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Manuals
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Yanmar Manuals
Engine
6BY
Service manual
Yanmar 6BY Service Manual
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
General Service Information
Table of Contents
Engine Outline Drawings
4BY - Inboard Version (Borg Warner Flange)
4BY - Stern Drive Version
6BY - Inboard Version (Borg Warner Flange)
6BY - Stern Drive Version
Engine Piping Diagrams
Location of Labels
Engine Nameplates (Typical)
Diesel Fuel
Diesel Fuel Specifications
Bleeding the Fuel System
Engine Oil
Engine Oil Specifications
Recommended Engine Oil
Recommended Marine Gear or Stern Drive Oil
Recommended Power Steering Fluid
Engine Coolant
Engine Coolant Specifications
Recommended Engine Coolant
Principal Engine Specifications
Tightening Torques for Standard Bolts and Nuts
Tightening Fasteners
Hexagon Bolts and Nuts
Hose Clamps
Abbreviations and Symbols
Abbreviations
Symbols
Periodic Maintenance
Before You Begin Servicing
EPA Requirements
Conditions to Ensure Compliance with EPA Emission Standards
Inspection and Maintenance
Introduction
The Importance of Periodic Maintenance
Performing Periodic Maintenance
Yanmar Replacement Parts
Required EPA Maintenance
Periodic Maintenance Schedule
Periodic Maintenance Procedures
After Initial 50 Hours of Operation
Every 50 Hours of Operation
Every 250 Hours of Operation
Every 500 Hours of Operation
Engine
Before You Begin Servicing
Introduction
Specifications
General Information
Test and Adjustment Specifications
Repair Specifications
Special Torque Chart
Special Service Tools
Measuring Instruments
Tests and Adjustments
Testing Compression
Repair
Cylinder Head
Cylinder Head Components
General Guidelines
Remove and Install Cylinder Head Cover
Remove and Install Glow Plugs
Removal of Cylinder Head
Disassembly of Cylinder Head
Cleaning Cylinder Head Components
Pressure Testing Cylinder Head
Inspection of Cylinder Head Components
Replacing Valve Stem Seals
Assembly of Cylinder Head
Determining Cylinder Head Gasket Thickness
Installation of Cylinder Head
Pistons and Cylinders
Removal and Disassembly of Piston and Connecting Rod
Inspection of Pistons and Piston Rings
Assembling Piston and Connecting Rod
Installation of Piston and Connecting Rod
Flywheel and Flywheel Housing
Remove and Install Flywheel Housing
Remove and Install Drive Coupling
Removal of Flywheel
Replacement of Rear Crankshaft Seal
Installation of Flywheel
Camshaft and Timing Gear Train
Components
Checking and Adjusting Camshaft Timing
Removing and Installing Vibration Damper - 4BY
Removing and Installing Vibration Damper - 6BY
Removing Timing Case Cover
Removing and Installing Timing Chain
Installing Timing Case Cover
Removing and Installing Timing Chain Tensioner
Removal of Camshafts
Installation of Camshafts
Cylinder Block and Crankshaft
Components
Removal of Crankshaft
Measuring Oil Clearance
Inspection of Crankshaft
Inspection of Cylinder Block
Crankshaft Installation
Replacing Front Crankshaft Seal
Intake Manifold
Removal
Installation
Exhaust Manifold
Remove
Install
Attaching Engine to Repair Stand
Fuel System
Before You Begin Servicing
Introduction
Specifications
Test and Adjustment Specifications
Special Service Tools
Fuel System Components
4BY Engines
Fuel Flow Diagram
Tests and Adjustments
Measuring Fuel Feed Pump Pressure
Testing Return Fuel Pressure
Repair
Removal of Fuel Injector
Cleaning Fuel Injector Cavities
Installation of Fuel Injector
Removing and Installing High-Pressure Fuel Lines
Replacing the Fuel Feed Pump
Replacing High-Pressure Fuel Pump
Replacing Fuel Filters
Removing and Installing Fuel Rail
Replacing Injector Return Fuel Line
Bleeding the Fuel System
Cooling System
Before You Begin Servicing
Introduction
Specifications
Test and Adjustment Specifications
Special Torque Chart
Special Service Tools
Cooling Flow Diagram
Tests and Adjustments
Pressure Testing Cooling System and Filler Cap
Testing Thermostat
Repair
Prepare Engine for Long-Term Storage
Drain Seawater Cooling System
Check and Replace Zinc Anodes
Draining and Filling Closed Cooling System
Disconnect and Connect Quick-Connect Fittings
Remove and Install Hydraulic Oil Cooler
Inspect and Clean Hydraulic Oil Cooler
Remove and Install Charge Air Cooler
Disassemble and Assemble Charge Air Cooler
Remove and Install Heat Exchanger
Disassemble and Assemble Heat Exchanger
Remove and Install Coolant Pump
Remove and Install Thermostat
Seawater Pump
Lubrication
Before You Begin Servicing
Introduction
Specifications
Test and Adjustment Specifications
Special Torque Chart
Measuring Instruments
Special Service Tools
Tests and Adjustments
Engine Oil Flow
Checking Engine Oil Pressure
Repair
Engine Lubrication System Components
Replace Engine Oil and Engine Oil Filter Element
Remove and Install Oil Cooler
Remove and Install Oil Filter Housing
Remove and Install Oil Sump
Oil Pump
Turbocharger
Before You Begin Servicing
Introduction
Specifications
Test and Adjustment Specifications
Special Torque Chart
Special Service Tools
Tests and Adjustments
Measuring Charge Pressure
Adjusting Charge Pressure - 4BY
Repair
Turbocharger Removal
Turbocharger Installation
Alternator
Before You Begin Servicing
Introduction
Specifications
General Specifications
Special Torque Chart
Repair
Replace Alternator Belt
Remove and Install Alternator
Remove and Install Alternator Belt Tensioner
Electrical and Ecu
Before You Begin Servicing
Introduction
Specifications
Special Torque Chart
Function Description - Engine Management System
Component Locations
Electrical Panel Connector (X1) Connections
Component Tests
Relays
Oil Pressure Sensor
Fuel Injector
Engine Coolant Temperature Sensor
Fuel Rail Pressure Control Valve
Water-In-Fuel Sensor
Crankshaft Speed Sensor
Glow Plug / Control Unit
Fuel Temperature Sensor
Fuel Volume Regulator
Charge Air Temperature Sensor
Charge Air Pressure Sensor
Fuel Rail Pressure Sensor
Camshaft Speed Sensor
Throttle Position Sensor
Repair
Replace Coolant Temperature Sensor
Replacing Engine Control Unit (ECU)
Replacing Charge Air Pressure Sensor
Replacing Charge Air Temperature Sensor
Replacing Camshaft Sensor
Replacing Crankshaft Sensor
Replacing High-Pressure Fuel Control Valve
Replacing High-Pressure Fuel Sensor
Replacing Fuel Temperature Sensor
Replacing Fuel Volume Regulator
Remove and Install Oil Pressure Sensor
Troubleshooting
Engine Faults and Torque Limitations
Torque Limitation for Failed Sensors
Torque Limitation for Smoke Limitation
Torque Limitation for Overheat Protection
Introduction
Troubleshooting Chart
Starting Trouble
Exhaust Color
Vibration - Drive Disengaged
Vibration - Drive Engaged
Engine Knocks
Low Power Output
Engine Overheat
Engine Runs Cold
Coolant Loss
Helm Panel Display
Trouble Codes
Working Procedure
Diagnostic Trouble Codes
After Troubleshooting or Repair
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6By - Inboard Version (Borg Warner Flange)
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SERVICE MANUAL
BY series
4BY
6BY
Table of
Contents
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Advertisement
Chapters
General Service Information
22
Periodic Maintenance
44
Engine
56
Fuel System
130
Cooling System
160
Lubrication
182
Turbocharger
200
Alternator
220
Electrical and Ecu
228
Troubleshooting
262
Table of Contents
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