Manual de taller de Motor YANMAR Marino SM_8LV_uk.pdf
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About This Presentation
Manual de Taller YANMAR 8LV Marino.
Slide Content
YANMAR
MARINE ENGINES
8LV Series
MARINE ENGINES
8LV Series
California
Proposition 65 Warning
California
Proposition 65 Warning
Battery posts, terminals, and related
accessories contain lead and lead
‘Compounds, chemicals known 10 the
State of Caliomia o cause cancer and
reproductive harm.
Wash hands atterhanding
Diesel engine exhaust and some of ts
constituents are known tothe state of
Callormia to cause cancer, bith
detects, and other reproductive harm
‘This Service Manual has been developed forthe exclusive use of service and repair
Professionals such as Yanmar authorized Distributors and Yanmar authorized Dealers
‘Ris writen with these professionals in mind and may not contain the necessary detal or
safety statements that may ba required for a non-professional to perform the service or
repair proper andor safely. Please contact an authorized Yanmar repair or service
professional Before working on yaur Yanmar product
Disclaimers:
Al information, ilustations and specifications inthis manual are based onthe latest
information availabe a the time of publishing The lustatons used in this manual are
intended as representative reference views only. Moreover, because of our continuous
product improvement policy, we may modify information, iustraons and/or specications
to explain andlor exemplty a product, servico or maintenance improvement. We reserve
the right to make any change at any ime without notice. Yanmar and VANMAR are
registered trademarks of YANMAR CO,, LTD. in Japan, the United States andor other
counties,
All Rights Reserved:
No par of his publication may be reproduced or used in any form by any means -
graphie, electronic, or mechanical, including photocopying, recording, taping, or informa:
tion storage and retrieval systems - without the writen permission of YANMAR CO.,LTD.
Date of issue: Dee, 2011
ose vans ]
SERVICE MANUAL
EN EE) ]
Ahh mel Copete VANMAR CO, LTD.
Proposition 65 Warning
California
Proposition 65 Warning
Battery posts, terminals, and related
accessories contain lead and lead
‘Compounds, chemicals known 10 the
State of Caliomia o cause cancer and
reproductive harm.
Wash hands atterhanding
Diesel engine exhaust and some of ts
constituents are known tothe state of
Callormia to cause cancer, bith
detects, and other reproductive harm
‘This Service Manual has been developed forthe exclusive use of service and repair
Professionals such as Yanmar authorized Distributors and Yanmar authorized Dealers
‘Ris writen with these professionals in mind and may not contain the necessary detal or
safety statements that may ba required for a non-professional to perform the service or
repair proper andor safely. Please contact an authorized Yanmar repair or service
professional Before working on yaur Yanmar product
Disclaimers:
Al information, ilustations and specifications inthis manual are based onthe latest
information availabe a the time of publishing The lustatons used in this manual are
intended as representative reference views only. Moreover, because of our continuous
product improvement policy, we may modify information, iustraons and/or specications
to explain andlor exemplty a product, servico or maintenance improvement. We reserve
the right to make any change at any ime without notice. Yanmar and VANMAR are
registered trademarks of YANMAR CO,, LTD. in Japan, the United States andor other
counties,
All Rights Reserved:
No par of his publication may be reproduced or used in any form by any means -
graphie, electronic, or mechanical, including photocopying, recording, taping, or informa:
tion storage and retrieval systems - without the writen permission of YANMAR CO.,LTD.
Date of issue: Dee, 2011
ose vans ]
SERVICE MANUAL
EN EE) ]
Ahh mel Copete VANMAR CO, LTD.
TABLE OF
CONTENTS
Page
Introduction a
Safety 24
General Service Information a
Engine 44
Cooling System 5
Turbocherger. 61
Starter. 7
Altemator. 81
EHER nn, O1
‘Troubleshooting. 10
Service Sd nn HA
YANMAR suis
CONTENTS
Page
Introduction a
Safety 24
General Service Information a
Engine 44
Cooling System 5
Turbocherger. 61
Starter. 7
Altemator. 81
EHER nn, O1
‘Troubleshooting. 10
Service Sd nn HA
YANMAR suis
TABLE OF CONTENTS:
This Page Intentionally Left Blank
4 caves serena! YANMAR
This Page Intentionally Left Blank
4 caves serena! YANMAR
Section 1
INTRODUCTION
‘This manual gives specific instructions forthe proper repair of Yanmar BLV series marine engines.
Please follow the procedures caretlly to ensure quai service.
‘Yanmar recommends reading this Service Manual completely before stating with repairs.
‘Along with standard toos, Yanmar recommends the use of special tools necessary to perform repars
correct,
‘Yanmar products are continuously undergoing improvement. This Service Manual has been checked
care inorder fo avoid errors. However, Yanmar isnot lable for any misrepresentatons, errors of
(description or omissions. Contact your authorized Yanmar Marine dealer or dstibutor for any questions
you have regarding this Service Manual.
YANMAR so 02020 500000000
INTRODUCTION
‘This manual gives specific instructions forthe proper repair of Yanmar BLV series marine engines.
Please follow the procedures caretlly to ensure quai service.
‘Yanmar recommends reading this Service Manual completely before stating with repairs.
‘Along with standard toos, Yanmar recommends the use of special tools necessary to perform repars
correct,
‘Yanmar products are continuously undergoing improvement. This Service Manual has been checked
care inorder fo avoid errors. However, Yanmar isnot lable for any misrepresentatons, errors of
(description or omissions. Contact your authorized Yanmar Marine dealer or dstibutor for any questions
you have regarding this Service Manual.
YANMAR so 02020 500000000
INTRODUCTION Revision History
REVISION HISTORY
‘Tis manual isa ving document, Period manual revisions are published to document product
Improvements and changes. This practice ensures the manual has the most curent information,
As manual revisions become necessary, individual pages are prepared and sent to those who need the
information. I a page or number of pages shouldbe replaced, the replacement information's sent along
witha revised Revision Control Table, Discard the older, obsolete information,
Attimes, the revision involves inserting adalional pages in one or more sections. Replace the Revision
Control Table and inser the new pages.
This method of revision contol represents the most costellectve solution to providing current, updated
Information as needed,
Revision Control Table
Finn Dato | Ww Page Number pea
vision Number news
‘gust 2001 a Int rons
Del 4
REVISION HISTORY
‘Tis manual isa ving document, Period manual revisions are published to document product
Improvements and changes. This practice ensures the manual has the most curent information,
As manual revisions become necessary, individual pages are prepared and sent to those who need the
information. I a page or number of pages shouldbe replaced, the replacement information's sent along
witha revised Revision Control Table, Discard the older, obsolete information,
Attimes, the revision involves inserting adalional pages in one or more sections. Replace the Revision
Control Table and inser the new pages.
This method of revision contol represents the most costellectve solution to providing current, updated
Information as needed,
Revision Control Table
Finn Dato | Ww Page Number pea
vision Number news
‘gust 2001 a Int rons
Del 4
Section 2
SAFETY
SAFETY STATEMENTS
‘Yanmar is concerned for your safety and tho
condiian of your marine engin. Safety statements
are one of the primary ways to cal your attention to
the potential hazards associated with Yanmar
‘marine engines. Follow the precautions listed
‘throughout the manual before of
‘operation and during periodic
procedures for your safely, ne safety of others and
1 protect the performance of your marine engine.
Koop Ihe decals rom becoming dirty of tom and
replace them if they ae lost or damaged, Also la
‘bart needs to be replaced that has a decal attached
10 1, make sure to order the now part and decal at
the same te.
This safety alert symbol appears
‘with most safety statements I
means attonion, become alen your
safely is involved Please read and
abide bythe message that follows
the safety alen symbol
YANMAR so 02020 500000000
À DANGER
DANGER indicates a hazardous situation
which, if not avoided, will result in deat
serious injury
WARNING indicates a hazardous situation
Which, if not avoided, could result in death or
Serious injury.
À CAUTION
CAUTION indicates a hazardous situation
Which, if not avoided, could result in minor or
moderate injury
NOTICE
NOTICE indicates a situation which can cause
(damage to the machine, personal property andlor
the environment or cause the equipment to operate
improper.
SAFETY
SAFETY STATEMENTS
‘Yanmar is concerned for your safety and tho
condiian of your marine engin. Safety statements
are one of the primary ways to cal your attention to
the potential hazards associated with Yanmar
‘marine engines. Follow the precautions listed
‘throughout the manual before of
‘operation and during periodic
procedures for your safely, ne safety of others and
1 protect the performance of your marine engine.
Koop Ihe decals rom becoming dirty of tom and
replace them if they ae lost or damaged, Also la
‘bart needs to be replaced that has a decal attached
10 1, make sure to order the now part and decal at
the same te.
This safety alert symbol appears
‘with most safety statements I
means attonion, become alen your
safely is involved Please read and
abide bythe message that follows
the safety alen symbol
YANMAR so 02020 500000000
À DANGER
DANGER indicates a hazardous situation
which, if not avoided, will result in deat
serious injury
WARNING indicates a hazardous situation
Which, if not avoided, could result in death or
Serious injury.
À CAUTION
CAUTION indicates a hazardous situation
Which, if not avoided, could result in minor or
moderate injury
NOTICE
NOTICE indicates a situation which can cause
(damage to the machine, personal property andlor
the environment or cause the equipment to operate
improper.
SAFETY
Safety Precautions
SAFETY PRECAUTIONS
There is no substiute for common sense and
carelu practices, Improper practices or
carelessness can cause burs, cts, mutation,
asptxiaton, oher bodily injury or death. This
information contains general safety precautions
and guidelines that must be fellowed to reduce risk
10 personal sal. Special salat precautions are
listed spect procedures. Read and understand
all ofthe safety precautions before operating or
Performing repairs or maintenance
À DANGER
= Never permit anyone to instal or
operate th engine without proper
traning
+ Read and understand this Service Manuel
before operating or servicing the engine to
ensure that safe operating practices and
maintenance procedures are followed.
+ Safety signs and decals are adcitional
reminders for sae operating and maintenance
techniques.
+ Contact your Yanmar RHQ for additional
training,
À DANGER
Crush Hazard
+ When attaching an engine to
repair stand, be sure to use a
stand of adequate capacity to
Safely support the engine to be
repaired, and that itis securely
‘attached to the engine.
+ Never stand under a hoisted engine. If the
hoist mechanism fails, the engine wil fall on
you.
+ Always secure the engine solidly to prevent
the engine from falling during maintenance.
Explosion Hazard
+ While the engine is running or the
battery is charging, hydrogen gas
Is being produced and can be
‘easly ignited. Keep the are
around the battery well-ventilated
and keep sparks, open flame and
any other form of ignition out of
the
+ Always turnoff the battery switch (
equipped) or disconnect the negative ()
battery cable before servicing the equipment.
Fire and Explosion Hazard
+ Diesel fuel is flammable and
‘explosive under certain
conditions.
+ Never use a shop rag to catch the uel
+ Wipe up all spills immediately.
+ Never refuel with the engine running.
+ Store any containers containing fuel in a
well-ventilated area, away from any
fire
nam
AS:
AA
+ Have appropriate safety
+ Always read and follow safety-related
electrical fire.
Contact with hot surfaces or insulation
materia.
Safety Precautions
SAFETY PRECAUTIONS
There is no substiute for common sense and
carelu practices, Improper practices or
carelessness can cause burs, cts, mutation,
asptxiaton, oher bodily injury or death. This
information contains general safety precautions
and guidelines that must be fellowed to reduce risk
10 personal sal. Special salat precautions are
listed spect procedures. Read and understand
all ofthe safety precautions before operating or
Performing repairs or maintenance
À DANGER
= Never permit anyone to instal or
operate th engine without proper
traning
+ Read and understand this Service Manuel
before operating or servicing the engine to
ensure that safe operating practices and
maintenance procedures are followed.
+ Safety signs and decals are adcitional
reminders for sae operating and maintenance
techniques.
+ Contact your Yanmar RHQ for additional
training,
À DANGER
Crush Hazard
+ When attaching an engine to
repair stand, be sure to use a
stand of adequate capacity to
Safely support the engine to be
repaired, and that itis securely
‘attached to the engine.
+ Never stand under a hoisted engine. If the
hoist mechanism fails, the engine wil fall on
you.
+ Always secure the engine solidly to prevent
the engine from falling during maintenance.
Explosion Hazard
+ While the engine is running or the
battery is charging, hydrogen gas
Is being produced and can be
‘easly ignited. Keep the are
around the battery well-ventilated
and keep sparks, open flame and
any other form of ignition out of
the
+ Always turnoff the battery switch (
equipped) or disconnect the negative ()
battery cable before servicing the equipment.
Fire and Explosion Hazard
+ Diesel fuel is flammable and
‘explosive under certain
conditions.
+ Never use a shop rag to catch the uel
+ Wipe up all spills immediately.
+ Never refuel with the engine running.
+ Store any containers containing fuel in a
well-ventilated area, away from any
fire
nam
AS:
AA
+ Have appropriate safety
+ Always read and follow safety-related
electrical fire.
Contact with hot surfaces or insulation
materia.
SAFETY
Safety Precautions
Entanglement Hazard
+ Never leave the key in the key
switch when servicing the engine.
Attach a “Do Not Operate” tag
near the key switch white
performing maintenance on the
equipment.
+ Always stop the engine before beginning
+ Ifthe engine must be serviced while itis
‘operating, remove al jewelry, ie back long
hair and keep hands, other body parts and
clothing away from moving/rotating parts,
high pressure fuel epray, obtain
prompt medical treatment.
+ Never check for a fuel leak with your hands.
Always use a piece of wood or cardboard.
Piercing Hazard
+ Avoid skin contact with
high-pressure diesel fuel spray
caused by a fuel system leak such
as a broken fuel injection
High-pressure fuel can penetrate
your skin and result in serious
injury. you are exposed to
Flying Object Hazard
Always wear eye protection when,
servicing the engine or when using
compressed air or high-pressure
water, Dust flying debris,
Compressed ai, pressurized water
or steam may injure your eyes.
Coolant Hazard
Wear eye protection and
>@ rubber gloves when
handling Long Life
Coolant (LLC). Y contact
with the eyes or ski
‘should occur, flush eyes.
‘and wash immediately
with clean water.
YANMAR 209 coo: 000 ares
‘Sever Hazard
+ Never wear jewelry, unbuttoned
cuts, ies or loose-fting clothing
‘and always te long hair back
when working near
movingrotating parts such.
flywheel or PTO shatt. Keep
hands, feet and tools away from
‘moving parts.
+ The propeller may rotate during towing or it
the engine is running at ile speed. Never
‘service the engine while being towed or when
the engine is running.
+ Ifthe vessel has more than one engine, never
service an engine i either of the engines is
running. In multi-engine configurations th
Propeller for an engine that is shut down may
rotate if any of the other engines are running,
+ Never operate the engine without the guards
in place.
+ Never operate the engine while wearing a
headset to listen to music or radio because it
the
Exhaust Hazard
a “Mieratenstoeres
PAR neo
EE
ares
willbe difficult to hear the warning signals.
create carbon monoxide gas
+ Never block windows, vents or other means of
tightened to specifications ater repair is
during operation and special
ventilation ifthe engine is operating in an
made to the exhaust system.
Safety Precautions
Entanglement Hazard
+ Never leave the key in the key
switch when servicing the engine.
Attach a “Do Not Operate” tag
near the key switch white
performing maintenance on the
equipment.
+ Always stop the engine before beginning
+ Ifthe engine must be serviced while itis
‘operating, remove al jewelry, ie back long
hair and keep hands, other body parts and
clothing away from moving/rotating parts,
high pressure fuel epray, obtain
prompt medical treatment.
+ Never check for a fuel leak with your hands.
Always use a piece of wood or cardboard.
Piercing Hazard
+ Avoid skin contact with
high-pressure diesel fuel spray
caused by a fuel system leak such
as a broken fuel injection
High-pressure fuel can penetrate
your skin and result in serious
injury. you are exposed to
Flying Object Hazard
Always wear eye protection when,
servicing the engine or when using
compressed air or high-pressure
water, Dust flying debris,
Compressed ai, pressurized water
or steam may injure your eyes.
Coolant Hazard
Wear eye protection and
>@ rubber gloves when
handling Long Life
Coolant (LLC). Y contact
with the eyes or ski
‘should occur, flush eyes.
‘and wash immediately
with clean water.
YANMAR 209 coo: 000 ares
‘Sever Hazard
+ Never wear jewelry, unbuttoned
cuts, ies or loose-fting clothing
‘and always te long hair back
when working near
movingrotating parts such.
flywheel or PTO shatt. Keep
hands, feet and tools away from
‘moving parts.
+ The propeller may rotate during towing or it
the engine is running at ile speed. Never
‘service the engine while being towed or when
the engine is running.
+ Ifthe vessel has more than one engine, never
service an engine i either of the engines is
running. In multi-engine configurations th
Propeller for an engine that is shut down may
rotate if any of the other engines are running,
+ Never operate the engine without the guards
in place.
+ Never operate the engine while wearing a
headset to listen to music or radio because it
the
Exhaust Hazard
a “Mieratenstoeres
PAR neo
EE
ares
willbe difficult to hear the warning signals.
create carbon monoxide gas
+ Never block windows, vents or other means of
tightened to specifications ater repair is
during operation and special
ventilation ifthe engine is operating in an
made to the exhaust system.
SAFETY
Safety Precautions
Electrical Hazard
+ Make welding repairs safely.
+ Always turn off the battery switch (it
equipped) or disconnect the negative (-)
battery cable and the leads to the alternator
‘when welding on the equipment.
+ Remove the multipin connector o the engine
Control unit. Connect the weld clamp to the
‘component tobe welded and as close as
Possible tothe welding point.
+ Never connect the weld clamp to the engine
‘or in a manner which would allow current 10.
pass through a mounting bracket.
+ When welding is complete, reconnect the
leads tothe alternator and engine control unit
prior to reconnecting the batteries.
+ Always keep the electrical connectors and
terminals clean, Check the electrical
harnesses for cracks, abrasions, and
damaged or corroded connectors.
+ Never turn off the battery switch (if equipped)
‘or Short the battery cables during operation.
Damage tothe electrical system will result.
Burn Hazard
+ Some of the engine surfaces
become very hot during operation
and shorty after shutdown.
+ Keep hands and other body parts away from
hot engine surfaces.
+ Handle hot components with heot-resistant
gloves.
‘Sudden Movement Hazard
+ To prevent accidental equipment movement,
Never start the engine in gear.
+ Shift the marine gear into the NEUTRAL
position any time the engine is at ile.
1g Hazard
+ The engine lifting eyes are engineered to lit
the weight of the marine engine only. Always
use the engine lifting eyes when lifting the
engine.
+ Additional equipment is necessary to it the
‘marine engine and marine gear together.
‘Always use ling equipment with sufficient
capacity to lift the marine engine.
+ If transport is needed for engine repair, have a
holper assist in attaching ito a hoist and
loading it onto a truck,
‘Alcohol and Drug Hazas
Never operate the engine while
under the influence of alcohol,
drugs or when il.
Exposure Hazard
Always wear personal protective
equipment including appropriate
clothing, gloves, work shoes and
eye and hearing protection as.
required by the task at hand.
Tool Hazard
Always remove any tools or shop rags used
during maintenance from the area before
operation
Safety Precautions
Electrical Hazard
+ Make welding repairs safely.
+ Always turn off the battery switch (it
equipped) or disconnect the negative (-)
battery cable and the leads to the alternator
‘when welding on the equipment.
+ Remove the multipin connector o the engine
Control unit. Connect the weld clamp to the
‘component tobe welded and as close as
Possible tothe welding point.
+ Never connect the weld clamp to the engine
‘or in a manner which would allow current 10.
pass through a mounting bracket.
+ When welding is complete, reconnect the
leads tothe alternator and engine control unit
prior to reconnecting the batteries.
+ Always keep the electrical connectors and
terminals clean, Check the electrical
harnesses for cracks, abrasions, and
damaged or corroded connectors.
+ Never turn off the battery switch (if equipped)
‘or Short the battery cables during operation.
Damage tothe electrical system will result.
Burn Hazard
+ Some of the engine surfaces
become very hot during operation
and shorty after shutdown.
+ Keep hands and other body parts away from
hot engine surfaces.
+ Handle hot components with heot-resistant
gloves.
‘Sudden Movement Hazard
+ To prevent accidental equipment movement,
Never start the engine in gear.
+ Shift the marine gear into the NEUTRAL
position any time the engine is at ile.
1g Hazard
+ The engine lifting eyes are engineered to lit
the weight of the marine engine only. Always
use the engine lifting eyes when lifting the
engine.
+ Additional equipment is necessary to it the
‘marine engine and marine gear together.
‘Always use ling equipment with sufficient
capacity to lift the marine engine.
+ If transport is needed for engine repair, have a
holper assist in attaching ito a hoist and
loading it onto a truck,
‘Alcohol and Drug Hazas
Never operate the engine while
under the influence of alcohol,
drugs or when il.
Exposure Hazard
Always wear personal protective
equipment including appropriate
clothing, gloves, work shoes and
eye and hearing protection as.
required by the task at hand.
Tool Hazard
Always remove any tools or shop rags used
during maintenance from the area before
operation
Safety Precautions
SAFETY
À CAUTION
Poor Lighting Hazard
Ensuro that the work area is adequately
illuminated. Always install wire cages on
portable safety lamps.
A CAUTION
Tool Hazard
Ensuro that the work area is adequately
illuminated. Always install wie cages on
portable safety lamps.
NOTICE
‘Any part which is found defective as a result of
inspection or any part whose measured value does
‘ot alisty the standard or nit must be replaced,
NOTICE
Always tighten components tothe spacliod torque.
Loose parts can cause equipment damage or
cause to operate impropety
Only use replacement paris specified. Other
replacement parts may afec waranty coverage.
NOTICE
Never attempt to modi the engine design or safety
features such as defealing the engine speed mit
contol or the diesel fuel injecton quantity control
NOTICE
Modifications may impat the engine's safety and
performance characteristics and shorten the
‘engine's ie. Any alterations otis engine may void
lis waranty. Be sure to use Yanmar genuine
replacement pars.
YANMAR wesen
NOTICE
Follow the guidlines ofthe EPA or
‘ther governmental agencies forthe
proper disposal of hazardous
Materials such as engine ol, esol
fuel and engine coolant. Consult he
local authori or reclamation facility.
Never dispose of hazardous materials by dumping
thom into a sowor on the ground, or into
groundwaloror waterways,
NOTICE
i any indicator uminates during engine operation,
stop the engine immediately, Determine the cause
and repair he problem before contnuingto operate
the engine.
Make sure the engine is installed ona leve surface.
Ita Yanmar Marine engine is installed at an angle
that excoeds the specications stated inthe
‘Yanmar Marine installation Manuals, engine oll may
center the combustion chamber causing excessive
engine speed, white exhaust smoke and serious
engine damage. This applies to engines that run
Continuously or those that un for short periods of
SAFETY
À CAUTION
Poor Lighting Hazard
Ensuro that the work area is adequately
illuminated. Always install wire cages on
portable safety lamps.
A CAUTION
Tool Hazard
Ensuro that the work area is adequately
illuminated. Always install wie cages on
portable safety lamps.
NOTICE
‘Any part which is found defective as a result of
inspection or any part whose measured value does
‘ot alisty the standard or nit must be replaced,
NOTICE
Always tighten components tothe spacliod torque.
Loose parts can cause equipment damage or
cause to operate impropety
Only use replacement paris specified. Other
replacement parts may afec waranty coverage.
NOTICE
Never attempt to modi the engine design or safety
features such as defealing the engine speed mit
contol or the diesel fuel injecton quantity control
NOTICE
Modifications may impat the engine's safety and
performance characteristics and shorten the
‘engine's ie. Any alterations otis engine may void
lis waranty. Be sure to use Yanmar genuine
replacement pars.
YANMAR wesen
NOTICE
Follow the guidlines ofthe EPA or
‘ther governmental agencies forthe
proper disposal of hazardous
Materials such as engine ol, esol
fuel and engine coolant. Consult he
local authori or reclamation facility.
Never dispose of hazardous materials by dumping
thom into a sowor on the ground, or into
groundwaloror waterways,
NOTICE
i any indicator uminates during engine operation,
stop the engine immediately, Determine the cause
and repair he problem before contnuingto operate
the engine.
Make sure the engine is installed ona leve surface.
Ita Yanmar Marine engine is installed at an angle
that excoeds the specications stated inthe
‘Yanmar Marine installation Manuals, engine oll may
center the combustion chamber causing excessive
engine speed, white exhaust smoke and serious
engine damage. This applies to engines that run
Continuously or those that un for short periods of
SAFETY Location of Safety Decals
LOCATION OF SAFETY DECALS.
Figure 2:1 and Figure 2-2 show the location of safety decals on Yanmar BLV series marine engines.
Salely decals are additonal reminders for safe operation and maintenance procedures. Keep the decals
from becoming dry or damaged and replace them i they are missing or damaged.
RE
Figure 2-4
Te] Fan Naber
‘I raa2se-a72e0
21 rer
LOCATION OF SAFETY DECALS.
Figure 2:1 and Figure 2-2 show the location of safety decals on Yanmar BLV series marine engines.
Salely decals are additonal reminders for safe operation and maintenance procedures. Keep the decals
from becoming dry or damaged and replace them i they are missing or damaged.
RE
Figure 2-4
Te] Fan Naber
‘I raa2se-a72e0
21 rer
Location of Safety Decals, SAFETY
SAFETY Location of Safety Decals
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… sms YANMAR
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… sms YANMAR
Section 3
GENERAL SERVICE
INFORMATION
Page
Salety Precautions 33
‘Component identification 34
Service Side . 34
Non-Serice Side. 34
Diesel Fuel 35
Diesel Fuel SPGGICANONS nn DE
Filing the Fuel Tank 97
Bleeding the Fuel System, 87
Engine Oil 38
Engine OÙ Specticaions mm 98
Engine OÙ VISOS nm DO
Checking the Engine Ol... 39
Adding Engine Ol. 39
Engine Coolant 310
Engine Coolant SpGACANDNS..… mn. $10
Coolant (Closed Cooling Syste) mn 8-10
Checking and Adding Coolant, 310
Checking ne Engine Ol and Engine Coolant an
Piping Diagrams. 312
BLV3ZOIZ),BLVASO(Z), LVI7OLZ)
Lubrication System Diagram a2
BLV320, 8LV3S0, 8L 370 Cooling System Diagram, 313
BLVS20(2), BLVSS0(2),8L VS70(Z) Fuel System Diagram... 3:14
Location of Nameplate. 316
Principal Engine Speciicalons …...... 9:16
LV Series Engine Specifications. 316
LV Series Marine Gear Specifications. 317
YANMAR su cercos
GENERAL SERVICE
INFORMATION
Page
Salety Precautions 33
‘Component identification 34
Service Side . 34
Non-Serice Side. 34
Diesel Fuel 35
Diesel Fuel SPGGICANONS nn DE
Filing the Fuel Tank 97
Bleeding the Fuel System, 87
Engine Oil 38
Engine OÙ Specticaions mm 98
Engine OÙ VISOS nm DO
Checking the Engine Ol... 39
Adding Engine Ol. 39
Engine Coolant 310
Engine Coolant SpGACANDNS..… mn. $10
Coolant (Closed Cooling Syste) mn 8-10
Checking and Adding Coolant, 310
Checking ne Engine Ol and Engine Coolant an
Piping Diagrams. 312
BLV3ZOIZ),BLVASO(Z), LVI7OLZ)
Lubrication System Diagram a2
BLV320, 8LV3S0, 8L 370 Cooling System Diagram, 313
BLVS20(2), BLVSS0(2),8L VS70(Z) Fuel System Diagram... 3:14
Location of Nameplate. 316
Principal Engine Speciicalons …...... 9:16
LV Series Engine Specifications. 316
LV Series Marine Gear Specifications. 317
YANMAR su cercos
GENERAL SERVICE INFORMATION
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- sms YANMAR
This Page Intentionally Left Blank
- sms YANMAR
Safety Precautions
GENERAL SERVICE INFORMATION
SAFETY PRECAUTIONS
Before servicing the engine, review the folowing
messages and the Safety Section on page 2-1.
Fire Hazard
Undersized wiring systems can cause an
electrical fire.
Electrical Hazard
Always keep the electrical connectors and
terminals clean. Check the electrical harnesees
for cracks, abrasions, and damage
‘corroded connectors. Never turn.
‘switch (it equipped) or short the battery cables.
during operation. Damage to the electrical
‘system will result.
YANMAR 209 coo: 000 ares
GENERAL SERVICE INFORMATION
SAFETY PRECAUTIONS
Before servicing the engine, review the folowing
messages and the Safety Section on page 2-1.
Fire Hazard
Undersized wiring systems can cause an
electrical fire.
Electrical Hazard
Always keep the electrical connectors and
terminals clean. Check the electrical harnesees
for cracks, abrasions, and damage
‘corroded connectors. Never turn.
‘switch (it equipped) or short the battery cables.
during operation. Damage to the electrical
‘system will result.
YANMAR 209 coo: 000 ares
GENERAL SERVICE INFORMATION ‘Component identification
COMPONENT IDENTIFICATION
Service Side
Figure 34 and Figure 3-2 ilustrate a typical version of a BL series engine. Your engine may have
diffrent equipment om that iustated
Non-Service Side
COMPONENT IDENTIFICATION
Service Side
Figure 34 and Figure 3-2 ilustrate a typical version of a BL series engine. Your engine may have
diffrent equipment om that iustated
Non-Service Side
Diesel Fuel
GENERAL SERVICE INFORMATION
DIESEL FUEL
À DANGER
Diesel fuel is flammable and explosive under
certain conditions. See Safety on page 2-1.
iesel Fuel Specifications
Only use diesel fuels recommended by Yanmar
Marine for the best engine performance, to prevent
engine damage and to comply with EPA warranty
requirements. Only use clean diese ful.
Diesel tul should comply wih the folowing
specications. The table lists several worldwide
specications for diesel fuels.
Diesel Fuel Specication Locator
a 2D,No.1.D,ASIMDOZS [USA
FENSo0 96 European Union
150 8217 ONDE international
(BS 2065 At or RD United Kingdom
[sis 2204 Gradeto.2@ Japan
u Bio-Diesel Fuels
‘Yanmar approves the use o biodiesel fuels that do
‘ot excoed a blend of 5% non mineral ol based
{uo with 95 % standard diese uel Such biodiesel
{els are known in ho marketplace as BS biodiesel
fuels, 85 biodiesel fuel can reduce partculate
matter and the emission of “greenhouse” gases.
‘compared to standard diesel uel
AA CAUTION
It the BS biodiesel fuel used does not meet the
approved specifications, it wil cause abnormal
wear of injectors, reduce the life of the engine
and it may affect the warranty coverage of your
YANMAR 209 coo: 000 ares
85 diesel fuels must meet certain specifications
‘The biodiesel fuels must meet he minimum
specications forthe country in which they are
used
+ In Europe, biodiesel fuels must comply withthe
European Standard EN14214,
+ In the United States, biodiesel fuels must comply
‘wth the American Standard ASTM 0.6751
Biodiesel should be purchased only trom
recognized and authorized diesel fel supp.
Precautions and concerns regarding the use of
bio-fuels:
+ Biodiesel fuels have a higher content of
meihykesters, which may deteriorate certain
meta, rubber and plastic components ofthe fuel
system. The customer andior boat builder are
responsible to very the usage of biodiesel
‘compatible components onthe vesso uel supply
and tur systems.
+ Froo watorin biodiesel may result in plugging of
{el titers and increased bacterial growth,
+ High viscosity at low temperatures may result in
{uo delivery problems, injection pump seizures,
and poor injection nozzle spray atomization.
+ Biodiosel may have adverse elacis on some
lastomers (Seal materials) and may result in tuo
leakage and dation a ho engine lubvcating ol
+ Even biodiesel uels that comply with a suitable
standard as delivered, ll require addtional caro
“and attention to maintain the qualiy ofthe fue in
the equipment or other ol tanks. Its important
tomaintain a supply o clean, fresh fuel. Regular
ttushing ofthe fuel system, andlor fuel storage
containers, may be necessary.
+ The use of biodiesel als that d not compl with
the standards as agreod to by the diesel engine
manufacturer and the diese uel injection
‘equipment manulacturer, or biodiesel lues that
have degraded as per the precautions and
concerns above, may affect the warranty
‘coverage of your engine.
GENERAL SERVICE INFORMATION
DIESEL FUEL
À DANGER
Diesel fuel is flammable and explosive under
certain conditions. See Safety on page 2-1.
iesel Fuel Specifications
Only use diesel fuels recommended by Yanmar
Marine for the best engine performance, to prevent
engine damage and to comply with EPA warranty
requirements. Only use clean diese ful.
Diesel tul should comply wih the folowing
specications. The table lists several worldwide
specications for diesel fuels.
Diesel Fuel Specication Locator
a 2D,No.1.D,ASIMDOZS [USA
FENSo0 96 European Union
150 8217 ONDE international
(BS 2065 At or RD United Kingdom
[sis 2204 Gradeto.2@ Japan
u Bio-Diesel Fuels
‘Yanmar approves the use o biodiesel fuels that do
‘ot excoed a blend of 5% non mineral ol based
{uo with 95 % standard diese uel Such biodiesel
{els are known in ho marketplace as BS biodiesel
fuels, 85 biodiesel fuel can reduce partculate
matter and the emission of “greenhouse” gases.
‘compared to standard diesel uel
AA CAUTION
It the BS biodiesel fuel used does not meet the
approved specifications, it wil cause abnormal
wear of injectors, reduce the life of the engine
and it may affect the warranty coverage of your
YANMAR 209 coo: 000 ares
85 diesel fuels must meet certain specifications
‘The biodiesel fuels must meet he minimum
specications forthe country in which they are
used
+ In Europe, biodiesel fuels must comply withthe
European Standard EN14214,
+ In the United States, biodiesel fuels must comply
‘wth the American Standard ASTM 0.6751
Biodiesel should be purchased only trom
recognized and authorized diesel fel supp.
Precautions and concerns regarding the use of
bio-fuels:
+ Biodiesel fuels have a higher content of
meihykesters, which may deteriorate certain
meta, rubber and plastic components ofthe fuel
system. The customer andior boat builder are
responsible to very the usage of biodiesel
‘compatible components onthe vesso uel supply
and tur systems.
+ Froo watorin biodiesel may result in plugging of
{el titers and increased bacterial growth,
+ High viscosity at low temperatures may result in
{uo delivery problems, injection pump seizures,
and poor injection nozzle spray atomization.
+ Biodiosel may have adverse elacis on some
lastomers (Seal materials) and may result in tuo
leakage and dation a ho engine lubvcating ol
+ Even biodiesel uels that comply with a suitable
standard as delivered, ll require addtional caro
“and attention to maintain the qualiy ofthe fue in
the equipment or other ol tanks. Its important
tomaintain a supply o clean, fresh fuel. Regular
ttushing ofthe fuel system, andlor fuel storage
containers, may be necessary.
+ The use of biodiesel als that d not compl with
the standards as agreod to by the diesel engine
manufacturer and the diese uel injection
‘equipment manulacturer, or biodiesel lues that
have degraded as per the precautions and
concerns above, may affect the warranty
‘coverage of your engine.
GENERAL SERVICE INFORMATION
Diesel Fuel
m Additional Technical Fuel Requirements.
+ The fuel cetane number should be 45 or higher
+The sulur content must not exceed 0.5 % by
volume. Less than 0.05 % Is preferred.
+ Never mix kerosene, used engine ol, or residual
fuels withthe diesel fuel
+ Water and sediment inthe ful should not exceed
0.05 % by volume.
+ Koop the fuel tank and fuel handling equipment
dean at all times.
+ Ash content noto exceed 0.01 % by volume.
+ Carbon residue content not 0 exceed 0.25 % by
volume, Less than 0.1 % is prelered,
+ Total aromatics content should not exceed 35 %
by volume. Less than 30 % is preferred
+ PAH (polyeylc aromatic hydrocarbons) content
should be below 10 % by volume,
+ Do nat use Blocide,
M Handling of Diesel Fuel
1. Water and dust inthe fuel may cause engine
failure. When fuels stored, be sure that the
inside of the storage container is clean and dry,
and thal he uals stored away from dt or rain,
Figure 3-3
2. Keep the fuel container stationary for several
hours to allow any dir or water to settle o the
bottom ofthe container. Use a pump to extract
the clear, tered ful from the top ofthe
container.
m Fuel Tank (Option)
Figure 3-4
Install drain cock 2, Figure 3-4 at the bottom of
the fuel tank to remove water and contaminants
‘om the sediment bow (1, Figure 3-4)
“The fuel outlet should be positioned 20 to 30 mm
(0.810 1.2 in) above the bottom ofthe tank so nat
only clean fuel is distributed to the engine
(3, Figure 3-4)
Diesel Fuel
m Additional Technical Fuel Requirements.
+ The fuel cetane number should be 45 or higher
+The sulur content must not exceed 0.5 % by
volume. Less than 0.05 % Is preferred.
+ Never mix kerosene, used engine ol, or residual
fuels withthe diesel fuel
+ Water and sediment inthe ful should not exceed
0.05 % by volume.
+ Koop the fuel tank and fuel handling equipment
dean at all times.
+ Ash content noto exceed 0.01 % by volume.
+ Carbon residue content not 0 exceed 0.25 % by
volume, Less than 0.1 % is prelered,
+ Total aromatics content should not exceed 35 %
by volume. Less than 30 % is preferred
+ PAH (polyeylc aromatic hydrocarbons) content
should be below 10 % by volume,
+ Do nat use Blocide,
M Handling of Diesel Fuel
1. Water and dust inthe fuel may cause engine
failure. When fuels stored, be sure that the
inside of the storage container is clean and dry,
and thal he uals stored away from dt or rain,
Figure 3-3
2. Keep the fuel container stationary for several
hours to allow any dir or water to settle o the
bottom ofthe container. Use a pump to extract
the clear, tered ful from the top ofthe
container.
m Fuel Tank (Option)
Figure 3-4
Install drain cock 2, Figure 3-4 at the bottom of
the fuel tank to remove water and contaminants
‘om the sediment bow (1, Figure 3-4)
“The fuel outlet should be positioned 20 to 30 mm
(0.810 1.2 in) above the bottom ofthe tank so nat
only clean fuel is distributed to the engine
(3, Figure 3-4)
Diesel Fuel
GENERAL SERVICE INFORMATION
Filling the Fuel Tank
À DANGER
"Never refuel with the engine running. See
Safety on page 2-1
Before filing the fue tank fo the fist time, Anse the
fuel tank wih kerosene or diesel uel, Dispose of
waste propery.
To Fill the Fuel Tank
‘Operate the bilge ventilation (blowers) for a
minimum of 5 minutes to purge fumes from
engine compartment after refueling.
‘operate the bilge blower(s) while refueling.
Doing so can pump explosive fumes into the
engine compartment and result in an explosion.
‘Clean the area around the fuel cap.
2. Remove the fuel cap rom the uel tank.
3. Fillthe tank wih clean fuel ree of oll and di.
Hold the hose nozzle firmly against the filer
Port while filing. This prevents static
‘electricity buildup which could cause
‘parks and ignite fuel vapors.
4. Stop luging when the gauge shows the luel
tanks fal
À CAUTION
Never overfil the fuel tank
5. Replace the fuel cap and hand-ighten.
‘Over tightening the fuel cap wll damage
YANMAR 209 coo: 000 ares
Bleeding the Fuel System
Blocding must be done i any fuel system
maintenance has been performed (replacement of
fuel fte, etc.) ori the engine does not start after
several attempts
Figure 35
1. Check the fut level in the fuel tank
Fil il necessary.
2. Open the fuel cock ofthe fuel tank.
Always wear safety glasses when bleeding
the fuel system.
3. Loosen the air bleed crew (2, Figure 3-5).
4. Push up and down on the priming pump,
(1, Figure 3-5) to release air out ol the airbleed
5. Continue pumping uni a sold stream of tel
‘with no ai bubbles begins to flow.
6. Tighton he ar bleed screw.
GENERAL SERVICE INFORMATION
Filling the Fuel Tank
À DANGER
"Never refuel with the engine running. See
Safety on page 2-1
Before filing the fue tank fo the fist time, Anse the
fuel tank wih kerosene or diesel uel, Dispose of
waste propery.
To Fill the Fuel Tank
‘Operate the bilge ventilation (blowers) for a
minimum of 5 minutes to purge fumes from
engine compartment after refueling.
‘operate the bilge blower(s) while refueling.
Doing so can pump explosive fumes into the
engine compartment and result in an explosion.
‘Clean the area around the fuel cap.
2. Remove the fuel cap rom the uel tank.
3. Fillthe tank wih clean fuel ree of oll and di.
Hold the hose nozzle firmly against the filer
Port while filing. This prevents static
‘electricity buildup which could cause
‘parks and ignite fuel vapors.
4. Stop luging when the gauge shows the luel
tanks fal
À CAUTION
Never overfil the fuel tank
5. Replace the fuel cap and hand-ighten.
‘Over tightening the fuel cap wll damage
YANMAR 209 coo: 000 ares
Bleeding the Fuel System
Blocding must be done i any fuel system
maintenance has been performed (replacement of
fuel fte, etc.) ori the engine does not start after
several attempts
Figure 35
1. Check the fut level in the fuel tank
Fil il necessary.
2. Open the fuel cock ofthe fuel tank.
Always wear safety glasses when bleeding
the fuel system.
3. Loosen the air bleed crew (2, Figure 3-5).
4. Push up and down on the priming pump,
(1, Figure 3-5) to release air out ol the airbleed
5. Continue pumping uni a sold stream of tel
‘with no ai bubbles begins to flow.
6. Tighton he ar bleed screw.
GENERAL SERVICE INFORMATION
Engine Oi!
ENGINE OIL
Engine Oil Specifications
NOTICE
Using engine ol that does not moet or excoed the
following quidoines or specications may cause
seizure of parts, abnormal wear and shorten
engine io.
M Service Categories
{Use an engine ol hat meets or exceeds the
following guidelines and casscatons:
+ API Service Categories: CD, CF, CFA, Cl, C4
+ AECA: ES, £4, ES
+ JASO: DH2, DL
+ SAE Viscosiy: 15W40. Engine ol 15WW40 can be
‘used throughout the year
NOTICE
+ Make sure that the engine ol, engine ol storage
Containers, and engine ol ling equipment are
{rae of sediment or water.
+ Change he engine ol alter the frst $0 hours of
‘operation and hen at every 250 hours thereatter.
+ Yanmar does not recommend the use of engine
ol'addies”.
M Handling Engine Oil
1. When handling and string engin où, be
Carol no Lo allow dust and water to
‘contaminate the ol. Clean around he filer port
before filing
2. Do not mix lubrication ois of ferent ypes or
brands. Miing may cause the chemical
characiersis ofthe oll to change and
lubricating performance to decrease, reducing
the engines ie.
gin ol should be replaced atthe specified
Intervals, regardless i the engine has been
operated
Engine Oil Viscosity
‘SAE 1SW40 is the recommended où viscosiy
It you operate your equipment below -15 °C (5 °F)
er above 40 °C (104 “F), consult your authorized
‘Yanmar Marine dealer or distributor or special
lubeeants or staring aid,
‘The BLY series engine has an ol or por or
rockor am cover.
The engine has a dipstick on the sight side
An aianal dipstick on the let side is avaliable as
an option (Figure 3-1 on page 3-9.
Auen Temperate
Figure 36
Engine Oi!
ENGINE OIL
Engine Oil Specifications
NOTICE
Using engine ol that does not moet or excoed the
following quidoines or specications may cause
seizure of parts, abnormal wear and shorten
engine io.
M Service Categories
{Use an engine ol hat meets or exceeds the
following guidelines and casscatons:
+ API Service Categories: CD, CF, CFA, Cl, C4
+ AECA: ES, £4, ES
+ JASO: DH2, DL
+ SAE Viscosiy: 15W40. Engine ol 15WW40 can be
‘used throughout the year
NOTICE
+ Make sure that the engine ol, engine ol storage
Containers, and engine ol ling equipment are
{rae of sediment or water.
+ Change he engine ol alter the frst $0 hours of
‘operation and hen at every 250 hours thereatter.
+ Yanmar does not recommend the use of engine
ol'addies”.
M Handling Engine Oil
1. When handling and string engin où, be
Carol no Lo allow dust and water to
‘contaminate the ol. Clean around he filer port
before filing
2. Do not mix lubrication ois of ferent ypes or
brands. Miing may cause the chemical
characiersis ofthe oll to change and
lubricating performance to decrease, reducing
the engines ie.
gin ol should be replaced atthe specified
Intervals, regardless i the engine has been
operated
Engine Oil Viscosity
‘SAE 1SW40 is the recommended où viscosiy
It you operate your equipment below -15 °C (5 °F)
er above 40 °C (104 “F), consult your authorized
‘Yanmar Marine dealer or distributor or special
lubeeants or staring aid,
‘The BLY series engine has an ol or por or
rockor am cover.
The engine has a dipstick on the sight side
An aianal dipstick on the let side is avaliable as
an option (Figure 3-1 on page 3-9.
Auen Temperate
Figure 36
Engine Oil GENERAL SERVICE INFORMATION
Checking the Engine Oil Adding Engine Oil
1. Remove he yellow ol filer port cap from filer
por (1, Figure 3-7) and fil wih engine ol
NOTICE
Prevent dir and debs rom contaminating the
‘engine ol. Careful clean the dipstick and the
surrounding area before you remove the cap
2, Fill oi to the upper limit on the dipstick
(2, Figure 37)
"Never over Ie engine with engine ol
Figure 37
ee 3. Insert the dipstick ul o check the level
1
2. Remove dpi (2, Figure 3-7) and wipe wih NOTICE
can cloth
Always keep the ollovel between upper and
3. Fully reinsert dipstick Iomor nos on the dipstick
4. Remove dipstick. The oil level should bo
between upper and lower Ines onthe dipstick.
5. Addoilifnecessary. See Adding Engine Ol on
page 39.
6. Fully reinsert dipstick
4. Handtigon the filer port cap securely.
YANMAR aus mM
Checking the Engine Oil Adding Engine Oil
1. Remove he yellow ol filer port cap from filer
por (1, Figure 3-7) and fil wih engine ol
NOTICE
Prevent dir and debs rom contaminating the
‘engine ol. Careful clean the dipstick and the
surrounding area before you remove the cap
2, Fill oi to the upper limit on the dipstick
(2, Figure 37)
"Never over Ie engine with engine ol
Figure 37
ee 3. Insert the dipstick ul o check the level
1
2. Remove dpi (2, Figure 3-7) and wipe wih NOTICE
can cloth
Always keep the ollovel between upper and
3. Fully reinsert dipstick Iomor nos on the dipstick
4. Remove dipstick. The oil level should bo
between upper and lower Ines onthe dipstick.
5. Addoilifnecessary. See Adding Engine Ol on
page 39.
6. Fully reinsert dipstick
4. Handtigon the filer port cap securely.
YANMAR aus mM
GENERAL SERVICE INFORMATION
Engine Coolant
ENGINE COOLANT
Engine Coolant Specifications
+ Texaco Long Life Coolant (LLO), both standard
and premixed, product code 7987 and 7908
+ Havolne Extended Life AnteezelGoolant,
Product code 7994
Note: Inthe US, LLC is required for tho
warranty to be vl
NOTICE
Following the manufacturer's recommendations,
use a proper LLC which will not have any adverse
effects on the materials (cast ron, aluminum,
copper, ete) ofthe engine's coating system.
Always use the mixing ratios spectod by the
antireeze manufacturer forthe temperature range.
Coolant (Closed Cooling System)
‘Always add LLC to sol water-especally when
‘operating in cold weather. Never use hard water
Water should be clean and free from sludge or
Particles. Without LLC, cooing performance wi
‘eerease due to scale and ust in the coolant
system, Water alone may treezo and form ico it
‘expands approximately 9% in volume. Use the
proper amount of coolant concentrate forthe
ambient temperature as specild by the LLC
manufacturer. LLC concentration should be a
‘minimum of 30 % 10a maximum of 60%. Too much
LLC wil decrease the cooing efficiency Excessive
use of antireeze als lowers the cooling efficiency
ofthe engine, Never mix diferent ypes or brands of
LG, as a harmful sludge may tom, Mixing diferent
brands of anitreeze may cause chemical reactions,
and may make the antiteeze useless or cause
engine problems.
Checking and Adding Coolant
‘The BLY series engine has filter port onthe coolant
tank.
1. Ensure al drain cocks are closed.
Note: The dain cocks are opened beloro
Shipping rom tho factory
2. Loosen the filer cap (1, Figure 3-8) of he
coolant tank to relieve Ihe pressure, then
remove the filer cap,
Never remove the coolant
engine is hot. Steam and he
will spray out and seriously burn you. Allow
the engine to cool down before you attempt
to remove the cap.
EAS
wii
3. Pour coolant slow Into the cookant tank
(2, Figure 3:8) to avoid air bubbles. Fü un
Coolant overtlows fom te ile port.
NOTICE
Never pourcold coolant into a hot engine
user. YANMAR
Engine Coolant
ENGINE COOLANT
Engine Coolant Specifications
+ Texaco Long Life Coolant (LLO), both standard
and premixed, product code 7987 and 7908
+ Havolne Extended Life AnteezelGoolant,
Product code 7994
Note: Inthe US, LLC is required for tho
warranty to be vl
NOTICE
Following the manufacturer's recommendations,
use a proper LLC which will not have any adverse
effects on the materials (cast ron, aluminum,
copper, ete) ofthe engine's coating system.
Always use the mixing ratios spectod by the
antireeze manufacturer forthe temperature range.
Coolant (Closed Cooling System)
‘Always add LLC to sol water-especally when
‘operating in cold weather. Never use hard water
Water should be clean and free from sludge or
Particles. Without LLC, cooing performance wi
‘eerease due to scale and ust in the coolant
system, Water alone may treezo and form ico it
‘expands approximately 9% in volume. Use the
proper amount of coolant concentrate forthe
ambient temperature as specild by the LLC
manufacturer. LLC concentration should be a
‘minimum of 30 % 10a maximum of 60%. Too much
LLC wil decrease the cooing efficiency Excessive
use of antireeze als lowers the cooling efficiency
ofthe engine, Never mix diferent ypes or brands of
LG, as a harmful sludge may tom, Mixing diferent
brands of anitreeze may cause chemical reactions,
and may make the antiteeze useless or cause
engine problems.
Checking and Adding Coolant
‘The BLY series engine has filter port onthe coolant
tank.
1. Ensure al drain cocks are closed.
Note: The dain cocks are opened beloro
Shipping rom tho factory
2. Loosen the filer cap (1, Figure 3-8) of he
coolant tank to relieve Ihe pressure, then
remove the filer cap,
Never remove the coolant
engine is hot. Steam and he
will spray out and seriously burn you. Allow
the engine to cool down before you attempt
to remove the cap.
EAS
wii
3. Pour coolant slow Into the cookant tank
(2, Figure 3:8) to avoid air bubbles. Fü un
Coolant overtlows fom te ile port.
NOTICE
Never pourcold coolant into a hot engine
user. YANMAR
Checking the Engine Oil and Engine Coolant
GENERAL SERVICE INFORMATION
4. Tighten or cap,
Always tighten the coolant tank cap
securely after checking the coolant tank.
Steam can spray out during engine
‘operation if the cap is loose.
NOTICE
The coolant level ses inthe coolant reservar
tank during operation. Aer stopping the engine,
the coolant wll cool down and the extra coolant
wilreturn to the coolant tank.
5. Check the coolant ave inthe coolant reservoir
tank. The level shouldbe atte FULL mark
‘Add coolanti necessary,
NOTICE
Never pour cold coolant into a hot engine.
Figure 39
6. Remove coolant reservoir tank cap o add
‘coolant it necessary.
7. Replace flr cap and tighten fm. Faure to
0 So wil cause water leakage.
Coolant Reservoir Tank Capacity
NAT
8. Check he rubber hose connecting he coolant
reservoir tank tothe coolant tank/heat
‘exchanger. Replace if damaged,
Note:
+ The level ofthe coolant tank often decrease,
+ The level ofthe reservoir tank does not change.
Ininese cases, there may be water or lr leaks in
the cooing system.
Contact your authorized Yanmar Marine dealer or
istrbuor.
YANMAR 0 000 arcs
CHECKING THE ENGINE OIL
AND ENGINE COOLANT
en engine ci or coolant is supplied forthe fist
time or when they must be replaced, conduct a ial
‘operation ofthe engine and check the quantity ol
engine oll and coolant. The rial engine operation
il send the engine ol and coolant to the
passages, so the engine al and coolant levels will
‘top. Check and resupply as necessary:
1. Approximately 5 minutes ater stopping the
‘engine, remove the ol dipstick (2, Figure 3-7)
‘and check the où el. Adolf ne level is 100
tow
2. Add coolant tothe coolant reservoir tank to stay
‘within the upper oF lower init (Figure 3-9),
GENERAL SERVICE INFORMATION
4. Tighten or cap,
Always tighten the coolant tank cap
securely after checking the coolant tank.
Steam can spray out during engine
‘operation if the cap is loose.
NOTICE
The coolant level ses inthe coolant reservar
tank during operation. Aer stopping the engine,
the coolant wll cool down and the extra coolant
wilreturn to the coolant tank.
5. Check the coolant ave inthe coolant reservoir
tank. The level shouldbe atte FULL mark
‘Add coolanti necessary,
NOTICE
Never pour cold coolant into a hot engine.
Figure 39
6. Remove coolant reservoir tank cap o add
‘coolant it necessary.
7. Replace flr cap and tighten fm. Faure to
0 So wil cause water leakage.
Coolant Reservoir Tank Capacity
NAT
8. Check he rubber hose connecting he coolant
reservoir tank tothe coolant tank/heat
‘exchanger. Replace if damaged,
Note:
+ The level ofthe coolant tank often decrease,
+ The level ofthe reservoir tank does not change.
Ininese cases, there may be water or lr leaks in
the cooing system.
Contact your authorized Yanmar Marine dealer or
istrbuor.
YANMAR 0 000 arcs
CHECKING THE ENGINE OIL
AND ENGINE COOLANT
en engine ci or coolant is supplied forthe fist
time or when they must be replaced, conduct a ial
‘operation ofthe engine and check the quantity ol
engine oll and coolant. The rial engine operation
il send the engine ol and coolant to the
passages, so the engine al and coolant levels will
‘top. Check and resupply as necessary:
1. Approximately 5 minutes ater stopping the
‘engine, remove the ol dipstick (2, Figure 3-7)
‘and check the où el. Adolf ne level is 100
tow
2. Add coolant tothe coolant reservoir tank to stay
‘within the upper oF lower init (Figure 3-9),
ae
O1-E aunbig
HYVIANWA rencores sesos 118
e jo
22
s BIE
D z|m
ross sensor Sól2
CRE
3 r
e >|»
E 5 m
< 2
w 8 2/4
] nm | 8 FIO
1 Oi manga AE E
Ot eooter i 7 7 05
! ı 9 e 7
| Es ET ETT | | & E L 2
E | = | Ss (E
H sie ERA = Sa | 3 >
i 1 een] Y [tan | [ad] ER || S 2
i Gar Trike Esmas] |Lersenee | E 5 rc o
am | Es But [las io “5 Al S z
| = Es wy + à
‘ 2
©
S
nD
a
Same: one
3
2
STILO ETT 5
ODER [Sesso Q
[6100 Ce espero SES 3
[810.03 P_[peypropyers ge
[s 40) RF [Rubens MS u
LO Repuag va
ae ya
[sonia
= fo couts un
Sweuberg Bu
O1-E aunbig
HYVIANWA rencores sesos 118
e jo
22
s BIE
D z|m
ross sensor Sól2
CRE
3 r
e >|»
E 5 m
< 2
w 8 2/4
] nm | 8 FIO
1 Oi manga AE E
Ot eooter i 7 7 05
! ı 9 e 7
| Es ET ETT | | & E L 2
E | = | Ss (E
H sie ERA = Sa | 3 >
i 1 een] Y [tan | [ad] ER || S 2
i Gar Trike Esmas] |Lersenee | E 5 rc o
am | Es But [las io “5 Al S z
| = Es wy + à
‘ 2
©
S
nD
a
Same: one
3
2
STILO ETT 5
ODER [Sesso Q
[6100 Ce espero SES 3
[810.03 P_[peypropyers ge
[s 40) RF [Rubens MS u
LO Repuag va
ae ya
[sonia
= fo couts un
Sweuberg Bu
wenns ESPERANT
ere
Ls asnBig
1/4 rain
Possible 1 extract wale for cooing stem tube
En Laus
For}
Expansion tank
pera
un Zp
hee
L
oan E
a AO cane
Cylinder head RH ES a
De,
A nets =. HI i
Lp] once ton sl |:
8
RP
=
F3
gr
ERAS
Seawater out
arma
A
| Winter temp. sensor
issbl condon (a rated engine speed)
imum ow rte. 160 Iter,
Seawater ine
moma vacuum prossue: 38 kPa
—--— Freshwater ine
SE Name D Time
> (0DJSP [Ste pe
(0, P| Coppsr oo Da [vere
[50.0.5 PP | Pohpropyiens pe i
ORO Raber Ras MES
Fargo DA [ermano
Barjojont
Sereno om momento
Hose coming pra,
102
10D OLEATE ‘OSEATS ‘OZEAT8
weußerq uajsÁs 6
swesberg 6uidig
NOILLVINHOSNI 391AU3S 1VHIN39
ere
Ls asnBig
1/4 rain
Possible 1 extract wale for cooing stem tube
En Laus
For}
Expansion tank
pera
un Zp
hee
L
oan E
a AO cane
Cylinder head RH ES a
De,
A nets =. HI i
Lp] once ton sl |:
8
RP
=
F3
gr
ERAS
Seawater out
arma
A
| Winter temp. sensor
issbl condon (a rated engine speed)
imum ow rte. 160 Iter,
Seawater ine
moma vacuum prossue: 38 kPa
—--— Freshwater ine
SE Name D Time
> (0DJSP [Ste pe
(0, P| Coppsr oo Da [vere
[50.0.5 PP | Pohpropyiens pe i
ORO Raber Ras MES
Fargo DA [ermano
Barjojont
Sereno om momento
Hose coming pra,
102
10D OLEATE ‘OSEATS ‘OZEAT8
weußerq uajsÁs 6
swesberg 6uidig
NOILLVINHOSNI 391AU3S 1VHIN39
pee
HWBENWA wren cones sous me
aie unig
Fuctinot
Hove 1D. ot
0
Peimssibe ve
ma ot98P
3 um pressure: 20 kPa or ess
‚np 08? me 4
es
co À
Fuel overt oti
Fuel color
file onen
Fuel tomo, sr 3
Y “Common tai RH Ha |
3 de
pes 7 srsne .
Zane i
ESSE 4
3 q
de
Sinon
STE CE ML
DCDEMENNTT
[9 (0.)CP | Copper pipe Dave
fs (001 PP [robes
S(O} Rabber pose CRE
[Tios ont
= Banjo joint
[== sam ont
1 [rose cooing
Fue pressure sensor
wesBeiq wayshg ¡ena (ZJOLENT8 (Z)0oseA78 ‘(2)02€A718
NOILVINHOSNI 39/483S 1VHAN39
SweBeig 6uidig
HWBENWA wren cones sous me
aie unig
Fuctinot
Hove 1D. ot
0
Peimssibe ve
ma ot98P
3 um pressure: 20 kPa or ess
‚np 08? me 4
es
co À
Fuel overt oti
Fuel color
file onen
Fuel tomo, sr 3
Y “Common tai RH Ha |
3 de
pes 7 srsne .
Zane i
ESSE 4
3 q
de
Sinon
STE CE ML
DCDEMENNTT
[9 (0.)CP | Copper pipe Dave
fs (001 PP [robes
S(O} Rabber pose CRE
[Tios ont
= Banjo joint
[== sam ont
1 [rose cooing
Fue pressure sensor
wesBeiq wayshg ¡ena (ZJOLENT8 (Z)0oseA78 ‘(2)02€A718
NOILVINHOSNI 39/483S 1VHAN39
SweBeig 6uidig
Location of Nameplate GENERAL SERVICE INFORMATION
LOCATION OF NAMEPLATE
The nameplate of Yanmar BLY series engines are
shown in Figure 3-13. Check the engine's model,
‘output, rpm and serial number on the nameplate.
Please replace if damaged or lest.
“The engine nameplate is attached tothe top
surface ofthe engine air cooler (Figure 3-18),
Figure 3-13
Figure 3-14
YANMAR sis oe
LOCATION OF NAMEPLATE
The nameplate of Yanmar BLY series engines are
shown in Figure 3-13. Check the engine's model,
‘output, rpm and serial number on the nameplate.
Please replace if damaged or lest.
“The engine nameplate is attached tothe top
surface ofthe engine air cooler (Figure 3-18),
Figure 3-13
Figure 3-14
YANMAR sis oe
GENERAL SERVICE INFORMATION
Principal Engine Specifications
PRINCIPAL ENGINE SPECIFICATIONS
8LV Series Engine Speci
Engine Model EX EXEC ENE TO)
Tee Pleasure use
Type Va Oye, water cooled diesel engine
rarkchaf tation (viewed om whe) ‘Gounterdockise
Combustion system Dirección
spain Turbo charger with ar er
Nurber of finders vs
Fig oder TAT S4568
Bore ao Smm- mm Sain 38m)
Diplacement 4461 E (72 Guin)
High ding speed 4000 = 25 min
Tow iding speed 50225 mine
Continous rating ouput at anale ET ESTU ET
(a1 8083 ma (pm) (291 PS) 18PS) (697 PS)
eaximam ouput at ran 235 KW EU EAU
{at 8800 mar! om) (820 PS) 212 (703)
instalation ble mouning
Main power take of Allies end
Coting system Freshwateroocing wih heal exchanger
Engine rio apse
Engine ol capaci at rake ange 07
(Eteciveot
nelosed forced with rochod pump
e108 (mos q)
Oi pressure max ang
EP A TIPS
‘Oi pressure ow ee at 550 min (mm)
60 KPa (= 87 PSI)
Turbocharger MITOS
Suter mar DEV 27
orar VIDA
Orla Tes mn ot m)
Ergin mension [veal wath A rm (3480)
Droga 7535 mm (9085)
Dey wich (ih mae gear EE
mu Bary capacity
FEV IZDA Pour rat, 6 14BGBT or SNIE
Principal Engine Specifications
PRINCIPAL ENGINE SPECIFICATIONS
8LV Series Engine Speci
Engine Model EX EXEC ENE TO)
Tee Pleasure use
Type Va Oye, water cooled diesel engine
rarkchaf tation (viewed om whe) ‘Gounterdockise
Combustion system Dirección
spain Turbo charger with ar er
Nurber of finders vs
Fig oder TAT S4568
Bore ao Smm- mm Sain 38m)
Diplacement 4461 E (72 Guin)
High ding speed 4000 = 25 min
Tow iding speed 50225 mine
Continous rating ouput at anale ET ESTU ET
(a1 8083 ma (pm) (291 PS) 18PS) (697 PS)
eaximam ouput at ran 235 KW EU EAU
{at 8800 mar! om) (820 PS) 212 (703)
instalation ble mouning
Main power take of Allies end
Coting system Freshwateroocing wih heal exchanger
Engine rio apse
Engine ol capaci at rake ange 07
(Eteciveot
nelosed forced with rochod pump
e108 (mos q)
Oi pressure max ang
EP A TIPS
‘Oi pressure ow ee at 550 min (mm)
60 KPa (= 87 PSI)
Turbocharger MITOS
Suter mar DEV 27
orar VIDA
Orla Tes mn ot m)
Ergin mension [veal wath A rm (3480)
Droga 7535 mm (9085)
Dey wich (ih mae gear EE
mu Bary capacity
FEV IZDA Pour rat, 6 14BGBT or SNIE
Principal Engine Specifications. GENERAL SERVICE INFORMATION
m Cylinder Arrangement
000 |
Koooch
Figure 3.15
8LV Series Marine Gear Specifications
av er
Engine Model aa
ann
Mars geared CE Ta BER
Spectzaon EE ES
E T7210 248 —| 120,450,208, 2aT | 185178
Tubing eng (EME | 0420704210) | GABA 046709 | 289239
Dry weight seen | siga | 100% 21 B)
YANMAR su wos conso tons
m Cylinder Arrangement
000 |
Koooch
Figure 3.15
8LV Series Marine Gear Specifications
av er
Engine Model aa
ann
Mars geared CE Ta BER
Spectzaon EE ES
E T7210 248 —| 120,450,208, 2aT | 185178
Tubing eng (EME | 0420704210) | GABA 046709 | 289239
Dry weight seen | siga | 100% 21 B)
YANMAR su wos conso tons
GENERAL SERVICE INFORMATION Principal Engine Specifications
This Page Intentionally Left Blank
21. user. YANMAR
This Page Intentionally Left Blank
21. user. YANMAR
Section 4
ENGINE
Page
Salety Precautions 43
Introduction 43
Disassembling the Engine and Components pa
Precautions Boloro Engine Disassombly 43
Special Tool... 44
SST. 45
General Hand Tools az
Special Hand Tool 43
‘Tool Usage. 49
Sealants, Adhosivs, Lubricans and Cioanors. an
Engine Diassemby. 412
Engine Assembly. 449
Engine Inspection. 4122
YANMAR www cercos
ENGINE
Page
Salety Precautions 43
Introduction 43
Disassembling the Engine and Components pa
Precautions Boloro Engine Disassombly 43
Special Tool... 44
SST. 45
General Hand Tools az
Special Hand Tool 43
‘Tool Usage. 49
Sealants, Adhosivs, Lubricans and Cioanors. an
Engine Diassemby. 412
Engine Assembly. 449
Engine Inspection. 4122
YANMAR www cercos
ENGINE
This Page Intentionally Left Blank
… sms YANMAR
This Page Intentionally Left Blank
… sms YANMAR
Safety Precautions
SAFETY PRECAUTIONS
Before servicing the engine, review the Safty
Section on page 2-1
INTRODUCTION
This section of the Service Manual describes the
disassombay inspection and reassombly ofthe 8LV
series engines.
YANMAR 209 coo: 000 ares
ENGINE
DISASSEMBLING THE ENGINE
AND COMPONENTS
Precautions Before Engine
Disassembly
+ Diagnose the cause of he trouble, and
disassemble only those parts which are
necessary.
+ Keep all disassembled parts in oder.
+ Have all required tools on hand,
+ Clean parts with an approved ceaner in a
suitable location.
+ Clear an adequate area for removed parts and
prepare a container.
+ Drain coolant, seawater and ol
+ Close the seacock
SAFETY PRECAUTIONS
Before servicing the engine, review the Safty
Section on page 2-1
INTRODUCTION
This section of the Service Manual describes the
disassombay inspection and reassombly ofthe 8LV
series engines.
YANMAR 209 coo: 000 ares
ENGINE
DISASSEMBLING THE ENGINE
AND COMPONENTS
Precautions Before Engine
Disassembly
+ Diagnose the cause of he trouble, and
disassemble only those parts which are
necessary.
+ Keep all disassembled parts in oder.
+ Have all required tools on hand,
+ Clean parts with an approved ceaner in a
suitable location.
+ Clear an adequate area for removed parts and
prepare a container.
+ Drain coolant, seawater and ol
+ Close the seacock
ENGINE Special Tools
SPECIAL TOOLS
The folowing tools are required when disassembling and reassembing the engine rubber mount
Please use them as instructed,
26)
pS
Par No: 11970802120
SPECIAL TOOLS
The folowing tools are required when disassembling and reassembing the engine rubber mount
Please use them as instructed,
26)
pS
Par No: 11970802120
‘Special Tools ENGINE
sst
Toot Name Inseraten
Ian so EA csrosors
sst
Toot Name Inseraten
Ian so EA csrosors
‘Special Tools
ENGINE
NOA Pao)
AL
Ÿ
3
=)
or
LA,
a |
22
es go
vasa M
o
ENGINE
NOA Pao)
AL
Ÿ
3
=)
or
LA,
a |
22
es go
vasa M
o
‘Special Tools ENGINE
General Hand Tools
LIT DS Fe
sonne 00.7
nen
>
ee
ET
ET
(=
=
pu E de
scr .
see =
emt =
YANMAR 0 000 arcs
General Hand Tools
LIT DS Fe
sonne 00.7
nen
>
ee
ET
ET
(=
=
pu E de
scr .
see =
emt =
YANMAR 0 000 arcs
ENGINE Special Tools
Special Hand Tools
Local surely
Special Hand Tools
Local surely
‘Special Tools ENGINE
Tool Usage
Messe st bending, sion
+ |Datinsear lens a spe
Massana on aod cea ples wich
2 [Yen sour toner be measure wi a dl sao.
3 [magna sand Keeps ha gage try patin
©
a
¿
pm
L
lasse a inner am tte ir
5 | ovine: case nr and bongs
6 |Vemerenper Er
7 | Dept metemete
| square os and aan fens.
si nt man a ares. CA
0
‘soso on bos and nts oo
10 [Forint sand.
YANMAR soon «o
Tool Usage
Messe st bending, sion
+ |Datinsear lens a spe
Massana on aod cea ples wich
2 [Yen sour toner be measure wi a dl sao.
3 [magna sand Keeps ha gage try patin
©
a
¿
pm
L
lasse a inner am tte ir
5 | ovine: case nr and bongs
6 |Vemerenper Er
7 | Dept metemete
| square os and aan fens.
si nt man a ares. CA
0
‘soso on bos and nts oo
10 [Forint sand.
YANMAR soon «o
ENGINE Special Tools
We LIT Tee LE
sessires sh cts Demente ng and
11 [raserguao ner a shat and eat
fmt e ee sary,
2 | Rado cs
sn E,
8 | sara cor too
4 | Dian nemomate Mesas tempera varios pas.
ensure te ttn speedy ga.
conser ype | eotar not whichis paca on acom!
coro al
| Terorsiae
assure he san spas ga
Phone ype | atrae ich placed te arr
ere
some assure ne essence, otage aná
‘Yor Grice won) only are al ico
We LIT Tee LE
sessires sh cts Demente ng and
11 [raserguao ner a shat and eat
fmt e ee sary,
2 | Rado cs
sn E,
8 | sara cor too
4 | Dian nemomate Mesas tempera varios pas.
ensure te ttn speedy ga.
conser ype | eotar not whichis paca on acom!
coro al
| Terorsiae
assure he san spas ga
Phone ype | atrae ich placed te arr
ere
some assure ne essence, otage aná
‘Yor Grice won) only are al ico
‘Special Tools ENGINE
Sealants, Adhesives, Lubricants and Cleaners
em Tra oa EI
amero |, 2090 LE pur sort sa ame.
passes Lau EEE
RTE EI EL Er
m ee een costa apro fu
‘alia avalabie) resistance.
A er
sus ES
A | Bg, Il
ene cgi | etary aa ee
Twente] O
Ter211 912502) |remperature areas (50° to 250 °C (-58" to 482 °F)
a gern
er namen „FE Emm a men Tanz
on LI e Mao Son bo. 1018 20% ago an tog ra
ters SUPER | sagen) | Exatent acres rang boue bots zamarany
A | SRA SRE sep a
sue ge [eee
een
Saas re
{LOWCOL PASTE) 50.9117 22) | por assembly of engine cylinders, pistons, marais shat, et.
[EP Men Brand name ray Type faciitates application work.
[Molybdenum | Paste spaavı soguzon [PU
a
Sane ve | PRA cae aran aries
EE FESSES
Tier RTE TU
CE A | ma
rm + |. Popa te code (na oso an arcu at
= Te ER
u | |
MC |. Depa srsentiniattoshet enon sale Te
se soe Rent
+ cman ptr paa et
ie sone - | Nesta ed sr ne or. roots
sh Eee pets pare
See om ow are rane ee
ES
= a oe
Ten
mean = |: decenio nine pepe 604% acs eee
Borate ny serene her
TO
eee o ose comitat rues ro wa py
Cieanng agent tortubecharger LET Genres tor Slower oltoochrgor und charge at coo
PAN
YANMAR su wos conso tons
Sealants, Adhesives, Lubricants and Cleaners
em Tra oa EI
amero |, 2090 LE pur sort sa ame.
passes Lau EEE
RTE EI EL Er
m ee een costa apro fu
‘alia avalabie) resistance.
A er
sus ES
A | Bg, Il
ene cgi | etary aa ee
Twente] O
Ter211 912502) |remperature areas (50° to 250 °C (-58" to 482 °F)
a gern
er namen „FE Emm a men Tanz
on LI e Mao Son bo. 1018 20% ago an tog ra
ters SUPER | sagen) | Exatent acres rang boue bots zamarany
A | SRA SRE sep a
sue ge [eee
een
Saas re
{LOWCOL PASTE) 50.9117 22) | por assembly of engine cylinders, pistons, marais shat, et.
[EP Men Brand name ray Type faciitates application work.
[Molybdenum | Paste spaavı soguzon [PU
a
Sane ve | PRA cae aran aries
EE FESSES
Tier RTE TU
CE A | ma
rm + |. Popa te code (na oso an arcu at
= Te ER
u | |
MC |. Depa srsentiniattoshet enon sale Te
se soe Rent
+ cman ptr paa et
ie sone - | Nesta ed sr ne or. roots
sh Eee pets pare
See om ow are rane ee
ES
= a oe
Ten
mean = |: decenio nine pepe 604% acs eee
Borate ny serene her
TO
eee o ose comitat rues ro wa py
Cieanng agent tortubecharger LET Genres tor Slower oltoochrgor und charge at coo
PAN
YANMAR su wos conso tons
ENGINE Engine Disassembly
ENGINE DISASSEMBLY
Pas Temiow to Dizsorbe stration
+ [Remove the Top Cover 7
1. Remove Ihe tp cover wih the studs and nus
3° [Remove the Engine Control Unt (ECU)
1 Remove he Engine Control Um (ECU) wth ho bots
3 [Remove tie Engine Wire
rare.
Cars pan sos Era sun sar
pere Ceres
u. essere Mars YANMAR
ENGINE DISASSEMBLY
Pas Temiow to Dizsorbe stration
+ [Remove the Top Cover 7
1. Remove Ihe tp cover wih the studs and nus
3° [Remove the Engine Control Unt (ECU)
1 Remove he Engine Control Um (ECU) wth ho bots
3 [Remove tie Engine Wire
rare.
Cars pan sos Era sun sar
pere Ceres
u. essere Mars YANMAR
Engine Disassembly
ENGINE
Toman to Dinssomble
Tiuetraon
[Remove he Belt Cover
Y Remove he bel cover.
| Remove the Breather Howe
1. Remove the breather hose (3).
2. Remove the seawater pipe (2) and rubor hose (1
5 [Remove the Exhowst Band
1 Remove the V’band (2) and bracket (3,
2. Remove the exhaust bona (1) and mig elbow (4
YANMAR su wos conso tons
ENGINE
Toman to Dinssomble
Tiuetraon
[Remove he Belt Cover
Y Remove he bel cover.
| Remove the Breather Howe
1. Remove the breather hose (3).
2. Remove the seawater pipe (2) and rubor hose (1
5 [Remove the Exhowst Band
1 Remove the V’band (2) and bracket (3,
2. Remove the exhaust bona (1) and mig elbow (4
YANMAR su wos conso tons
ENGINE Engine Disassembly
Pea Temfiow to Disassemble Msiration
7 Remove the Turbocharger
Y Remove the turbocharge lbicating ol net pe (5)
and ut pipe (4).
2. Ramone tne mts (2,
5. Ramone the turbocharger (1) (RH sido nd LH id).
4, Remove Io gasket (2,
8 [Remove the Charge Al Cooler
1. Remove the 2 bolts (5) andthe hanger suppor (4)
fist
2 Remove the ai duct 2) and gasket (3)
5. Remove the charge a cooler (1.
Pea Temfiow to Disassemble Msiration
7 Remove the Turbocharger
Y Remove the turbocharge lbicating ol net pe (5)
and ut pipe (4).
2. Ramone tne mts (2,
5. Ramone the turbocharger (1) (RH sido nd LH id).
4, Remove Io gasket (2,
8 [Remove the Charge Al Cooler
1. Remove the 2 bolts (5) andthe hanger suppor (4)
fist
2 Remove the ai duct 2) and gasket (3)
5. Remove the charge a cooler (1.
Engine Disassembly ENGINE
ear Toman to Dienssembi Miostraon,
‘| Remove the Fuel Oil Cooler
1. Remove he seawater pipes) 9
2 Remove the let ol cose (1).
10 | Remove the Heat Exchanger
1. Remove the bolts (2) (9) aed the hea exchanger (1).
2 Remove he bats (5) (6) and bracket)
YANMAR 209 coo: 000 ares as,
ear Toman to Dienssembi Miostraon,
‘| Remove the Fuel Oil Cooler
1. Remove he seawater pipes) 9
2 Remove the let ol cose (1).
10 | Remove the Heat Exchanger
1. Remove the bolts (2) (9) aed the hea exchanger (1).
2 Remove he bats (5) (6) and bracket)
YANMAR 209 coo: 000 ares as,
ENGINE
Engine Disassembly
Pea
Temfow to Disassemble
Msiration
Remove the Exhaust Manifold (AH and LH Side)
Remove he bat (5) annul (4 fom the cyinder
head
2. Remove the exhaust manto (9) (RH se),
the gasket 2 and studs (1),
move the exhaust mandold onthe LH ide in the
12 | Remove the FiyuhestHousing
1. Remove tho bots (2) an het housing (1).
73 | Remove the Coupling
Y Remove he 8 als ana the coupling (3.
14 [Remove the Spacer
1 Remove he 8 bol and he space 2)
TS | Remove the Fywhoot
{Remove the bla and the ht (2)
u essere Mars YANMAR
Engine Disassembly
Pea
Temfow to Disassemble
Msiration
Remove the Exhaust Manifold (AH and LH Side)
Remove he bat (5) annul (4 fom the cyinder
head
2. Remove the exhaust manto (9) (RH se),
the gasket 2 and studs (1),
move the exhaust mandold onthe LH ide in the
12 | Remove the FiyuhestHousing
1. Remove tho bots (2) an het housing (1).
73 | Remove the Coupling
Y Remove he 8 als ana the coupling (3.
14 [Remove the Spacer
1 Remove he 8 bol and he space 2)
TS | Remove the Fywhoot
{Remove the bla and the ht (2)
u essere Mars YANMAR
Engine Disassembly ENGINE
Tear Hanıow to Dinssomble Miosiraton,
1 Remove the Fuel Oi Fiter
1 Remoue the felt (2) and cule pipe (3.
2 Remove hotel tr (3) om the Ica ol iter
‘bracket.
7 Remove the Lubricating Oil Fiter
1 Remove the lbrating oie).
union (2) fom the bracket (9)
here fo neces.
1. Tum the bettensoner counterclockwise and loosen
the V bed bl.
2, Remove!
erator instalation bo (1)
5 Remove the aerator
4 ithe pis (2) ao abraded, remove hom.
YANMAR 209 coo: 000 ares ar
Tear Hanıow to Dinssomble Miosiraton,
1 Remove the Fuel Oi Fiter
1 Remoue the felt (2) and cule pipe (3.
2 Remove hotel tr (3) om the Ica ol iter
‘bracket.
7 Remove the Lubricating Oil Fiter
1 Remove the lbrating oie).
union (2) fom the bracket (9)
here fo neces.
1. Tum the bettensoner counterclockwise and loosen
the V bed bl.
2, Remove!
erator instalation bo (1)
5 Remove the aerator
4 ithe pis (2) ao abraded, remove hom.
YANMAR 209 coo: 000 ares ar
ENGINE
Engine Disassembly
Pes
Temfiow to Disassemble
Msiration
Disassembly ofthe Saawater Pump
4: Remove te Urea bet (1
2: Remove the pump instalation bots (MS 4 unt (2)
and seawater pump (3).
Femove the Ling Brackat
Y Remove he fiyaneel side engine ting bracket
2. Remove the engine tin racket on the opposite
sde ol theo
a
Remove the Engine Dive Unit (EDU)
1. Remove he EDU, viraion roo uber and
brackets,
Engine Disassembly
Pes
Temfiow to Disassemble
Msiration
Disassembly ofthe Saawater Pump
4: Remove te Urea bet (1
2: Remove the pump instalation bots (MS 4 unt (2)
and seawater pump (3).
Femove the Ling Brackat
Y Remove he fiyaneel side engine ting bracket
2. Remove the engine tin racket on the opposite
sde ol theo
a
Remove the Engine Dive Unit (EDU)
1. Remove he EDU, viraion roo uber and
brackets,
Engine Disassembly
ENGINE
Tear
Hanıow to Dienssembi
Tiuetraton
Remove the Grankshat Pulley
‘This procedure sintondedtorthe removainstalation
the crankshal pul only. Do not us this
procedure forthe removalintalaon of he ywhoel
‘ive plate and ing gar
{Install the 2 bots tthe bot holes ofthe eankshal
rear sido
2. Using’ br, um th crankshaft uni the crankshal
ploy servo hole itl othe lta the batom
‘Sead centr
Install 14 mm » 15 ich semis bok with alent
‘of 70 mm or more to he crankshal ply sevice
hoe, ad ol he erankhaf using the ting chain
cover pren.
E
iemove he Chain Cover and Compressor Bracket
Disconnect the wre hares.
2 Remove he bol chain cover and compressor
bracket.
E
Remove the Fan Bracket Sub Assembly
"Remove the 4 ote alan bracket,
F
‘Disconnect the Cooler Hose
1 Disconnect he No and No, 2 ll colo hoses
YANMAR 209 coo: 000 ares
ENGINE
Tear
Hanıow to Dienssembi
Tiuetraton
Remove the Grankshat Pulley
‘This procedure sintondedtorthe removainstalation
the crankshal pul only. Do not us this
procedure forthe removalintalaon of he ywhoel
‘ive plate and ing gar
{Install the 2 bots tthe bot holes ofthe eankshal
rear sido
2. Using’ br, um th crankshaft uni the crankshal
ploy servo hole itl othe lta the batom
‘Sead centr
Install 14 mm » 15 ich semis bok with alent
‘of 70 mm or more to he crankshal ply sevice
hoe, ad ol he erankhaf using the ting chain
cover pren.
E
iemove he Chain Cover and Compressor Bracket
Disconnect the wre hares.
2 Remove he bol chain cover and compressor
bracket.
E
Remove the Fan Bracket Sub Assembly
"Remove the 4 ote alan bracket,
F
‘Disconnect the Cooler Hose
1 Disconnect he No and No, 2 ll colo hoses
YANMAR 209 coo: 000 ares
ENGINE
Engine Disassembly
Pea
Temfiow to Disassemble
Msiration
remove the leer Pulley
1 Remove the ba (C) and ier puy.
E
Lal
1. Side ho clamp and remove the water bypass pipe.
35 | Remove the Intake Pipe
1. Remove he 4 bols, 2 nuts andinike pipe.
2 Remove he gasket.
30 | Remove the No. 2 Engine Wire
1. Disconnect the star connecter.
2. Remove the nt and disconnect the state wire
ames,
3. Discomact he wir hamess clamp,
Remove the Sot
Engine Disassembly
Pea
Temfiow to Disassemble
Msiration
remove the leer Pulley
1 Remove the ba (C) and ier puy.
E
Lal
1. Side ho clamp and remove the water bypass pipe.
35 | Remove the Intake Pipe
1. Remove he 4 bols, 2 nuts andinike pipe.
2 Remove he gasket.
30 | Remove the No. 2 Engine Wire
1. Disconnect the star connecter.
2. Remove the nt and disconnect the state wire
ames,
3. Discomact he wir hamess clamp,
Remove the Sot
Engine Disassembly
ENGINE
Tear
Tomo to Dienssembi
uso.
ve the No.6 Injection Pipe Sub-Assambly
Mer among ue pipe fo prevent ito foreign
(jet rom entering he pe int cover the
common ral vil letal aps, Also protect the
ecole with electrical ape or pls bags.
1. Remove the 2 nuts and 2 pipe camps.
2. Using SST, toon tho union nts and remove the
inecton pipe.
®
Remove the Injection Pipe RH
Nor omg the fuel pipe 1 prevent ito foreign
‘object rom entering he pe int cover the
common ral vil letal ape, Also protect the
Injector dete with electrical ape or plastic bags.
1.Using SST, loosen the union nuts and remove the 4
injection pipes.
= DAA
Famove tha Injection Pipe LH
Mer moving the ue pipe, fo prevent ito foreign
jc rom entering he pe Inle, cover the
common tal vih etai tape, Alo protect the
injector lee wäh electrical ape or pa bag:
1. Using SST, loosen the union nus and remove he 4
injection ps.
YANMAR 209 coo: 000 ares
ENGINE
Tear
Tomo to Dienssembi
uso.
ve the No.6 Injection Pipe Sub-Assambly
Mer among ue pipe fo prevent ito foreign
(jet rom entering he pe int cover the
common ral vil letal aps, Also protect the
ecole with electrical ape or pls bags.
1. Remove the 2 nuts and 2 pipe camps.
2. Using SST, toon tho union nts and remove the
inecton pipe.
®
Remove the Injection Pipe RH
Nor omg the fuel pipe 1 prevent ito foreign
‘object rom entering he pe int cover the
common ral vil letal ape, Also protect the
Injector dete with electrical ape or plastic bags.
1.Using SST, loosen the union nuts and remove the 4
injection pipes.
= DAA
Famove tha Injection Pipe LH
Mer moving the ue pipe, fo prevent ito foreign
jc rom entering he pe Inle, cover the
common tal vih etai tape, Alo protect the
injector lee wäh electrical ape or pa bag:
1. Using SST, loosen the union nus and remove he 4
injection ps.
YANMAR 209 coo: 000 ares
ENGINE Engine Disassembly
Pes Temfiow to Disassemble Msiration
©: | Remove the Fuel Hose
Sie the lamps and remove he tel hose.
Remove the No.6 Fuel Pipe Sub:Assombly
1: Remove he bol and injection pipe mp.
2: Remove the camp and isconnect hs hose
2: Remove the nt, nio bo el pipe and gaste.
Remove the Common Ral RH
1. Using SST, Base Ihe union nut and disconnect the
No 3 mjecion pipe
2. Disconnect te tel pressure sensor connecter.
2: Remove the 2 bots and common a
Do not remove Ihe Tal pressure sensor rm the
‘common rl. removed, replace the common al
F
Remove the Common Rall Lt
1. Remove the 2 bole and common rai.
Do no remove tho Tal pressure sensor rom the
common ra removed, replace the common al
Pes Temfiow to Disassemble Msiration
©: | Remove the Fuel Hose
Sie the lamps and remove he tel hose.
Remove the No.6 Fuel Pipe Sub:Assombly
1: Remove he bol and injection pipe mp.
2: Remove the camp and isconnect hs hose
2: Remove the nt, nio bo el pipe and gaste.
Remove the Common Ral RH
1. Using SST, Base Ihe union nut and disconnect the
No 3 mjecion pipe
2. Disconnect te tel pressure sensor connecter.
2: Remove the 2 bots and common a
Do not remove Ihe Tal pressure sensor rm the
‘common rl. removed, replace the common al
F
Remove the Common Rall Lt
1. Remove the 2 bole and common rai.
Do no remove tho Tal pressure sensor rom the
common ra removed, replace the common al
Engine Disassembly
ENGINE
Fea
Hanıon to Dienssembi
uso.
Femave the No. Injection Pipe Sub-Assambiy
1. Using ST, loosen o union nut and remove the
No.8 injection ip.
39 | Remove the Fuel Pump Motor Wire
{Remove the 2 bots
0 [Remove the Wo. 3 intake Manifold
1 Remove the 16 bls, 2 gaskets and intake manila
a
Remo the No.4 Nozzio Leakage Pipe Assembly
1. remove the camp and dsconneat the ose,
2 Remove the union bol and gasket,
3 Remove the bl and nazleleskage pipe.
am. late
YANMAR soon
ENGINE
Fea
Hanıon to Dienssembi
uso.
Femave the No. Injection Pipe Sub-Assambiy
1. Using ST, loosen o union nut and remove the
No.8 injection ip.
39 | Remove the Fuel Pump Motor Wire
{Remove the 2 bots
0 [Remove the Wo. 3 intake Manifold
1 Remove the 16 bls, 2 gaskets and intake manila
a
Remo the No.4 Nozzio Leakage Pipe Assembly
1. remove the camp and dsconneat the ose,
2 Remove the union bol and gasket,
3 Remove the bl and nazleleskage pipe.
am. late
YANMAR soon
ENGINE
Engine Disassembly
Temfiow to Disassemble
Msiration
Remove the No. 3 Nozzle Leakage Pipe Assembly
1. Remove the clamp and disconect he hose
2: Remove ine union ol and gasket
2: Remove te alt and nro leskage pp.
#
Remove the No 1 Water By-Pass Pipe
Y Remove he union bot and 2 gasket,
2 Remove the bal and water by psss pe.
Remove the Fuel Pump Motor Wire
"Disconnect the 2 connectors
Remove the No. 1 Fuel Pipe
1. Remove he union bol, (ul pipe and 2 gaskets,
Engine Disassembly
Temfiow to Disassemble
Msiration
Remove the No. 3 Nozzle Leakage Pipe Assembly
1. Remove the clamp and disconect he hose
2: Remove ine union ol and gasket
2: Remove te alt and nro leskage pp.
#
Remove the No 1 Water By-Pass Pipe
Y Remove he union bot and 2 gasket,
2 Remove the bal and water by psss pe.
Remove the Fuel Pump Motor Wire
"Disconnect the 2 connectors
Remove the No. 1 Fuel Pipe
1. Remove he union bol, (ul pipe and 2 gaskets,
Engine Disassembly ENGINE
Fear Hanıow to Dissomble Tiuetraton
a
Remove the No. Intake Manifold
1 Remove the 9 bots take mano and gasket.
35 [Remove tho Fuel Pump Motor Wire
1 Remoue the We! pump maton wir,
Remove the No. Y Glow Plug Connector
1. Remove the 2 serew grommets and 2 nuts, and
(iscomect the 2 wre harnesses
2.Romove the 8 serew grommets, nuts and glow
plug connectors.
YANMAR cc sexos
Fear Hanıow to Dissomble Tiuetraton
a
Remove the No. Intake Manifold
1 Remove the 9 bots take mano and gasket.
35 [Remove tho Fuel Pump Motor Wire
1 Remoue the We! pump maton wir,
Remove the No. Y Glow Plug Connector
1. Remove the 2 serew grommets and 2 nuts, and
(iscomect the 2 wre harnesses
2.Romove the 8 serew grommets, nuts and glow
plug connectors.
YANMAR cc sexos
ENGINE
Engine Disassembly
Pea
Temfiow to Disassemble
Msiration
Remove the Glow Plug Assembly
{Using a 10 mm deep socket wrench, move the 8
lw plugs.
a
Remove the Mozzi Holder Seal AF
Using a smal acrewsive rome the 4 holder onto
‘pring the potion been each holder sean
the cou par ofthe cylinder head cover.
oe
Tape the screwtive tp before use
Fomova the Nozzi Holder Soal LH
4 Using a smal crewaiver remove the 4 holder seals
‘pring the potion been cach holder sealand
the cou par cl the cylinder hand covet.
Noe
Tape he scroudivo ip lo use.
Engine Disassembly
Pea
Temfiow to Disassemble
Msiration
Remove the Glow Plug Assembly
{Using a 10 mm deep socket wrench, move the 8
lw plugs.
a
Remove the Mozzi Holder Seal AF
Using a smal acrewsive rome the 4 holder onto
‘pring the potion been each holder sean
the cou par ofthe cylinder head cover.
oe
Tape the screwtive tp before use
Fomova the Nozzi Holder Soal LH
4 Using a smal crewaiver remove the 4 holder seals
‘pring the potion been cach holder sealand
the cou par cl the cylinder hand covet.
Noe
Tape he scroudivo ip lo use.
Engine Disassembly
ENGINE
ear
Hamıon to Dinssomble
Tiuetaton
Famove the Ol Separator Assembly
1.Side the clamp and asconneat he hose
2 Remove the 3 bots ol separator and gasket.
5
5
Femove the Cylinder Head Cover Sub Assembly RH
1 Remove the 16 bols cylinder headcover and gust
emov the Cylinder Head Gover Sub-Assambiy LH
1 Sid the clamp and isoonnet the No. S vention
hose
2. Remove he 17 bois, cyinder head cover and gast
=
Remove the Fuel Injector LH
1 Remove the unin bo, holow crew, 5 gaskets
‘and No 2nazl leakage pipe,
+ When removing the norze leakage pipe place a
‘cushion under the pipe
+ Be nel no! deform or seats union sea
aura.
+ Ar removing the tulipe put in aplastic bag
16 preven foreign mar rom contaminating ts
injector init
2. Remove the 4 bots, 4 washers, & pozle holder
‘lamps and injectors,
‘note
“Arango the injectors, holder camp, washers and
bate in imo cornet order.
3.Remove he Oring ram each injector.
& Remove ine injection nozzle sets fromthe cylinder
hend,
YANMAR cc conso tons
ENGINE
ear
Hamıon to Dinssomble
Tiuetaton
Famove the Ol Separator Assembly
1.Side the clamp and asconneat he hose
2 Remove the 3 bots ol separator and gasket.
5
5
Femove the Cylinder Head Cover Sub Assembly RH
1 Remove the 16 bols cylinder headcover and gust
emov the Cylinder Head Gover Sub-Assambiy LH
1 Sid the clamp and isoonnet the No. S vention
hose
2. Remove he 17 bois, cyinder head cover and gast
=
Remove the Fuel Injector LH
1 Remove the unin bo, holow crew, 5 gaskets
‘and No 2nazl leakage pipe,
+ When removing the norze leakage pipe place a
‘cushion under the pipe
+ Be nel no! deform or seats union sea
aura.
+ Ar removing the tulipe put in aplastic bag
16 preven foreign mar rom contaminating ts
injector init
2. Remove the 4 bots, 4 washers, & pozle holder
‘lamps and injectors,
‘note
“Arango the injectors, holder camp, washers and
bate in imo cornet order.
3.Remove he Oring ram each injector.
& Remove ine injection nozzle sets fromthe cylinder
hend,
YANMAR cc conso tons
ENGINE Engine Disassembly
Pes Temfiow to Disassemble Msiration
57 _| Remove the Fuel Injector BH
‘Remove he union bo, 4 bolo crew, 5 gaskets
and nro leakage pe
+ Wien removing the nozzle leakage pipe place a
cushion under he pipe.
+ Be cael nto deform or seatch the union seat
suce
+ Aller removing the ue pie, pu tina plas bag
to provent foreign mater rom containing ts
injector
2. Remove ie 4 bol, 4 washers, 4 nozle haider
lamps and 4 ijectors
Note
“Arango the injectors, holder clamps, washers and
bots in he corec order.
3, Remove ine O-ing om each nic.
4: Remove the injection nozzle seats amtha onder
hea
56 | Remove tho Wator Pump Assombly
1. Romovo te 9 bols, 2 nul, water pump and gaste,
59 | Remove th Crankshaft Poston Sensor
1. Remove he bot and sensor
Pes Temfiow to Disassemble Msiration
57 _| Remove the Fuel Injector BH
‘Remove he union bo, 4 bolo crew, 5 gaskets
and nro leakage pe
+ Wien removing the nozzle leakage pipe place a
cushion under he pipe.
+ Be cael nto deform or seatch the union seat
suce
+ Aller removing the ue pie, pu tina plas bag
to provent foreign mater rom containing ts
injector
2. Remove ie 4 bol, 4 washers, 4 nozle haider
lamps and 4 ijectors
Note
“Arango the injectors, holder clamps, washers and
bots in he corec order.
3, Remove ine O-ing om each nic.
4: Remove the injection nozzle seats amtha onder
hea
56 | Remove tho Wator Pump Assombly
1. Romovo te 9 bols, 2 nul, water pump and gaste,
59 | Remove th Crankshaft Poston Sensor
1. Remove he bot and sensor
Engine Disassembly
ENGINE
ea
Ton to Dnssombie
Tiuetraton
Remove the Timing Chain Cover Sub Assembly
Yo Remove ha à rte and 16 ote,
2. Using a seoudve, remove ho timing chain cover
"oy ing between the timing chain cœur and cylinder
head or ender Bock,
Tape the serewära ip beore use
3 Remove the Ong ram the ning gar.
YANMAR su wos conso tons
ENGINE
ea
Ton to Dnssombie
Tiuetraton
Remove the Timing Chain Cover Sub Assembly
Yo Remove ha à rte and 16 ote,
2. Using a seoudve, remove ho timing chain cover
"oy ing between the timing chain cœur and cylinder
head or ender Bock,
Tape the serewära ip beore use
3 Remove the Ong ram the ning gar.
YANMAR su wos conso tons
ENGINE
Engine Disassembly
Pea Homo to Disassemble
Msiration
61 [Setiho No. 1 Cylinder to TOC Compression
1. Tempore install the erankahaı pulley andthe 2
(rankaatt pully set bots 1 the rnkahaf.
2 Tumthe erankshat cc to set he No einer
tobe.
5. With the crankshal hey 45° countercockwi rom
the top postion chockthat th ming marks ofthe RH
and LH camahaft ing gears are algned. not as
specie, tum the crankshaft 1 revoiton (800) and
aga he
4, Remove the 2 erankshaf puley se bts,
‘| Remove the No, Y Crankshaft Position Sensor Pat]
1 Usinga 130 TORI wrench, temoro tho 2 crows
and erankshaf postion senor plato,
Engine Disassembly
Pea Homo to Disassemble
Msiration
61 [Setiho No. 1 Cylinder to TOC Compression
1. Tempore install the erankahaı pulley andthe 2
(rankaatt pully set bots 1 the rnkahaf.
2 Tumthe erankshat cc to set he No einer
tobe.
5. With the crankshal hey 45° countercockwi rom
the top postion chockthat th ming marks ofthe RH
and LH camahaft ing gears are algned. not as
specie, tum the crankshaft 1 revoiton (800) and
aga he
4, Remove the 2 erankshaf puley se bts,
‘| Remove the No, Y Crankshaft Position Sensor Pat]
1 Usinga 130 TORI wrench, temoro tho 2 crows
and erankshaf postion senor plato,
Engine Disassembly
ENGINE
Tear Hanıon to Dinssomble
Tiuetraton
3 [Remove the Pump Drive Shaft Gear
1-Using SST, hold the pump dive sat gar,
ARO PERO PRD
2. Remove the 4 bots and pump dive shat gear.
3. Remove the 2 bots and No. 1 chain tensione,
| Remove the No. 1 Chain Tensioner Slipper
| Remove he Wo. 1 Chain Vibration Damper
‘Remove the 2boltandNo chain vibration damper.
YANMAR su wos conso tons
ENGINE
Tear Hanıon to Dinssomble
Tiuetraton
3 [Remove the Pump Drive Shaft Gear
1-Using SST, hold the pump dive sat gar,
ARO PERO PRD
2. Remove the 4 bots and pump dive shat gear.
3. Remove the 2 bots and No. 1 chain tensione,
| Remove the No. 1 Chain Tensioner Slipper
| Remove he Wo. 1 Chain Vibration Damper
‘Remove the 2boltandNo chain vibration damper.
YANMAR su wos conso tons
ENGINE
Engine Disassembly
Pea
Temfiow to Disassambie
Msiration
Remove the No, 1 Camshaft Timing Sprocket and
No. 1 Timing Chain
and push tn plunger ino tv tensioner.
2 Move ie stopper plato counterclockwise to sel the
look. and insert a hoxagon wrench tothe stopper
Pit helo
9, Remove the 2 bots and No, 2 chain ersionor
Remove the No, Chain Tensioner Spar
Remove the No. 2 Chain Vibration Damper
1. Remove the 2 bli and No, 2chai vation damper.
Engine Disassembly
Pea
Temfiow to Disassambie
Msiration
Remove the No, 1 Camshaft Timing Sprocket and
No. 1 Timing Chain
and push tn plunger ino tv tensioner.
2 Move ie stopper plato counterclockwise to sel the
look. and insert a hoxagon wrench tothe stopper
Pit helo
9, Remove the 2 bots and No, 2 chain ersionor
Remove the No, Chain Tensioner Spar
Remove the No. 2 Chain Vibration Damper
1. Remove the 2 bli and No, 2chai vation damper.
Engine Disassembly
ENGINE
Tear
Hanıon to Dienssembi
Tiuetraton
remove the No.2 Camshaft Timing Sprocket and
No.2 Timing Chain
‘Using SST, hold the No. 2 camenat timing sprocket,
TR A TA
2. Remove the 4 bots, No. 2 camehalt timing sprocket
‘and No. 2 timing chan
72
=
Remove the Fuel Supply Pump Dive Gear Nut
"Using SST, hold No. ll gear,
2. Remove the na,
Remove the Wo. Y iio Gear
1 Remove the 2 bots, ie gear thrust plate and de
gear.
YANMAR su osos conso tons
ENGINE
Tear
Hanıon to Dienssembi
Tiuetraton
remove the No.2 Camshaft Timing Sprocket and
No.2 Timing Chain
‘Using SST, hold the No. 2 camenat timing sprocket,
TR A TA
2. Remove the 4 bots, No. 2 camehalt timing sprocket
‘and No. 2 timing chan
72
=
Remove the Fuel Supply Pump Dive Gear Nut
"Using SST, hold No. ll gear,
2. Remove the na,
Remove the Wo. Y iio Gear
1 Remove the 2 bots, ie gear thrust plate and de
gear.
YANMAR su osos conso tons
ENGINE
Engine Disassembly
Pea
Temfiow to Disassambie
Msiration
Remove the No. 1 alo Gear Sat
Remove the Fuel Supply Pump Drive Gear
{Using SST, remove te fue soppy pump ve gear,
TE TOTS QE EN DOOR,
en RSS 08020, 2606608031),
Remove the Starter Assembly
1. Detach te harness amp and disconnect the wire
hare,
2 Disconnect the starter connector
Remove ie nu and disconnect the starter wie.
4, Remove the 2 bots and starter
Engine Disassembly
Pea
Temfiow to Disassambie
Msiration
Remove the No. 1 alo Gear Sat
Remove the Fuel Supply Pump Drive Gear
{Using SST, remove te fue soppy pump ve gear,
TE TOTS QE EN DOOR,
en RSS 08020, 2606608031),
Remove the Starter Assembly
1. Detach te harness amp and disconnect the wire
hare,
2 Disconnect the starter connector
Remove ie nu and disconnect the starter wie.
4, Remove the 2 bots and starter
Engine Disassembly ENGINE
Tea Tomo to Dinssombie Tiuetraton
77 Remove the Water Outlet Pipe
Y Remove he 4 bots, water ele pipe and gaskets
7a Separate the No, 1 and Wo. 2 Water Outer Pipes and
Water By-Pass Outlet
{Remove the 2 bots and No. Y water out pipe rom
the No 2 water outlet pipe
2. Disconnect the No, 2 water ote pipe tom the No. 1
‘water hose Jon.
3. Disconnect the water by-pass cute fom the No. 1
‘wale hove Jon.
YANMAR aus se
Tea Tomo to Dinssombie Tiuetraton
77 Remove the Water Outlet Pipe
Y Remove he 4 bots, water ele pipe and gaskets
7a Separate the No, 1 and Wo. 2 Water Outer Pipes and
Water By-Pass Outlet
{Remove the 2 bots and No. Y water out pipe rom
the No 2 water outlet pipe
2. Disconnect the No, 2 water ote pipe tom the No. 1
‘water hose Jon.
3. Disconnect the water by-pass cute fom the No. 1
‘wale hove Jon.
YANMAR aus se
ENGINE Engine Disassembly
Pea Temfiow to Disassemble Msiration
79 | Remove ine Fuel Supply Pump Assembly
{Using a 6 mm hexagon wrench rome the hexagon |
bot Then remove the 2 ute and ul Supply pump.
2. Remove the Oring
Remove the No, 1 and No. 2 Camshafts
1.Venga6 mm» 1.0 pitch bot wih a length 116 mm
orme. the No. carshat in place
2.Looten the 2 union bos
5. Uneaten ans remove ne 20 ots nthe
de shown te Roa
One cansa and aan pes vto
and
Pea Temfiow to Disassemble Msiration
79 | Remove ine Fuel Supply Pump Assembly
{Using a 6 mm hexagon wrench rome the hexagon |
bot Then remove the 2 ute and ul Supply pump.
2. Remove the Oring
Remove the No, 1 and No. 2 Camshafts
1.Venga6 mm» 1.0 pitch bot wih a length 116 mm
orme. the No. carshat in place
2.Looten the 2 union bos
5. Uneaten ans remove ne 20 ots nthe
de shown te Roa
One cansa and aan pes vto
and
Engine Disassembly
ENGINE
Fear Hanıow to Dnssombie
Tiuetraton
4 Romane he? uionbots and N+ and Wo ZONES
pies.
5. Remove the 8 No.3 camshaft bearing caps and
No. 1 cha bearing ap.
ou:
‘Arrange the removed pars inthe coset order
6. Remave the No, 1 and No, 2 camshals.
HT [inspection
1 Ingpect tho camsha
(S00 Inspec the Camshat on page 4.127)
2 Inspect ho camehat ol clearance.
(500 Inspec the Camshaft Ol Garance on
age 4128)
Inspect Ih No. 1comahat thrust clearance (or ho
ahaust camahat)
(See Inspec the No, 1 and No. 4 Camshaft Trust
‘Gearanee(Forthe Exhaust Camahat on
page 4128),
2 Inspect the No, 2 camshaft thus clearence (orto.
irae cama,
(See spot the No, 2 and No. 3 Camshaft Trust
‘Gearancs (Fr ta Intake Camanaf on page 4 124)
YANMAR su wos conso tons
ENGINE
Fear Hanıow to Dnssombie
Tiuetraton
4 Romane he? uionbots and N+ and Wo ZONES
pies.
5. Remove the 8 No.3 camshaft bearing caps and
No. 1 cha bearing ap.
ou:
‘Arrange the removed pars inthe coset order
6. Remave the No, 1 and No, 2 camshals.
HT [inspection
1 Ingpect tho camsha
(S00 Inspec the Camshat on page 4.127)
2 Inspect ho camehat ol clearance.
(500 Inspec the Camshaft Ol Garance on
age 4128)
Inspect Ih No. 1comahat thrust clearance (or ho
ahaust camahat)
(See Inspec the No, 1 and No. 4 Camshaft Trust
‘Gearanee(Forthe Exhaust Camahat on
page 4128),
2 Inspect the No, 2 camshaft thus clearence (orto.
irae cama,
(See spot the No, 2 and No. 3 Camshaft Trust
‘Gearancs (Fr ta Intake Camanaf on page 4 124)
YANMAR su wos conso tons
ENGINE Engine Disassembly
Pea Temfiow to Disassemble
> | Remove the No. 2 Camshaft Bearing Cap
‘82 | Remove the Wo, 1 Valve Rocker Arms
1. Remove he 1 No. Y valve rocker nm,
Remove the No, 1 Valve Lash Adjustor Assombly
1 Remove te 10No. lash asters
2 Loosen the 2 union boe
Pea Temfiow to Disassemble
> | Remove the No. 2 Camshaft Bearing Cap
‘82 | Remove the Wo, 1 Valve Rocker Arms
1. Remove he 1 No. Y valve rocker nm,
Remove the No, 1 Valve Lash Adjustor Assombly
1 Remove te 10No. lash asters
2 Loosen the 2 union boe
Engine Disassembly
ENGINE
Fear
Hanıon to Dissombie
Tiuetaton
Sram manner ve DOR ie
Sn
Or canot and ha pes vo
Hs
4. Remove the 2unienbols an No, and No. dei
pies.
5. Remove the 8 No, 3 camshaft bearing caps and
No camehalt bearing cap.
Nove
Arango the removed pars inthe correct order
6. Remove the No.9 and No.4 amet.
YANMAR su wos conso tons
ENGINE
Fear
Hanıon to Dissombie
Tiuetaton
Sram manner ve DOR ie
Sn
Or canot and ha pes vo
Hs
4. Remove the 2unienbols an No, and No. dei
pies.
5. Remove the 8 No, 3 camshaft bearing caps and
No camehalt bearing cap.
Nove
Arango the removed pars inthe correct order
6. Remove the No.9 and No.4 amet.
YANMAR su wos conso tons
ENGINE
Engine Disassembly
Pea
Temfiow to Disassemble
Msiration
inspection
Tihgpeat the camaras.
(Soe inspect the Camsha on page 4127)
2: Inspect the camshat ol clearance.
(S00 Inspect me Camsha Oi Cearance on
page 4-128)
5. Inspec the No. 1 camshaft trust clearance lr the
‘exhaust cometa
(See Inspect the No. 1 and No.4 Camshaft Trust
Clearance (or the Exhaust Camshat on
page #125)
4. Inspect the No. 2 camshaft trust lance (forthe
intake cama
(See Inspect the No. 2and No. 3 Camshaf Trust
Clearance (Forte Intake Camshat on page 4-124)
Remove the No, & Camshaft Bearing Cap
Remove the No.2 Valve Rocker Arms
Y Remove the 18 No. 2 valve rocker ams.
Remove the No. 2 Valve Lash Adjuster Assembly
move he 10No. 2 ash adjusters.
Engine Disassembly
Pea
Temfiow to Disassemble
Msiration
inspection
Tihgpeat the camaras.
(Soe inspect the Camsha on page 4127)
2: Inspect the camshat ol clearance.
(S00 Inspect me Camsha Oi Cearance on
page 4-128)
5. Inspec the No. 1 camshaft trust clearance lr the
‘exhaust cometa
(See Inspect the No. 1 and No.4 Camshaft Trust
Clearance (or the Exhaust Camshat on
page #125)
4. Inspect the No. 2 camshaft trust lance (forthe
intake cama
(See Inspect the No. 2and No. 3 Camshaf Trust
Clearance (Forte Intake Camshat on page 4-124)
Remove the No, & Camshaft Bearing Cap
Remove the No.2 Valve Rocker Arms
Y Remove the 18 No. 2 valve rocker ams.
Remove the No. 2 Valve Lash Adjuster Assembly
move he 10No. 2 ash adjusters.
Engine Disassembly
ENGINE
Hamıon to Dinssomble
Tiuetraton
Remove the Ol Cooler Assembly
Y: Remove he 2 bot, 2 nuts and ol ook.
2, Remove the 2 O.1ngs anol color gasket.
o
Remove the No, 1 Ol Pan Sub Assembly
{Remove the 20 bot, 2 nuts and seal washer
Nove
Be sure to clean the bots and stud bolts, and check
the ead or erack o ther damage.
2. Remove the oipanty prying between theo pan and
‘jor block wha sereno
Bo carl not to damage the contact surlacos of the
cinderblock and ol pan,
Note
Tape tho sorowdiver ip Botero use.
YANMAR 209 coo: 000 ares
ENGINE
Hamıon to Dinssomble
Tiuetraton
Remove the Ol Cooler Assembly
Y: Remove he 2 bot, 2 nuts and ol ook.
2, Remove the 2 O.1ngs anol color gasket.
o
Remove the No, 1 Ol Pan Sub Assembly
{Remove the 20 bot, 2 nuts and seal washer
Nove
Be sure to clean the bots and stud bolts, and check
the ead or erack o ther damage.
2. Remove the oipanty prying between theo pan and
‘jor block wha sereno
Bo carl not to damage the contact surlacos of the
cinderblock and ol pan,
Note
Tape tho sorowdiver ip Botero use.
YANMAR 209 coo: 000 ares
ENGINE Engine Disassembly
Pea Temfiow to Disassemble Tustration
[Remove the Oring om the où regulator,
‘| Remove th Où Strainer Sub-Assombiy
Y Remove te bola, atraer and © ing
the Ol Regulator Assembly
move he 4 bos ano reguiator
‘G4_| Remove tho Rear Engine OW Seal Retainer
Y Remove the 10 bot,
2 Remove thei scalretainer ty pringbetween theo
Soalrtainar and ylnder Dock wh a cree
Kot:
Tape he screwsiver ip before use
Pea Temfiow to Disassemble Tustration
[Remove the Oring om the où regulator,
‘| Remove th Où Strainer Sub-Assombiy
Y Remove te bola, atraer and © ing
the Ol Regulator Assembly
move he 4 bos ano reguiator
‘G4_| Remove tho Rear Engine OW Seal Retainer
Y Remove the 10 bot,
2 Remove thei scalretainer ty pringbetween theo
Soalrtainar and ylnder Dock wh a cree
Kot:
Tape he screwsiver ip before use
Engine Disassembly
ENGINE
Tea
Hanıon to Dinssombie
Tiuetraton
Famove the Ol Pump Assembly
4 Remove he 4 bots and ol pur.
{5 | Remove the Timing Gear Case Sub Assembly
1 Remove the 22 Bee and 2 re shonin the
stration,
2, Remove the 2 © tng aná timing guar case gasket
57 | Remove the Cylinder Head Sub-Assombiy AH
1. Untormly losen and remove the 10 bs and 10
Pace I tho sequence shown ith station,
op washers int the ender
+ Head warpege o racing can resul tom
remouing bolls in an icatect order.
Nove:
‘range the removed pars the correct order and
Separate.
* x
00000.
YANMAR su wos conso tons
ENGINE
Tea
Hanıon to Dinssombie
Tiuetraton
Famove the Ol Pump Assembly
4 Remove he 4 bots and ol pur.
{5 | Remove the Timing Gear Case Sub Assembly
1 Remove the 22 Bee and 2 re shonin the
stration,
2, Remove the 2 © tng aná timing guar case gasket
57 | Remove the Cylinder Head Sub-Assombiy AH
1. Untormly losen and remove the 10 bs and 10
Pace I tho sequence shown ith station,
op washers int the ender
+ Head warpege o racing can resul tom
remouing bolls in an icatect order.
Nove:
‘range the removed pars the correct order and
Separate.
* x
00000.
YANMAR su wos conso tons
ENGINE
Engine Disassembly
Temfiow to Disassemble
Msiration
inspection
{inspect hecyinder heed AH
(S00 Inspect me Oyinder Head Sub Assambiy on
page 123)
2 Inspec the valve ash ajustor assonby.
(See Inspect the Valo Lash Auster Assembly on
page 4.132)
3 Inspect the cier head bok
(See Inspect the Oyinder Head Bolt on page 424.)
5
‘Arrange the vales mer compression spins, valve
Song retainers and valve sng retainer looks ne
cone order
1, Place the liner head on a wooden Block
2 Using SST, compress the inner compression spring
and remove he valve sprig tater ok.
2, Remove te inner compression spring nd valve
sping retainer.
Eu
o
Remove the No 1 Cylindr Head Gasket
wo
Hamas ma ind Food Amar
Masten ened a an 0
at ha eae ES
cil oem sr o ide
ES
auge ic anton
Note
Arrango io romoved patin tho croc order aná
‘separa.
E
mi
oe
UA
Je“ ©
5
>
inspection
Y. Ines he cyinder hand LH
(S00 Inspect me Cynder Head Sub Assembly on
page 123)
2: Inspec th vale lash aduster assonby.
(Soe inspect the Vale Lash Aduster Assombiyon.
page 132)
2. Inspec the cier head bok.
(S00 Inspect the Oyindor Head Bot on pago 4124)
Remove the No. 2 Cylinder Head Gasket
Engine Disassembly
Temfiow to Disassemble
Msiration
inspection
{inspect hecyinder heed AH
(S00 Inspect me Oyinder Head Sub Assambiy on
page 123)
2 Inspec the valve ash ajustor assonby.
(See Inspect the Valo Lash Auster Assembly on
page 4.132)
3 Inspect the cier head bok
(See Inspect the Oyinder Head Bolt on page 424.)
5
‘Arrange the vales mer compression spins, valve
Song retainers and valve sng retainer looks ne
cone order
1, Place the liner head on a wooden Block
2 Using SST, compress the inner compression spring
and remove he valve sprig tater ok.
2, Remove te inner compression spring nd valve
sping retainer.
Eu
o
Remove the No 1 Cylindr Head Gasket
wo
Hamas ma ind Food Amar
Masten ened a an 0
at ha eae ES
cil oem sr o ide
ES
auge ic anton
Note
Arrango io romoved patin tho croc order aná
‘separa.
E
mi
oe
UA
Je“ ©
5
>
inspection
Y. Ines he cyinder hand LH
(S00 Inspect me Cynder Head Sub Assembly on
page 123)
2: Inspec th vale lash aduster assonby.
(Soe inspect the Vale Lash Aduster Assombiyon.
page 132)
2. Inspec the cier head bok.
(S00 Inspect the Oyindor Head Bot on pago 4124)
Remove the No. 2 Cylinder Head Gasket
Engine Disassembly
ENGINE
Fea
Hanıow to Dinssombie
Tiuetraton
Temove the Piston Sub-Assembiy with he
Connecting Rod
1 Using tige reamer, remove aile carbon rom the
top a the eyinder.
2. Untommlyloaen the connecting rx bots, and
remove Ih connecing od cap wäh the bearing
5 Push out the piston and eonneeing rod wih the
‘bering tough the top ofthe cyider block,
ot:
‘ange ie piston and connecting rod ssembies in
the correct oder
Remove the Piston Ring Sat
1. ing a piston ing expande
No 2 compression ngs
2, Using piston ring expander remove th ising
8: Remove the ol ing expander by hand
remove the No, and
Remove the Piston with the Pin Sub-Assembiy
1 Gheck the ing condition between to piston and
piston pin by tying to move the pon back and fort
‘nthe piston pin
any movement sft, replace 1
*
ston andpinas
2, Using a cree, py ut he 2 snap eng
YANMAR 209 coo: 000 ares
ENGINE
Fea
Hanıow to Dinssombie
Tiuetraton
Temove the Piston Sub-Assembiy with he
Connecting Rod
1 Using tige reamer, remove aile carbon rom the
top a the eyinder.
2. Untommlyloaen the connecting rx bots, and
remove Ih connecing od cap wäh the bearing
5 Push out the piston and eonneeing rod wih the
‘bering tough the top ofthe cyider block,
ot:
‘ange ie piston and connecting rod ssembies in
the correct oder
Remove the Piston Ring Sat
1. ing a piston ing expande
No 2 compression ngs
2, Using piston ring expander remove th ising
8: Remove the ol ing expander by hand
remove the No, and
Remove the Piston with the Pin Sub-Assembiy
1 Gheck the ing condition between to piston and
piston pin by tying to move the pon back and fort
‘nthe piston pin
any movement sft, replace 1
*
ston andpinas
2, Using a cree, py ut he 2 snap eng
YANMAR 209 coo: 000 ares
ENGINE
Engine Disassembly
Pea
Temfiow to Disassemble
Msiration
wen.
Noe:
+ Tho piston and pinar a mated se
In ie eomeet order.
[Gradual eat me piston to appromimat 60°C
4. Using a plas 4aced hammer and bass bar itty
tap out the piston pin and remove the connecting od
1 Arango he piton andconnecing rod assemblies
707 | Remove the Connecting Rod Bearing
boating.
1 Remove ho connecting fed and connading rod cap
108 | Remove the Crankshatt
1. Using several steps. sen and remove the 10
crash basing cap set bots unr in the
‘Sequence shown in he Huston
Engine Disassembly
Pea
Temfiow to Disassemble
Msiration
wen.
Noe:
+ Tho piston and pinar a mated se
In ie eomeet order.
[Gradual eat me piston to appromimat 60°C
4. Using a plas 4aced hammer and bass bar itty
tap out the piston pin and remove the connecting od
1 Arango he piton andconnecing rod assemblies
707 | Remove the Connecting Rod Bearing
boating.
1 Remove ho connecting fed and connading rod cap
108 | Remove the Crankshatt
1. Using several steps. sen and remove the 10
crash basing cap set bots unr in the
‘Sequence shown in he Huston
Engine Disassembly
ENGINE
Fear
Tomo to Dinssombie
Tiuetraton
Tang several steps loosen and remove te 20
‘cranial bearing cap se bt unforin the
Sequence shown nthe usta,
3, Remove the 2 cylinder Bock sien plates.
4. Using 2 crankshat bearing cap set bts, pl out the
5 bearing caps.
5. Remove the cranks
YANMAR su wos conso tons
ENGINE
Fear
Tomo to Dinssombie
Tiuetraton
Tang several steps loosen and remove te 20
‘cranial bearing cap se bt unforin the
Sequence shown nthe usta,
3, Remove the 2 cylinder Bock sien plates.
4. Using 2 crankshat bearing cap set bts, pl out the
5 bearing caps.
5. Remove the cranks
YANMAR su wos conso tons
ENGINE Engine Disassembly
Pea Temfiow to Disassemble Msiration
409. | Remove the Crankshaft Thrust Washer Set
Remove the Crankahait Boring
Remove the No.1 Ol Nozzle Sub Assembly
1. Uing a 5 mm bexagon wrench, eave the 4 bots
and dol nozzles.
Pea Temfiow to Disassemble Msiration
409. | Remove the Crankshaft Thrust Washer Set
Remove the Crankahait Boring
Remove the No.1 Ol Nozzle Sub Assembly
1. Uing a 5 mm bexagon wrench, eave the 4 bots
and dol nozzles.
Engine Assembly
ENGINE
ENGI
INE ASSEMBLY
=
Teton Am
Install the No, 1 Oil Nozzle Sub Assembly
Using a5 mm hoxagon wrench al the 4 ol
nozzles wh the 4 bots
Tor
NAAA
Tnatal the Piston Pin Hote Snap Ring
{Using serewdve, metal a new aap ing on one
side ofthe piston pin hole
‘ote:
Be sue tha the end gap of the snap rng snot
ned win ie pinhole att orten of a piston.
1° Gradual hea th piston to approximatay 20°C
en
2. Goat the piston pin wth engine il
a.
‘Algnthetrontmatks ofthe piston and connecting rod,
‘and push inthe piston pin wth your tur,
‘Note
The piston and pin are a matched set.
= The piton has 2 ont marks.
YANMAR 209 coo: 000 ares
ENGINE
ENGI
INE ASSEMBLY
=
Teton Am
Install the No, 1 Oil Nozzle Sub Assembly
Using a5 mm hoxagon wrench al the 4 ol
nozzles wh the 4 bots
Tor
NAAA
Tnatal the Piston Pin Hote Snap Ring
{Using serewdve, metal a new aap ing on one
side ofthe piston pin hole
‘ote:
Be sue tha the end gap of the snap rng snot
ned win ie pinhole att orten of a piston.
1° Gradual hea th piston to approximatay 20°C
en
2. Goat the piston pin wth engine il
a.
‘Algnthetrontmatks ofthe piston and connecting rod,
‘and push inthe piston pin wth your tur,
‘Note
The piston and pin are a matched set.
= The piton has 2 ont marks.
YANMAR 209 coo: 000 ares
ENGINE
Engine Assembly
HUE
Face tho tont marks othe piston and connecting red
Inopposte drena, and push nthe piston pin wh
your amb,
Note
+ The piston and pin are a matched set
© The piston has ont mark
5. Chock the ting condition between the piston and
‘ston pin by tying to move the piston back and oth
one piston pi,
install the Piston Pin Hole Snap Ring
Y Using serendiver, sal a new snap nga the
‘ter nd ofthe piston pin ole
Nos
Be sur that the and gap of the snap ing i not
aligned withthe pin ele cutout por ol he piston
Engine Assembly
HUE
Face tho tont marks othe piston and connecting red
Inopposte drena, and push nthe piston pin wh
your amb,
Note
+ The piston and pin are a matched set
© The piston has ont mark
5. Chock the ting condition between the piston and
‘ston pin by tying to move the piston back and oth
one piston pi,
install the Piston Pin Hole Snap Ring
Y Using serendiver, sal a new snap nga the
‘ter nd ofthe piston pin ole
Nos
Be sur that the and gap of the snap ing i not
aligned withthe pin ele cutout por ol he piston
Engine Assembly ENGINE
> | Intel tho Piston Ring Sat
Y Instale ol ing expardor by hand
2. Using a piston rng expander instal th i ing.
Neve
‘Align the ong end and colin as show in the
usan,
YANMAR soon es
> | Intel tho Piston Ring Sat
Y Instale ol ing expardor by hand
2. Using a piston rng expander instal th i ing.
Neve
‘Align the ong end and colin as show in the
usan,
YANMAR soon es
ENGINE
Engine Assembly
Using piston ing expander, instalo No. and
"No.2 compression rings o thatthe code mark aro.
position as shown in o train,
* Irsa th No. 1 compression in with the code
‘mark (71 or 11) facing upward.
+ Install the No.2 compression ring with he code
mark (12) facing upward.
4. Poston the piston rings so thatthe ing ends are as
shown nthe station below
7
Engine Assembly
Using piston ing expander, instalo No. and
"No.2 compression rings o thatthe code mark aro.
position as shown in o train,
* Irsa th No. 1 compression in with the code
‘mark (71 or 11) facing upward.
+ Install the No.2 compression ring with he code
mark (12) facing upward.
4. Poston the piston rings so thatthe ing ends are as
shown nthe station below
7
Engine Assembly
ENGINE
Thatall ho Connecting Rod Boaring
Align the baring cae th he ca groove a he
‘connecting tod cap-
+ Clean the contact surface of the bearing and
connecting rod cap.
+ Do net apply engine oto the bearing nit
contact suce.
2. ligne boating claw wth ho claw groove a he
‘coneting tod
2 Chant coat safe oben and
cir
+ Sonata sico bering adie
oat ce
inatall the Crankahafi Bearing
Be sure o instale selected bearing.
Note:
Hain Bearings come in widths of 205 mm (0.807 in)
‘and 225 mm (0.886 in)
andra aural Diamar
specication
[RESET EN
No 29 an pura bones | 205 mar)
1. Glean each main ural and bearing,
YANMAR soon
ENGINE
Thatall ho Connecting Rod Boaring
Align the baring cae th he ca groove a he
‘connecting tod cap-
+ Clean the contact surface of the bearing and
connecting rod cap.
+ Do net apply engine oto the bearing nit
contact suce.
2. ligne boating claw wth ho claw groove a he
‘coneting tod
2 Chant coat safe oben and
cir
+ Sonata sico bering adie
oat ce
inatall the Crankahafi Bearing
Be sure o instale selected bearing.
Note:
Hain Bearings come in widths of 205 mm (0.807 in)
‘and 225 mm (0.886 in)
andra aural Diamar
specication
[RESET EN
No 29 an pura bones | 205 mar)
1. Glean each main ural and bearing,
YANMAR soon
ENGINE
Engine Assembly
Agno Bearing claw wth ho claw groove othe
“er lock, and push nto 5 upper eran
bearings
+ Gant coast sa th bearing a
Souris
«Bonet oan othe bering ai
Pa
«Bes de oor inte eee bk
haute etn iar a lolis ne
wayne o ll
Tech
3. Align the bearing claw withthe claw groove of he
‘baring cap. and puc nthe 5 lower erarkshalt
bearings
> an oc sal anta
ER
ms otto
ET
ote
The number marked on exch bearing cap indcates
the instalan postion.
Install the Grankahatt
Clean the contact surface ofeach main joumal aná
‘rank pin,
+. Apply new engine otto the upper erankahaft bearing
‘ahd instal he crank on he cylinder oc
2, Pushthe crankshaft toward the rear thus irecionto
raie clearence, and install ut washer othe
AN. 3 journal postion wth he il grove facing the
front othe engine
|. Push the craneal toward the forward thrust
(Grein crete clearance andina trust
‘washer theNe.3jouralpositon withthe groove
facing ho rear ofthe engine
Engine Assembly
Agno Bearing claw wth ho claw groove othe
“er lock, and push nto 5 upper eran
bearings
+ Gant coast sa th bearing a
Souris
«Bonet oan othe bering ai
Pa
«Bes de oor inte eee bk
haute etn iar a lolis ne
wayne o ll
Tech
3. Align the bearing claw withthe claw groove of he
‘baring cap. and puc nthe 5 lower erarkshalt
bearings
> an oc sal anta
ER
ms otto
ET
ote
The number marked on exch bearing cap indcates
the instalan postion.
Install the Grankahatt
Clean the contact surface ofeach main joumal aná
‘rank pin,
+. Apply new engine otto the upper erankahaft bearing
‘ahd instal he crank on he cylinder oc
2, Pushthe crankshaft toward the rear thus irecionto
raie clearence, and install ut washer othe
AN. 3 journal postion wth he il grove facing the
front othe engine
|. Push the craneal toward the forward thrust
(Grein crete clearance andina trust
‘washer theNe.3jouralpositon withthe groove
facing ho rear ofthe engine
Engine Assembly ENGINE
Far Toe BS T Tor
En te ron marks and numbers angina he
‘bearing capa onthe eylnder Bock
Tenge rath cant botrgcp ro
en
pa
Pa tar eg pin a
cients teem el
Stet
Fel cot ct rg ote mecs tte
pi
into ST cet ag ap bots
e
EE
Do noltap the bearing cap with plas taced
hammer.
8. Remove the rankehat being cap boks and
spacers
9. Sethe 2 cylinder block titening plates on the
‘nde back.
Rete
‘Make sure the amours onthe stifenng pats tae the
engine ton.
YANMAR aus ess
Far Toe BS T Tor
En te ron marks and numbers angina he
‘bearing capa onthe eylnder Bock
Tenge rath cant botrgcp ro
en
pa
Pa tar eg pin a
cients teem el
Stet
Fel cot ct rg ote mecs tte
pi
into ST cet ag ap bots
e
EE
Do noltap the bearing cap with plas taced
hammer.
8. Remove the rankehat being cap boks and
spacers
9. Sethe 2 cylinder block titening plates on the
‘nde back.
Rete
‘Make sure the amours onthe stifenng pats tae the
engine ton.
YANMAR aus ess
ENGINE
Engine Assembly
ENTE
No
* Te crankshal bearing cup bas ar igtenedin4
progressive stops,
+ Trany crankshat bearing cap bot is broken or
form, replace 1
App a ht coat of engine lo he trends and
Under the heads line 20 cankshat bearing cep
bots A and 8.
Bot Cana
5
À imossa | ramiro
Bosa) | SOSH BSE
2 Intl he 20 crankshaft bearing cap bot. Using
several steps, gene bots nom in the
Sequence shown inthe lust,
Bora
Ea
ica eo Nm (12 ge Au)
ssp
"Mark ie ont side ofthe cankshal beating cap
bol Aand wäh pa,
Tighten the erankaaft beaing cap bots A and B
90" the sequence as shown inthe sustain,
+
Engine Assembly
ENTE
No
* Te crankshal bearing cup bas ar igtenedin4
progressive stops,
+ Trany crankshat bearing cap bot is broken or
form, replace 1
App a ht coat of engine lo he trends and
Under the heads line 20 cankshat bearing cep
bots A and 8.
Bot Cana
5
À imossa | ramiro
Bosa) | SOSH BSE
2 Intl he 20 crankshaft bearing cap bot. Using
several steps, gene bots nom in the
Sequence shown inthe lust,
Bora
Ea
ica eo Nm (12 ge Au)
ssp
"Mark ie ont side ofthe cankshal beating cap
bol Aand wäh pa,
Tighten the erankaaft beaing cap bots A and B
90" the sequence as shown inthe sustain,
+
Engine Assembly
ENGINE
PSE
‘Tighten the cankshal being cap bot another
90° inthe sequence as shown in ho ration
a Check that the pated marke of Bot Aare now a à
180° angle tothe ton,
14 Check hat the painted marke of bo 8 ate now at a
90 ange tothe rom.
15.Check tip cankshaf turns smooth.
16Sepa:
eng several steps instal he 10 rankahat
‘bearing cap bots uno the sequence shown
inne ration
Togs | angen
2.Ghck hat the crankshaft tums smoothly
Inspection
1 spot the crankshaft rut clearance.
(See Inspec the Cranksha Trust Clearance on
page 4144)
Tita ho Piston Sub Assembly wih the Connecting Rod
App engin ol othe cyinder walls pitos, andthe surfaces ofthe connecting rod brings.
2: Check he postions of he piston ing end,
YANMAR cc sexos
ENGINE
PSE
‘Tighten the cankshal being cap bot another
90° inthe sequence as shown in ho ration
a Check that the pated marke of Bot Aare now a à
180° angle tothe ton,
14 Check hat the painted marke of bo 8 ate now at a
90 ange tothe rom.
15.Check tip cankshaf turns smooth.
16Sepa:
eng several steps instal he 10 rankahat
‘bearing cap bots uno the sequence shown
inne ration
Togs | angen
2.Ghck hat the crankshaft tums smoothly
Inspection
1 spot the crankshaft rut clearance.
(See Inspec the Cranksha Trust Clearance on
page 4144)
Tita ho Piston Sub Assembly wih the Connecting Rod
App engin ol othe cyinder walls pitos, andthe surfaces ofthe connecting rod brings.
2: Check he postions of he piston ing end,
YANMAR cc sexos
ENGINE
Engine Assembly
facing the corea direction:
Mach tho numbered connecting rod cap with tho
‘connecting tod,
5. Apply a ight coat of engine ol to the trea and
‘nor the heed ofthe connecting rod exp bal,
6. top:
Asa and altematoly ighton the bots ofthe
‘connecting rod cap In several steps.
(ae
Note
+ Tighten the connecting rod cap bts in 2
propressive stops.
+ any connecting bot cap bot i broken or
delemed replace 1
FF Using a hammer hand and piston in comprossor, prosa pion and comecting 10d assembly wo
(each ylnder wäh th rot mark ol vo piston facing lor,
4. ntl he connecting rod oxp so tha its potion
Engine Assembly
facing the corea direction:
Mach tho numbered connecting rod cap with tho
‘connecting tod,
5. Apply a ight coat of engine ol to the trea and
‘nor the heed ofthe connecting rod exp bal,
6. top:
Asa and altematoly ighton the bots ofthe
‘connecting rod cap In several steps.
(ae
Note
+ Tighten the connecting rod cap bts in 2
propressive stops.
+ any connecting bot cap bot i broken or
delemed replace 1
FF Using a hammer hand and piston in comprossor, prosa pion and comecting 10d assembly wo
(each ylnder wäh th rot mark ol vo piston facing lor,
4. ntl he connecting rod oxp so tha its potion
Engine Assembly
ENGINE
7?
Y Marko front de cl each connecting rod ap alt
pat.
Tighten ie cap bol in step 190%.
3 Check thatthe painted mars are now at a 0°
‘angle oth ont.
2. Check thatthe rant tums amoat.
install he Nozzle Holder Clamp Seat
‘ital he nozzle older amp seat,
Install the Valve Spring Seat Pate Washer
Install the Valve Siem OW Seal
1 Apply alight coal of engine ot the valve str ll
ie
2, Using SST, push na new valve stem sea,
Tard Praia aight Label
Bon 147 mm 570
YANMAR su osos conso tons
ENGINE
7?
Y Marko front de cl each connecting rod ap alt
pat.
Tighten ie cap bol in step 190%.
3 Check thatthe painted mars are now at a 0°
‘angle oth ont.
2. Check thatthe rant tums amoat.
install he Nozzle Holder Clamp Seat
‘ital he nozzle older amp seat,
Install the Valve Spring Seat Pate Washer
Install the Valve Siem OW Seal
1 Apply alight coal of engine ot the valve str ll
ie
2, Using SST, push na new valve stem sea,
Tard Praia aight Label
Bon 147 mm 570
YANMAR su osos conso tons
Engine Assembly
ENGINE
18 | natal the Valve =
{Apply plenty of engine oto the ip area ofthe va
‘Shown a me astron
2 ue cheat oa Woden ck
et ke mon ar vaa
Seer
EA
ETT
4, Using SST, compress the inner compression spring
‘and place the valve sping retain lock around ho
Vamo stom
[S| a]
5, Using plas faced hammer. ight tap the valve
stomtip fo onsuo a proper
Be careful not 1 damage the valo stem ip.
ENGINE
18 | natal the Valve =
{Apply plenty of engine oto the ip area ofthe va
‘Shown a me astron
2 ue cheat oa Woden ck
et ke mon ar vaa
Seer
EA
ETT
4, Using SST, compress the inner compression spring
‘and place the valve sping retain lock around ho
Vamo stom
[S| a]
5, Using plas faced hammer. ight tap the valve
stomtip fo onsuo a proper
Be careful not 1 damage the valo stem ip.
Engine Assembly ENGINE
15 | Select tho No. Y Cyindor Head Gaskat
1 Setthe 2 ranks ploy st bos othe cranks,
2. Gan he cer Bock with solver.
3 Inspect the pretusions or each citer.
1 Set he piston ofthe oyinder to be measured to
ligt before TOC.
2 Pace dal indicator on the cer block. an set
‘the measuring tip as shown nthe uso,
Make sur
the eynder block top suce,
Sete dal cat at © mm (On).
Note
Make sure that he measuring tps lat against the
cylinder lock sure andpston head when aking
the measurement.
Finde poston where the ison head protrudes
‘most by slow fuming the crankshaft deceso
and counterclockwise.
‘Measure he piston protrusion valu o each
‘fier a2 places as shown 1h station
below, making total of 8 measurement.
Tanda Paton Pron
LE 60760 mm (00208 WERT]
the protrusion i no as speed, remove and
reinstate piston and connecting ro.
YANMAR 209 coo: 000 ares
N
{
15 | Select tho No. Y Cyindor Head Gaskat
1 Setthe 2 ranks ploy st bos othe cranks,
2. Gan he cer Bock with solver.
3 Inspect the pretusions or each citer.
1 Set he piston ofthe oyinder to be measured to
ligt before TOC.
2 Pace dal indicator on the cer block. an set
‘the measuring tip as shown nthe uso,
Make sur
the eynder block top suce,
Sete dal cat at © mm (On).
Note
Make sure that he measuring tps lat against the
cylinder lock sure andpston head when aking
the measurement.
Finde poston where the ison head protrudes
‘most by slow fuming the crankshaft deceso
and counterclockwise.
‘Measure he piston protrusion valu o each
‘fier a2 places as shown 1h station
below, making total of 8 measurement.
Tanda Paton Pron
LE 60760 mm (00208 WERT]
the protrusion i no as speed, remove and
reinstate piston and connecting ro.
YANMAR 209 coo: 000 ares
N
{
ENGINE
Engine Assembly
Seika now cylinder hend gasket
Moto: anna
Oyinderhond gaskets are marked A,B,C, Dor E ©
Second. maso @
en sil Cynder Hand Gat Ten no
Tem Cutout) Spectied Condition () m O
à EEE
CE EE TEE TE) ©
CE ET |
CN E
= [5 Trato 10 me oso oso
Note:
“The specified condienindicatos the gaskets
thickness ater tightening the opie head
1-Selet the largest piston proton value from the
measurement and then select now appropiate
‘gasket according othe abe below
Piston Pri
‘Specie Condon
GES 087 wen 9020410 HART
05750062 mm 022640 0248 in
ZE 087 mm BEEN 003857
Gere 072 (2687 DIZE
572810780 mem 20541 009071 in}
BECERE
5, Remove the 2 crankshaft putey set bts,
18 | instal the Wo. + Cylinder Had Gasket
Y, Remove any ol rom tho contact surco,
2: Paco th cdo head gasket onthe ender block
face withthe ent ace o th indeed mark À emma
par nd ang ho ochaust io,
as user. YANMAR
Engine Assembly
Seika now cylinder hend gasket
Moto: anna
Oyinderhond gaskets are marked A,B,C, Dor E ©
Second. maso @
en sil Cynder Hand Gat Ten no
Tem Cutout) Spectied Condition () m O
à EEE
CE EE TEE TE) ©
CE ET |
CN E
= [5 Trato 10 me oso oso
Note:
“The specified condienindicatos the gaskets
thickness ater tightening the opie head
1-Selet the largest piston proton value from the
measurement and then select now appropiate
‘gasket according othe abe below
Piston Pri
‘Specie Condon
GES 087 wen 9020410 HART
05750062 mm 022640 0248 in
ZE 087 mm BEEN 003857
Gere 072 (2687 DIZE
572810780 mem 20541 009071 in}
BECERE
5, Remove the 2 crankshaft putey set bts,
18 | instal the Wo. + Cylinder Had Gasket
Y, Remove any ol rom tho contact surco,
2: Paco th cdo head gasket onthe ender block
face withthe ent ace o th indeed mark À emma
par nd ang ho ochaust io,
as user. YANMAR
Engine Assembly ENGINE
= Toe BS T Tor
17 | natal the Gylnder Head Sub-Assembiy AH
Place to ond head on Ie eyed head gasket,
Ensure that no ol on ho mounting surface ol the
fier bead
2. Apply ih coat of engine of the toad and
Under the heads of he cinder head boto
ap
Note:
+ Tighten te cyinder head bots in 4 progressive
2 Tighton he eye ad bots 90" inthe sequence
om in step 1
5.803:
"Tighten te elndor head bolt aer 60" in ho
‘sequence shown instep 1
YANMAR aus ss
= Toe BS T Tor
17 | natal the Gylnder Head Sub-Assembiy AH
Place to ond head on Ie eyed head gasket,
Ensure that no ol on ho mounting surface ol the
fier bead
2. Apply ih coat of engine of the toad and
Under the heads of he cinder head boto
ap
Note:
+ Tighten te cyinder head bots in 4 progressive
2 Tighton he eye ad bots 90" inthe sequence
om in step 1
5.803:
"Tighten te elndor head bolt aer 60" in ho
‘sequence shown instep 1
YANMAR aus ss
ENGINE
Engine Assembly
DET
phone ylndr head bots by an adetonal 90°
Inthe sequence shown inst Y
7. Check tat he pained mar are now acing the LH
ske
Select the No, 2 Cylinder Head Gasket
1 Sete 2 cranks pully set bolts ote cranks
2 Clean the yinder block with solvent
5: Inspec the potions or each eye
"Sethe ston othe eynde lobe measured o
sig belo TOC.
2 Place a cal indicator onthe cyhnder block. and set
the measuring ip as shown nthe iusrabo,
Make sure that he ca indiators at ight angle to
he oylnder lok op suse
Seth Gal indicator at 0 mm in)
‘Not
Make sue thatthe measuring is fat against the
cyinder blck surface and piston head when aking
the measurements,
A Fist poston where he piston head provudes
‘most by son uming the crankshalt clocks
an courterlockie.
Measure te piston protrusion value of each
finder a2 places as shown in the istration
below. making a total of 8 measurement.
Standard Paton Peto
TER 0 780 rm 10206 10 00907
Ihe persion snot a speci, remove and
‘eintl piston and connecing od
|
+
y
a)
2
Engine Assembly
DET
phone ylndr head bots by an adetonal 90°
Inthe sequence shown inst Y
7. Check tat he pained mar are now acing the LH
ske
Select the No, 2 Cylinder Head Gasket
1 Sete 2 cranks pully set bolts ote cranks
2 Clean the yinder block with solvent
5: Inspec the potions or each eye
"Sethe ston othe eynde lobe measured o
sig belo TOC.
2 Place a cal indicator onthe cyhnder block. and set
the measuring ip as shown nthe iusrabo,
Make sure that he ca indiators at ight angle to
he oylnder lok op suse
Seth Gal indicator at 0 mm in)
‘Not
Make sue thatthe measuring is fat against the
cyinder blck surface and piston head when aking
the measurements,
A Fist poston where he piston head provudes
‘most by son uming the crankshalt clocks
an courterlockie.
Measure te piston protrusion value of each
finder a2 places as shown in the istration
below. making a total of 8 measurement.
Standard Paton Peto
TER 0 780 rm 10206 10 00907
Ihe persion snot a speci, remove and
‘eintl piston and connecing od
|
+
y
a)
2
Engine Assembly
ENGINE
5d anew aynder howd get
‘Note:
OJindor head gaskets aro marked A B,C, DorE
‘ecordingly
Titled Cynder Head Goat Tits
ite | Cutout | Species Condition ()
a AD Soin (004721900512)
<=
FFFEY
dde de ds À)
T1 sb er AN
TD Dm POB 190055 A)
13511 men (205311900871)
O
1010180 mm (6055119005014)
The specified condition indcats ho gastar
thickness ale tightening Ihe cyinder head.
"Selec the largest piston profusion value rom
measurements and then selec anew appropri
asko according othe abe below.
Paton Prost
jon] Speced Condon —
A TE
EEN
©] Dev 067 rm 000881 0002
E
E
CE EN
[oras 0780 nm (2054 0207 m}
5. Remove he 2 crankshaft pulley set bols.
(00000
F
Tita ho No.2 Oylindor Head Gasket
1 Remote any ol rom the contact surface,
2. Place to cylinder head gasket onthe eynder block
ue wh th ron face ofthe Indented mark Y
‘upward an facing the exhaust side
YANMAR su wos conso tons
ENGINE
5d anew aynder howd get
‘Note:
OJindor head gaskets aro marked A B,C, DorE
‘ecordingly
Titled Cynder Head Goat Tits
ite | Cutout | Species Condition ()
a AD Soin (004721900512)
<=
FFFEY
dde de ds À)
T1 sb er AN
TD Dm POB 190055 A)
13511 men (205311900871)
O
1010180 mm (6055119005014)
The specified condition indcats ho gastar
thickness ale tightening Ihe cyinder head.
"Selec the largest piston profusion value rom
measurements and then selec anew appropri
asko according othe abe below.
Paton Prost
jon] Speced Condon —
A TE
EEN
©] Dev 067 rm 000881 0002
E
E
CE EN
[oras 0780 nm (2054 0207 m}
5. Remove he 2 crankshaft pulley set bols.
(00000
F
Tita ho No.2 Oylindor Head Gasket
1 Remote any ol rom the contact surface,
2. Place to cylinder head gasket onthe eynder block
ue wh th ron face ofthe Indented mark Y
‘upward an facing the exhaust side
YANMAR su wos conso tons
ENGINE
Engine Assembly
20
Install the Oylinder Head Sub-Assembiy UH
finder head,
2, apply a tt coat of engine 011 the treads ana
‘Ur the head ofthe einer oad bats
8. Stop 1
"nal and uniformly hte the 10 cier head
bots wih he spacer in several steps, in the
‘Sequence shown inthe lusration,
= a]
Note
mo ndo etd bote na popes
spe
+ agde had bot rene deo,
ma
e sia
"Mark to eye hea bot heads wih paint as
shown inthe uta
2.Tighton the der head aa 90” intho sequence
shownin step 1
5.803.
‘Tighten Ihe ende head bots nether 90 inthe
sequence shown a step 1
1 Place the oidor head onthe der hoad gasket
Ensure that no is onthe mounting surface ofthe
Engine Assembly
20
Install the Oylinder Head Sub-Assembiy UH
finder head,
2, apply a tt coat of engine 011 the treads ana
‘Ur the head ofthe einer oad bats
8. Stop 1
"nal and uniformly hte the 10 cier head
bots wih he spacer in several steps, in the
‘Sequence shown inthe lusration,
= a]
Note
mo ndo etd bote na popes
spe
+ agde had bot rene deo,
ma
e sia
"Mark to eye hea bot heads wih paint as
shown inthe uta
2.Tighton the der head aa 90” intho sequence
shownin step 1
5.803.
‘Tighten Ihe ende head bots nether 90 inthe
sequence shown a step 1
1 Place the oidor head onthe der hoad gasket
Ensure that no is onthe mounting surface ofthe
Engine Assembly
ENGINE
2 Gheck hal he pated make arenowtocagtheLH
2
GTR
‘Tightenthe cyindorhend bot by an aditona! 90° CENT
inthe sequence shown in ep Y
Install he Timing Gear Case Sub Assembly
Vin he contact surcos shown below are we,
wine them wi an lts cl before applying seal
packing,
YANMAR 209 coo: 000 ares
ENGINE
2 Gheck hal he pated make arenowtocagtheLH
2
GTR
‘Tightenthe cyindorhend bot by an aditona! 90° CENT
inthe sequence shown in ep Y
Install he Timing Gear Case Sub Assembly
Vin he contact surcos shown below are we,
wine them wi an lts cl before applying seal
packing,
YANMAR 209 coo: 000 ares
ENGINE
Engine Assembly
T App al packing fo he timing gear cane as how
In ie folowing Austral.
Seal Packing
Alo apy et pcg be rg ga
ua
Satchel de
+ A pci il.
ote
+ Te seu packing nei shown bow
App} the soa! packing unto along the FPG
lino. also, opiy packing too 5 seal surface
2. instala new ting gear case gasket
5, Apply engine alto 2 new O rings ail intl hem to
the ting gear case
2s mmeoniny |] "20m Ten
Engine Assembly
T App al packing fo he timing gear cane as how
In ie folowing Austral.
Seal Packing
Alo apy et pcg be rg ga
ua
Satchel de
+ A pci il.
ote
+ Te seu packing nei shown bow
App} the soa! packing unto along the FPG
lino. also, opiy packing too 5 seal surface
2. instala new ting gear case gasket
5, Apply engine alto 2 new O rings ail intl hem to
the ting gear case
2s mmeoniny |] "20m Ten
Engine Assembly
ENGINE
“Taal te ining gear caso wih the 22 bala an
nun
DEEE
(canal)
mas
su
FLE
(onen Sun
gan alan 20
oem zn
0 fem zn
+ The cases “dy when there à absohtey no
engine où on he 4 mm ead bote and elder
hed’ bot hes
+ Thecasets we when therels engine ollon he 14
mmm head bots rider head's bol Nees.
Tech Bon loath
CT Tai
CIN O
EEN
ia
re
=
Install the Oi Pump Assembly
Y instale of pump wäh he 4 bots.
B
instal ho Engine Roar Où Seal Retainer
Y App) soa packing a continuous ine a shown in
E
Pano sy Fem a acc.
OCA Cri Sims en te
[teo te
Ped
+ Bote te ga oh lo
foie
YANMAR su wos conso tons
gone D ere
ENGINE
“Taal te ining gear caso wih the 22 bala an
nun
DEEE
(canal)
mas
su
FLE
(onen Sun
gan alan 20
oem zn
0 fem zn
+ The cases “dy when there à absohtey no
engine où on he 4 mm ead bote and elder
hed’ bot hes
+ Thecasets we when therels engine ollon he 14
mmm head bots rider head's bol Nees.
Tech Bon loath
CT Tai
CIN O
EEN
ia
re
=
Install the Oi Pump Assembly
Y instale of pump wäh he 4 bots.
B
instal ho Engine Roar Où Seal Retainer
Y App) soa packing a continuous ine a shown in
E
Pano sy Fem a acc.
OCA Cri Sims en te
[teo te
Ped
+ Bote te ga oh lo
foie
YANMAR su wos conso tons
gone D ere
ENGINE
Engine Assembly
2 tal he of sea rtaner win tho 10 ol as shown
Inte iutaton
ae I eg]
+ en intaling te ole rte, make sure the
ori oll seals not damaged,
+ Vihoninsaling the oi soa ttainer make sur the
lp oh ol seas not ldedincomocy.
=
25
26
instal the OW Regulator Assembly
Y. instal orgullo wih the 4 bolis.
EA]
instal the Oi Strainor Sub Assembly
1 Apply agit coat engine oo new ring,
2 Intl the Oving tothe oi sainer
Fatals où trainer win the ots.
CR]
instal the Où Pan Sub Assembly
Y. Instala new O-ring to the ll regular.
+ Securely insta the O-ring tothe o regulators
ing groove.
+ Dont top the © ing.
Engine Assembly
2 tal he of sea rtaner win tho 10 ol as shown
Inte iutaton
ae I eg]
+ en intaling te ole rte, make sure the
ori oll seals not damaged,
+ Vihoninsaling the oi soa ttainer make sur the
lp oh ol seas not ldedincomocy.
=
25
26
instal the OW Regulator Assembly
Y. instal orgullo wih the 4 bolis.
EA]
instal the Oi Strainor Sub Assembly
1 Apply agit coat engine oo new ring,
2 Intl the Oving tothe oi sainer
Fatals où trainer win the ots.
CR]
instal the Où Pan Sub Assembly
Y. Instala new O-ring to the ll regular.
+ Securely insta the O-ring tothe o regulators
ing groove.
+ Dont top the © ing.
Engine Assembly
ENGINE
7 Apply soa packing a continuous nos show in
euren
Sea Packng,
+ Forte ol holes abel, app he sealpacking
on ho cute edges. For the ater bot holes, apply
the seal packing onthe inner edge.
+ Mako sure 1 apply a continuous bead of seal
packing as shown nthe stain. th bead
breaks verla 3 mm (0.118) of seal packing
‘and contin the bea,
Remove aro rom the contact surface
Ital the of pan thin 8 minutes and tighten the
bol and nus win 15 minos sto apphingseal
packing
+ Do nat stan the engine frat fast 2 hour aer
instan
3. natal a new seal washer and he oil pan wth the 20
bols and 2 te
EEE TENTE)
ET
om Length] Thrnd Dameter
EEE mon
OE IN
CO AN
E
installe OW Cooler Assembly
Appl alight coat ol engine oo 2 new O-inganda
new ol cooler bracket and instal emt Ihe ol
cooler,
2. state of cooler wth the 2 bolis and 2 ats.
EEE TENTE
YANMAR soon
ENGINE
7 Apply soa packing a continuous nos show in
euren
Sea Packng,
+ Forte ol holes abel, app he sealpacking
on ho cute edges. For the ater bot holes, apply
the seal packing onthe inner edge.
+ Mako sure 1 apply a continuous bead of seal
packing as shown nthe stain. th bead
breaks verla 3 mm (0.118) of seal packing
‘and contin the bea,
Remove aro rom the contact surface
Ital the of pan thin 8 minutes and tighten the
bol and nus win 15 minos sto apphingseal
packing
+ Do nat stan the engine frat fast 2 hour aer
instan
3. natal a new seal washer and he oil pan wth the 20
bols and 2 te
EEE TENTE)
ET
om Length] Thrnd Dameter
EEE mon
OE IN
CO AN
E
installe OW Cooler Assembly
Appl alight coat ol engine oo 2 new O-inganda
new ol cooler bracket and instal emt Ihe ol
cooler,
2. state of cooler wth the 2 bolis and 2 ats.
EEE TENTE
YANMAR soon
ENGINE
Engine Assembly
=
Insta the Fuel Supply Pump Assembly
Y Using @ mm » 128 pth ap, remove ho adhesive
from the ming oar caso aide bal hae,
2. Apply adhesive 102 or more treads ofthe timing,
gear case side Bot hole.
“Ths Bons 144 or elt
5. Age engine oil anew Gang and instal tothe
suppl pump.
ta spp amp ein goes
When sang eee pr, dnote
Tee
1-Temporan instal he 2 nut,
2 Using a 6 mmhexagon wench, instalo hexagon
bot aná en ga he 2 uta
En
Engine Assembly
=
Insta the Fuel Supply Pump Assembly
Y Using @ mm » 128 pth ap, remove ho adhesive
from the ming oar caso aide bal hae,
2. Apply adhesive 102 or more treads ofthe timing,
gear case side Bot hole.
“Ths Bons 144 or elt
5. Age engine oil anew Gang and instal tothe
suppl pump.
ta spp amp ein goes
When sang eee pr, dnote
Tee
1-Temporan instal he 2 nut,
2 Using a 6 mmhexagon wench, instalo hexagon
bot aná en ga he 2 uta
En
Engine Assembly ENGINE
2
1. Instale 16 lash ajustors o th oder head,
‘Bata the No. Y Valve Rocker Arms"
App engine ol othe lash adjuter ps and valve
‘tom ends.
2. Install 16No. Y vale rocker arms as shown inthe
istration,
Inst ach valve rocker arm atthe same place tas
removed om.
YANMAR 209 coo: 000 ares
2
1. Instale 16 lash ajustors o th oder head,
‘Bata the No. Y Valve Rocker Arms"
App engine ol othe lash adjuter ps and valve
‘tom ends.
2. Install 16No. Y vale rocker arms as shown inthe
istration,
Inst ach valve rocker arm atthe same place tas
removed om.
YANMAR 209 coo: 000 ares
ENGINE
Engine Assembly
Sr
instal the No-2 Camshaft Boaring Cap
Y Al he camahaf boring ap and the ng pins of
‘he yinder head, and instal tho cap.
[Sat tho No.1 Cylinder To 4 Baters TOC
1. Tum th crankshaft counerlockuie une No. 1
dor ata postion 45 boro TOC.
eet ra ain tl tr tig
foo nad
Note:
The No. 1 efinderi ata postion 45" betoro TOC
the crankshof counterweight i overapping he
‘jer Dock hole shown in ho veran.
Install the No. 1 and No, 2 Camshaft
{Ack more han 1808 (1204: ol engin o into the
der head ide of holes
2 Age engine ot the valve rocker rm or ae
‘camshaft housing of the oye hea,
Engine Assembly
Sr
instal the No-2 Camshaft Boaring Cap
Y Al he camahaf boring ap and the ng pins of
‘he yinder head, and instal tho cap.
[Sat tho No.1 Cylinder To 4 Baters TOC
1. Tum th crankshaft counerlockuie une No. 1
dor ata postion 45 boro TOC.
eet ra ain tl tr tig
foo nad
Note:
The No. 1 efinderi ata postion 45" betoro TOC
the crankshof counterweight i overapping he
‘jer Dock hole shown in ho veran.
Install the No. 1 and No, 2 Camshaft
{Ack more han 1808 (1204: ol engin o into the
der head ide of holes
2 Age engine ot the valve rocker rm or ae
‘camshaft housing of the oye hea,
Engine Assembly ENGINE
a Tannen T Tor
Fe amaba
"Apply engine lo th carshal journal and bes
2 ign th ring marks (2 aot mark) ho No 1
‘end No, 2 camshaft timing gear backside shownin
the tation.
Pl the camshats into the cylinder he
Before and afer setting ho camshats my set the
rocker arme tothe lash adjusters,
YANMAR aus eos
a Tannen T Tor
Fe amaba
"Apply engine lo th carshal journal and bes
2 ign th ring marks (2 aot mark) ho No 1
‘end No, 2 camshaft timing gear backside shownin
the tation.
Pl the camshats into the cylinder he
Before and afer setting ho camshats my set the
rocker arme tothe lash adjusters,
YANMAR aus eos
ENGINE
Engine Assembly
Fatal he No carahat bearing cap
YAlgn the No, 1 camahalbooring cap and th ing
fins ol the No, 2 carahalibeamng cp.
2 Femporaiy instal the 4 bons by hand
5. Install he No.3 camahat bearing caps
Y Conirmtho marks and numbers on ho camshaft
bearing caps and place them in their proper
potion and direction.
2 Temporary fatal the 8 bots, which aro not
instalo wi he ot fod pipe by hand.
6. Temporaiy instal No. 1 and No. 2 camshat ot
eed pipes wih the 8 bo by hand
A ven one ol he pipe bolt holes doesnot match its
‘camshaft bearing cap boll hl, replace the pie,
Note
The ei banton the intake side and strain e
exaust side
7. Temporarily instal the 2 union bot,
Engine Assembly
Fatal he No carahat bearing cap
YAlgn the No, 1 camahalbooring cap and th ing
fins ol the No, 2 carahalibeamng cp.
2 Femporaiy instal the 4 bons by hand
5. Install he No.3 camahat bearing caps
Y Conirmtho marks and numbers on ho camshaft
bearing caps and place them in their proper
potion and direction.
2 Temporary fatal the 8 bots, which aro not
instalo wi he ot fod pipe by hand.
6. Temporaiy instal No. 1 and No. 2 camshat ot
eed pipes wih the 8 bo by hand
A ven one ol he pipe bolt holes doesnot match its
‘camshaft bearing cap boll hl, replace the pie,
Note
The ei banton the intake side and strain e
exaust side
7. Temporarily instal the 2 union bot,
Engine Assembly ENGINE
UE gion re 20 basin several steps into
order shou inthe tution.
a EI EN
Taten rias | 16 em 6 tom 74-80
4. itn the union bts
10.Remove the bot rm the No. y eamahat
natal the No. 2 Valve Rocker Arma
‘apply engine of tothe lash adjuster tps ana vale
2 Install 16No, 2 valve rocker ams as shoun inthe
istration,
Nove
Inst each vate rocker arm atthe same place twas
removed ton.
YANMAR aus en
UE gion re 20 basin several steps into
order shou inthe tution.
a EI EN
Taten rias | 16 em 6 tom 74-80
4. itn the union bts
10.Remove the bot rm the No. y eamahat
natal the No. 2 Valve Rocker Arma
‘apply engine of tothe lash adjuster tps ana vale
2 Install 16No, 2 valve rocker ams as shoun inthe
istration,
Nove
Inst each vate rocker arm atthe same place twas
removed ton.
YANMAR aus en
ENGINE
Engine Assembly
instal the No.2 Valve Lash Adjustor Assombly
Be suet inspect the valve lsh adjuster before
ing à
Instat the 16 ah ajustes to the cindor head
Note
Int each ah autor a m amo pic tn
Install the Ho. $ Camshaft Bearing Cap
Y Al he camehalt bearing ep and th ing pin of
the older head and inte cp.
7
instal the No, 3 and No 4 Camahañ
ra
A A
oo Erie ip
o a ne
AA
1. Addmorothan 19 6 (124 o engine oto o
finder head ido of holes
Engine Assembly
instal the No.2 Valve Lash Adjustor Assombly
Be suet inspect the valve lsh adjuster before
ing à
Instat the 16 ah ajustes to the cindor head
Note
Int each ah autor a m amo pic tn
Install the Ho. $ Camshaft Bearing Cap
Y Al he camehalt bearing ep and th ing pin of
the older head and inte cp.
7
instal the No, 3 and No 4 Camahañ
ra
A A
oo Erie ip
o a ne
AA
1. Addmorothan 19 6 (124 o engine oto o
finder head ido of holes
Engine Assembly
ENGINE
camsha housing of the oyinder head.
3. Intl th No. and No. 4 camshate,
Pics the camshats ino the older ha
YANMAR su wos conso tons
ZA ange a oto valve rocker am ales an
AD engine ot the came our and bos
2g the matchenarks ofthe No. and No.4
cash ming gears shown in he Huston
ENGINE
camsha housing of the oyinder head.
3. Intl th No. and No. 4 camshate,
Pics the camshats ino the older ha
YANMAR su wos conso tons
ZA ange a oto valve rocker am ales an
AD engine ot the came our and bos
2g the matchenarks ofthe No. and No.4
cash ming gears shown in he Huston
ENGINE
Engine Assembly
Talis No carahat bearing cap
YAlgn the No, 4 camahalbooring cap and th ing
pins ol he No carshalt bearing cap.
2 Femporaniy ial the 4 bons by hand
5. ntl he No. 3 camahat bearing caps
Conti te marks and numbers o he camshaft
bearing caps and place thor in thar propor
postion and recon
2-Temporaiy instal the 8 bois, which aro not
inet wi ho ot fed pip by hand
6, Terporaiy instal the No.3 and No, 4 camshat ot
tod pp wh th 8 bo by hand
I von one ol the pipe bel hols dows not match its
«ara bearing ap bo hol, replace the pipe.
oe:
The pie is bentontheintake side and sraight onthe
exhaust sido
7. Temporary instal the 2 union bots
Engine Assembly
Talis No carahat bearing cap
YAlgn the No, 4 camahalbooring cap and th ing
pins ol he No carshalt bearing cap.
2 Femporaniy ial the 4 bons by hand
5. ntl he No. 3 camahat bearing caps
Conti te marks and numbers o he camshaft
bearing caps and place thor in thar propor
postion and recon
2-Temporaiy instal the 8 bois, which aro not
inet wi ho ot fed pip by hand
6, Terporaiy instal the No.3 and No, 4 camshat ot
tod pp wh th 8 bo by hand
I von one ol the pipe bel hols dows not match its
«ara bearing ap bo hol, replace the pipe.
oe:
The pie is bentontheintake side and sraight onthe
exhaust sido
7. Temporary instal the 2 union bots
Engine Assembly ENGINE
UE gion re 20 basin several steps into
order shou inthe tution.
a EI EN
Trew [rome | 10 Nm 62 kom 7180)
9. Tighen the 2 union bos
WATER
10.Remove the Bol rom the No. 4camshat ning
gear
m
Do not drop the bot into the engine
Neve
ie bolts eut 1 remove, rotate the camshat
‘and remove the bol. Then realign Ihe matchmar of
the No. Sand No.4 camshaft ming gears.
11 Temporary instal the No.2 camshat ing
‘sprocket and Ne. 2timingchaintothe No. Scams
he 2 bot,
YANMAR soon
UE gion re 20 basin several steps into
order shou inthe tution.
a EI EN
Trew [rome | 10 Nm 62 kom 7180)
9. Tighen the 2 union bos
WATER
10.Remove the Bol rom the No. 4camshat ning
gear
m
Do not drop the bot into the engine
Neve
ie bolts eut 1 remove, rotate the camshat
‘and remove the bol. Then realign Ihe matchmar of
the No. Sand No.4 camshaft ming gears.
11 Temporary instal the No.2 camshat ing
‘sprocket and Ne. 2timingchaintothe No. Scams
he 2 bot,
YANMAR soon
ENGINE
Engine Assembly
ang SST, late No, 2 cams ring aprecia
Tighten the 2 bots
xe | a]
EEE
19 Rote the crankshaft pe cacheo that
remaining pump dive shalt gear bots canbe
‘real,
2
14 Tomporaiy install the 2 bot the No. 9 cash
16.Using ST, hate No, 2 camela timing sprocket
"Tien the? bots
EE ENT
EE EE]
Temporal instal the Fuel Supply Pump Drive
Gear
{Align the cutout othe suppy pump die gear andthe
key of he supply pump.
2. Temporary and the dto ger wih ih ur.
Engine Assembly
ang SST, late No, 2 cams ring aprecia
Tighten the 2 bots
xe | a]
EEE
19 Rote the crankshaft pe cacheo that
remaining pump dive shalt gear bots canbe
‘real,
2
14 Tomporaiy install the 2 bot the No. 9 cash
16.Using ST, hate No, 2 camela timing sprocket
"Tien the? bots
EE ENT
EE EE]
Temporal instal the Fuel Supply Pump Drive
Gear
{Align the cutout othe suppy pump die gear andthe
key of he supply pump.
2. Temporary and the dto ger wih ih ur.
Engine Assembly
ENGINE
hat
30 | lata ho No. Talo Gear Shaft
{Apply engin o othe contact saco of he ilo
2. Install he ie gear shat othe elindr block
“20 | Install the No. ie Gear
{alge he timing marks fhe supply pump dive gear
‘nd le gear, and the ring marks othe cankshatt
‘ining gear and ile ge a shown nthe istration
2. Rep engin ol othe do gear hrs plato.
YANMAR su wos conso tons
ENGINE
hat
30 | lata ho No. Talo Gear Shaft
{Apply engin o othe contact saco of he ilo
2. Install he ie gear shat othe elindr block
“20 | Install the No. ie Gear
{alge he timing marks fhe supply pump dive gear
‘nd le gear, and the ring marks othe cankshatt
‘ining gear and ile ge a shown nthe istration
2. Rep engin ol othe do gear hrs plato.
YANMAR su wos conso tons
ENGINE
Engine Assembly
Tata he le ger hus plato wih o Wei,
[xe | aE]
Tighten the Fool Supply Pump Orive Gear Nut
1. Using SST, hol the le goar and ightontho ma.
Gear]
PARO A
Engine Assembly
Tata he le ger hus plato wih o Wei,
[xe | aE]
Tighten the Fool Supply Pump Orive Gear Nut
1. Using SST, hol the le goar and ightontho ma.
Gear]
PARO A
Engine Assembly ENGINE
a A T Tor
“22 _| Check tho No.1 Cylindor to TOCICompression
Check tha the timing mark of tho following par o
pas ar ale 1) supply pump ave goar and ile
‘Sear. 2}erarkshat ring gear ande get, and 3)
Rand LH camabatt inn gears,
YANMAR 209 coo: 000 ares us
a A T Tor
“22 _| Check tho No.1 Cylindor to TOCICompression
Check tha the timing mark of tho following par o
pas ar ale 1) supply pump ave goar and ile
‘Sear. 2}erarkshat ring gear ande get, and 3)
Rand LH camabatt inn gears,
YANMAR 209 coo: 000 ares us
Engine Assembly
ENGINE
45 [instalo No.2 Camshaft Timing Sprocket and
No.2 Timing Chain
Fig he 2 mark pates (yoo) onthe No.2 ting
han wah the timing mark (1 dot mani fhe No. à
‘carnal ning sprocket shown inthe stato.
>. align the No.2 timing chan plat yen) with the
Supply pump deve gearing mark, and temporary
insalthe No.2 camehal timing sprocket wi ho à
bot
9, Using SST, hold he No, 2 camahat timing sprocket,
and ight the 4 bots
= a)
ENGINE
45 [instalo No.2 Camshaft Timing Sprocket and
No.2 Timing Chain
Fig he 2 mark pates (yoo) onthe No.2 ting
han wah the timing mark (1 dot mani fhe No. à
‘carnal ning sprocket shown inthe stato.
>. align the No.2 timing chan plat yen) with the
Supply pump deve gearing mark, and temporary
insalthe No.2 camehal timing sprocket wi ho à
bot
9, Using SST, hold he No, 2 camahat timing sprocket,
and ight the 4 bots
= a)
Engine Assembly
ENGINE
=
Tnatall the No. Y Camshaft Timing Sprockat and
No.1 Timing Chain
Align o 2 mark plates (low) onthe No, ting
‘hain win he timing mar (1 dt ma) ae No, 4
‘camshaft ining sprocket shown inthe Huston.
2.Algn the No. ining cain pate (yellow) withthe
Supply pump dive gear timing mark, and temporary
incline No. Y comahat tng sprocket
install the Pump Drive Shan Gear
1 Temporary instal pump ive shal gear withthe
‘bot,
2 Using SST, hold the pump dive shaft gear and
tighten the 4 bo
Tom ME EE A
A A IA
Tnetall the Wo. 2 Chain Vibration Damper
‘No. 2 chin vaio damper with the 2
NA
YANMAR soon
ENGINE
=
Tnatall the No. Y Camshaft Timing Sprockat and
No.1 Timing Chain
Align o 2 mark plates (low) onthe No, ting
‘hain win he timing mar (1 dt ma) ae No, 4
‘camshaft ining sprocket shown inthe Huston.
2.Algn the No. ining cain pate (yellow) withthe
Supply pump dive gear timing mark, and temporary
incline No. Y comahat tng sprocket
install the Pump Drive Shan Gear
1 Temporary instal pump ive shal gear withthe
‘bot,
2 Using SST, hold the pump dive shaft gear and
tighten the 4 bo
Tom ME EE A
A A IA
Tnetall the Wo. 2 Chain Vibration Damper
‘No. 2 chin vaio damper with the 2
NA
YANMAR soon
ENGINE
Engine Assembly
instal the Wo: 2 Chain Tensioner Sippar
4
Install the No. Chain Tensioner Assembly
{Move the stopper plat clocks release the lock,
and push the plunger no Ih tensioner.
2, Move the stopper plate counterclockwise to sl the
Teck, and insert a hexagon wrench to he stopper
Pit ole
2. ntl he No. chain tensioner wth the 2 bots.
a]
4, Remove the hexagon wrench
install the No.1 Chain Vibration Damper
1. Inline No. cha vibration damper withthe 2
tote,
instal the No. Y Chain Tens
or Sippor
Engine Assembly
instal the Wo: 2 Chain Tensioner Sippar
4
Install the No. Chain Tensioner Assembly
{Move the stopper plat clocks release the lock,
and push the plunger no Ih tensioner.
2, Move the stopper plate counterclockwise to sl the
Teck, and insert a hexagon wrench to he stopper
Pit ole
2. ntl he No. chain tensioner wth the 2 bots.
a]
4, Remove the hexagon wrench
install the No.1 Chain Vibration Damper
1. Inline No. cha vibration damper withthe 2
tote,
instal the No. Y Chain Tens
or Sippor
Engine Assembly
ENGINE
”
Tnatall ho No. Y Chain Tensioner Assembly
Move the stopper pate clockwise t release th lock,
‘and push he plunger into the tensioner.
2. Move the topper plate eountresckwi o act he
lock and nson a hexagon wrench into he stopper
plate hale
state No.1 hain tensioner with the 2 bots
LT NET EEE
4 Remove he hexagon wrench,
F
Tnatall the Wo. Y Grankahaft Postion Sensor Plato
App adhesive o 2 oF treads lo? crow,
LIT
Tee Bond at or man
2. Wang a 130-TORX wrench, instalo No. 1
cranksha postion sensor lat wth the? crow
Toa TORE =
YANMAR cc conso tons
ENGINE
”
Tnatall ho No. Y Chain Tensioner Assembly
Move the stopper pate clockwise t release th lock,
‘and push he plunger into the tensioner.
2. Move the topper plate eountresckwi o act he
lock and nson a hexagon wrench into he stopper
plate hale
state No.1 hain tensioner with the 2 bots
LT NET EEE
4 Remove he hexagon wrench,
F
Tnatall the Wo. Y Grankahaft Postion Sensor Plato
App adhesive o 2 oF treads lo? crow,
LIT
Tee Bond at or man
2. Wang a 130-TORX wrench, instalo No. 1
cranksha postion sensor lat wth the? crow
Toa TORE =
YANMAR cc conso tons
ENGINE
Engine Assembly
[Ghock the No. Cylinder To TOCICOMpression
+. Temporal intl tho raat pulley anto 2
rot pulley et bot 1 he cranial
2, Rotate te rankshat 2 revolutions or mare 0 hat
the cankshat Key le 45" courtereloekwee fom he
top. Check hat the timing marks (1 do mark each of
the Ai and LH camshaft ing gears abgn. nt as
“pected, tum the crankshaft reveiton (3607 and
ign the ining mara, the tiring marks do nat
‘gn, oinstal to chain nd camahat
Engine Assembly
[Ghock the No. Cylinder To TOCICOMpression
+. Temporal intl tho raat pulley anto 2
rot pulley et bot 1 he cranial
2, Rotate te rankshat 2 revolutions or mare 0 hat
the cankshat Key le 45" courtereloekwee fom he
top. Check hat the timing marks (1 do mark each of
the Ai and LH camshaft ing gears abgn. nt as
“pected, tum the crankshaft reveiton (3607 and
ign the ining mara, the tiring marks do nat
‘gn, oinstal to chain nd camahat
Engine Assembly ENGINE
54 | lta ho Timing Chain Cover Sub-Assamlıy
en he contact surlaces shou below are wet
vio them with an ore ct beore applying se
packing
{Install anew O-ing to tho timing gear case
2 App sel packing tthe timing chan cover shown in
‘the folowing istration,
E
Ties Bond 120780 espia
+ Air apphing sal packing, alga ho timing gear
Case withthe engine win 3 muutes and gen
‘he bots and nt thin 15 minutes.
+ apy the seal packing ina continuous tne.
+ Mako sur the seal packing does not become
Aimer than à mm (000157 In) at th areas
labeled Bin the station
Mot:
+ The seal packing ine is shown below:
= Apply the cea packing unto along the IPG
fine. As, apply packing 1 the 6 seal surface
YANMAR aus um
54 | lta ho Timing Chain Cover Sub-Assamlıy
en he contact surlaces shou below are wet
vio them with an ore ct beore applying se
packing
{Install anew O-ing to tho timing gear case
2 App sel packing tthe timing chan cover shown in
‘the folowing istration,
E
Ties Bond 120780 espia
+ Air apphing sal packing, alga ho timing gear
Case withthe engine win 3 muutes and gen
‘he bots and nt thin 15 minutes.
+ apy the seal packing ina continuous tne.
+ Mako sur the seal packing does not become
Aimer than à mm (000157 In) at th areas
labeled Bin the station
Mot:
+ The seal packing ine is shown below:
= Apply the cea packing unto along the IPG
fine. As, apply packing 1 the 6 seal surface
YANMAR aus um
ENGINE
Engine Assembly
ara es me)
8. Align and instal timing chan cover tothe ing
gear case knock pin and supply pump bearing,
4. Apply engine ol the ol sell.
$5 Intl aneurin gon the 16 bas and 4 nts in
the order shown nthe tation
GA]
ote
Ie stud bots aro loose, tighten thom toro
performing Bi procedure, Using an E7 “TOR
French, tighten the sud Bot
De Tree]
6. Make sure nat the po the ol seals property
reales.
Engine Assembly
ara es me)
8. Align and instal timing chan cover tothe ing
gear case knock pin and supply pump bearing,
4. Apply engine ol the ol sell.
$5 Intl aneurin gon the 16 bas and 4 nts in
the order shown nthe tation
GA]
ote
Ie stud bots aro loose, tighten thom toro
performing Bi procedure, Using an E7 “TOR
French, tighten the sud Bot
De Tree]
6. Make sure nat the po the ol seals property
reales.
ENGINE
Engine Assembly
a E T Tor
55 [instal he Water Pump Assombly
{installa new gasket andthe water pump wh the 9
bols and? te
Tor EAN
ENT
Bm Tong [Tres dare
E E | mm Gars)
de | mien) | most)
After stalin al fhe bts and nus, check ht al
the bots and nu re gent the toque
Specticaton
55 | Connect the Ol Cooler Hose
{Connect the Ne 1 and No 2 oi cooler hoses.
57 natal the Fan Bracket Sub Assembly
Fatal he fn brooks wh ne bat,
Ton EL TENTE
EN
Ten Tongih _ [Trend Omer
BR mnt | bmn 3m
se | eommatsa) | amm(aisin)
YANMAR 209 coo: 000 ares
Engine Assembly
a E T Tor
55 [instal he Water Pump Assombly
{installa new gasket andthe water pump wh the 9
bols and? te
Tor EAN
ENT
Bm Tong [Tres dare
E E | mm Gars)
de | mien) | most)
After stalin al fhe bts and nus, check ht al
the bots and nu re gent the toque
Specticaton
55 | Connect the Ol Cooler Hose
{Connect the Ne 1 and No 2 oi cooler hoses.
57 natal the Fan Bracket Sub Assembly
Fatal he fn brooks wh ne bat,
Ton EL TENTE
EN
Ten Tongih _ [Trend Omer
BR mnt | bmn 3m
se | eommatsa) | amm(aisin)
YANMAR 209 coo: 000 ares
ENGINE Engine Assembly
50 | Assomblo the No.1 and No.2 Water Outlet Pipes
and Visto By-Pass Outlet
‘Align the painted marco the No, 1 water hose jon
the proton ol the war by pass cute and
Connect the water by pass oul athe No. Y water
ose joint
2 Align the parted mark ol he No. water hose joint
with the parted mark ol the No 2 water out pipe
‘and connect he No. water out pipe tothe No
rar has jot
Connect a new gasket andthe No, and No.2 water
out pipes wth the 2 bots
Cae aa]
Not:
The gastes clans can face te No. 1 or No.2 water
cule pe
Y. instal starter wth I 2 bots
CONE
2. atch the hamess clamp and connect ne wre
ames
2. Intl he starter wire wth e
Car]
4. Comecthe starter connector
50 | Assomblo the No.1 and No.2 Water Outlet Pipes
and Visto By-Pass Outlet
‘Align the painted marco the No, 1 water hose jon
the proton ol the war by pass cute and
Connect the water by pass oul athe No. Y water
ose joint
2 Align the parted mark ol he No. water hose joint
with the parted mark ol the No 2 water out pipe
‘and connect he No. water out pipe tothe No
rar has jot
Connect a new gasket andthe No, and No.2 water
out pipes wth the 2 bots
Cae aa]
Not:
The gastes clans can face te No. 1 or No.2 water
cule pe
Y. instal starter wth I 2 bots
CONE
2. atch the hamess clamp and connect ne wre
ames
2. Intl he starter wire wth e
Car]
4. Comecthe starter connector
Engine Assembly
ENGINE
y
Tnatal No: take Monto
‘installa. now gasket andthe take manu the
‘bots
or
instal he No Intake Manifold
‘installa new gasket and the intake manifold ith the
‘bats
®
instalho Wo. Y Water By-Pass Pipo
install on, ater by-pass pipe with
the union bot,
2 lta bot
inatallthe Wo. 3 Nozzle Leakage Pipe
1. Gonnes the hose tothe ful Pipe No 5.
2 Install new gasket and the nezle leakage pipe wth
the union bot and bot
am RECETA ELOTE
YANMAR su wos conso tons
ENGINE
y
Tnatal No: take Monto
‘installa. now gasket andthe take manu the
‘bots
or
instal he No Intake Manifold
‘installa new gasket and the intake manifold ith the
‘bats
®
instalho Wo. Y Water By-Pass Pipo
install on, ater by-pass pipe with
the union bot,
2 lta bot
inatallthe Wo. 3 Nozzle Leakage Pipe
1. Gonnes the hose tothe ful Pipe No 5.
2 Install new gasket and the nezle leakage pipe wth
the union bot and bot
am RECETA ELOTE
YANMAR su wos conso tons
ENGINE Engine Assembly
(64 | instal the Wo. 4 Nozzle Leakage Pipe
Connect ne ose tothe ft pe Ho 5
> ittlanewgnctanste nee tag po wa | | 2
DER EEE EE
Toren as 10m (02 gem TR.
if
Re
¡CAP
[natal the No.1 Fuel Pipe
Y Inst new gaskets ad the No. 1 fuel pipe wih the
union bol
CRA
66 | natal the Glow Plug Assembly
{Apply Locket the teed parol the glow plugs.
Seal Packing
2. Usinga 10mm doop socket wrench, instalo 8 gow
pags.
CRA
(64 | instal the Wo. 4 Nozzle Leakage Pipe
Connect ne ose tothe ft pe Ho 5
> ittlanewgnctanste nee tag po wa | | 2
DER EEE EE
Toren as 10m (02 gem TR.
if
Re
¡CAP
[natal the No.1 Fuel Pipe
Y Inst new gaskets ad the No. 1 fuel pipe wih the
union bol
CRA
66 | natal the Glow Plug Assembly
{Apply Locket the teed parol the glow plugs.
Seal Packing
2. Usinga 10mm doop socket wrench, instalo 8 gow
pags.
CRA
Engine Assembly
ENGINE
CZ
Tnstathe No: Y Glow Plug Connector
sta 62 low Plug connectors by uno
igenng the 6 nut
OA AA
2 Intl 8 screw grommets
3. Connect the 2 wie harnesses withthe 2 nus and2
‘grommets.
intel ho No. take ME
installa now gosket othe No. 1 intake manto and
‘a now gasket tho No. 2 intake mantel.
2. Ital he o. eke mandold wah the 16 bot
25 mm (0388 1
Install the Common Rail LA
Y instale common ral wth the 2 bots,
YANMAR 209 coo: 000 ares
ENGINE
CZ
Tnstathe No: Y Glow Plug Connector
sta 62 low Plug connectors by uno
igenng the 6 nut
OA AA
2 Intl 8 screw grommets
3. Connect the 2 wie harnesses withthe 2 nus and2
‘grommets.
intel ho No. take ME
installa now gosket othe No. 1 intake manto and
‘a now gasket tho No. 2 intake mantel.
2. Ital he o. eke mandold wah the 16 bot
25 mm (0388 1
Install the Common Rail LA
Y instale common ral wth the 2 bots,
YANMAR 209 coo: 000 ares
ENGINE Engine Assembly
70 [instal the Common Rall AH
sale common a wh th 2 bot
COIE
2 Using SST, then union nut onthe common rai
NTRA DA
wassı [31 mr gran 2586)
Mako sure tro no foolgn matter or damage on
‘the senlsuen.
ote
+ Use torque ranch witha rum eng of em
CB
+ Make sure SST andthe wrench aro conneeisdina
‘stag ine
5. Connect he fuel pressure sensor connect.
71 install the Fast nector LF
Be sure oinaalheirecor, haber clamp and boltin.
thai orginal posions.
tn
head
4 now injection nozzle seats tthe cylinder
2 Age a Eh amount of clan engine ito 4 new
Os.
5. Install an ©-ingto each recor shown inthe
brain, _
4. Inset the injectors into the ender he ATI
+ Insertthe injector un touches Ihe nozzle seat toc ei
surface
+ Alerinstalingtheinjctorto the cyinder head. the
(ing may prevent be incor tom al seating
lso, pl out the injector and reist
+ Always eum each incor othe same place it
‘ras removed om.
5. For each recor that has been replaced with anew
injector, register tho now injoctor compensation code
70 [instal the Common Rall AH
sale common a wh th 2 bot
COIE
2 Using SST, then union nut onthe common rai
NTRA DA
wassı [31 mr gran 2586)
Mako sure tro no foolgn matter or damage on
‘the senlsuen.
ote
+ Use torque ranch witha rum eng of em
CB
+ Make sure SST andthe wrench aro conneeisdina
‘stag ine
5. Connect he fuel pressure sensor connect.
71 install the Fast nector LF
Be sure oinaalheirecor, haber clamp and boltin.
thai orginal posions.
tn
head
4 now injection nozzle seats tthe cylinder
2 Age a Eh amount of clan engine ito 4 new
Os.
5. Install an ©-ingto each recor shown inthe
brain, _
4. Inset the injectors into the ender he ATI
+ Insertthe injector un touches Ihe nozzle seat toc ei
surface
+ Alerinstalingtheinjctorto the cyinder head. the
(ing may prevent be incor tom al seating
lso, pl out the injector and reist
+ Always eum each incor othe same place it
‘ras removed om.
5. For each recor that has been replaced with anew
injector, register tho now injoctor compensation code
Engine Assembly
ENGINE
TG Temporary natal 4 new washers andthe 4 noz
lampe wi tho à mp bol
+ Thotorkporton ofthe nozleholderclunp must be
alto injector.
+ Before tightening the bos, check at the nozzle
Poker clamps are set proper.
+ Tolasten the clap bok fl ghten them by
hand unt ey can be tured further. Then.
tighten the Bos othe spectied logue ina ater
step,
+ When tohtening the bots, pay attention not ot
the bo and clamp.
+ Do mot reuse the washer.
1. Temporary install injector pipes the common.
ral and injector.
8. Check ho noce leakage pipe. Check hat there ave
ro Seat orden on the 5 union seal ours I
cales or dens are preset replace the nozzle
leakage pipe
8, Sette leakage pipe and new gaskets in pace
10 Temporary instal the leakage pio withthe 4holow
“screw and union bo
Nove
To potion the injactors loosely gen the 4 how
sons and union bo
YANMAR su wos conso tons
ENGINE
TG Temporary natal 4 new washers andthe 4 noz
lampe wi tho à mp bol
+ Thotorkporton ofthe nozleholderclunp must be
alto injector.
+ Before tightening the bos, check at the nozzle
Poker clamps are set proper.
+ Tolasten the clap bok fl ghten them by
hand unt ey can be tured further. Then.
tighten the Bos othe spectied logue ina ater
step,
+ When tohtening the bots, pay attention not ot
the bo and clamp.
+ Do mot reuse the washer.
1. Temporary install injector pipes the common.
ral and injector.
8. Check ho noce leakage pipe. Check hat there ave
ro Seat orden on the 5 union seal ours I
cales or dens are preset replace the nozzle
leakage pipe
8, Sette leakage pipe and new gaskets in pace
10 Temporary instal the leakage pio withthe 4holow
“screw and union bo
Nove
To potion the injactors loosely gen the 4 how
sons and union bo
YANMAR su wos conso tons
ENGINE
Engine Assembly
Tighten the 4 holder camp bot
EURE EN
12 Romove he 4 injection pipes
18 Tighten the 4 hollow serous
DT er
la holow sorewis accdertaly tightened beyond the
torque specication, must be replaced,
onthe oon bot
(ge eo
Hihe union bat acedenalytigtened beyond the
torque specication, # must be replaced
Engine Assembly
Tighten the 4 holder camp bot
EURE EN
12 Romove he 4 injection pipes
18 Tighten the 4 hollow serous
DT er
la holow sorewis accdertaly tightened beyond the
torque specication, must be replaced,
onthe oon bot
(ge eo
Hihe union bat acedenalytigtened beyond the
torque specication, # must be replaced
Engine Assembly
ENGINE
a
natal ho Fuel injecter AA
Be sure instal the injector. holder clamp and bot in
thoi original positon
1. sta 4 now injection nozale seats tothe ander
bond.
2. Apply alight amount of clean engine ito 4 new
Org.
2. Ital an Oring o wach injector shown inthe
istration,
Insort ho injctr unit fouches the nozzle soat
‘dace
+ Aor ntling he injector tothe cylinder hea, the
‘Oring may prevent tho jctor trom fly seating,
N30 pullout the meter and rit it
+ Aways rtum each injector othe same place &
‘eas removed rom.
5. For aninjctr that has been replace wih a new
injector. register the new injecor compensation code,
6. Temporary instal 4 now washers andthe 4 nozzle
camps hho à clamp bot
+ Thetorkpotionofthe nozzle olderclanp must be
setto he mjor
Before tightening the bolis, check hat th nozzle
holder clamps are set proper
Tolaste he clamp bots, fst üghten them by
hand unthey cannot be tured further. Then.
tighten the Bos tothe spectied drque ina er
sop.
‘Win gering the bots, pay ation nolo
the bo and lamp,
+ Do nat reuse th wachen
YANMAR su wos conso tons
ENGINE
a
natal ho Fuel injecter AA
Be sure instal the injector. holder clamp and bot in
thoi original positon
1. sta 4 now injection nozale seats tothe ander
bond.
2. Apply alight amount of clean engine ito 4 new
Org.
2. Ital an Oring o wach injector shown inthe
istration,
Insort ho injctr unit fouches the nozzle soat
‘dace
+ Aor ntling he injector tothe cylinder hea, the
‘Oring may prevent tho jctor trom fly seating,
N30 pullout the meter and rit it
+ Aways rtum each injector othe same place &
‘eas removed rom.
5. For aninjctr that has been replace wih a new
injector. register the new injecor compensation code,
6. Temporary instal 4 now washers andthe 4 nozzle
camps hho à clamp bot
+ Thetorkpotionofthe nozzle olderclanp must be
setto he mjor
Before tightening the bolis, check hat th nozzle
holder clamps are set proper
Tolaste he clamp bots, fst üghten them by
hand unthey cannot be tured further. Then.
tighten the Bos tothe spectied drque ina er
sop.
‘Win gering the bots, pay ation nolo
the bo and lamp,
+ Do nat reuse th wachen
YANMAR su wos conso tons
ENGINE
Engine Assembly
7 Temporary mathe comme ra A Wah Tho 2
ot
8. Terporaiy instalo 4 into pipes tothe common.
rad and eco.
8. Check he nozze leakage pie. Check tha thre are
‘no soraches or denon thes union seal suioss. I
Scratches or deis are present, replace the nozzle
leakave pipe
10'S te leakage pipe and now gaskets in pace
*+1.Tomporaiy ota leakage pip wihthe low
ern and union bl
Topostion he ilctors, losa) tigton the 4 ha
ores and union batt.
12.Tighton the 4 holder camp bots
NACER
ac tajo pre
Engine Assembly
7 Temporary mathe comme ra A Wah Tho 2
ot
8. Terporaiy instalo 4 into pipes tothe common.
rad and eco.
8. Check he nozze leakage pie. Check tha thre are
‘no soraches or denon thes union seal suioss. I
Scratches or deis are present, replace the nozzle
leakave pipe
10'S te leakage pipe and now gaskets in pace
*+1.Tomporaiy ota leakage pip wihthe low
ern and union bl
Topostion he ilctors, losa) tigton the 4 ha
ores and union batt.
12.Tighton the 4 holder camp bots
NACER
ac tajo pre
Engine Assembly
ENGINE
Forro tho jection pipes,
4 Remove the 2 bots and common ri AH
18 Tighton the 4 hollow serows
Na holowscrowisaccideraly tightened beyond the
torque speciation, must be replaced.
icone union bot
ithe union bot is acidotaly tightened yon the
torque specication, muse replaced.
YANMAR su wos conso tons
ENGINE
Forro tho jection pipes,
4 Remove the 2 bots and common ri AH
18 Tighton the 4 hollow serows
Na holowscrowisaccideraly tightened beyond the
torque speciation, must be replaced.
icone union bot
ithe union bot is acidotaly tightened yon the
torque specication, muse replaced.
YANMAR su wos conso tons
ENGINE Engine Assembly
73 | natal the Cylinder Head Cover Sub-Assembiy AÑ
Y Apply soa packing as shown nthe tation
Seal Packing
{+ Remove any oll rom the contact suce.
* Instat cynder headcover iin minutes aed
tighten the bie wie 15 minutes ar app
seal packing
+ Donotstant
ination,
gine for atleast 2 hour after
2 at new gasket othe cyber head cover
Remove any ol rom the contact sua.
5. Terporaiyintalthe cylinder had cover withthe 18
bal, Tghten the 18 bats tho order shown in he
‘statin,
EG] mara]
73 | natal the Cylinder Head Cover Sub-Assembiy AÑ
Y Apply soa packing as shown nthe tation
Seal Packing
{+ Remove any oll rom the contact suce.
* Instat cynder headcover iin minutes aed
tighten the bie wie 15 minutes ar app
seal packing
+ Donotstant
ination,
gine for atleast 2 hour after
2 at new gasket othe cyber head cover
Remove any ol rom the contact sua.
5. Terporaiyintalthe cylinder had cover withthe 18
bal, Tghten the 18 bats tho order shown in he
‘statin,
EG] mara]
Engine Assembly
ENGINE
Tnatall ho Cylnder Head Cover Sub-Assambiy LH
Y App sel packing as shown in he tation,
Seal Pace,
+ Remove any ai rom he contact surface.
+ Inctaltheylnderhead cover hin minutos and
tighten the ale within 1 minutes alter opi,
sea packing
+ Do nel sta the engine for atleast 2 hours ato
instalation.
2. Install now gasket to ho yindor head cover.
Remove any i rom ho contact suce.
8. Temporary instaba cylinder head cover wth the 17
ol. Tien the 17 bots in he cer shown in he
istration,
LT AE
4. Conneet the No. verilation hose.
Tnatall the OW Separator Assembly
‘installa now gaskot o ol separator
Remove any i rom the contact surco,
2. Install he soporto with he bot
Ta TON Cee Ren T RA
8.Conneet the hose,
7
instal ho Nozzie Holder Seal TA
1. Prosa new hokor seas ino the ander headcover
in
Install he Nozzle Holder Seal RH
‘Press 4 new heder eal int he cylnderheadcover
A
YANMAR su wos conso tons
ENGINE
Tnatall ho Cylnder Head Cover Sub-Assambiy LH
Y App sel packing as shown in he tation,
Seal Pace,
+ Remove any ai rom he contact surface.
+ Inctaltheylnderhead cover hin minutos and
tighten the ale within 1 minutes alter opi,
sea packing
+ Do nel sta the engine for atleast 2 hours ato
instalation.
2. Install now gasket to ho yindor head cover.
Remove any i rom ho contact suce.
8. Temporary instaba cylinder head cover wth the 17
ol. Tien the 17 bots in he cer shown in he
istration,
LT AE
4. Conneet the No. verilation hose.
Tnatall the OW Separator Assembly
‘installa now gaskot o ol separator
Remove any i rom the contact surco,
2. Install he soporto with he bot
Ta TON Cee Ren T RA
8.Conneet the hose,
7
instal ho Nozzie Holder Seal TA
1. Prosa new hokor seas ino the ander headcover
in
Install he Nozzle Holder Seal RH
‘Press 4 new heder eal int he cylnderheadcover
A
YANMAR su wos conso tons
ENGINE Engine Assembly
78 [install the Injection Pipo (For Bank 1)
Y Using ST, instal new jection pps to the
common rl and tel injectors wh fhe union nus.
=
A RA
Wassı [Nm om 29)
hate sre ers sage cla matron
Et
Note
+ Use oque urenen witha flram length 130m
(mam
+ Mao sore SST and ranch ar conecto ina
saigne
78 | Instal the Injection Pipe (For Bank 2)
1 Using SS, intl 4 now injection pipas 1 e
comin rand fel ijetors wth the unen ut,
Winer Sot [Sn DA
WaSsT [a Rem 1 ron 2046)
Mako suro tro à o damage o foreign matter on
tho seal surcos.
oe
torque wrench wih uerum ingth of Dem
(rain)
+ Make sure SST and wrench ar connected in a
‘stag ine
78 [install the Injection Pipo (For Bank 1)
Y Using ST, instal new jection pps to the
common rl and tel injectors wh fhe union nus.
=
A RA
Wassı [Nm om 29)
hate sre ers sage cla matron
Et
Note
+ Use oque urenen witha flram length 130m
(mam
+ Mao sore SST and ranch ar conecto ina
saigne
78 | Instal the Injection Pipe (For Bank 2)
1 Using SS, intl 4 now injection pipas 1 e
comin rand fel ijetors wth the unen ut,
Winer Sot [Sn DA
WaSsT [a Rem 1 ron 2046)
Mako suro tro à o damage o foreign matter on
tho seal surcos.
oe
torque wrench wih uerum ingth of Dem
(rain)
+ Make sure SST and wrench ar connected in a
‘stag ine
Engine Assembly ENGINE
‘| lata ho No.6 Injection Pipo Sub-Assombly
Using SST, nal a now No. 6 econ pipe o th.
‘common i with he ion rs.
= LEE]
Wee ST EE item AT
Wanssı AE
Make sure tro is no damage or foreign mat
the seal surtaces,
Note
+ Usea torque wrench ina fer length 90cm
ram
+ Make sure SST and wrench ao connected ina
straight Io.
2. state 2 No. 2 ijecion pipe clams wih the 2
nun
Bi [instalino Wo. 5 Fuel Pipe Sub Assembly
installa now gasket andthe ua pipe wth ho union
bot.
2. state injection pipe camp wih the bol.
Tom RL NET
TEE
8. Inst ton pie camp wit the bo.
4. Connect he hose othe ue pipe
Noe
+ Algo the markings and connect th hose
+ alg the pinching por of te clamp vith the
hoso making and annette hose.
YANMAR 209 coo: 000 ares
‘| lata ho No.6 Injection Pipo Sub-Assombly
Using SST, nal a now No. 6 econ pipe o th.
‘common i with he ion rs.
= LEE]
Wee ST EE item AT
Wanssı AE
Make sure tro is no damage or foreign mat
the seal surtaces,
Note
+ Usea torque wrench ina fer length 90cm
ram
+ Make sure SST and wrench ao connected ina
straight Io.
2. state 2 No. 2 ijecion pipe clams wih the 2
nun
Bi [instalino Wo. 5 Fuel Pipe Sub Assembly
installa now gasket andthe ua pipe wth ho union
bot.
2. state injection pipe camp wih the bol.
Tom RL NET
TEE
8. Inst ton pie camp wit the bo.
4. Connect he hose othe ue pipe
Noe
+ Algo the markings and connect th hose
+ alg the pinching por of te clamp vith the
hoso making and annette hose.
YANMAR 209 coo: 000 ares
ENGINE
Engine Assembly
Theil the o. Injection Pipe Sub-Assamiy
Y. Temporary install te 2 union ut the now No, 5
Ion Io con al nda Pump ty
2. Intl he injection pipe lamp wth he bot.
EEE
TE
5. Using SST. tighten te common rl sde union nut ot
the No. nection pi
Wann Sot
Was
Tanner glam SA
A 25H)
Aske ure ero ro ron mater or damage on
ES
Note
+ Uso torque uronch wi flerum engi af som
(iain)
+ Make sure SST andthe ranch are connected ina
‘alg ine
4, Using SST, gen he supp pump ido union nto
the No, 5 icon pipe,
LUE
SE en DA
roue 31 Ram gr, 2
Note:
+ Use a torque wrench witha flora length of Oem
(isin)
+ Make cure SST andthe wrench are connected a
straight ine
Engine Assembly
Theil the o. Injection Pipe Sub-Assamiy
Y. Temporary install te 2 union ut the now No, 5
Ion Io con al nda Pump ty
2. Intl he injection pipe lamp wth he bot.
EEE
TE
5. Using SST. tighten te common rl sde union nut ot
the No. nection pi
Wann Sot
Was
Tanner glam SA
A 25H)
Aske ure ero ro ron mater or damage on
ES
Note
+ Uso torque uronch wi flerum engi af som
(iain)
+ Make sure SST andthe ranch are connected ina
‘alg ine
4, Using SST, gen he supp pump ido union nto
the No, 5 icon pipe,
LUE
SE en DA
roue 31 Ram gr, 2
Note:
+ Use a torque wrench witha flora length of Oem
(isin)
+ Make cure SST andthe wrench are connected a
straight ine
Engine Assembly
ENGINE
Fear Toe BS T Tain
89 | natal ho Fuel Hose,
Y Install et hoso tthe common aan No. ful
Pipe
Woe
2 Aign the makings and connect the hose,
+ “alge the pinching porn othe clamp wth the
ose markıng and omnect me ose.
Tnatalthe Wo. § Nozzle Leakage Pipo
‘installa new gasket andthe eakago pipe withthe
non bat
Toga] SN ET
Make sure there isn foreign mater or damage on
the sel suce,
Install tho Fuel Pump Motor Wire
‘Install the fuel pump wire with the bo
EE EE TE
oo
‘tach the claw ofthe bracket othe timing gear case
hen instala be bracket.
Tata ho Wo. 2 Engine Wire
Y instale engine wre wi the 2 bots,
Tr EIGN COREE
YANMAR su wos conso tons
ENGINE
Fear Toe BS T Tain
89 | natal ho Fuel Hose,
Y Install et hoso tthe common aan No. ful
Pipe
Woe
2 Aign the makings and connect the hose,
+ “alge the pinching porn othe clamp wth the
ose markıng and omnect me ose.
Tnatalthe Wo. § Nozzle Leakage Pipo
‘installa new gasket andthe eakago pipe withthe
non bat
Toga] SN ET
Make sure there isn foreign mater or damage on
the sel suce,
Install tho Fuel Pump Motor Wire
‘Install the fuel pump wire with the bo
EE EE TE
oo
‘tach the claw ofthe bracket othe timing gear case
hen instala be bracket.
Tata ho Wo. 2 Engine Wire
Y instale engine wre wi the 2 bots,
Tr EIGN COREE
YANMAR su wos conso tons
ENGINE Engine Assembly
‘87 | natal he intake Pipe
Y Intl now gasket
2 Instale ppe with ho à bot and 2 rte
GARA]
instal the No. 2 Water By Pass Pipe
Y. instalo water by pass ppe.
Note
+ Algn he markings and connect he hose.
+ An ie pinching porn fe clamp withthe
oso marking and connec ne hose
install the Chain Cover and Compressor Bracket
Y. Instale chan cover and compressor bracket with
bot
cE
2. Comect ne wie harness
install the Crankshaft Postion Sensor
{Apply alight coat of engine ott the Ong
oe
2 When rousing the sensor, iapoct ho Ong
+ ¡Ho Oring has scratches o cus, replace tho
cranksha positon sonsor
‘87 | natal he intake Pipe
Y Intl now gasket
2 Instale ppe with ho à bot and 2 rte
GARA]
instal the No. 2 Water By Pass Pipe
Y. instalo water by pass ppe.
Note
+ Algn he markings and connect he hose.
+ An ie pinching porn fe clamp withthe
oso marking and connec ne hose
install the Chain Cover and Compressor Bracket
Y. Instale chan cover and compressor bracket with
bot
cE
2. Comect ne wie harness
install the Crankshaft Postion Sensor
{Apply alight coat of engine ott the Ong
oe
2 When rousing the sensor, iapoct ho Ong
+ ¡Ho Oring has scratches o cus, replace tho
cranksha positon sonsor
Engine Assembly
ENGINE
al he sensor with the bol
LT SO ET gen ARB
3 Connect the wire hamess tothe damp.
91 | Install the Camshaf Postion Sensor
Apply light oat of engine othe ving,
Neve
+ hen rousing the sensor, inspect the O-ing
+ Ifthe Orang has sorates or eu replace the
camshañ postion sensor.
2. natalie sensor vith the bt
A ARA
YANMAR su wos conso tons
ENGINE
al he sensor with the bol
LT SO ET gen ARB
3 Connect the wire hamess tothe damp.
91 | Install the Camshaf Postion Sensor
Apply light oat of engine othe ving,
Neve
+ hen rousing the sensor, inspect the O-ing
+ Ifthe Orang has sorates or eu replace the
camshañ postion sensor.
2. natalie sensor vith the bt
A ARA
YANMAR su wos conso tons
ENGINE
Engine Assembly
instal the V-ihbed Ber Tensioner
Fatal bole and Vb bi onsoner
CIE
CRETE EEE
DESCARTA
®
install the ier Pulley
Y natal Bot nd lar ply
install the Crankshaft Pulloy
‘This procedures intendodfortheromovalinstalaon
ele crenisha pull only. Do nat use hs
procedure forth removalntlation ofthe unes!
and he ive pate and ing gear
1 Align he crankshaft pulley andthe cranksha kick
pin. and temporany instal ne cranhal pully wth
thea tots
2 Instale 2 bots tothe bo hols of the rankahat
tear ede
3. Using a bar, tum the crankshaft unl the crankshaft
pally service Hoa itl to tha ight te boto
‘sad contr
4. Install 14 men» 1.5 pich service bol with length
9170 mm or more tothe crankshal pully serve
hol, sn old the eras sing he tring chin
cover protusion
5. Unimly tighten he 8 bots in 2 passes inthe order
‘how nthe astron
6, Remove the see bo.
Engine Assembly
instal the V-ihbed Ber Tensioner
Fatal bole and Vb bi onsoner
CIE
CRETE EEE
DESCARTA
®
install the ier Pulley
Y natal Bot nd lar ply
install the Crankshaft Pulloy
‘This procedures intendodfortheromovalinstalaon
ele crenisha pull only. Do nat use hs
procedure forth removalntlation ofthe unes!
and he ive pate and ing gear
1 Align he crankshaft pulley andthe cranksha kick
pin. and temporany instal ne cranhal pully wth
thea tots
2 Instale 2 bots tothe bo hols of the rankahat
tear ede
3. Using a bar, tum the crankshaft unl the crankshaft
pally service Hoa itl to tha ight te boto
‘sad contr
4. Install 14 men» 1.5 pich service bol with length
9170 mm or more tothe crankshal pully serve
hol, sn old the eras sing he tring chin
cover protusion
5. Unimly tighten he 8 bots in 2 passes inthe order
‘how nthe astron
6, Remove the see bo.
Engine Assembly ENGINE
35 | lata ho Engine Drive Unit DU)
‘instal tho EDU (A) brackets (1) othe heat exchanger
‘bracket wh the top cover bote (2)
2. sta the bracket 1) the rack (2). ne install the
rue fuse holier (9)
Install vibration prot rubbers (5), and int
bracket (D).
4 Insta the fuse holder (4 andinstalthe injetor dior
(2) wth tho bots).
EDIT)
PEA)
YANMAR soon as
35 | lata ho Engine Drive Unit DU)
‘instal tho EDU (A) brackets (1) othe heat exchanger
‘bracket wh the top cover bote (2)
2. sta the bracket 1) the rack (2). ne install the
rue fuse holier (9)
Install vibration prot rubbers (5), and int
bracket (D).
4 Insta the fuse holder (4 andinstalthe injetor dior
(2) wth tho bots).
EDIT)
PEA)
YANMAR soon as
ENGINE Engine Assembly
‘96 | natal the Ling Bracket
Y. instalo yhoo sie engine ting bracket
2. ntalle engine ting bracket on he opposie sie
alt hee.
7
Install the Seawater Pump
Y. instalo pump instalan bls (MS 4 uni) 2) and
seawater pup (9.
2 Tighten Vidbod bt (1,
Terna
ee 2INMRO= 03m
install the Añemator
{insert the pis (2) ony when os exchange them)
2 Install he sorte (9) vto bol 1)
‘96 | natal the Ling Bracket
Y. instalo yhoo sie engine ting bracket
2. ntalle engine ting bracket on he opposie sie
alt hee.
7
Install the Seawater Pump
Y. instalo pump instalan bls (MS 4 uni) 2) and
seawater pup (9.
2 Tighten Vidbod bt (1,
Terna
ee 2INMRO= 03m
install the Añemator
{insert the pis (2) ony when os exchange them)
2 Install he sorte (9) vto bol 1)
Engine Assembly ENGINE
3. Tum the bat Tonsionorcoclvise and stall The
Vol
Con hat the bo Hs correct into he dich,
Ie Lol does nt wl break
{ata he Lubricating OW Fir
Y Insalto racket (3), union (2) and köreating où
ern,
the lubricating Re with the ter wrench,
Faking are nn TN
fa T8UNF (eam
Tang eo otter | 147-198 Nm
fa rue) 65-204)
Install the Fuel ON Fiter
"Install the fue iter (1 1 he bricting ol fier
‘bracket.
2 Intl the fuel int pipe (2) and
It pipe (9)
YANMAR su wos conso tons
3. Tum the bat Tonsionorcoclvise and stall The
Vol
Con hat the bo Hs correct into he dich,
Ie Lol does nt wl break
{ata he Lubricating OW Fir
Y Insalto racket (3), union (2) and köreating où
ern,
the lubricating Re with the ter wrench,
Faking are nn TN
fa T8UNF (eam
Tang eo otter | 147-198 Nm
fa rue) 65-204)
Install the Fuel ON Fiter
"Install the fue iter (1 1 he bricting ol fier
‘bracket.
2 Intl the fuel int pipe (2) and
It pipe (9)
YANMAR su wos conso tons
ENGINE Engine Assembly
101 | natal the Fiypwhoo!
naa the Bearing (1),
2 ntl he yt (2) wah the 8 bot
es ETES
”
Insta the Spacer
Y. instalo Spacer (2) eth he bots
LT
instal the Couping
instal the coupling (3) wih the 8 bots,
mo
Install the Fywhee! Housing
Y. instal Bots (2) and the yhoo housing (1).
mos
instal the Exhaust Manifold (AH and LH Sic
Y. instalo studs (1)to he yinderheadandinsalihe
gasket 2)
2. Intalthe exhaust mantol (3) and tighten tt the
pect’ torque wi bot (5) and nts (4,
>, ntl he xt manto onthe LH ido in the
TES
or
ER
101 | natal the Fiypwhoo!
naa the Bearing (1),
2 ntl he yt (2) wah the 8 bot
es ETES
”
Insta the Spacer
Y. instalo Spacer (2) eth he bots
LT
instal the Couping
instal the coupling (3) wih the 8 bots,
mo
Install the Fywhee! Housing
Y. instal Bots (2) and the yhoo housing (1).
mos
instal the Exhaust Manifold (AH and LH Sic
Y. instalo studs (1)to he yinderheadandinsalihe
gasket 2)
2. Intalthe exhaust mantol (3) and tighten tt the
pect’ torque wi bot (5) and nts (4,
>, ntl he xt manto onthe LH ido in the
TES
or
ER
Engine Assembly ENGINE
106 instal ho Heat Exchange
‘inthe bracket) a ik webs (2) 3)
2 Install he heat exchanger (1) and cit wth he bos
Qe.
107 instal the Fuel Oil Cooler
‘inal th fuel ol cooler (1)
2 Intl the seawater pipes (2) (2)
YANMAR 209 coo: 000 ares a7
106 instal ho Heat Exchange
‘inthe bracket) a ik webs (2) 3)
2 Install he heat exchanger (1) and cit wth he bos
Qe.
107 instal the Fuel Oil Cooler
‘inal th fuel ol cooler (1)
2 Intl the seawater pipes (2) (2)
YANMAR 209 coo: 000 ares a7
ENGINE Engine Assembly
708
the 2 brackets (4)
cooler)
5 my ghten o 2 backet (3).
4: ntl hea duc (2) and gasket (3)
5: Install he hanger suppon (5) wth the 2 bots (6
708
the 2 brackets (4)
cooler)
5 my ghten o 2 backet (3).
4: ntl hea duc (2) and gasket (3)
5: Install he hanger suppon (5) wth the 2 bots (6
Engine Assembly
ENGINE
108
nstal he Turbocharger
instal he gasket.
2 ntl th urbocharger (1) (AH ide and side and
erw then (3)
9. Intl the turbocharger rica lit pipe (5)
‘nd outlet pipe (A).
install he Exhaust Bond
state exhaust bend (1) and mbing elbow (4)
2 rta Vas (2) and racket 3)
3 Alor tightening at 6 1 Nam hito outer
‘rcurference with aplastic hammer (times evenly
[a3 places or more) ad reichten at 6+ IN,
YANMAR su wos conso tons
ENGINE
108
nstal he Turbocharger
instal he gasket.
2 ntl th urbocharger (1) (AH ide and side and
erw then (3)
9. Intl the turbocharger rica lit pipe (5)
‘nd outlet pipe (A).
install he Exhaust Bond
state exhaust bend (1) and mbing elbow (4)
2 rta Vas (2) and racket 3)
3 Alor tightening at 6 1 Nam hito outer
‘rcurference with aplastic hammer (times evenly
[a3 places or more) ad reichten at 6+ IN,
YANMAR su wos conso tons
ENGINE
Engine Assembly
THT | ital he Broathor Hose
1 instal the seawater pp (2) and rubber hose (1).
2 intl he Deiner hose (3).
Install the Bat Cover
Y instalo bat over.
13 [install the Engine Wire
inton 1987
Engine Assembly
THT | ital he Broathor Hose
1 instal the seawater pp (2) and rubber hose (1).
2 intl he Deiner hose (3).
Install the Bat Cover
Y instalo bat over.
13 [install the Engine Wire
inton 1987
Engine Assembly ENGINE
114 | natal tho Engine Control Unit (ECU)
Y Instale Engine Canto Unit ECU wh th bots
755 | inatall he Top Cover
Y Install tp cover with the studs and mts,
YANMAR 209 coo: 000 ares a
114 | natal tho Engine Control Unit (ECU)
Y Instale Engine Canto Unit ECU wh th bots
755 | inatall he Top Cover
Y Install tp cover with the studs and mts,
YANMAR 209 coo: 000 ares a
ENGII
INE
Engine inspection
ENGINE INSPECTION
lean the Oyindor Head Sub-Assamlıy
1. Using a gasket scraper, removal the gasket
‘mata om the oidor block contact surface.
Be careful not 1 scratch the ylnder block contact,
sata
2 Usage irte, enor can om
Sonn ts
ut otto damage th combustion chambars
and vale seat,
3. Using vato guido bushingbrush and solvent. lean
alte valve guide bushes
(Lang ct mht st rt cn
INE
Engine inspection
ENGINE INSPECTION
lean the Oyindor Head Sub-Assamlıy
1. Using a gasket scraper, removal the gasket
‘mata om the oidor block contact surface.
Be careful not 1 scratch the ylnder block contact,
sata
2 Usage irte, enor can om
Sonn ts
ut otto damage th combustion chambars
and vale seat,
3. Using vato guido bushingbrush and solvent. lean
alte valve guide bushes
(Lang ct mht st rt cn
Engine inspection
ENGINE
een
Tnapeat the Oylindor Hoad Sub-Assambiy
1 Using a predsionstaightedge and tele gauge.
measure the warpage ofthe cornet surace been.
the older bead and oyinder lock, aná In ner
head and mantos
LT
Specie’ Condon
1000: mote 001973
CO
DEN
‘yr ks
Take mano de
Tiara Waa
Ten Species Condon
ind seda | 005 men (000197 in)
E 068 men (560181)
ER ION
ithe warpage ie gestor nan the maximum replace
the cylinder head zub-assembh.
2, Using a dj penetrar, check he intake por,
‘exhaust ports and liner suce for racks,
ithore are cracks, pla te older Head
sure
ee
YANMAR su osos conso tons
ENGINE
een
Tnapeat the Oylindor Hoad Sub-Assambiy
1 Using a predsionstaightedge and tele gauge.
measure the warpage ofthe cornet surace been.
the older bead and oyinder lock, aná In ner
head and mantos
LT
Specie’ Condon
1000: mote 001973
CO
DEN
‘yr ks
Take mano de
Tiara Waa
Ten Species Condon
ind seda | 005 men (000197 in)
E 068 men (560181)
ER ION
ithe warpage ie gestor nan the maximum replace
the cylinder head zub-assembh.
2, Using a dj penetrar, check he intake por,
‘exhaust ports and liner suce for racks,
ithore are cracks, pla te older Head
sure
ee
YANMAR su osos conso tons
ENGINE
Engine Inspection
Toa ape
Inspect tho Oylinder Head Bolt
Y Using a vomir lpr monsure the outside rond
Tossing Poe
msn)
AN
Tian Snake Dana
A
Note
Wa visual check revels no excessively thin areas,
check the centro th bl (se Huston) and nd.
the area that has the lowest ameter
ihe dametr is less han he minimum, replace he
finder head bot
Inspect tha No, and No.3 Coms Thrust
|Ciarance (For the Intake Camshaft)
instal No.2 and No, 5 eamahalt boning cap to
the eyinder head,
2, Pace tho camaha onthe cylinder hood
5. Temporary int tho No. 1 and No. à camahatt
‘boating cape wi à bolls by hand
Do nottu the cametal.
4. state No, 3 casal bearing caps
"Conti tho marke and numbers onthe camshalt
bearing caps aná place ham in ha proper
postion and direction.
2-Temperañy instal he 16 bots
Engine Inspection
Toa ape
Inspect tho Oylinder Head Bolt
Y Using a vomir lpr monsure the outside rond
Tossing Poe
msn)
AN
Tian Snake Dana
A
Note
Wa visual check revels no excessively thin areas,
check the centro th bl (se Huston) and nd.
the area that has the lowest ameter
ihe dametr is less han he minimum, replace he
finder head bot
Inspect tha No, and No.3 Coms Thrust
|Ciarance (For the Intake Camshaft)
instal No.2 and No, 5 eamahalt boning cap to
the eyinder head,
2, Pace tho camaha onthe cylinder hood
5. Temporary int tho No. 1 and No. à camahatt
‘boating cape wi à bolls by hand
Do nottu the cametal.
4. state No, 3 casal bearing caps
"Conti tho marke and numbers onthe camshalt
bearing caps aná place ham in ha proper
postion and direction.
2-Temperañy instal he 16 bots
Engine inspection ENGINE
a Teor apt T Tor
5 Undormiy Mahon re 20 bain sevorl apa Im 0
order spot nthe Must.
a ELA EN
rm he | 10 Nm 62 kom 780)
6. Using a a indicator, measure he trust clearance
le moving the camahaı back and fot
andra Tran Caran
PEE
6180 men (6.00709)
the trust larance is gear than the maximum,
replace tho cyindor head sub-assembly
Tnapect the No. 1 and Wo. 4 Camshan Thrust
Clearance (For the Exhaust Camshaft)
Tinta the No, 2 and No. $ camehaf bearing aps to
the ceder head.
2, Place te carats onthe older had
3 Temporary instal the No. 1 and No. 4 camshaft
Do nottur ho camsbats
YANMAR esto encon en
a Teor apt T Tor
5 Undormiy Mahon re 20 bain sevorl apa Im 0
order spot nthe Must.
a ELA EN
rm he | 10 Nm 62 kom 780)
6. Using a a indicator, measure he trust clearance
le moving the camahaı back and fot
andra Tran Caran
PEE
6180 men (6.00709)
the trust larance is gear than the maximum,
replace tho cyindor head sub-assembly
Tnapect the No. 1 and Wo. 4 Camshan Thrust
Clearance (For the Exhaust Camshaft)
Tinta the No, 2 and No. $ camehaf bearing aps to
the ceder head.
2, Place te carats onthe older had
3 Temporary instal the No. 1 and No. 4 camshaft
Do nottur ho camsbats
YANMAR esto encon en
ENGINE Engine inspection
a Tow apa
Tata he Ro-Scamaha bearing capa
1 Conti the mas and numbers on ho cometa
bearing caps and pce them in otr proper
postion and drecion.
2 Temporary instal the 16 bot
sunt ttn the 20 btn several taps inte
Order shown ho star
EE
es md | 16m 62m TR
a Tow apa
Tata he Ro-Scamaha bearing capa
1 Conti the mas and numbers on ho cometa
bearing caps and pce them in otr proper
postion and drecion.
2 Temporary instal the 16 bot
sunt ttn the 20 btn several taps inte
Order shown ho star
EE
es md | 16m 62m TR
Engine inspection
ENGINE
LT EI
6 Dino si atr, mensure he TT IE
‘whe moving the camata ack and forth
rara Tar Ceac
533810160 rm (000196 ADS ET
Tima Tras rane
Seo en (0.00708)
Tnopect the Camshat
Inspect the camshal for runout,
"Plage cama on bock.
2.Using a dal indicator measure the runout atthe
center joumal.
Tarim Ranaut
Ts wen one
Iho runoutsgreaterthan the maximum, roplace the
cata
2 Inspect he cam lobo height.
"Using a mctemelr measure the cam be height
Tew Speciied Condon
No.2andNo Searshat | 9727703787 m
Vendo Acera | 585881088
No rand samen | Trsogto Stan)
nim Cam Lobe Ha
Te Speciied Condition
No BandN enr
(rae)
ome
57277 me (14880)
$8524 (15084)
cam lobe height is less than he minimum.
replace the cash
YANMAR 209 coo: 000 ares
ENGINE
LT EI
6 Dino si atr, mensure he TT IE
‘whe moving the camata ack and forth
rara Tar Ceac
533810160 rm (000196 ADS ET
Tima Tras rane
Seo en (0.00708)
Tnopect the Camshat
Inspect the camshal for runout,
"Plage cama on bock.
2.Using a dal indicator measure the runout atthe
center joumal.
Tarim Ranaut
Ts wen one
Iho runoutsgreaterthan the maximum, roplace the
cata
2 Inspect he cam lobo height.
"Using a mctemelr measure the cam be height
Tew Speciied Condon
No.2andNo Searshat | 9727703787 m
Vendo Acera | 585881088
No rand samen | Trsogto Stan)
nim Cam Lobe Ha
Te Speciied Condition
No BandN enr
(rae)
ome
57277 me (14880)
$8524 (15084)
cam lobe height is less than he minimum.
replace the cash
YANMAR 209 coo: 000 ares
ENGINE Engine inspection
a Toa ape
apoco cama journal comte
Y Using a micrometer measure the journal diameter
andara Joumal Dameter
Tem Species Condition
DEM [a8 0 29 005 180011811]
es | 25089102698 mm 9211055]
Ihe oumalclameterk not ns spocted, checkthe oll
77 [inspect the Camshaft ON Clearance
Y, Clean the camshat bearing caps and camshan
fours
2. Pace tho camshats onthe cier hood
5. Lay a sp of Pasgage across each ofthe camahat
penal.
4. Temporal instalo camshaft bearing cap with the
tots by hand.
Do not tum the camshat
a Toa ape
apoco cama journal comte
Y Using a micrometer measure the journal diameter
andara Joumal Dameter
Tem Species Condition
DEM [a8 0 29 005 180011811]
es | 25089102698 mm 9211055]
Ihe oumalclameterk not ns spocted, checkthe oll
77 [inspect the Camshaft ON Clearance
Y, Clean the camshat bearing caps and camshan
fours
2. Pace tho camshats onthe cier hood
5. Lay a sp of Pasgage across each ofthe camahat
penal.
4. Temporal instalo camshaft bearing cap with the
tots by hand.
Do not tum the camshat
Engine inspection ENGINE
YANMAR 209 coo: 000 ares ar
YANMAR 209 coo: 000 ares ar
ENGINE Engine Inspection
2 Baron ape
EDEN on the 20 bt in aevra pa mie
order shown no rio,
Traba Nero SEY
eos rad | 16m 62m TI
7. Uritomlylosen a remove the 20 bots inthe
‘sequence shown in he urn
2 Baron ape
EDEN on the 20 bt in aevra pa mie
order shown no rio,
Traba Nero SEY
eos rad | 16m 62m TI
7. Uritomlylosen a remove the 20 bots inthe
‘sequence shown in he urn
Engine inspection
ENGINE
ee
B Mason Tho Pastigngo atts WG FO
Sanda ON Garance.
EF 0062 mm 00804 D HAE
Tim ON Circo
oc)
assembly
8. Remove ho Pasigago completo.
10 Remove the camshate
4
Inopocting Valve Rocker Arm Sub Assembly
1° Tumiherolerby had to check hat Rtas sm.
Ihe ole does na un smoot. replace the valo
rocker arm,
YANMAR su wos conso tons
ENGINE
ee
B Mason Tho Pastigngo atts WG FO
Sanda ON Garance.
EF 0062 mm 00804 D HAE
Tim ON Circo
oc)
assembly
8. Remove ho Pasigago completo.
10 Remove the camshate
4
Inopocting Valve Rocker Arm Sub Assembly
1° Tumiherolerby had to check hat Rtas sm.
Ihe ole does na un smoot. replace the valo
rocker arm,
YANMAR su wos conso tons
ENGINE Engine Inspection
a Toa ape coy
Lash Adjustor ASEO
Koup the austere rom det and foreign
objects.
+ Use ri clean engine ol.
1. Place the lash ter into a ontiner tlt new
‘engin a
2. neto ol he SST into the lash ajuster plunger
and use opto press dem one check ball nx.
the plunger.
2. Squeeze the SST and he lash aduser together to
mate tho plunger up and down 5106 times
4. Chock te movement of ho plunge and bed a
(GK: Plungor moves up and down
When bldg hah iss ao e
Ceras Done, nats area pote
roy sra o ics ato so
tt! Hse che bat stereos owt
os
3 me ms ae
5, Alter blading thea, remove the SST, Then yto
(Quick and em pres th plunger st your gor,
(Ok: Plunger ean be pressed mas,
e conrad peer
Stes, replace tho Inh agnor wath anew ne.
a Toa ape coy
Lash Adjustor ASEO
Koup the austere rom det and foreign
objects.
+ Use ri clean engine ol.
1. Place the lash ter into a ontiner tlt new
‘engin a
2. neto ol he SST into the lash ajuster plunger
and use opto press dem one check ball nx.
the plunger.
2. Squeeze the SST and he lash aduser together to
mate tho plunger up and down 5106 times
4. Chock te movement of ho plunge and bed a
(GK: Plungor moves up and down
When bldg hah iss ao e
Ceras Done, nats area pote
roy sra o ics ato so
tt! Hse che bat stereos owt
os
3 me ms ae
5, Alter blading thea, remove the SST, Then yto
(Quick and em pres th plunger st your gor,
(Ok: Plunger ean be pressed mas,
e conrad peer
Stes, replace tho Inh agnor wath anew ne.
Engine inspection ENGINE
a ee T Tor
0 |inspsetihe Innor Compression Spring
inner compression sping
Taxim Devon,
Hamm sn)
Ith deviations greater than he maximum. replace
‘he inner compression sping
2 Inspect Ihe inner compression spring rs length
"Using aver caliper, measure the re ong 0
‘he inner compression sping,
I
Srandara Free Leth
Sarma)
Iho tee length nt as spect replace the inner
compression spring
Inspect Ihe inne compression spring tension
1 Using pring tater, measure the tension ofthe
Inner compression spring athe spectedinsaled
lena
Trad Tension
EEE TETE EL]
Aminen
It instate tension is not as spec, replace the
Inner compression sping,
YANMAR esto encon e
a ee T Tor
0 |inspsetihe Innor Compression Spring
inner compression sping
Taxim Devon,
Hamm sn)
Ith deviations greater than he maximum. replace
‘he inner compression sping
2 Inspect Ihe inner compression spring rs length
"Using aver caliper, measure the re ong 0
‘he inner compression sping,
I
Srandara Free Leth
Sarma)
Iho tee length nt as spect replace the inner
compression spring
Inspect Ihe inne compression spring tension
1 Using pring tater, measure the tension ofthe
Inner compression spring athe spectedinsaled
lena
Trad Tension
EEE TETE EL]
Aminen
It instate tension is not as spec, replace the
Inner compression sping,
YANMAR esto encon e
ENGINE Engine Inspection
a Baron ape
11 |inspaetihe Valve Guido Bush Où Clearance
Y Using a eater gag, measure th nido ameter
‘the guide bush
Tiara Boah ade Diamar
toc mm (075661602976 0
2. Subtract he vale stom dameter measurement tom
‘he guido bush nido diameter measurement
om ‘Spectied Condition
Toke AAN
East [0.09519 0.70 ran (00013 e 000277
Take D120 rm (cose my
En DEAN
Ihe où larance i greater han the maximun,
replace he valve quo bush,
12 | Clean the Valve
1. Using a gasket scraper chip of any carbon rom the
ato sd
Be careful not 10 damage the valo seats.
2. Using awe brut, thoroughly clan the vate
a Baron ape
11 |inspaetihe Valve Guido Bush Où Clearance
Y Using a eater gag, measure th nido ameter
‘the guide bush
Tiara Boah ade Diamar
toc mm (075661602976 0
2. Subtract he vale stom dameter measurement tom
‘he guido bush nido diameter measurement
om ‘Spectied Condition
Toke AAN
East [0.09519 0.70 ran (00013 e 000277
Take D120 rm (cose my
En DEAN
Ihe où larance i greater han the maximun,
replace he valve quo bush,
12 | Clean the Valve
1. Using a gasket scraper chip of any carbon rom the
ato sd
Be careful not 10 damage the valo seats.
2. Using awe brut, thoroughly clan the vate
Engine inspection ENGINE
a re Tor
13 | Inspect to Vaio
inspect ho valve stom diameter
"Using micrometr, measure the diameter ol the
‘Sanchar Vole Stem Darter
am Species Condition
ira | 537010 5.56 mm 230100235875
Ea 59801 575 mm 02340 023820)
2. Inspect ho va face angle.
Gin he valve enough o remove pt and carbon,
2.Check thatthe valves ground the comet valo
face ange.
9. Inspect the valve head margin icknes
being a vero calper measure the valve head
margin thickness
‘andar Mara Teh
ROT
Maira Maga Tekno Mere
5m DIET
the margin hiekness is less han he minimum,
replace tho vate
4. nape tho vate overlong
Using a vere calper, measure the ovealtngth,
Tandard Gera nat
em Species Condition
Tr COEN EA
En a
Timon Dago
iem Specie’ Condtion
Take CIEN mo
En] NETO
Ih verallengthis ess than the minimum, opaco
the ave,
YANMAR esto encon une
a re Tor
13 | Inspect to Vaio
inspect ho valve stom diameter
"Using micrometr, measure the diameter ol the
‘Sanchar Vole Stem Darter
am Species Condition
ira | 537010 5.56 mm 230100235875
Ea 59801 575 mm 02340 023820)
2. Inspect ho va face angle.
Gin he valve enough o remove pt and carbon,
2.Check thatthe valves ground the comet valo
face ange.
9. Inspect the valve head margin icknes
being a vero calper measure the valve head
margin thickness
‘andar Mara Teh
ROT
Maira Maga Tekno Mere
5m DIET
the margin hiekness is less han he minimum,
replace tho vate
4. nape tho vate overlong
Using a vere calper, measure the ovealtngth,
Tandard Gera nat
em Species Condition
Tr COEN EA
En a
Timon Dago
iem Specie’ Condtion
Take CIEN mo
En] NETO
Ih verallengthis ess than the minimum, opaco
the ave,
YANMAR esto encon une
ENGINE
Engine Inspection
= a ==
Es sem LE
Vene sacs va tm lr wear EN
(QA
Do no rnd of more than the minimum lg
ithe valo stom tii worn, roue th tp wth 2
inde oF roplace the vate
aq
Gan the Valve Seat
1. Usinga 45° carbide ctor, resurface the valve seas.
Be careful not to damage the combustion chambors
and valve seats
2 Clean the valve sats,
inspect he Intake Valve Seat
{Apply ag coat of Prssian blue tothe valve face
2 Lay press the valve face against the valve seat
Do not reat he vale whl pressing the valve,
3. Check the vale face and valve se
Check hat ho contact surface ofthe valve seat
‘and valve face ano i the mid area ol hor
Fespecive surfaces, wth the wäh beeen 1.010
14 mm (008041060851 in)
1 ol comect the valve sat
2-Gheck hat the conc sacos ofthe vale seat
‘and valve face aro even sound he entre valve
oat
Tot, conet the alv seat
Engine Inspection
= a ==
Es sem LE
Vene sacs va tm lr wear EN
(QA
Do no rnd of more than the minimum lg
ithe valo stom tii worn, roue th tp wth 2
inde oF roplace the vate
aq
Gan the Valve Seat
1. Usinga 45° carbide ctor, resurface the valve seas.
Be careful not to damage the combustion chambors
and valve seats
2 Clean the valve sats,
inspect he Intake Valve Seat
{Apply ag coat of Prssian blue tothe valve face
2 Lay press the valve face against the valve seat
Do not reat he vale whl pressing the valve,
3. Check the vale face and valve se
Check hat ho contact surface ofthe valve seat
‘and valve face ano i the mid area ol hor
Fespecive surfaces, wth the wäh beeen 1.010
14 mm (008041060851 in)
1 ol comect the valve sat
2-Gheck hat the conc sacos ofthe vale seat
‘and valve face aro even sound he entre valve
oat
Tot, conet the alv seat
Engine inspection
ENGINE
eee
16
Thapoat the Exhaust Valve Seat |
APP aight coat of Prusia blue 1 the vale face,
2: Lig poss tho value face again the valve set.
Do nol ote the vale while pressing the val
3. Ghock the valo face and valve sot
Check thatthe coin surface ol ho vato seat
‘nd valve face ao inthe mie aoa li
teapectvesurtces, wih the wish between 1.010
14 men (0.0598 600581 in)
not Comet the valve act
2 Check nat the contact suceso ne valve set
‘od valve fae ae even around te entre valve
Wok, comet he valve set
Visual Cheek the Oylinder Block
1: Visual check he finder or vralsrathes.
I ep seras aro present, bot al 8 oyinder
Nnecessany. replace Ie ende block.
w
Tnspoctino Oylindor Block for Fsimess
1 Using presten staightedge and toler gauge,
moosure the warpage ofthe cornet urtace bein
‘he ci head and eylnder head gasket
Ta Warp
35 men (000197 nj
the warpage ie greater than the maximum. replace
the cade lock sub-assembly.
YANMAR su wos conso tons
ENGINE
eee
16
Thapoat the Exhaust Valve Seat |
APP aight coat of Prusia blue 1 the vale face,
2: Lig poss tho value face again the valve set.
Do nol ote the vale while pressing the val
3. Ghock the valo face and valve sot
Check thatthe coin surface ol ho vato seat
‘nd valve face ao inthe mie aoa li
teapectvesurtces, wih the wish between 1.010
14 men (0.0598 600581 in)
not Comet the valve act
2 Check nat the contact suceso ne valve set
‘od valve fae ae even around te entre valve
Wok, comet he valve set
Visual Cheek the Oylinder Block
1: Visual check he finder or vralsrathes.
I ep seras aro present, bot al 8 oyinder
Nnecessany. replace Ie ende block.
w
Tnspoctino Oylindor Block for Fsimess
1 Using presten staightedge and toler gauge,
moosure the warpage ofthe cornet urtace bein
‘he ci head and eylnder head gasket
Ta Warp
35 men (000197 nj
the warpage ie greater than the maximum. replace
the cade lock sub-assembly.
YANMAR su wos conso tons
ENGINE
Engine Inspection
2 Tao ape coy
19 | inspect tho Connecting Rod Bor
Usha vemir apo. ose mo ein grin | [I pm)
Sander Dana
5m)
Ihe cfameter ils than the mim replace the
‘connecting rod bo.
135 | nopect the Crankshaft Boaring Cap Belt
Y Using a vomir calper measure tn tension porton
meter Bot A snd 8
E
mr Specified Condon
Bora 06m (7
LE E
Messung Port ns
Bora Tamm ern)
Para
nda anata for Bor
TR 10 mm 428 949 8)
Ba 100mm Rose] ner ee
LIT Tor oh
EA
Tiaras DB
Gsm sem
Note
la visual check reves no excessive in areas,
check the center aie bal (ee Mustaton) and find
the area that has the lowes meter.
the cameter less tan he minimum, replace te
cranksha beanng cap se bat
ene essere Mars YANMAR
Engine Inspection
2 Tao ape coy
19 | inspect tho Connecting Rod Bor
Usha vemir apo. ose mo ein grin | [I pm)
Sander Dana
5m)
Ihe cfameter ils than the mim replace the
‘connecting rod bo.
135 | nopect the Crankshaft Boaring Cap Belt
Y Using a vomir calper measure tn tension porton
meter Bot A snd 8
E
mr Specified Condon
Bora 06m (7
LE E
Messung Port ns
Bora Tamm ern)
Para
nda anata for Bor
TR 10 mm 428 949 8)
Ba 100mm Rose] ner ee
LIT Tor oh
EA
Tiaras DB
Gsm sem
Note
la visual check reves no excessive in areas,
check the center aie bal (ee Mustaton) and find
the area that has the lowes meter.
the cameter less tan he minimum, replace te
cranksha beanng cap se bat
ene essere Mars YANMAR
Engine inspection
ENGINE
eee
a
Inspoetine Paton with the Pin Sub-Assambhy
1 Vaig a mitemeter, measure the piston damater at
‘ght angle o to son pn conter in, 12 mm
(0.472 orto pston ki.
andara Paton Drama
21 0600 men 38193 HH)
CAU
live iamataris ee han the minimum, replace the
pisto wi pin sub-assembly.
=
Inspectihe Cylinder Bore
"Using a cyindergauge, measure the older bore
‘lamer a postions A and B inthe ts and ail
‘directions
Sonder Date
EEE OT rm PIO
Bm BST In)
the lamers greater than the maximum, replace
the ey block
Tngpeat the Piston Ol Clearance
Y Subtract the piston ameter measurement fom the
finder bore diameter measurement
ENTE
TE EE
Tim OF Carne
So mm 0888)
the ol clearance is gear than ho maximum,
replace at pistns. necessary replace he
finder book.
Fins
YANMAR su osos conso tons
ENGINE
eee
a
Inspoetine Paton with the Pin Sub-Assambhy
1 Vaig a mitemeter, measure the piston damater at
‘ght angle o to son pn conter in, 12 mm
(0.472 orto pston ki.
andara Paton Drama
21 0600 men 38193 HH)
CAU
live iamataris ee han the minimum, replace the
pisto wi pin sub-assembly.
=
Inspectihe Cylinder Bore
"Using a cyindergauge, measure the older bore
‘lamer a postions A and B inthe ts and ail
‘directions
Sonder Date
EEE OT rm PIO
Bm BST In)
the lamers greater than the maximum, replace
the ey block
Tngpeat the Piston Ol Clearance
Y Subtract the piston ameter measurement fom the
finder bore diameter measurement
ENTE
TE EE
Tim OF Carne
So mm 0888)
the ol clearance is gear than ho maximum,
replace at pistns. necessary replace he
finder book.
Fins
YANMAR su osos conso tons
ENGINE Engine Inspection
Far Taw ape coy
24 | nepect the Piston Pin Ol Clearance
1 Check each mak on ho piston. piston pin and
connecting rod,
2. Using a caper gauge, measur the inside diameter
‘ofthe piston pin hoe.
Wai ‘Spectied Condition
EOI
0 EDEN
ETA
Far Taw ape coy
24 | nepect the Piston Pin Ol Clearance
1 Check each mak on ho piston. piston pin and
connecting rod,
2. Using a caper gauge, measur the inside diameter
‘ofthe piston pin hoe.
Wai ‘Spectied Condition
EOI
0 EDEN
ETA
Engine inspection
ENGINE
LT T
3
Tanga micrometer measure to platon pin EMI
Standard Peon Pin Dimmer
ork [Fco] Specified Condition
à | ine [erroneo Ay
E ET EME
O E
Subtract the piston pin diameter measurement rom
‘the piton pi hole diameter measurement
ENTRE
EA semer) LE
Tim Dl Cane L
EN sum
3 clearance is gear than ho maximum.
replace the piston and piston in as a st
Using a calor gauge, measure the inside diameter
‘ol the connecting rod bush
ENE
EEN
3] 290231029087 713426 11875)
| 28a 9 28051 me OTD LEBEN)
Subtat piston pin diameter measurement rom
‘he bush sie diameter measurement
TI |
2088 mn (0.00170)
the ol clearance is greater than the maximum.
replace the connecting rod ae piston withthe pn as
as
YANMAR soon
ENGINE
LT T
3
Tanga micrometer measure to platon pin EMI
Standard Peon Pin Dimmer
ork [Fco] Specified Condition
à | ine [erroneo Ay
E ET EME
O E
Subtract the piston pin diameter measurement rom
‘the piton pi hole diameter measurement
ENTRE
EA semer) LE
Tim Dl Cane L
EN sum
3 clearance is gear than ho maximum.
replace the piston and piston in as a st
Using a calor gauge, measure the inside diameter
‘ol the connecting rod bush
ENE
EEN
3] 290231029087 713426 11875)
| 28a 9 28051 me OTD LEBEN)
Subtat piston pin diameter measurement rom
‘he bush sie diameter measurement
TI |
2088 mn (0.00170)
the ol clearance is greater than the maximum.
replace the connecting rod ae piston withthe pn as
as
YANMAR soon
ENGINE Engine Inspection
2 Tow ape
25 | napeet the Ring Groove Clearance
Y Using a lolo gauge, measure the cearance
between a new piston ing andthe wat ofthe ng
go.
“Sandan ing Groove Taare
EAN
i EAN
ithe clearanceienat ss specie, replace the piston
5 [Inspect the Piston ing End Gap
set he piston ing to tho cylinder bore,
2. Usinga piston, pushtho piston nga te beyond the
tom othe ring avs, 0 mm (2 95] om he top
tthe onde Dock
8. Using oor gauge, measure the end gap.
Banded End Gap
‘Specie’ Condon
21 0 2 wn (0 00906 001561)
Ne2 | 047 190.2 mm (0785 can)
ing | 01019040 me sou 00157
LOT
tem Specie’ Condon .
cS EEN
[ECO ION
CE ELTON
Ins end gap is greater than tho maximum replace
tho piton ig, the end gap is grato than the
maximum even witha new piston ung, replace the
finder beck.
2 Tow ape
25 | napeet the Ring Groove Clearance
Y Using a lolo gauge, measure the cearance
between a new piston ing andthe wat ofthe ng
go.
“Sandan ing Groove Taare
EAN
i EAN
ithe clearanceienat ss specie, replace the piston
5 [Inspect the Piston ing End Gap
set he piston ing to tho cylinder bore,
2. Usinga piston, pushtho piston nga te beyond the
tom othe ring avs, 0 mm (2 95] om he top
tthe onde Dock
8. Using oor gauge, measure the end gap.
Banded End Gap
‘Specie’ Condon
21 0 2 wn (0 00906 001561)
Ne2 | 047 190.2 mm (0785 can)
ing | 01019040 me sou 00157
LOT
tem Specie’ Condon .
cS EEN
[ECO ION
CE ELTON
Ins end gap is greater than tho maximum replace
tho piton ig, the end gap is grato than the
maximum even witha new piston ung, replace the
finder beck.
Engine inspection ENGINE
a Teor at T Tor
27 Tinspserine Connecting Rod Sub-AssambIy
Y Using od aligner and tester gauge, check the
‘conneting tod agent
‘Check or bend,
Trimm Bond
BATA per 10 MSTA
th bend is reator than the maximum, replace the
‘connecting rod sub-assembly
2.check or twists.
‘SHS mm Base per 10 BAN)
the wits greater han the maximum. replace
‘connecting red sub-accemb
28 | napect the Crankshaft
1 Using a dial indicator and V-locks, measure the
runout ae shown nthe iluso.
nan Gree Rano
De en Ori
Ith ciclo ruout greater than the maximum,
replace ho erankaal.
2 Using a micrometer, measure the ameter ofeach
ain jour
Dane
EN
Ihe diameters not as speed check ho oil
learanoe necessary, replace the crankshal.
8 Gheck the tapar and out round of each main
our as shown inthe ilustran.
aia Taparand Oar at RUN
OE
he taper and out ofround is greater han the
maximum replace the rankcha
YANMAR esto encon “o
a Teor at T Tor
27 Tinspserine Connecting Rod Sub-AssambIy
Y Using od aligner and tester gauge, check the
‘conneting tod agent
‘Check or bend,
Trimm Bond
BATA per 10 MSTA
th bend is reator than the maximum, replace the
‘connecting rod sub-assembly
2.check or twists.
‘SHS mm Base per 10 BAN)
the wits greater han the maximum. replace
‘connecting red sub-accemb
28 | napect the Crankshaft
1 Using a dial indicator and V-locks, measure the
runout ae shown nthe iluso.
nan Gree Rano
De en Ori
Ith ciclo ruout greater than the maximum,
replace ho erankaal.
2 Using a micrometer, measure the ameter ofeach
ain jour
Dane
EN
Ihe diameters not as speed check ho oil
learanoe necessary, replace the crankshal.
8 Gheck the tapar and out round of each main
our as shown inthe ilustran.
aia Taparand Oar at RUN
OE
he taper and out ofround is greater han the
maximum replace the rankcha
YANMAR esto encon “o
ENGINE
Engine Inspection
Tao ape
Using a mierometer, menzure tho Glamor o adh
crank pe
Standard Dameter
55631056000 mn 210481021055
Hin diameter is nat as specie, check th of
‘learance. necessary. replace the erankshat,
5. Chacktnetaperandout ot ound cechcrankin as
‘shown nthe ution,
mn Taper ard Ouro Round
ithe taper and outobround i greater than the
maximum, replace te erankshal
a
Inspeetihe Crankshaft Thrust Glarance
1 Using a al ndcatr. measure the trust clearance
he prying the rankshaı back and for wih a
ere.
arr Twa rames
DIM)
lv thus clearance is greater than the maximum.
replace the hust washers a à set
‘andra Tran Washer Thebes
I necessary, replace the rarkshat
spect Crankshaft Ol Clearance
ote
Main bearings come in wis 020.5 mm (0807 in)
and 225 mm (0.886)
Se Bearing Wath
Tem T Socle Conon
No Tad puralbeatngs | 225 rm ossi)
No.2 Sans ipuralbennge | 308 rm BT)
+. Clean each man journal and bearing
me SO ze
Engine Inspection
Tao ape
Using a mierometer, menzure tho Glamor o adh
crank pe
Standard Dameter
55631056000 mn 210481021055
Hin diameter is nat as specie, check th of
‘learance. necessary. replace the erankshat,
5. Chacktnetaperandout ot ound cechcrankin as
‘shown nthe ution,
mn Taper ard Ouro Round
ithe taper and outobround i greater than the
maximum, replace te erankshal
a
Inspeetihe Crankshaft Thrust Glarance
1 Using a al ndcatr. measure the trust clearance
he prying the rankshaı back and for wih a
ere.
arr Twa rames
DIM)
lv thus clearance is greater than the maximum.
replace the hust washers a à set
‘andra Tran Washer Thebes
I necessary, replace the rarkshat
spect Crankshaft Ol Clearance
ote
Main bearings come in wis 020.5 mm (0807 in)
and 225 mm (0.886)
Se Bearing Wath
Tem T Socle Conon
No Tad puralbeatngs | 225 rm ossi)
No.2 Sans ipuralbennge | 308 rm BT)
+. Clean each man journal and bearing
me SO ze
Engine inspection
ENGINE
LT EI
7 Align ho boring cl wäh he eb groove To
‘yer back, aná pueh in he 5 upper bongs
+ Do net apply engine ol the bearings andthe
contact surcos
Do not allow oolat to come nto contact with the
Dearing mer surface. any coolant comes into
contact va Hho bearing inner suce, replace the
‘bearing with anew one
Both soso theo groove in the ceder block
‘shouldbe visi trough theo feed toes inthe
bearing. The amour vise on each sie fh
holes shouldbe qual,
à Ant being ew icon poe lito
EE rr
Dorel py egin clon bats andthe
EE
ama cr tht
re
+ PE ve ro conc vit neg
racine esta nor
Noto:
A number marked on sach main bearing ao
indicate ie instalation postion.
4. Place the crnkapa on the cinder lock.
5. Lay asi of Plasigage across each journal
YANMAR 209 coo: 000 ares
ENGINE
LT EI
7 Align ho boring cl wäh he eb groove To
‘yer back, aná pueh in he 5 upper bongs
+ Do net apply engine ol the bearings andthe
contact surcos
Do not allow oolat to come nto contact with the
Dearing mer surface. any coolant comes into
contact va Hho bearing inner suce, replace the
‘bearing with anew one
Both soso theo groove in the ceder block
‘shouldbe visi trough theo feed toes inthe
bearing. The amour vise on each sie fh
holes shouldbe qual,
à Ant being ew icon poe lito
EE rr
Dorel py egin clon bats andthe
EE
ama cr tht
re
+ PE ve ro conc vit neg
racine esta nor
Noto:
A number marked on sach main bearing ao
indicate ie instalation postion.
4. Place the crnkapa on the cinder lock.
5. Lay asi of Plasigage across each journal
YANMAR 209 coo: 000 ares
ENGINE
Engine Inspection
Toa ape
5 Examino Theron mari and numbers ana ano
crash boring capa onthe oylnder block
7. Temporary instal the rankshat bering cap bots to
the A or poston
Note
Impiace of ender lock stterin plates, instal
‘mon(0351n ik spacers o ho crankshaf bearing
threads ofthe
the 2 crankshal bearing cap bats
foreach bearing cap in several passes 1 ensure a
rope fl
Do nottap the bearing cap wäh aplatotaced
hammer
10.Remove the orankahat bearing cp bolis and
spacers
11.8010 2 cido lock tiferng plate onthe
jeder block
Mako sure ha raus onthe siting pates ce the
engine ont
Engine Inspection
Toa ape
5 Examino Theron mari and numbers ana ano
crash boring capa onthe oylnder block
7. Temporary instal the rankshat bering cap bots to
the A or poston
Note
Impiace of ender lock stterin plates, instal
‘mon(0351n ik spacers o ho crankshaf bearing
threads ofthe
the 2 crankshal bearing cap bats
foreach bearing cap in several passes 1 ensure a
rope fl
Do nottap the bearing cap wäh aplatotaced
hammer
10.Remove the orankahat bearing cp bolis and
spacers
11.8010 2 cido lock tiferng plate onthe
jeder block
Mako sure ha raus onthe siting pates ce the
engine ont
Engine inspection ENGINE
a re T Tor
Top F
‘ow
+ Tighten the erankehaft baring cap bl in
progress steps
+ Fany crntshaf bearing cap bots broken or
dolores, replace
App a ight coat engine oto the theads and
Under he heeds ofthe 20 cranishal earngcap
bots
Insta Ih 20 ernkshaft bearing cap bos. Using
Several stop. tighten the bats untormly inthe
‘Sequence shown in tho Ita,
RENE ET HOT
Bot CATE NOA
1382
Mark ho ont sido fhe cranks beating cap
bots Aand B seh pai
Tighten the cria Boning cap bot A and 6
90° Ie sequence as shown n ho Ilan
YANMAR esto encon eo
a re T Tor
Top F
‘ow
+ Tighten the erankehaft baring cap bl in
progress steps
+ Fany crntshaf bearing cap bots broken or
dolores, replace
App a ight coat engine oto the theads and
Under he heeds ofthe 20 cranishal earngcap
bots
Insta Ih 20 ernkshaft bearing cap bos. Using
Several stop. tighten the bats untormly inthe
‘Sequence shown in tho Ita,
RENE ET HOT
Bot CATE NOA
1382
Mark ho ont sido fhe cranks beating cap
bots Aand B seh pai
Tighten the cria Boning cap bot A and 6
90° Ie sequence as shown n ho Ilan
YANMAR esto encon eo
ENGINE
Engine Inspection
Tao ape
Tas
"Tighten the crankshal beating cap bat A another
88° inthe sequence as shown inthe istration,
2 Check alto paltodmark lol A aro now at a
180° angle tothe ron,
5 Gheck hal he pated mats of bol Bare now ata
30 to
CS
Do nottum the erankshat,
Spa
"Using several steps, instal 10 crankshat
eating capote unm the sequence show
Inthe istration
Be EE
16 Remove the crankshat bearing caps.
Step
‘Using several steps, loosen and remove the 10
crankshaft bearing cap st bots unforiy inthe
Sequence shown in he dla
2Stp2
Using several steps loosen and remove the 20
crankshaft boaring ap st bots untomy inthe
Sequence shown nthe urn
Engine Inspection
Tao ape
Tas
"Tighten the crankshal beating cap bat A another
88° inthe sequence as shown inthe istration,
2 Check alto paltodmark lol A aro now at a
180° angle tothe ron,
5 Gheck hal he pated mats of bol Bare now ata
30 to
CS
Do nottum the erankshat,
Spa
"Using several steps, instal 10 crankshat
eating capote unm the sequence show
Inthe istration
Be EE
16 Remove the crankshat bearing caps.
Step
‘Using several steps, loosen and remove the 10
crankshaft bearing cap st bots unforiy inthe
Sequence shown in he dla
2Stp2
Using several steps loosen and remove the 20
crankshaft boaring ap st bots untomy inthe
Sequence shown nthe urn
Engine inspection
ENGINE
TUE
T7 Remove the oylnde block stforng plato.
18 Using? crankshaft bering cap sat bts, pulloutihe
5 bearing caps
19.Measure the Plsiage at ts west pon,
ES
en Specie Condon
paras. LEGO Ie 000180 ny
fara (EN)
Spec Condon
(068 mn 0.00180)
Fon amo
faunas (0650 mm (6.00296)
al earancs ls grster than the maximum, use
an under size beating and cores reg the
‘rant that he
olelearance eas shown nthe
{able below
‘a Caran es Tr ander Sas Bearing)
co Species Condition
ES 0021100061 mm
mas {A GT 0020)
FRS 2,405
SN 0078 mer
mas (0013016000257)
Noto:
Make sure 1 replace the upper and ome main
bearings as ono sot
20 Complete romo the Pasting.
YANMAR so osos sexos
ENGINE
TUE
T7 Remove the oylnde block stforng plato.
18 Using? crankshaft bering cap sat bts, pulloutihe
5 bearing caps
19.Measure the Plsiage at ts west pon,
ES
en Specie Condon
paras. LEGO Ie 000180 ny
fara (EN)
Spec Condon
(068 mn 0.00180)
Fon amo
faunas (0650 mm (6.00296)
al earancs ls grster than the maximum, use
an under size beating and cores reg the
‘rant that he
olelearance eas shown nthe
{able below
‘a Caran es Tr ander Sas Bearing)
co Species Condition
ES 0021100061 mm
mas {A GT 0020)
FRS 2,405
SN 0078 mer
mas (0013016000257)
Noto:
Make sure 1 replace the upper and ome main
bearings as ono sot
20 Complete romo the Pasting.
YANMAR so osos sexos
ENGINE
Engine Inspection
Toa ape
2 Trepiacg a boarig replace wah one tat haa he
same number. he number fhe beating cannot Be
determined, selec the cosa bearing by 2689
together he numbers mprinedon the eynder Dock
09 crankshaft, then eer ote appropriate bearing
‘umber. There aro 7 sizes standard beatinge,
marked "1" 9. 3,74: 9 and 7 cordingly.
EXAMPLE
(Ge block man joumalbore damater"1" (A) +
Crankshaft main joua diameter 2" (8) =Total
number uso bearing "3 (C)}
THE on Cynder Bo
Gide Block | Crankahaft | Use Searing
a ® ©
2 2
7 7 =
= + D caspa
Ga
Engine Inspection
Toa ape
2 Trepiacg a boarig replace wah one tat haa he
same number. he number fhe beating cannot Be
determined, selec the cosa bearing by 2689
together he numbers mprinedon the eynder Dock
09 crankshaft, then eer ote appropriate bearing
‘umber. There aro 7 sizes standard beatinge,
marked "1" 9. 3,74: 9 and 7 cordingly.
EXAMPLE
(Ge block man joumalbore damater"1" (A) +
Crankshaft main joua diameter 2" (8) =Total
number uso bearing "3 (C)}
THE on Cynder Bo
Gide Block | Crankahaft | Use Searing
a ® ©
2 2
7 7 =
= + D caspa
Ga
Engine inspection
ENGINE
a EL T Tor
‘Sandor Cynder Sock Han Journal Bare Darter [A]
Tem ar Spectied Condon
> E
Faro. tan na EA
3] TE PERRET EME EN
700515 78.006 (1025 9 81087)
Forte 2 and puma [27
Vera an 7800610 79012 mm rae man 210710339102)
Were han 7 121 79018 mm free han 1107010311080
Sandra Carat a Jounal Data
Tone Mare
Spected Gonaon
Were Han PE 75.00 mn (re han 295351025]
Foro. rends puma |
Were ar 7 0681 7098 mm (roo han 2062281020826 m)
T2 0 E PRE m 205204 O ZA
Vera ian TESTS mm rare an 292510 PRATER)
or 2, and joumals
Were han 74.9689 74.998 mm (rare han 29825110 2382323)
720821074098 mm (29820870 26522814)
‘iad Erankaha Being Caner Wall ricknase (©
em marc | Speeied Condition ‘Spcied Conalion
(ler Upper Bearing) dor Lower Gearing)
A EAN]
(ea han 007823100 783510) | (man an 8077761000767)
2 | ester tante 18m | Modan 197811381 rm
er an 00788510 0 07868 | or an 0778716077001}
Worethan 88101496 men] Moe than 188110138070
(nee hun 007881 007888 2) | mie han 02772010 007811 in)
Foro dans fora
marge
Were van 1996101990mm | More an 196410 197 ren
moe ran 007858 a 0079701) | (nore ar 00781 o 0.0782)
Votan 1226102002 mm | | Mae han 136710 1360 rm
moe an 078706 0.07862) | (ror an 0.078250 07601)
More an 2002102008 mm | Mare han 1 86010 1363 rm
frere han 0079210 0788412) | (rare han 0.078310. 00084 1)
Vas van 290810 2008 mm] | Mas than 150010156 rm
(ra a 0.078041 0.7908 2) | (mera ran 007040 o 007650 n)
Here van 1075101970mm | Mae an 1987101900 ren
mer Wan 0777616007787) | nor Pan PRES 078801}
Were ran 17810 987 | More han 19001 1.905 rm
(re rar 00178710 0.978) | mer ran 00789 o 007840 1}
(nore an 00778900781! in) | nor an 007848 o 0.0785 in)
FerNe.2,¢ands una |
Bras
area 128410 1887 mm || Mas han 150610158 mm
frere han 0.7971 1007623 | (rare an 0.078581. 007670)
Votan 128710 920 mm | | Marsan 50610200 rm
Amor an 267823100 07955 7)
| mer man 5767010007602) |
[AAA
(rove nan 0.078451 007888 1 | (rea un 0.0789 o 0.0905
YANMAR su wos conso tons
ENGINE
a EL T Tor
‘Sandor Cynder Sock Han Journal Bare Darter [A]
Tem ar Spectied Condon
> E
Faro. tan na EA
3] TE PERRET EME EN
700515 78.006 (1025 9 81087)
Forte 2 and puma [27
Vera an 7800610 79012 mm rae man 210710339102)
Were han 7 121 79018 mm free han 1107010311080
Sandra Carat a Jounal Data
Tone Mare
Spected Gonaon
Were Han PE 75.00 mn (re han 295351025]
Foro. rends puma |
Were ar 7 0681 7098 mm (roo han 2062281020826 m)
T2 0 E PRE m 205204 O ZA
Vera ian TESTS mm rare an 292510 PRATER)
or 2, and joumals
Were han 74.9689 74.998 mm (rare han 29825110 2382323)
720821074098 mm (29820870 26522814)
‘iad Erankaha Being Caner Wall ricknase (©
em marc | Speeied Condition ‘Spcied Conalion
(ler Upper Bearing) dor Lower Gearing)
A EAN]
(ea han 007823100 783510) | (man an 8077761000767)
2 | ester tante 18m | Modan 197811381 rm
er an 00788510 0 07868 | or an 0778716077001}
Worethan 88101496 men] Moe than 188110138070
(nee hun 007881 007888 2) | mie han 02772010 007811 in)
Foro dans fora
marge
Were van 1996101990mm | More an 196410 197 ren
moe ran 007858 a 0079701) | (nore ar 00781 o 0.0782)
Votan 1226102002 mm | | Mae han 136710 1360 rm
moe an 078706 0.07862) | (ror an 0.078250 07601)
More an 2002102008 mm | Mare han 1 86010 1363 rm
frere han 0079210 0788412) | (rare han 0.078310. 00084 1)
Vas van 290810 2008 mm] | Mas than 150010156 rm
(ra a 0.078041 0.7908 2) | (mera ran 007040 o 007650 n)
Here van 1075101970mm | Mae an 1987101900 ren
mer Wan 0777616007787) | nor Pan PRES 078801}
Were ran 17810 987 | More han 19001 1.905 rm
(re rar 00178710 0.978) | mer ran 00789 o 007840 1}
(nore an 00778900781! in) | nor an 007848 o 0.0785 in)
FerNe.2,¢ands una |
Bras
area 128410 1887 mm || Mas han 150610158 mm
frere han 0.7971 1007623 | (rare an 0.078581. 007670)
Votan 128710 920 mm | | Marsan 50610200 rm
Amor an 267823100 07955 7)
| mer man 5767010007602) |
[AAA
(rove nan 0.078451 007888 1 | (rea un 0.0789 o 0.0905
YANMAR su wos conso tons
ENGINE Engine Inspection
2 Toute
31 | nepect the Connecting Rod Thrust Clearance
Y Using a dal nentor, measure the thus clearance
hie mouing the connecting 104 back and tr.
ETATS
FE DA mm 0661 10942130)
CON
He trust clearance is reser han the maximum.
replace one or more connecting rod 25 necessary
Ihecessary, replace the rankaha.
Tnopect the Connecting Rod Ol Clearance
Y. Instale crankshaf bearing,
2 Intl he crank
8. Lay asin of pasigage across the crak pin.
4. ntl he connecting rod cap so that it prorsion is
facing he comect drecion.
NOTICE
Match the numbered connecting rod cap withthe
‘connecting ro,
5. apply a E coat of engine 0110 tho treads of ho
‘connecting rod cap bots.
2 progresse stops.
+ any connecting rd bearing cap bot = broken or
delomed. place
“Ital and untorm tighten the connecting rod cap
basin sequence.
LAA]
2 Toute
31 | nepect the Connecting Rod Thrust Clearance
Y Using a dal nentor, measure the thus clearance
hie mouing the connecting 104 back and tr.
ETATS
FE DA mm 0661 10942130)
CON
He trust clearance is reser han the maximum.
replace one or more connecting rod 25 necessary
Ihecessary, replace the rankaha.
Tnopect the Connecting Rod Ol Clearance
Y. Instale crankshaf bearing,
2 Intl he crank
8. Lay asin of pasigage across the crak pin.
4. ntl he connecting rod cap so that it prorsion is
facing he comect drecion.
NOTICE
Match the numbered connecting rod cap withthe
‘connecting ro,
5. apply a E coat of engine 0110 tho treads of ho
‘connecting rod cap bots.
2 progresse stops.
+ any connecting rd bearing cap bot = broken or
delomed. place
“Ital and untorm tighten the connecting rod cap
basin sequence.
LAA]
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