Yanmar 4BY Manuals

Manuals and User Guides for Yanmar 4BY. We have 1 Yanmar 4BY manual available for free PDF download: Service Manual

Yanmar 4BY Service Manual

Yanmar 4BY Service Manual (275 pages)

Brand: Yanmar | Category: Engine | Size: 22.04 MB

Table of Contents

General Service Information

22
- Table of Contents
  22
- Engine Outline Drawings
  24
- Engine Piping Diagrams
  28
- Location of Labels
  30
  - Engine Nameplates (Typical)
    30
- Diesel Fuel
  31
  - Diesel Fuel Specifications
    31
  - Bleeding the Fuel System
    32
- Engine Oil
  32
- Engine Coolant
  36
  - Engine Coolant Specifications
    36
  - Recommended Engine Coolant
    37
- Principal Engine Specifications
  38
- Tightening Torques for Standard Bolts and Nuts
  40
  - Tightening Fasteners
    40
  - Hexagon Bolts and Nuts
    40
  - Hose Clamps
    40
- Abbreviations and Symbols
  41
  - Abbreviations
    41
  - Symbols
    41
Periodic Maintenance

44
Engine

56
- Before You Begin Servicing
  58
- Introduction
  62
- Specifications
  62
- Special Torque Chart
  66
- Special Service Tools
  69
- Measuring Instruments
  70
- Tests and Adjustments
  72
  - Testing Compression
    72
- Repair
  73
- Cylinder Head
  74
- Pistons and Cylinders
  91
- Flywheel and Flywheel Housing
  97
- Camshaft and Timing Gear Train
  101
  - Components
    101
  - Checking and Adjusting Camshaft Timing
    103
  - Removing and Installing Vibration Damper - 4BY
    105
  - Removing and Installing Vibration Damper - 6BY
    106
  - Removing Timing Case Cover
    107
  - Removing and Installing Timing Chain
    107
  - Installing Timing Case Cover
    108
  - Removing and Installing Timing Chain Tensioner
    109
  - Removal of Camshafts
    109
  - Installation of Camshafts
    112
- Cylinder Block and Crankshaft
  115
  - Components
    115
  - Removal of Crankshaft
    117
  - Measuring Oil Clearance
    118
  - Inspection of Crankshaft
    119
  - Inspection of Cylinder Block
    121
  - Crankshaft Installation
    121
  - Replacing Front Crankshaft Seal
    123
- Intake Manifold
  125
  - Removal
    125
  - Installation
    126
- Exhaust Manifold
  127
  - Remove
    127
  - Install
    127
- Attaching Engine to Repair Stand
  128
Fuel System

130
- Before You Begin Servicing
  132
- Introduction
  135
- Specifications
  135
  - Test and Adjustment Specifications
    135
- Special Service Tools
  137
- Fuel System Components
  138
  - 4BY Engines
    138
- Fuel Flow Diagram
  139
- Tests and Adjustments
  140
  - Measuring Fuel Feed Pump Pressure
    140
  - Testing Return Fuel Pressure
    141
- Repair
  142
  - Removal of Fuel Injector
    142
  - Cleaning Fuel Injector Cavities
    143
  - Installation of Fuel Injector
    145
  - Removing and Installing High-Pressure Fuel Lines
    146
  - Replacing the Fuel Feed Pump
    148
  - Replacing High-Pressure Fuel Pump
    149
  - Replacing Fuel Filters
    153
  - Removing and Installing Fuel Rail
    156
  - Replacing Injector Return Fuel Line
    157
  - Bleeding the Fuel System
    158
Cooling System

160
- Before You Begin Servicing
  162
- Introduction
  164
- Specifications
  164
  - Test and Adjustment Specifications
    164
  - Special Torque Chart
    164
- Special Service Tools
  165
- Cooling Flow Diagram
  166
- Tests and Adjustments
  167
  - Pressure Testing Cooling System and Filler Cap
    167
  - Testing Thermostat
    168
- Repair
  169
Lubrication

182
- Before You Begin Servicing
  184
- Introduction
  187
- Specifications
  187
  - Test and Adjustment Specifications
    187
  - Special Torque Chart
    187
- Measuring Instruments
  188
- Special Service Tools
  188
- Tests and Adjustments
  189
  - Engine Oil Flow
    189
  - Checking Engine Oil Pressure
    190
- Repair
  192
  - Engine Lubrication System Components
    192
  - Replace Engine Oil and Engine Oil Filter Element
    193
  - Remove and Install Oil Cooler
    195
  - Remove and Install Oil Filter Housing
    196
  - Remove and Install Oil Sump
    197
  - Oil Pump
    198
Turbocharger

200
- Before You Begin Servicing
  202
- Introduction
  204
- Specifications
  204
  - Test and Adjustment Specifications
    204
  - Special Torque Chart
    204
- Special Service Tools
  205
- Tests and Adjustments
  206
  - Measuring Charge Pressure
    206
  - Adjusting Charge Pressure - 4BY
    207
- Repair
  208
  - Turbocharger Removal
    208
  - Turbocharger Installation
    209
Alternator

220
- Before You Begin Servicing
  222
- Introduction
  224
- Specifications
  224
  - General Specifications
    224
  - Special Torque Chart
    224
- Repair
  225
Electrical and Ecu

228
- Before You Begin Servicing
  230
- Introduction
  232
- Specifications
  232
  - Special Torque Chart
    232
- Function Description - Engine Management System
  233
  - Component Locations
    233
  - Electrical Panel Connector (X1) Connections
    238
- Component Tests
  241
  - Relays
    241
  - Oil Pressure Sensor
    243
  - Fuel Injector
    243
  - Engine Coolant Temperature Sensor
    244
  - Fuel Rail Pressure Control Valve
    244
  - Water-In-Fuel Sensor
    245
  - Crankshaft Speed Sensor
    245
  - Glow Plug / Control Unit
    246
  - Fuel Temperature Sensor
    247
  - Fuel Volume Regulator
    248
  - Charge Air Temperature Sensor
    248
  - Charge Air Pressure Sensor
    249
  - Fuel Rail Pressure Sensor
    249
  - Camshaft Speed Sensor
    250
  - Throttle Position Sensor
    250
- Repair
  252
- Replace Coolant Temperature Sensor
  252
- Replacing Engine Control Unit (ECU)
  252
- Replacing Charge Air Pressure Sensor
  253
- Replacing Charge Air Temperature Sensor
  253
- Replacing Camshaft Sensor
  254
- Replacing Crankshaft Sensor
  254
- Replacing High-Pressure Fuel Control Valve
  255
- Replacing High-Pressure Fuel Sensor
  256
- Replacing Fuel Temperature Sensor
  258
- Replacing Fuel Volume Regulator
  259
- Remove and Install Oil Pressure Sensor
  260
Troubleshooting

262
- Engine Faults and Torque Limitations
  264
- Introduction
  264
- Troubleshooting Chart
  267
  - Starting Trouble
    267
  - Exhaust Color
    267
  - Vibration - Drive Disengaged
    268
  - Vibration - Drive Engaged
    268
  - Engine Knocks
    269
  - Low Power Output
    269
  - Engine Overheat
    269
  - Engine Runs Cold
    270
  - Coolant Loss
    270
  - Helm Panel Display
    270
- Trouble Codes
  271
  - Working Procedure
    271
  - Diagnostic Trouble Codes
    271
- After Troubleshooting or Repair
  275

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