SERVICE MANUAL MARINE PROPULSION ENGINE NL a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. Itis 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. Please contact an authorized Yanmar repair or service professional before working on your Yanmar product. Disclaimers: Al 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 WANMAR are registered trademarks of YANMAR 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 - graph- ic, electronic, or mechanical, including photocopying, recording, taping, or information storage and retrieval systems - without the written permission of YANMAR CO., LTD. MODEL 6HYM-WET CODE OBGHY-ENO010 OPERATION MANUAL All Rights Reserved, Copyright WANMAR GO. LTD.CONTENTS FOR YOUR SAFETY 41 Safety Precautions 2 ‘Waring Labels 6 Safety Precautions when Lifting the Engine 7 8 ENGINE SPECIFICATIONS Location of Components Piping Diagram Fuel Oil, Lubricating Oil and Coolant 12 SI Unit Conversions 15 DISASSEMBLY AND REASSEMBLY. Precautions for Disassembly and Reassembly 16 Disassembly and Reassembly Tools. 7 Disassembly Procedures 26 Reassembly “4 INSPECTING AND SERVICING OF ENGINE’S MAJOR PARTS .. Preliminaries Standard for Parts Replacement (Including Correction) Cylinder Head Cylinder Block Cylinder Liner. Piston 81 Connecting Rod 85 Crankshaft and Main Bearing 88 Camshaft and Tappets "1 Timing Gear 94 Flywheel! 96 Viscous Damper 96 Fuel injection Equipment co Eo oe 7 Fuel Feed Pump 101 Boost Compensator 102 Fuel Injector 104 Adjustment of the Injection Timing 107 Fuel Filter 108 Lubricating Oil System 109 Cooling Water System 15 Turbocharger 122 Electrical System. 141MAINTENANCE INSPECTIONS. - 146 Precautions for Maintenance and Inspections 146 Periodic maintenance schedule 146 STORAGE STANDARD 148 TROUBLESHOOTING AND COUNTERMEASURES. . 149 Starting Failure 149 REFERENCE ADJUSTMENT VALUE ..... SERVICE REFERENCE TABLE . 155 TIGHTENING TORQUES FOR MAJOR BOLTS AND NUTS ... 159 Tightening Torque for Major Bolts and Nuts. 159 Cylinder head Tightening Bot 160 Standard Tightening Torque 161 Torque for Pipe Joint Bolts 161 TEST RUNNING 162FOR YOUR SAFETY — 1 FOR YOUR SAFETY The main causes for accidents is that basic safety rules and precautions were not obeyed. It is important to prevent accidents before they happen by avoiding their causes. 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. Itis not possible to predict all dangers that can occur during repair or maintenance and indicate them in a manual. Therefore it is necessary to carefully consider workspace safety beyond what is expressed in this manual and on the safety decals, Especially during repair or maintenance work that is not described in the manual, obey the instructions by qualified mechanics. About safety decals (warning labels) Safety decals (warning labels) are attached to the engine. Please consider them for your safely. Make sure that you replace safety decals that are lost or difficult to read. Obey the handling instructions for used engines as you do with new engines. The symbols on the safety decals have the following meanings. DANGER indicates a hazardous situation which, if not avoided, will result PCa in death or serious injury. WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. AWARNING | 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, NOTICE personal property andlor the environment or cause the equipment to operate improperly.2 — FOR YOUR SAFETY Safety Precautions Make sure that you obey these precautions for safe maintenance. 1 Precautions for the maintenance facility (room) ANAS Do your work in a room that has good airflow Make sure that the airflow is sufficient when: + The engine operates. + You weld parts. + You remove paint with sandpaper. If you do not obey this: You can breathe in poisonous gas or dust. This is very dangerous to the body. ACAUTION Make the room bright Make sure that your workspace has sufficient lighting. f your workspace is dark and visfon is Poor, use a portable safety lamp. Use lamps with light bulbs that are covered with a wire cage. If you do not obey this: The light bulb can accidentally break and ignite leaked oil Do your work in a room that is sufficiently wide and flat The floor area in the maintenance facility (room) must be sufficiently large and flat with no holes. If you do not obey this: You can fall or other unforeseen accidents can occur. Do your work in a room that is clean and tidy Make sure that no dust, oil or parts are on the floor. If you do not obey this: Unforeseen accidents can occur. Fully equip the facility with fire-extinguishing equipment Place a fire extinguisher in your vicinity in case a fire breaks out. Also, do an appropriate inspection of the fire-e:FOR YOUR SAFETY — 3 Precautions for your work ad | AWARNING Do all holding and lifting in an appropriate manner Do not hold or lift when supported only by a block, wooden piece or a jack. Do all holding and lifting from the specified lifting points and fixtures, and use equipment that easily handles the weight. If you do not obey this: Serious accidents can occur. ACAUTION Put on safe work clothes Worker must put on a helmet, work jacket, boiler suit, safety shoes and safety equipment that matches their task. The work clothes must fit well If you do not obey this: You can get caught in the engine and serious accidents can occur. Use the applicable tools + Use the correct tools for your work. Use tools of the correct size when you loosen or tighten the engine. If you do not obey this: You can get seriously hurt or damage the engine. + Make sure that you tighten all spaces that are indicated in the manual to the specified torque. If you do not obey this: Parts may become loose and fall, causing parts damage or personal injury. + Do not work in an uncomfortable position. If you do not obey this: Unforeseen injuries can occur. 1 Precautions for handling parts ADANGER y & Be careful when filling fuel Keep away all fire such as cigarettes and matches when filling fuel. If you do not obey this: Fire and explosions can occur. Be careful when opening the coolant filler cap Do not open the coolant filler cap when it is hot. If you do not obey this: Hot water blows out and burn injury can occur.4 — FOR YOUR SAFETY Be careful with rotating parts Keep away your hands and tools from rotating parts during engine operation. Hf you do not obey this: You can get caught and injury can occur. Be careful with short-circuits of the harness Remove the (-) terminal of the battery during maintenance. If you do not obey this: You may get an electric shock, and a short-circuit of the harness can cause a fire. Be careful when charging the battery The battery makes flammable gas when it charges. Keep away all fire. Make sure that there is good airflow. Ifyou do not obey this: An explosion can occur. Be careful when starting the 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. Then start the engine. Remove the turning handle, and store it in the speci If you do not obey this: Injury can occur. location. ACAUTION Be careful with hot parts Do not touch the engine's hot parts during or after operation. If you do not obey this: The high temperature can cause burn injury. Be careful the battery fluid Battery fluid is diluted sulfuric acid, so make sure that you do not get it on your clothes or skin. If you do not obey this: You can make a hole in your clothes and buri injury can occur.FOR YOUR SAFETY — 5 About the use of genuine parts NOTICE Use genuine parts Ifyou do not obey this: You can shorten the operating life of the engine and unforeseen accidents can occur. Use NOx-compliant parts ‘According to the laws preventing environmental pollution and sea hazards, itis necessary to make a record signed by a supervisor when certain parts are replaced, The parts in question are listed in the engine service manual. About disposing waste NOTICE Be careful when disposing waste Fil all waste oll and waste fluids into containers and do not spill Never dumb them outdoors or into sewage, rivers or the sea. Appropriately dispose of waste materials in accordance with laws and regulations, e.g. commission a professional collector to dispose of the waste materials.6 — FOR YOUR SAFETY Warning Labels For safe operation, the waming labels should be affixed in the correct place. Replace the labels with new ones if lost or damaged. PS ea OREM TERT BOTT, omibate MLO ees oRnay hover renove the cap shile the fraine is etill Ret. eft water may spurt ut and burn you o “aq ooo ld 4 3 prtae A had weFOR YOUR SAFETY — 7 Safety Precautions when Lifting the Engine ‘The engine can cause serious injury when it falls during lifting. Obey the below instructions to prevent accidents during fitting, + 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. For the mass, refer to Specifications in the Operation Manual.8 — ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Engine Unit SHYMAWET Type = Vertical, water-cooled, 4-cycle diesel engine [Combustion chamber = Direct injection type No. of cylinders cylinder bore * stroke [mm 61929 165 Total cylinder displacement @ 1373 Rating = s v M # Rated output (at flywheel) ww(P8)_| 515 (700) | 478 (650) | 441 (600) 368 (500) Rated snaine speed mint 2200 2160 2100 1850 [Crankshaft tation direction = Counterelockwise (viewed from the flywheel) Fiing order = 1-4-2-6-8-5-1 Fuel injection pump = YANMAR 6 incline Injection timing (FIC) ruieyuen [O22 100) des. tez05 | 15205 | 45205 13205 Hole type 8 - 00.28 x 165° Hole ype 8-00.24 » 155° ‘Type of injection nozzle |mm * degree pene pean Injection pressure MPa 304205 Lubricating = Forced lubricating wit gear pump Cooling = Freshwater (coolant) cooling Lubricating sais Lubricating ollpressure | MPa 04-05 Lubricating ot [OW pan @ 6 capacity [Piping @ 10 Seawater pump = Rubber impeller, gear driving type [Cooling water | Water pump (cooiant) = Centrifugal, gear driving type system Cooling = Freshwater (coolant) cooling (with @ heat exchanger) Coolant capacity @ 40 (engine), 15 (reservoir) oe = RHG7 (twincturbo) Cooling = Air cooling a = Fin and tube Cooling = Seawater cooling Staring system = Electric starting Engine dry mass (without marine gear) kg 1385 Note: Cylinder numbers are counted from gear side (No. 1) o flywheel side (No. 6).Location of Components Operation side Iniake manta (Ar cooler} Coolant an m (Heat exchanger) T ENGINE SPECIFICATIONS — 9 ra OK Fuel priming pur Fuel food pump i Non-operation side Exhaust manifold ee 1 Fuel injection pure Governor 0 fier esp Dipstick Tuecharger Seawater pump Wate pump (Cootans Engine of fer10 —— ENGINE SPECIFICATIONS Piping Diagram Cooling water system Reservoir Seawater inlet ee Lub. ol cooler (O) Fy) “orenaine) Treas mente : Exh gos maniols 2 Press. cap g i i se 01 Me 3 boa 2 Coolant pump i+ [Cylindericyinder head Air cooler p= Seawater outot Seawater line Coolant ines = Lubricating oil system Lub oll cooler fk “Thermostat ser 65-80°C aes Oil gallery Bi) 8) # Ells ub Lob, of pump alla] % a||§ alg @! Me Lejle} #8 7 8 Suction ilpanENGINE SPECIFICATIONS — 11 Fuel oil, exhaust gas and air system Fuel system Exh. gas and air system Fuel injection valve To each valve sh gos man 3 Air enoler Tutto-charger || Turbo- vt Mist pipe | Feleed perp service tank) i [ee] A12 —— ENGINE SPECIFICATIONS Fuel Oil, Lubricating Oil and Coolant Fuel ‘The following table shows the fuel oil specifications for this engine model Fuel oil properties affect the smooth running of the engine, its maintenance intervals and the service life of its parts, They come in a broad range and can be uncertain. Thus, depending on the applied fuel ol, it might be necessary to add attachments or change the specifications of the engine. @ Quality criteria of fuel oil Viecosty at 60°C mile 3-8 Specific gravity at 15°C gfom® = 086 Flash point °c 560 Residual carbon mass <07 Sullur content mass 10 [Ash content mass 008 Moisture content vol% =O. Vanadium ppm - Sodium ppm = Aluminum ppm = Diesel index (Cetane no. of = 45) AST DST 20 Quality criteria equivalent fuel oil 55-2068 Glass At or AP 150 8217 DMX EN 500 NOTICE The fuel injection system consists of precision parts. For that reason, only use fuel that is free of water and dust, Contaminated fuel causes malfunctions. Thus, pay attention to the following when supplying fuel. ‘Also, drain and do maintenance servicing of the fuel filter as described in P171 (Maintenance Inspections] during daily maintenance. When supplying fuel + When supplying fuel stored in a drum, let the drum rest for one day or longer so that impurities can settle, and fil the top layer of oll to the engine. + If supplying fuel from a storage tank to the service tank, wait one day or more after the fuel was filled to the stor- age tank before you supply the fuel to the service tank.ENGINE SPECIFICATIONS — 13 Lubricating oil Selection of lubricating oil is very important for a diesel engine. If improper lubricating oil is used or change of lubri- cating oil is neglected, it causes sticking of piston rings, seizure or early wear of pistons and cylinder liners and faster wear of bearings and various other moving parts that reduce the durability of the engine. Choosing the lubricating oil Service categories Use an engine oil that meets or exceeds the following guidelines and classifications: + API. Classification: Grade CD, CF + SAE Viscosity grade: 30, 40, 15Vv-40 (Only if the sulfur content of the used fuel is less than 0.5 %) + TB.N. [MgKOHIg}: 9 - 15 Viscosity | Specific | Flash point °C) , Kinetic viscosity (mm/s) Viscosity Pour point (°C) (SAE) gravity {open type) 40°C 700"¢ index 30 089 3220 a0 705-195 1-125 96-110 40 0895) 5240) =15 140-155 74-185 96-110 Tawa 0.88 > 230 <=30 > 100 14-155 > 140 NOTICE * Do not blend, (If you cannot avoid blending different brands of lubricating oll, consult your lubricating oil supplier.) + Ifyou use a lubricating oil with a high total base number (T.B.N.) and a fuel oil with low sulfur content, the additive (calcium carbonate) of the lubricating oil sticks to high-temperature areas and deposits with carbon residue. This causes the adverse effects mentioned below. Thus, use the proper lubricating oil Accumulation of these deposits in the combustion chamber hinders the sliding of the piston rings and may cause ‘scuffing on the rings, cylinder liners and other parts. Also, the deposits may cause bite- the exhaust valves. and blow-by if they enter Selecting the marine gear oil Refer to the Operation Manual of the marine gear.14 —— ENGINE SPECIFICATIONS Coolant ™ Coolant selection Use clean water (tap water) as coolant. Select water that has the properties shown in the following table. Water quality for coolant pH (25°C) 65-80 Total hardness (CaCO,) = 100 ppm M alkalinity 30-100 ppm Ammenonium ion (NHg*) = 0.05 ppm Chioride ion (Ch) <100 ppm Sulfate fon (0,2) = 100 ppm Evaporation residue = 400 ppm Hi Long Life Coolant (LLC) mixture selection As a coolant, only use tap water mixed with Long Life Coolant (LLC). 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. ees Ifyou choose an LLC different from the above, make sure that it does not have any adverse effects on the materials used in the engine's cooling system (cast iron, aluminum, copper, etc.) Without this mixture, scale and rust develops inside the coolant system, thus deteriorating the cooling performance. Always use LLC in winter. If you do not use LLC, the cooling water freezes and expands inside the engine, causing parts of the coolant system to break ‘The mixing ratio of LLC depends on the temperature. Be careful to use the mixing ratio specified by the LLC manu- facturer, NOTICE + Too much LLC reduces the cooling effect of the coolant. Too little LLC does not provide sufficient protection against the lowest temperatures. The cooling water system freezes and is damaged + Never mix different types or brands of LLC. Chemical reactions may make the LLC useless and engine trouble could resultENGINE SPECIFICATIONS — 15 SI Unit Conversions ™ Conversion table Conversion values between the international unit system (Sl) and the metric unit system are shown below: Force N gt 1 0.101972 9.80665 1 Torque Nem kgf 1 o101072 0.80665 1 Pressure Pa kgtlem? 1 1.0197 x 105 9.80665 * 104 1 9.80665 * 105 1.0000 * 104 Power Kw PS 1 13596 0.7355 116 —— DISASSEMBLY AND REASSEMBLY DISASSEMBLY AND REASSEMBLY Precautions for Disassembly and Reassembly Disassembly 1, Prepare the disassembly tools, measuring instru- ments and recording sheets. 2. Prepare the cleaning machines and cleaning ves- sel 3.Provide a space and containers for disassembled parts 4,Drain the cooling water and lubricating oll com- pletely out of the engine. 5. Put the disassembled parts in order. 6. The material and dimensions of bolts and nuts dif- fer from each other. To prevent use of wrong bolts or nuts, put them temporarily in their orginal posi- tion immediately atter removal 7. If trouble is located, frst determine the cause of the trouble to prevent removal or disassembly of parts unrelated to the trouble. lM Reassembly 41. Wash and check the parts to be assembled with due care, 2. Apply new engine oil or the specified lubricant to sliding parts and moving parts before assembly 3.Replace gasket packings, O-rings, copper pack- ings and other packings with new ones. 4, Use liquid packing, if necessary, to prevent water and oil leakage. 5. Fit each part while checking oil clearance and thrust clearance. 6. Align all marked parts carefully during assembly. When fiting replacement parts, pay attention to their combination. 7.Do not confuse the bolts, nuts and washers, and tighten the major nuts and bolts to the specified torque. Take special care not to damage when tightening parts made of aluminum alloy 8. Apply engine oil to the threads and bearing sur- faces of major bolts and tighten them to the speci- fied tightening torque Disassembly and reassembly Use a spanner wrench during disassembly and a torque wrench during assembly. Note: It describes the points of importance and pre- cautions in overhaul work.DISASSEMBLY AND REASSEMBLY — 17 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. Mlustration| Name of tool code No. Mlustration eu) Turning bar L600 | Screw driver, reversible 126410-02720 D:18 1104200-92350 L a7 Oil teeder pecan te SF os 8 « 10 28110-08010 12 14 28110-120140 17 «19 28110-170190 nan24 ronozz02i0| GP) 2730 28110270300 Toot box Offset wrench 10 * 27 28160-100120 Monkey wrench 1417 28160-140170 28120-00200 19 « 22 28160-190220] © Thickness gauge 0.1 mm 28912-100750 0.35 mm 28312-95075018 —— DISASSEMBLY AND REASSEMBLY Special hand tools [Connecting red small end bushing insemion/extraction tool p75 alg Loe thos | Dimensions Varad = z = z atrial 0572 | 06282 | 62 100 s4sC intake and exhaust valve guide insertion tool = AaB r Insertion oo el o awe quite a Dimensions ( = = = = Material 02292 | 016293 25 150 asc Lubricating of fier case remover Part No. 127610-82750DISASSEMBLY AND REASSEMBLY — 19 [Camehatt insertion tool Dimensions A;[BI[cCJOJETFIG H 1 J[K u MIN ame 200| 30 | 15 | 76 | 61 | 10 | 650 |#50h7 *B%\na0 x P1.5] 037 | a44]e62 92 10° | 20 | Ss400 ‘Stem seal insertion tool (for inserting stem seal) QC Screw lock super 5 © Stem seal M ATSB ]ec)]e]Te,TFTS TAT’ ]K].L)]™ oi | 19 | 31 | 27 | 080 [ots] om | 160 | 50 | 2 | 60 | Me20 —— DISASSEMBLY AND REASSEMBLY Nozzle sleeve tightening tool ; . KO) Ik 7 : a i) 20 760 | 01093] 0156 . Buen Upper) 1 d b 20 Liner pier (Lowe) ©DISASSEMBLY AND REASSEMBLY —— 21 Piston neering tol J Impeller extraction tool Part No. 127881-02420 Bolt (io 20) i Mar = 20 Canshal gear exradton too I ATSB ]C)]D [el [FS jos [730 | 30 | 26 | 2a [mia | wtD22 —— DISASSEMBLY AND REASSEMBLY Fuel injection nozzle extraction tool M2 « 1.25 q 6 020 Mis [Oil pan positioning tool M ° ulead u Fle o € 1 cs c| oles kK A ‘ 4 ATe lc ]o,Te]FL[S¢|]A,]I1]s][K]L [MIN wa [ie2[ 0 [89 | 7% | | 8 | 2 [oes] 5 | 6 | oo | 19 |2MeDISASSEMBLY AND REASSEMBLY —— 23 Measuring instruments Application of tools No, | _[nstrument name Description IMustration _|_ (Yanmar code No.) fae 0 01 mm ‘To measure the bending 1 |ial gauge Bas ‘and gap ofthe shaft, sur- Papen face distortion, etc 1 div...0.01 mm ‘To measure postions too 2. | Testindicator Range nartow and too deep for 0-08mm normal dial indicators 7 Mainbar ——-Subbar (Giameter* (diameter To attach dial indicators to 3. Magnet stand length) tength) various positions for easy 12*176 10165 and accurate viewing 14x183 12% 165 Range (mm) To measure the outside 0-25 75-100 diameter of the crank- 4 | Micrometer eae 25-50 100-125 ‘haf, piston, piston pin, 50-75 125-150 ete a ore Tome terete | 5 5 | cylinder gauge ee deter tte cyinserin-| 04 __e- 0, 35-60 a ee 1 div...0.05 mm ‘To measure outside diam- 6 | Vemier calipers Range tet, depth, thickness, (0-150 mm width, ete —— Range (rm) ‘To measure valve sinkage 7 [Pepin micrometer 9-35 mm ‘and liner projection, ‘To measure the incination alee Size ‘of valve springs and 400 (mm) ‘squareness of various pars, Sze Use when measuring the 8 |leck 4100 x 50% 55 (mm) bending ofa shat.24 —— DISASSEMBLY AND REASSEMBLY Instrument name (973100-FPRDO) Cleaning agent (0.45 2) (973100-00FRQ) No. Description IMustration (Yanmar code No.) bi Use when tightening bots and nuts tothe speciied | —r remem torques, 10 | Torque wrench Range 392-176.4Nm = 39-11.8Nm 302 .2/8N G2 9.8-44.1 Nim m 392-4116 Nm To measure oll clearance between piston rings and 11. | Thickness gauge Length 75 « 9 sheets piston grooves or between shat couplings during installation To inspect antireeze solu- | we ley Seaton | Moet tion and elecroiye for oo UFBN, speeitc gravity, ani (95500-00013) J pecife gravy, end charging condition Nozzle tester ° (73760093401) cna To inspect spray condition 13 |High pressure pipe |°- “2 MP2 and the injection pressure . as of the fuel injection valve ee M14 1.8 pusher fiting To measure deflection of 14 [Detection gauge crankshaft with crankshat (42221 -000011) end Penetrant (0.45 2) Penetration test (Vorftaw detection) | (97S100-00F PS) fall sche Developer (0.45 2) ‘To be used in detecting Ft nd ot (battles) (973100-00FDS) flaws and cracks.@ Other material DISASSEMBLY AND REASSEMBLY —— 25 items Usual contents Features and application Thre ere 2008 Non-dryng liquid gasket; solventess type, easy to remove, supe- weriar | (1 KG so avaible) | riorin seawater resistance, applicable io various mating surfaces, Three Bond fore 2009 Non-dryng liquid gasket; easy to apply, superior in water resis- 1 kg also avaliable) |tance and ol resistance, especially superorin gasoline resistance rene | (1K ) , especially superior in Three Bond we oe - Dying film. low viscosity and forming of thin fm, appropriate for mating surtace of precision pats Liquid gasket 81103 8 p Pp Three Bond 009 ‘Semiining viscoelastic material applicable to non at surface Not | i gacestatante [M9 many indentations and potions, superrin heat resis- TB1104 2 tance, water resistance, and oil resistance. Deere wong | S2Nent ess ype sliconebete sealant. ppoable a igh meee 5 9 meee qe ture areas (-50 °C to 250°C) ene 100 Silicone-base, non fluid type, thick application possible. nee @ ile id te, thick application p Prevention offoase bolts, gas leakage, and corosion Lock tight 2009 ‘Torque required to loosen bolt: 10 % to 20 % larger than tightening Te1401 torque Adhesive Tock tight SUPER 509 Excellent adhesive strength locks bot semi-permanent. 7813908 | Sealing material for threaded parts of various pipes. Seal tape 5 mround tape : [ Ambient temperature range: -150 °C to 200 °C 31.000m diameter 7 e24zmdiameter 1 | 6 ins op . wh 4 ovate sic re | neceeceee e 83.52-m diameter: 1 L a aed 7 sia) 95.72:m diameter 4 Brand nar ee ae Fe bly of find tc tals, shafts, et EP ubicant | PASTE) Spray ypeaciaesaplaton wor a (molybdenum Brand name 330 disfeature) (PASTE SPRAY) 2 Brand name | mo Prevention of seizure of tireaded paris at high temperature, Appi (MOLYPASTE) iu cable to intake and exhaust valves. (stem, guide, face) m Cleaners Teme Usual contents Features and application Cleaning agent [+ The cleaning agent removes even carbon adhering to disassem-| bled parts + Ifa cleaning machine is used, prepare 4 % to 6 9% mixture of 60 "C to 80 °C to ensure more effective cleaning Cleaning agent for turbocharger ‘Special cleaning agent that requires no water, specially designed {or blower of turbocharger and intercooler.26 —— DISASSEMBLY AND REASSEMBLY Disassembly Procedures 1 Drain cooling water Coolant Drain through four cocks located on. ‘© Cylinder block © Coolant pump ‘© Exhaust manifold (two cocks) ‘© Coolant passage coverSeawater @ Heat exchanger ‘© Drain by removing seawater pump side cover ‘@ Loosen drain cock of lubricating oil cooler Drain lubricating oil Puta tube into oil drain hole of the oil pan, and use draining pump to drain the lubricating oil DISASSEMBLY AND REASSEMBLY —— 2728 —— DISASSEMBLY AND REASSEMBLY ™ Drain fuel oil 1. Loosen drain plug of fuel filter and fuel water sep- arator. 2. Loosening round pipe joint accelerates the drain- ing 1 Removing electrical wiring Remove the wiring from the engine. 1 Removing the filter and fuel pipe 1, Remove the fuel pipes (1) (fuel fiter- feed pump, fuel filter - fuel pump and fuel nozzle - fuel filter). 2.Remove the fuel fter assy (2). together with mount from the engine 3. Remove the cooling water pipe (3) (air cooler - heat exchanger). Removing the starting motor Remove the starting motor (1) from the flywheel hous- ing1 Removing the alternator 1, Remove the V-belt cover (6). 2, Loosen the alternator adjuster bar (3) and remove the Vebelt (4). 3, Remove the alternator cover (6). 4, Remove the altemator (2). 5, Remove the altemator driving unit (1). 1 Removing the fuel injection pipe 1, Remove the fuel injection pipe support. 2. Loosen the cap nuts on both ends of the fuel injec- tion pipe and remove the fuel injection pipe. DISASSEMBLY AND REASSEMBLY —— 2930 —— DISASSEMBLY AND REASSEMBLY Removing the air duct Remove the air duct (turbocharger - intake manifold) and the expansion joint (1) @ Removing the intake manifold and air cooler 1. Remove the seawater rubber hose (intake mani- {old - lubricating oil cooler). 2, Remove the boost compensator inlet rubber hose (). 3, Remove the boost sensor (2) 4, Remove the intake manifold and air cooler.Removing the turbocharger 1, Remove the oil pan side rubber hose for the tur- bine lubricating oil return pipe (4) from the oil pan 2. Remove the turbine lubricating oil pipe (1) (turbine inlet), 3, Remove the exhaust bend (3). 4, Remove the turbocharger (2) § Removing the cooling water pipe (coolant) Remove the coolant pipe (exhaust manifold - heat ‘exchanger (1), head - exhaust manifold (2)). @ Removing the exhaust manifold 1.Remove the exhaust manifold cover (1). 2, Remove the exhaust manifold. DISASSEMBLY AND REASSEMBLY —— 3132 —— DISASSEMBLY AND REASSEMBLY Removing the coolant pump 1, Remove the cooling water pipes and rubber hoses. 2.Remove the coolant pump (1). 1 Removing the lubricating oil cooler and lubricating oil filter 1, Remove the lubricating oll iter (1) 2. Remove the cooling water pipe and rubber hoses. 3. Remove the lubricating oil cooler (2). 1 Removing the heat exchanger 1. Remove the reserve tank. 2. Remove the coolant tank (heat exchanger) (1). 3. Remove the coolant tank (heat exchanger) mount. ™@ Removing the viscous dumper 1.Remove the viscous dumper cover. 2.Remove the viscous dumper (1). Mf Removing the seawater pump 1, Remove the cooling seawater pipes and rubber hoses. 2.Remove the seawater pump (1) together with mount.DISASSEMBLY AND REASSEMBLY — 33 1 Removing the fuel return pipe Remove the fuel return pipe (1), (2) (ocker arm case inside and outside) 1M Removing the intake/exhaust valve rocker arm assy, and push rod 1,Remove the bolts for the rocker arm shaft support. ‘and remove the entire rocker arm shaft assembly, ), + Identify the components by cylinder No. 1-3 and No. 4-6. 2, Remove the valve bridge (2) 3. Pullout the push rods (3) + Identify the components by cylinder Nos. and intake/exhaust. 4, Pull out the fuel injector (4) + Use fuel injection nozzles extraction tool. Note: If fuel nozzle seat stays in the cylinder head, make a note of the cylinder number and be sure to remove it when disassembling the oylinder head. 1 Removing the valve rocker arm case Remove the valve rocker arm case (1)34 —— DISASSEMBLY AND REASSEMBLY Removing the cylinder head 1, Remove the cylinder head (1). Note: Loosen the securing bolts. Identify the bolts by cylinder No. 1 - 3 and No. 4 - 6 2.Remove the cylinder head gasket. 3.Be sure that the stud bolts (2) are tightened surely. 1 Removing the fuel injection pump 1.Remove the remote control cable and cable mount. 2, Remove the lubricating oil pipes of the fuel injec- tion pump and drive shaft. 3.Mark the matching mark (1) to the timer and the coupling 4, Remove the fuel pump driving shaft joint coupling bolts (2), ‘5. Remove the fuel pump support bolts and then fuel ump fitting bots (3)Removing the fuel injection pump mount 1, Remove the fuel injection pump mount (1) 2. Remove the shim (2). 1 Removing the cylinder block side cover 1, Pull out the oll dipstick (1). 2. Remove the cylinder block side cover (2). 1 Removing the piston and connecting rod assy 1.Remove the connecting rod bolts and then the caps 2.Push up rod and pullout piston rod assy upward. + Identity the components by cylinder Nos. DISASSEMBLY AND REASSEMBLY — 3536 —— DISASSEMBLY AND REASSEMBLY 1 Removing the cylinder liners 4. Pull out liners (1) using eylinder liner special tool f + Identify the components by cylinder Nos. lm Removing the tappets 1. Take out tappets (1). + Identify the components by cylinder Nos. and intake/exhaust Removing the gear case cover 1, Remove the oil seal with case. + Use installation bolt by putting it into the pull-out hole. 2. Loosen the gear case cover bolts, and remove the gear case cover. + Use pullout hole.DISASSEMBLY AND REASSEMBLY —— 37 Removing the driving gears 1. Flatten the bend washers, remove nuts, pull out fuel injection pump driving gears (1) and then remove the driving unit (4) 2.Flatten the bend washers, remove nuts, and then pull out the cam gears (2) using cam gear special tool. '3.Remove the idle gear (3) and mount. Removing the flywheel 1. Loosen the flywheel bolts and remove the flywheel . + For safer and easier works, use of guide bars is recommended. ‘Note: Be careful not to scratch the ring gear. 2, Remove the oil seal with case (2), 238 —— DISASSEMBLY AND REASSEMBLY Turn cylinder block upside down Place a wood block on the floor and put the cylinder block upside down. ™ Removing the oil pan 1, Remove the oil pan (1). Note: Tighten the pull out bolts evenly. 1 Removing the engine foot Remove the mounting foot (1) 1 Removing the camshaft 1.Remove the camshaft thrust metal. 2. Pull out camshaft (1). ‘Note: Check that tappets have been removed.DISASSEMBLY AND REASSEMBLY —— 39 1 Removing the flywheel housing Remove the flywheel housing (1). 1 Removing the lubricating oil pump 1, Remove the lubricating oil suction pipe (1), dis- ‘charge pipe (2) and support (3) (4). 2.Remove the lubricating oil pump.40 —— DISASSEMBLY AND REASSEMBLY @ Removing the crankshaft 1, Remove the idle gear for lubricating oil pump driv- ing 2.Loosen the main bearing cap side bolts and remove the main bearing cap side bots. 3. Loosen the main bearing bolts and remove the main bearing bolts. 4.Remove the main bearing cap and lower main bearing (1) Note: The thrust bearing (lower) is mounted to the base main bearing cap. 5. Lift up orankshaft to remove. ‘Noto + The thrust bearing (upper) is mounted to the standard main bearing. + Remove the main bearing (upper) from the cylinder block. Note: Identify main bearing bolts and main bearing by cylinder Nos. 1 Removing the piston cooling nozzle Remove the piston cooling nozzle (1).Reassembly Clean all parts Clean all parts using by the cloth and diesel oil (or cleaning agent) before reassembly. Note: ifthe dust remain with the parts, engine may cause the seizing or damage. + The cleaning agent removes even carbon adhering to disassembled parts. @ Cylinder block 1.Completely clean each oil hole. After cleaning, check that no scaling remains on cylinder block. 2. Attach cylinder block blind plug 3. Drive connection pipe B with notch looking down- ward, lI Fitting piston cooling nozzle Fit each piston cooling nozzle (1). Check that nozzle end is positioned on piston head side. Also check that there is no gap between the nozzle mounting surface and the cylinder block mounting seat. Tighten the noz~ zle to the specified torque, Tightening torque: Pipe joint bolts M16 _6 pes. 5525Nm Note+ Make sure that there is no dust in the nozzle oil holes and nozzle fitting holes. + Tighten the nozzle body and bend the bend washer securely. Cooling water partition plate (A), (B) 1. Attach cooling water partition plate A (1) and B (2). Tightening torque: Bolt MB» 22 18 pes Ma « 65 17 pes 2322Nm 2. Cooling water partition plate B (2) has a draining cock (3). DISASSEMBLY AND REASSEMBLY —— 41 PT 1/8 tapera thread plug ‘Connecting pipe & ‘Comecing pine A Hexagonal plug42 —— DISASSEMBLY AND REASSEMBLY I Fitting camshaft bearing 1. Pull off the camshaft bushing as follows 1-Place a metal plate on the bushing and hitit lightly with a copper hammer until the bushing is removed 2-Thoroughly wash the bushing holes of the oy inder block. 2. |nsert the camshaft bushing as follows: ‘Apply engine oil to the bushing holes in the cyl- inder block side and around the bushing cir cumference, Press-fit the bushing 2-Match the oil holes so that the joint ofthe bear- ings are directed upward, 3-Afler press-fiting the bushing, measure its inner diameter to check for distortion. Taner diameter of bush after 163 $8989 mm press-fiting 909 38H ™ Camshaft Apply lubricating oil to bearing of camshaft and then fit camshaft (1). Fit thrust plate, and secure it by tightening 2 bolts of M10 x 22 mm. Thrust plate tightening torque Bolt M1022 2pes hdeheialil Note: Camshaft bearing have two types: + Gear side bearing: Width 33 mm, 1 pe + Other bearings: Width 28 mm, 6 pes Idle gear mount 41, Mount the idle gear bracket (1). (Mount it so that the oil hole (3) comes to the left upper side.) Tightening torque’ 4545Nm M10x22_4pes. iste ‘Tighten the blind cover (2) to the specified torque. Blind cover tightening torque’ Bolt MB = 18 2 pes. 2322Nm Make sure that there is no dust or foreign matter, inside the main gallery. 25 it hole ot hole 20.15 2 A Joint (cinch) Detail: A1 Mounting the crankshaft 1. Apply engine oll to each crank journal hole of eylin- der block and each block side main bearing (1). Bearings having an oil groove should be positioned on upper side (block side). Fit thrust bearing (2) so that oll rooves are respectively positioned out- side. 2.Apply engine oil to each crank pin and crank jour- nal and fit each journal to main bearing 3, Check that the matching numbers shown on the bearing cap (3) and cylinder block match. *F" embossed on the bearing cap should face the flywheel before tightening it to the specified torque. 4. Apply engine oil to the thread and the contacting surface of the bearing cap bolt. Tighten the bearing cap bolt (4) Bearing cap tightening torque: Bolt M20x25 14 pcs, 375 £10 Nm 5.Fix the bearing side bolt (6). Tighten the side bolt with mounting foot on the non-operating side, anti- flywheel, Bearing cap side bolt ightening torque M14x1.8 1408. 14010 Nm 6. Check that the crankshaft rotates smoothly. 7.Measure the side clearance of the crankshaft, Side clearance 0070-0219 mm Check the crankshaft oil clearance. Refer to P89 [Measurement of the crank pin and crank journal} DISASSEMBLY AND REASSEMBLY — 4344 —— DISASSEMBLY AND REASSEMBLY I Idle gear (lubricating oil pump) 1,Set the mount along the dowel pin 2.Assemble the idle gear (1). ‘3. Tighten the bolts (2) to the specified torque. Tightening torque! Bolt M12*82 1 pe. bedehealil Lubricating oil pump 1. Fit the end face of the lubrication pump driving gear (2) with that of the idle gear (3). 2.Tighten the bolts forthe lubricating oil pump (1) to the specified torque after turning the crankshaft (4). Tubicating 61 pump tightening torque 45£6Nm Bok M1030 Apes Check the backlash. Tale gear. Lubricating oll pump driving gear Tile gear, Crankshaft gear 0.15- 023mm 0.42-0.20mm Check the gear side clearance. Tile gear side clearance 0.15- 030mmDISASSEMBLY AND REASSEMBLY — 45 1 Lubricating oil suction pipe and dis- charge pipe 1, Mount the lubricating oil suction pipe (1). Lubricating oil suction pipe: tightening torque 4525Nm Bot M1040 4pes, 2.Fit the support (3) (4) of the lubricating oil suction pipe, and tighten it to the specified torque. Lubricating oil suction pipe ightening torque Beer 2322Nm Bolt MB x14 Apes, ‘Suppor (3) 5 Bot M10*16 pes, 468Nm 3. Mount the lubricating oil discharge pipe (2). Lubricating oil discharge pipe ightening torque Bolt M10x40 pes M10x85 — 2pes, 4525Nm (for pump side) M10x25 2pes. (for eylinder block side)46 —— DISASSEMBLY AND REASSEMBLY Oil pan 4. Temporally fit the oll pan (1) to the gear case side to check the fitting condition (use the positioning tools (2)). 2. Apply Three Bond (TB1114) to the three fiting sur- faces. 3.After the three surfaces are fitted in place, tighten the oil pan’s bolts to the specified torque. Oil pan tightening torque: Bolt M10*30 20 pcs. 4525Nm M10x65 tps. Flywheel housing 1.Fit flywheel housing (1) while adjusting position of 2 parallel pins. ‘Secure housing by tightening bolts listed below: M10 x 40 mm, 15 bolts 2.After assembling the flywheel housing to the cyl der block, measure the following points: Play at clutch mounting part (A) Play at surface: (8) Play at oll seal case mounting part (©) 0.25 mm orless 1 Oil seal (flywheel housing) 1. Fit the oil seal into the oil seal case. Oil seal Oil seal case set bolts: M8 20 mm, 6 bolts Soar vier te Note: When replacing oil seal: TI oi seal case + Use a press machine to assemble the oil seal. If no press machine is available, put t the oil seal on the case hole horizontally, put 4 pad board on the oil seal as shown, and Oiseal gear side | Ol sea huhee sie tap it on its edge evenly with a hammer so 7 thatthe component is inserted without tit i Lo! js | bros + Apply thin coat of oil on the circumference of 3 $ i $ the oil seal fo prevent damage fo the rubber. a 2 2 # + Apply engine oil to the lip of the oil seal, not § : grease, because threaded seal is used for the oil seal + Be careful not to damage the lip when {Oil seal mounting assembling. Rightnanded screw | Lot handed sevaw ction)1 Mount the engine foot Fit engine foot (1) while adjusting position of 2 parallel Pin. Tightening torque: Bolt M16 * 50 Mis «60 Apes, 200 15 Nm 4 pes, Turn cylinder block upside down The cylinder block is reversed, and it fixes to the stand ), Flywheel 1. Apply engine oil to the threads and contact sur- faces. Use two guide rods (2) (too!) to install the ‘component. 2,Mount the flywheel (1) along with the knock pin. 3, Tighten the setbolts to the specified torque. Flywheel tightening torque: Bolt M18 _ 10 pes. 275 £20 Nem 4. Fil the top indication plate after measuring the top. position. DISASSEMBLY AND REASSEMBLY —— 4748 —— DISASSEMBLY AND REASSEMBLY ™ Gear case 1.Apply Three Bond (TB1114) to the three fitting sur- faces of the oil pan (2) and cylinder block (3). 2,Mount the gear case (1) along the dowel pin. (Gear case tightening torque: Bot Max20 12p08. | 2322Nm Mex16 1 pes Cam gear 1. Tighten the cam gear (1) assembly and the end nut, to the specified torque, Make sure the gears aligning mark. ‘Cam gear tightening torque Nut M301 pe. 490 +20 Nm 2.Check the camshaft side clearance. Side clearance 01-035 mm1 Fuel injection pump driving unit 41, Mount the fuel pump driving unit (1) on the gear case 2.Mount the bearing case bracket 2) Fuel pump driving shaft support ightening torque 4525Nm Bolt_M10*30 6 pes, Bracket tightening torque! ae Bolt M8 8pes. 1 Fuel injection pump driving gear and idle gear 1.Mount the fuel injection pump driving gear (1). Fuel ingection pump driving tightening torque Bolt_M27__1pe. 20010 Nm Mount the idle gear (2) and check the matching mark of each gear. Check the backlash of each gear. Backlash 0.12-020mm Check the side clearance. Side clearance 015-030mm '5.Once the end nut is tightened, be sure to bend the tongued washer. DISASSEMBLY AND REASSEMBLY —— 49 te gear B Fuel pump gear Sea water pum gear 37 * f ersolinn, Fresh water pump gear . / ene 8 naw Ko tGearteainy J50 —— DISASSEMBLY AND REASSEMBLY ™ Gear case cover 1. Mount the gear case cover with two parallel pins, measure the following: Gear case cover Play at the front driving part Play at the surfaces: (0.25 mmor less Tightening torque: Ma * 40 28 pes 2342Nm Me * 90 10 pes. 2. Assemble the oil seal on the oil seal case and fit to the gear case cover, 3.Apply engine oil to the oil seal circumference.Cylinder liner 1.Clean the liner (1) fitting grooves in the cylinder block. (Assemble the O-rings, taking care not to distort them. 2.Apply white paint to the O-rings and press them in by hand, Note: Direct the ‘W" mark on the liner’s upper sur- face to the control side. 3, Check the projection of the liner. Measure the four points: A, B, C and D shown in the figure, Liner projection (0.03- 0.09 mm DISASSEMBLY AND REASSEMBLY — 51 | Projection52 —— DISASSEMBLY AND REASSEMBLY 4, Check and measure the distortion of the liner by measuring inside diameter with cross direction Distortion oftiner 0.08 mm or less i Assembling piston and connecting rod The piston and connecting rod should be assembled so that the YANMAR mark on the connecting rod and the size mark on the piston top face the same direc- {ion. Install the piston and connecting rod assembly with those marks facing flywheel side. Note: Ifthe piston is installed in opposite direction, crankshat cannot be tumed because the piston hits the cooling nozzle. Fel injecton pump sice YYANMAR mark (Fywheet si)DISASSEMBLY AND REASSEMBLY —— 53 Piston and connecting rod 1, Use the piston inserting tool ‘Apply engine oil to the crank pin bearing 2.After assembling the pistons and connecting rods, insert the pistons into the cylinder liners so that the Yanmar" mark of the connecting rods faces to fly- wheel side. (At this time, the marking pressed on the connecting rods faces control side.) 3. Apply engine oilto the rod bolt threads and contact surfaces 4,Tighten the rod bolts of both sides altemately three times Rod bok sttime [2nd time | 3rd time tightening torque Bolt M12_24 pes. 39N-m | 69N-m | 1104 5N-m Once the rod bolts are duly tightened, check the large end side clearance. Side clearance 0750-0524 mm “Tickles gage (Measuring side clearance between ‘crankshaft and connecting rod) 1 Tappet Install the intake/exhaust tappet (1). @ Cylinder block side cover Fit the side cover. Side cover tightening torque: Bot MB*16 24 pcs, et x £2Nm Sud bait Stud bolt MB*16 4 pes, wut Nut__Me 4 pes, us Nut . (Side cover)54 —— DISASSEMBLY AND REASSEMBLY Fuel injection pump bracket 4, Mount the fuel injection pump bracket (1) along the dowel pin Attach the adjusting shims (2) to their original posi- tions ‘Bracket tightening torque ‘M10 = 30, pes. 428Nm 2.Mount the fuel injection pump on the fuel pump bracket Fuel injection pump tightening torque: 4525Nm Bolt M1075 — 4pes, M10x18 1 pes, 3. Install the fuel injection pump mounting support ‘Suppor tightening torque: Bolt MB x20 Apes. enn Ma 22 2pes . Ma 16 2 pes. 4,Connect the fuel injection pump shaft joint. Deviation of shaft axial direction | # 0.25 mm or less Adjust the fuel injection timing, (Align the timer and pointer marker) ‘Shalt joint tightening torque! 103-113 Nim M12 _ 4 pes. 5, Mount and connect the lubricating oil pipes of the fuel injection pump and the drive oil shaft. 6. Connect the lubricating oll return pipe. 8 «20 miog7s v (Shaft joint) “Timing adjusting bots Timer Aligned™ Cylinder head 1, Mount the cylinder head and the gasket on the cyl inder block along the dowel pin. 2.Apply engine oil to the cylinder head bolt threads and con| tact surfaces, 3, Head bolt tightening order. Tightening of cylinder head bolts (main bolt M16 (1) - (14): Angular control method) The cylinder head bolts are tightened by the angu- lar control method. Tighten the bolt in 3 steps. ‘Step Method Tightening valve tat |_Te*aHe contol method | 160# 10 Nim Verify" 160Nm ‘2nd | Angular control method 90" rd | Angular control method oor “1 Sure to venty the tightened torque tightening with the samo torque. Note + Stamp a punch mark on the bolt head with- out fail after angle tightening ends. (The use frequency of the bolt is recorded.) + The main bolt can be re-used 5 times, ‘There are § punch marks on the head of the bolt, replace it with a new one. Tightening of sub bolts (M12 (15) - (17): Torque method). After tightening the main head bolts, tighten the sub bolts according to the following 2 steps, ‘Step Method Tightening valve st 35m Torque control method 2nd S5r5Nm 4, Paint marking of the cylinder head bolts and cylin- der head after torque tightening. + In order to make it easy to check the tuned angle, paint a mark on each bolts and cylinder head after torque tightening. Paint the mark at the non-operating side of the bolt head. Two bolls in the No. 3 cylinder (*marked) are to be painted at the opposite side. + Confirm the direction of the mark after angular tightening + The position of the mark is at the operating side. (Two “bolt’s mark are opposite.) DISASSEMBLY AND REASSEMBLY —— 55 o® @ No tate of Xo Xo [no 2asey | {Wo cy.) 4O»_4O» Punch mark No-operaing 88056 —— DISASSEMBLY AND REASSEMBLY 5. Measure the top clearance. oo ae iene 1 Valve rocker arm case ‘Assemble the valve rocker arm case (1) after making sure that there is no dust or foreign matter. Tightening torque: Bolt M10*28 20 pcs. 4525Nm Bot M10*38 6 pes, Valve rocker arm 1 Install the intake/exhaust push rod (1). 2. Install the intake/exhaust valve rocker arm (2). ‘Suclion/exhaust valve rocker arm tightening torque: m Bot M10x95 — 12pes, SoxSN Nut_M10 2pes.Fuel injector Make sure that there is no dust or foreign matter in the fuel injector mounting hole of the cylinder head. Tightening torque! Nut M10 8 pes. Soe 8Nm Note+ Be sure (0 replace the gasket and insulation, + Before assembling the fuel injector into the engine, be sure to apply molybdenum sulphide to the circumference of the component. Fuel oil return pipe Connect the fuel pipe (1) 2). (Fue! injection valve - rocker arm case) (Rocker arm case - fuel tank) 1.Connect the pipe joints to both ends of the fuel injection pip (1) with the specified torque. High-pressure pipe cap nuts tightening torque M1412 pes. 4525Nm Fix the fuel injection pipe supports on the intake manifold. Fuel injection pipe steady-rest tightening torque Bolt M6 x20 8 pes. Nut__M6 8 pcs. 10£1Nm 3.Fix the fuel injection pipe oil seal (2) on the rocker am case. DISASSEMBLY AND REASSEMBLY —— 57 Fual injector58 —— DISASSEMBLY AND REASSEMBLY @ Engine lifter 4. Install the liting fhdure (1) for gear side Tightening torque’ Bolt M12 x 32 Apes. Schein 2. Install the lifing fixture (2) for flywheel side. Tightening torque: M14 «30 2 pes. eebataiee Ml Intake manifold 1.Mount the intake manifold (1). 2. Install the bend for bypass (2) and pipes. Tightening torque: Bot — MB* 451 pe. Max 115 2pes. 2322Nm Stud bolt MB*50 3 pes, Nut MB 3pes. Bot -M10*25 7 pes. M10 x 190 11 pes. aici @ Lubricating oil cooler Assemble the lubricating oll cooler (1). Lubricating oil cooler tightening torque: Bot M10x35 pes. Bolt M10x110 pes. 4525Nm M10x 140 4pes. M10 170 4pes. M10x200 1 pes. 2. Tighten the lubricating oil fiter (2) fully by hand, land then use a fiter wrench to further tighten the fiter. (Turn to the right) 3. Install the cooling seawater pipes of the lubricating oll cooler. Lubricating oil thermostat Mount the lubricating oil thermostat. Lubricating oil thermostat tightening torque: 2342Nm Bolt__Ms x22@ Exhaust manifold Mount the exhaust manifold so that the part to be fitted with the gasket is positioned as shown in the figure. Nut Bott Exhaust manifold hightening torque M10 120 10 pos. M10% 160 1 pe. M10 [Stud bolt M10 = 120 1 pe. 5025Nm Bolt Mg « 20 [Cover tightening torque: 20 pes. 2322Nm Cooling water bend Connect the coolant bend (1) and tighten the bolts at cylinder head side and exhaust manifold side. Frightening toraue , Bolt M8 «65 4 pes. 2322Nm MHO* 25 4 pes. vem ‘M10 * 55 1 pc. eaten M2*28 3 pos M12* 75 1 pe poe DISASSEMBLY AND REASSEMBLY —— 59 10x25) (Cooling water bend)60 —— DISASSEMBLY AND REASSEMBLY l§ Turbocharger and exhaust bend 4. Install the turbocharger on the exhaust manifold. Turbocharger tightening torque Stud bolt M10*22 4 pes. 5025Nm U-nut__ M10 Apes. Install the exhaust bend (assembly) and the sup- port. Exhaust bend (ass'y) and support ightening torque 50r5Nm Bolt M1018 Apes Note: The connection between the exhaust bend and turbocharger is sealed with a 3-piece seal ring and three seal rings. Note + 3-piece seal ring is composed of an upper side rail, lower side rail and a center spacer expander. + Assemble 1-Mount the center spacer expander. 2-Mount the upper side rail. Press-fit either end of the side rail into the groove, and securely hold the rail with hand, then press-fit the entire ral 3-Mount the lower side rail similarly. 4-Position the upper and lower side rails so that the ends of side rail stagger by 90" from the end gap of the spacer, Note: Mount the three seal rings so that the end gap of the seal rings stagger equally each other. ‘Spacer expander side rails (upper) side rails (upper) (3-plece seal ring assembly) (Turbocharger) S-ece soa ing FN wi0x18 (Exhaust bend) Side rat end \ (eal ring gap mounting position)DISASSEMBLY AND REASSEMBLY —— 61 3, Mount the turbocharger’s oil pipe. Union rion YA Turbocharger (ep fie iy cg g y | & rice, ne a feteres ee ‘L.O. pipe (out), we Va = = ease, encore (Turbocharger’s oiling pipe) Air duct 1.Install the air duct (1), the rubber joint and support. Note: Tighten the rubber joint firmly with a nose lip f0 prevent air leak.62 —— DISASSEMBLY AND REASSEMBLY i Lubricating oil sender unit Install the sender unit (1) on the lubricating oil cooler. ™ Rocker arm cover Fit rocker arm cover (1), and secure it by tightening. Tightening torque: Knob M8 SB pes. ew) 1 Coolant tank (heat exchanger) Mount the coolant tank (heat exchanger) (1) to the gear case Tightening torque: Bolt M10*32 — 3pes, 4525Nm M10x 150 __3pes, Coolant bend Install the bend (1). (Exhaust manifold - heat exchanger)DISASSEMBLY AND REASSEMBLY — 63 Seawater pump Mount the seawater pump, ‘Seawater pump driving gear tightening torque 180 10.Nm Nut__M20 ‘Seawater pump tightening torque: Bolt MB x 25 6 pes. bedeieialil Coolant pump 1. Assemble the driving gear on the coolant pump. Driving gear tightening torque poems 13025Nm Nut_ M20 ‘pe. 2.Mount the coolant pump. Coalant pump tightening torque eed ee colant pum Bot _Max22 __8pes (Mounting the coolant pump) 3.Connect the coolant bend and tighten the bolts. © Coolant bend oar ease Tightening torque Bot MBx30 1 pe 23£2Nm MB* 60 tpe Maxa0 Maceo OW Berd YRiberione Coatant pump ‘© Connect the coolant pump outlet bend Tightening torque: Bolt M8 x 22 2 pe. 2322Nm64 —— DISASSEMBLY AND REASSEMBLY Alternator 1. Install the alternator driving device, 4-Assemble drive shaft, bearing, oil seal, drive gear and \V-pulley into the bearing case. Driving gear tightening toraue: pulley tightening torque: 13025 N-m Nut__M20 T*6. eae @, 0g, Driving seviee Max25 Z ha SS Gear case cover 2-Attach driving unit to the gear case cover. Tightening torque: n Bot MBx25 6 pes ane 2.Fit the alternator hold [Aerator tightening torque veNm Bot M1040 1 po seen Bot Mié* 140 1 po Hie 120 10Nm 3, Set the V-belt Vebet sae AG? 2 pos 4. Set the V-belt adjuster. Bot _MB = 40 Te 5. Install the V-belt cover. ‘Sud bok MB*25 2 pes Rubber 5 pes. Nut MB 5 pes. Lock nut_MB Spe1 Damper Mount the viscous damper (1). Viscous damper tightening torque: Bolt M20 * 6 pes. 275 £20 Nm Starting motor Install the starting motor (1). ‘Starting motor tightening torque Bolt M14*35 ps, 12010 Nm § Cooling water bend (seawater pump) 1, Connect the seawater pump inlet bend 2.Connect the seawater pump outlet bend. Tightening torque: Bolt M1230 4pes 7425Nm Connect the heat exchanger outlet bend. Tightening torque’ Bolt M12x28 pes, 7525Nm DISASSEMBLY AND REASSEMBLY — 6566 —— DISASSEMBLY AND REASSEMBLY 1 Stopping solenoid 1.Fit motor solenoid bracket (1) flywheel side, and install the stopping solenoid. 2.Fit remote control cable bracket (2). Bracket tightening torque: Bolt MB x12 2pes, 2322Nm 1 Boost compensator pipe and boost sensor Fit boost pipe (1) and boost sensor (2) to intake mani- fold and fuel injection pump.DISASSEMBLY AND REASSEMBLY —— 67 Fuel filter 1, Mount the cooling pipe (1). 2.Mount the fue! fiter (2). (Install the vibration-proof rubber pads.) Vibration-proof rubber pad: 3 pes. Fuel fiter assembly tightening torque 35-40 Nm Nut_M12 3.Connect the fuel oil pipe (3). (Feed pump - fuel fiter) (Fuel fiter - fuel pump) (Fuel fiter - fuel tank) Pipe joint tightening torque: Joint bott_ MB 6 pes. 12-17Nm t2 stud Rubber pad Fuel fier From tet ank68 — DISASSEMBLY AND REASSEMBLY 1 Lubricating oil dipstick Install the dipstick (1). @ Thermostat ‘Assemble the thermostat (71 - 85 *C) in the heat exchanger thermostat casing, and attach the thermo- stat cover, Thermostat cover tightening torque ; M8 x 55, 7 pes. 2322NmWarning switch 1.Fit cooling water temperature switch (1) to bend. Operating temperature ON: 1002 3°C OFF 95 23°C 2. Fit cooling water level sender unit (2) to bend. 3. Fit cooling water level sensor (3) to heat exchanger. Operating water evel From switch attaching surface Less than 76 mm 4. Fit engine lubricating lubricating oil cooler. oil pressure switch (4) to Operating pressure 0.052 0020 MPa (0.50.2 katlom?) Fit engine lubricating lubricating oil cooler. oil temperature switch (5) to Operating temperature ‘ON 9522°C OFF 8822°C 6.Fit lubricating oil fiter pressure sensor (6) to oil fi- ter ‘Operating pressure aes (20.3 kglfom?) Bypass valve opens Cees (60.3 kalfom?) Wire harness 1.Connect each wire according to the identification marks on the terminal Is. 2. Fix the terminals securely. DISASSEMBLY AND REASSEMBLY —— 6970 —— INSPECTING AND SERVICING OF ENGINE’S MAJOR PARTS INSPECTING AND SERVICING OF ENGINE’S MAJOR PARTS Preliminaries 1. Wash each part with care, and remove dust, car- bon deposits, oil, moisture ete. 2. Blow air through the oil holes to remove deposits to 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, judging based on past wear limit data, Is likely to exceed that limit before the next service.INSPECTING AND SERVICING OF ENGINE’S MAJOR PARTS — 71 Cylinder Head The cylinder head is a three cylinder type of water cooled, intake and exhaust ports crossed-flow 4- valved construction mounted with 17 bolts Special alloy stellite 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. Hem ‘Standard Wear limit Direction of erankshaft Cylinder head 0.08 or less a a distortion Rotating direction 0.02 or less 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.72 — INSPECTING AND SERVICING OF ENGINE’S MAJOR PARTS ™ 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: Take 120° Seat angle Exhaust 20" ‘Seat width ‘Standard Limit Intake 23 28 Exhaust 28 33 Correction of the valve seat The most common method for correcting unevenness of the seat surface with a seat grinder is as follows: 1, Use a seat grinder to make the surface even As the valve seat width will be enlarged, first use a 70° grinder, then grind the seat to the standard dimension 45° by using the seat grinder with a 15° chanter. Intake vane 30" Seat angle 8 : Exhaust valve ae 2. Knead valve compound with oil and finish the valve seat with a lapping tool 3. Final finishing should be done with oil only 4,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, NOTICE ‘When seat adjustment is necessary, be sure to check the valve and valve guide. Ifthe clearance exceeds the tolerance, replace the valve or the valve guide, and then grind the seat. oat width Stolite paddingINSPECTING AND SERVICING OF ENGINE’S MAJOR PARTS — 73 i Inspection of intake/exhaust valves, valve guides Wearing and corrosion of the valve stem Measure the outside diameter of valve stem. Replace the vaive, if the stem is excessively wom or corroded. Valve stem out- ‘ide diameter ‘Standard Limit Intake 9935-9.950 9.85 Exhaust 9.800 9.020 088 Valve measurement position A: 85 mm, B: 85 mm 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. item Standard Limit Valve sink 404202 os Valve guide 1. Measuring inside diameter of valve guide. Measure the inside diameter of the valve guide and replace it if it exceeds the wear limit. rm item Standard | limit Valve guide inside diameter | 10.000- 10.015 | 10.10 Intake 0.050-0.080 | 02 Clearance lexhaust | 000-0118 | 02 NOTICE The inside diameter standard dimensions are measured after insertion. Sink yi head74 — INSPECTING AND SERVICING OF ENGINE’S MAJOR PARTS 00 Vale sie foszoanm yin nea [ _— Hammer 2,Replacing the valve guide, Use the insertion tool and tap valve guide with a mallet. Valve guide projection: The valve guide should project the specified value from the top of the cylinder head. (See the right fig- ure.) Valve stem seal The valve stem seals on the intake/exhaust valve guide cannot be re-used once they are removed. Be sure to replace them with new ones. When assembling the intake/exhaust valves, apply an adequate quantity of lubricating oil on the valve stem before inserting, (Valve stem seal) Fitting too! Put the guide pin on te fing tol to keep the vai stom from fling over. Whore spring is attached, be careful oto lt the spring fal of Release the upper part the valve ‘tom Seal rom the fitng tool and use it push in the shoul secon, Fit the upper surface of he valve guide ‘andthe waive stem seal so hat thy adhere dosaly togethar. When using a hartmer or srr tol, //// auach a poatorieg stopper 'o provost ‘damago io tho stom sealINSPECTING AND SERVICING OF ENGINE’S MAJOR PARTS — 75 Valve springs Checking valve springs 41, Check the spring for scratches or corrosion. 2, Measure the free length of the spring 3, Measure inclination. mm Time inelnation 15 4. Measure spring tension. Valve spring Standard Time Free length 7670+05mm | 515mm K1=11.20Nimm | ‘Tension (1.14 kgfmm) 7 (1 mm pressure) | “K2=1544 Nimm (1.54 kgf-mm) - + Assembling valve springs ‘The side with the smaller pitch should face down (cylinder head). Note: The pitch of this valve spring is not even. Pay attention to the up-down direction of the spring when assembling. 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 area is less than 70 %, or when the spring cotter has been recessed because of wear. Free length Spring tension tester up side i Smal ich side (yellow) 4 Down sie76 —— INSPECTING AND SERVICING OF ENGINE’S MAJOR PARTS Valve rotator Check the valve rotator, 1.Remove valve rocker arm chamber during the operation to check if the valve rotates. 2.Check the state of the valve rotator at around the valve rocker arm of the valve head after disassem- bly. 3,Replace the sheet spring if wom excessively, M Nozzle sleeve 1. When assembling, apply lubricating oil to O-ring, 2. Fit the sleeve to cylinder head and tighten it. Tightening torque 1502 10Nm 1M Measuring top clearance 1,Place a high quality fuse (62 mm, 10 mm long) in four 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 ditection of engine revolu- tion), 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. [Top clearance 06 -118mm Top clearance Piston Fuse wieINSPECTING AND SERVICING OF ENGINE’S MAJOR PARTS — 77 Assembling the cylinder head 1,Clean out the cylinder head bolt holes 2.Check for dust and dirt on the cylinder head sur- face where it comes in contact with the block. 3. Coat thread and flange surface of the head bolt with lubricating 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. 6, When clamping the cylinder head tighten the bolts, refer to the P160 [Cylinder head Tightening Bott] IM Intake and exhaust rocker arms ‘The wear of rocker arm and rocker arm bushing may change opening/closing timing of the valve, and may in tum affect the engine performance according to the extent of the change. Rocker arm shaft and rocker arm bushing Measure the outer diameter of the shaft and the inner- Rocker am spring ‘Rocker arm shaft support Exhaust diameter of the bushing, and replace if wear exceeds eran the limit, mm Tem ‘Standard | Limit exhaust rocker atm bushing Inside diameter of intake and 26,000-26.061 | - exhaust rocker arm shaft Outside diameter ofintake and 24,967 -24.980 | 24.90 and bushing at assembly Clearance of racker arm shat 0.020-0.094 | 0.30 Replace rocker arm bushing if it moves. Replace entire rocker arm if there is no tightening clearance. Rocker arm spring Check the rocker arm spring and replace it if tis cor. roded or worn. Rocker arm and valve top retainer wear Inspect the contact surface of rocker arm and replace it if there is abnormal wear or flaking. Adjusting bolt Inspect the contact surface of adjusting bolt and push rod. Replace if there is abnormal wear or flaking,78 —— INSPECTING AND SERVICING OF ENGINE’S MAJOR PARTS Adjustment of the valve clearance Adjustment of the valve clearance should be done while the engine is cold. 1.Perform the tuming of the flywheel in the direction of rotation to move the cylinder, whose clearance is adjusted, to the top dead center (T.D.C,) of the compression stroke. + Align the angle identification plate with the TOP mark on the flywheel, + Do not confuse this with the T.D.C. of the overlap stroke, 2, Loosen the adjusting screw and nut of the rocker am, and the adjusting screw and nut of the bridge. 3. While slightly holding down the rocker arm, tum the adjusting screw of the valve head part (bridge side), and tighten until the clearance between the adjusting screw end and the valve head part becomes zero. 4, When the valve clearance becomes 0 mm, lock the adjusting screw on the bridge side. 5, Adjust the valve clearance between the rocker arm and the bridge to the specified value and then lock the adjusting screw on the rocker arm side. Leck nu Take 0.35 mm Exhaust 0.48 mm Valve clearance When disassembling the timing gear etc, be sure to check the timing of both the intake and exhaust valves. Intake valve open B TDS ae Intake valve close a Bde. a Exhaust valve open | _b:BD.C 60" Exhaust vane close | a TDC. 46°INSPECTING AND SERVICING OF ENGINE’S MAJOR PARTS — 79 Cylinder Block Inspection of the parts If your engine which has already encountered such troubles as freezing, turnover etc., conduct visual checks carefully before disassembly. If cracking is sus- pected, investigate with the color checker. Replace any part for which the damage is irreparable. Cylinder Liner Since the cylinder liners are cooled in the high con- stant temperature cooling by the coolant, there is no possibility of abnormal wear of liner due to over-coo ing during low load operation of the engine. The liners are made of special non-plated cast iron that has low friction loss, The liner is given uniform wall thickness to prevent uneven local thermal expansion. There fea- tures provide high durability to the liners. (Pistons and liners are fit each other selectively.) Measurement of liner Use a dial gauge to measure the cylinder liner. Measure the inside diameter in the axial direction of the crankshaft and perpendicularly to the crankshaft, at, the points on the cylinder liner shown in the table below. If they exceed the limit, replace the liner. ‘oyinder gauge ving | cylinder ner Direction of tranksha center Tem ‘Standard Limit L | 13292-19283 | +02 Cylinder liner inside | ML |132.915-132.920] +02 diameter MS [192.010- 192015) +02 S | 19290-13291 | +02 Roundness 0.016 or less 5 Cylindricity 0.02 or less 5 i ‘About 40.mm t80 —— INSPECTING AND SERVICING OF ENGINE’S MAJOR PARTS 1 Insertion of the liner 1, Remove the rust from 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 “W" (hydraulic pressure mark) to the wheel side and insert into the cylinder. 5.IFit cannot be inserted entirely by hand, put a pad- ding wood on the liner and tap lightly. Mf Measurement of the projection Check that the flange of each cylinder is projecting the top of the cylinder block. mm i Cylinder block hole depth A [88-1187 A i Cylinder liner flange thickness” | 8 | 120-1202 Cylndr ner projection © [003-008INSPECTING AND SERVICING OF ENGINE’S MAJOR PARTS — 81 Piston 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. 1 Measurement of piston outside diame- terlinspection 41,Replace the piston ifthe outsides ofthe piston or ring grooves are worn. 2. Measure the outside diameter in the position of A from the piston bottom in the direction vertical to the piston pin If the piston outside diameter exceeds the limit, replace the piston with new one. z Bam Piston oie daar om Piston standard Limi c | aaa as vic | tae e20- T2095 | te2e80 us| a825- Tee 0 S| ests 28582 —— INSPECTING AND SERVICING OF ENGINE’S MAJOR PARTS 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 ofthe piston and the size mark of a cylinder liner is shown on the non-oper- ating side of the cylinder block. The service parts of pistons are provided Application table for piston and liner O: 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). Piston pin Measure the outer diameter and replace the pin if it is excessively worn, Hem ‘Standard | Limit Piston pin hole inside diameter] 52.000-62.076| _— Piston pin outside diameter _ | 61.987 -62.000 | 6295 Clearance 0- 0.028 = Moasuce at postions a, band ¢ Ineirecions A and & a 8 F t (Piston pin outside diameter)INSPECTING AND SERVICING OF ENGINE’S MAJOR PARTS — 83 Piston rings There are 2 compression rings and 1 oil ring, 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, tem Standard | Limit Groove wiath | 3575-3590 | — 7 Ring wath | 3445-3460 | 34 opneg [elearance | 0116-0145 | 025 Thickness 47520120 | 455 Groove wisth | 2555-2870 | — Ring wath | 2455-2470 | 24 Second ring Clearance | 0085-0175 | 0.20 Thickness 5520120 | 63 Groove width | 4020-4036 | — Ring with | 3970-3090 | 39 iting Clearance | 0030-0068 | 0.18 Thickness 2azo10 | 26 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. Tem ‘Standard | Limit FTop ring gap 035-050 | 15 ‘Second ring gap 050-065 | 15 Oilting gap 040-060 | 15 Too ring second i oitcing @ (Ring components) with Thickness Sickness gauge; Piston os Straight edge Piston ring 30mm Gap84 — INSPECTING AND SERVICING OF ENGINE’S MAJOR PARTS Replacing the piston rings 1. Thoroughly clean the ring grooves when replacing piston rings, 2. The side with the manufacturer's mark should face up. 3.Aflerfiting the piston ring, make sure it moves easily and smoothly. 4. Stagger the piston rings at 120° intervals, making sure none of them line up with the piston. 5.The oil rng is provided with a coil expander. The coll expander joint should be opposite (staggered 180%) the oll ring gap. Face the punched manufacturers mark upward Oilcng oap onring 9% _—13 piston ring 2 piston sing 0 ng ‘st piston ing a t a 2adioon eo Joint of cot ‘expanderINSPECTING AND SERVICING OF ENGINE’S MAJOR PARTS — 85 Connecting Rod The connecting rod is made of high-strength forged carbon steel The large end with the aluminum bearing can be sepa- rated into two and the small end has a 2-layer copper alloy coil bearing, i Inspection of the connecting rod Twist and parallelism of the large and small ends 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. Hem ‘Standard | Limit Connecting rod twist and 0.02 or less parallelism (at 100mm | 907 Connecting rod Piston pn bearing Connecting rod belt Crank pin bearing Connecting roc (bid one cap)86 —— INSPECTING AND SERVICING OF ENGINE’S MAJOR PARTS Crank pin bearing Checking crank pin bearing Check for faking, melting or seizure on the contact ‘surface of the crank pin bearing. mm Classification | Size mark Tse ‘Standard ‘ST 25 (0.25 and under 025 2625 (05 and under os 275 Measuring crank pin oil clearance Measure the crank pin outside diameter and the crank pin bearing inside diameter. Calculate the oil clearance. from the measured values. (Refer to P89 [Measurement of the crank pin and crank journal].) Replace the crank pin bearing 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 bearing if necessary. Red bolt tightening torque 705-115Nm mm Tem ‘Standard Tit Rod bearing inside diameter | 90.000-90.048 [~ — Crank pin outside diameter | 9.940-89.960 | 89.850 Bearing thickness 2487-2500 | — Clearance 0040-0108 | 013 + 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. T sak ‘Sze mark Cynder gaugeINSPECTING AND SERVICING OF ENGINE’S MAJOR PARTS — 87 Assembling of the crank pin bearing 41, Wash the crank pin bearing 2.Wash the large end cap, mount the crank pin bearing and make sure that it fts tightly onthe large end cap. When assembling the connecting rod, match up the large end and large end cap number. Coat the bolts with engine oil and gradually tighten them needa mark) alternately to the specified torque. 7 Ifa torque wrench is not available, make match marks on the bolt heads and large end cap (to indi- cate the proper torque position) and retighten the bolts to those positions Moree 4,Make sure there is no sand, metal cuttings or other dust in the lubricating ol, and that the crankshaft is oy not scratched, Take special care in cleaning the oil holes. Piston pin bearing Measuring piston pin clearance Excessive piston pin bearing wear may result in dam- age tothe 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 P82 [Piston pin].) Tem ‘Standard | Limit Piston pin beating inside 62.025 -62.040 | 52.1 diameter Gil clearance 0.025-0.053 | 00788 — INSPECTING AND SERVICING OF ENGINE’S MAJOR PARTS Crankshaft and Main Bearing ‘The crank pin and crank journal have been induction hardened for superior durability, and the crankshaft is, provided with for balance weights for optional balance. The crankshaft main bearing is of the hanger type. The upper bearing (cylinder block side) is provided with an oil groove. There is no oil groove on the lower bearing (bearing cap side). The bearing cap (location cap) of the flywheel side has a thrust bearing, which supports the thrust load. Main bearing (iermosia) “Thrust besrng asic side), Main bearing : (basic) k mA Main bearing = m Crankshaft Color checking of crankshaft Color check after cleaning the crankshaft, and replace the crankshaft if there is any cracking or considerable 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 check the extent of crankshaft bending, Tem ‘Standard | Limit Crankshaft bend limit ae ae (1/2 the dial gauge reading)INSPECTING AND SERVICING OF ENGINE’S MAJOR PARTS — 89 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 oF replace the crankshaft Crankshat ‘Standard | Limit ‘Shaft outside saes-sa06 | -0.15 diameter Pin [rank pin bearing inside diameter Caasien - Oil eearance 0049-0108 | 078 remotes 99.94 - 99.96 015 diameter JJoumal |Main bearing inside diameter (Oil dearance 0050-0128 | 0.14 100.010 - 100,068] - Note: If re-grinding is performed, use under size main bearing to adjust the oil clearance to a 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 orank- shaft to one side, placing a dial gauge on one end of the shaft to measure thrust clearance. Replace the thrust bearing ifit is wom beyond the limit mm item ‘Standard | Limit Crankshaft side clearance oo70-0219 | 03390 —— INSPECTING AND SERVICING OF ENGINE’S MAJOR PARTS Main bearing Main bearing mm Classification Size mark | Tse Standard sto | 309%, Intermediate Undersizeo25] Uo2s | 3.125 995 and gear side Stes 095 Underszeos | os | 325385, Standard sto | 302% Reference Bis “295, (tywhee! |Undersze0.25] ors | 3125-205, side) = undersizeos | os | 325385, Inspecting the main bearing Check for flaking, seizure or burning of the contact sur- face and replace if necessary. Measuring the inner diameter of bearing Tighten the cap to the specified torque and measure the inner diameter of the bearing. Tightening [Cap bat 365-385 Nm torque Side bok 130-150 Nm Tem ‘Standard Limit Bearing inside diameter | 100.070- 100.068 | __— Bearing thickness 2.950 - 2077 5 Note No oll grooves are provided on the lower bear- ings (at cap side), ‘+ Match the matching numbers with those of the cylinder block. + Bring the embossed ‘F” mark on the cap to the ‘flywheel side. + Set reference bearings at the flywheel side. + Only bearings at the gear side have oil holes (at the lower bearing). Tsizo Size mark cap bot lynne side ice otINSPECTING AND SERVICING OF ENGINE’S MAJOR PARTS — 91 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 lite Checking the camshaft side clearance Measure the thrust clearance before disassembly. As the cam gear is shrinkcfitted to the cam, be careful when replacing the thrust bearing, Trust etal cam stat Gam gear Tem ‘Standard | Limit Camshatt side clearance 010-036 | 042 Camshaft and bearing hole measurement Measure the camshaft outside diameter with a microm- 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 at gear case side is measured with a cylinder gage after insertion to the cylinder. Replace if they exceed the limit or are damaged Tem ‘Standard | Limit Bushing inside diameter 6302-6305 | 6315 Camshaft outside diameter | 6294-6297 | 628 Gil clearance 005-017 | 014 om 492 —— INSPECTING AND SERVICING OF ENGINE’S MAJOR PARTS Measure the camshaft height, and replace the cam if it is worn beyond the limit mm item ‘Standard | Limit Intake 53,000 -64.100| 635 Cam height Exhaust $3,000 -64.100| 635 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. Note: The reading on the dial gauge is divided by two to obtain the camshaft bend, Tem Limit Camshatt bend 0.04INSPECTING AND SERVICING OF ENGINE’S MAJOR PARTS —— 93 lM Tappets Sree x O thereby prevent uneven wearing. Check the contact of o a each tappet and replace if excessively or unevenly 4 “4 ie 4 worn Note: When removing tappets, be sure to keep them separated for each cylinder and intake/exhaust valve. Tepe | Ofc camshaft poe Measure the outer diameter of the tappet, and replace if worn beyond the limit Tem ‘Standard | Limit FTappet stem outside diameter | 38.940-35.965 | 35.90 FTappet guide hole inside diam- eter (oylinder block) Oil clearance 0.035-0.085 | 015 36,000 - 36.025 | 36.06 Measuring push rods Measure the bend of the push rods. mm Rem ‘Standard | Limit Push rod bend Lessthan 02 | 03 (Push rod bend)94 —— INSPECTING AND SERVICING OF ENGINE’S MAJOR PARTS 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, Note: 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. item ‘Standard Limit Crankshaft gear- ub pociosn|°2tng ol pump le | 0.15-028 | 0.95 gear Other gear 072-020 | 035 Idle gear The bushing is pressure fitted into the idle 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 Item ‘Standard | Limit Tile shaft diameter 29,.059-20980| - Tle gear bushing inside ales 30,000-30.021} - diameter Oil clearance 002-0062 | 0.18 Idle shaft diameter 47.950 -47.875 | — Tale gear bushing inside 3 |e 48,000 - 48.025 | - diameter Oil clearance 0028-0075 | 018 Item Standard Idle gear side clearance 018-030 Ice goar bushing \& ide gear BINSPECTING AND SERVICING OF ENGINE’S MAJOR PARTS — 95 1 Gear timing marks Match up the timing marks on each gear when assem- bling, Ie gear 8 Fuel pump am gear Alternator Sea water lie gear A Frost water pump gear Lub. pump gear96 — INSPECTING AND SERVICING OF ENGINE’S MAJOR PARTS Flywheel 1 Specifications of flywheel Outside diameter of fywheel 500mm Wath of fywheet 20mm Mass of fywheel (including rng gear) e2kgt Center diameter 497 mm Ma ees No. of teeth 142 Ring gear ‘When replacing the ring gear due to excessive wear or damaged teeth, heat the ring gear evenly at its circum ference, and after it has expanded drive it gradually off, the flywheel by tapping it with a hammer, a copper bar or something similar around the whole circumference ‘Shrink range ofring gear 066-088 mm 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- ‘sure the expansion of the damper cover. expansion of the damper cover = b - a a: Dent margin at center b: Dent margin at end The dimension (b -a) exceed 0 mm cor every 10000 hours NOTICE Do not modify the viscous damper, such as driling a hole, etc. The performance of the viscous damper will be lost. Replace period Fryhee! Ring gear ‘Conner bar Wooden stad Fixing botINSPECTING AND SERVICING OF ENGINE’S MAJOR PARTS — 97 Fuel Injection Equipment Fuel oil system The right figure shows the fuel oil system. The fuel injection pump is Bosch Corporation P-S7S pee type. ttttt The feed pump sucks up fue! oil from the fuel tank and Fvct injection pure] feeds the oil to the fuel fiter at a pressure of approxi- mately 0.4 - 0.5 MPa. The fittered fuel il is sent to the pump and is pressur- ized by the plunger. The fuel ol then flows through the injection pipe and Fuel injector ty Fuelfeed | injector and is injected from the nozzle to each cylin- pane der. ‘ervico tank) Fuel overtiow pipe (lo service lank) Fuel valve leakage pipe Fuel init pipe Fuel injection pump/governoritimer! feed pump The fuel injection pump assembly is the same as in the 6HYM-ETE engine. Therefore please refer to the 6HYM-ETE service manual (CODE: OB6HY-G00100) In addition, the following are described as a reference for maintenance Fuel injection system Bosch No. Tame Bosch Pars No Fens as Fuel injection pump 1 7 NP-PEBP190001PS7S a 1054472140 NP-EPIRSUV210-1250°P40/202 mer 105682:0160 NP-EPISDGBO0-025211R ceca pump 105237-5060 NP-FPIKO-P7S98 —— INSPECTING AND SERVICING OF ENGINE’S MAJOR PARTS Fuel injection system specifications Rotation direction ‘Clockwise viewed from ave side Injection order 1-4-2-6-3-8-1 ‘Cam it ram 30 Fuelinjection pump [Plunger (Mark No. S12) 13 Clockwise 30 both lead Delivery valve retraction volume maniist 120 [08 « 24 momjt=0.11 106086-9822 Delivery valve opening pressure MPa 0.85 Delivery valve spring Nira k= 5.88 Delivery valve holder damping valve 206 Orfeo ‘Alowable maximum pump speed nt 1500 Flyweight g 540 Tang fyweight lft back stroke ratio 1:23 High speed fyweight-lt back stroke ratio. 1:23 Governor ‘Governor spring Nien k= 108 05447-2140 ise srind ss Idle sub spring Nien k= 245 ‘Stating spring Nimo k= 00085 Boost compensator spring Nimo K=588 Timer in Nim K=726 +105662-0150 fwueetame Out Nimm k= 981 ean Planned delivery pressure M2 — at Min KPa 368 +105237-5080 Piston spring Niro Ke n8 Fuel injection pump service data ‘Adjustment specification Calibration spec.*? Engine spec? Nozzle and nozzle holder assy 05780-8130 YANMAR made (026613-83100) Nozzle 105780-0050 YANMAR made (155S298KZ) (126619-53050) Nozzle holder 7108780-2080 TYANMAR made (126634-53100) Nozzle opening pressure 172 MPa 275MPa Feed press 255 kPa 255 KPa Injection pipe Dx d-L 28 x a4 - 1000 mm 86 * 62.2 - 680 mm Fuel oil temperature 40-45°C 40-45 °C Note: “1 Test condition of the Bosch fuel injection system “2: Test conalion ofthis YANMAR engine fuel njaction system Calibration standard | Engine standard (reference) eon Pump Injection Injection ieee point | postion | spec | MRE | variation | MEE | Vartion | pressure (me hin (4 (4 kPa Gy an (mm2ist) ” (mist) a as z 44a 133 aaa Base ca 1100 | Each cylinder 7 Each cylinder zoe | echer | = = = 35220 7 245 F Each cylinder Each cylinder c fo | 288210 20 3 Rack limit average AverageINSPECTING AND SERVICING OF ENGINE’S MAJOR PARTS — 99 1 Installing a fuel injection pump assy If the fuel injection pump mounting bracket is not removed and the shim is used in its original position, shim adjustment is not required. © Alignment of fuel pump Use the adjusting shim (A) for centering the fuel pump and driving shat [Thickness of adjusting shim 07,02, 08mm ‘Specified concentricity of drive shaft in ‘and pump cam shaft eee [The axial displacement ofthe cou- pling atthe timer side and the driving | Within 0.36 mm shaft coupling Note: Measurement of the alignment in the case of using the tool A and the too! B. 1. Secure the gear case cover, bearing case, bearing case support and injection pump body support properly, ‘When assembling the driving shatt to the bearing case, fit the proper cover to the shafts key groove 50 as not to damage the oil seal 2.Put the alignment measuring tool A equivalent to the pump on the mount, Attach the tool B to the drive shaft and, with respect to this, measure the Concentricity (1) to the drive shaft and the deflec- tion angle (2) at the position of #80 mm about the drive shaft. Gauge (1) Max Min = 0.30 mm Gauge (2) Max Min = 0.35 mm © Adjustment the fluctuation of engine speed Ifthe fluctuation of engine speed occurs while operat- ing the engine at the minimum speed, even when the engine is fully warmed up (cooling water temperature gauge indicates 70 °C), adjust it as follows by manipu- lating the idle sub-spring and the idle adjust bolt: 1, Remove the seal which locks the idle sub-spring and the idle adjust bolt, remove the cap nut and loosen the lock nut. 2. Loosen the idle sub-spring guide and use the idle adjust bolt to set the idling speed to 600 min" Gauge (1). Gauge 2) £ } ‘Tension ever FT] T_futcnd stopper bat (Cotas of ale sub-spring)