Yanmar 4BY & 6BY Series Marine Diesel Engine Repair Service Manual

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This Workshop Service Repair manual PDF download for the 4BY & 6BY Series Yanmar Marine Diesel Engine has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.


APPLICABLE MODELS :

Yanmar Marine Diesel Engine 4BY150 / 4BY150Z
Yanmar Marine Diesel Engine 4BY180 / 4BY180Z
Yanmar Marine Diesel Engine 6BY220 / 6BY220Z
Yanmar Marine Diesel Engine 6BY260 / 6BY260Z

Series 4BY with KM H40A
Series 6BY with KM H40A

4BY2 150 : Yanmar Inboard Engine 150hp/110kW - EPB5664
4BY2 180 : Yanmar Inboard Engine 180hp/132kW - EPB5664
6BY2 220 : Yanmar Inboard Engine 220hp/152kW - EPB5664
6BY2 260 : Yanmar Inboard Engine 260hp/191kW - EPB5664


TABLE OF CONTENTS :

Safety
General Service Information
Periodic Maintenance
Engine
Fuel System
Cooling System
Lubrication
Turbocharger
Starter Motor
Alternator
Electrical and ECU
Troubleshooting


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Part Number : OBBYO-G00102
Total Pages : 233


This Service / Repair / Workshop Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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Cover
Table of Contents
Introduction
Revision History
Revision Control Table
Safety
Safety Precautions
General Service Information
Safety Precautions
Engine Outline Drawings
4BY with KMH40A
6BY with KMH40A
Engine Piping Diagrams
Location of Nameplates
Engine Nameplates (Typical)
Diesel Fuel
Diesel Fuel Specifications
Additional Technical Fuel Requirements
Diesel Fuel Lines
Bleeding the Fuel System
Engine Oil
Engine Oil Specifications
Service Categories
Definitions
Engine Oil Viscosity
Acceptable Engine Oil
Recommended Marine Gear or Stern Drive Oil
Recommended Power Steering Fluid
Engine Coolant
Engine Coolant Specifications
Engine Coolant Mixture
Acceptable Engine Coolant
Principal Engine Specifications
Tightening Torques for Standard Bolts and Nuts
Tightening Fasteners
Hexagon Bolts and Nuts
Hose Clamps
Prepare Engine for Long-Term Storage
Abbreviations and Symbols
Abbreviations
Symbols
Unit Conversions
Unit Prefixes
Units of Length
Units of Volume
Units of Mass
Units of Force
Units of Torque
Units of Pressure
Units of Power
Units of Temperature
Periodic Maintenance
Introduction
The Importance of Periodic Maintenance
Performing Periodic Maintenance
Yanmar Replacement Parts
Required EPA Maintenance
EPA Requirements
Conditions to Ensure Compliance with EPA Emission Standards
Inspection and Maintenance
Periodic Maintenance Schedule
Periodic Maintenance Procedures
After Initial 50 Hours of Operation
Every 50 Hours of Operation
Every 250 Hours of Operation
Every 500 Hours of Operation
Every 1000 Hours of Operation
Every 2000 Hours of Operation
Engine
Before You Begin Servicing
Introduction
Specifications
General Information
Test and Adjustment Specifications
Repair Specifications
Special Torque Chart
Special Service Tools
Measuring Instruments
Sealants and Compounds
Tests and Adjustments
Test Compression
Repair
Cylinder Head
Cylinder Head Components
General Guidelines
Remove and Install Cylinder Head Cover
Cylinder Head Cover Components
Removal
Installation
Remove and Install Glow Plugs
Remove Cylinder Head
Disassemble Cylinder Head
Clean Cylinder Head Components
Pressure Test the Cylinder Head
Inspect Cylinder Head Components
Inspection of Valve Guides
Replace Valve Stem Seals
Assemble Cylinder Head
Determine Cylinder Head Gasket Thickness
Install Cylinder Head
Pistons and Cylinders
Remove and Disassemble Piston and Connecting Rod
Inspect Pistons and Piston Rings
Assemble Piston and Connecting Rod
Install Piston and Connecting Rod
Flywheel and Flywheel Housing
Remove and Install Flywheel Housing
Remove and Install Drive Coupling
Engines with Marine Gear
Engines with Stern Drive
Remove Flywheel
Replace Rear Crankshaft Seal
Install Flywheel
Camshaft and Timing Gear Train
Components
Check and Adjust Camshaft Timing
Check Camshaft Timing
Adjust Camshaft Timing
Remove and Install Vibration Damper - 4BY
Remove and Install Vibration Damper - 6BY
Remove Timing Case Cover
Remove and Install Timing Chain
Install Timing Case Cover
Remove and Install Timing Chain Tensioner
Remove Camshafts
Install Camshafts
Cylinder Block and Crankshaft
Components
Remove Crankshaft
Measure Oil Clearance
Inspect Crankshaft
Crankshaft Specifications
Inspect Cylinder Block
Install Crankshaft
Replace Front Crankshaft Seal
Intake Manifold
Remove
Install
Exhaust Manifold
Remove
Install
Attach Engine to Repair Stand
Fuel System
Safety Precautions
Introduction
Specifications
Test and Adjustment Specifications
Special Torque Chart
Special Service Tools
Fuel System Components
4BY Engines
6BY Engines
Fuel Flow Diagram
Tests and Adjustments
Measure Fuel Feed Pump Pressure
Procedure
Results
Test Return Fuel Pressure
Results
Repair
Remove Fuel Injector
Clean Fuel Injector Cavities
Install Fuel Injector
Remove and Install High-Pressure Fuel Lines
Replace the Fuel Feed Pump
Replace High-Pressure Fuel Pump
Removal
Installation
Replace Fuel Filters
Replace Fuel Fine Filter
Replace the Fuel Filter / Water Separator
Remove and Install Fuel Rail
Replace Injector Return Fuel Line
Bleed the Fuel System
Cooling System
Before You Begin Servicing
Introduction
Specifications
Test and Adjustment Specifications
Repair Specifications
Special Torque Chart
Special Service Tools
Measuring Instruments
Cooling Flow Diagram
Tests and Adjustments
Pressure Test Cooling System and Filler Cap
Cooling System
Filler Cap
Test Thermostat
Repair
Drain and Refill Seawater Cooling System
Check and Replace Zinc Anodes
Drain and Fill Closed Cooling System
Disconnect and Connect Quick-Connect Fittings
Disconnect
Connect
Remove and Install Hydraulic Oil Cooler
Inspect and Clean Hydraulic Oil Cooler
Remove and Install Charge Air Cooler
Disassemble and Assemble Charge Air Cooler
Remove and Install Heat Exchanger
Disassemble and Assemble Heat Exchanger
Remove and Install Coolant Pump
Remove and Install Thermostat
Removal
Installation
Seawater Pump
Inspect / Replace Impeller
Remove and Install Seawater Pump
Replace Seawater Pump Belt
Lubrication
Introduction
Specifications
Test and Adjustment Specifications
Special Torque Chart
Special Service Tools
Measuring instruments
Tests and Adjustments
Engine Oil Flow
Check Engine Oil Pressure
Results:
Repair
Engine Lubrication System Components
Change Engine Oil and Replace Engine Oil Filter Element
Remove and Install Oil Cooler
Remove and Install Oil Filter Housing
Remove and Install Oil Sump
Oil Pump
Remove Oil Pump
Install Oil Pump
Turbocharger
Introduction
Specifications
Test and Adjustment Specifications
Special Torque Chart
Special Service Tools
Sealants and compounds
Tests and Adjustments
Measure Charge Pressure
Results:
Specifications
Adjust Charge Pressure - 4BY
Repair
Remove Turbocharger
Install Turbocharger
Starter Motor
Before You Begin Servicing
Introduction
Starter Motor Specifications
General Specifications
Special Torque Chart
Starter Motor Troubleshooting
Remove and Install Starter Motor
Alternator
Before You Begin Servicing
Introduction
Specifications
General Specifications
Special Torque Chart
Repair
Replace Alternator Belt
Remove and Install Alternator
Remove and Install Alternator Belt Tensioner
Electrical and ECU
Introduction
Specifications
Special Torque Chart
Function Description - Engine Management System
Component Locations
4BY
6BY
Electrical Panel Components
Electrical Panel Connector (X1) Connections
Connector X1 Pin Assignments
Component Tests
Relays
Start Relay (K1)
Main Relay (K2)
Fuel Pump Relay (K3)
Oil Pressure Sensor
Results of Failed Sensor
Test Values
Fuel Injector
Results of Failed Injector
Test Values
Engine Coolant Temperature Sensor
Results of Failed Sensor
Test Values
Fuel Rail Pressure Control Valve
Results of Failed Valve
Test Values
Water-in-Fuel Sensor
Results of Failed Sensor
Test Values
Crankshaft Speed Sensor
Results of Failed Sensor
Glow Plug / Control Unit
The System
Function
Results of Component Failure
Test Values
Fuel Temperature Sensor
Results of Failed Sensor
Test Values
Fuel Volume Regulator
Results of Failed Regulator
Test Values
Charge Air Temperature Sensor
Results of Failed Sensor
Test Values
Charge Air Pressure Sensor
Results of Failed Sensor
Test Values
Fuel Rail Pressure Sensor
Results of Failed Sensor
Test Values
Camshaft Speed Sensor
Results of Failed Sensor
Throttle Position Sensor
Results of Failed Sensor
Test Values
Repair
Replace Engine Control Unit (ECU)
Replace Coolant Temperature Sensor
Replace Charge Air Pressure Sensor
Replace Charge Air Temperature Sensor
Replace Crankshaft Sensor
Replace Camshaft Sensor
Replace High-Pressure Fuel Control Valve
Replace High-Pressure Fuel Sensor
Replace Fuel Temperature Sensor
Replace Fuel Volume Regulator
Replace Oil Pressure Sensor
Troubleshooting
Introduction
Engine Faults and Torque Limitations
Torque Limitation for Failed Sensors Mode
Torque Limitation for Smoke Limitation Mode
Torque Limitation for Overheat Protection Mode
Troubleshooting Chart
Starting Trouble
Exhaust Color
Vibration - Drive Disengaged
Vibration - Drive Engaged
Engine Knocks
Low Power Output
Engine Overheat
Engine Runs Cold
Coolant Loss
Helm Panel Display
Trouble Codes
Working Procedure
Diagnostic Trouble Codes
After Troubleshooting or Repair

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