6AYE Service Manual - Unlocked (OCR)

YA"MAR
Foreword:
This Service Manual has been developed for the exclusive use of service and repair
professionals such as YANMAR authorized distributors and YANMAR authorized dealers.
It is written with these professionals in mind and may not contain the necessary detail or
safety statements that may be required for a non-professional to perform the service or
repair properly and/or safely.
Disclaimers:
All information, illustrations and specifications in this manual are based on the latest
information available at the time of publishing. The illustrations used in this manual are
intended as representative reference views only. Moreover, because of our continuous
product improvement policy, we may modify information, illustrations and/or specifications
to explain and/or exemplify a product, service or maintenance improvement. We reserve
the right to make any change at any time without notice. YANMAR and YANMAA are
registered trademarks ofYANMAR CO., LTD. in Japan, the United States and/or other
countries.
All Rights Reserved:

No part of this publication may be reproduced or used in any form by any means -
graphic, electronic, or mechanical, including photocopying, recording, taping, or informa-
tion storage and retrieval systems - without the written permission of YANMAR CO., LTD.
MODEL 6A YEM-GT, 6A YEM-ET, 6A YEM-ST

SERVICE MANUAL
CODE OBA YE-EN001 0
All Rights Rosorvod, Copyright YANMAA CD.. LTD.

CONTENTS
FOR YOUR SAFETY ......................................................... 1
Warning Symbols ................................................................................ .
Safety Precautions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 2
Warning Labels.................................................................................... 6
Precautions for Lifting the Engine ............................................................ 8
ENGINE SPECIFICATIONS ................................................ 9

Location of Components ........................................................................ 10
Piping Diagram .................................................................................... 11
Fuel Oil, Lubricating Oil and Coolant......................................................... 13
SI Unit Conversions .............................................................................. 15
DISASSEMBLY AND ASSEMBLY ....................................... 16

Disassembly and Reassembly Tools...... ...... ... ...... ... ...... ... ...... ... ...... ... ...... 16
Precautions for Disassembly and Reassembly .......................................... 26
Disassembly Procedures... ... ...... ... ...... ... ...... ... ...... ...... ... ...... ... ...... ... ...... 27
Reassembly Procedures... ... ...... ... ...... ...... ... ...... ... ...... ... ...... ... ...... ... ...... 43
INSPECTING AND SERVICING OF ENGINE'S MAJOR PARTS ... 67

Preliminaries ....................................................................................... 67
Standard for Parts Replacement (Including Correction) ... ...... ... ...... ...... ... ...... 67
Cylinder Head ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 68
Cylinder Block ...... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 77
Cylinder Liner... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 77
Pistons ............................................................................................. 79
Connecting Rods ................................................................................. 83
Crankshaft and Main Bearing.................................................................. 86
Oil Seal of the Crankshaft ..................................................................... 89
Camshaft and Tappets... ...... ...... ... ...... ... ...... ... ...... ... ...... ... ...... ...... ... ...... 90
Timing Gear ....................................................................................... 93
Viscous Damper ......... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 95
Fuel Oil System... ...... ... ...... ... ...... ... ...... ... ...... ... ...... ...... ... ...... ... ...... ... ... 96
Lubricating Oil System... ...... ... ...... ...... ... ...... ... ...... ... ...... ... ...... ...... ... ... 103
Cooling Water System... ...... ...... ... ...... ... ...... ... ...... ... ...... ... ...... ...... ... ... 108
Air Cooler ....................................................................................... 115
Turbocharger... ...... ... ...... ... ...... ... ...... ...... ... ...... ... ...... ... ... ...... ...... ... ... 116
Electrical System .............................................................................. 135
MAINTENANCE INSPECTIONS 141

Precautions for Maintenance and Inspections.......................................... 141
Periodic Maintenance Schedule............................................................ 141
LONG-TERM STORAGE ................................................... 144

TROUBLESHOOTING AND COUNTERMEASURES ............ 145
Troubleshooting... ...... ... ...... ...... ... ...... ... ...... ... ...... ... ...... ... ...... ...... ... ... 145
SERVICE REFERENCE TABLE ....................................... 146

REFERENCE ADJUSTMENT VALUE ................................. 149
TIGHTENING TORQUES FOR MAJOR BOLTS AND NUTS ... 150
TEST RUNNING AFTER SERVICING ................................. 155
FOR YOUR SAFETY - 1
FOR YOUR SAFETY
Before you start any repair or maintenance work: Read this manual carefully and make sure that you understand the
applicable inspection or maintenance procedures and the safety precautions.
If you do repair or maintenance work without the necessary knowledge, you can cause unforeseen accidents.
It is not possible to predict all dangers that can occur during repair or maintenance and indicate them in a manual.
Therefor it is necessary to carefully consider safety on workspace beyond what is expressed in this manual.
Warning Symbols
These are the warning signs used in this manual and on the product.
Please read and abide by the message that follows the safety alert symbol.
This safety alert symbol appears with most safety statements.

It means attention, become alert, your safety is involved.
DANGER indicates a hazardous situation which, if not avoided, will result

in death or serious injury.
WARNING indicates a hazardous situation which, if not avoided, could

result in death or serious injury.
CAUTION indicates a hazardous situation which, if not avoided, could

ACAUTION result in minor or moderate injury.
NOTICE indicates a situation which can cause damage to the machine,

personal property and/or the environment or cause the equipment to operate
improperly.
• The descriptions captioned by "IMPORTANT" are particularly attentions on

- IMPORTANT - the work.
2 - FOR YOUR SAFETY
Safety Precautions
Make sure that you obey these safety precautions before performing repairs or maintenance .
• Maintenance service area (room)
Sufficient Ventilation
Inhalation of exhaust gas and dust particles may be hazardous to health.
Running engines, welding, sanding, painting, and polishing tasks should be only done in well
ventilated areas.
A CAUTION
Safe/Adequate Area
The service area should be sufficiently wide, clean, flat without any holes in the floor, to
prevent "fall" or other unexpected accidents.
Clean, Order Area

No dust, mud, oil or parts should be left on the floor surface, to prevent an unexpected
accident.
Brightness/Lighting Area
~ The work area should be well illuminated in a safe manner. For work in enclosed or dark areas
111/1111 \\~~ where it is difficult to see, use a portable safety lamp. Use lamps with light bulbs that are
covered with a wire cage, to prevent bulb breakage and possible ignition of leaking oil.
Safety Equipment
Keep the fire extinguisher close at hand in preparation.
Have all fire extinguishers checked periodically for proper operation and/or readiness.
FOR YOUR SAFETY - 3
• Working
Appropriate Lifting/Holding
When lifting an engine, use only a lifting device (crane, jack, etc.) with sufficient lifting
capacity. Do not overload the device, serious injury may result.
Use only a chain, cable, or lifting strap as an attaching device. Do not use rope, serious injury
may result.
To hold or support an engine, secure the engine to a support stand, test bed or test cart
designed to carry the weight of the engine. Do not overload this device.
A. CAUTION
Safe Work Clothing
Appropriate safety wear (a helmet, working clothes, safety shoes/boots and other safety
protectors) should be used/suited to match the work.
Wear well-fitting work clothes to prevent "getting caught in the engine" or serious accidents.
Appropriate Tools
Always use the correct tools that are matched and designed for the work.
Incorrect usage of tools may result in damage to the engine and or serious personal injury.
Tightening Torque
Always tighten components to the specified torque as indicated in the service manual.
Loose parts can cause the equipment and the engine damage.
Stepping Engine
Don't step on engine or parts cover to prevent "slipping" or "falling".
4 - FOR YOUR SAFETY
• Handling engine
Scalding Hot Water

Never open the coolant filler cap if the engine is hot.
Steam and hot coolant will spray out and seriously burn you. Allow the engine to cool down
I I before attempt to open the filler cap.
Fire at Fueling/Refueling
Keep sparks, open flames or any other fire source (match, cigarette, etc.) away when fueling/
refueling.
Be Careful when Starting Engine

Make sure that nobody is near the engine.
If somebody is near the engine, give a signal and make sure that they are safe.
Remove the turning handle, and store it in the specified location.
Rotating Parts
Be careful around moving/rotating parts. Remove all jewelry, loose-fitting clothing and keep
hands, other body parts and tools away from all moving parts.
Always stop the engine before beginning service.
Side Cover Opening

Do not open the side cover when the engine is hot. The new air intrusion may lead to an
explosion.
4, CAUTION
Hot Surfaces
Don't touch the hot engine (or any of its components) during running and shortly after
shutdown. Allow the engine to cool down before attempting to approach the unit.
No Modification
Never attempt to modify the engine ECU.
Modifying will damage the engine or shorten the engine life.
FOR YOUR SAFETY - 5
• Electrical
Explosion at Battery Charging

While the engine is running or the battery is charging, hydrogen gas is being produced and
can be easily ignited.
Keep the area around the battery well-ventilated and keep sparks, open flame and any other
form of ignition away.
Short Circuits
Always turn off the battery switch or disconnect the negative (-) battery cable before working
on the electrical system.
Always check the electrical harnesses for cracks, abrasions, and damaged or corroded
connectors. Always ensure that all connectors are tightened surely.
Always keep the connectors and terminals clean.
A CAUTION
Battery Electrolyte
Batteries electrolyte is diluted sulfuric acid, do not let it be splashed on to clothes or
skin.
• Genuine parts
Using Genuine Parts

YJUfMAR Always use genuine YANMAR parts or YANMAR recommended parts and goods.
GENUINE PARTS
Non-genuine parts may cause damage to the engine, shortened engine life and unexpected acci-
dents.
Using NOx-compliant Parts

According to the laws preventing environmental pollution and sea hazards, it is necessary to make a
record signed by a supervisor when certain parts are replaced.
• Disposing waste
Waste Treatment
Waste materials such as oil, fuel, coolant, solvents, filter elements and batteries, shall be treated according to the
respective laws and regulations. Consult the local authorities or reclamation facility.
Discharged waste fluids shall be carefully put into containers and do not spill.
Don't dispose of waste materials irresponsibly by dumping them into the sewer, on the gland, natural waterways or
sea.
6 - FOR YOUR SAFETY
Warning Labels
For safe operation, the affixed position of the warning labels is indicated.
Read the remarks of the warning labels carefully to attempt prevention of the accident.
Also, if you need to replace a part that has a label affixed to it, make sure you order the new part and label at the
same time.
If the warning labels are damaged or fallen, order them from your authorized YANMAR dealer or distributor.
• Operation side
1 2
_ .a:.
A ~ 1=1
WARNING
~
.i\'ii~~I::I;t"""\"' ';I :1~llIllt
.. t,;:~\l::l"~~\o .i!I!ilfJ{lIX~
I±l L-\Oltc~"t"Mi!l::ni!b~)o
eNever remove the cap wh i I e the
eng i ne is st i II hot. .Hot water
may spurt out and burn you.
12829Hl7260
• l!I!:*ii'i'I;t, if?t::~\I::'f.-\Om~
A:nt,;:L\l::<t=~L\ •
• 'TjJ~"t" -l>liil::nfJ<i!b LJ i/;"t".
m Exposed mav i ng parts
m Can cause injury 141615-07210
A ~
WARNING
i5-
• w!l:~, 1 0 ~r,lHillll~tt..:p<''F~Po
No. Part No. • '1f~1:d:fJII~liil:tLfJl';t;,fJ *9" 0
1
-------------- 128296-07260
----------------------------------
• Don't open 10 min. after stop
2 141616-07210 • Can cause injury by explosion

-------------- ---------------------------------- 141616-{)7200
3 141616-07200
FOR YOUR SAFETY - 7
• Non-operation side
1
A;±~
CAUTION
lllllt;t;
· ~t>-l>.!:-I'>lt.!:~T-l>
i'l!:h.iJ<iI;~iIOT.
· Hot surface
• May cause burn
1411116-07220
A =
WARNING 1S-
· 'iii"''''I;I;. tf?t=L'I~'l'-I'>Iif'
A:h.f.l;L'"l!(t::i!'L'.
No. Part No. • ".:t.if'T-l>i'l!:h.»(iI;~iIOT.
1 i 041616-07220 • Exposed mav i ng parts
------"2------ ----14T616-=-072To----
i
• Can cause injury 141818-07210
069618-00XOO
8 - FOR YOUR SAFETY
Precautions for Lifting the Engine

The engine can cause serious injury when it falls during lifting. Obey the below instructions to prevent accidents
during lifting.
• Make sure that the engine is lifted by qualified persons.

• Before lifting, make sure that the engine lifting bracket and mounting bolt have no damage and are in
good shape. If you find a fault, stop immediately and contact your authorized YANMAR dealer or distribu-
tor.
• Select lifting tools (e.g. wire rope and shackle) that are appropriate for heavy loads.
• Select the wire rope length so that the engine does not tilt during lifting.
• Before lifting, examine the lifting tools and make sure that they have no damage and are in good shape.
• Protect the parts of the engine or driven equipment that touch the wire rope with protective material.
• The tension of the wire rope changes depending on the lifting angle. Make sure that the angle is within
60°.
• If you use a marine gear that is not listed in this operation manual, separate the marine gear from the
engine, and lift the marine gear and engine separately.
• During lifting and moving the engine, do not go under the engine or near the engine.
Less than 60 degrees
Ot;9119-00ENOO
For the mass, refer to Specifications in the Operation Manual.

ENGINE SPECIFICATIONS - 9
ENGINE SPECIFICATIONS
6AYEM-ET 6AYEM-ST
Engine model Unit 6AYEM-GT 6AYEM-ET
(for EPA) (for EPA)
Type - Vertical, water-cooled, 4-cycle diesel engine
Combustion chamber - Direct injection
No. of cylinders - 6
Cylinder bore x stroke mm 155 x 180
Displacement L 20.379
S L M H M H
Rated output (at flywh ee I) kW(PS)
737 (1002) 670 (911) 610(829) 555 (755) 599 (814) 485 (659)
Rated engine speed min- 1 2000 1938 1900 1840 1900 1900
Crankshaft rotation direction - Counterclockwise (viewed from the flywheel side)
1-4-2-6-3-5-1
Firing order -
(No.1 cylinder = Flywheel side)
Fuel injector - Modular Commom Rail (MCRS)
Fuel Fuel supply pump - High pressure pump
system Injection timing - Variable timing (Electronic control)
Injection pressure MPa Variable pressure (Maximum 160)
Lubricating - Forced lubricating with gear pump
Cooling - Fresh water (coolant) cooling
Lubricating
Lubricating oil pressure MPa Forced lubrication with gear pump
system
Standard oil pan: 91
Lubricating oil capacity L
Shallow oil pan: 53
Coolant seawater 2 system cooling
Cooling -
(Engine/oil cooler: Coolant, Other cooler: Seawater)
Cooling
Seawater pump - Rubber impeller, gear driving type
system
Coolant pump - Centrifugal, gear driving type
Coolant capacity L Engine: 65 Reservoire: 3
Exhaust gas turbocharger (with air cooler)
Turbo- Type -
TD13L TD13M1 TD13M
charger
Cooling - Air cooling
Type - Fin and tube
Air cooler
Cooling - Seawater cooling
Starting system - Electric starting
Engine dry mass
kg 2418
(without marine gear)
Note· The rating shown represents net brake power at the flywheel.
• Cylinder numbers are counted from flywheel side (No.1).
10 - ENGINE SPECIFICATIONS
Location of Components
• Operating side
Intake manifold
Fuel high - - - Seawater pump

pressure pump
Oil filler cap
Dipstick----
069115 -OOENOl
• Non-operating side
Exhaust manifold
Water pump
(coolant)
069116 -OOENOO
Piping Diagram
• Cooling water system
Seawater outlet pipe lubricating

r--EJ--
, Coolant pump
oil cooler
-J'/ Thermostat
Filler cap
,
r'--- -- L-------'
Coolant
reservoir 1 Q;
Y_J
(5
o
<..l
'-
«
Seawater pump
Seawater line : - - -
Coolant line o Seawater inlet pipe
OOENOO
• Lubricating oil system
lubricating oil filter
lubricating
oil cooler
lubricating oil main gallery
0..
E
:::l
0..
~
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OJ Q; if)
E ¢:! c if)
ro Ol
..c
.~ c 2' ~
Q; if) (J) .8 Ol
..c
0..
..a if) .c
E <..l
""<..l0 Ol
0
C
·iii
i:L 0
-2
.2'
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a:: ::;:'; :::> Qi
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(J) :::J
> LL
""iii 4=
> if)
>- if)
]2 Ol
0..
Ol >-
(j) III
Oil pan
• Fuel oil system
Injector
----------1 1----------------- "I

"
,+\')i:/
~
II,+\! ,+
-+-~ I -J-
\1/
-I I - - --+
\
Fuel high pressure pipe
iNo.6 i i i i i i iii No.1 i i
-
lCYI i i i I l i i i lCYI i I
_C--", , - _c--", - _C
---E------1! I " I I I
I ~,~~--~---r--_.
Fuel high pressure pump
Fuel filter
Feed pump
Priming pump
Fuel inlet Fuel outlet

104728 -OOENOl
Fuel Oil, Lubricating Oil and Coolant

Fuel
• Diesel fuel selection

Use clean Marine Gas Oil (Diesel Fuel) for the fuel oil.
Diesel fuel should comply with the following guidelines. The fuel specifications need to comply with each national
standard or international standards.
ASTM 0975 No. 20 equivalent

Quality critical equivalent fuel oil EN 590
BS-2869 Class A 1 or A2
Sulfur content Below 0.5 % by volume
Property critical value Diesel index Cetane No. 45 or higher
Viscosity at 50°C 3 - 8 mm-2/s
• Use clean Ultra Low Sulfur Diesel Fuel (ULSDF) for the EPA satisfied engine.
- IMPORTANT ------;;;;;;;
• Only use the recommended fuel to obtain the best engine performance and to keep the durability of the engine, as
well as to comply with the emission regulations.
• The fuel injection system consists of precision parts and for that reason, do not use fuel to which water and dust
are mixed in. If such fuel is used, it causes trouble.
Consequently, pay attention to water or dust when supplying fuel.
Beside these, carry out draining and maintenance servicing of the fuel filter as mentioned in the Periodic Mainte-
nance Schedule.
Lubricating oil
• Selection
Use an engine oil that meets or exceeds the following guidelines.
• Oil grade: A.PI. CF
• SAE viscosity: 15W-40
• T.B.N [mgKOH/g]: 9 - 15
- IMPORTANT _ _ _ _ _ !0@V;;;;;;;;
• Do not mix lubricating oils of different types or brands. Mixing may cause lubricating performance to decrease,
reducing the engine's life.
• YANMAR does not recommend the use of engine oil "additives".
• When supplying engine oil, pay attention to water or dust. Clean around the filler port before filling.
• Make sure to carry out changing of the engine oil and maintenance servicing of the oil filter as mentioned in the
Periodic Maintenance Schedule.
• Marine Gear Oil: Refer to the operation manual of the marine gear.
Coolant
• Coolant selection
Use clean coolant (tap water) for the coolant. Do not use hard water.
Use the water having the properties shown in the following table.
Water quality for coolant

pH 298K (25°C) 6.5 - 8.0
Total hardness (CaC0 3 ) :s; 100 ppm
M alkalinity :s; 100 ppm
Ammonium ion (NH4+) concentration :s; 0.05 ppm
Chloride ion (CI-) concentration :s; 100 ppm
Sulfate ion (S042 -) concentration :s; 100 ppm
Evaporation residue :s; 400 ppm
• Long Life Coolant (LLC) mixture selection

Always add Long Life Coolant (LLC) to the tap water. This mixture serves as the coolant.
YANMAR recommends the following Long Life Coolant (LLC):
• TEXACO LONG LIFE COOLANT/standard and premixed
Product Code 7997 and 7998
• HAVOLINE EXTENDED LIFE ANTIFREEZE/COOLANT
Product Code 7994
or products equivalent to the above LLC.
- IMPORTANT _ _ _ _ _ _ ffN""""
Choose LLC which will not have any adverse effects on the materials (cast iron, aluminum, copper, etc.) used in the
engine's cooling system, if different from the above.
Without this mixture, scale or rust is generated inside the parts of the coolant system, thus deteriorating cooling per-
formance. In winter, never neglect to us LLC in order to prevent freezing.
If LLC use is neglected, the coolant freezes and expands inside the engine, resulting in breakage of parts in the cool-
ant system. The mixing ratio of LLC depends on the temperature. Be careful in using the mixing ratio specified by
the manufacturer.
- IMPORTANT _ _ _ _ _ '0ljjjljjj;;;
• Excess LLC deteriorates cooling performance.

A thin mixture which does not provide protection sufficient for the lowest temperature will freeze and damage the
coolant system.
• Never mix different types (brands) of LLC, chemical reactions may make the LLC useless and engine trouble
could result.
SI Unit Conversions
• Conversion table
Conversion values between the international unit system (SI) and the metric unit system are shown below:
Force
N kgf
0.101972
9.80665
Torque
Nom kgfom
0.101972
9.80665
Pressure
Pa kg fIe m2
1 1.0197 x 10-5
9.80665 x 104 1
9.80665 x 103 1.0000 x 10- 1
Power
kW PS
1.3596
0.7355
16 - DISASSEMBLY AND ASSEMBLY
DISASSEMBLY AND ASSEMBLY
Disassembly and Reassembly Tools

The following tools are required when disassembling and reassembling the engine.
Please use them as instructed .
• General hand tools

Name of tool/Code No. Illustration Name of tool/Code No. Illustration
Starling pliers Screw driver, reversible

28190-000020 104200-92350
Double ended wrench

Circlip pliers 7 x 8 28110-070080
28190-000130 8 x 10 28110-080100
10 x 13 28110-100130
12 x 14 28110-120140
Offset wrench 17 x 19 28110-170190
17 x 19 28160-170190 22 x 24 28110-220240
22 x 24 28160-220240 27 x 30 28110-270300
Thickness gauge
Adjustable wrench
0.3 mm 28312-300750
28120-002000
0.5 mm 28312-500750
001414-00X
~
"S "S
Size (mm)
Turning bar L: 500 Pliers
126410-92720 D: 18 127610-92760
L T: 17 001392 -oox
OlS271-00X
Piston ring replacer

(for removal/insertion)
Local supply
001411--00X
DISASSEMBLYANDASSEMBLY - 17
• Special hand tools

Connecting rod small end bushing insertion/extraction
tool
mm
A B C 0 E F Material
067 -0.2 062- 0 .45 62 100 20 10.8 0 S45C
-0.5 -0.48
Intake and exhaust valve guide insertion tool
Insertion 1001
~t~-~-~---------
Ie!
: >. 0
]
>
I
008184-00X
Valve guide
mm
A B C 0 Material
030 -0.1
-0.5 016 :8:1 20 ± 0.3 120 S45C
Flywheel insertion/extraction tool
A Ci
009291-00XOI
mm
A B
020 M20
Lubricating oil filter case remover Part No. 133615-92350
mm
1.77~ 1371
Fuel injector extractionlinsertion tool

Part No. 148661-92010, 148661-92030 (Tool)
148661-92020 (Tool bolt - 2 pieces)
159636-32360 (Joint bolt M10)
26106-060122 (Bolt M6)
26106-100202 (Bolt M10)
26366-100202 (Nut M10)
l05295-00XOO
Cylinder liner extracting tools Part No. 748620-92030
Cylinder block
(Upper)
t Cylinder liner
~
00736?-OOENOl
~
@
® 013238-01XOO
DISASSEMBLYANDASSEMBLY - 19
Stem seal insertion tool (intake valve)
1\ ~\-.----------------~--~
E F G H f-----,-)--- -~/--------------- ft 11
/
B
A
030818-00XOl
mm
ABC 0 E F G H
80 27.5 23.5 ± 0.1 9 026 ± 1 021 ± 0.1 019.5 +g.2 017.2±0.1 011 +0.018
o
Stem seal insertion tool (exhaust valve)
-t-F~~r~,~~~~,~::;;;j::' _ _ _ _ --J1
l:: II - , ::: -
TIl
I "'
F i'-H
CD f.r..lo
~
A MeN
K L
J
014283-00X
mm
ABC 0 E F G H J K L M N o
80 56 10 14 3 2 012h7 (90.018 ) M8 011 :g:g~ 165 60 105 27 15 23 ± 0.1
P Q R S T u V W X Y
11 034 023 019.6±0.2 017.2±0.1 012H7(+g·018) 025 23 20 1.5

Nozzle sleeve tightening tool
RO.5
J K
e~4
Sock
R\ \ f
,(Ci/C1
1\l\1
f f
If
F G
fl
i H I
1\
E
0
B C * Hard ing the head
A
014282-00ENOl
mm
Bend plug insertion tool
c[~ ~l
. J B
.1
OO1492-03X
Ir-------------------~ mm
If
Plug
2 - 3mm A B C 0
001491-04X diameter
030 029.9 - 30.0 040
035 3 100 024.9 - 35.0 050
040 039.9 - 40.0 050
DISASSEMBLY AND ASSEMBLY - 21
Piston insertion tool
Part No. 148660-92140
~ l~
(Piston insertion tool)
mm
I~ ~I
A B C c
B
0190.0 0178+g· 63 0155.0 +g.63
A
013239-00X
Part No. 148660-92200
~
(Piston eyeboltlM6)
018180 -00X01
013247-01XOO
Camshaft gear install tool
A
014284-00X
mm
A B C D E F G H I J K L M N
M16
145 25 120 60 15 3 045 -0.03 30 70 020 010 M20 x 1.5 41
-0.06 Depth 95/105
014285 -oox
mm
A B C D E F G H
145.5 125.5 20 3 10 070 045 :g:1 021

Camshaft insertion tool
m
o
8H
A-A
e
b c d
a
014237 -OlX
mm
9 x 40 = 360
q r s t u V W
069.5_~.1 070 -0.08

-0.11 65 028 :g. g~ 68 010 6 x 10 - 020
Impeller extraction tool Part No. 133688-92100
mm
A B C o E F
45 12 25 M6 M10 65
Crankshaft oil seal insertion tool
Note: The order for this tool is made a YANMAR Tsukaguchi factory.
• Measuring instruments
Application of tools
Instrument name
No. Description Illustration
(YANMAR code No.)
1 div.... 0.01 mm
To measure the bending
Range
Dial gauge and gap of the shaft, sur-
0-5 mm
face distortion, etc.
0-10 mm 001429-00X
~
1 div.... 0.01 mm To measure positions too
2 Test indicator Range narrow and too deep for
0- 0.8 mm normal dial indicators.
r0 001430-00X
Main bar Sub bar

(diameter x (diameter x To attach dial indicators to
3 Magnet stand length) length) various positions for easy
12 x 176 10 x 165 and accurate viewing.
14 x 183 12 x 165
001431-00X
Range (mm) To measure the outside

0-25 75 - 100 diameter of the crank-
4 Micrometer
25 - 50 100 - 125 shaft, piston, piston pin,
50 - 75 125 - 150 etc.
Range (mm)
To measure the inside
5 Cylinder gauge
10 - 18 50 - 100
18 - 35 100 - 150
diameter of the cylinder lin- ~~ t!
4 \..,
ers and bearings.
35 - 60
1 div.... 0.05 mm To measure outside diam-

6 Vernier caliper Range
0-150mm
eter, depth, thickness,
width, etc. 01"
===Ummj
001434-00X
!=.
Range (mm) To measure valve sinkage

7 Depth micrometer
0-25 mm and liner projection.
001435-00X
To measure the inclination

Size of valve springs and
8 Square
100 (mm) squareness of various
parts.
Size Use when measuring the

9 V-block
100 x 50 x 55 (mm) bending of a shaft.
Instrument name
No. Description Illustration
(YANMAR code No.)
Size Range
Use when tightening bolts
(mm) (N·m) and nuts to the specified
6 - 14 3.0 - 7.8 torques.
001005
10 Torque wrench
17,19,21 3.0-15.7
Range
~
3.9 -11.8 N·m 39.2 -176.4 N·m [IdiI])
000995 -OOXOI
9.8-44.1 N·m 39.2 - 274 N·m
To measure oil clearance

between piston rings and
11 Thickness gauge Length 75 x 9 sheets piston grooves or between
shaft couplings during
installation. 001426-00X
To inspect antifreeze solu-

Battery electrolyte Model tion and electrolyte for
12
tester UFB-N2 specific gravity, and
charge.
To measure the deflection

Deflection gauge
13 of the crankshaft and
(42221 -000020)
crankshaft end.
Mirror for deflection To measure the deflection

14 gauge of the crankshaft and
(42111 -001420) crankshaft end.
Penetration test Penetrant (0.45 L)

15 (for flaw detection) Developer (0.45 L) To detect flaws and cracks.
Spray set Cleaning liquid (0.45 L)
• Other material
Items Usual contents Features and application
Three Bond
200 g Non-drying liquid gasket; solventless type, easy to remove, supe-
No.1
(1 kg also available) rior in seawater resistance, applicable to various mating surfaces.
TB1101
Three Bond
200 g Non-drying liquid gasket; easy to apply, superior in water resis-
No. 2
(1 kg also available) tance and oil resistance, especially superior in gasoline resistance.
TB1102
Three Bond
Drying film. low viscosity and forming of thin film, appropriate for
No.3 150 g
mating surface of precision parts.
TB1103
Three Bond Semi-drying viscoelastic material, applicable to non-flat surface
Liquid gasket 200 g
No. 4 having many indentations and protrusions, superior in heat resis-
(1 kg also available)
TB1104 tance, water resistance, and oil resistance.
Three Bond
Solvent less type silicone-base sealant, applicable to high tempera-
No. 10 100 g
ture areas (-50 to 250°C)
TB1211
Three Bond
100 g Silicone-base, non fluid type, thick application possible.
TB1212
Three Bond Silicone-base sealant, applicable to engine oil and coolant.

TB1207C 100 g C: Reddish brown color
TB1207F F: Aluminum color
Prevention of loose bolts, gas leakage, and corrosion.
Lock tight
200 g Torque required to loosen bolt: 10 to 20 % larger than tightening
TB1401
torque.
Adhesive
Lock tight
SUPER 50 g Excellent adhesive strength locks bolt semi-permanently.
TB1330B
Sealing material for threaded parts of various pipes.
Seal tape 5 m round tape
Ambient temperature range: -150 to 200°C
01.92-m diameter: 1
02.42-m diameter: 1
O-ring of any size can be prepared, whenever required.
O-ring kit 03.12-m diameter: 1
(Including adhesive, release agent, cutter, and jig)
03.52-m diameter: 1
05.72-m diameter: 1
Brand name
(LOWCOL 50 g
For assembly of engine cylinders, pistons, metals, shafts, etc.
EP lubricant PASTE)
Spray type facilitates application work.
(molybdenum Brand name
330 g
disfeature) (PASTE SPRAY)
Brand name Prevention of seizure of threaded parts at high temperature. Appli-
50 g
(MOLYPASTE) cable to intake and exhaust valves. (stem, guide, face)
• Cleaners
Items Usual contents Features and application
• The cleaning agent removes even carbon adhering to disassem-
bled parts.
Cleaning agent -
• If a cleaning machine is used, prepare 4 to 6 % mixture of 60 to
80°C to ensure more effective cleaning.
Precautions for Disassembly and Reassembly

• Disassembly
1. Prepare the tools, measuring instruments and recording sheets used in disassembly.
2. Prepare the cleaning machines and cleaning containers.
3. Provide a space and containers for disassembled parts.
4. Drain the cooling water and lubricating oil completely out of the engine.
5. Put the disassembled parts in order.
6. The bolts or nuts with the difference are mixed, so fix them temporarily in their original position immediately after
removing.
7.lf it's a trouble shoot, after judging cause of breakdown accurately, do not remove or disassemble parts unre-
lated to the trouble.
- IMPORTANT _ _ _ _ _ !000Y;;;;;;;;
• Drain the lubricating oil and the cooling water completely.

• Use a fixed tool (spanner wrench) during disassembly.
• To prevent damage and loss, the disassembled parts taken apart cleans .
• Reassembly
1. Wash and check well the assembled parts.
2. Apply new engine oil or the specified lubricant to sliding parts and moving parts before assembly.
3. Replace new gasket packing, O-rings, copper packing and other packing.
4. Use liquid packing, if necessary, to prevent water and oil leakage.
5. Attach each part while checking oil clearance and thrust clearance.
6. Align all marked parts carefully during assembly. When fitting replacement parts, pay attention to their combina-
tion.
7. Do not confuse the kind of bolts, nuts and washers.
8. Tighten the major bolts and nuts to the specified torque by using a torque wrench.
Take special care to tightening parts made of aluminum alloy.
Apply engine oil to the threads and seat surfaces of major bolts.
- IMPORTANT _ _ _ _ _ """"!!h««
• Service parts use a genuine or designation parts.

• The parts with the location or right marking are assembled on the original position certainly.
• When attaching packing, sprayer liquid paste to a packing not to an engine directly.
• Perform the tightening confirmation after last torque tightened.
• Removed protect covers and heat shearing covers are restored as it used to be.
Disassembly Procedures
Item and disassembly points Illustration
[1] Marine gear
Disconnect the marine gear from the engine.
- IMPORTANT -----"""';;;;;;;
Refer to the marine gear manual.
[2] Electrical equipments • Wiring • Harness

1. Remove the engine top cover.
2. Remove the relay cover and harness cover.
3. Disconnect the wiring from the electrical equipment, and
make a note of each wiring terminal's position.
• Starter
• Alternator
• Injector
• Sensor and switch
• Others (Relay fuse etc.)
4. Disconnect the wiring of engine ECU and remove the wire
harness and ECU.
[3] Starter
1 . Remove the starter.
[4] Mist separator

• Standard
1. Remove the mist separator and pipe .
• EPA model only

1. Remove the hoses (2) and pipe (3).
2. Remove the mist separator (1) from the bracket.

[5] Air duct
1. Remove the air duct cover (1) (2).
2. Remove the expansion joint (3) and the air duct (4).
(Turbocharger - Intake manifold)
[6] Turbocharger
1. Remove the cylinder block side expansion pipe for the tur- 2 4 5
bine lubricating oil pipes (1).
2. Remove the exhaust bend (2) and support (3).
3. Remove the turbocharger (4) and outlet air duct (5).
060783-01XOO

[7] Coolant pipe
1. Remove the coolant pipe bend.
(Exhaust manifold - Heat exchanger)
2. Remove the coolant pipe bend.

(Cylinder head - Exhaust manifold)
[8] Cooling water pipe

1. Remove the cooling water pipe, supports and rubber joints.
(Intake manifold side)
[9] Exhaust manifold

1. Remove the exhaust manifold supports (1).
2. Remove the exhaust manifold (2).

[10] Coolant pump
1. Remove the cooling water pipe and the rubber hose.
(Coolant pump - Lubricating oil cooler)
2. Remove the coolant pump.
[11] Lubricating oil by-pass filter

1. Remove the by-pass filter and pipe.
[12] Lubricating oil cooler and lubricating oil filter

1. Remove the lubricating oil filter.
2. Remove the cooling water pipe.

(Lubricating oil cooler - Heat exchanger)
3. Remove the lubricating oil cooler.

[13] Oil pressure control valve
1. Remove the oil pressure control valve.
[14] Alternator
1. Remove the V-belt cover.
2. Loosen the alternator setting bolt (3).

Loosen the nut and support (5) of belt adjuster (4).
Remove the V-belt (6).
3. Remove the belt adjuster.
4. Remove the alternator (2).
- IMPORTANT _ _ _ _ _ '010lI0lL'"
• When removing the alternator, remove the earth float

spacers A (7) and B (8) on the mounting section together
with the alternator.
• If the earth float spacers (7) or (8) are damaged or
cracked, replace them with new ones.
5. Remove the alternator driving unit (1).


[15] Coolant pump and alternator driving case
1. Remove the lubricating oil pipe (1).
2. Remove the driving case cover (2).
3. Remove the coolant pump driving gear (3).

4. Remove the case (4).
OOX02
[16] Heat exchanger

1. Remove the coolant tank (1).
2. Remove the coolant tank bracket (2).

[17] Seawater pump
1. Remove the inlet and outlet bends (1).
2. Remove the seawater pump (2).
[18] Air cooler

1. Remove the support (2) and air duct (3).
2. Remove the air cooler (1).
[19] Intake manifold

1. Remove the intake manifold.

[20] Engine lifter
1. Remove the lifters (1) (2).
[21] Fuel return pipe

1. Remove the fuel return pipe (1).
(Cylinder head outside)
[22] Fuel high pressure pipe

1. Remove the fuel high pressure pipes that connect the fuel high
pressure pump to the injectors. Also, remove the end plugs.
- IMPORTANT -----"""';;;;;;;
o While loosening the cap nuts when removing the fuel
high pressure pipes, fuel may splash out due to residual
pressure inside the common rail. Before removing the
pipes, be sure to cover the pipes with a waste cloth.
o After removing the fuel high pressure pipes, cover the
ends of the high pressure pipes and the female thread
that connects the injector and the fuel high pressure
pump to prevent foreign matter from entering.

[23] Injector
1. Remove the access cover of the bonnet.
2. Loosen the injector retaining bolt (1) to remove the injector
retainer (2).
3. Attach the injector extraction/insertion tool.
4. Use the injector extraction/insertion tool to pull out and
remove the injector. Remove the injector retainer together
with the injector.
5. Remove the nozzle gasket, and then clean the injector
mounting hole.
- IMPORTANT _ _ _ _ _ """"!!N""""
• Do not hang spanners or wrenches on high pressure fuel

parts during work .
• Refer to P100 [How to use the fuel injector extraction/
insertion tool].
[24] Valve rocker arm • Push rod • Valve bridge

1. Remove the bonnet (1) and gasket (2).
2. Remove the support of the rocker arm shaft assembly (3).
Loosen the adjusting screw so that the rocker arm is easily
removed.
3. Remove the valve bridge (4).
4. Remove the push rods (5).

[25] Valve rocker arm case
1. Remove the valve rocker arm case and packing.
[26] Cylinder head

1. Remove the cylinder head bolts (1).
Check no loosen of the bridge guide stud bolts.
2. Remove the cylinder head gasket.
[27] Fuel filter

1. Remove the fuel filter connecting pipes.
2. Remove the fuel pipes and equipment connected to the
fuel high pressure pump.
3. Remove the fuel inlet and outlet pipes, and then remove
the priming pump.
QJ
4. Remove the fuel filter. (J)
r3
5. Remove the fuel filter bracket. ffi
~.~~
Fuel inlel
Fuel filler Feed pump lorive unil
Fueloullel
[28] Fuel high pressure pump

1. Remove the lubricating oil pipe connected to the fuel high
pressure pump drive shaft.
2. Remove the mounting bolts that connect the fuel high pres-
sure pump and pump support.
3. Remove the mounting bolts forthe fuel high pressure pump
drive unit.
4. Remove the fuel high pressure pump while it is attached to
the drive unit.
5. Remove the pump support.

[29] Piston and connecting rod ass'y
1. Clean the top section of the cylinder liner.
- IMPORTANT _ _ _ _ _ !0I!D!'ff;;;;;
If carbon deposits have adhered to the top section of the

cylinder liner, the cylinder liner will come out together with
the piston.
2. Remove the connecting rod bolts and then the caps.
- IMPORTANT _ _ _ _ _ !0I!D!'ffN""""
01:<247 -OOX05
• Ensure the nut and bolt combinations remain the same

(do not mix them) .
• Caps are firmly attached to the nuts. Lightly tap the caps
with a copper hammer to remove them.
3. Push up rod and pull out piston rod ass'y upward.

Identify the components by cylinder Nos.
[30] Cylinder liners

1. Pull out liners using cylinder liner extracting tool.
Identify the components by cylinder Nos.
- IMPORTANT _ _ _ _ _ _ ffN""""
Check the cylinder block, cylinder liners, and flange of the

cylinder liners for wear or damage.
Ol1425-00X06
[31] Tappets
1 . Take out tappets.
Identify the components by cylinder Nos. and intake/
exhaust.
- IMPORTANT _ _ _ _ _ _ ffN""""
Attach packaging tape to the cylinder block to prevent dust

or other foreign matter from falling into the cam area.
011428 - OOX07

[32] Flywheel
1. Loosen the flywheel bolts and remove the flywheel (2).
For safer and easier works, use of flywheel lifting guide
bars (1).
- IMPORTANT _ _ _ _ _ Rl07ffN""""
Be careful not to scratch the ring gear. 1
2. Remove the oil seal case (3).
O1l417--02XOO
[33] Viscous damper

1. Remove the viscous damper (1).
012734-01XOO
[34] Viscous damper cover

1. Remove the oil seal case (1).
Use installation bolt by putting it into the pull-out hole.
2. Loosen the viscous damper cover bolts, and remove the

viscous damper cover (2).
Ol?250-00X05

[35] Turn reverse the cylinder block
Make a cylinder block reversed and the crankshaft is made a
surface.
- IMPORTANT _ _ _ _ _ !0@VPP""
Consider that a head face isn't damaged.
[36] Engine foot

1. Remove the mounting foot (1).
1
011420 -OOX02
[37] Flywheel housing

1. Remove the flywheel housing (1).

[38] Driving gears
1. Remove the idle gear (1).
2. Remove the cam gear (2).
3. Remove the idle gear (3).
[39] Gear case

1. Remove the idle gear mount (2) (3).
2. Remove the gear case (1).
[40] Oil pan

1. Remove all oil pan bolts.
2. Remove the oil pan.

[41] Lubricating oil pump
1. Remove the lubricating oil suction pipe (1).
1------i
2. Remove the lubricating oil pump (2).

2
[42] Camshaft
1 . Remove the key.
2. Remove the camshaft thrust metal.
3. Pull out camshaft (1).
013256-00X03

[43] Crankshaft
1. Loosen and remove the main bearing cap side bolts (1).
2. Loosen and remove the main bearing bolts (2).
3. Remove the main bearing cap (3) and lower main bearing
metal.
The thrust metal (lower) is mounted to the base main bear-
ing cap.
4. Lift up crankshaft (4) to remove.
- IMPORTANT _ _ _ _ _ !000Y;;;;;;;;
• The thrust metal (upper) is mounted to the standard main

01:<257 - OOX03
bearing.
• Remove the main bearing metal (upper) from the cylin-
der block.
Identify metal caps and main metal by cylinder No.
Identify upper and lower of main metals.
• Set the No.3 and 4 crankpins to the top. Make sure that
the balance weights are not caught on other parts, and
then lift up the crankshaft.
011176 -OOXOI
[44] Piston cooling nozzle

1. Removing the piston cooling nozzle (1).
Reassembly Procedures
Item and reassembly points Illustration
[1] Cylinder block
1. Completely clean all oil passages and check that no scal-
ing remains on cylinder block. 1
2. Fit the cover (1) to cylinder block.
3. Attach the cup plugs (2) and taper plugs (3).
Ol1406-01XOO

[2] Piston cooling nozzle
1. Check that no scaling remains on nozzle and nozzle setting
hole. Replace if necessary.
2. Turn to a nozzle point on the piston head side. And set the
nozzle as not touching cylinder block.
3. Tighten the nozzle joint bolts (1) by the specified torque.
Nozzle joint tightening torque:

49 - 59 N·m
M 16 pipe joint bolt
Ol1402-00X02
[3] Camshaft
1. Set in the camshaft bushing as follows: Joint (Clinch)
1- Apply engine oil to the bushing holes in the cylinder
block side and around the bushing circumference.
Press-fit the bushing. ~~~:
+1
L()
N 4
i
,
2- Mach the oil holes so that the joint of the metals are
directed upward. 60°
Detail of oil groove
2. After press-fitting the bushing, measure its inner diameter Ol1404-00E
to check for distortion.
Inner diameter of bush after

press-fitting
70 :gg;g mm
3. Apply lubricating oil to bearing of camshaft and then fit

camshaft (1).
4. Fit camshaft metal by tightening 2 bolts.
When installing the thrust bearing, make sure that the 0132S6-00X04
clearance is even between the outer diameter of the cam-

Oil clearance
shaft and inner diameter of the thrust bearing. Side clearance
- IMPORTANT _ _ _ _ _ """"!!N""""
Camshaft metal has 2 types:

• Flywheel side and front side metal: Width 35 mm, 2 pcs
• Other metals: Width 30 mm, 5 pcs
Thrust metal
Cylinder block Cam gear

/' l05430-00ENOO

[4] Crankshaft
1. Apply engine oil to each crankjournal hole of cylinder block
and each block side main bearing (1).
- IMPORTANT _ _ _ _ _ !0@VPP""
Bearings having an oil groove should be positioned on

upper side (block side).
2. Fit thrust metal (4) so that oil grooves are respectively posi-
tioned outside.
3. Apply engine oil to each crank pin and crank journal (2) and
fit each journal to main bearing. 003173 - OOX04
4. Fix the bearing side bolt (5).

5. Check that the matching numbers shown on the bearing
cap (3) and cylinder block match. "AY" embossed on the
bearing cap should face the anti-flywheel before tightening
it to the specified torque.
6. Method of tightening main bearing refer of P153 [Tighten-
ing of the main bearing bolts (angular tightening)].
7. Check that the crankshaft rotates smoothly.
8. Measure the side clearance of the crankshaft.
ISide clearance I 0.08 - 0.229 mm
013257-00X04
9. Measure the oil clearance of crankshaft.
Crank pin outside diameter 106 -0.04 mm

-0.06
Oil clearance 0.050 - 0.120 mm
Crank journal outside diameter 134 :g:g~5 mm

Oil clearance 0.045 - 0.135 mm
007695-00XOI

[5] Lubricating oil pump
1. Fit the lubricating oil pump (1). 1
2. Tighten the lubricating oil pump set bolt by the specified
torque.
Three Bond 1207 is apply on the cylinder block lubricating

oil inlet flange face.
3. Check the gear backlash.
Lubricating oil pump driving gear 0.15 - 0.25 mm
[6] Lubricating oil suction pipe

1. Mount the lubricating oil suction pipe (1).
1-------.;,
011410-00X02
[7] Gear case

1. Apply Three Bond (TB1212) to the fitting surfaces of the
gear case.
1
2. Mount the gear case (1) along the dowel pin.
3. Mount the idle gear retainer (2) (3).
Mount the retainer (2) so that the "UP" mark comes to the
upper (cylinder head) side.

[8] Idle gear
Apply engine oil to the bolt thread and contact surface.
1.Align the match marks of the idle gear and crankshaft gear,
and install the idle gear.
Idle gear tightening torque:

196 ± 20 N·m
M18bolt
2. Check the backlash of each gear.
I Backlash 0.15 - 0.25 mm
3. Check the side clearance.
I Thrust clearance 0.2 - 0.4 mm

l05290-00XOO
[9] Cam gear

1. Tighten the cam gear assembly and bolt to the specified
torque. Make sure the gears aligning mark.
2. Check the pulser.
Camshaft gear tightening torque:

300 ± 20 N·m
M20 bolt
3. Check the camshaft side clearance.
I Side clearance 0.1 - 0.35 mm
4. Check the backlash.
[10] Idle gear (CR)

1.Align the match marks of the idle gear (CR) and the cam
gear, and tighten the retainer to the specified torque. Install
the idle gear.
Idle gear (CR) tightening torque:

120 ± 10 N·m
M14 bolt
2. Check the backlash.


[11] Flywheel housing
1. Fit flywheel housing (1) while adjusting position of 2 parallel
pins.
2. Using the crankshaft as a reference, check the inlaid part of
the housing for center offset, and the flange for face offset.
Inlaid part center offset :s; 0.20 mm

Flange face offset :s; 0.20 mm
3. Install the oil seal (3) to the oil seal case (2) by using a tool.
3
• The arrow of the oil seal is matched to the rotating direc-
tion.
• Spread the lubricating oil to the crankshaft and oil seal.
• Dispose of the removed oil seal, and replace it with a Ol1417-03XOO
new one.
[12] Oil pan

1. Temporally fit the oil pan (1) using 4 guide bars.
2. Check and adjust the gear case side fitting.
3. Apply Three Bond (TB1207) to the three fitting surfaces at
the flywheel housing side.
4. After the three surfaces are fitted in place, tighten the bolts
to the specified torque.
- IMPORTANT _ _ _ _ _ !0I!D!'ff;;;;;
Make sure that the fitting surfaces of the flywheel housing,

oil pan, and the cylinder block are flat and even. If the 011418 - OOX03
surface is not even, lubricating oil may leak from the gap.

[13] Engine foot
1. Fit engine foots (1) along the parallel pin.
011419-00X02
1
Ol1420-00X02
[14] Turn cylinder block upside down

1. The cylinder block is reversed, and it fixes to the stand (1).
Ol1421-01XOO
[15] Flywheel
1. Apply engine oil to the threads and contact surfaces.
Use 2 guide bars (1) to install the component.
2. Mount the flywheel (2) along with the knock pin.
3. Tighten the set bolts to the specified torque.
Flywheel tightening torque: M20 bolt 481 ± 15 N·m

1
4. Fit the turning view hole cover.
011422 -OlXOO

[16] Cover (front drive)
1.Apply Three Bond (TB1212) to the three fitting surfaces of
the oil pan (2) and cylinder block (3).
2. Mount the cover (1) along the dowel pin.
3. After assembling the cover to the cylinder block, measure
the following points.
Center offset of fitting parts 0.25 mm or less

Flange surface offset 0.25 mm or less
4. Item of importance for reassembling the crankshaft oil seal.

1- Press-fit the oil seal to the oil seal case (5) with a spe-
cial insertion tool the reassembly of the oil seal (4). 4
- IMPORTANT _ _ _ _ _ '010lI0lL'"
• The arrow of the oil seal is matched to the rotating direc-

tion. 011424-00XOI
• Spread the lubricating oil to the crankshaft and oil seal.

• Dispose of the removed oil seal, and replace it with a
new one.

[17] Cylinder liner
1. Clean the liner fitting grooves in the cylinder block.
(Assemble the O-rings, taking care not to distor them)
2.Apply white paint to the O-rings and press them in by hand.
Direct the "w' mark on the liner's upper side to the

operation side.
011425-00XO?
053265-00ENOl
3. Check the projection of the liner.

Measure the four points: A, 8, C and D shown in the figure.
ILiner projection 0.03 - 0.09 mm

Projection
4. Check and measure the distortion of the liner by measuring

inside diameter with cross direction.
IDistortion of liner 0.03 mm or less


[18] Piston and connecting rod
1. The piston and connecting rod should be assembled so
that the Maker mark on the connecting rod and the ID mark
on the piston top face the same direction.
Make sure that no foreign matter or metal pieces intrude

into the crank pin, piston ring, connecting rod cap, bearing
surface, or bolt thread.
2. After assembling the pistons and connecting rods, insert

01:<247 -OlXOO
the pistons into the cylinder liners so that the maker mark
of the connecting rods faces flywheel side. (At this time, the
ID mark pressed on the piston faces flywheel side.)
3. Mount the connecting rod on the crank pin (tighten to spec-
ified torque as three stage tighten with PROTEC-grease or
PROTEC oil pasted).
Method of tightening connecting rod nuts (M14)
(Tighten the respective nut in three steps)
Tightening torques
15t temporary 50 ± 5 N·m
2nd temporary 70 ± 5 N·m
Fuel injection
Third time 137±5N·m pump side
(Refer to P154 [Tightening of connecting rod bolts])

4. The rod bolts are duly tightened, check the large end side
clearance.
ISide clearance 0.150 - 0.324 mm

Maker mark
(Fly wheel side)
014874 -OOENOI
[19] Tappet
1. Install the tappet applying with lubricating oil.

[20] Cam cover
1. Fit the cam cover (1).
[21] Cylinder block side cover

1. Fit the side cover (1).
0114:<0 -OOX02
[22] Cylinder head

1. Clean out the cylinder head bolt holes.
2. Use the positioning pins to line up the head gasket with the
cylinder block.
3. Coat the head bolt (1) threads with PROTEC oil.
4. Tightening of cylinder head bolts.
- IMPORTANT _ _ _ _ _ IE0Y;;;;;;;;
Method of tightening cylinder head bolts refer of P152

[Tightening of cylinder head bolts].
Tightening is "Plastic region tightening for angle method".
5. Measure the top clearance.
ITop clearance 1.56±O.10Smm
6. Set the valve bridge.
007386 - OlEOO

[23] Valve rocker arm case
1. Assemble the valve rocker arm case.
- IMPORTANT _ _ _ _ _ !0I!D!';;;;;;;
Put the valve rocker arm case on the intake manifold side,
and then install.
[24] Valve rocker arm

1. Install the push rods (1) for the intake and exhaust valves.
2. Install the rocker arm shaft assembly (2).
Shaft tightening torque:

23 ± 5.0 N·m
M8 bolt
Shaft stand tightening torque:
44 ± 5.0 N·m
M12 pipe joint bolt
Rocker arm tightening torque:
74±10N·m
M12 bolt
3. Ensure a clearance between the valve rotator and the

valve bridge of 0.5 mm or above.
4. Adjust the valve clearances.
Intake 0.3 mm
Valve clearance
Exhaust 0.5 mm
- IMPORTANT _ _ _ _ _ !0I!D!';;;;;;;
• Adjust the valve clearance when the piston is at com-

pression TO.C.
There are two kinds of TO.C.
- overlap TO.C. and compression TO.C .
• Checking for compression TO.C.
Align the flywheel with the TOP mark (1 .6T) on the angle
identification plate.
Compression TO.C. is when both the intake and exhaust
valves are closed.
Overlap TO.C. is when both the intake and exhaust
valves are open.
007493-00ENOO

[25] Fuel oil return pipe
1. Connect the fuel return pipe (1).
[26] Bonnet
1. Fit the bonnets, and secure by tightening.
[27] Fuel high pressure pump

1. Install the pump support.
2. Install the fuel high pressure pump while it is attached to
the drive unit.
3. Attach the mounting bolts for the fuel high pressure pump
drive unit.
Fuel high pressure pump installing

90 ± 5 N·m
tightening torque: M12 bolt
4. Attach the mounting bolts that connect the fuel high pres-
sure pump and pump support
S.lnstall the lubricating oil pipe that connects to the fuel high
pressure pump drive shaft.
[28] Fuel filter

1. Install the fuel filter bracket.
2. Install the fuel filter.
3. Install the fuel inlet and outlet pipes, and then install the
priming pump.
4. Install the fuel filter connecting pipes.
Ql
S.lnstall the fuel oil pipes and equipment that connect to the UJ
r.l
fuel high pressure pump. tu
- IMPORTANT _ _ _ _ _ !000Y;;;;;;;;
~.~~
Fuel inlel
Fuel filler Feed pump 'Drive unil
When installing equipment in the fuel system, tighten them to Fuel outlet
the specified torque. (See P98 [Fuel high pressure pump pipes
and their torque].)

[29] Fuel high pressure pipe
1. Install the fuel high pressure pipe connecting from the fuel
high pressure pump to the No.1 injector.
l05J34-00XOO
[30] Injector (No.1)

1. Check that the injector mounting hole is clean, and then
install a new gasket.
2. Insert the injector retainer and bolt so that the fuel high
pressure pipe (from the fuel high pressure pump) can be
connected to the injector.
- IMPORTANT - - - - - - " "

• Set the injector, so that the connector harness can be
installed/removed from the side opposite from the fly-
wheel. Failure to do so may result in the harness being
cut.
• Make sure that the injector retainer bolt hole is clean,
with no residual oil.
• Refer to P100 [How to use the fuel injector extraction/ l05378-00XOO
insertion tool].
3. Attach the injector extraction/insertion tool, and insert the

injector.
4. Adjust the injector position, and connect the injector to the
fuel high pressure pipe (from the fuel high pressure pump).
5. Fix the injector retainer using the injector retainer bolts.
- IMPORTANT -----"""';;;;;;;
Make sure that the injector retainer does not interfere with
the valve spring.
6. Connect the fuel high pressure pipe to the No.2 injector.


[31] Injector (After No.2)
1. As with the No.1 injector, use the special tool to install the
No.2 and other injectors to the correct position with the
",.,S ','/''~
S,S'''-~~ ~
connector harness facing to the side opposite from the fly-
wheel. Set the injectors to a position whereby the fuel high
pressure pipe can be easily connected from the No.1 ,~,' 'iff
injector. Fix the injectors. /: ' W '
2. Connect the fuel high pressure pipe to the injectors.
I I ¥i
I ~ I
3. After inserting the No.6 injector, cover the end with a plug. ,:
[32] Engine lifter

1. Install the lifter (1) for flywheel side.
2. Install the lifter (2) for front side.
[33] Intake manifold

1. Mount the intake manifold.
2. Fit the automatic drain cock.

[34] Lubricating oil cooler
1. Assemble the lubricating oil cooler.
[35] Lubricating oil filter and by-pass filter

1. Tighten the lubricating oil filter (1) fully by hand, and then
use a filter wrench to further tighten the filter. (Turn to the
right)
2. Fit the lubricating oil by-pass filter (2) on the cylinder block.
[36] Oil pressure control valve

1. Fit the oil pressure control valve (1).
012718-00XOI

[37] Exhaust manifold
1. Mount the exhaust manifold (1) so that the part to be fitted
with the gasket (2) is positioned as shown in the figure.
Tighten the bolts by tightening torque for standard bolt.
2. Mount the support (3) at 2 place.
3. Fit the water drain cocks (1/4) at 2 place.
[38] Cooling water (coolant) bend (cylinder head outlet)

1. Connect the coolant bends and tighten the bolts at cylinder
head side and exhaust manifold side one after the other.
- IMPORTANT _ _ _ _ _ !000Y;;;;;;;;
Tighten the mounting bolts (x4) for the coolant bends

alternately to prevent uneven tightening.

[39] Heat exchanger
1. Mount the coolant tank bracket (2) to the cylinder block.
2. Fit the coolant tank (1) with 4 zinc anodes.
[40] Cooling water (coolant) bend

1. Install the bend. (Exhaust manifold - Heat exchanger).

[41] Air cooler
1. Mount the air cooler (1) with 4 zinc anodes.
2. Fit the automatic drain cock.
3. Fit the support (2).
4. Install the air duct (3).
[42] Cooling water pipe (seawater)

1. Install the cooling water pipe (1).
When installing, adjust a piping center.
Between the pipe and the rubber hose, apply silicon oil.
2. Fit the 3 supports (2).

[43] Turbocharger and exhaust bend
2 4 5
1. Install the turbocharger (4) unite with the air duct (5).
2. Install the exhaust bend (2) (assembly) and the support (3).
3. Mount the turbocharger's oil pipes (1).
Before installing the oil inlet pipe, oil and lubricating oil.
- IMPORTANT _ _ _ _ _ """"!!k""""
For beginning lubrication, oiling is needed.
[44] Air duct

1. Install the support (1).
2. Install the expansion joint (2) and the air duct (3).
3. Install the expansion joint (2) and the air duct (4).
- IMPORTANT _ _ _ _ _ Hlk§;;;
When assembling the expansion joints, make sure that the

arrow mark of expansion joints will face to the air cooler
side.

[45] Coolant pump drive case and cover
1. Mount the case (4) along the dowel pin.
2. Install the pump driving gear (3).
3. Install the case cover (2).

4. Install the lubricating oil pipe (1).
[46] Coolant pump

1.Assemble the driving gear on the coolant pump.
Driving gear tightening torque: M20 bolt 127 -147 N·m
2. Mount the coolant pump (1).

3. Connect the cooling water pipe and the rubber hose.
Between the pipe and the rubber hose, apply silicon oil.
4. Fit the drain cock.
[47] Seawater pump

1. Assemble the driving gear on the seawater pump.
Driving gear tightening torque: M27 nut 235 - 255 N·m
2. Mount the seawater pump (2).

3. Connect the seawater inlet and outlet bends (1).
Between the joint pipe and the rubber hose, apply silicon
oil.
Ol3230-00X02

[48] Alternator
1. Install the alternator driving device.
• Assemble drive shaft, bearing, oil seal, drive gear and
V-pulley into the bearing case.
V-pulley tightening torque: M20 nut 125 - 135 N·m
2. Install the alternator (2).
• When installing the alternator, attach earth float spacers

A (7) to both ends of the bracket, and earth float spacers
B (8) to the belt adjuster support.
• Before attaching the earth float spacers, remove oil from
the mounting surface.
• Make sure to attach the earth float spacers as indicated
in the parts list.
3. Install the belt adjuster (4), and then install the nuts and
support (5).
4. Install the V-belt (6).
5. Adjust the V-belt with the adjuster nuts until the application
X( Adjuster nut
of 100 N of load at the center of the maximum belt span ;) Adjuster 052880
results in a deflection of 12 mm.

6. After adjusting the V-belt, tighten the set bolt (3).
7. Attach the belt cover.
The belt cover is fixed with grommets.

[49] Viscous damper
1. Mount the viscous damper (1).
Viscous damper tightening torque:

235 - 255 N·m
M20 bolt
[50] Mist separator

• Standard
1. Mount the mist separator and connect the drain pipe .
• EPA model only

1. Install the mist separator (1).
2. Connect the hoses (2) and pipe (3).
[52] Air duct cover

1. Mount the cover (1) (2) on the air duct.

[53] Wire harness
1. Install the wire harness and ECU to the engine.
2. Install the relay cover and the harness cover.
3. Install the engine top cover.
[54] Electrical equipments and wiring

1. Install the starter.
2. Connect the wiring to the electrical equipments.
• Starter
• Alternator
• Relay box
• Fuse box
[55] Marine gear

1. Connect the marine gear to the engine.
- IMPORTANT
Refer to the marine gear manual.
INSPECTING AND SERVICING OF ENGINE'S MAJOR PARTS - 67
INSPECTING AND SERVICING OF ENGINE'S

MAJOR PARTS
Preliminaries
1. Wash each part with care, and remove dust, car-
bon deposits, oil, moisture etc.
2. Blow air through the oil holes to remove deposits
and make sure that there are no obstructions in the
holes.
3. Remove carbon sticking to the cylinder head, suc-
tion/exhaust valve etc., taking care not to damage
the parts.
4. Always place parts which belong together in order
to avoid confusion.
Standard for Parts Replacement

(Including Correction)
Measure the dimension of the parts in accordance with
the checking procedures. Replace any defective parts
or those parts that exceed the wear limit. Also replace
any part which, based on past wear limit data, is likely
to exceed the limit before the next servicing.
68 - INSPECTING AND SERVICING OF ENGINE'S MAJOR PARTS
Cylinder Head
The cylinder head is independent for each cylinder of
water cooled, intake and exhaust ports crossed-flow 4-
valved construction mounted with 6 bolts.
A special alloy satellite with superior resistance to heat
and wear is fitted on the seats, and the area between
the valves is cooled by a water jet.
• Inspection of the cylinder head

The cylinder head is subjected to very severe operat-
ing conditions with repeated high pressure, high tem-
perature and cooling. Thoroughly remove all the
carbon and dirt after disassembly and carefully inspect
all parts.
Distortion of the combustion surface

Carefully check for cylinder head distortion as this
leads to gasket damage and compression leaks.
1. Clean the cylinder head surface.
2. Place a straight-edge along each of the four sides
and each diagonal. Measure the clearance
between the straight-edge and combustion surface
with a feeler gauge.
mm
Item Standard limit
Cylinder head distortion 0.035 or less 0.15
Checking for cracks in the combustion

surface
Remove the fuel injection nozzle, intake and exhaust
valve and clean the combustion surface. Check for dis-
coloration or distortion and conduct a color check test
to check for any cracks.
010912-00.1:
• Checking the intake and exhaust valve

seats
Check the surface and width of the valve seats.
If seat width is too wide, or if the surface is rough, cor-
rect to the following standards:
I
Seat aogle
Intake
Exhaust
mm
Seat width Standard Limit
Intake 3.46 3.96
Exhaust 2.48 2.98
Correction of the valve seat

Correct the seat with a seat grinder as follows.
1. Grind a roughened seat surface with a seat
grinder.
Intake valve seat grindstone Angle 8= 30°

Exhaust valve seat grindstone Angle 8= 45°
2. Grind the seat surface using a grinder with an

angle of70° and then finish off the surface width to
the standard dimension using a grinder with an
angle of 15°.
3. Knead valve compound with oil and finish the valve
seat with a lapping tool.
4. Final finishing should be done with oil only.
5. Clean the valve and cylinder head with light oil or
the equivalent after valve seat finishing is com-
pleted and make sure that there are no grindings
remaining.
- IMPORTANT _ _ _ _ _ !000Y;;;;;;;;
When seat adjustment is necessary, be sure to

check the valve and valve guide.
If the clearance exceeds the tolerance, replace the
valve or the valve guide, before grinding the valve
seat.
• Inspection of intake/exhaust valves,

d
valve guides
Wearing and corrosion of the valve stem

Measure the outside diameter of the valve stem.
B
Replace the valve, if the stem is excessively worn or
corroded.
mm
Valve stem out-
Standard Limit
side diameter
Intake
10.928 - 10.950 10.82
Exhaust
Valve measurement position

A: 68 mm, B: 102 mm
0073S9-00XOO
Valve sink
Over long periods of use and repeated lapping, com-
bustion efficiency may drop.
Measure the sinking distance by depth gauge. Replace
the valve and valve seat if the valve sink exceeds the
tolerance.
Cylinder head
mm
Item Standard Limit
Valve sink (+0.1) - (-0.4) -0.5
Note: +; Projection, -; Sink
Valve guide
1. Measuring the inside diameter of valve guide.
Measure the inside diameter of the valve guide
and replace it if it exceeds the wear limit.
mm
Item Standard limit
Valve guide inside diameter 11.000 - 11.018 11.12
Intake
Clearance 0.050 - 0.090 0.2
Exhaust
- IMPORTANT _ _ _ _ _ !0I!D!';;;;;;;
The inside diameter standard dimensions are

measured after the guide is installed.
2. Replacing the valve guide. Use the insertion tool

and tap the valve guide with a mallet.
Valve guide projection:

The valve guide should project the specified value
from the top of the cylinder head.
Valve stem seal Fitting tool
The valve stem seals on the intake/exhaust valve

Put the guide pin on the fitting tool to
guide cannot be re-used once they are removed. keep the valve stem from falling over.
Be sure to replace them with new ones. Where spring is attached, be careful
not to let the spring fall off.
When assembling the intake/exhaust valves, apply an
Release the upper part to the valve
adequate quantity of lubricating oil on the valve stem stem seal from the fitting tool and use
before inserting. it to push in the shoulder section.
Fit the upper surface of the valve guide
and the valve stem seal so that they
1-... adhere closely together.
~;; /j~ When using a hammer or similar tool,
~ ~ attach a positioning stopper to prevent
damage to the stem seal.
I stem sea I)
(Vave 00655200E
• Valve springs
Checking valve springs

1. Check the spring for scratches or corrosion.
OOlS09-01X
2. Measure the free length of the spring.

3. Measure inclination. Inclination
mm
Limit
1.8
00ISI0-00E
/)\
/
001511-00X
4. Measure spring tension.
(Inside) mm
Valve spring Standard Limit
Free length 57.9 57.7
Length when attached 47.0 46.8
119.86
Load when attached -
(12.22 kgf)
(Outside) mm
Valve spring Standard Limit
Free length 60.2 60.0 Spring tension tester
Length when attached 50.0 48.8
Load when attached 216.92 N -
5. Spring retainer and spring cotter

Inspect the inside face of the spring retainer, the
outside surface of the spring cotter, the contact
area of the spring cotter inside surface and the
notch in the head of the valve stem. Replace the
spring retainer and spring cotter when the contact 0011)1 ?-OlEOO
area is less than 70 %, or when the spring cotter

has been recessed because of wear.
• Valve rotator
The valve is equipped with a valve rotator for allowing
the intake and exhaust valves to continuously rotate
during operation.
Inspection procedures
1. Remove the valve rocker arm case cover while the
engine is in operation and check the condition of
the valve rotation.
2. Visually check the valve head for the valve rocker
arm contact while the valve is disassembled. If the
contact condition is defective, replace the valve as
an assembly.
• Nozzle sleeve O-ring-O
1. When assembling, apply lubricating oil to O-ring.

2. Attach the sleeve to the cylinder head and tighten Nozzle ~..
sleeve -~
it.
o-ring<@
ITightening torque 157 -167 N·m
• Measurement of the top clearance

1. Place a high quality fuse (02 mm, 10 mm long) in
the 4 positions on the flat part of the piston head.
2. Assemble the cylinder head gasket and the cylin-
der block and tighten the bolts in the specified
order to the specified torque.
3. Turn the crank (in the direction of engine rotation),
and press the fuse against the piston until it
breaks.
4. Remove the head and take out the broken fuse.
5. Measure thickness of broken fuse at four positions
and calculate the average.
ITop clearance 1.452 - 1.668 mm

• Assembly of the cylinder head

Partially tighten the bolts in the specified order and
then tighten to the specified torque, being careful that
the head does not get distorted.
1. Clean out the cylinder head bolt holes.
2. Check on the cylinder head surface where it
comes in contact with the block.
3. Coat the head bolt threads with PROTEC oil.
4. Use the positioning pins to line up the head gasket
with the cylinder block.
5. Match up the cylinder head with the head gasket
and mount it.
6. When tightening the cylinder head tighten the
respective bolts, refer to the P1S2 [Tightening of
cylinder head bolts].
Tightening method is "Plastic region tightening for
angle method".
• Intake and exhaust rocker arms

The wear of the rocker arm and the rocker arm bush-
ing may change the open/close timing of the valve,
and may in turn affect the engine performance accord- Bush
1
'h
® \~I~
ing to the extent of the change. Rocker arm ~ ~ ';'
,,1_.
Shaft.suppot"" ~I. ___ I D",' . Rocker arm
Bush ~~~,,/ I shaft
® \ J~ 9
Adjust ~G'/ Exhaust ~~
screw1~~ rocker arm }~
~( ~ 7 !/Retainer /"
Intake
Itj9
rocker arm
t':l\
," ~
"~
Valve bridge
___
I 016S07-01ENOO
Rocker arm shaft and rocker arm bushing

Measure the outer diameter of the shaft and the inner-
diameter of the bushing, and replace if wear exceeds
the limit.
mm
Item Standard Limit
Inside diameter of the intake
and exhaust rocker arm bush- 32.010 - 32.065 32.180
ing
(Rocker arm hole diameter)
Outside diameter of the intake
31.966 - 31.991 31.880
and exhaust rocker arm shaft
Clearance of the rocker arm
0.019 - 0.099 0.20
shaft and bushing at assembly
Replace the rocker arm bushing if it moves.

Replace the entire rocker arm if there is no tightening
clearance.
Rocker arm and valve top retainer wear

Inspect the contact surface of rocker arm and replace it
if there is abnormal wear or flaking.
(Rocker arm shaft diameter)
Adjusting bolt
Inspect the contact surface of adjusting screw and
push rod. Replace if there is abnormal wear or flaking.
• Adjustment of the valve clearance

1. When the engine is cold, adjust the valve clear-
ance in the sequence of the firing order.
Firing order
(the side opposite from the flywheel is No.1)
1-4-2-6-3-5-1
Angle identification
2. Turn the flywheel and move the relevant cylinderto plate I
TO.C. of the compression stroke .

• Align the angle identification plate and the fly- !
wheel TOP mark .
• Note that the compression TO.C. and overlap
TO.C are different.
3. Loosen the adjusting screws and lock nuts of the
rocker arm and valve bridge.
4. While lightly pressing the rocker arm, turn the
adjusting screw of the valve head (valve bridge)
until there is no clearance between the adjusting
screw end and the valve head.
5. When the valve head clearance is 0 mm, tighten and
lock the adjusting screw on the valve bridge side.
6. Adjust the valve clearance (A) as specified below.
Tighten the adjusting screw on the rocker arm.
Intake 0.3 mm
Valve clearance
Exhaust 0.5 mm
7. If the timing gear was also disassembled, be sure to

check and adjust the valve timing for the intake and
exhaust valves. (To check the valve opening and
closing timing, turn the flywheel and read the angle
resulting from the movement of the push rods.)
Valve timing
Intake valve open b: TO.C. 50 ± 2°
Intake valve close a: B.O.C. 40 ± 2°
Exhaust valve open b: B.O.C. 76 ± 2°
6AYEM-GT(S) 60 ± 2°
6AYEM-ET,
171 ± 2°
Exhaust valve close a: TO.C. ST (EPA)
Other than
176 ± 2°
above
• Measurement of the clearance between

the valve rotator and valve bridge
Ensure 0.5 mm or more clearance between the valve
rotator and the valve bridge. When grinding the valve
bridge, place a metal piece to protect other parts, and
then grind to adjust the clearance.
Cylinder Block
• Inspection of the parts
If your engine has already encountered such troubles
as freezing, turnover etc., conduct visual checks care-
fully before disassembly. If cracking is suspected,
investigate by color checking.
Replace any part for which the damage is irreparable.
Cylinder Liner
Since the cylinder liners are cooled by high constant
temperature cooling by the coolant, there is no possi-
bility of abnormal wear of liner due to over-cooling
during low load operation of the engine. The liners are '~--O-ring
made of a special non-plated cast iron that has low
friction loss. The liner is given uniform wall thickness to
- - - Cylinder liner
prevent uneven local thermal expansion. These fea-
tures provide high durability to the liners.
(Pistons and liners fit each other selectively.)
007774-00E
• Measurement of the liner
Use a dial gauge to measure the cylinder liner. Mea-
sure the inside diameter in the axial direction of the
crankshaft and perpendicularly to the crankshaft, at the --- Direction of
crankshaft center
points on the cylinder liner shown in the table below. If
they exceed the limit, replace the liner.
,....,_ _ _--,--,-----1
, IYiston of top rinQ, About 25 mm
mm -----,
Item Standard Limit
L 155.020 - 155.030
155.40 Center
Cylinder liner inside ML 155.015 -155.020
Deflection
diameter MS 155.010- 155.015
wear of 0.2
S 155.000 - 155.010
Roundness 0.008 or less -
Aboul 60 mm
Cylindricity 0.010 or less - -----, 016500-00EOI
• Insertion of the liner

1. Remove rust from the contact part of the liner
inside the cylinder block.
2. Fit the rubber packing to the liner, taking care not
to twist it.
3. Apply water-proof white paint to the rubber packing.
4. Bring the upper surface of the liner marked with
"@" (hydraulic pressure mark) to the suction port
side and insert it into the cylinder.
S.lf it cannot be inserted entirely by hand, put a piece
of wood on the liner and tap lightly.
OS826S-00EN03
• Measurement of the projection

Check that the flange of each cylinder is projecting the
top of the cylinder block.
mm
Cylinder block hole depth: A 14.96 -15.0
Cylinder liner flange thickness: B 15.03 - 15.05 C
Cylinder liner projection: C 0.03 - 0.09 B A
(Cylinder block)
Measure the 4 points.
(Measurement point)
Pistons
Pistons are made of a special light alloy with superior
thermal expansion characteristics, and the top of the
piston forms a swirl type combustion chamber. The
opposite face of the piston combustion surface is oil-jet
cooled .
• Piston head and combustion surface

Remove the carbon that has accumulated on the pis-
ton head and combustion surface, taking care not to
scratch the piston. Check the combustion surface for
any damage .
• Measurement of piston outside diame-

ter
1. Replace the piston if the outside of the piston or
the ring grooves are worn.
2. Measure the outside diameter at position of A from
the piston bottom in the direction vertical to the pis-
ton pin.
A 47 mm
If the piston outside diameter exceeds the limit,

replace the piston with a new one. 007506- OOE
Piston outside diameter mm

Piston ID
Standard Limit
mark
L 154.935 -154.945
M 154.925 -154.935 154.780
S 154.915 -154.925
• Selective pairing of cylinder liner and

piston
Piston must be paired with cylinder liner according to
the below table. The size mark of a piston is shown on
the top surface of the piston and the size mark of a cyl-
inder liner is shown on the non-operating side of the
cylinder block. The service parts of the pistons are pro-
vided.
Application table for piston and liner

Liner
L ML MS S
Piston
L
• 0 x x
M x
• • x
S x x 0
•
Combination
.: Recommended
0: Acceptable
x: Not acceptable
Removing the piston

A floating type piston pin is used in this engine. The
piston pin can be pressed into the piston pin hole at
room temperature (coat with oil to make it slide easily).
00655S-00X
• Piston pin
Measure the outer diameter and replace the pin if it is
excessively worn.
Measure at positions a, band c in directions A and B.
mm
Item Standard Limit
Piston pin hole inside diameter 62.010 - 62.020 62.120
Piston pin outside diameter 61.971 - 61.980 61.867
Clearance 0.030 - 0.049 0.06
a b c
t I
tI - - - - f----- ~-I
I
001520-02XOl
• Piston rings
There are 2 compression rings and 1 oil ring. TOP~
Second rin
(Ring components)
001522 -OlE
Measuring the rings

Measure the thickness and width of the rings, and the
ring-to-groove clearance after installation. Replace if
wear exceeds the limit.
tjJ~d"
I...
.-
Thickness ..
_.
I 016584-00E
mm
Item Standard Limit
Ring thickness 5.580 - 5.820 5.380
Top ring Ring width 3.470 - 3.490 3.370
Clearance 0.140-0.175 0.280
Ring thickness 6.580 - 6.820 6.380
Second ring Ring width 2.970 - 2.990 2.870
Clearance 0.105-0.140 0.240
Ring thickness 2.850 - 3.150 2.680
Oil ring Ring width 3.970 - 3.990 3.770
Clearance 0.030 - 0.070 0.180
Measuring piston ring gap

Press the piston ring into a piston liner and measure
the piston ring gap with a gauge. Press on the ring
about 30 mm from the bottom of the liner.
mm
Item Standard Limit
Top ring gap 0.40 - 0.55 1.5
Second ring gap 0.55 - 0.70 1.5
Oil ring gap 0.40 - 0.60 1.5
Piston ring
30mm
Gap
Rep/acing the piston rings

1. Thoroughly clean the ring grooves when replacing Face the punched manufacturer's mark upward
piston rings. ---=_. . . _. .....;;;;;;;;;;;;;:=:---.

2. The side with the manufacturer's mark should face
up.
3. After fitting the piston ring, make sure it moves
easily and smoothly.
4. Stagger the piston rings at 180° intervals, making
sure none of them line up with the piston. 001525-02E
5. The oil ring is provided with a coil expander. The

coil expander joint should be opposite (staggered
180°) the oil ring gap. 1st piston ring
2nd piston ring
Oil ring
1st piston ring gap

Oil ring gap
.....--=::::z:::~
Joint of coil
expander
01658S-00E
Connecting Rods Connecting rod
The connecting rod is made of high-strength forged

Connecting rod boll
low alloy steel.
The large end with the aluminum metal can be sepa-
rated into two parts and the small end has a 2-layer
copper alloy coil bearing.
Connecting rod
(big end cap)
Connecting rod nut

014872 -OOE
• Inspection of the connecting rod
Twist and parallelism of the large and

small ends Parallelism
Insert the measuring tool into the large and small ends
of the connecting rod. Measure the extent of twist and
parallelism and replace if they exceed the tolerance.
mm
Item Standard Limit
Connecting rod twist and par- 0.03 or less
0.07
allelism (at 100 mm)
• Crank pin metal
Checking crank pin metal

Check for flaking, melting or seizure on the contact
surface of the crank pin metal.
Cylinder gauge
Measuring crank pin oil clearance
Measure the crank pin outside diameter and the crank
pin metal inside diameter. Calculate the oil clearance
from the measured values.
Replace the crank pin metal if the oil clearance
becomes about the limit dimension of the below table.
Correct by grinding if unevenly wear, roundness
exceeding the limit or insufficient outside diameter is
found. Also use an undersized metal if necessary.
• Mount the connecting rod on the crank pin (tighten
to specified torque as three stage tighten with PRO-
TEC-grease or PROTEC oil pasted).
008302--00E
Method of tightening connecting rod nuts
(tighten the respective nut in three steps)
Tightening torques
1st temporary 50 ± 5 N·m
2nd temporary 70±5N·m
Third time 137±5N·m
mm
Item Standard limit
Rod metal inside diameter 106.010- 106.060 106.1
Crank pin outside diame-
105.940 -105.960 105.85
ter
Clearance 0.050 - 0.120 0.15
Crank pin metal

mm
Classification Size mark T size TSize
Standard STD 2.5 ~g:g1§
Size mark
0.25 and under U025 2.625 ~gB~§
0.5 and under U05 2.75 :8:8~~
• Other procedure of measuring crank pin oil clear-

ance.
1. Use the press gauge (plastic-gauge) for measuring
the oil clearance of the crank pin.
2. Mount the connecting rod on the crank pin and
tighten to specified torque.
3. Remove the connecting rod and measure the bro-
ken plastic-gauge with measuring paper.
Assembling of the crank pin metal

1. Wash the crank pin metal.
2. Wash the large end cap, mount the crank pin metal
and make sure that it fits tightly on the large end cap.
3. When assembling the connecting rod, match up
the large end and large end cap number. Apply
PROTECT grease to the threaded part of connect- Alignment mark(Punched mark)
Cylinder No.
ing rod bolt and gradually tighten them alternately 014973-00E
to the specified torque.

Make match marks on the bolt heads and large
end cap (to indicate the proper torque position).
Matching mark..,.....,..+--++--"""\.
4. Make sure there is no sand, metal cuttings or other (Operation side)
dust in the lubricating oil, and that the crankshaft is

not scratched. Take special care in cleaning the oil
holes.
01:<276 -OOE
• Piston pin bearing
Measuring piston pin clearance

Excessive piston pin bearing wear may result in dam-
age to the piston pin or the piston itself. Measure the
piston pin bearing inside diameter and the piston pin
outside diameter. Calculate the oil clearance from the
measured values. (Refer to P8D [Piston pin].)
mm
Item Standard Limit
Piston pin bearing inside
62.034 - 62.049 62.134
diameter
Oil clearance 0.054 - 0.078 0.15
Crankshaft and Main Bearing

The crank pin and crank journal have been induction
hardened for superior durability, and the crankshaft is
provided with 4 balance weights for optional balance.
The crankshaft main bearing is of the hanger type. The
upper metal (cylinder block side) is provided with an oil
groove. There is no oil groove on the lower metal
(bearing cap side). The bearing cap (location cap) of
the flywheel side has a thrust metal, which supports
the thrust load.
014974 -OOENOl
Main bearing
(inlermdeiale)
~~
(j Thrust bearing
(base side) Main bearing
(base)
071498-00ENOO
• Crankshaft
C%r checking of crankshaft

Color check after cleaning the crankshaft, and replace
the crankshaft if there is any cracking or significant
damage.
Bending of the crankshaft

Support the crankshaft with V-blocks at both ends of
the journals. Measure the deflection of the center jour-
nal with a dial gauge while rotating the crankshaft to
Deflection
check the extent of crankshaft bending.
mm
Item Standard Limit 1/2
Crankshaft bend limit
0.018 or less 0.05
(1/2 the dial gauge reading)
Measurement of the crank pin and crank

journal
When the difference between the maximum wear the
minimum wear of these parts (i.e. roundness) exceeds
the limit, grind or replace the crankshaft.
mm
Crankshaft Standard Limit
Shaft outside
105.940 -105.960 105.85
diameter
Pin
Crank pin metal
106.010 -106.060 106.10
inside diameter
Shaft outside
133.930 -133.955 133.85
diameter
Journal
Main metal inside
134.000 -134.065 134.10
diameter
- IMPORTANT _ _ _ _ _ _ ffN""""
If re-grinding is performed, use an under-sized main

metal to adjust the oil clearance to the specified value.
Checking the side clearance of a crank-

shaft
After assembling the crankshaft, tighten the main bear-
ing cap to the specified torque, and move the crank-
shaft to one side, placing a dial gauge on one end of
the shaft to measure thrust clearance.
Replace the thrust bearing if it is worn beyond the limit.
mm
Item Standard Limit
Crankshaft side clearance 0.080 - 0.229 0.33 007695- OOXOl
• Main bearing
mm TSize
Classification Size mark T size
Size mark
Standard STD 3.0 l020
Main
(Intermediate Under size 0.25 U 025 3.125l020 007529-01E
and gear side)

Under size 0.5 U05 3.25_8.020
Standard STD 4.0 l020
Thrust Under size 0.25 U 025 4.125l020
Under size 0.5 U05 4.25_8.020
007536 -OOE
Inspecting the main bearing

Check for flaking, seizure or burning of the contact sur-
face and replace if necessary.
Measuring the inner diameter of metal

Tighten the cap to the specified torque and measure
the inner diameter of the metal.
• Forthe method of tightening procedures of the main
bearing, refer to P153 [Tightening of the main bear-
ing bolts (angular tightening)].
mm 007537-00X
Item Standard Limit

Metal inside diameter 134.000 -134.065 -
Metal thickness 2.980 - 3.000 -
- IMPORTANT ------;;;;;;;
• No oil grooves are provided on the lower bearings
(at cap side).
• Match the matching numbers with those of the cylin-
der block.
• Bring the embossed "AY" mark on the cap to the
front side.
• Set reference bearings at the flywheel side.
008220-00E
Oil Seal of the Crankshaft

• Disassembly and reassembly of the crankshaft oil seal
Items of importance for disassembling the crankshaft oil seal

1. Use a special tool when disassembling, to avoid damage to the crankshaft.
2. Remove damage with emery paper damage to the crankshaft.
3. After detaching the oil seal, it cannot be used again.
- IMPORTANT ------="'"
• The oil seal must apply the new seal. (Do not use the seal pulled out again.)
• The oil seal is different according to the rotation of the crankshaft. use the one corresponding to the engine rotation.
• Damage neither crankshaft nor the inside of the oil seal case when you work slipping out the oil seal.
Opposite side from the flywheel Flywheel side
Pay attention to the following when reassembling the crankshaft oil seal
The oil seal of this engine is a slinger type oil seal. Work according to the following procedure using a specialized
insertion tool.
1. Press-fit the lip and slinger to the crankshaft with an insertion tool specialized for the reassembly of the oil seal.
2. The insertion tool must project 0.15 mm from the side of the lip on the slinger side.
3. When the oil seal is reassemble spread lubricating oil between the crankshaft and slinger.
4. Insert it in the direction shown in figure after confirming the inside and outside of the oil seal.
Opposite side of flywheel Flywheel side
\J~A I~
Lip side
_Mll_~_
Camshaft and Tappets

• Camshaft
The camshaft is normalized and the cam and bearing
surfaces are surface hardened and ground. The cams
have a curve that minimizes repeated shocks to the
valve seats and maximizes valve seat life.
Checking the camshaft side clearance

Measure the thrust clearance before disassembly.
As the cam gear is shrink-fitted to the cam, be careful
when replacing the thrust bearing.
mm
Item Standard Limit
Camshaft side clearance 0.10 - 0.35 0.45
Camshaft and bearing hole measurement

Measure the camshaft outside diameter with a microm- Oil clearance
Side clearance
eter. The oil clearance shall be calculated by subtract-
ing the measured camshaft outside diameter from the
inside diameter of the camshaft bearing or bushing.
The camshaft bushing on the gear housing side is
measured with a cylinder gauge after insertion into the
cylinder.
Replace if they exceed the limit or are damaged. Thrust metal
mm
Item Standard Limit Cam gear
Bushing inside diameter 70.02 - 70.07 70.16 l05430-00ENOO
Camshaft outside diameter 69.91 - 69.94 69.82

Oil clearance 0.08 - 0.16 0.25
Bending of the camshaft

Support both ends of the camshaft with V-blocks, place
a dial gauge at the central bearing areas and measure
bending. Replace if excessive.
mm
Item Limit
Camshaft bend
0.05
(1/2 dial gauge reading)
Measure the camshaft height, and rep/ace

the cam if it is worn beyond the limit
mm
Cam height
Item
Intake
Exhaust
Standard
59.850 - 59.950
59.950 - 60.050
Limit
59.4
59.5 -@z
--r . ,
,
"
Height
007709-01ENOl
• Camshaft assembly point

1. Apply lubricating oil to the camshaft.
Camshaft metal
2. Install the camshaft from the opposite side of the (Thrust metal)
flywheel.
3. When installing the thrust bearing, make sure that
\
the clearance is even between the outer diameter
of the camshaft and inner diameter of the thrust
bearing.
4. Use the installation tool to install the cam gear.
Cam gear tightening torque:

280 - 320 N·m 105390 - OOENOO
M20
5. Measure the side clearance of the camshaft.

Cam gear
').
ISide clearance
~ "O'm'~
0.10 - 0.35 mm
• Checking the match mark of the camshaft i

and pulsar
If the pulsar was removed, when re-installing align the Pulsar 7~ ~
) l~
0-
pulsar and the camshaft with the "0" mark. ,
Parallel pin
)~~
l06361-UUENOO
• Tappets
The tappets are offset to rotate during operation and Tapp\l
thereby prevent uneven wearing. Check the contact of
Offset
each tappet and replace if excessively or unevenly
worn.
camsh~_ _-I
- IMPORTANT _ _ _ _ _ """!!N""""
When removing tappets, be sure to keep them

015324
separated for each cylinder and intake/exhaust valve.
013840-00.1:00
Measure the outer diameter of the tappet,

and rep/ace if worn beyond the limit
mm
Item Standard Limit
Tappet stem outside diameter 44.940 - 44.965 44.90
Tappet guide hole inside diam-
45.000 - 45.025 45.06
eter (cylinder block)
Tappet stem and guide hole oil
0.035 - 0.085 -
clearance
014926-00X
Measuring push rods

Measure the bend and diameter of the push rods.
mm
Item Standard Limit
Push rod bend 0.2 or less 0.4
/
Thickness gauge
Push rod diameter 15 - l----~-----
(Push rod bend)

001554-01E
Timing Gear
The timing gear is a helical type gear for minimum
noise and is specially treated for high durability.
• Inspecting the gears

Inspect the gears and replace them if the teeth are
damaged or worn.
Measure the backlash of all gears that mesh, and
replace the meshing gears as a set if wear exceeds
the limit.
- IMPORTANT _ _ _ _ _ !000Y;;;;;;;;
If backlash is excessive, it will not only result in

excessive noise and gear damage, but also lead to
bad valve and fuel injection timing and a decrease in
engine performance.
mm
Item Standard Limit
Backlash 0.15 - 0.25 0.40
Idling gear
The bushing is pressure fitted into the idling gear.
Measure the bushing inner diameter and the outer
diameter of the shaft, and replace the bushing or idling
gear shaft if the oil clearance exceeds the wear limit.
mm
Idle gear Standard Limit
Shaft diameter 59.940 - 59.970 59.83
A
Bush inside diameter 60.000 - 60.030 60.14
B
Oil clearance 0.03 - 0.09 0.2
Shaft diameter 49.950 - 49.975 49.86
CR Bush inside diameter 50.000 - 50.025 50.11
Oil clearance 0.025 - 0.075 0.17
IIdling gear side clearance 0.2 - 0.4 mm
Tightening torques
Idle gear tightening bolt: M 18 180 - 220 N·m
Idle gear (CR) tightening bolt:
110 -130 N·m
M14
Idle gear support tightening bolt:
110 -130 N·m
M14, M12
• Gear timing marks

Match up the timing marks on each gear when assem- Seawater pump Cam gear
gear
bling.
Fuel high pressure

pump gear
Crank shaft gear
105380 -OOENOO
• Water pump (coolant) and alternator Cam gear (front side)
driving gear (OFW)

The water pump (coolant) and alternator driving gear is
a helical type gear.
Measure the backlash of all gear.
Altemator
mm Water (coolant)
driving gear
Item Standard Limit pump gear
Ol?274-00EOI
Backlash 0.15 - 0.25 0.40

Viscous Damper
When the viscous damper ceases to function, the tor-
sional vibrations of the axial systems increase with
adverse effects on the engine, and this can lead to
breakage of the crankshaft and other parts.
Check and replace the viscous damper as follows:
1. Check the damper every 5000 hours. operation.
2. Remove the damper from the engine, and mea-
su re the expansion of the damper cover.
expansion of the damper cover = b - a
a: Dent margin at center
b: Dent margin at end
3. Replace it when the expansion of the damper
cover exceeds 0.5 mm or after use for over 10000
hours. a
- IMPORTANT _ _ _ _ _ !0I!D!';;;;;;;
Do not alter the viscous damper, such as drilling a

hole, etc.
The performance of the viscous damper will be
Fixing boll
lost.
070667-00ENOO
Fuel Oil System

Fuel system
Fuel that is sent from the fuel tank through the water separator is supplied from the fuel feed pump. Fuel is filtered
through the fuel filter, and then sent to the fuel high pressure pump and supply pump. By using a fuel high pressure
pump, the injectors deliver finer injection than those with a built-in accumulator. Oil leaked from the injectors or fuel
high pressure pump is discharged into the fuel tank.
Injector solenoid valves are electronically controlled by the engine controller unit (ECU). The ECU controls the oper-
ating conditions including engine speed and engine load via signals sent from the sensors, and optimizes the injec-
tion timing, fuel pressure, and fuel amount.
high pressure pipe
"el fillee ~~------:l t

Fuel inlet
Feed pump Fuel high pressure Fuel outlet

pump
• Precautions during fuel system maintenance

o Prevent foreign matter from contaminating the fuel system.
o While loosening the cap nuts when the fuel high pressure pipes are removed, fuel may splash out due to residual
pressure inside the common rail. Before removing the pipes, be sure to cover the pipes with a waste cloth.
o After removing the fuel high pressure pipes, cover the ends of the high pressure pipes and the female thread that
connects the injector and the fuel high pressure pump to prevent foreign matter from entering.
o When the fuel high pressure pump or injector needs replacement, it should be replaced as an assembly.
Therefore, always handle these parts with care.
Fuel high pressure pump (supply pump)

• The fuel high pressure pump is a BOSCH built-in accumulator type.
• The fuel high pressure pump is force-lubricated with lubricating oil.
• The fuel high pressure pump is equipped with a feed pump.
Fuel high pressure pump BOSCH with two plungers

Feed pump Trochoid type
• Precautions during maintenance

• The fuel high pressure pump (including the feed pump and the driving unit) cannot be disassembled or maintained.
When maintenance is required, replace the fuel high pressure pump together with the feed pump and the driving
unit.
• The PLV, metering unit, and rail pressure sensor can be replaced independently.
• When installing the pipes or equipment connected to the fuel high pressure pump, tighten them to the torque
specified on P98 [Fuel high pressure pump pipes and their torque].
Rail pressure sensor
t
Fuel inlel
~.
Fuel filler Feed pump , Driving unil
Fueloullel l04737-00ENOl
• Precautions during rail pressure sensor

replacement
• There is a thrust piece mounted at the rear of the rail
pressure sensor. When inspecting or replacing the
rail pressure sensor, clean the thrust piece.
• After cleaning the thrust piece, be sure to fit it again. o
• If a magnet is used to remove the thrust piece,
installing apply grease both to the rail pressure sen-
sor and thrust piece.
• Tighten the rail pressure sensor to 136 ± 2 N·m.
• Precautions during metering unit replace-

ment
• When removing the wire harness, be sure to keep
fuel away from the connector on the harness side. If
fuel intrudes into the connector, contact failure
between terminals may occur.
• When installing the metering unit, apply lubricating
oil to the O-ring, and install it to the correct position.
Do not tighten the three installation bolts while install-
ing the metering unit. The O-ring may be damaged.
As with removal, when installing the metering unit,
adjust and tilt the harness connector.
• Use three hexagonal socket-head bolts for installation.
Tighten the bolts in accordance with the following
torques:
1st: 2.5 ± 0.5 N'm
2nd: 6.5 ± 0.5 N'm
• Check the metering unit for fuel leakage .
• Fuel high pressure pump pipes and their torque

To prevent oil or fuel leakage from the fuel high pressure pump pipes, tighten bolts and nuts to the specified torque.
Note: B =Face to face width (mm)

70 ± 5 N'm 95 ± 5 N'm 75 ± 5 N'm 60 ± 5 N'm 75 ± 5 N'm
B =30 B =36 B =36 B =24 B =27
95±5N'm 70 ± 5 N'm
B =36 B =30
70 ± 5 N'm 90 ± 5 N'm 90 ± 5 N'm 95 ± 5 N'm 95 ± 5 N'm

B =30 B = 17 B =41 B =41 B =36
l0473B-OOENOO
Injector type
The injector is BOSCH. (Head)
Injector type BOSCH CR/1 PL35/ZEREW 91 OS (Filling part of high pressure pipe)
Nozzle Staggered layout multi-hole nozzle

Damper ring ---~~~
Maximum nominal
1600
system pressure (bar) Connector hamess
• Precautions during maintenance

• The injector has a built-in nozzle. Therefore, the
injector cannot be disassembled or maintained. Fur- O-ring -a-
thermore, the nozzle cannot be independently main- O-ring -o~
tained.
When the nozzle needs replacement, replace the
injector also. (Nozzle) l0473S-00ENOO
• When replacing the injector, be careful not to dam-

age the nozzle tip.
• When replacing the injector, replace the fuel high
pressure pipe connected to the injector at the same
time.
The fuel high pressure pipes can be re-used three
times. However, if fuel leaks from the fuel high pres-
sure pipe, replace with a new one even if the pipe
has not been used three times.
• When replacing the injector, always replace the 0-
ring with a new one.
Inspect the damper ring. If the damper ring is dam-
aged, replace it with a new one.
The damper ring and O-rings are installed to the new
injector assembly.
• When removing or installing the injector, be sure to
use the special extraction/insertion tool. (Refer to
P18 [Fuel injector extraction/insertion tool].)
• Before installing the injector, make sure that the con-
nector harness is facing to the opposite side of the
flywheel. Failure to do so may result in the harness
being cut.
• Before installing the injector, check that the injector
mounting hole is clean, and then install a new nozzle
gasket.
• Before installing the injector, apply silicon oil to the
damper ring and O-rings.
How to use the fuel injector extraction/

insertion tool
eRemoval
1. Insert two tool bolts to the bolt holes on the bonnet.
2. Mount the jig to the injector head.
• Attach the M6 bolt to the recessed part of the
injector.
• Insert the two M1 0 bolts until they gently contact
the injector.
• Make sure that the jig is mounted parallel to the
injector head as shown in the figure.
3. Mount the jig (steel plate), and fix the tool bolts
with the M8 nuts. Attach an M1 0 nut to the joint
bolt.
4. Turn the M1 0 nut by using an offset wrench or
spanner to remove the injector.
5. After removing the injector from the bonnet,
remove the nuts of the tool bolts, and remove the
tool bolts together with the jig.
elnsertion
1. Apply silicon oil to the damper ring and O-rings of
the injector.
2. Insert two tool bolts to the bolt holes on the bonnet.
3. Mount the jig to the injector head.
4. Attach the M1 0 nut to the joint bolt of the jig, and
then attach the jig (steel plate). Fix the tool bolts
with M8 nuts.
Attach the M1 0 double nut to the joint bolt of the
jig.
5. Use an offset wrench to fix the double nut, and turn
the M1 0 nut by using a spanner to insert the injec-
tor.
Fuel priming pump

To bleed air from the fuel, a plunger-type single-action
fuel priming pump is included to send fuel from the fuel
tank to the fuel feed pump.
I Discharge Max. 9.3 cc/stroke
• Precautions during assembly

Make sure that there is no dust or damage on the plunger.
Piston
~
II ___ Ball
Spring 'iJ 0---
spring
~
Ball
o
o 0
I~() eicJ
o
o 0 Packing
I.. /
o O-ring
~
t@ Plunger
PI""9 ee body
~ ~~ Spring
"'~
.:::' 12
l04740-00ENOO
Fuel filter
The fuel filter is equipped with a paper element (2 IJ).
If the filter is clogged, fuel cannot be properly primed,
and fuel oil may run out. Therefore, periodically
replace the cartridge type filter.
IFuel filter replacement Every 1000 hours
• Precautions during assembly

• Before installing the filter, clean the mounting sur-
face, and apply fuel to the gasket on the mounting
surface .
• Tighten the filter by hand until the filter mounting sur-
face gasket touches the housing. Use a filter wrench
and tighten the element by approximately 3/4 of a
turn.
Fuel primary filterlWater separator (Local option)

The fuel primary filter and water separator (Racor7S/
1OOOFH-1 0 IJ) are installed in the section between the
fuel tank and the fuel inlet (on the hull side).
Periodically drain, and change the element.
Draining Every 50 hours of operation

Element replacement Every 1000 hours
Lubricating Oil System

The lubricating oil pump is a gear-type pump with a built-in safety valve. It is on the bottom of the cylinder block.
The pump compresses the lubricating oil and sends it through the cooler and the filter to the oil gallery of the cylinder
block. A pressure valve maintains the specified oil pressure. From the gallery, the oil lubricates and cools each part
of the engine. Then it returns to the oil pan.
The lubricating oil filter has a main paper filter and a centrifugal-type bypass filter.
Lubricating oil filter
Lubricating
oil cooler
Lubricating oil main gallery
0.
E
::l
0.
~
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OJ
E c ~ '"'"~
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c '"
0:: 0
u ..c:
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0
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Qj
I- :::J
(j)
> $] LL
Lubricating ""iii ~
>
oil pump .i::'
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'"'"C1l
0.
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(/) III
Oil pan
OS7558-00ENOl
• Lubricating oil pump

Adjusting plate
Lubricating oil pump design
The gear-type lubricating oil pump is mounted on the Relief valve (8) ~
~
cylinder block, and the pump is driven by the crank-
shaft gear.
The lubricating oil pump is fitted with the pressure Spring
relief valve A, B.
~R";'f"'"
Specifications of the lubricating oil pump
Pump test performance
Delivery 15800 Llh
IAI
Engine speed 2000 min- 1 ~
Delivery pressure 1.5 MPa ~Spring

Relief pressure
A 1.2-1.4MPa ~AdjUsting plate
B 1.0-1.2MPa 013279-00ENOl
Lubricating oil pump inspecting

The oil pump should be disassembled only when oil
pressure does not rise sufficiently even after adjusting
with the pressure control valve.
We recommend that you replace the whole pump set.
• Removing
1. Remove the oil pan, oil inlet pipe and the oil pump .
• Inspection
1. Remove the oil pump cover and measure the oil
pump gear-to-oil pump body and the gear-to-cover
clearances.
2.lfthe measured value exceeds the service limit or
if there is local wear, replace the oil pump assem-
bly.
mm
Item Standard Limit
Gear to pump clearance 0.20 - 0.28 0.50
0.06 - 0.12
Gear to cover clearance (on both sides 0.15
of the shield)
• Installing
1. Install the oil pump drive gear on the oil pump.
Oil pump gear tightening torque:

157 -177 N·m
M24 006607 -OOE
2. Make sure that the drive gear rotates smoothly.

3. Tighten the pump bolts temporarily. Rotate the
crankshaft so that the engagement of the teeth is
parallel. Then tighten the pump bolts.
4. Use new gasket and attach the oil inlet pipes.
5. Check the backlash of the drive gear.
• Lubricating oil pressure control valve

Lubricating oil travels from the lubricating oil cooler to
the oil filter and is sent on to the main gallery of the cyl-
inder body. Adjust the pressure of the valve located
just before the entrance to the main gallery.
When the pressure of the lubricating oil entering the
main gallery of the cylinder body exceeds the stan-
dard, the pressure control valve piston opens an
escape outlet and allows excess oil to drain into the oil
pan.
IRegulating pressure 0.44 - 0.54 MPa

Oil pressure control valve replacement

The control valve has been adjusted and assembled at
the factory, so it should not be disassembled without a
good reason.
Adjusting screw
If the oil pressure control valve is disassembled due to
spring trouble, etc., set a pressure gauge on the oil
pressure sender unit mounting seat, and adjust the
pressure with adjusting screw until it is at the specified
value.
IAdjusting pressure 0.44 - 0.54 MPa
• Lubricating oil filter OIJ281-00E
Lubricating oil filter

The lubricating oil filters are full-flow paper element
type filters, mounted to the side of the cylinder body
with the lubricating oil cooler.
Lubricating oil filter is installed in parallel with the line,
in which a bypass valve is built in.
If the filter is clogged, its filtering capacity will be lost.
Unfiltered lubricating oil will be fed to various parts if
the pressure loss exceeds 0.2 ± 0.03 MPa.
IFiltration (nominal) 20 I-lm
1. When replacing the oil filter:

1- Remove the filter with the filter wrench. (Turn
to the left.)
2- Before installing the filter, carefully wipe the
installation side and apply lubricating oil to the
r-----.
packing surface.
3- Tighten the lubricating oil filter fully by hand,
and then use a filter wrench to further tighten
I
the filter. (Turn to the right.)
4- Check for oil leakage during operation. ___ --.J
I
Lubricating oil bypass filter
007541-00X
The lubricating oil system is equipped with a lubricat-
ing oil bypass filter.
Stop the engine before cleaning the bypass filter.

Do not disassemble while the engine is running.
• Disassembly
Disassemble and clean the lubricating oil bypass filter
according to the following procedures.
1. Loosen the cap nut and then remove the cover.
2. Loosen the nut and remove the rotor body.
3. Loosen the lock nut and remove the rotor cover, Cover
~Nut
then remove the insulator and spring.
4. Remove the sludge inside the rotor with a spatula ®
completely.
Residual sludge may cause any damage to the
Rotor body
Nozzle 0
__ ~
' @ ~j.
/2.0--..
,,~
~
'
)
Lock
nut
Rotor
spindle shaft. O-ring -CI) -- cover
5. Check for clogging of the nozzle and clean the
'-r--' ,0-
nozzle a brass wire brush.
6. Check each part and the O-rings. If any damage or
excessive wear is found, replace the part .
Sp;odl, 'h'ft L,/ O-ring
• Assembly
Assemble the filter in the sequence reverse to disas- 014205-02E
sembly while observing the following precautions.

1. Install the insulator spring into the rotor body and
cover the rotor body with the rotor cover.
Ensure that the rotor and rotor cover fit well.
No good aligned fitting may damage the equip-
ment.
2. Tighten the rotor cover to the rotor body with a lock
nut.
ILock nut tightening torque Hand-tighten
3. Insert the rotor to the spindle shaft and tighten the

nut by hand.
INut tightening torque Hand-tighten
4. Cover the cover, install the thrust collar (upper),

and tighten the cap nut.
Cap nut tightening torque:

9.S N·m
Nut MS 1pc.
- IMPORTANT _ _ _ _ _ """"!!k""""
Do not tighten the nut and cap nut with too much
torque, it looses its tightening power when it is
loosened the next time and it can cause the
spindle shaft to loosen.
5. While operating the filter, make sure oil does not

leak from connected sections. Also, make sure the
filter is not vibrating abnormally.
• Replacing mist separator element ~~'-<:----Indicalor
(EPA model only)

1. Remove the drain line at the separator can.
2. Release the clamps holding the separator can.
3. Remove the separator can and the internal filter O-ring
element carefully.
There may be oil in the can.
4. Clean inside the separator can.
5. Replace the element with a new one.
+----Element
6. When installing the new element and can, use new
O-rings and fixed it with the clamps.
7. Reinstall the drain line.
8.lf the indicator on the top of the separator is red,
remove the indicator cover and reset the indicator.
°'---
B
Can---
, - - - - - Clamp
• Lubricating oil cooler

The lubricating oil cooler is a plate type cooler.
The lubricating oil and cooling water flow alternate into
the plate, and are cooled with cooling water (coolant).
Inspecting and service

1. Use new packing and O-ring during assembly.
2. When cleaning the cooling water system, use
cleaning agent to remove scales.
3. Clean the inside of the water passageway side with
a wire brush to prevent the build-up of scale.
4. Apply the following water pressure to the water Ol?280-00X
and lubricating oil lines to check for any leakage.

Repair or replace the cooler if there are any leak.
Lubricating oil circuit 1.47 MPa

Cooling water circuit 0.39 MPa
5. When cleaning the inside of the plate, use a pres-

surized air which blow off the inside scale.
Cooling Water System

The cylinder and the cylinder head are cooled by a constant high-temperature coolant cooling system (coolant circu-
lation with heat exchanger). This keeps the temperature of the coolant nearly constant at any engine load. Thus the
engine performance is kept stable.
• Seawater system
The seawater pump sends seawater to the air cooler, where it cools the air. Then the seawater is send to the heat
exchanger, where it cools the coolant. Then it flows back into the sea.
• Coolant system
The coolant pump sends coolant to the lubricating oil cooler, where it cools the lubricating oil. Then coolant is sent to
the cylinder block jacket. There it cools the cylinder, cylinder liner and cylinder head. Then it flows through the
exhaust manifold into the thermostat. Then it flows from the thermostat to the coolant tank and the heat exchanger.
Then it flows back to the coolant pump.
Seawater outlet pipe Lubricating

I,--EJ-- oil cooler
I Coolant pump
I
--1:; Thermostat
r'--- --
:
Filler cap L-------'
Coolant
reservoir 1
Y_J
Seawater pump
Seawater line : - - -
Coolant line : - - - - o Seawater inlet pipe
OS7557-00ENOO
• Seawater pump
The seawater pump has a rubber impeller. The seawa- Rubber impeller
ter pump is mounted to the gear housing and is driven

by the gear.
Specifications of the seawater pump

Performance
Crankshaft speed 2000 min- 1

Delivery capacity 34000 Llh 014945 -OOE
Total head 10m (Suction: 2 m)

Seawater pump Inspection Gear

1. Inspection of rubber impeller
Remove the cover at the pump side and then pull
out the impeller by using the special tool.
Check the impeller and the pump body for dam-
age. If it is damaged, replace it. Mechanical seal
2. Mechanical seal
If too much water leaks from the drain pipe,
replace the mechanical seal.
3. Assembling the seawater pump
1- Apply grease to the seawater pump shaft, the
inside and outside surfaces of the impeller.
2-Apply vaseline to the seawater pump impeller,
the inside and outside surfaces. Wear plate
3- When fitting the impeller to the pump body,

Seawater pump body
notice the correct direction of the impeller
blades with respect to the rotation direction of
the impeller.
4- Use new O-rings.
5- Use new packing. Apply sealant (THREE
BOND No.4 or equivalent) to the packing sur-
face.
6- Use new oil seals.
7- Carefully clean the bearings .
• Water pump (coolant)
Water pump construction

The water pump (coolant) is a centrifugal (volute) type.
The water pump (coolant) consists of the pump body, Cover
impeller, pump shaft, bearing unit and mechanical Packing

seal. Impeller
The bearing unit assembled in the pump shaft uses

grease lubricated ball bearings and cannot be disas-
sembled.
The totally enclosed mechanical seal spring presses
the impeller seal mounted on the impeller side away
from the pump body side.
Specifications of water pump (coolant)

Crankshaft speed 2000 min- 1
Delivery capacity 48500 Llh
Total head 12.0 m·Aq
Inspection of water pump (coolant)

1. Bearing unit inspection
Rotate the impeller smoothly. If the rotation is not
smooth or abnormal noise is heard due to exces-
sive bearing play or contact with other parts,
replace the pump as a unit.
2. Impeller inspection
Check the impeller blade, and replace if damaged
or corroded or if the impeller blade is worn due to
contact with pump case.
3. Check the holes in the cooling water and bypass
lines, clean out any dirt or other foreign matter and
repair as necessary.
4. Replace the pump as a unit if there is excessive
water leakage due to mechanical seal or impeller
sealwearordamage. Clearance
S.lnspect the pump body and flange, clean off scale

and rust, and replace if corroded.
6. Measure the clearance between the impeller and
the pump body.
Measure the clearance between the impeller and
the pump case by pushing the impeller all the way
towards the body, and inserting it in the case.
mm
Clearance Standard
Clearance between impel-
0.3 - 0.9
ler and body
Precautions for assembly and service

• Use new packing, oil seals and O-rings. Drive gear U nul
• If water leaks, replace the mechanical seal.

• Before installing the bearing, completely clean it and
apply grease to it.
• The impeller fitting screw is right-handed screw.
IImpeller tightening torque: M18 I 83 -103 N·m
• The drive gear tightening nut (U nut M20) is right-

handed screw.
Pump drive gear tightening torque:

127 -147 N·m Ol3304-0lENOO
M20
• The rotating direction of the impeller is clockwise

(viewed from the drive gear side).
• Heat exchanger (coolant cooler)

The heat exchanger is multi-pipe type, cooled by sea-
water and equipped with a resin coolant reservoir. The
seawater flowing inside the pipe core cools the coolant
that passes through the outside of the core. The ther-
mostat installed inside the coolant circuit controls the
temperature of coolant at the ideal point. A water level
alarm is provided at the upper part of the coolant tank.
When the alarm sensor detects a reduction in water
amount, the alarm lamp will light and the buzzer
(Multi-pipe type cooler, pipe cooler diameter 8/10)
sounds .
• Pressure cap
The pressure cap mounted on the coolant filler neck Pressure valve operation Pressure valve spring
incorporates a pressure control valve.
Pressure cap pressure control

The pressure valve and vacuum seal both seal the
Overflow lube
valve seat when the pressure in the coolant system is
within the specified value of 0.11 MPa. This seals the Pressure valve
coolant system.
Vacuum valve operation
When the pressure within the coolant system exceeds
the specified value, the pressure valve opens, and
steam is discharged through the overflow pipe. When
coolant is cooled and the pressure within the coolant
system drops below the normal value, atmospheric
pressure opens the vacuum valve, and air is drawn in
through the overflow pipe. 008135-00E
The coolant reservoir keeps the water level from drop-

ping due to discharge of steam when the pressure
valve opens. Pressure value
Action of pressure control valve
IPressure valve Open at 93 - 123 kPa

Pressure cap inspection

Remove the cap only after the water has had a chance
to cool down.
Do not open the pressure cap while the engine is run-
ning or right after shutting down because high tem-
perature steam will be blown out.
1. Remove scale and rust, check the seat and seat
valve, etc. for scratches or wear, and the spring for
corrosion or settling. Replace if necessary.
2. Attach the adapter on the tester to the pressure
cap. Pump until the pressure gauge is within the
specified pressure range 93 - 123 kPa and note
the gauge reading. The cap is normal if the pres-
sure holds for six seconds. If the pressure does not
rise, or drops immediately, inspect the cap and
repair or replace as necessary.
• Coolant reservoir Filler cap Coolant tank

The pressure valve opens to discharge steam when
the steam pressure in the coolant tank exceeds 93 -
-- d., I ~
123 kPa. This consumes water. The coolant reservoir
maintains the water level by preventing this discharge Coolant reservoir -J
of water.
The steam discharged into the coolant reservoir con-
denses into watch, and the water level in the coolant
reservoir rises.
When the pressure in the coolant system drops below
the normal value, the water in the coolant reservoir is
sucked back into the coolant tank to raise the water
back to its original level.
The coolant reservoir facilitates long hours of operation
without water replacement and ejected from the filler 008294-01E
neck because the pressure cap does not need to be

removed.
Specifications of coolant reservoir
Overall capacity 3.4 L

Full scale capacity 1.5 L
Low scale capacity 0.43 L
Precautions for service

1. Check the coolant reservoir when the engine is
cool. Refill with coolant as necessary to bring the
water level between the low and full marks.
2. Check the overflow pipe and replace if bent or
cracked. Clean out the pipe if it is clogged up.
3. The coolant reservoir is mounted at approximately
the same height as the pressure cap on coolant
tank. (Allowable difference in height: 300 mm or
less)
4. The overflow pipe should be less than 1000 mm
long, and mounted so that it does not sag or bend .
• Thermostat
The thermostat is installed in the coolant tank. It helps
to keep the coolant temperature consistent at all times.
There are two types (A and 8) of thermostat as shown
in the table below. Arrange the thermostat as shown in
the illustration.
Characteristics of thermostat Lift of the element

(Lift when fully opened: 8 mm) -'--------=".....-
item A B
Opening temperature 71°C 76.5°C
Full open temperature 85°C 90°C
Leak hole (jiggle valve) x 0
Valve lift at full open 8 mm or more
Valve bore 33 mm
Number 3 3
Thermostat inspection
Clean off scale and rust and inspect, and replace if the
characteristics (performance) have changed, or if the
spring is broken, deformed or corroded.
Testing the thermostat

1. Put the thermostat in beaker with freshwater. and
heat it on an electric stove. The thermostat is func-
tioning normally if it starts to open between 71 - 85
Thermostat
°C, 76.5 - 90°C, and opens 8 mm or more at.
Replace the thermostat if it is not functioning nor-
mally.
2. Normally, the thermostat should be inspected
every year, but, it should be inspected before this if
the cooling temperature rises abnormally or white
013 9S3-00E
smoke is emitted for a long time after engine start-
ing.
• Seawater system cleaning

As the engine is used, coolers become fouled, their
cooling effect deteriorates, and coolant temperatures
become abnormally high (above 85 - 90°C). Conse-
quently, eliminate fouling of the seawater system, cool-
ers in particular.
• Coolant system cleaning

As the coolant system becomes dirty during normal
operation, cooling efficiency deteriorates, and coolant
temperatures become abnormally high (above 85 - 90
°C when the engine is operated for long time), clean
coolant system periodically. At the same time, clean
the thermostats.
• Checking and replacing zinc anodes

In the seawater line, zinc anodes are built into the heat
exchanger and air cooler.
Remove the zinc and scrape or remove with a wire
brush the zinc.
If more than 50 % of the zinc is corroded away,
it should be replaced with new zinc.
~---
013295 - OlX
Air Cooler
The air cooler is a fin-tube type, seawater cooling sys-
tem. High temperature air compressed in the turbo-
charger is cooled in the air duct by the air cooler. Then,
the air is sent to the cylinder via the intake manifold.
Seawater passes through the fin tubes while the air
passes between fin tubes and is cooled.
If the fins in the air cooler is clogged, the boost pres-
sure is lowered due to resistance, reducing the cooling
performance. Therefore, inspect and clean the fins,
and make sure that they are not clogged.
Air cooler
Periodically inspect the four zinc anodes attached to
the air cooler on the seawater inlet/outlet sides.
- IMPORTANT _ _ _ _ _ _ ffN""""
• If the boost pressure does not rise even when the

turbocharger blower is flushed with water, remove
the air duct and intake manifold to inspect and clean
the fins. If the fins are clogged, clean using a carbon
remover such as Blower Wash.
Do not damage the fins while cleaning.
• Replace the gaskets and O-rings with new ones
during inspection.
• When installing the expansion joints, make sure that
the arrow mark engraved on the joint faces towards
the air cooler side, as indicated in the figure.
Turbocharger
• Specifications
Turbocharger maker MITSUBISHI HEAVY INDUSTRIES, LTD. (MHI)
Turbine type Radial flow
Blower type Centrifugal
Bearing type Full floating
Lubricating system Forced lubricating with engine oil
Cooling system AIR cooled
Turbocharger model TD13M(1), TD13L
• Design and function
, - - - - - - - - - - - - - - < 1 1 1 Thrust bearing

,------<111 Turbine back plate
Compressor wheel ~-----. Shaft & turbine wheel
AirinletQ "GaSoutlet
' - - - - - - - - - - -...... Bearing

Vane distortion,
damage, signs of
rubbing contact
on back face and
gas erosion
Signs of rubbing
contact with turbine
wheel and damage
15 27 18 17 28
Damage and gas erosion of bearing hole Vane distortion. damage. signs
and distortion of turbine-side flange of rubbing contact on back face.
gas erosion and damage to ring
grooves
1 - Bolt 11 - Oil deflector 21 - Snap ring

2 - Compressor cover 12 - Thrust ring (compressor side) 22 - Snap ring
3 - O-ring 13 - Thrust bearing 23 - Bearing
4 - Lock nut 14 - Thrust ring (turbine side) 24 - Snap ring
5 - Compressor wheel 15-Bolt 25 - Bearing housing
6 - Snap ring 16 - Turbine housing 26 - Lock plate
7 - Insert 17 - Shaft and turbine wheel 27 - Lock plate
8 - Piston ring 18 - Piston ring 28 - Lagging
9 - Finger sleeve 19 - Turbine back plate
10 - O-ring 20 - Bearing
• Standards for maintenance and inspection
Service standards
mm
Parts or item Service standard Service limit Remarks
Inside diameter of bearing bores in bearing housing - 30.006 E
Outside diameter - 29.876 C
Bearing Inside diameter - 18.050 B
length - 17.440 D
Diameter of journals - 17.996 A
Shaft and turbine wheel
Bend of shaft - 0.015 -
Axial play of shaft and wheel 0.075 - 0.135 - -
Tightening torque
Thread
secured part or component Width across flats Tightening torque Remarks
diameter - pitch
Refer to page
Compressor wheel lock nut 11 -1.0 mm 19.0 mm Apply Molycoat to
P130.
threads
Turbine housing bolt - - 23.5 ± 0.98 N·m
• Periodic inspection
Periodic inspection intervals

Check the overall status and contamination of turbocharger at regular intervals.
The inspection intervals vary depending on the conditions of use. Perform inspection work at the intervals as shown
below.
Check item Every 6 months (Recommendation) Every 12 months

Rotation of turbine shaft 0 -
Disassembly, cleaning and checking - 0
Checking the rotation of turbine shaft

Check the rotation of the turbine shaft by listening to whether it produces an abnormal sound or not during rotation.
When using a listening rod, tap the tip of it closely to the turbocharger case and pick up the engine speed gradually.
If a high-pitched sound is heard successively every 2 - 3 seconds, it means that the rotation of rotor is abnormal.
When such a symptom is observed, the bearing and turbine shaft may be in trouble. In such case, the turbocharger
should be replaced or disassembled and repaired.
• Disassembly procedures
Preparations for disassembly

When assembling and disassembling the turbocharger, the special tools as shown below are required.
Name of tool Purpose of use Remarks
Mounting and dismounting of snap ring of

Pliers
floating bearing
Fixing of compressor wheel

Box wrench
(19mm x 6sq)
Available in the market

Mounting of turbine housing
Torque wrench
23.5 ± 0.98 N·m for M8
OOIOGS-OOX
Check before disassembly

1. Check that the turbine blade wheel and compressor wheel rotate smoothly.
The wheel do not make contact with each other or turbine shaft.
2. Measure the play of the turbine shaft.
Play of the turbine shaft in axial direction.
ILimit of use 0.075 - 0.135 mm
Disassembly
1. Hold the flange of the turbine housing (16) in a
vise.
- IMPORTANT _ _ _ _ _ !000Y;;;;;;;;
Hold the turbine housing securely to prevent it from

moving during disassembly work.
2. Removal of the compressor cover

1-Using a box wrench, remove the bolts (1) and
lock plate (26).
2- Using a plastic hammer, lightly tap around the
compressor cover (2) to remove the cover.
Also, remove the O-ring (3) from the bearing
housing.
Before separating the compressor cover (2)

bearing housing (25) and turbine housing (16) be
sure to make a match mark across each joint with
a punch or quick drying ink pen to aid reassembly.
3. Removal of the compressor wheel

1- Hold the boss of the shaft and turbine wheel
(17) remove the lock nut (4) securing the com-
pressor wheel (5).
Be careful not to bump the compressor wheel

against the compressor cover.
2- While holding the turbine wheel in one hand,

turn the compressor wheel (5) back and forth
with the other hand to lift it off the shaft.
4. Removal of snap ring

Using the snap ring pliers (A), remove snap ring
(6).
- IMPORTANT _ _ _ _ _ !0I!D!'ff;;;;;
Hold down the snap ring by hand while pinching

the ring ends with the snap ring pliers, so that the
ring will not fly off just in case the ring ends slip off
the pliers.
5. Removal of the insert, oil deflector and other parts

1- Using two screwdrivers, gently lift insert (7) off
the bearing housing (25).
2- Separate finger sleeve (9) complete with piston
ring (8) from insert.
3- Remove the following parts from bearing hous-
ing (25).
• (10) O-ring
• (11) Oil deflector
• (12) Thrust ring (compressor side)
• (13) Thrust bearing
• (14) Thrust ring (turbine side)
6. Remove of Bolts
Using a box wrench, remove bolts (15), and dis-
place its installation position.
7. Removal of the shaft and turbine wheel

1- Lift the bearing housing (25) complete with the
shaft and turbine wheel (17) off the turbine
housing (16) with one hand holding the shaft
and the other hand holding the bearing hous-
ing.
2- Turn the bearing housing (25) upside down
(with the turbine wheel up) and lay it on the
compressor cover (2).
Under this condition, remove the following
parts:
• (17) Shaft and turbine wheel
• (18) Piston ring
• (19) Turbine back plate
• (20) Bearing (compressor side)
8. Removal of snap ring and bearing

Lay bearing housing (25) on the bench with the
compressor side up, and remove the following
parts:
• (21) Snap ring (compressor side)
• (22) Snap ring
• (23) Bearing (turbine side)
• (24) Snap ring
- IMPORTANT _ _ _ _ _ """"!!N""""
• Use the snap ring pliers to remove the snap

rings.
• When removing the snap ring, be careful not to
damage the inside surface of the bearing, the
bearing housing and the sealing face (turbine
side) of piston ring .
• Cleaning and inspection procedures
Checking before cleaning

Before cleaning, visually check the disassembled parts for any seizure, wear, foreign matter or carbon deposits.
Closely check for the above-mentioned abnormalities in case of any trouble, and pinpoint the cause of trouble at this
stage.
Check item Position to be checked

Carbon deposits 1. Turbine shaft, wheel (17) turbine-side piston ring, and turbine wheel
backside.
2. Mounts for bearing housing and shroud, and bearing housing inside wall.
Lubricating (wear, seizure, discoloration, etc.) 1. Turbine shaft, wheel (17), piston ring (8), (18) (Compressor and Turbine
side).
2. Bearing (20) (23), thrust bearing (13) and thrust ring (12) (14).
3. Bearing housing, and inner periphery of bearing snap ring.
Oil leak 1. Turbine housing inside wall.
2. Outer periphery of bearing housing, and turbine back plate mount.
3. Turbine shaft, wheel (17), turbine-side piston ring, and turbine wheel
backside.
4. Compressor cover (2) inside wall.
5. Compressor wheel (5) backside.
6. Finger sleeve (9) surface and piston ring insertion groove.
Cleaning procedure
In cleaning the parts, keep the following points in mind.
Section Tools and detergent Cleaning procedure

Turbine shaft 1. Turbine shaft tools 1. Immerse the turbine shaft in the washing bucket
• Washing bucket (500 x 500) and heat the solution. Do not beat the wheel for
• Heat source: steam or gas burner removal of carbon deposit.
• Brush 2. Immerse the parts until dirt deposits become soft by
2. Detergent: Carbon remover sold in penetration of detergent.
the market may be used. 3. When the deposits get soft, remove them with use
of a plastic spatula or a bristle brush.
4. Protect the bearing surface of the turbine shaft and
the piston ring groove from damage during clean-
ing.
5. Incomplete cleaning will leave residual deposits
which may cause an imbalance in shaft rotation. Do
not use a wire brush for cleaning.
Turbine housing 1. Tools: Same as for cleaning the tur- 1. Apply cleaning fluid to heavily soiled parts of the
bine shaft turbine housing.
2. Detergent: Same as for cleaning the 2. Use a plastic scraper or a stiff natural bristle brush
turbine shaft to clean.
Compressor cover 1. Tools 1. Immerse the parts until dirt deposits become soft by
• Washing bucket (500 x 500) the penetration of detergent.
• Brush 2. When the deposits get soft, remove them with a
2. Detergent plastic spatula or bristle brush. Do not use a wire
brush.
Others 1. Wash all the other parts with engine oil.
2. Clean the lubricating oil passages by blowing compressed air.
3. In the cleaning work, pay close attention not to damage the parts or allow them to rust.
043906-00ENOO
Inspecting procedure
1. Compressor cover (2)
Check the compressor cover. Make sure there is
no contact with the compressor wheel, no flaws on
the mating surface, no bruises or cracks or other
damages. A defective compressor cover is to be
replaced with new one.
2. Turbine housing (16)
Check the components for damage from contact
with the turbine wheel, exfoliation from deteriora-
tion due to oxidation of the casting surface, thermal
deformation, cracks and other damages. A defec-
tive turbine housing is to be replaced with a new
one.
3. Compressor wheel (5)
Check the components for damage from contact,
breakage, corrosion, deformation and other dam-
ages. A defective compressor wheel is to be
replaced with a new one.
4. Turbine shaft (17)
1- Check the turbine wheel section for damage
from contact, breakage, thermal discoloration,
deformation and other damage. Check the tur-
bine shaft for bend, thermal discoloration at the
journal section, flaws from abnormal wear,
flaws and wear in piston ring groove, and other
damages. Defective components are to be
replaced with new ones.
2- Measure the outer diameter of the turbine shaft
journal section (A).
Replace components when the dimensions
exceed the allowable limit described below
Journal outside diameter

17.996 mm
(A) Allowable limit
3- Measure the run-out of the turbine shaft.

Replace components when the run-out is
0.015 mm or over.
S.lnsert (7) 7
Place a new piston ring (8) in the groove in the End gap ~8
~
insert, and measure the end gap or the ring. If the
gap exceeds the standard clearance, replace the
insert.
Item Standard clearance

End gap of piston ring 0.05 - 0.25 mm
6. Bearing housing (25)

Measure the inside diameter of bearing bores in
the housing. If it exceeds the Service limit, replace
the housing.
Item Service limit

Inside diameter of bearing bores in
30.006 mm
housing (E)
7. Bearing (20) (23)

1- Measure the inside diameter of the bearing. If it
D
exceeds the service limit, replace the bearing.
B
Item Service limit

Inside diameter of bearing (8) 18.050 mm 0
O1J261-00X
2- Measure the inside diameter of the bearing. If it

exceeds the service limit, replace the bearing.
Item Service limit

Outside diameter of bearing (C) 29.876 mm
013260- oox
3- Measure the length of the bearing. If it is less

than the service limit, replace the bearing.
D
0
Item Service limit
Length of bearing (0) 17.440 mm
0
O1J262-00X
• Reassembly procedures
Preparations for reassembly

• When reassembling the turbocharger, prepare the general and special tools, fluid sealant (Molycote).
• Be sure to replace the following parts before reassembly.
• Compressor-side piston ring (8) x 1 pc
• Turbine-side piston ring (18) x 1 pc
• O-ring (large) (3) x 1 pc
• O-ring (small) (10) x 1 pc
2 7 6 10 13 12 20 21 23 25 24 19 16
4 5 8 9 3 14 11 22 15 27 18 17 28
I Reassembly sequence I
25->24->22->23->21->19 ]
-> 20 -> 14 --+ 13 --+ 10 --+ 12 --+ 11
18--+ 17 ] --+ 6 --+ 5--+ 4 --+ 16 --+ 27 --+ 15 --+ 3 --+ 2 --+ 26 --+ 1
9--+ 8--+ 7
- IMPORTANT - - - - - - " "

• Replace the compressor wheel or shaft and turbine wheel if the vanes are badly distorted or cracked.
A single blade having minor distortions or scratching is not a cause for replacement; in such a case, never attempt
to re-shape the distorted vane .
• After installing and overhauled turbocharger of the engine, crank the engine with the starter to permit the engine
oil into flow to the turbocharger.
Reassembly procedures
1. Installation of shaft and turbine wheel and bearings 21 22 23 24
II! /
1- Reassemble the following parts:
• (25) Bearing housing
• (24) Snap ring
• (23) Bearing (turbine side) @J-@J-@j-@
• (22) Snap ring
• (21) Snap ring (compressor side)
- IMPORTANT _ _ _ _ _ !0I!D!'ff;;;;;
• Use the snap ring pliers to install the snap rings.

After installing each snap ring, make sure that it
can be finger rotated freely.
• Apply engine oil to the inside and outside sur-
faces of bearing.
2- Lay the bearing housing (25) on compressor

cover (2), and install the turbine back plate ~Large
(19).
3-lnstall the piston ring (18) in the groove formed ~small
on the shaft and turbine wheel (17).
End gap
4- When installing the shaft and turbine wheel
(17) complete with the piston ring to the bear-
ing housing (25), position the piston ring as
shown, and insert the shaft and turbine wheel
into the housing while rotating it back and forth.
- IMPORTANT _ _ _ _ _ !0I!D!'ffN""""
• When installing the piston ring to the shaft and

turbine wheel, be careful neither to expand the
ring more than is necessary nor to twist its end
gap.
• After installing the piston ring in its groove, apply
Molykote to it.
• Piston rings are common to turbine and com-
pressor sides.
• Never force the shaft and turbine wheel unless it
is in line with the turbine back plate and bearing
housing.
2. After installing the shaft and turbine wheel

Hold the end of the shaft by hand, and turn it
upside down so that its compressor side is up.
Apply engine oil to the inside and outside surfaces
of the bearing (20) and install it on the shaft. Then,
install the bearing housing (25) to the turbine hous-
ing (16) by the tightening bolts (15) and lock plate
(27) temporarily.
3. Installation of the thrust bearing

Apply engine oil to the inside and outside surfaces
of the thrust ring (14) and the thrust bearing (13),
and install the ring and bearing in place. Position
the thrust bearing by inserting the groove pin into
the locating hole.
4. Installation of the O-ring

Apply engine oil to the O-ring (10), and install it in
place.
10
5. Installation of the oil deflector

Apply engine oil to both sides of thrust ring (12),
and install it to the oil deflector (11). Install the oil
deflector with its baffle.
6. Reassembly of the insert subassembly

7
1- Reassemble the insert parts in the following
sequence:
• (9) Finger sleeve
• (8) Piston ring
• (7) Insert
- IMPORTANT _ _ _ _ _ !000Y///;;;;;
• When installing the piston ring to the finger

sleeve, be careful neither to expand the ring
more than is necessary for installation nor to
twist its end gap.
• Apply Molykote to the piston ring fitted to the fin-
ger sleeve, and install the sleeve onto the insert,
taking care not to damage the ring.
2-lnstall the insert subassembly to the bearing

housing (25).
7. Installation of the snap ring
Using the snap ring pliers, install the snap ring (6)
to the bearing housing (25) with its tapered side
facing upward.
- IMPORTANT _ _ _ _ _ Rl07//N""""
• Be sure to position the snap ring as specified

above when installing it.
• Give light hammer blows to the ends of the snap
ring with a screwdriver to fit the ring in the
groove in the bearing housing.
• When giving hammer blows to the snap ring, be
careful not to damage the bearing housing.
8. Measuring the clearance between the turbine

wheel and bearing housing
Set up a dial indicator on the shaft and turbine
wheel (17) as shown. Move the shaft in the axial
direction to measure the clearance. If the clear-
ance is not compliant with the standard clearance,
disassemble the part, and investigate for the
cause.

Clearance between the shaft
and turbine wheel and the tur- 0.29 - 0.91 mm
bine wheel and turbine housing
9. Installation of the compressor wheel

Install the compressor wheel (5), apply Molykote to
the threads of the lock nut (4), and tighten the nut
to the following specified torque.
1- Tighten the lock nut to 10 N· m and loosen it.
4
2- Tighten the lock nut to 10 N·m again. CYliLrg;
3-ln addition, tighten the lock nut by angle 80 ± 3
degrees.
fJ
Compressor side
10. Measurement of the axial play of the shaft and tur-

bine wheel
Set up a dial indicator on the shaft and turbine 17
wheel (17) as shown. Move the compressor wheel
(5) in the axial direction to measure the play. If the
play is not compliant with the standard clearance,
5----;'-z-~
disassemble the parts, and investigate for the
cause.

Axial play of shaft and turbine
0.075 - 0.135 mm
wheel
11. Measurement of clearance between turbine back

plate and turbine wheel
Remove the turbine housing from the bearing
housing (25), and install the compressor cover (2).
Using feeler gauges, measure the clearance
between turbine back plate (19) and turbine wheel.
If the clearance is not compliant with the standard
clearance, disassemble the parts, and investigate
for the cause.
- IMPORTANT _ _ _ _ _ """"!!N""""
Measure the clearance at the tips of the vanes with

two feeler gauges.

Clearance between the turbine
0.55 -1.15 mm
back plate and turbine wheel
12. Installation of the turbine housing

1-lnstall the turbine housing (16) to the bearing
housing (25), making sure that it is correctly
positioned in respect to the housing.
2-lnstall the lock plate, spread Molykoat on the

bolt screw, and tighten the bolts to the speci-
fied torque.
ITightening torque 23.5 ± 0.98 N·m
13. Installation of the compressor cover

Install the compressor cover (2), making sure that
it is correctly positioned with respect to the turbine
housing.
Apply grease to the O-ring (3) when installing it.
14. Installation of the snap ring

Install the lock plate (26) and bolts (1) to the com-
pressor cover (2).
1
26
• Handling after reassembly

In mounting or handling the turbocharger, keep the fol-
lowing points in mind.
Use particular care to prevent any foreign materials
from coming into the turbocharger.
Precautions for mounting the turbo-

charger to the engine
• Lubricating system
• Before mounting the turbocharger to the engine,
pour fresh engine oil from the oil filler port, and turn
the turbine shaft by hand to lubricate the bearing and
thrust bearing.
• Clean up the oil inlet pipe and outlet pipe running
from the engine, and check them for any damage or
dust and dirt remaining in the pipes.
• Connect the oil pipes securely to their connections in
order to prevent any oil leaks from the connections.
• Suction system
• Make sure that there is no rubbish or foreign matter
in the suction system.
• Mount the turbocharger securely to avoid any air
leaks at the suction air duct and air cleaner connec-
tion.
• Exhaust system
• Make sure that there is no rubbish or foreign mate-
rial in the exhaust system.
• Bolts and nuts made of heat-resisting steel are used
for the exhaust system. Do not confuse them with
ordinary bolts and nuts used for other systems.
Apply anti-seizure agent to the lock bolts and nuts.
(Heat-resisting bolts are used for the turbine wheel
chamber.)
• Connect the exhaust pipes securely to avoid any
gas leak at the connections.
• Troubleshooting
If there are any problems with the turbocharger, it will not perform as expected and the specified engine power can
not be attained.
In this case, first check each part of the engine for any trouble, and when it is confirmed that there is no problem with
the engine, then check the turbocharger, referring to the tables below, and take proper measures.
Exhaust gas is dense

Insufficient suction air
Possible cause Correction

1. Air cleaner element is clogged. o Replace or clean the element.
2. Air intake port is blocked up. o Remove obstruction.
3. Air leaks at pipe connection. o Check and repair the pipe.
Turbocharger does not operate

1. Impurities contained in oil buildup at seal of turbine and o Change the engine oil and disassemble and clean the turbo-
hamper smooth rotation of turbine shaft. charger.
2. Seizure of bearing o Disassemble and repair the turbocharger.
o Insufficient oil feed or clogging of pipe o Check the engine oil system, and repair the trouble spot and
o Too high oil temperature at the same time change the oil.
o Imbalance of rotating parts o Replace or clean the rotating part.
o Insufficient warm-up operation or abrupt stopping of o Observe the operating precautions described in operation
operation under load (No-load operation) manual.
3. Contact or breakage of turbine wheel or compressor wheel o Check each part of the engine and repair as required.
o Over-rotation o Disassemble the wheels and remove foreign matters com-
o Excessive rise of exhaust gas temperature pletely and at the same time check the air cleaner and the
o Entry of foreign matters engine and repair as required.
o Wear of bearings o Disassemble and repair the turbocharger.
o Wrong reassembly o Reassemble the turbocharger.
Effect of exhaust gas resistance

1. Rotating speed does not pick up due to exhaust gas leak o Check the pipe connection and repair as required.
before the turbocharger.
2. Turbocharger fails to increase its speed due to deformed o Repair the pipe to normal state.
or blocked exhaust gas pipe.
Whitish exhaust gas

1. Oil flows into compressor side or turbine side due to o Repair or replace the pipe.
clogged or deformed oil return pipe.
2. Piston ring is worn abnormally or broken due to excessive o Disassemble and repair the turbocharger.
bearing abrasion.
Too early oil shortage

3. Piston ring is worn abnormally or broken due to excessive • Disassemble and repair the turbocharger.
bearing abrasion.
Output drop
1. Gas leaks at part (s) in exhaust gas system. • Disassemble and repair the turbocharger.
2. Air leaks at discharge side of compressor.
3. Clogging of air cleaner element. • Clean or replace the element.
4. Turbocharger is contaminated or damaged. • Disassemble and repair or replace the turbocharger.
Poor follow-up of turbocharger

1. Carbon deposits stuck on turbine side (wheel seal) ham- • Change the engine oil and at the same time disassemble
per smooth rotation of turbine shaft. and clean the turbocharger.
2. Incomplete oil combustion. • Check the engine combustion system and restore its com-
bustion state.
Unusual sound or vibration

Unusual sound
1. If gas passage gets too narrow due to blockage of nozzle • Disassemble and clean the turbocharger.
in turbine housing or gas flow speed is too fast, air dis-
charged from compressor is blocked and airflow is
reversed. (This phenomenon is generally called "surging".)
2. Rotating part is making contact. • Disassemble and repair or replace the turbocharger.
Unusual vibration

1. Connection between turbocharger and suction or exhaust • Check installation state of the turbocharger, and restore the
pipe or oil pipe is loose. loose part.
2. Turbine wheel or compressor wheel is broken due to trou- • Disassemble and repair or replace the turbocharger.
ble with bearing, contact of rotating part with peripheral In the case of entry of foreign matter, remove it completely.
part(s) or entry of foreign materials.
3. Imbalance in rotating part(s). • Repair or replace the rotating part(s).
Electrical System
• Starting motor
Specifications
YANMAR parts No. 148660-77080
Model No. (Maker: Sawafuji) 0360-802-0132
Nominal output/mass 8 kW/18.3 kg
Rotating direction (as viewed from pinion side) Clockwise
Gear engagement Magnetic shift
Pinion method Electromagnetic shift
Terminal voltage 24 V
Circuit system/Polarity Earth floatl2 pole
Pinion module/No. of teeth 3.5/11
Configuration
Engage switch
Lever
Pinion clutch assy.
Armature
Brush holder Gear assy.
Yoke assy. OOENOO
Output characteristic curves Wiring diagram
E N T P
01) (min') iN'm) (kW)
28 8000
T
26 7000
24 6000
20 5000
16 4000
12 3000
8 2000
4 1000
o
o o 0 400 800 1200 1600 2000
I (A)
Troubleshooting
Pinion fails to advance when starting switch is closed
Problem Cause Corrective action

Wiring Open or loose battery or switch terminal Repair or retighten
Threaded part connected to pinion section of armature shaft is Repair contacts, or replace
Starter
damaged, and the pinion does not move switch
Magnetic switch Plunger or magnetic switch malfunctioning or coil shorted Repair or replace
Pinion is engaged and motor rotates, but rotation is not transmitted to the engine

Starter Overrunning clutch faulty Replace
Motor rotates at full power before pinion engages ring gear

Starter Torsion spring permanently strained Replace
Pinion engages ring gear, but starter fails to rotate

Wires connecting battery and magnetic switch open or wire Repair, retighten, or replace
Wiring
connecting ground, magnetic switch and motor terminals loose wire
Pinion and ring gear engagement faulty Replace
Motor mounting faulty Remount
Brush worn or contacting brush spring faulty Replace
Starter
Commutator dirty Repair
Armature, field coil faulty Repair or replace
Field coil and brush connection loose Retighten
Contactor contact faulty Replace
Magnetic switch
Contactor contacts pitted Replace
Motor fails to stop when starting switch is opened after engine starts

Starter switch Switch faulty Replace
Magnetic switch Switch faulty Replace
• Alternator Output characteristic curves

27.5 V constant
The alternator is a brush less charging generator of 75~----------------------------~
SAWAFUJI ELECTRIC and built in fully-transistorized

regulator. 60
~
Specifications C 45
~
::0
tl
Sawafuji model name 0201 172 3211
~ 30
YANMAR part No. 127699-77201 :5
o
Rated voltage 24 V
15
Rated output 24 V-60 A
Rated current 60A
Charge start speed 1000 min- 1 o 1000 2000 3000 4000 5000 6000 7000
Alternator speed (rnin"')
Left when viewed from the
Direction of rotation
drive side Wiring diagram
Regulator IC regulator built-in type r - - - - - - - - - - - -- - - - - - - - - - - - - - - --I
,
Mass 8.6 kg Is
Fuse
,,
-------- -- I
Li R
,
~:L'
'R I
, r--'-+----<>--o
! R I t :c Start switch
, egu a or ?
! 'p
Battery T
I
I
-'-
lrJ5rJ49-00ENOO
Precaution for service and handling

• When removing or installing the alternator, be sure
to attach the earth float spacers A and B.
Inspect the earth float spacers. If damaged or
cracked, replace with new ones.
Make sure to attach the earth float spacers as indi-
cated in the parts list.
• Do not perform a insulation resistance test in assem-
bly.
• Do not perform a withstand voltage test in assembly.
• Do not short-circuit each terminal.
• During the alternator operation, do not turn off the
Spacer B
battery switch.
l0527B-OOENOO
• Do not operate the alternator with the battery open.
• When the alternator is stopped, turn off the battery
switch.
Disassembling/assembling alternator
For service which needs disassembly/assembly of the
alternator unit, make a request to manufacture's autho-
rized service shop.
• Wire harness
- IMPORTANT _ _ _ _ _ """"Ph««
• Before maintaining the wire harness, always turn OFF the power switch.
• After wiring, check to ensure it is correct. If wires are incorrectly connected, it will cause a fire or electric shock.
• Ensure enough slack for the connectors and connecting sections of the cords.
• If the connectors and other parts are wet, wipe off the moisture. If moisture adheres, the connectors may short cir-
cuit, resulting in poor insulation.
• If fuel oil adheres to the rubber section (orange color) of the connectors, the rubber section may expand and
become damaged. Make sure that they do not get splashed with fuel oil.
• Ensure that each connector is firmly inserted.
• Re-install the supports to the original position.
Engine wire harness
<Connector>
Coolant temperature
Rail pressure sensor

switch
Boost pressure/temperature
Metering unit
).Lj::::::=:S:):::l~sor
temperature Fuel pressure/temperature
sensor sensor
l05387-00ENOO
• Position of engine's sensor and switch
Injector
Fuel pressure/temperature sensor Metering unit Rail pressure sensor
Lubricating oil pressure sensor

Crank sensor
MAINTENANCE INSPECTIONS - 141
MAINTENANCE INSPECTIONS
Precautions for Maintenance and Inspections

To keep the engine in good condition, periodic inspections are necessary to prevent serious problems. The inspec-
tion period cannot be fixed indiscriminately because it is influenced by the application of the engine, usage condi-
tions, the quality of fuel oil and lubricating oil used, and daily handling.
The following inspection tables show the standard inspection frequency.
Perform the servicing according to these inspection tables. Then, based on the inspection results (on wear, corro-
sion, accumulation of carbon, accumulation of sludge and others), make the most economical inspection schedule
suitable for the engine, and conform to the specified schedule.
Periodic Maintenance Schedule

0: Check 0: Replace .: YANMAR dealer or distributor
Service period
Item Every Every Every Every Every Remarks
Daily
50 hours 250 hours 500 hours 6 months year
Check fuel level and refill 0
E 0
(]) Drain fuel tank deposit and water
(j) (When replenished)
i'n"
(jj Drain fuel-water separator deposit and water 0
::l
IL Replace fuel filter and fuel/water separator ele- Every 1000
0
ment hours
Check oil pressure 0
Check oil level and refill (oil pan) 0
0
Replace oil filter 0
(1st time)
E
(]) 0
(j) Clean by-pass filter 0
i'n" (1st time)
c
0
~
Clean oil cooler •
(.)
.;:: 0
.0 Standard oil pan 0
::l
...J Replace oil (1st time)
(oil pan) 0 Every 300
Shallow oil pan 0
(1st time) hours
Replace mist separator element Every 1000
0
(Only for EPA engine) hours
Check coolant temperature 0
E Check coolant level 0
~
i'n" Change coolant 0
"E
(lJ
0
Clean coolant system •
0
(.)
0)
Check and clean thermostat •
§ Check water leakage from water pump 0
0
0 Replace if found
()
Replace mechanical seal • water leakage
142 - MAINTENANCE INSPECTIONS
0: Check 0: Replace .: YANMAR dealer or distributor

Service period
Item Every Every Every Every Every Remarks
Daily
50 hours 250 hours 500 hours 6 months year
....
Gl Check cooling seawater discharging condition 0
m Replace seawater pump impeller 0
~ GlE
Gl
(J)1l)
0>>-
Check and replace zinc I Heat exchanger 0 0
.!;
(5
(J)
anodes IAir cooler 0 0
D
0
a.
Clean seawater system •
E
.e :::>
,9> a.
.e Gl
Replace pump In the event of a failure, or after 20000 hours
4i :J
:::> (J)
LL (J)
~
a.
Check and adjust valve clearance • •

Every 1500
-giii-o (!I
(1st time) hours
=>- .e
Gl
Check valve rotator, stem seal, valve spring •
D
_
....
0
Check oil feeding condition of rocker arm •
Gl-
~.~ Replace injector In the event of a failure, or after 20000 hours
.5
~<I:;:
c: (!I
(!I.e
(3 (J)
Measure and adjust deflection •
Q; Clean pre-filter and washing blower 0
0
........
.0
:::>
0)
(!I
Re place pre-filte r 0
1-'-15 Check air/gas leakage 0
Clean air cooler •
Re-tighten hose clips 0
0
(Fuel, lubricating oil, coolant, breather and air line) (1st time)
Check rubber hoses
0
(Fuel, lubricating oil, coolant, breather and air line)
Check battery electrolyte level and specific grav-
0
Gl
ity
(.)
':;: Check battery terminals 0
(J)
-0
(.) 0
Check alternator V-belt tension 0 0
~(J) (1st time)
iIi
Replace electric devices
In the event of a failure, or after 20000 hours
(ECU, sensors, harness, etc,)
....
0 Check looseness of bolts and nuts 0
~x Check water/oil/gas leakage at various parts 0
w
Marine gear The servicing shall be referred to the marine gear manual
MAINTENANCE INSPECTIONS - 143
• Inspection and maintenance of EPA emission-related parts for CI marine engines

Action Minimum interval
Clean fuel injector 1500 hours
Check turbocharger adjustment
Check fuel injector
4500 hours
Check electronic engine control unit and it's associated sen-
sors and actuators
• Recommendation for top overhaul (every 2 - 3 years or 6000 - 9000 hours)

For items with an inspection frequency shown by both the accumulated hours of operation and number of days,
schedule the inspection at the earlier timing.
Service period
No. Replace item
Years Hours
1 Replace the thermostat of coolant system 2 5000 - 6000
2 Replace the rubber hoses 2 5000 - 6000
3 Replace the expansion joint of air duct 2 5000 - 6000
Replace the impeller shaft and mechanical seal of cooling water pump (cool-
4 3 9000 - 10000
ant)
Service period
No. Check and replace item
Years Hours
1 Check and then replace the piston rings if the wear limit is exceeded 3 9000 -10000
Check and then replace the floating bearings and thrust bearings of turbo
2 3 9000 - 10000
charger if the wear limit is exceeded
3 Lap the intake/exhaust valves 3 9000 - 10000
Inspect viscous damper, replace if external body damaged/ swollen or leaking
4 3 9000 - 10000
fluid
144 - LONG-TERM STORAGE
LONG-TERM STORAGE
In storing the engine for a long time and re-starting the engine after long-term storage, the following treatments are
required.
And more, when the engine is stored for more than a year without operating, the engine overhaul is required.
The treatment of storing for a long time

Lift the vessel out of the water as far as possible. This prevents accidental flooding during mooring.
• For the items that periodic maintenance is approaching, do the check and maintenance before storing for a long
time.
• In cold conditions, drain the cooling water for prevention of a freeze.
• Loosen the V-belt.
• Remove the battery cable from the minus terminal side. Charge the battery at least once a month to prevent volt-
age drop by self-discharge.
• Carefully wipe off dust and oily dirt and apply a rust inhibitor or clean oil to the outside of the engine.
• Provide protection covering for the exhaust pipe, intake port, and electric parts to protect against humidity.
• To prevent condensation in the fuel tank, either drain or fill up the tank with fuel oil.
• Close the fuel cock (valve) and sea cock (valve) .
• Draining water from the cooling water channel

Be sure to drain all cooling water from both coolant channel and the seawater.
It is not necessary to drain the coolant when Long Life Coolant is mixed.
If does not drain water, the coolant and seawater left inside the engine will be frozen and will be damaged the water
channel.
• When Long Life Coolant is not being used for freshwater coolant, the drain tap of a coolant channel is opened
then drain the coolant.
• Drain the seawater from the drain tap of a sea water channel or a seawater pump is opened.
Restarting the engine after long-term storage

• Take off the rust inhibitor and do the same start preparation as for the initial start of a new engine.
Check fuel amount and lubricating oil level.
• Check coolant level. We recommend addition of Long Life Coolant to coolant.
If the coolant is drained with the drain cock opened, let water flow for washing the coolant channel.
Then close the water drain cock and fill coolant.
• Check the rubber impeller of a seawater pump for damage and apply white Vaseline.
• Check the V-belt for damage and replace with a new one if needed. Adjust the V-belt tension.
• Install the battery cable from the plus terminal side.
• In order to spread lubricating oil over each part before starting the engine, carried out the cranking certainly.
• Do an engine warm-up surely after starting the engine.
• Check the level of engine lubricating oil and coolant after engine warm-up operation.
Refill the amount whichever is decreased.
TROUBLESHOOTING AND COUNTERMEASURES - 145
TROUBLESHOOTING AND COUNTERMEASURES
For correct troubleshooting, you need to thoroughly understand each system of the engine and the function of each
part. In addition, in the event of a failure, it is important to carefully observe and systematically analyze the defective
part to find the cause.
Troubleshooting
This engine is an electronically controlled engine. If a failure occurs, take corrective actions in accordance with the
"Troubleshooting" or "Diagnosis tool (SA-D)".
1. Check the customer data for the engine operating history.

• Check the engine model and engine serial No.
• Date/operating hours at last maintenance date, problems (failures) and maintenance for the problems
• Operating hours since last maintenance
• Corrective actions for failures, and replaced parts
2. Conduct the detailed investigation with the operator(s).
• When and how the failure occurred
• Any signs of failure
Changes in engine speed, engine operation, color of the exhaust emissions, or unusual sound or vibration
• Did the failure occur suddenly, or were there any signs of failure
• Has anything else of note occurred or currently occurring.
3. Check how the failure occurred.
• Inspect the engine and reduction reversing gear, and check the "DTC code" and "Failure name" displayed on
the LCD monitor
4. Refer to the troubleshooting, and use the diagnosis tool (SA-D) to take corrective actions.
• Use the latest failure diagnosis tool (SA-D) or troubleshooting manual
146 - SERVICE REFERENCE TABLE
SERVICE REFERENCE TABLE
mm
Dimension Standard Maximum
Usage limit of
Item clearance allowance Sketch
Normal Tolerance parts
assembling time clearance
Inner diameter of cylinder +0.046
upper part 0 h
181 A = 0.025 - 0.101 i
~
Outer diameter of cylinder -0.025 .,....A
liner upper part -0.055
lower part 0
=
~
Q) 177 B = 0.015 - 0.085
c Outer diameter of cylinder -0.015 ~B
~
~
Q)
""0
liner lower part -0.045
.~ 016865 -oox
>. Projection h = 0.03 - 0.09 h = 0.09
()
""0
c Top clearance 1.56 ±0.108 C = 1.452 - 1.668 2.0 -
.:
III
~
C
Q)
""0
+0.4*1
.~
>. 155 Deflection wear
u liner 0
of 0.2
Outer diameter of piston
152.675 ±0.015 D = 2.305 - 2.365
head I
I
I
Outer diameter of piston
154.930 ±0.015 E=0.055-0.115 E = 0.17 -0.15
skirt part ~
No.1 = 5.7 No.1 = 5.38
Radial thick. of piston rings
No.2 = 6.7
±0.12
No.2 = 6.38 :::fF1
mmmmlFJ
Radial thick. of oil ring 3 ±0.15 2.68 ~
i:&
016867-00X
Width of piston ring, No.1 No.1 = 3.5 -0.010 No.1 = 3.37

and No.2 No.2 = 3.0 -0.030 No.2 = 2.87
Width of piston ring groove, +0.145
CJ) No.1 = 3.5 G = 0.140 - 0.175 G = 0.28 3.745
0)
c No.1 +0.130
·c
""0 Width of piston ring groove, +0.110
c No.2 = 3.0 G = 0.105 - 0.140 G = 0.24 3.21
III
c
No.2 +0.095
.0..
c -0.010 G
{D~JtJ:1H
0 Width of oil ring 3.77
Ui
.0..
c
4
-0.030
+0.040
H= 0.030 - 0.070 H= 0.18
0 Width of oil ring groove 4.14
Ui +0.020 IIII ~m
0::: IU T UI
Inner diameter of piston pin +0.074 J
metal +0.059
J = 0.079 - 0.103 J = 0.15
62.134
kl1l(( 016868 -oox
-0.020
Outer diameter of piston pin 61.867
-0.029
62
Inner diameter of piston pin +0.020
62.120
hole +0.010
K = 0.030 - 0.049 K = 0.06
-0.020
Outer diameter of piston pin 61.867
-0.029
*1: Indicates the limit atthe 1st ring area when the piston is at T.D.C.
SERVICE REFERENCE TABLE - 147
mm
Usage limit of
Inner diameter of crank pin +0.060
+0.10
bearing +0.010
0106 L = 0.050 - 0.120 L = 0.15
-0.040 Deflection wear
Outer diameter of crank pin
-0.060 of 0.05
+0.074
Length of crank pin
o
· db· 66 f--_-.-- -----jg=0.150-0.324 g = 0.41
Width
1 af can neet Ing ro Ig 0 150
end -0.250
Inner diameter of main +0.065
¢:' bearing 0
0134 f - - - - - - - l M = 0.045 - 0.135 M = 0.18
~ -0.045 Deflection wear
J:1 Outer diameter of journal
c -0.070 of 0.08
ro ~----------------_+----------~------~------------r_----------_+----------~ 1
U Width of datum part main +0.030
52
bearing +0.011
-0.055
Thickness of thrust bearing 4 N = 0.080 - 0.229 N = 0.33
-0.105
+0.030
Width of datum part journal 60
o
Adjusting value
Deflection P = -0.018 - 0.018
(cold state)
016871- OOX
Clearance of valve head T = 0.3 (Intake) T = 0.3 (Intake)

(Tappet clearance) T = 0.5 (Exhaust) T = 0.5 (Exhaust)
Outer diameter of intake -0.050
-0.18
valve -0.072
11 f - - - - - - - l V = 0.050 - 0.090 V =0.2
Inner diameter of intake +0.018
+0.12
valve guide o
Outer diameter of exhaust -0.050
-0.18
valve -0.072
11 f - - - - - - - l V = 0.050 - 0.090 V =0.2
Inner diameter of exhaust +0.018
+0.12
valve guide o
Outer diameter of valve +0.046
-0.07
bridge guide +0.028
13 U = 0.014 - 0.052 U =0.2
.~ Inner diameter of valve +0.080
+0.18
~ bridge +0.060
n
Q)
~-----------------+----------~------~------------r_----------_+----------~--------------_1
E
Q) Margin thickness of intake/ Q =3.9 (In.) Q =3.2 (In.)
>
~ exhaust valve poppet part Q = 2.25 (Exh.) Q = 1.8 (Exh.)
Sink of intake/exhaust valve (+0.1) - (-0.4) -0.5
Intake 3.46 3.96

Width of valve
seat
exhaust 2.48 2.98
Outer diameter of rocker -0.009

-0.12
~
arm shaft -0.034
32 W = 0.019 - 0.099 W=0.2
Inner diameter of rocker +0.065
arm bush +0.010
+0.18
~
148 - SERVICE REFERENCE TABLE
mm
Usage limit of
Outer diameter of camshaft -0.060
-0.18 Y X
datum part -0.090
70 Y = 0.08 - 0.16 Y = 0.25
~ui
-'
Inner diameter of camshaft +0.070
+0.16
datum part bearing +0.020 --~- [itl~
----;
~ :16~600X
Thrust clearance of
X = 0.10 - 0.35 X = 0.45
camshaft datum part
¢:' Outer diameter of camshaft -0.060

III
.r:: intermediate part -0.18
•
CJ) -0.090 - Ii:
E
III
U Inner diameter of camshaft
70
+0.070
Z = 0.08 - 0.16 Z = 0.25 I _ ~ _! _
+0.16 , ,
intermediate part +0.020 '
016877--00X
.
~'
Cam height of intake 59.9 ±0.05 h = 59.4
I I
-! - ~
Cam height of exhaust 60.0 ±0.05 h = 59.5 ; ~
016878 - oox
Idle gear support shaft -0.030

-0.17
diameter -0.060
60 0.030 - 0.090 0.2
Inner diameter of the +0.030
+0.14
above's bush 0
Idle gear side clearance 0.20 - 0.40
Idle gear (CR) support shaft -0.025
~ -0.14
III
Q)
diameter -0.050
C) 50 0.025 - 0.075 0.17
Inner diameter of the +0.025
+0.11
above's bush 0
Idle gear backlash
~
Cam gear backlash
f= 0.15 - 0.25 f = 0.4 '" '- ,,/
Lub. oil pump gear

backlash 016881-00X
Outer diameter of lubricat- -0.020

-0.12
ing oil pump -0.033
30 a = 0.040 - 0.074 a = 0.15
:t.r
0..
E Inner diameter of the +0.041
+0.10 . /a
::J
0.. above's bush +0.020
'0
,.... - 'ILL
0) II .1 --J[]
c Gear to pump clearance b = 0.20 - 0.28 b = 0.5
~ Ic::-
u
~
(I I
::J
--'
J
""EI!ii:::r
Gear to cover clearance c = 0.060 - 0.120 C = 0.15 -
016879-00X
0..
E
::J
0..
L.., I~
~
Q)
iii Clearance of blade

5: g = 0.3 - 0.9
V
I l~ g
0)
.~
0
0
U
~~
=tL-1_...L jLL-o±Sso-oox
.
U
REFERENCE ADJUSTMENT VALUE - 149
REFERENCE ADJUSTMENT VALUE
No. Inspection item Standard
Intake 0.3
1 Valve clearance mm
Exhaust 0.5
2 Coolant capacity Engine (heat exchanger)/reservoir L 65/3
111 (standard)
Engine lubricating oil capacity
3 Oil pan + piping L
at rake angle 0 degree
73 (shallow)
4 Lubricating oil pressure MPa 0.44 - 0.54
Valve opening temperature °C 71 (A), 76.5 (8)

5 Cooling water thermostat
Full opening lift mm 8 or above (85°C, 90°C)
6 Top clearance mm 1.50±0.10

150 - TIGHTENING TORQUES FOR MAJOR BOLTS AND NUTS
TIGHTENING TORQUES FOR MAJOR BOLTS

AND NUTS
• Table of tightening torque
- IMPORTANT _ _ _ _ _ _ ffN""""
• The main bolts shall be tightened according to the specified method.

• Note that the tightening of bolts or nuts in error can cause engine damage and malfunctions.
• Unless otherwise specified, apply lubricating oil on the thread and bearing surface and then tighten it.
Do not use molybdenum disulfide lubricating oil.
• Tighten the mounting bolts of the fuel pipes for the fuel high pressure pump to the specified torque.
Diameter x Face-to-face
Tightening
Pitch of bolt width of bolt
No. Name of bolt or nut torque Remarks
or nut ornut
(mm) (mm) (N·m)
Refer to P152 for
1 Cylinder head bolt M18x2.5 24 the tightening
method
Refer to P153 for
2 Main bearing tightening bolt M24 x 2 30 the tightening
method
Refer to P153 for
3 Side bolt (main bearing cap) M16 x 2 22 the tightening
method
Refer to P154 for
4 Connecting rod tightening bolt M14 x 1.25 19 the tightening
method
5 Flywheel clamping bolt M20 x 1.5 24 480 ± 15
6 Camshaft gear tightening bolt M20x1.5 30 300 ± 20
7 Idle gear tightening bolt M18x1.5 27 200 ± 20
M12 x 1.75 17
8 Idle gear support tightening bolt 120 ± 10
M14x1.5 19
9 Idle gear (CR) support tightening bolt M12 x 1.75 19 120 ± 10
10 Rocker arm shaft stand tightening pipe joint bolt M12 x 1.75 17 44 ± 5
11 Rocker arm shaft tightening bolt M8 x 1.25 12 23 ± 5
12 Piston cooling nozzle bolt M16x1.5 22 49 - 59
13 Injector holding bolt M14x1.5 19 130 ± 5
14 Nozzle sleeve M22 x 1.5 - 157 +10
15 Viscous damper tightening bolt M20x1.5 30 245 ± 10
16 Lubricating oil pump driving gear tightening nut M24 x 2 36 167 ± 10
17 Lubricating oil pump setting bolt M10 x 1.5 14 44 ± 5
18 Fuel high pressure pump driving gear tightening nut M36 x 3 55 400 ± 25
19 Fuel high pressure pump installing bolt M12 x 1.75 17 90 ± 5
20 Fuel injection pipe nut (pump side) M24 x 1.5 27 75 ± 5
21 Fuel injection pipe nut (nozzle side) M24x1.5 27 75 ± 5
TIGHTENING TORQUES FOR MAJOR BOLTS AND NUTS - 151
Diameter x Face-to-face
Tightening
Pitch of bolt width of bolt
Noo Name of bolt or nut torque Remarks
or nut ornut
(mm) (mm) (Nom)
Fuel feed pump inlet tightening pipe joint union
22 M27 x 2 41 95 ± 5
(pump side)
Fuel feed pump outlet tightening pipe joint bolt
23 M22 x 1.5 30 70 ± 5
(pump side)
Fuel high pressure pump fuel inlet tightening pipe joint
24 M22 x 2 30 70 ± 5
bolt
Fuel high pressure pump fuel return tightening pipe joint
25 M27 x 2 36 95 ± 5
bolt
26 Fuel high pressure pump PLV tightening pipe joint bolt. M18x1.5 24 60 ± 5
27 Crank/cam sensor fitting bolt M6 x 1 10 8± 1
28 Boost pressure/temperature sensor fitting bolt M6 x 1 10 8± 1
29 Fuel pressureitemperature sensor fitting bolt M6 x 1 10 10 ± 1
30 Freshwater temperature sensor fitting bolt M12 x 1.75 19 20 ± 2
31 Turbocharger installing nut M12 x 1.75 19 74 ± 10
32 Coolant pump impeller M18x1.5 27 93 ± 10
33 Seawater pump driving gear tightening nut M27 x 2 41 245 ± 10
34 Rocker arm cover bolt M8x1.25 12 18 ± 2
Details of tightening torque around the fuel high pressure pump
Note: B =Face to face width (mm)

70 ± 5 N·m 95 ± 5 N·m 75 ± 5 N·m 60 ± 5 N·m 75 ± 5 N·m
B =30 B =36 B =36 B =24 B =27
95±5N·m 70 ± 5 N·m
B =36 B =30
70 ± 5 N·m 90 ± 5 N·m 90 ± 5 N·m 95 ± 5 N·m 95 ± 5 N·m

B =30 B = 17 B =41 B =41 B =36
104738 - OOENOO
• Tightening of cylinder head bolts

When tightening the cylinder head bolts, according to
Cylinder head bolts tightening order
the following clamping sequence.
1. Apply PROTEC oil to the thread of cylinder head
bolts.
2. Order for tightening the cylinder head bolts is given
E'h'iport
in right figure.
3. Tighten the head bolts in the order shown on the
following table.
Tightening
Steps Tightening torques
method
1st step 100 N·m Torque
Suction port
2nd step 210 ± 10 N·m method
012714-00EN02
Rotate 90 degrees from the

3rd step
2nd turn
Rotate 90 degrees from the Angle
3rd turn control
4th step Total tightening from the 2nd method
and 3rd turns
180 degrees 0 + 30 degrees
elndication method for paint and punch mark- 4th time

.•9 - 30 0
(tolerance)
ing on the bolt head and the head bearing
surface at the angle control tightening t 7
1. After the torque tightening, mark the bolt head and
3rd time
the head bearing surface with paint to the exhaust
side in the same direction.
2. After rotating the bolt 90 degrees for the 2nd angle
control tightening, check that paint on the bolt head 2nd time 048356-01ENOO
is in the intake air direction.
Q
3. After the angle control tightening, make sure to
punch mark the bolt head. (Record the number of
uses of the bolt.)
Note: Use a hexagon 6 points socket (depth 19
mm) for torque wrench. Punch mark 048357-00ENOO
Do not use 12 points socket.
e Head bolt replacement criteria

The number of times of use of a head bolt is up to 5.
(The number of times of reuse is up to 4.) When the
number of punch marks on the bolt head reaches 4,
replace it with a new one next time. If you do not know
the number of times of use of a head bolt, measure the
thread outer diameter of the maximum neck (40 to 50
mm from the bolt tip) with a caliper. If the thread outer
diameter is less than 17.4 mm, replace it with a new
one. 048358-00XOO
TIGHTENING TORQUES FOR MAJOR BOLTS AND NUTS - 153
• Tightening of the main bearing bolts (angular tightening)

• Apply PROTECT oil to the threaded part of the main bearing bolts and its seating face.
• When tightening the main bearing bolts, tighten the respective bolts in steps as the following table and figure.
Steps Tightening bolts Tightening torque and angle

1st step Operating and Non-operating side Surface clamping torque of 49 ± 5 N· m
2nd step Operating side bolt Angle 30° from 0° position
3rd step Non-operating side bolt Angle 50° from 0° position
Angle 68° ± 2° from 0° position
4th step (final) Operating side bolt
(Reference: 38° from 2nd step)
Angle 68° ± 2° from 0° position
5th step (final) Non-operating side bolt
(Reference: 18° from 3rd step)
• Tighten the side bolts after the final tightening of the main bearing bolts as below.
Main bearing tightening bolt

""49Nom ~
(Non-operating side) /" ." Side bolt
o deg. Position (Non-operating side)
//
3rd/50 deg.
Main bearing cap 0 deg. Position

5th (final)
I 68 deg. ± 2 deg.
~
2nd/30 deg.
S;d, bolt ~ l'l/ \

(operatlngSlde)~~""'0 /;/
j, 4th (final)
"".~
I
68 deg. ± 2 deg .
• Tightening of the side bolts (After tightening of the main bearing bolts)
• Apply PROTECT oil to the threaded part of side bolts and its seating face.
• Tighten the side bolts in steps as the following table.
Steps Tightening bolts Tightening torques

1st step Operating side bolt 68.5 N'm
2nd step Non-operating side bolt 147 N'm
3rd step Operating side bolt 8
196+2 N'm
4th step Non-operating side bolt 196+28 N'm
- IMPORTANT - - - - - - " "

• Before tightening the main bearing, check that the "AY" mark on the bearing cap should face the anti-fly-
wheel.
• When using the same bolt as time of shipment from the factory, use the identical procedure as described
above. After tighten the bolts, make sure that the matching mark on the nut is within a tolerance of 0.5 mm
from the matching line.
• Tightening of connecting rod bolts

• Apply PROTECT oil to the threaded part of the connecting rod bolt and its seating surface .
• Tighten the connecting rod bolts in steps as the following table.
Steps Tightening torques

1st step 50 ± 5 N'm
2nd step 70±5N'm
3rd step 137±5N'm
• Tightening torque for standard bolt and nut
Thread diameter mm M6 M8 M10 M12 M14 M16
Pitch mm 1.0 1.25 1.5 1.75 1.5 (2.0) 1.5 (2.0)
Width across flat mm 10 12 14 17 19 24
Tightening torque N'm 10 ± 1 23 ± 2 45 ± 5 75 ± 10 120 ± 15 200 ± 15
Note: Use 80 % of the torque for bolts made of aluminum or aluminum alloys.
Do not apply oil on bolts. nuts or washers.
• Tightening torque for pipe joint bolts
Thread diameter mm M8 M12 M14 M16 M18 M20 M22
Pitch mm 1.25 1.25 1.5 1.5 1.5 1.5 1.5
Width across flat mm 14 17 19 22 24 27 30
Carbon
12 - 17 25 - 35 40 - 50 50 - 60 70 - 80 90 - 100 150 - 200
Tightening steel
N'm
torque Free-cut-
8 - 12 18 - 25 27 - 34 34 - 41 48 - 55 62 - 69 98 - 137
ting brass
Note: Do not apply oil on bolts.

TEST RUNNING AFTER SERVICING - 155
TEST RUNNING AFTER SERVICING
After the completion of service, make sure to perform the operation checks according as the following.
• Checks after assembly

• Check that all the bolts/nuts are securely tightened and locked in the specified manner.
Pay special attention to places where visual inspection is difficult during running.
• Check that the piping connections are surely tightened.
• Check that there are no mistake and troubles in every connections of sensors and harnesses.
• Record the details on the service and the replaced parts on the service sheets.
• Checks after installation

After installing the engine, make sure to check the
shaft alignment when connecting the engine and pro-
peller shaft (or intermediate shaft).
Allowable tolerances
Center misalignment Less than 0.05 mm
Coupling face gap Less than 0.05 mm
• Checks before test running

• Use only fuel oil, lubricating oil, and coolant/LLC recommended by YANMAR.
• Check the fuel oil system and fill fuel.
• Check and fill lubricating oil.
Use lubricating oil recommended by YANMAR.
• Check and fill coolant.
Use only Long Life Coolant (LLC) recommended by YANMAR.
• Check and confirm that engine's battery charged condition is good.
• Check and make sure ventilating the engine room well.
• Check that there are no defects in each part of the engine by turning and priming.
• Check that the turning device or the turning bar used is in the removed/OFF state.
• Be sure to cranking the engine, lubricate each engine part, and confirm that there is no abnormal noise etc.
Cranking should be done under safe condition.
156 - TEST RUNNING AFTER SERVICING
• Test running procedures and check points

Item Procedure Precautions
1 Checking 1. Check the fuel system and fill the fuel.
before running 1- Clean the fuel tank, fuel oil pipes and
other interior parts with the fuel oil.
2- Fill the fuel tank with clean fuel oil that is Dirt, dust and water content can damage the parts in
free of water and dirt. the fuel system.
Open the fuel valve. Make sure that you fill with correct fuel oil.
3- Bleed the air from the fuel oil system. Do not forget bleeding air from the fuel pre-filter.
After bleeding the fuel pre-filter/water
separator, bleed the engine fuel filter.
2. Check the lubricating oil and fill.
1- Check that there are no contamination, Do not let dust and water content enter the fuel sys-
water, and fuel oil mixture in the oil pan. tem.
2- Fill with engine lubricating oil. Engine lubricating oil capacity (in the standard oil pan)
Total capacity: 91 L
3- Turn the flywheel and sends lubricating The moving part can be seized up by lack of oil.
oil to all lubrication points.
4- Fill with lubricating oil to the marine gear Refer to the marine gear manual.
side.
3. Check and fill the coolant.
1- Close the coolant drain cock. Check adding proper LLC.
2- Remove the filler cap of the freshwater Coolant capacity: 65 L
tank/cooler, and fill coolant.
3- Remove the filler cap of the reservoir, Coolant capacity: 3 L
and fill coolant.
4- Close the seawater drain cock.
5- Check that the side cover bolt of the sea-
water pump is tightened.
6- Check that the sea water strainer is clean
up.
7- Open the Kingston cock.
4. Check and confirm that engine's battery
charged condition is good.
5. Turn on the battery switch and power switch, A pointer of the engine speed is "0" indication.
and make sure that a LCD monitor screen
indicate gauges.
Beside confirm that there are no alarm indica-
tions in a screen.
6. Check that the remote control head switches
and lamps operate correctly.
Check that the remote control handle is work-
ing smoothly.
7. Confirm the safe conditions around the The remote control handle is N/neutral.
engine and do cranking (no-load running) the
engine.
8. After cranking, check the lubricating oil again
and refill if necessary.
TEST RUNNING AFTER SERVICING - 157
Item Procedure Precautions

2 Warming up 1. Start the engine, and warm up the engine at
with no-road no-load for about 5 minutes.
Check for the following after starting.
o There are no leakage of water, oil, air and o When there are leakage, stops engine and repair
gas. the leakage part.
o There is no fuel leakage from fuel high pres- o When there is abnormality, stops engine and check.
sure pipe joints or connections.
o There is no fuel leakage from around the
fuel system/high-pressure pump.
o There is sufficient discharge cooling water
from the cooling seawater outlet.
o There are no abnormal fever, vibration or
noise.
o There are no abnormal exhaust gas color.
o Lubricating oil pressure is good.
o There are no abnormal indication or alarm
on the LCD monitor screen.
3 Running with 1. Engage with marine gear and gradually rise o Do not operate the engine under excessive running
load the engine speed for about 10 minutes to as sudden acceleration and over-road.
rated speed and run-in for 5 minutes. o Avoid operate the engine speed at resonance
Check for the above item in warming up. (critical speed).
o Take all kinds detailed data by SA-D.
2. Check the exhaust gas color and tempera- A difference temperature between the cylinder shall
ture. be less than 40°C.
3. Check the marine gear operation. Refer to the marine gear manual.
4 Stopping 1. Perform cool-down operation at no load for at Do not stop the engine suddenly at high speed, or
least 5 minutes before stopping. without cool-down operation.
2. Turn off the power switch after engine stop- Turn off the battery switch after the lamp on the
ping, and then turn off the battery switch after backup panel has stopped flashing.
waiting for about 10 seconds.
5 Checking after 1. Re-check water, oil and gas leaks. Especially check fuel oil leakage and each oil seals.
stopping 2. Check no bolts and nuts are loose. The engine installation parts especially.
3. Close the Kingston cock and the fuel cock.
4. When the temperature is expected to fall Drain the seawater from the seawater pump.
below freezing, drain the seawater and cool-
ant with no added LLC.
158 - TEST RUNNING AFTER SERVICING
• Inspection of the crankshaft deflection

When checking installation after maintenance, measure the crankshaft deflection.
- IMPORTANT ------;;;;;;;
• Carry out deflection measurements when the engine is cold .
• Surely check the crankshaft deflection after the shock absorbing rubbers or the bolts securing the engine bed are
reassembled or re-tightened.
1. Turn the flywheel to a point 40° (EB) past bottom dead center (bottom).
2. Attach the deflection gauge and set the pointer to zero.
3. Slowly turn the flywheel in the normal direction and read the gauge at the E, T, P, and PB positions.
4. The PB location as the standard, the maximum value of each measured value is the deflection. Check that the
value is within the tolerance.
IAllowable deflection limit ± 0.0180 mm
Location of the deflection gauge Deflection measurement points
EB : 40° past B.D.C.

E : 90° before TO.C.
T : TO.C.
Db[ p E
P
PB
: 90° past TO.C.
: 40° before B.D.C.
\ B : B.D.C.
Deflection gauge Crank pin position

D=Crankshaft diameter 020977 -OGE
The relation between the deflection value (reading of dial gauge) and crankshaft
Gauge + -
Crankshaft ~ O17780-00X
~ 017781-00X
(lower spread) (lower contact)

YANMAR CO., L.TD.
• Large Power Products Management Division
Quality Assurance Division
5-3-1, Tsukaguchi-honmachi, Amagasaki
Hyogo,661-0001, Japan
Phone: +81-6-6428-3137 Fax: +81-6-6421-5549
Overseas Office
.Yanmar Europe B.V. (YEU)

Brugplein 11, 1332 BS Almere-de Vaart, Netherlands
Phone: +31-36-5493200 Fax: +31-36-5493209
.Yanmar Asia (Singapore) Corporation Pte. Ltd. (YASC)

4 Tuas Lane, Singapore 638613
Phone: +65-6861-3855 Fax: +65-6862-5189
.Yanmar America Corporation (YA)

101 International Parkway,
Adairsville, GA 30103, U.S.A.
Phone: +1-770-877-9894 Fax: +1-770-877-9009
.Yanmar Engine (Shanghai) Co., Ltd.

10F, E-Block Poly Plaza, No.18 Dongfang Road,
Pudong Shanghai, China P.R.C. 200120
Phone: +86-21-6880-5090 Fax: +86-21-6880-8090
.Yanmar South America Industria De Maquinas Ltda (YSA)

AV. Presidente Vargas, 1400 Indaiatuba/SP
Sao Paulo, Zip Code 13338-901, BRAZIL
Phone: +55-19-3801-9224 Fax: +55-19-3875-3899, 2241
As of April 1st, 2016
6AYEM-GT, 6AYEM-ET, 6AYEM-ST
1st edition: June 2017
Issued by:YANMAR CO., LTD. Large Power Products Management Division

Edited by: YANMAR TECHNICAL SERVICE CO., LTD.
YANMAR
OBAYE-EN0010
PRINTED IN JAPAN
"'-NM'
Jr. . . .-R
.. CO., •• •-rD
j "

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YA"MAR

All Rights Reserved:

MODEL 6A YEM-GT, 6A YEM-ET, 6A YEM-ST

All Rights Rosorvod, Copyright YANMAA CD.. LTD.

ENGINE SPECIFICATIONS ................................................ 9

DISASSEMBLY AND ASSEMBLY ....................................... 16

INSPECTING AND SERVICING OF ENGINE'S MAJOR PARTS ... 67

MAINTENANCE INSPECTIONS 141

LONG-TERM STORAGE ................................................... 144

SERVICE REFERENCE TABLE ....................................... 146

FOR YOUR SAFETY

This safety alert symbol appears with most safety statements.

DANGER indicates a hazardous situation which, if not avoided, will result

WARNING indicates a hazardous situation which, if not avoided, could

CAUTION indicates a hazardous situation which, if not avoided, could

NOTICE indicates a situation which can cause damage to the machine,

• The descriptions captioned by "IMPORTANT" are particularly attentions on

• Maintenance service area (room)

Clean, Order Area

Scalding Hot Water

Be Careful when Starting Engine

Side Cover Opening

Explosion at Battery Charging

Using Genuine Parts

Using NOx-compliant Parts

2 141616-07210 • Can cause injury by explosion

Precautions for Lifting the Engine

• Make sure that the engine is lifted by qualified persons.

Less than 60 degrees

For the mass, refer to Specifications in the Operation Manual.

Fuel high - - - Seawater pump

Seawater outlet pipe lubricating

• Lubricating oil system

lubricating oil filter

lubricating oil main gallery

• Fuel oil system

----------1 1----------------- "I

Fuel inlet Fuel outlet

Fuel Oil, Lubricating Oil and Coolant

• Diesel fuel selection

ASTM 0975 No. 20 equivalent

Water quality for coolant

• Long Life Coolant (LLC) mixture selection

• Excess LLC deteriorates cooling performance.

DISASSEMBLY AND ASSEMBLY

Disassembly and Reassembly Tools

• General hand tools

Starling pliers Screw driver, reversible

Double ended wrench

Piston ring replacer

• Special hand tools

Intake and exhaust valve guide insertion tool

Flywheel insertion/extraction tool

Lubricating oil filter case remover Part No. 133615-92350

Fuel injector extractionlinsertion tool

Cylinder liner extracting tools Part No. 748620-92030

Stem seal insertion tool (intake valve)

Stem seal insertion tool (exhaust valve)