a 30 micron fuel filter / water separator (pre-filter) (Figure 3-9, (1)) be installed • Keep the fuel tank and fuel-handling equipment between the fuel tank and the fuel connection point clean at all times.

  • Page 32: Bleeding The Fuel System

    Choose engine oil from the table Recommended Engine Oil on page 3-12. ENGINE OIL Yanmar does not recommend the use of engine oil “additives.” CAUTION • Only use the engine oil specified. Engine Oil Viscosity Other engine oils may affect warranty...

  • Page 33: Recommended Engine Oil

    GENERAL SERVICE INFORMATION Engine Oil Recommended Engine Oil LongLife 01 Oils Trade Name Producer/Supplier Addinol Super power MV 0537 Addinol Lube Oil GmbH Agip Formula LL B 01 ENI S.p.A. Refining and Marketing Division Agip Sint 2000 Evolution ENI S.p.A. Refining and Marketing Division Agip TECSINT SL ENI S.p.A.
  • Page 34 Engine Oil GENERAL SERVICE INFORMATION Trade Name Producer/Supplier Megol Motorenöl New Generation Meguin GmbH Mobil 1 ExxonMobil Mobil 1 Turbo Diesel ExxonMobil Mobil 1 Spezial XS ExxonMobil Motorex Profile B-XL Bucher AG Motorex Select SP-X Bucher AG Motul Specific LL-01 Motul S.A.

  • Page 35: Recommended Marine Gear Or Stern Drive Oil

    GENERAL SERVICE INFORMATION Engine Oil LongLife 04 Oils Trade Name Producer/Supplier Addinol Super power MV 0537 Addinol Lube Oil GmbH Agip Formula MS B04 ENI S.p.A. Aral SuperTronic Aral BMW Longlife-04 Castrol Edge Sport Castrol Limited Castrol Edge Turbo Diesel Castrol Limited Castrol Formula RS Castrol Limited...

  • Page 36: Engine Coolant

    Engine Coolant GENERAL SERVICE INFORMATION ENGINE COOLANT CAUTION • Only use the engine coolant specified. DANGER Other engine coolants may affect warranty coverage, cause an internal buildup of rust and scale and / or shorten engine life. • Prevent dirt and debris from contaminating the engine coolant.

  • Page 37: Recommended Engine Coolant

    GENERAL SERVICE INFORMATION Engine Coolant Following the manufacturer’s recommendations. Remove scale from the cooling system periodically Use the proper LLC which will not have any by flushing the system. adverse effects on the materials (cast iron, aluminum, copper, etc.) of the engine’s fresh water cooling system.

  • Page 38: Principal Engine Specifications

    Principal Engine Specifications GENERAL SERVICE INFORMATION PRINCIPAL ENGINE SPECIFICATIONS Engine Model 4BY150 / 150Z 4BY180 / 180Z 6BY220 / 220Z 6BY260 / 260Z Models numbers with no suffix letter are used in marine gear applications. Application Design Models having a “Z” suffix are used with stern drive. Number of Cylinders In-line 4 In-line 6...
  • Page 39 GENERAL SERVICE INFORMATION Principal Engine Specifications Engine Model 4BY150 / 150Z 4BY180 / 180Z 6BY220 / 220Z 6BY260 / 260Z Coolant Capacity 10.0 L (10.6 qt) 13.5 L (14.3 qt) (Approximate) Seawater Pump Rubber impeller, belt-driven Capacity 140 L/min (37 gpm) at 4000 engine rpm Maximum Lift 2000 mm (78.75 in.) Hydraulic Oil Cooler...

  • Page 40: Tightening Torques For Standard Bolts And Nuts

    Tightening Torques for Standard Bolts and Nuts GENERAL SERVICE INFORMATION TIGHTENING TORQUES FOR STANDARD BOLTS AND NUTS Tightening Fasteners Use the correct amount of torque when tightening fasteners. Applying excessive torque may damage the fastener or component and not enough torque may cause a leak or component failure. Hexagon Bolts and Nuts Grade (Lubricated) Nominal...

  • Page 41: Abbreviations And Symbols

    GENERAL SERVICE INFORMATION Abbreviations and Symbols ABBREVIATIONS AND JASO Japanese Automobile Standards Organization SYMBOLS kelvin kilogram Abbreviations kgf/cm² kilogram force per square centimeter kgf/m kilogram force per meter ampere kilometers kilopascal alternating current kilowatt ACEA Association des Constructeurs liter Européens d’Automobilies L/hr liter per hour ampere-hour...
  • Page 42 Unit Conversions GENERAL SERVICE INFORMATION UNIT CONVERSIONS Units of Torque ft-lb 1.3558 = N·m Unit Prefixes ft-lb 0.1383 = kgf/m in.-lb 0.1130 = N·m Prefix Symbol Power mega x 1,000,000 in.-lb 0.0115 = kgf/m kilo x 1,000 kgf/m 7.2330 = ft-lb centi x 0.01 kgf/m...
  • Page 43 GENERAL SERVICE INFORMATION Unit Conversions This Page Intentionally Left Blank 3-22 BY Service Manual...
  • Page 44 Before You Begin Servicing ............4-2 Introduction..................4-6 The Importance of Periodic Maintenance........4-6 Performing Periodic Maintenance ..........4-6 Yanmar Replacement Parts ............4-6 Required EPA Maintenance ............4-6 EPA Requirements................4-6 Conditions to Ensure Compliance with EPA Emission Standards..............4-6 Inspection and Maintenance............

  • Page 45: Before You Begin Servicing

    PERIODIC MAINTENANCE Before You Begin Servicing BEFORE YOU BEGIN DANGER SERVICING DANGER SCALD HAZARD! • NEVER remove the coolant filler cap if EXPLOSION HAZARD! the engine is hot. Steam and hot engine coolant will escape and • Keep the area around the battery seriously burn you.
  • Page 46 Before You Begin Servicing PERIODIC MAINTENANCE DANGER DANGER FIRE AND EXPLOSION HAZARD! FIRE AND EXPLOSION HAZARD! • Diesel fuel is flammable and explosive • Diesel fuel is flammable and explosive under certain conditions. under certain conditions. • When you remove any fuel system •...
  • Page 47 PERIODIC MAINTENANCE Before You Begin Servicing DANGER WARNING SEVER HAZARD! CRUSH HAZARD! • Keep hands and other body parts • When you need to transport an engine away from moving / rotating parts for repair, have a helper assist you to such as the flywheel or PTO shaft.
  • Page 48 Before You Begin Servicing PERIODIC MAINTENANCE WARNING WARNING EXHAUST HAZARD! BURN HAZARD! • NEVER operate the engine in an • Keep your hands and other body parts enclosed area such as a garage, away from hot engine surfaces such tunnel, underground room, manhole or as the muffler, exhaust pipe, ship’s hold without proper ventilation.

  • Page 49: Introduction

    Introduction INTRODUCTION Yanmar Replacement Parts This section of the Service Manual describes the Yanmar recommends that you use genuine Yanmar procedures for proper care and maintenance of the parts when replacement parts are needed. engine. Genuine replacement parts help ensure long The Importance of Periodic engine life.

  • Page 50: Inspection And Maintenance

    EPA Requirements PERIODIC MAINTENANCE Pay particular attention to these important points: • Replacing the engine oil • Replacing the lube oil filter • Replacing the fuel filter • Cleaning the air filter Note: Inspections are divided into two sections in accordance with who is responsible for performing the inspection: the user or the maker.

  • Page 51: Periodic Maintenance Schedule

    PERIODIC MAINTENANCE Periodic Maintenance Schedule PERIODIC MAINTENANCE SCHEDULE Daily and periodic maintenance is important to keep the engine in good operating condition. The following is a summary of maintenance items by periodic maintenance intervals. Periodic maintenance intervals vary depending on engine application, loads, diesel fuel and engine oil used and are hard to establish definitively.
  • Page 52 Periodic Maintenance Schedule PERIODIC MAINTENANCE : Check : Replace Periodic Maintenance Interval Every 50 Every 250 Every 500 hours or hours or one hours or System Item Daily monthly year 2 years whichever whichever whichever comes first comes first comes first Visual inspection of cooling Before system...
  • Page 53 PERIODIC MAINTENANCE Periodic Maintenance Schedule : Check : Replace Periodic Maintenance Interval Every 50 Every 250 Every 500 hours or hours or one hours or System Item Daily monthly year 2 years whichever whichever whichever comes first comes first comes first Check the alarm and indicators (if equipped) Check or change power steering...

  • Page 54: Periodic Maintenance Procedures

    Periodic Maintenance Procedures PERIODIC MAINTENANCE PERIODIC MAINTENANCE • Check or Replace the Seawater Pump Impeller PROCEDURES • Replace the Turbocharger Heat Shield • Check the Exhaust / Water Mixing Elbow After Initial 50 Hours of Operation • Clean or Replace the Air Filter Element Perform the following maintenance after the initial •...
  • Page 55 PERIODIC MAINTENANCE Periodic Maintenance Procedures This Page Intentionally Left Blank 4-12 BY Service Manual...
  • Page 56 Section 5 BY Service Manual ENGINE Page Before You Begin Servicing ............5-3 Introduction..................5-7 Specifications .................. 5-7 General Information..............5-7 Test and Adjustment Specifications .......... 5-7 Repair Specifications..............5-8 Special Torque Chart ..............5-11 Special Service Tools..............5-14 Measuring Instruments..............5-15 Tests and Adjustments..............
  • Page 57 ENGINE Pistons and Cylinders ..............5-36 Removal and Disassembly of Piston and Connecting Rod ..5-36 Inspection of Pistons and Piston Rings ........5-37 Assembling Piston and Connecting Rod ........5-38 Installation of Piston and Connecting Rod ....... 5-39 Flywheel and Flywheel Housing............. 5-42 Remove and Install Flywheel Housing ........

  • Page 58: Before You Begin Servicing

    Before You Begin Servicing ENGINE BEFORE YOU BEGIN DANGER SERVICING DANGER CRUSH HAZARD! • ALWAYS use the engine lifting eyes FIRE AND EXPLOSION HAZARD! when lifting the marine engine. The lifting eyes are engineered to lift the • Diesel fuel is flammable and explosive weight of the marine engine only.
  • Page 59 ENGINE Before You Begin Servicing WARNING WARNING ENTANGLEMENT HAZARD! FUME / BURN HAZARD! • Stop the engine before you begin to • Always read and follow safety related service it. precautions found on containers of hazardous substances like parts • NEVER leave the key in the key switch cleaners, primers, sealants and when you are servicing the engine.
  • Page 60 Before You Begin Servicing ENGINE CAUTION CAUTION • Only use the engine coolant specified. Other engine coolants may affect warranty coverage, cause an internal buildup of rust and scale and / or shorten engine life. • Prevent dirt and debris from FLYING OBJECT HAZARD! contaminating engine coolant.
  • Page 61 ENGINE Before You Begin Servicing CAUTION Protect the air cleaner, turbocharger (if equipped) and electric components from damage when you use steam or high-pressure water to clean the engine. 0000014en CAUTION NEVER hold the key in the START position for longer than 10 seconds or the starter motor will overheat.

  • Page 62: Introduction

    Introduction ENGINE INTRODUCTION This section of the Service Manual describes the disassembly, inspection, and reassembly of the 4BY and 6BY engines. SPECIFICATIONS General Information Engine Model Number of Cylinders In-Line 4 In-Line 6 Bore 84 mm 84 mm Stroke 90 mm 90 mm Effective Displacement 1995 cc (122 cu in.)

  • Page 63: Repair Specifications

    ENGINE Specifications Repair Specifications Component Remarks Specification Cylinder Head Must Not Be Machined Valve Guides Are Not Available as Replacement Parts 6.0 +0.015 mm Standard Valve Guide ID - Intake (0.2362 +0.0006 in.) 6.0 +0.015 / +0.03 mm Standard Valve Guide ID - Exhaust (0.2362 +0.0006 / +0.0012 in.) 0.5 mm Valve Side Movement (Max.) (Valve-to-Guide Wear)
  • Page 64 Specifications ENGINE Component Remarks Specification 59.977 - 59.983 mm Standard Yellow (2.3613 - 2.3615 in.) 59.970 - 59.976 mm Standard Green (2.3610 - 2.3613 in.) 59.964 - 59.969 mm Standard White (2.3608 - 2.3610 in.) 59.727 - 59.733 mm Undersize 1 (U 0.25) Yellow (2.3514 - 2.3517 in.) 59.720 - 59.726 mm Undersize 1 (U 0.25) Green...
  • Page 65 ENGINE Specifications Component Remarks Specification 0.12 - 0.16 mm 1st Groove Side Clearance (0.005 - 0.006 in.) 0.20 - 0.35 mm 1st Groove End Gap (0.008 - 0.014 in.) Engine Piston, Rings, 0.07 - 0.11 mm 2nd Groove Side Clearance Pins (0.003 - 0.004 in.) 0.30 - 0.45 mm...

  • Page 66: Special Torque Chart

    Special Torque Chart ENGINE SPECIAL TORQUE CHART System Component Model Thread Comments Specification Main Bearing M10x80 Initial Torque 23 N·m (204 in.-lb) Replace, wash and oil Steel Bolts Torque Angle Plus 90° Coolant Drain Plug to M14x1.5 Replace Sealing Ring 25 N·m (221 in.-lb) Crankcase Engine Block...
  • Page 67 ENGINE Special Torque Chart System Component Model Thread Comments Specification Main Bearing Cap Crankshaft and M10x80 Initial Torque 22 N·m (195 in.-lb) Replace Bolts Bearings 12.9 PHR Torque Angle Plus 90° Lightly oil threads Oil Pick-Up to Oil Pump M6x20 10 N·m (89 in.-lb) Oil Pump Reinforcement Shell...
  • Page 68 Special Torque Chart ENGINE System Component Model Thread Comments Specification Fuel Injector in Cylinder Head 9 N·m (80 in.-lb) Cover High-Pressure Line Union M14x1.5 23 N·m (204 in.-lb) Nuts Fuel System Fuel Injection Pressure Sensor to Fuel Rail 70 N·m (52 ft-lb) Nozzles and Lines Pressure Regulator to Fuel 80 N·m (59 ft-lb)

  • Page 69: Special Service Tools

    Note: The tool numbers used in this section 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 70: Measuring Instruments

    Measuring Instruments ENGINE MEASURING INSTRUMENTS Instrument Name Application Illustration Dial Indicator For measuring shaft bend and end play 0000831 Magnetic Stand For holding the dial indicator when measuring 0000833 For measuring the outside diameters of Micrometer crankshaft, pistons, piston pins, etc. 0000834 For measuring the inside diameters of cylinder Cylinder Bore Gauge...
  • Page 71 ENGINE Measuring Instruments Instrument Name Application Illustration For measuring piston ring gaps and piston ring Feeler Gauge side clearance 0000841 5-16 BY Service Manual...

  • Page 72: Tests And Adjustments

    Tests and Adjustments ENGINE TESTS AND ADJUSTMENTS CAUTION NEVER hold the key in the START Testing Compression position for longer than 10 seconds or The compression tester is used to quickly and the starter motor will overheat. simply check wear and damage primarily to the 0000201en cylinder head valves, but also to cylinders and piston rings.

  • Page 73: Repair

    ENGINE Repair REPAIR If the engine is to be completely disassembled, 10. Drain engine oil into a suitable container. perform the following preliminary steps: Remove oil filter. 1. Disconnect battery cables at the battery. Always disconnect negative (-) battery cable first. 2.

  • Page 74: Cylinder Head

    Cylinder Head ENGINE CYLINDER HEAD Cylinder Head Components (15) (14) (13) (12) (10) (11) 0003654 Figure 5-2 1 – Exhaust Camshaft 12 – Head Gasket Identification Holes 2 – Intake Camshaft 13 – Cylinder Head 3 – Hydraulic Rocker Arm Pivot 14 –...

  • Page 75: General Guidelines

    ENGINE Cylinder Head General Guidelines Remove and Install Cylinder Head Cover CAUTION Cylinder Head Cover Components Identify all parts and their location using an appropriate method. It is important that all parts are returned to the same position during the reassembly process. 0000080en IMPORTANT Mark all valve train components so they can...
  • Page 76 Figure 5-5 ( 5 ) 2. Apply a thin uniform bead of Three Bond 1207F (Yanmar part No. 977770-1207F) approximately 2 mm high and 2 mm wide at the transition to each end of the half-moon section (Figure 5-5). 3. Install cylinder head cover gasket. Ensure...

  • Page 77: Remove And Install Glow Plugs

    ENGINE Cylinder Head ( 1 ) R11 0854 A Figure 5-7 Figure 5-6 3. Release locks and remove connector Note: Double-ended bolts (Figure 5-6, (1)) are (Figure 5-7, (1)) from glow plug. used on the inner row only. 4. Install cylinder head cover. Tighten bolts in two stages to 9.5 N·m (84 in.-lb).

  • Page 78: Removal Of Cylinder Head

    Cylinder Head ENGINE Removal of Cylinder Head 8. Remove cylinder head cover. See Remove and Install Cylinder Head Cover on page 5-20. 1. Disconnect negative (-) battery cable. IMPORTANT When working on the oil, coolant or fuel circuits you must protect the alternator from contamination.
  • Page 79 ENGINE Cylinder Head ( 1 ) ( 2 ) 0003766 Figure 5-13 Figure 5-11 16. Remove high-pressure fuel rail. See Removing 12. Remove screw (Figure 5-11, (1)) that retains oil and Installing Fuel Rail on page 6-27. cooler return pipe to cylinder head. 17.
  • Page 80 Cylinder Head ENGINE Figure 5-15 Figure 5-17 19. Remove timing case cover bolts 21. 6BY Engines: Remove cylinder head bolts in (Figure 5-15, (1)). reverse sequence, beginning with number 14 (Figure 5-17). 22. Remove cylinder head. 23. Remove the cylinder head gasket. Figure 5-16 20.

  • Page 81: Disassembly Of Cylinder Head

    ENGINE Cylinder Head Disassembly of Cylinder Head Figure 5-20 Figure 5-18 3. Insert special tool OEM No. 11 9 006 and lock with special tool OEM No. 11 9 005 in direction 1. Attach cylinder head to special tool OEM No. of arrows (Figure 5-20).
  • Page 82 Cylinder Head ENGINE Figure 5-22 Figure 5-24 5. Secure cylinder head to special tool OEM No. 1 – Valve 2 – Valve Stem Seal 11 9 001 (Figure 5-22). 3 – Valve Spring 6. Install spring compressor OEM No. 11 9 015 on 4 –...

  • Page 83: Cleaning Cylinder Head Components

    ENGINE Cylinder Head Cleaning Cylinder Head Components Note: Special tool OEM No. 11 6 407 consists of fourteen screws for mounting special tools 11 6 401 to cylinder head. If WARNING 11 6 407 is not available, use the old cylinder head bolts to secure special tools No.

  • Page 84: Replacing Valve Stem Seals

    Cylinder Head ENGINE Replacing Valve Stem Seals CAUTION 1. Remove the valve spring. It is not necessary to Any part which is found defective as a remove valve. result of inspection or any part whose measured value does not satisfy the standard or limit must be replaced.

  • Page 85: Assembly Of Cylinder Head

    ENGINE Cylinder Head 6. Install valve spring and retainer. Figure 5-30 Figure 5-32 6. Press valve stem seal into place with special tool OEM No. 11 6 380 until it is seated 7. Press down to compress valve spring and lock (Figure 5-30).

  • Page 86: Determining Cylinder Head Gasket Thickness

    Cylinder Head ENGINE Determining Cylinder Head Gasket 5. Slide fixture and indicator over cleaned area of piston (Figure 5-34, (1)). Rotate the crankshaft Thickness to determine the highest point of piston travel 1. Thoroughly clean all old gasket material from and record the measurement.

  • Page 87: Installation Of Cylinder Head

    ENGINE Cylinder Head Installation of Cylinder Head 4BY Engine 1. If the pistons, connecting rods or crankshaft were refurbished or replaced, check piston height to determine correct cylinder head gasket thickness. See Determining Cylinder Head Gasket Thickness on page 5-31. If those items remain unchanged, select a gasket that matches the one removed during disassembly.
  • Page 88 Cylinder Head ENGINE IMPORTANT NEVER reuse cylinder head bolts. New bolts must be installed whenever they are removed. DO NOT wash off bolt coating. 6. Lightly oil threads of new bolts and install new bolts. Tighten the bolts in stages, and in the sequence shown (Figure 5-37).
  • Page 89 ENGINE Cylinder Head IMPORTANT ( 1 ) NEVER mix used valve train components. Whenever installing valve train components, be sure to install them in their original positions. ( 2 ) 17. Install all hydraulic rocker arm pivots and cam followers. 18.
  • Page 90 Cylinder Head ENGINE 24. Install heat exchanger. See Remove and Install ( 2 ) Heat Exchanger on page 7-16. 25. Install turbocharger. See Turbocharger Installation on page 9-10. 26. Fill engine with coolant. 27. Connect negative (-) battery cable. ( 3 ) 28.

  • Page 91: Pistons And Cylinders

    ENGINE Pistons and Cylinders PISTONS AND CYLINDERS Removal and Disassembly of Piston IMPORTANT Engines with high operating hours may and Connecting Rod have a ridge near the top of the cylinders that will catch the piston rings and make it CAUTION impossible to remove the pistons.

  • Page 92: Inspection Of Pistons And Piston Rings

    Pistons and Cylinders ENGINE IMPORTANT 13. Use a piston ring expander (Figure 5-48, (1)) to remove the piston rings, taking care not to Do not allow the connecting rod to bump the scratch the surface of the piston. crankshaft journal during piston removal. Damage to the bearing journal may result.

  • Page 93: Assembling Piston And Connecting Rod

    ENGINE Pistons and Cylinders 2. Clean piston ring grooves using a piston ring Assembling Piston and Connecting groove cleaning tool. Follow tool manufacturer’s instructions for correct operation. 1. Clean the piston and rings thoroughly without 3. Wash pistons in an appropriate solvent using a damaging the ring grooves.

  • Page 94: Installation Of Piston And Connecting Rod

    Pistons and Cylinders ENGINE IMPORTANT Installation of Piston and Connecting Pistons and wrist pins are matched. NEVER mix parts. IMPORTANT 6. Insert the wrist pin and install the second ALL parts that are being reused MUST be retaining ring. installed in their original location and orientation.
  • Page 95 ENGINE Pistons and Cylinders IMPORTANT 7. Position the piston rings so that the ring gaps are distributed evenly (approximately 120° Ensure the bearing inserts, and connecting apart) around the piston and not in line with the rod and cap mounting surfaces are absolutely clean and oil-free.
  • Page 96 Pistons and Cylinders ENGINE 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 Figure 5-61 air, pressurized water or steam may 11. Apply a light coat of clean engine oil to the injure your eyes.

  • Page 97: Flywheel And Flywheel Housing

    ENGINE Flywheel and Flywheel Housing FLYWHEEL AND FLYWHEEL HOUSING Remove and Install Flywheel Housing 4. Remove bolts securing oil sump to flywheel housing. 1. Disconnect the negative (-) battery cable from 5. Remove 11 bolts (Figure 5-63, (3)). Remove the battery. housing (Figure 5-63, (4)).
  • Page 98 Flywheel and Flywheel Housing ENGINE Stern Drive Engines Installation 1. Install flywheel holding tool to prevent flywheel rotation. IMPORTANT ( 4 ) Ensure all mating surfaces are clean and dry. ( 3 ) 2. Stern drive engines: Install coupler adapter and tighten eight bolts to specification.

  • Page 99: Removal Of Flywheel

    ENGINE Flywheel and Flywheel Housing Removal of Flywheel 1. Remove the flywheel housing and drive coupling See Remove and Install Flywheel Housing on page 5-42 and Remove and Install Drive Coupling on page 5-42. ( 2 ) Figure 5-66 ( 1 ) 4.

  • Page 100: Installation Of Flywheel

    Flywheel and Flywheel Housing ENGINE 7. Install bolts and tighten securely. 5. Tighten flywheel bolts to final torque specification. 8. Install oil sump. See Remove and Install Oil Sump on page 8-16. 6. Install drive coupling (See Remove and Install Drive Coupling on page 5-42).

  • Page 101: Camshaft And Timing Gear Train

    ENGINE Camshaft and Timing Gear Train CAMSHAFT AND TIMING GEAR TRAIN Components (22) (21) (20) (19) (18) (17) (16) (13) (12) (15) (14) (10) (11) 0004027 Figure 5-69 5-46 BY Service Manual...
  • Page 102 Camshaft and Timing Gear Train ENGINE 1 – Exhaust Camshaft 2 – Intake Camshaft 3 – Guide Rail 4 – High-Pressure Fuel Pump 5 – Guide Rail Pin 6 – Upper Timing Chain 7 – Sprocket 8 – Timing Case Cover Gasket 9 –...

  • Page 103: Checking And Adjusting Camshaft Timing

    ENGINE Camshaft and Timing Gear Train Checking and Adjusting Camshaft IMPORTANT DO NOT rotate the crankshaft backward. If Timing the crankshaft is turned past TDC, rotate two more turns (720°) to bring No. 1 piston Checking Camshaft Timing back to TDC. 1.
  • Page 104 Camshaft and Timing Gear Train ENGINE Adjusting Camshaft Timing 4. Verify position by checking the camshaft timing marks (Figure 5-74, (2)) on gears are aligned. The single mark on intake camshaft gear must fall between the two marks on the exhaust camshaft gear.

  • Page 105: Removing And Installing Vibration Damper - 4By

    ENGINE Camshaft and Timing Gear Train 0003831 Figure 5-78 Note: A shop-made flywheel holder can be fabricated using a piece of an old ring 0003773 gear. Figure 5-77 Note: Special tool shown on intake camshaft. Exhaust camshaft is checked in the same manner but has no adjustment.

  • Page 106: Removing And Installing Vibration Damper - 6By

    Camshaft and Timing Gear Train ENGINE 0003833 Figure 5-80 8. Tighten bolt to specification. Use a torsion angle tool such as that shown (Figure 5-80). Figure 5-81 Specifications 3. Remove bolts (Figure 5-78, (1)). 4. Remove the vibration damper. Vibration Damper Bolt Specification Torque 5.

  • Page 107: Removing Timing Case Cover

    ENGINE Camshaft and Timing Gear Train Removing Timing Case Cover 10. Remove bolts securing cover and remove timing case cover (Figure 5-82). IMPORTANT When working on the oil, coolant or fuel circuits you must protect the alternator from contamination. Cover alternator with suitable materials.

  • Page 108: Installing Timing Case Cover

    (Figure 5-85, (1)). Install gasket High-Pressure Fuel Pump on page 6-20. (Figure 5-85) and apply a thin coat of Three Bond 1207F (Yanmar part No. 977770-1207F) 6. Remove sprockets and timing chains. sealing agent to gasket at ends (arrow) on both 7.

  • Page 109: Removing And Installing Timing Chain Tensioner

    ENGINE Camshaft and Timing Gear Train Removing and Installing Timing Removal of Camshafts Chain Tensioner CAUTION 1. Remove timing case cover. See Removing Identify all parts and their location using Timing Case Cover on page 5-52. an appropriate method. It is important that all parts are returned to the same position during the reassembly process.
  • Page 110 Camshaft and Timing Gear Train ENGINE 0003774 Figure 5-88 Figure 5-90 Note: One bolt must be removed prior to rotating No. 1 piston to TDC position. 9. Use a wrench (Figure 5-90, (2)) to turn exhaust camshaft (Figure 5-90, (1)) in direction of arrow 6.
  • Page 111 ENGINE Camshaft and Timing Gear Train 13. Secure crankshaft in TDC position with flywheel ( 2 ) holding tool (Figure 5-93). ( 1 ) 0003771 Figure 5-92 11. Rotate the crankshaft in the normal running direction until No. 1 cylinder is at TDC of the Figure 5-94 power stroke.

  • Page 112: Installation Of Camshafts

    Camshaft and Timing Gear Train ENGINE Figure 5-96 Figure 5-98 18. Remove camshaft sprocket (Figure 5-96, (2)) IMPORTANT from chain (Figure 5-96, (1)) as shown by NEVER remove bolts retaining loop casting arrow. (Figure 5-98). Installation of Camshafts 1. Lubricate all camshaft bearings, caps and journals with clean engine oil.
  • Page 113 ENGINE Camshaft and Timing Gear Train Install bearing caps in their proper locations. ( 1 ) • Intake camshaft bearing caps are marked E1 - E7. • Exhaust camshaft bearing caps are marked A1 - A7 5. Lightly oil the threads of all bolts and install finger-tight.
  • Page 114 Camshaft and Timing Gear Train ENGINE This Page Intentionally Left Blank BY Service Manual 5-59...

  • Page 115: Cylinder Block And Crankshaft

    ENGINE Cylinder Block and Crankshaft CYLINDER BLOCK AND CRANKSHAFT Components (17) (16) (18) (12) (15) (13) (14) (12) (10) (11) 0004029 Figure 5-102 5-60 BY Service Manual...
  • Page 116 Cylinder Block and Crankshaft ENGINE 1 – Cylinder Block 2 – Coolant Drain Plug 3 – Seal 4 – Dowel Sleeve 5 – Dowel Sleeve 6 – Piston Cooling Jet 7 – Crankshaft Pulse Generator Wheel 8 – Rear Crankshaft Seal Assembly 9 –...

  • Page 117: Removal Of Crankshaft

    ENGINE Cylinder Block and Crankshaft Removal of Crankshaft 1. Remove flywheel housing. See Remove and Install Flywheel Housing on page 5-42. 2. Remove flywheel. See Removal of Flywheel on page 5-44. 3. Remove rear crankshaft seal housing. See Replacement of Rear Crankshaft Seal on page 5-44.

  • Page 118: Measuring Oil Clearance

    Cylinder Block and Crankshaft ENGINE Measuring Oil Clearance Oil clearance should be checked during disassembly to determine the extent of wear, and during reassembly to ensure long engine life. The same procedure is done for both connecting rods and main bearings. 1.

  • Page 119: Inspection Of Crankshaft

    ENGINE Cylinder Block and Crankshaft Connecting Rod Bearings Figure 5-108 Figure 5-110 6. Compare the width of the flattened 1 – Crankshaft PLASTIGAGE to the graduation marks on the 2 – Oil Clearance package (Figure 5-108, (1)). The mark that 3 –...
  • Page 120 Cylinder Block and Crankshaft ENGINE Crankshaft Specifications Thrust Bearing Specification 25.00 +0.020 / +0.066 mm Main Bearing Standard Specification (0.9842 +0.0008 / +0.0026 in.) Journals 25.2 +0.020 / +0.066 mm 59.977 - 59.983 mm Size 1 Standard Yellow (0.9921 +0.0008 / +0.0026 in.) (2.3613 - 2.3615 in.) 25.4 +0.020 / +0.066 mm 59.970 - 59.976 mm...

  • Page 121: Inspection Of Cylinder Block

    ENGINE Cylinder Block and Crankshaft Inspection of Cylinder Block Crankshaft Installation 1. Remove all main bearing inserts. Ensure the 1. Select the correct bearing as follows: bearing seating surfaces are free of any debris. 2. Ensure that oil passages are clear and unobstructed.
  • Page 122 Cylinder Block and Crankshaft ENGINE IMPORTANT Install ONLY bearing inserts with yellow identifying paint in the cylinder block main bearing bores. 2. Install yellow-painted main bearing inserts in the cylinder block and main bearing caps. Apply a generous amount of clean engine oil to the bearing inserts.

  • Page 123: Replacing Front Crankshaft Seal

    ENGINE Cylinder Block and Crankshaft 8. Loosen bolts of the thrust bearing retaining cap 16. Install vibration damper. See Removing and and tighten finger-tight. Installing Vibration Damper - 4BY on page 5-50 or Removing and Installing Vibration Damper - 9. Move each end of the crankshaft to center 6BY on page 5-51.
  • Page 124 Cylinder Block and Crankshaft ENGINE 6BY Engines Figure 5-119 Figure 5-120 Note: Back the center screw out of the tool before attaching to seal. 7. Install seal protector tool OEM No. 11 7 400 (4BY) or 11 6 470 (6BY) on end of crankshaft. 4.

  • Page 125: Intake Manifold

    ENGINE Intake Manifold 4BY Engines INTAKE MANIFOLD Removal ( 1 ) ( 2 ) 6BY Engines 0003780 Figure 5-122 1. Remove injector harness connectors (Figure 5-122, (1)) from all fuel injectors. 2. Remove screws (Figure 5-122, (2)) and move injector harness out of the way. ( 5 ) ( 3 ) Figure 5-121...

  • Page 126: Installation

    Intake Manifold ENGINE ( 1 ) ( 4 ) ( 2 ) ( 3 ) 0003783 Figure 5-126 Figure 5-124 2. Install new sealing rings (Figure 5-126, (1)). 5. Disconnect inlet (Figure 5-124, (1)) and outlet 3. Check condition of rubber mounts (Figure 5-124, (2)) hoses from the fuel fine (Figure 5-126, (2)) and replace if damaged.

  • Page 127: Exhaust Manifold

    ENGINE Exhaust Manifold 6BY Engine Shown ( 5 ) ( 3 ) ( 1 ) ( 2 ) ( 4 ) ( 1 ) ( 2 ) 0003798 Figure 5-129 0003781 3. Remove nuts (Figure 5-129, (1)). Figure 5-128 4. 6BY Engines: Remove plates (Figure 5-129, (2)).

  • Page 128: Attaching Engine To Repair Stand

    Attaching Engine to Repair Stand ENGINE ATTACHING ENGINE TO REPAIR STAND 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.
  • Page 129 ENGINE Attaching Engine to Repair Stand This Page Intentionally Left Blank 5-74 BY Service Manual...
  • Page 130 Section 6 BY Service Manual FUEL SYSTEM Page Before You Begin Servicing ............6-3 Introduction..................6-6 Specifications .................. 6-6 Test and Adjustment Specifications .......... 6-6 Special Torque Chart..............6-7 Special Service Tools..............6-8 Fuel System Components ............... 6-9 4BY Engines................6-9 6BY Engines................
  • Page 131 FUEL SYSTEM This Page Intentionally Left Blank BY Service Manual...

  • Page 132: Before You Begin Servicing

    Before You Begin Servicing FUEL SYSTEM BEFORE YOU BEGIN WARNING SERVICING DANGER ENTANGLEMENT HAZARD! • Stop the engine before you begin to service it. FIRE AND EXPLOSION HAZARD! • NEVER leave the key in the key switch • Diesel fuel is flammable and explosive when you are servicing the engine.
  • Page 133 • Failure to comply may result in minor hands. ALWAYS use a piece of wood or moderate injury. or cardboard. Have your authorized 0000003en Yanmar marine dealer or distributor repair the damage. CAUTION • Failure to comply could result in death or serious injury.
  • Page 134 Before You Begin Servicing FUEL SYSTEM CAUTION CAUTION Never use a steel wire brush to clean DO NOT remove special tools until fuel injectors. Damage to the nozzle and high-pressure pump is installed. If the other components is likely to result. special tools are removed, the drive sprocket will no longer be held in the 0000172en...

  • Page 135: Introduction

    FUEL SYSTEM Introduction INTRODUCTION This section of the Service Manual describes the procedures necessary to remove, install, and repair fuel system components as used on the Yanmar 4BY and 6BY engines. SPECIFICATIONS Test and Adjustment Specifications Inspection Item Specification Reference Page...
  • Page 136 Specifications FUEL SYSTEM Special Torque Chart Lubricating Oil Application (Thread Component Tightening Torque Reference Page Portion and Seat Surface) Installation of Fuel Fuel Injector Retaining Nut 9 N·m (80 in.-lb) Injector on page 6-16 Replacing High-Pressure Fuel High-Pressure Fuel Regulator Retaining Nut 80 N·m (59 ft-lb) Control Valve on page 12-27...

  • Page 137: Special Service Tools

    Note: The tool numbers used in this section 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 acquired locally.

  • Page 138: Fuel System Components

    Fuel System Components FUEL SYSTEM FUEL SYSTEM COMPONENTS 6BY Engines 4BY Engines Figure 6-1 0003675 Figure 6-2 1 – High-Pressure Line, Cylinders No. 1 and 3 2 – High-Pressure Line, Cylinders No. 2 and 4 1 – High-Pressure Line, Cylinders No. 1, 3 and 5 3 –...

  • Page 139: Fuel Flow Diagram

    FUEL SYSTEM Fuel Flow Diagram FUEL FLOW DIAGRAM (10) (11) (17) (15) (12) (16) (11) (18) (13) 0003634 (14) Figure 6-3 Note: 4BY system shown. 6BY is similar. 1 – Fuel Inlet from Tank 10 – Fuel Injector 2 – Fuel Filter / Water Separator (10 micron) 11 –...

  • Page 140: Tests And Adjustments

    Tests and Adjustments FUEL SYSTEM TESTS AND ADJUSTMENTS IMPORTANT After completing work that involves opening the fuel system do the following: Bleed the system. See Bleeding the Fuel System on page 6-29. Start engine and check for leaks. Allow engine to run until it is running smoothly. Check and delete any trouble codes that are registered in the ECU after the work has 0003682...

  • Page 141: Testing Return Fuel Pressure

    FUEL SYSTEM Tests and Adjustments 6. Repeat procedure at the outlet end of the fuel fine filter (Figure 6-5, (2)). Specification Inspection Item Specification Fuel Feed Pump Pressure 5 bar (73 psi) (Minimum) Results • If pressure reading is not within specification, inspect pre-filter (if equipped), fuel filter / water 0003634A separator, fuel fine filter, and fuel feed pump.

  • Page 142: Repair

    Repair FUEL SYSTEM REPAIR 2. Shut off all valves in the fuel supply system. 3. Remove intake manifold. See Intake Manifold IMPORTANT on page 5-70. After completing work that involves opening 4. Remove return fuel line from fuel injector. See the fuel system do the following: Replacing Injector Return Fuel Line on page 6-28.

  • Page 143: Cleaning Fuel Injector Cavities

    FUEL SYSTEM Repair ( 1 ) Figure 6-8 0003679 Figure 6-10 7. Remove two nuts retaining fuel injector flange. Remove fuel injector and flange. 2. Ensure the injector seal has been removed from the bottom of the injector cavity (Figure 6-10, (1)). ( 4 ) ( 5 ) ( 2 )
  • Page 144 Repair F U E L S Y S T E M Figure 6-14 Figure 6-12 9. Clean sides of cavity by sliding tool in and out 7. Insert brush and sleeve into injector cavity until (Figure 6-14). it touches the bottom (Figure 6-12). CAUTION FLYING OBJECT HAZARD! •...

  • Page 145: Installation Of Fuel Injector

    ALWAYS use a piece of wood 4. Place the retainer (Figure 6-15, (3)) on the or cardboard. Have your authorized injector as shown. Yanmar marine dealer or distributor Note: If installing used fuel injectors, clean the repair the damage. stem and nozzle prior to installation.

  • Page 146: Removing And Installing High-Pressure Fuel Lines

    ALWAYS use a piece of wood When working on the oil, coolant or fuel or cardboard. Have your authorized circuits you must protect the alternator from Yanmar marine dealer or distributor contamination. Cover alternator with repair the damage. suitable materials. Failure to comply may •...
  • Page 147 FUEL SYSTEM Repair 7. Remove high-pressure fuel line(s). IMPORTANT Use care not to mix new high-pressure fuel injection lines. - Injection lines having an even numbered ( 1 ) last digit are used on even-numbered cylinders. - Injection lines having an odd numbered last digit are used on odd-numbered cylinders.

  • Page 148: Replacing The Fuel Feed Pump

    12. Start the engine and check for leaks. or cardboard. Have your authorized 13. Check and delete any trouble codes that are Yanmar marine dealer or distributor registered in the ECU after the work has been repair the damage. completed. See Fault Codes on page 13-20.

  • Page 149: Replacing High-Pressure Fuel Pump

    FUEL SYSTEM Repair Replacing High-Pressure Fuel Pump ( 2 ) ( 4 ) DANGER ( 1 ) ( 3 ) FIRE AND EXPLOSION HAZARD! • Diesel fuel is flammable and explosive under certain conditions. • When you remove any fuel system component to perform maintenance 0003687 (such as changing the fuel filter) place...
  • Page 150 Repair FUEL SYSTEM Figure 6-22 Figure 6-24 10. Hold crankshaft to prevent turning and remove 12. Thread special tool OEM No. 13 5 191 without nut (Figure 6-22, (1)). jack screw (Figure 6-24, (1)) into sprocket by hand until firmly seated. 13.
  • Page 151 FUEL SYSTEM Repair Figure 6-26 Figure 6-28 2. Ensure gasket surfaces of the engine block and CAUTION high-pressure pump are clean. Install new gasket (Figure 6-28, (1)). DO NOT remove special tools until high-pressure pump is installed. If the special tools are removed, the drive sprocket will no longer be held in the correct position for reassembly.
  • Page 152 Repair FUEL SYSTEM R13 0673A Figure 6-30 Figure 6-32 4. Remove special tool OEM No. 13 5 192 from 6. Install new O-ring on plug (Figure 6-32, (1)). timing case cover (Figure 6-30). Apply a light coat of oil to O-ring and install plug.

  • Page 153: Replacing Fuel Filters

    • NEVER check for a fuel leak with your 0000009en hands. ALWAYS use a piece of wood or cardboard. Have your authorized Yanmar marine dealer or distributor repair the damage. • Failure to comply could result in death or serious injury.
  • Page 154 Repair FUEL SYSTEM CAUTION • ALWAYS be environmentally responsible. • Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as engine oil, diesel fuel and engine coolant. Consult the local authorities or reclamation facility. •...
  • Page 155 FUEL SYSTEM Repair Replacing the Fuel Filter / Water Separator 1. Disconnect the battery negative (-) cable. 2. Close the fuel supply valve. ( 2 ) ( 1 ) ( 3 ) 0003649 0003650 Figure 6-35 Figure 6-36 3. Loosen the drain plug (Figure 6-35, (3)) on the 6.

  • Page 156: Removing And Installing Fuel Rail

    0003677B hands. ALWAYS use a piece of wood Figure 6-38 or cardboard. Have your authorized Yanmar marine dealer or distributor 5. Remove all high-pressure fuel lines repair the damage. (Figure 6-38, (1)). See Removing and Installing High-Pressure Fuel Lines on page 6-17.

  • Page 157: Replacing Injector Return Fuel Line

    FUEL SYSTEM Repair Replacing Injector Return Fuel Line DANGER FIRE AND EXPLOSION HAZARD! • Diesel fuel is flammable and explosive under certain conditions. • When you remove any fuel system component to perform maintenance Figure 6-39 (such as changing the fuel filter) place an approved container under the IMPORTANT opening to catch the fuel.

  • Page 158: Bleeding The Fuel System

    Repair FUEL SYSTEM Bleeding the Fuel System The fuel system needs to be bled under the following conditions: ( 1 ) • Before starting the engine for the first time. • After running out of fuel and fuel has been added to the fuel tank.
  • Page 159 FUEL SYSTEM Repair This Page Intentionally Left Blank 6-30 BY Service Manual...
  • Page 160 Section 7 BY Service Manual COOLING SYSTEM Page Before You Begin Servicing ............7-3 Introduction..................7-5 Specifications .................. 7-5 Test and Adjustment Specifications .......... 7-5 Repair Specifications..............7-5 Special Torque Chart..............7-5 Special Service Tools..............7-6 Measuring Instruments..............7-6 Cooling Flow Diagram ..............7-7 Tests and Adjustments..............
  • Page 161 COOLING SYSTEM This Page Intentionally Left Blank BY Service Manual...

  • Page 162: Before You Begin Servicing

    Before You Begin Servicing COOLING SYSTEM BEFORE YOU BEGIN WARNING SERVICING DANGER ENTANGLEMENT HAZARD! • Stop the engine before you begin to service it. • NEVER leave the key in the key switch SCALD HAZARD! when you are servicing the engine. •...
  • Page 163 COOLING SYSTEM Before You Begin Servicing WARNING CAUTION FUME / BURN HAZARD! PINCH HAZARD! • Always read and follow safety related Use care not to catch finger between precautions found on containers of belt and pulley while installing belt. hazardous substances like parts Failure to comply may result in minor or cleaners, primers, sealants and moderate injury.

  • Page 164: Introduction

    Introduction COOLING SYSTEM INTRODUCTION This section of the Service Manual describes the procedures necessary to service the 4BY and 6BY marine engine cooling systems. SPECIFICATIONS Test and Adjustment Specifications Note: All pressure specifications are with engine at normal operating temperature. Inspection Item Model Specification...

  • Page 165: Special Service Tools

    Note: The tool numbers used in this section 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 166: Cooling Flow Diagram

    Cooling Flow Diagram COOLING SYSTEM COOLING FLOW DIAGRAM (11) (12) 0003635 (10) Figure 7-1 Note: Typical 4BY engine shown. 6BY is similar. 1 – Seawater Supply 2 – Seawater Pump 3 – Hydraulic Oil Cooler 4 – Charge Air Cooler 5 –...

  • Page 167: Tests And Adjustments

    TESTS AND ADJUSTMENTS Pressure Testing Cooling System and Filler Cap Cooling System Use a cooling system tester with connections compatible with the Yanmar BY series cooling system. DANGER 0003702 Figure 7-2 3. Install the tester and adapter in place of the filler cap.

  • Page 168: Testing Thermostat

    Tests and Adjustments COOLING SYSTEM Filler Cap Testing Thermostat 1. The design temperature for the thermostat is stamped into the thermostat body. Find and record this number. 2. Immerse the thermostat into a container of water. Suspend it so that it does not come into contact with the walls or bottom of the container.

  • Page 169: Repair

    COOLING SYSTEM Repair REPAIR Drain Seawater Cooling System IMPORTANT Prepare Engine for Long-Term If water fails to drain from any open drain Storage cock or port, remove the cock completely and probe the opening with a small piece of IMPORTANT wire to loosen debris.

  • Page 170: Check And Replace Zinc Anodes

    Repair COOLING SYSTEM Check and Replace Zinc Anodes There are zinc anodes in the seawater cooling system and they should be inspected and replaced periodically. See Periodic Maintenance Schedule on page 4-8 for the recommended frequency. ( 1 ) 0003663 Figure 7-5 6.

  • Page 171: Draining And Filling Closed Cooling System

    COOLING SYSTEM Repair Draining and Filling Closed Cooling System ( 1 ) DANGER SCALD HAZARD! • NEVER remove the coolant filler cap if the engine is hot. Steam and hot 0003660 engine coolant will escape and seriously burn you. Allow the engine Figure 7-7 to cool before attempting to remove Note: The charge air cooler has been removed...

  • Page 172: Disconnect And Connect Quick-Connect Fittings

    Repair COOLING SYSTEM 7. Inspect the cap gasket and flange on the filler 2. Ensure the O-ring is in place and in good neck for damage. condition. 8. Check the rubber hose connecting the coolant 3. Align the two fittings and push together until the recovery tank to the heat exchanger.

  • Page 173: Inspect And Clean Hydraulic Oil Cooler

    COOLING SYSTEM Repair 11. Check level of power steering fluid or marine Remove and Install Charge Air gear oil and add if necessary. Cooler Inspect and Clean Hydraulic Oil Cooler ( 5 ) ( 1 ) ( 2 ) ( 4 ) ( 2 ) ( 6 ) 0003659D...

  • Page 174: Disassemble And Assemble Charge Air Cooler

    Repair COOLING SYSTEM 13. Install and secure air inlet pipe between 8. If any internal deposits remain in the tubes, turbocharger and intake air cooler. consult a local radiator repair shop. 14. Start the engine and check for coolant leaks. Note: Always install new O-rings.

  • Page 175: Remove And Install Heat Exchanger

    COOLING SYSTEM Repair Remove and Install Heat Exchanger ( 1 ) ( 2 ) ( 3 ) ( 7 ) ( 7 ) 0003695 Figure 7-15 10. Install two new O-rings on coolant pipe 0003659E (Figure 7-15, (1)) and connect to heat Figure 7-14 exchanger.

  • Page 176: Remove And Install Coolant Pump

    Repair COOLING SYSTEM 12. Install spacer (Figure 7-16, (2)), remaining O-ring (Figure 7-16, (3)), and outlet cover (Figure 7-16, (1)). 13. Install new zinc anode (Figure 7-16, (7)) and washer (Figure 7-16, (6)). See Check and Replace Zinc Anodes on page 7-11. 14.
  • Page 177 COOLING SYSTEM Repair IMPORTANT Use caution not to damage the sealing surface of the cylinder block when cutting old gasket. 6. Cut old gasket (Figure 7-18, (2)) at locations (Figure 7-18, (1)) using a sharp chisel (Figure 7-18, (3)). 7. Remove the old gasket and clean any material off engine block.

  • Page 178: Remove And Install Thermostat

    Repair COOLING SYSTEM Remove and Install Thermostat 5. Remove four bolts (Figure 7-20, (2)). Note: The thermostat and housing are serviced as a single assembly. CAUTION 6. Remove the thermostat and housing assembly and pull off from coolant pipe (Figure 7-20, (1)). 7.

  • Page 179: Seawater Pump

    COOLING SYSTEM Repair Seawater Pump 6. Inspect the housing and cover for excessive wear. Inspect / Replace Impeller ( 1 ) 0003655 Figure 7-22 1. Drain the seawater circuit by loosening the drain cock (Figure 7-22, (1)) in the outlet pipe. 2.
  • Page 180 Repair COOLING SYSTEM ( 2 ) ( 2 ) ( 1 ) ( 1 ) 0003697 0003691 Figure 7-25 Figure 7-26 3. Disconnect seawater supply hose from 6. Install special tool (Figure 7-26, (1)) between seawater pump. seawater pump pulley and belt. 4.
  • Page 181 COOLING SYSTEM Repair This Page Intentionally Left Blank 7-22 BY Service Manual...
  • Page 182 Section 8 BY Service Manual LUBRICATION Page Before You Begin Servicing ............8-3 Introduction..................8-6 Specifications .................. 8-6 Test and Adjustment Specifications .......... 8-6 Special Torque Chart..............8-6 Special Service Tools..............8-7 Measuring instruments ..............8-7 Tests and Adjustments..............8-8 Engine Oil Flow .................
  • Page 183 LUBRICATION This Page Intentionally Left Blank BY Service Manual...

  • Page 184: Before You Begin Servicing

    Before You Begin Servicing LUBRICATION BEFORE YOU BEGIN WARNING SERVICING DANGER ENTANGLEMENT HAZARD! • Stop the engine before you begin to service it. • NEVER leave the key in the key switch CRUSH HAZARD! when you are servicing the engine. •...
  • Page 185 LUBRICATION Before You Begin Servicing CAUTION WARNING BURN HAZARD! • ALWAYS be environmentally responsible. • Keep your hands and other body parts away from hot engine surfaces such • Follow the guidelines of the EPA or as the muffler, exhaust pipe, other governmental agencies for the turbocharger and engine block during proper disposal of hazardous...
  • Page 186 Before You Begin Servicing LUBRICATION CAUTION If the oil pump must be replaced, replace it as an assembly only. Do not replace individual components. 0000030en BY Service Manual...

  • Page 187: Introduction

    LUBRICATION Introduction INTRODUCTION This section of the Service Manual describes the procedures necessary to service the 4BY and 6BY lubrication systems. SPECIFICATIONS Test and Adjustment Specifications Note: All pressure specifications are with engine at normal operating temperature. Inspection Item Model Test RPM Specification Idle...

  • Page 188: Special Service Tools

    Note: The tool numbers used in this section 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 189: Tests And Adjustments

    LUBRICATION Tests and Adjustments TESTS AND ADJUSTMENTS Engine Oil Flow (11) (12) (10) 0003789 Figure 8-1 1 – Camshaft Bearings 2 – Hydraulic Valve Adjuster 3 – Oil Galleries 4 – Piston Cooling Jet 5 – Crankshaft Bearings 6 – Oil Gallery for Pressure Regulator Valve 7 –...

  • Page 190: Checking Engine Oil Pressure

    Tests and Adjustments LUBRICATION Checking Engine Oil Pressure ( 1 ) Perform an engine oil pressure check if there is any indication of low oil pressure. ( 2 ) 1. Start the engine and allow it to warm to normal operating temperature.
  • Page 191 LUBRICATION Tests and Adjustments Figure 8-4 Note: Special tools OEM No. 13 6 054, 13 6 051, and O-ring (Figure 8-4, (1)) are used with DIS Tester. 6. Connect test pressure gauge (Figure 8-4) special tool OEM No. 13 3 063 and 13 3 061. 7.

  • Page 192: Repair

    Repair LUBRICATION REPAIR Engine Lubrication System Components ( 1 ) ( 2 ) ( 3 ) ( 4 ) ( 5 ) ( 6 ) ( 7 ) ( 8 ) ( 9 ) 0003788 Figure 8-5 1 – Engine Oil Cooler 2 –...

  • Page 193: Replace Engine Oil And Engine Oil Filter Element

    LUBRICATION Repair Replace Engine Oil and Engine Oil CAUTION Filter Element The engine oil on a new engine becomes contaminated from the initial break-in of internal parts. It is very important that the initial oil replacement is performed as scheduled. •...
  • Page 194 Repair LUBRICATION 4. Remove the engine oil dipstick 11. Fill with new engine oil. (Figure 8-6, (1)). Attach an oil drain pump and CAUTION pump out the oil. Dispose of waste properly. 5. Remove the engine oil cap and filter assembly. •...

  • Page 195: Remove And Install Oil Cooler

    LUBRICATION Repair Remove and Install Oil Cooler ( 1 ) ( 2 ) IMPORTANT When working on the oil, coolant or fuel circuits you must protect the alternator from ( 3 ) contamination. Cover alternator with suitable materials. Failure to comply may result in an alternator failure.

  • Page 196: Remove And Install Oil Filter Housing

    Repair LUBRICATION Remove and Install Oil Filter Housing 1. Drain engine coolant. See Draining and Filling Closed Cooling System on page 7-12. 2. Remove oil filter cartridge. See Replace Engine Oil and Engine Oil Filter Element on page 8-12. ( 1 ) ( 2 ) 0003791 Figure 8-11...

  • Page 197: Remove And Install Oil Sump

    LUBRICATION Repair ( 2 ) ( 1 ) ( 3 ) ( 1 ) 0003795 0003793 Figure 8-15 Figure 8-14 2. Remove bolts (Figure 8-15, (1)) that secure oil 6. Remove coolant pipe (Figure 8-14, (1)) from sump to flywheel housing. engine.

  • Page 198: Oil Pump

    Repair LUBRICATION 8. If removed, install oil drain plug and tighten to 3. Install oil sump. See Remove and Install Oil 25 N·m (221 in.-lb). Sump on page 8-16. 9. Fill engine with clean engine oil. 4. Fill crankcase to proper level with new engine oil.
  • Page 199 LUBRICATION Repair This Page Intentionally Left Blank 8-18 BY Service Manual...
  • Page 200 Section 9 BY Service Manual TURBOCHARGER Page Before You Begin Servicing ............9-3 Introduction..................9-5 Specifications .................. 9-5 Test and Adjustment Specifications .......... 9-5 Special Torque Chart..............9-5 Special Service Tools..............9-6 Tests and Adjustments..............9-7 Measuring Charge Pressure............9-7 Adjusting Charge Pressure - 4BY..........
  • Page 201 TURBOCHARGER This Page Intentionally Left Blank BY Service Manual...

  • Page 202: Before You Begin Servicing

    Before You Begin Servicing TURBOCHARGER BEFORE YOU BEGIN SERVICING DANGER WARNING FIRE HAZARD! ENTANGLEMENT HAZARD! Hot engine surfaces, such as the • Stop the engine before you begin to exhaust pipe and turbocharger can service it. cause material such as oil and grease to •...
  • Page 203 TURBOCHARGER Before You Begin Servicing CAUTION WARNING 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 BURN HAZARD! • Keep your hands and other body parts away from hot engine surfaces such as the muffler, exhaust pipe, turbocharger and engine block during...

  • Page 204: Introduction

    Introduction TURBOCHARGER INTRODUCTION This section of the Service Manual describes the removal, inspection, and installation of turbochargers used on 4BY and 6BY engines. SPECIFICATIONS Test and Adjustment Specifications Inspection Item Engine Limit Reference Page Minimum - 1600 mbar Maximum - 1750 mbar 4BY150 (23.2 psi) (25.4 psi)

  • Page 205: Special Service Tools

    Note: The tool numbers used in this section 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: Tests And Adjustments

    Tests and Adjustments TURBOCHARGER TESTS AND ADJUSTMENTS Specifications Inspection Item Engine Limit Measuring Charge Pressure Minimum Maximum The turbocharger charge pressure can be 4BY150 1600 mbar 1750 mbar (23.2 psi) (25.4 psi) measured using console digital display. Minimum Maximum Low charge pressure can be due to compressor 4BY180 1650 mbar 1800 mbar...

  • Page 207: Adjusting Charge Pressure - 4By

    TURBOCHARGER Tests and Adjustments Adjusting Charge Pressure - 4BY 5. Operate engine under normal load conditions and verify pressure reading is within Note: The waste gate control rod on 6BY specification. See Measuring Charge Pressure engines is not adjustable. on page 9-7. IMPORTANT NEVER change the length of the wastegate control rod without doing it in coordination...

  • Page 208: Repair

    Repair TURBOCHARGER REPAIR Turbocharger Removal IMPORTANT Observe strict cleanliness procedures at all times when working on the turbocharger. Never leave connections for oil inlets or outlets unprotected. Foreign bodies in the bearing housing will lead to turbocharger breakdown. ( 1 ) ( 2 ) ( 3 ) 0003787...

  • Page 209: Turbocharger Installation

    TURBOCHARGER Repair Turbocharger Installation DANGER Note: When installing the turbocharger, replace all gaskets with new ones. Change the oil and oil filter. 1. Clean mounting surfaces of all gasket material. FIRE HAZARD! Hot engine surfaces, such as the exhaust pipe and turbocharger can cause material such as oil and grease to ignite.
  • Page 210 Repair TURBOCHARGER ( 1 ) ( 2 ) ( 3 ) ( 4 ) ( 6 ) ( 5 ) 0003786 Figure 9-6 5. Connect mixing elbow to turbocharger and tighten clamps (Figure 9-6, (6)) securely. 6. Install new gaskets and connect lubrication return line (Figure 9-6, (4)) and supply line (Figure 9-6, (3)).
  • Page 211 TURBOCHARGER Repair This Page Intentionally Left Blank 9-12 BY Service Manual...
  • Page 212 Section 10 BY Service Manual STARTER MOTOR Page Before You Begin Servicing ............10-3 Introduction..................10-5 Starter Motor Specifications ............10-5 General Specifications............. 10-5 Special Torque Chart............... 10-5 Starter Motor Troubleshooting............10-6 Remove and Install Starter Motor..........10-7 BY Service Manual 10-1...
  • Page 213 STARTER MOTOR This Page Intentionally Left Blank 10-2 BY Service Manual...
  • Page 214 Before You Begin Servicing STARTER MOTOR BEFORE YOU BEGIN WARNING SERVICING WARNING SHOCK HAZARD! • Turn off the battery switch (if equipped) or disconnect the negative ENTANGLEMENT HAZARD! battery cable before servicing the • Stop the engine before you begin to electrical system.
  • Page 215 STARTER MOTOR Before You Begin Servicing 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. •...
  • Page 216 Introduction STARTER MOTOR INTRODUCTION This section of the Service Manual covers servicing of starter motor on 4BY and 6BY engines. STARTER MOTOR SPECIFICATIONS General Specifications Item Bosch (4BY) Denso (6BY) Nominal Power 2.0 kW 2.0 kW Nominal Voltage Test Voltage 13 ±...
  • Page 217 STARTER MOTOR Starter Motor Troubleshooting STARTER MOTOR TROUBLESHOOTING 0000102 10-6 BY Service Manual...
  • Page 218 Remove and Install Starter Motor STARTER MOTOR REMOVE AND INSTALL IMPORTANT Check the starter pinion for damage. If the STARTER MOTOR starter pinion is damaged, the flywheel ring gear must also be checked for damage. 1. Disconnect the battery negative (-) cable and turn the battery master switch OFF (if 6.
  • Page 219 STARTER MOTOR Remove and Install Starter Motor This Page Intentionally Left Blank 10-8 BY Service Manual...
  • Page 220 Section 11 BY Service Manual ALTERNATOR Page Before You Begin Servicing ............11-3 Introduction..................11-5 Specifications ................11-5 General Specifications............. 11-5 Special Torque Chart............... 11-5 Repair.................... 11-6 Replace Alternator Belt............11-6 Remove and Install Alternator ..........11-7 Remove and Install Alternator Belt Tensioner ......11-7 BY Service Manual 11-1...
  • Page 221 ALTERNATOR This Page Intentionally Left Blank 11-2 BY Service Manual...

  • Page 222: Before You Begin Servicing

    Before You Begin Servicing ALTERNATOR BEFORE YOU BEGIN WARNING SERVICING WARNING SHOCK HAZARD! • Turn off the battery switch (if equipped) or disconnect the negative ENTANGLEMENT HAZARD! battery cable before servicing the • Stop the engine before you begin to electrical system.
  • Page 223 ALTERNATOR Before You Begin Servicing CAUTION CAUTION Do not remove the positive (+) battery cable from alternator terminal B while the engine is operating. Damage to the alternator will result. 0000037en FLYING OBJECT HAZARD! CAUTION • ALWAYS wear eye protection when NEVER operate the engine with the servicing the engine and when using batteries disconnected.

  • Page 224: Introduction

    Introduction ALTERNATOR INTRODUCTION This section of the Service Manual describes servicing of the 4BY and 6BY charging systems. SPECIFICATIONS General Specifications Item Specification Manufacturer Valeo Model TG15 150A KSR-DF Nominal Voltage Nominal Output 150A Special Torque Chart Item Specification Alternator Mounting Bolts 38 N·m (28 ft-lb) Positive Cable Nut 13 N·m (115 in.lb)

  • Page 225: Repair

    ALTERNATOR Repair REPAIR CAUTION Replace Alternator Belt 1. Disconnect battery negative (-) cable from the battery. 2. Remove belt guard. 3. Remove seawater pump belt. See Replace PINCH HAZARD! Seawater Pump Belt on page 7-21. Use care not to catch finger between Belt Routing belt and pulley while installing belt.

  • Page 226: Remove And Install Alternator

    Repair ALTERNATOR Remove and Install Alternator 7. Remove two bolts (Figure 11-3, (3)) and remove alternator from engine. 1. Disconnect battery negative (-) cable from the 8. Install alternator and tighten mounting bolts to battery. 38 N·m (28 ft-lb). 2. Remove belt guard. 9.
  • Page 227 ALTERNATOR Repair Note: Bolt (Figure 11-4, (3)) must be removed and installed with the belt tensioner spring assembly. 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.
  • Page 228 Section 12 BY Service Manual ELECTRICAL AND Page Before You Begin Servicing ............12-3 Introduction..................12-5 Specifications ................12-5 Special Torque Chart............... 12-5 Function Description - Engine Management System ....12-6 Component Locations.............. 12-6 Electrical Panel Connector (X1) Connections ....... 12-11 Engine Control Unit (ECU) Assignments.......
  • Page 229 ELECTRICAL AND ECU Repair....................12-24 Replacing Engine Control Unit (ECU) ........12-24 Replace Coolant Temperature Sensor........12-24 Replacing Charge Air Pressure Sensor ......... 12-25 Replacing Charge Air Temperature Sensor ......12-25 Replacing Crankshaft Sensor..........12-26 Replacing Camshaft Sensor........... 12-26 Replacing High-Pressure Fuel Control Valve......12-27 Replacing High-Pressure Fuel Sensor ........

  • Page 230: Before You Begin Servicing

    ALWAYS use a piece of wood obstructions before increasing rpm. or cardboard. Have your authorized • Failure to comply could result in death Yanmar marine dealer or distributor or serious injury. repair the damage. 0000006enMarine • Failure to comply could result in death or serious injury.
  • Page 231 ELECTRICAL AND ECU Before You Begin Servicing CAUTION • ALWAYS be environmentally responsible. • Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as engine oil, diesel fuel and engine coolant. Consult the local authorities or reclamation facility.

  • Page 232: Introduction

    ELECTRICAL AND ECU INTRODUCTION This section of the Service Manual describes the operation of and procedures to test and replace the components of the electrical system and engine control unit (ECU) as used on the Yanmar 4BY and 6BY marine engines. SPECIFICATIONS...

  • Page 233: Function Description - Engine Management System

    ELECTRICAL AND ECU Function Description - Engine Management System FUNCTION DESCRIPTION - ENGINE MANAGEMENT SYSTEM Component Locations Figure 12-1 12-6 BY Service Manual...
  • Page 234 Function Description - Engine Management System ELECTRICAL AND ECU 1 – Oil Pressure Sensor 2 – Fuel Injectors 3 – Engine Coolant Temperature Sensor 4 – Fuel Rail Pressure Control Valve 5 – Low-Pressure Fuel Pump 6 – Water-in-Fuel Sensor 7 –...
  • Page 235 ELECTRICAL AND ECU Function Description - Engine Management System 0004120 Figure 12-2 12-8 BY Service Manual...
  • Page 236 Function Description - Engine Management System ELECTRICAL AND ECU 1 – Oil Pressure Sensor 2 – Fuel Injectors 3 – Engine Coolant Temperature Sensor 4 – Fuel Rail Pressure Control Valve 5 – Low-Pressure Fuel Pump 6 – Water-in-Fuel Sensor 7 –...
  • Page 237 ELECTRICAL AND ECU Function Description - Engine Management System Electrical Panel Components ( 2 ) ( 4 ) ( 1 ) ( 6 ) ( 3 ) ( 8 ) ( 5 ) ( 10 ) ( 13 ) ( 7 ) ( 9 ) ( 11 ) ( 14 )

  • Page 238: Electrical Panel Connector (X1) Connections

    Function Description - Engine Management System ELECTRICAL AND ECU Electrical Panel Connector (X1) Connections The ECU is connected to other components and systems via connector X1 (Figure 12-4). The graphic and table show the pin locations and assignments. R Q P 0003304 Figure 12-4 Connector X1 Pin Assignments...
  • Page 239 ELECTRICAL AND ECU Function Description - Engine Management System Engine Control Unit (ECU) Assignments (10) (8) (9) ( 4 ) ( 5 ) X1/C KL50 KL15 KL87 (49) 201 203 205 (12) (211, 224) (11) X1/B ϑ ϑ X1/H (48) (44) (13) (43)
  • Page 240 Function Description - Engine Management System ELECTRICAL AND ECU 1 – Engine Control Unit (ECU) 27 – CAN Signal - Low 2 – Internal ECU Sensors (operating voltage 28 – CAN Signal - High and ambient air pressure) 29 – Panel, ECU, and CAN Ground 3 –...

  • Page 241: Component Tests

    ELECTRICAL AND ECU Component Tests Not all inputs are monitored by the ECU. Low oil pressure and water in fuel are two examples. Either of these conditions will result in a warning indicator and possible audible alarm. Low oil pressure will also be indicated by the oil gauge at the helm.
  • Page 242 Component Tests ELECTRICAL AND ECU Main Relay (K2) Fuel Pump Relay (K3) 12 V is supplied directly to terminal 30. An internal 12 V is supplied by fuse F3 to terminal 30. An connection connects one end of the winding to internal connection connects one end of the terminal 30.

  • Page 243: Oil Pressure Sensor

    ELECTRICAL AND ECU Component Tests Oil Pressure Sensor Fuel Injector This sensor measures the engine oil pressure and The fuel injectors are continuously supplied with sends the signal to the helm gauge. It is a pressure high-pressure fuel and are electronically triggered sensitive variable resistor.

  • Page 244: Engine Coolant Temperature Sensor

    Component Tests ELECTRICAL AND ECU Engine Coolant Temperature Sensor Fuel Rail Pressure Control Valve This sensor measures the temperature of the This valve controls the fuel pressure in the fuel rail. engine coolant. It is a NTC (negative temperature The ECU uses values supplied by several sensors coefficient) type sensor.

  • Page 245: Water-In-Fuel Sensor

    ELECTRICAL AND ECU Component Tests Water-in-Fuel Sensor Crankshaft Speed Sensor This sensor monitors fuel for the presence of water This sensor measures the speed of the crankshaft. and sends the signal to the helm display. If water is This value is compared with the camshaft speed by present, the resistance between the probes drops the ECU.

  • Page 246: Glow Plug / Control Unit

    Component Tests ELECTRICAL AND ECU 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 0004167 on-time will increase up to a maximum of 2.7 Figure 12-14 seconds, depending on temperature.

  • Page 247: Fuel Temperature Sensor

    ELECTRICAL AND ECU Component Tests Fuel Temperature Sensor This sensor measures the temperature of the fuel being supplied to the high-pressure fuel pump. It is a NTC (negative temperature coefficient) type sensor. It is mounted in the fuel line just upstream 0004172 from the high-pressure fuel pump.

  • Page 248: Fuel Volume Regulator

    Component Tests ELECTRICAL AND ECU Fuel Volume Regulator Charge Air Temperature Sensor This component controls fuel volume in the fuel This sensor measures the temperature of the injection system. The ECU uses values supplied by compressed air coming from the turbocharger. It is several sensors and sends corresponding signals mounted on the charge air pipe.

  • Page 249: Charge Air Pressure Sensor

    ELECTRICAL AND ECU Component Tests Charge Air Pressure Sensor Fuel Rail Pressure Sensor This sensor measures the charge air pressure as This sensor measures the fuel pressure in the fuel absolute value (charge air pressure + atmospheric rail. The values are used by the ECU for fuel pressure).

  • Page 250: Camshaft Speed Sensor

    Component Tests ELECTRICAL AND ECU Camshaft Speed Sensor Throttle Position Sensor This sensor measures the speed of the camshaft. This sensor is located in the remote control head. It This value is compared with the crankshaft speed communicates with the ECU with varying signals by the ECU.
  • Page 251 ELECTRICAL AND ECU Component Tests 0004167 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...

  • Page 252: Repair

    Repair ELECTRICAL AND ECU REPAIR Replacing Coolant Temperature Sensor Replacing Engine Control Unit (ECU) 1. Drain engine coolant. IMPORTANT 2. Remove intake manifold. The ECU may be damaged if it is powered when you unplug it. Turn the key switch OFF and disconnect the battery before disconnecting the ECU from the electrical harness.

  • Page 253: Replacing Charge Air Pressure Sensor

    ELECTRICAL AND ECU Repair Replacing Charge Air Pressure Replacing Charge Air Temperature Sensor Sensor 1. Disconnect battery negative (-) cable. 1. Disconnect battery negative (-) cable. ( 1 ) ( 1 ) Figure 12-25 Figure 12-27 2. Disconnect electrical connector 2.

  • Page 254: Replacing Crankshaft Sensor

    Repair ELECTRICAL AND ECU Replacing Crankshaft Sensor Replacing Camshaft Sensor 1. Disconnect battery negative (-) cable. 2. Remove starter motor. See Remove and Install Starter Motor on page 10-7. ( 1 ) ( 2 ) ( 3 ) ( 2 ) ( 1 ) 0003769 Figure 12-29...

  • Page 255: Replacing High-Pressure Fuel Control Valve

    ELECTRICAL AND ECU Repair Replacing High-Pressure Fuel Control Valve CAUTION • ALWAYS be environmentally responsible. • Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as engine oil, diesel fuel and engine coolant. Consult the local authorities or reclamation facility.

  • Page 256: Replacing High-Pressure Fuel Sensor

    • NEVER check for a fuel leak with your hands. ALWAYS use a piece of wood or cardboard. Have your authorized Yanmar marine dealer or distributor repair the damage. • Failure to comply could result in death or serious injury.
  • Page 257 ALWAYS use a piece of wood 0000199en or cardboard. Have your authorized Yanmar marine dealer or distributor 4. Hold sensor hex (Figure 12-32, (2)) with repair the damage. wrench and loosen retaining nut (Figure 12-32, (3)).

  • Page 258: Replacing Fuel Temperature Sensor

    ( 2 ) • NEVER check for a fuel leak with your hands. ALWAYS use a piece of wood or cardboard. Have your authorized Yanmar marine dealer or distributor 0003688A repair the damage. Figure 12-33 • Failure to comply could result in death 4.

  • Page 259: Replacing Fuel Volume Regulator

    ELECTRICAL AND ECU Repair Replacing Fuel Volume Regulator CAUTION ( 2 ) ( 1 ) • ALWAYS be environmentally responsible. • Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous Figure 12-34 materials such as engine oil, diesel 5.

  • Page 260: Remove And Install Oil Pressure Sensor

    • NEVER check for a fuel leak with your hands. ALWAYS use a piece of wood or cardboard. Have your authorized Yanmar marine dealer or distributor repair the damage. Figure 12-35 • Failure to comply could result in death or serious injury.
  • Page 261 ELECTRICAL AND ECU Repair This Page Intentionally Left Blank 12-34 BY Service Manual...
  • Page 262 Section 13 BY Service Manual TROUBLESHOOTING Page Introduction..................13-3 Engine Faults and Torque Limitations........... 13-3 Torque Limitation for Failed Sensors........13-3 Torque Limitation for Smoke Limitation ........13-3 Torque Limitation for Overheat Protection....... 13-5 Troubleshooting Chart..............13-6 Starting Trouble ............... 13-6 Exhaust Color ................
  • Page 263 TROUBLESHOOTING This Page Intentionally Left Blank 13-2 BY Service Manual...

  • Page 264: Introduction

    Introduction TROUBLESHOOTING INTRODUCTION This section of the Service Manual contains information and diagnostic troubleshooting charts to accurately diagnose engine, starter, or alternator problems. ENGINE FAULTS AND TORQUE If an electronic fault occurs, it will be displayed on the display-alarm and a P-Code is saved in the LIMITATIONS system.
  • Page 265 TROUBLESHOOTING Engine Faults and Torque Limitations Torque Reduction Chart Based on Boost Pressures Using the boost pressure on the display, it can be determined if the engine is in this mode and approximately where in the map it is. The present relative boost pressure is displayed on the instrument display.

  • Page 266: Torque Limitation For Overheat Protection

    Engine Faults and Torque Limitations TROUBLESHOOTING Torque Reduction Chart Based on Intake Air Temperature The intake air temperature will limit the torque at 3000 rpm if the air temperature is increasing. Engine speed 2000 rpm 2000 rpm Intake air Intake air Torque Torque [N·m] Torque [N·m]...

  • Page 267: Troubleshooting Chart

    TROUBLESHOOTING Troubleshooting Chart TROUBLESHOOTING CHART Starting Trouble Problem / Symptom Cause Action Discharged battery Charge / replace battery Blown fuse Replace fuse Defective starter motor Replace starter motor Engine Will Not Crank Loose wiring connections Tighten connections Electrical panel power circuit breaker Reset circuit breaker tripped Check fuel level in tank...

  • Page 268: Vibration - Drive Disengaged

    Troubleshooting Chart TROUBLESHOOTING Problem / Symptom Cause Action Clogged air filter Replace / clean air filter Incorrect valve timing Check / correct camshaft installation Defective (leaking) fuel injector Test / replace fuel injector Black Smoke Under Load Clean or replace air filter Low charge air pressure Damaged turbocharger Excessive exhaust backpressure...

  • Page 269: Engine Knocks

    TROUBLESHOOTING Troubleshooting Chart Engine Knocks Problem / Symptom Cause Action Defective fuel injector Check / replace fuel injector Excess Fuel Injected Check / replace fuel pressure regulator / High fuel injection pressure sensor Incorrect or poor quality fuel Drain and refill tank Noise Changes with Engine Load Worn crankshaft / bearings Repair as necessary...

  • Page 270: Engine Runs Cold

    Troubleshooting Chart TROUBLESHOOTING Engine Runs Cold Problem / Symptom Cause Action Defective sensor / instrument Repair as necessary Instrument Shows Low Temperature Defective thermostat Replace Cabin heater / boiler too large Replace with smaller unit or remove Coolant Loss Problem / Symptom Cause Action Defective cylinder head gasket (external...

  • Page 271: Trouble Codes

    TROUBLESHOOTING Trouble Codes TROUBLE CODES Working Procedure Try to form a comprehensive view of the problem. Start by asking the operator the following: • Symptoms • Conditions in which the fault occurs • How often the fault occurs • If the trouble codes have been erased Then, extract all the stored trouble codes.
  • Page 272 Trouble Codes TROUBLESHOOTING Engine Check Run or Code Fail Mode Engine Condition Start Alarm Fuel Rail Pressure reduce or depends P0088 Fuel rail pressure out of range alarm System Deviation shut off on fault Fuel Rail Pressure P0089 Fuel rail pressure out of range alarm System Deviation Fuel Pressure...
  • Page 273 TROUBLESHOOTING Trouble Codes Engine Check Run or Code Fail Mode Engine Condition Start Alarm Both throttle signals are missing / short circuit to Throttle Signal 1600 alarm Ground P0222 Throttle Signal Throttle signal 2 is missing / short circuit to Ground reduce alarm Throttle Signal...
  • Page 274 After Troubleshooting or Repair TROUBLESHOOTING Engine Check Run or Code Fail Mode Engine Condition Start Alarm Sensor Supply P0653 Short circuit reduce alarm Monitoring 3 Glow Plug Control P0670 Failure, short circuit, over-current alarm Module Glow System - Glow P0671 Not connected, short circuit alarm Spark No.

  • Page 275: After Troubleshooting Or Repair

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

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