6LY3

series
6LY3 Service Manual
SERVICE MANUAL

P/N: 0BLY3-U00100

MARINE
ENGINES

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 This Service Manual has been developed for the exclusive use of service and repair professionals such as
Yanmar authorized distributors and Yanmar authorized dealers. It is written with these professionals in mind
and may not contain the necessary detail or safety statements that may be required for a non-professional to
perform the service or repair properly and / or safely. Please contact an authorized Yanmar repair or service
professional before working on your Yanmar product.
Disclaimers:
All information, illustrations and specifications in this manual are based on the latest information available at
the time of publishing. The illustrations used in this manual are intended as representative reference views
only. Moreover, because of our continuous product improvement policy, we may modify information,
illustrations, and / or specifications to explain and / or exemplify a product, service or maintenance
improvement. We reserve the right to make any change at any time.
Yanmar and are registered trademarks of Yanmar Co., Ltd. in Japan, the United States and / or
other countries.
All Rights Reserved:
No part of this publication may be reproduced or used in any form, by any means - graphic, electronic, or
mechanical, including photocopying, recording, taping, or information storage and retrieval systems - without
the written permission of Yanmar Marine International.
© 2007 Yanmar Marine International.
1107

ii 6LY3 Service Manual

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 TABLE OF
CONTENTS
Page
Introduction ......................................................................................... 1-1

Safety.................................................................................................... 2-1

General Service Information .............................................................. 3-1

Periodic Maintenance ......................................................................... 4-1

Engine .................................................................................................. 5-1

Fuel System ......................................................................................... 6-1

Coolant System ................................................................................... 7-1

Lubrication .......................................................................................... 8-1

Turbocharger ....................................................................................... 9-1

Starter................................................................................................. 10-1

Alternator ........................................................................................... 11-1

Electrical and ECU ............................................................................ 12-1

Troubleshooting ................................................................................ 13-1

Service Standards ............................................................................. 14-1

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 TABLE OF CONTENTS

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iv 6LY3 Service Manual

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 6LY3 Service Manual
Section 1

INTRODUCTION
This manual gives specific instructions for the Along with standard tools, Yanmar recommends the
proper repair of Yanmar 6LY3 series marine use of special tools necessary to perform repairs
engines. correctly.
Please follow the procedures carefully to ensure Yanmar products are continuously undergoing
quality service. improvement. This Service Manual has been
checked carefully in order to avoid errors. However,
Yanmar recommends reading this Service Manual Yanmar is not liable for any misrepresentations,
completely before starting with repairs. errors of description or omissions. Contact your
authorized Yanmar marine dealer or distributor for
any questions you have regarding this Service
Manual.

6LY3 Service Manual 1-1

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 INTRODUCTION Revision History

REVISION HISTORY
This manual is a living document. Periodic manual At times, the revision involves inserting additional
revisions are published to document product pages in one or more sections. Replace the
improvements and changes. This practice ensures Revision Control Table and insert the new pages.
the manual has the most current information.
This method of revision control represents the most
As manual revisions become necessary, individual cost-effective solution to providing current, updated
pages are prepared and sent to those who need information as needed.
the information. If a page or number of pages
should be replaced, the replacement information is
sent along with a revised Revision Control Table.
Discard the older, obsolete information.

Revision Control Table

Revision Date New Page Numbers Initiating
Remarks
Revision Number Involved Department
Aug. 2007
ALL Initial Release YMI
Rev. 0

1-2 6LY3 Service Manual

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 6LY3 Service Manual
Section 2

SAFETY
SAFETY STATEMENTS
Yanmar is concerned for your safety and the Indicates a hazardous situation which, if not
condition of your marine engine. Safety statements avoided, will result in death or serious injury.
are one of the primary ways to call your attention to
the potential hazards associated with Yanmar
marine engines. Follow the precautions listed
throughout the manual before operation, during Indicates a hazardous situation which, if not
operation and during periodic maintenance avoided, could result in death or serious injury.
procedures for your safety, the safety of others and
to protect the performance of your marine engine.
Keep the decals from becoming dirty or torn and Indicates a hazardous situation which, if not
replace them if they are lost or damaged. Also, if a avoided, could result in minor or moderate
part needs to be replaced that has a decal attached injury.
to it, make sure to order the new part and decal at
the same time.

This safety alert symbol appears Indicates a situation which can cause damage to
with most safety statements. It the engine, personal property and / or the

A means attention, become alert,

your safety is involved! Please read
and abide by the message that
environment or cause the equipment to operate
improperly.

follows the safety alert symbol.

6LY3 Service Manual 2-1

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 SAFETY Safety Precautions

SAFETY PRECAUTIONS
There is no substitute for common sense and The safety messages that follow have
careful practices. Improper practices or WARNING level hazards. These safety
carelessness can cause burns, cuts, mutilation, messages describe a hazardous situation
asphyxiation, other bodily injury or death. This which, if not avoided, could result in death or
information contains general safety precautions serious injury.
and guidelines that must be followed to reduce risk
to personal safety. Special safety precautions are Explosion Hazard
listed in specific procedures. Read and understand While the engine is running or the
all of the safety precautions before operating, battery is charging, hydrogen gas is
performing repairs or maintenance. being produced and can be easily
ignited. Keep the area around the
battery well-ventilated and keep sparks,
open flame and any other form of ignition out of the
The safety messages that follow have DANGER area.
level hazards. These safety messages describe
a hazardous situation which, if not avoided, will ALWAYS turn off the battery switch (if equipped) or
result in death or serious injury. disconnect the negative (-) battery cable before
servicing the equipment.
NEVER permit anyone to install or
operate the engine without proper
training. Fire and Explosion Hazard
Diesel fuel is flammable and explosive
• Read and understand this Service Manual before under certain conditions.
operating or servicing the engine to ensure that
safe operating practices and maintenance
procedures are followed.
• Safety signs and decals are additional reminders NEVER use a shop rag to catch the fuel.
for safe operating and maintenance techniques.
• See your authorized Yanmar marine dealer or Wipe up all spills immediately.
distributor for additional training.
NEVER refuel with the engine running.
Crush Hazard
NEVER stand under a hoisted Store any containers containing fuel in a
engine. If the hoist mechanism fails, well-ventilated area, away from any combustibles or
the engine will fall on you. sources of ignition.

ALWAYS secure the engine solidly to prevent the

engine from falling during maintenance.

2-2 6LY3 Service Manual

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 Safety Precautions SAFETY
12/05

Piercing Hazard
Avoid skin contact with high-pressure
Fire Hazard diesel fuel spray caused by a fuel
Have appropriate safety equipment system leak such as a broken fuel
available. Have all fire extinguishers injection line. High-pressure fuel can
checked periodically for proper penetrate your skin and result in
operation and / or readiness. serious injury. If you are exposed to high-pressure
fuel spray, obtain prompt medical treatment.

ALWAYS read and follow safety-related precautions

found on containers of hazardous substances like NEVER check for a fuel leak with your hands.
parts cleaners, primers, sealants and sealant ALWAYS use a piece of wood or cardboard. Have
removers. your authorized Yanmar marine dealer or distributor
repair the damage.

Undersized wiring systems can cause an electrical

fire. Flying Object Hazard
ALWAYS wear eye protection when servicing the
engine or when using compressed air or
Entanglement Hazard high-pressure water. Dust, flying debris,
NEVER leave the key in the key switch compressed air, pressurized water or steam may
when servicing the engine. Attach a injure your eyes.
“Do Not Operate” tag near the key
switch while performing maintenance
on the equipment. Coolant Hazard
Wear eye protection and rubber gloves
when handling Long Life Coolant (LLC).
ALWAYS stop the engine before beginning service. If contact with the eyes or skin should
occur, flush eyes and wash immediately with clean
If the engine must be serviced while it is operating, water.
remove all jewelry, tie back long hair and keep
hands, other body parts and clothing away from
moving / rotating parts.

6LY3 Service Manual 2-3

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 SAFETY Safety Precautions

ALWAYS keep the electrical connectors and

terminals clean. Check the electrical harnesses for
Sever Hazard cracks, abrasions and damaged or corroded
connectors.
NEVER wear jewelry, unbuttoned
cuffs, ties or loose-fitting clothing and NEVER turn off the battery switch (if equipped) or
ALWAYS tie long hair back when short the battery cables during operation. Damage
working near moving / rotating parts to the electrical system will result.
such as the flywheel or PTO shaft. Keep hands,
feet and tools away from all moving parts.
Exhaust Hazard
All internal combustion engines create
The propeller may rotate during towing or if the carbon monoxide gas during operation
engine is running at idle speed. NEVER service the and special precautions are required to
engine while being towed or when the engine is avoid carbon monoxide poisoning.
running.
• NEVER block windows, vents or other means of
ventilation if the engine is operating in an
If the vessel has more than one engine, NEVER enclosed area.
service an engine if either of the engines is running.
In multi-engine configurations the propeller for an • ALWAYS ensure that all connections are
engine that is shut down may rotate if any of the tightened to specifications after repair is made to
other engines are running. the exhaust system.

Electrical Hazard Burn Hazard

Make welding repairs safely. Some of the engine surfaces become
very hot during operation and shortly
• ALWAYS turn off the battery switch (if
after shutdown.
equipped) or disconnect the negative
(-) battery cable and the leads to the
alternator when welding on the
equipment. • Keep hands and other body parts away from hot
engine surfaces.
• Remove the multi-pin connector to the engine
control unit. Connect the weld clamp to the • Handle hot components with heat-resistant
component to be welded and as close as possible gloves.
to the welding point.
• NEVER connect the weld clamp to the engine or
in a manner which would allow current to pass
through a mounting bracket.
• When welding is complete, reconnect the leads to
the alternator and engine control unit prior to
reconnecting the batteries.

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 Safety Precautions SAFETY
12/05

Sudden Movement Hazard The safety messages that follow have CAUTION
The engine lifting eyes are engineered to lift the level hazards. These safety messages describe
weight of the marine engine only. ALWAYS use the a hazardous situation which, if not avoided,
engine lifting eyes when lifting the engine. could result in minor or moderate injury.
ALWAYS wear eye protection when
servicing the engine or when using
Lifting Hazard compressed air or high-pressure water.
Additional equipment is necessary to lift the marine Dust, flying debris, compressed air,
engine and marine gear together. ALWAYS use pressurized water or steam may injure
lifting equipment with sufficient capacity to lift the your eyes.
marine engine.

Poor Lighting Hazard

If transport is needed for engine repair, have a Ensure that the work area is adequately
helper assist in attaching it to a hoist and loading it illuminated. ALWAYS install wire cages on portable
onto a truck. safety lamps.

Alcohol and Drug Hazard Tool Hazard

NEVER operate the engine while ALWAYS use tools appropriate for the task at hand
under the influence of alcohol, drugs or and use the correct size tool for loosening or
when ill. tightening machine parts.

Exposure Hazard
ALWAYS wear personal protective
equipment including appropriate
clothing, gloves, work shoes, 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.

6LY3 Service Manual 2-5

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 SAFETY Safety Precautions

NEVER dispose of hazardous materials by

dumping them into a sewer, on the ground or into
The safety messages that follow have NOTICE groundwater or waterways.
level hazards.
Any part which is found defective as a result of If any indicator illuminates during engine operation,
inspection or any part whose measured value does stop the engine immediately. Determine the cause
not satisfy the standard or limit must be replaced. and repair the problem before continuing to operate
the engine.
ALWAYS tighten components to the specified
torque. Loose parts can cause equipment damage Make sure the engine is installed on a level surface.
or cause it to operate improperly. If a Yanmar Marine engine is installed at an angle
that exceeds the specifications stated in the
Yanmar Marine Installation Manuals, engine oil may
Only use replacement parts specified. Other
enter the combustion chamber causing excessive
replacement parts may affect warranty coverage.
engine speed, white exhaust smoke and serious
engine damage. This applies to engines that run
NEVER attempt to modify the engine design or continuously or those that run for short periods of
safety features such as defeating the engine speed time.
limit control or the diesel fuel injection quantity
control.

NEVER attempt to adjust the low or high idle speed

limit bolt. This may impair the safety and
performance of the engine and shorten its life.
Modifications of this type may void the warranty. If
adjustment is ever required, contact your
authorized Yanmar marine dealer or distributor.

Modifications may impair the engine’s safety and

performance characteristics and shorten the
engine’s life. Any alterations to this engine may void
its warranty. Be sure to use Yanmar genuine
replacement parts.

Follow the guidelines of the EPA or

other governmental agencies for the
proper disposal of hazardous materials
such as engine oil, diesel fuel and
engine coolant. Consult the local
authorities or reclamation facility.

2-6 6LY3 Service Manual

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 Location of Safety Decals SAFETY
12/05

LOCATION OF SAFETY DECALS

Figure 2-1 shows the location of safety decals on Yanmar 6LY3 series marine engines.
Figure 2-1

(3)
(2)

NEVER pour the

FULL engine oil across
(1) LOW the full line.
119773-07280

(4)

(5)

E
(6)
DO NOT STEP
ON COVERS.
POSSIBILITY
DO ANOT
OF STEP
FALL
ON COVERS.
POSSIBILITY 003025-02E
OF A FALL
0006329

Figure 2-1

1 – Part Number: 128296-07300 4 – Part Number: 128296-07260

2 – Part Number: 120324-07240 5 – Part Number: 128296-07350
3 – Part Number: 119773-07280 6 – Part Number: 119578-07890

6LY3 Service Manual 2-7

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 SAFETY Location of Safety Decals

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2-8 6LY3 Service Manual

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 6LY3 Service Manual
Section 3

GENERAL SERVICE
INFORMATION
Page
Safety Precautions .......................................................................... 3-3
6LY3-ETP Exterior Views................................................................ 3-4
Operation Side........................................................................... 3-4
Non-Operation Side................................................................... 3-4
Diesel Fuel ...................................................................................... 3-6
Diesel Fuel Specifications ......................................................... 3-6
Engine Oil........................................................................................ 3-8
Engine Oil Specifications........................................................... 3-8
Marine Gear Oil ............................................................................... 3-8
Engine Coolant................................................................................ 3-9
Handling of Coolant ................................................................... 3-9
Engine Outline Drawings............................................................... 3-10
6LY3-ETP / STP / UTP (YT-15 MOUNT) ................................ 3-10
6LY3-ETP ................................................................................ 3-11
Exhaust Gas Emission Regulations .............................................. 3-12
Engine Identification ................................................................ 3-12
EPA Exhaust Gas Emission Standard..................................... 3-13
EPA Guarantee Conditions for Emission Standard ................. 3-13
Engine Nameplate......................................................................... 3-14
Reduction and Reversing Gear ..................................................... 3-14
Principal Engine Specifications ..................................................... 3-15
Abbreviations and Symbols........................................................... 3-16
Abbreviations........................................................................... 3-16
Symbols................................................................................... 3-16

6LY3 Service Manual 3-1

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 GENERAL SERVICE INFORMATION
Unit Conversions ........................................................................... 3-17
Unit Prefixes ............................................................................ 3-17
Units of Length ........................................................................ 3-17
Units of Volume ....................................................................... 3-17
Units of Mass........................................................................... 3-17
Units of Force .......................................................................... 3-17
Units of Torque........................................................................ 3-17
Units of Pressure..................................................................... 3-17
Units of Power ......................................................................... 3-17
Units of Temperature............................................................... 3-17

3-2 6LY3 Service Manual

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 Safety Precautions GENERAL SERVICE INFORMATION
12/05

SAFETY PRECAUTIONS
Before servicing the engine review the Safety Section on page 2-1.

6LY3 Service Manual 3-3

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 GENERAL SERVICE INFORMATION 6LY3-ETP Exterior Views

6LY3-ETP EXTERIOR VIEWS

Operation Side
Figure 3-1

(1)
(2)
(9)

(8) (3)

(4)
(7) (6) (5)
0006254

Figure 3-1
Non-Operation Side
Figure 3-2

(17) (10)

(16)

(11)

(12)
(13)
(14) 0006255
(15)
Figure 3-2

3-4 6LY3 Service Manual

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 6LY3-ETP Exterior Views GENERAL SERVICE INFORMATION
12/05

1 – Filler Cap 10 – Coolant Tank (Exhaust Manifold)

2 – Electrical Control Unit Cover 11 – Dipstick
3 – Fuel Injection Pump 12 – Heat Exchanger
4 – Oil Cooler 13 – Seawater Pump
5 – Oil Filter 14 – Alternator
6 – Intercooler 15 – V-Belt
7 – Flywheel 16 – Fuel Filter
8 – Air Silencer 17 – Coolant Pump
9 – Turbocharger

6LY3 Service Manual 3-5

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 GENERAL SERVICE INFORMATION Diesel Fuel

DIESEL FUEL Additional Fuel Requirements

• Fuel cetane number should equal 45 or higher.
Diesel Fuel Specifications
• Sulfur content should not exceed 0.5% by
NOTICE: Use the correct fuel type to maintain volume. (Preferably it should be below 0.05%.)
engine performance and reduce engine wear and
ensure compliance with emission regulations. • Water and sediment in the diesel fuel should not
exceed 0.05% by volume.
Fuel Selection
• Ash should not exceed 0.01% by mass.
Diesel fuel should comply with the following
specifications: • Carbon residue content of the diesel fuel should
not exceed 0.35% by volume. (Preferably it
• The fuel specifications need to comply with should be below 0.1%.)
national and international standards.
• Total aromatic content of the diesel fuel should
• ASTM D975 No. 1-D not exceed 35% by volume. (Preferably it should
No. 2-D for USA be below 30% and aromatic polycyclic aromatic
hydrocarbons (PAH*) content of the diesel fuel
• EN590: 96 for EU
should be below 10%.)
• ISO 8217 DMX International
NOTICE: Mixing winter and summer fuel, using
• BS 2869-A1 or A2 for UK Kerosene, residual fuel or Biocide produces poor
fuel quality and will result in reduced engine
• JIS K2204-2 for JAPAN performance and excessive wear of internal
components.

3-6 6LY3 Service Manual

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 Diesel Fuel GENERAL SERVICE INFORMATION
12/05

Handling Diesel Fuel Diesel Fuel Lines

• Water and dust in the diesel fuel can cause Install the fuel supply line between the fuel tank and
operation failure. Use containers which are clean the fuel injection pump. Install a drain cock at the
inside to store diesel fuel. Store the containers bottom of the fuel tank to remove water and dust.
away from rain and dirt. Install a fuel / water separator and a fuel filter in the
middle of the fuel supply line.
• Allow fuel to settle for several hours before
pumping from container. Figure 3-4

(1)
(2)
• Before refilling fuel, let the fuel container rest for
several hours so that water and dust in the fuel (10) (8) (7)
are deposited on the bottom. Use only clean fuel.
Use the clear filtered fuel from the upper middle (3)
section of the container only (Figure 3-3), leaving (9)
any contaminated fuel at the bottom.
(5) (6)
Figure 3-3

(4)
0006256

Figure 3-4
1 – Diesel Fuel Strainer
2 – Diesel Fuel Return Pipe
3 – Diesel Fuel Tank
4 – Drain Cock
5 – Diesel Fuel Shutoff Valve
6 – Approximately 500 mm (20 in.)
7 – Fuel / Water Separator
0006257
8 – Diesel Fuel Priming Pump
Figure 3-3 9 – Less than 500 mm (20 in.)
10 – To Diesel Fuel Injection Pump

6LY3 Service Manual 3-7

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 GENERAL SERVICE INFORMATION Engine Oil

ENGINE OIL The following oils should not be used for 6LY3-ETP,
STP or UTP engines:
Engine Oil Specifications • API: CG-4, CH-4
NOTICE: Use the correct engine oil to maintain
• ACEA: E-1, E-2, B
engine performance and reduce engine wear.
• JASO: DH-2, DL-1
Selection of Engine Oil
Use an engine oil that meets or exceeds the Additional Technical Engine Oil
following classifications: Requirements
The engine oil must be changed when the Total
• API Service Category - CD or higher
Base Number (TBN) has been reduced to 2.0. TBN
• TBN Valve - 9 or more (mgKOH / g) test method; JIS K-2501-5.2-2 (HCI),
ASTM D4739 (HCI).
• SAE viscosity - 15W40
Handling Engine Oil
If the engine is operated at temperatures below
those shown in Figure 3-5, consult your Yanmar 1. Check that the engine oil, oil storage container
Marine dealer for special lubricants and starting and filling equipment are free of sediment and
aids. water.
Figure 3-5 2. NEVER mix engine oils of different types.
Selection of viscosity (SAE Service grade) 3. Extract any residual oil from the engine or
marine gear before servicing for the first time.
10W
20W
Always use fresh new oil.
10W-30 4. Engine oil degrades over time, even when the
15W-40 engine is not in use. Change oil at specified
#20 times regardless of engine usage.
#30
#40

-20 -10 0 10 20 30 40 50
MARINE GEAR OIL
Atmospheric temperature (°C) Refer to the Operation Manual for marine gear oil
0006258 specifications.
Figure 3-5

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 Engine Coolant GENERAL SERVICE INFORMATION
12/05

ENGINE COOLANT Handling of Coolant

Mix clean deionized soft water with Long Life 1. Replace the coolant periodically, according to
Coolant (LLC) in order to prevent rust buildup and the maintenance schedule in the Operation
freezing. NOTICE: NEVER use water only. Manual.
Freezing water will cause serious damage to the 2. Remove the scale from the coolant system
engine. periodically, according to the instructions for
your engine.
LLC must conform to the following specifications:
NOTICE: Excessive mixture of LLC lowers the
• JIS K-2234 cooling efficiency of the engine. Use the mixing
• SAE J814C, J1941, J1034, J2036 ratios specified by the LLC manufacturer for the
temperature range in which you will be operating.
• ASTM D3306
• ASTM D4985
Yanmar recommends using genuine Yanmar
coolant / antifreeze. Contact your authorized
Yanmar dealer or distributor.
Recommended Engine Coolants:
• TEXACO LONG LIFE COOLANT ANTIFREEZE,
both standard and pre-mixed. Product code
79947 and 7998.
• HAVOLINE EXTENDED LIFE ANTIFREEZE /
COOLANT. Product code 7994.
NOTICE:
• Always be sure to add LLC to soft water. It is
particularly important to add LLC during cold
weather. Without LLC, coolant performance will
decrease due to scale and rust in the coolant
system.
• Mix the proper amount of coolant concentrate
specified by the LLC manufacturer for the
ambient temperature in which you will be
operating. LLC concentration should be between
30% and 60%.
• Mixing different types of LLC is harmful because
it causes sludge buildup.
• NEVER use hard water.
• Use only clean deionized soft water when mixing
LLC.

6LY3 Service Manual 3-9

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 Figure 3-6

3-10
Parallel pin hole Water outlet ø37 / ø46 Unit : mm (in)
ø10 H7 ( +0.015 ) Depth 12 (Without mixing elbow)
0

)
761 235
61.5
12-M10 Depth 19

0
Water inlet ø38 / ø46 Direction of rotation

( -0.035
8-M10 Depth 15
6-M10 Depth 20

ø95

290

287
287

279.1

0
61

+0.13
+0.13
4

ø 150
ø 260

ø314
40 740.5
8
8

ø 409.58 0
ø 352.42
287
287
6.9 11
ø18.5 ø
21.5
PC

105
.6

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8 450
42 170 Detail of front coupling
ø

8
PC 210 Mounting block

3.3
Detail of flywheel output side (Option)

33
PCø
ENGINE OUTLINE DRAWINGS

(801.3)
GENERAL SERVICE INFORMATION

Fuel outlet 525.6

6LY3-ETP / STP / UTP (YT-15 MOUNT)

ø9 / ø16 fuel hose

381 420.3
Engine oil filters

2
Fuel filter

Figure 3-6
321.5
621.3

538.6

© 2007 Yanmar Marine International

39

Center of
(776.6)

crank shaft
Center of
crank shaft

170
238

740.5 (256.5) 252

Min. 83
Max. 103

786 (285)
1071 Fuel inlet
1300.4 ø9 / ø16 fuel hose
Center of gravity

6LY3 Service Manual

NOTES:
1.Drawing Shows mounting blocks at original height.
(Engine weight will compress blocks by approximately 3.5mm)
2.Mounting block parts number is 127495-08320.
(YT-15 mount)
3. Shows center of gravity.
4.Mixing elbow rubber hose inner diameter 5 in.
0006333
Engine Outline Drawings
 Engine Outline Drawings GENERAL SERVICE INFORMATION
12/05

6LY3-ETP
Figure 3-7

000633
S
Engine
Engine
Engine seawater Piping
Engine Coolant Piping

Diesel fuel
Diesel fuel piping

Diesel fuel

Engine coolant
Engine

pump

NOTES:
S

Figure 3-7

6LY3 Service Manual 3-11

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 GENERAL SERVICE INFORMATION Exhaust Gas Emission Regulations

EXHAUST GAS EMISSION REGULATIONS

6LY3 series engines are applicable with Marine Compression Ignition Engines Regulation of the EPA
(40 CFR Part 94) in the U.S. RCD Regulation and BSO Regulation in Europe and other regulations are
applied to this engine.

Engine Identification
With the regulations on exhaust gas emission worldwide, it has become necessary to identify engines in a
manner that determines which regulations they comply with.

EPA Emission Labels and Location

Figure 3-8

MARINE ENGINE EMISSION CONTROL INFORMATION

THIS ENGINE COMPLIES TO U.S. EPA REGULATIONS
40 CFR PART 94 WHICH APPLY TO MARINE ENGINES
MODEL YEAR : 2006 MODEL: 6LY3-ETP, STP, UTP
DISPLACEMENT PER CYLINDER : 0.969 LITERS
ENGINE FAMILY : 6YDXM5.81D6H APPLICATION : RECREATIONAL
STANDARDS THC+NOx : 7.2g/kWh CO : 5.0g/kWh PM : 0.30g/kWh
REFER TO OWNER'S MANUAL FOR MAINTENANCE
SPECIFICATIONS AND ADJUSTMENTS.

Emission control label

THIS ENGINE IS CATEGORIZED AS A RECREATIONAL

MARINE ENGINE UNDER 40 CFR PART 94. INSTALLATION
OF THIS ENGINE IN ANY NONRECREATIONAL VESSEL IS A
VIOLATION OF FEDERAL LAW SUBJECT TO CIVIL PENALTY.

Recreational marine engine label 0006259

Figure 3-8

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 Exhaust Gas Emission Regulations GENERAL SERVICE INFORMATION
12/05

EPA Engine Family Name as Assigned by EPA Identifying Engine Family Group
Figure 3-9

6 YDX M 5.81 D 6 H
Method of air aspiration
Number of cylinders
Combustion chamber design
Displacement (liter)
Marine engine
Yanmar
2006 Model Year
0006260

Figure 3-9

EPA Exhaust Gas Emission Standard

Engine Power Category Tier Model Year NMHC + NOx CO PM

37 kW (50.3 hp) and 7.2 g / kWh 5.0 g / kWh 0.3 g / kWh
0.9-1.2 L / cylinder Tier 2 2006
Above (0.186 oz / hph) (0.129 oz / hph) (0.007 oz / hph)

NOTICE: The transit smoke (ACC / LUG / PEAK) is not applicable. The EPA recommended fuel is used. As
for model year, the year which a regulation is applicable to for recreational use is shown.

EPA Guarantee Conditions for

Emission Standard
In addition to making sure that these conditions are
met, check for any deterioration that may occur
before the required periodic maintenance times.
1. Fuel: The diesel fuel ASTM D975 No. 1-D or
No. 2-D, equivalent (Cetane No. 3.45
minimum).
2. Oil: API grade, class CD.

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 GENERAL SERVICE INFORMATION Engine Nameplate

ENGINE NAMEPLATE
Figure 3-10 shows the location of the engine nameplate.
Figure 3-10

Model
Gear Model
Continuous power kW / min-1
Speed of prop,shaf t min-1
Fuel stop power kW / min-1
ENG.No.

119175-7202

0006420

Figure 3-10

REDUCTION AND REVERSING

GEAR
Refer to your Marine Gear Service Manual for
inspection, disassembly and reassembly
information.

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 Principal Engine Specifications GENERAL SERVICE INFORMATION
12/05

PRINCIPAL ENGINE SPECIFICATIONS

STP: 295 kW (401 hp) / 3198 rpm, UTP: 254 kW (345 hp) / 3198 rpm

Engine Model 6LY3-ETP 6LY3-STP 6LY3-UTP

Use Pleasure Use
Type Vertical water-cooled, 4-cycle diesel engine
Aspiration Turbocharger with Aftercooler
Combustion System Direct injection
Number of Cylinders 6
Firing Order 1-4-2-6-3-5
Bore x Stroke 105.9 × 110 mm (4.17 × 4.33 in.)
Displacement 5.813 L (6.14 qt)
Output at Crankshaft 3198 rpm
Continuous Rating Output Engine Speed (3198 rpm) 436 hp Metric 401 hp Metric 345 hp Metric
(Notes 1 and 2) 321 kW 295 kW 254 kW
3300 rpm
Output at Crankshaft
480 hp Metric 441 hp Metric 379 hp Metric
Maximum Output Engine Speed (3300 rpm)
353 kW 324 kW 279 kW
(Notes 1 and 2)
40°C (104°F) at fuel inlet temperature
High Idling (Note 3) 3500 ± 25 rpm
Low Idling (Note 3) 700 ± 25 rpm
Installation Flexible mounting
Direction of Rotation Crankshaft Counterclockwise viewed from stern
Coolant System Closed coolant system with heat exchanger
Lubrication System Complete enclosed forced lubrication
Engine: 28 L (30 qt)
Coolant Capacity
Coolant recovery tank: 1.5 L (30 qt)
Rake Angle 0°
Total (Note 4) 18.8 L (19.9 qt)
Effective (Note 5) 8.0 L (8.5 qt)
Type Electric
Starting System Starting Motor DC 12V - 3 kW
AC Generator 12V - 80A
Model RHC7W (IHI made)
Turbocharger
Type Water cooled
Overall Length 1300.4 mm (51.2 in.)
Engine Dimension Overall Width 801.3 mm (31.5 in.)
Overall Height 776.6 mm (30.6 in.)
Engine Dry Mass (Without Marine Gear) 640 kg (1410.96 lb)
Recommended Battery Capacity 12V-150Ah or more
Notes:
1. Rating condition: ISO 8665. Temperature of fuel: 40°C (104°F) at the fuel pump inlet.
2. 1 hp (metric horsepower) = 0.7355 kW
3. Fuel condition: Density at 15°C (59°F) = 0.860 g/cm3 (53.69 ft·lb3).
4. Fuel temperature at the inlet of the fuel injection pump.
5. The “Total Engine Oil Capacity” includes the oil in the oil pan, channels, coolers and filter.
6. The “Effective Engine Oil Capacity” indicates the difference in maximum scale of the dipstick and
minimum scale.

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 GENERAL SERVICE INFORMATION Abbreviations and Symbols

ABBREVIATIONS AND SYMBOLS

Abbreviations kgf/cm2 kilogram force per square
centimeter
A ampere kgf·m kilogram force per meter
AC alternating current km kilometers
ACEA Association des Constructeurs kPa kilopascal
Européens d’Automobilies kW kilowatt
Ah ampere-hour L liter
API American Petroleum Institute L/hr liter per hour
ARB Air Resources Board lb pound
ATDC after top dead center lbf pound-force
BDC bottom dead center lb-ft pound foot (Tightening Torque)
BTDC before top dead center lb-in pound inch (Tightening Torque)
°C degree Celsius m meter
CARB California Air Resources Board mL milliliter
CCA cold cranking amp mm millimeter
cfm cubic feet per minute mmAq millimeter Aqueous (water)
cm centimeter MPa megapascal
cm3 cubic centimeter mV millivolt
cm3/min. cubic centimeter per minute N newton
cu in. cubic inch N·m newton meter
D diameter No. number
DC direct current O.D. outside diameter
DI direct oz ounce
DVA direct volt adapter Pa pascal
EPA Environmental Protection Agency PS horsepower (metric)
ESG electronic speed governor psi pound per square inch
°F degree Fahrenheit qt quart (U.S.)
fl oz fluid ounce (U.S.) R radius
fl fluid ounce (U.S.) per minute rpm revolutions per minute
ft foot SAE Society of Automotive Engineers
ft-lb foot pound* sec. second
ft-lbf/min. foot pound force per minute t short ton 2000 lb
g gram TBN total base number
gal gallon (U.S.) TDC top dead center
gal/hr gallon (U.S.) per hour V volt
gal/min. gallon (U.S.) per minute VAC volt alternating current
GL gear lubricant VDC volt direct current
hp horsepower (metric) W watt
hr hour
ID inside diameter Symbols
ID identification
IDI indirect injection ° degree
in. inch + plus
inAq inches Aqueous (water) - minus
in. Hg inches Mercury ± plus or minus
in.-lb inch pound** Ω ohm
J joule μ micro
JASO Japanese Automobile Standards % percent
Organization
K kelvin * Work torque such as engine torque
kg kilogram ** Work torque such as starter motor torque

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 Unit Conversions GENERAL SERVICE INFORMATION
12/05

UNIT CONVERSIONS Units of Torque

Unit Prefixes lb-ft x 1.3558 = N·m

lb-ft x 0.1383 = kgf·m
Prefix Symbol Power
lb-in x 0.1130 = N·m
mega M x 1,000,000 lb-in x 0.0115 = kgf·m
kilo k x 1,000 kgf·m x 7.2330 = lb-ft
centi c x 0.01
kgf·m x 86.8000 = lb-in
milli m x 0.001
kgf·m x 9.8070 = N·m
micro μ x 0.000001
N·m x 0.7376 = lb-ft
Units of Length N·m x 8.8510 = lb-in
N·m x 0.1020 = kgf·m
mile x 1.6090 = km
ft x 0.3050 =m Units of Pressure
in. x 2.5400 = cm
psi x 0.0689 = bar
in. x 25.4000 = mm
km x 0.6210 = mile psi x 6.8950 = kPa
m x 3.2810 = ft psi x 0.0703 = kg/cm2
cm x 0.3940 = in. bar x 14.5030 = psi
mm x 0.0394 = in. bar x 100.0000 = kPa
bar x 29.5300 = in. Hg
Units of Volume kPa x 0.1450 = psi
kPa x 0.0100 = bar
gal (U.S.) x 3.78540 =L
kPa x 0.0102 = kg/cm2
qt (U.S.) x 0.94635 =L
cu in. x 0.01639 =L kg/cm2 x 98.0700 = psi
cu in. x 16.38700 = mL kg/cm2 x 0.9807 = bar
fl oz (U.S.) x 0.02957 =L kg/cm2 x 14.2200 = kPa
fl oz (U.S.) x 29.57000 = mL in. Hg (60°) x 0.0333 = bar
cm3 x 1.00000 = mL in. Hg (60°) x 3.3770 = kPa
cm3 x 0.03382 = fl oz (U.S.) in. Hg (60°) x 0.0344 = kg/cm2
mmAq x 0.0394 = inAq
Units of Mass
Units of Power
lb x 0.45360 = kg
oz x 28.35000 = kg hp (metric or PS) x 0.9863201 = hp SAE
kg x 2.20500 = lb hp (metric or PS) x 0.7354988 = kW
g x 0.03527 = oz hp SAE x 1.0138697 = hp (metric or PS)
hp SAE x 0.7456999 = kW
Units of Force kW x 1.3596216 = hp (metric or PS)
lbf x 4.4480 =N kW x 1.3410221 = hp SAE
lbf x 0.4536 = kgf
N x 0.2248 = lbf Units of Temperature
N x 0.1020 = kgf °F = (1.8 x °C) + 32
kgf x 2.2050 = lbf °C = 0.556 x (°F - 32)
kgf x 9.8070 =N

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 GENERAL SERVICE INFORMATION Unit Conversions

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 6LY3 Service Manual
Section 4

PERIODIC
MAINTENANCE
Page
Safety Precautions .......................................................................... 4-3
Introduction...................................................................................... 4-3
The Importance of Periodic Maintenance.................................. 4-3
Performing Periodic Maintenance ............................................. 4-3
Yanmar Replacement Parts ...................................................... 4-3
Required EPA Maintenance ...................................................... 4-3
EPA Requirements.......................................................................... 4-3
Inspection and Maintenance...................................................... 4-3
Inspection and Maintenance of EPA Emission-Related Parts... 4-5
Periodic Maintenance Procedures .................................................. 4-6
Inspect Before Starting .............................................................. 4-6
After Initial 50 Hours of Operation ............................................. 4-8
Every 50 Hours of Operation ................................................... 4-10
Every 250 Hours of Operation ................................................. 4-15
Every 500 Hours of Operation ................................................. 4-25
Every 1000 Hours of Operation ............................................... 4-28
Every 2000 Hours of Operation ............................................... 4-29
Testing Engine Operation........................................................ 4-31
Long-Term Storage ................................................................. 4-33

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 PERIODIC MAINTENANCE

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 Safety Precautions PERIODIC MAINTENANCE
12/05

SAFETY PRECAUTIONS Yanmar Replacement Parts

Before servicing the 6LY3 marine engines, review Yanmar recommends that using genuine Yanmar
the Safety Section on page 2-1. parts when replacement parts are needed.
Genuine replacement parts help ensure long
engine life.
INTRODUCTION
This section of the Service Manual describes the Required EPA Maintenance
procedures for proper care and maintenance of the It is essential to follow the Periodic Maintenance
engine. Schedule on page 4-4 and Periodic Maintenance
Procedures on page 4-6 to maintain optimum
The Importance of Periodic engine performance and compliance with the
Maintenance Environmental Protection Agency (EPA) Regulation
Engine deterioration and wear occurs in proportion Engines.
to the length of time the engine has been in service
and the conditions the engine is subjected to during EPA REQUIREMENTS
operation. Periodic maintenance prevents
The EPA emission regulation is applicable only in
unexpected downtime, reduces the number of
USA.
accidents due to poor machine performance and
helps extend the life of the engine. Inspection and Maintenance
Performing Periodic Maintenance This maintenance must be performed to keep the
emission values of your engine within standard
Perform periodic maintenance procedures in an
values during the warranty period. The warranty
open, level area free from traffic. If possible,
period is determined by the age of the engine or the
perform the procedures indoors to prevent
number of hours of operation.
environmental conditions such as rain, wind or
snow from damaging the engine. DANGER!
NEVER block windows, vents or other means of
ventilation if the engine is operating in an
enclosed area. All internal combustion engines
create carbon monoxide gas during operation.
Accumulation of this gas within an enclosure
will cause illness or even death.

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 PERIODIC MAINTENANCE Periodic Maintenance Schedule

PERIODIC MAINTENANCE SCHEDULE

Daily and periodic maintenance is important to keep the engine in good operating condition. The following is
a summary of maintenance items by periodic maintenance intervals. Periodic maintenance intervals vary
depending on engine application, loads, diesel fuel and engine oil used and are hard to establish definitively.
The following should be treated only as a general guideline.

c: Check ‘: Replace z: Contact your authorized Yanmar Marine dealer or distributor

Every 50
Every 250 Every 500 Every 1000 Every 2000
Before Hours or
System Item Hours or Hours or Hours or Hours or
Starting One
One Year* 2 Years* 4 Years* 8 Years*
Month*
Whole Visually inspect the engine. {
Check the fuel level. {
Drain the fuel tank. {
Drain the filter and the water
{
separator.
Fuel System Replace the filter element. ‘
Check the injection spray ●
●
pattern. Initial
Overhaul the fuel feed pump. ●

Replace the fuel hoses. Every two years or 2,000 hours of operation.*
Check the oil
Crankcase {
level.
Change the ‘
Lubricating Crankcase ‘
oil. Initial
System
‘
Replace the oil filter element. ‘
Initial
Clean the oil cooler. ●

{
Check the seawater outlet. During
operation
Check the coolant level. {
Check the seawater pump
{ ‘
impeller.
Every year
Coolant
Replace the engine coolant. When the Long Life Coolant (LLC) is used of a specified type (See Check the
System
Coolant Level on page 4-7), replacement period of two years can be obtained.
Clean and check the
seawater and coolant ●
passages.
Clean the seawater and
●
coolant system.
Replace the zinc anode plug. ‘
* Whichever comes first.

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 Periodic Maintenance Schedule PERIODIC MAINTENANCE
12/05

c: Check ‘: Replace z: Contact your authorized Yanmar Marine dealer or distributor

Every 50
Every 250 Every 500 Every 1000 Every 2000
Before Hours or
System Item Hours or Hours or Hours or Hours or
Starting One
One Year* 2 Years* 4 Years* 8 Years*
Month*
Clean the air intake silencer. {

Air Intake and Clean the exhaust / water mixing

{ ‘
Exhaust elbow.
System Clean the turbocharger blower. ●

Flush the intercooler. ●

Check the alarm indicators. {

Check the electrolyte level in the
{
Electrical battery.
System Adjust the tension of the
{ { ‘
alternator driving belt.
Check the wiring connections. {
{
Check for engine fluid leaks. After
starting
Cylinder Head,
Retorque all major nuts and
etc. ●
bolts.
Adjust the intake / exhaust valve ●
●
clearance. Initial
Check the electronic control {
{
system. Initial
Miscellaneous Adjust the propeller shaft ●
●
Items alignment. Initial
Check and replace engine
{ ‘
mounts, if necessary.
* Whichever comes first.

Inspection and Maintenance of EPA

Emission-Related Parts

Parts Interval
Clean Fuel Injection Nozzle 1500 hours
Adjust Fuel injection Nozzle
Adjust Fuel Injection Pump
Adjust Turbocharger 3000 hours

Check Electronic Engine Control Unit and

its Associated Sensors and Actuators

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 PERIODIC MAINTENANCE Periodic Maintenance Procedures

PERIODIC MAINTENANCE Check the Engine Oil Level (Crankcase)

PROCEDURES 1. Check the engine oil level with the dipstick
(Figure 4-1, (3)). Insert the dipstick fully to
Inspect Before Starting check the level.
Figure 4-1

Be sure to check the following before every engine 2

start:
1
• Visual Inspection of Engine 3

• Check the Fuel Level 4

5
• Check the Engine Oil Level (Crankcase)
• Seawater Outlet
• Check Coolant Level
0002051
• Check All Alarm Indicators
Figure 4-1
• Check for Engine Fluid Leaks
1 – Rocker Arm Cover
• Check the Electronic Control System 2 – Oil Filler Cap (Yellow)
3 – Dipstick
Visual Inspection of Engine 4 – Upper Limit
Correct any problems before operation. 5 – Lower Limit
The oil should not be dirty and should have
Look for: appropriate viscosity. No coolant or diesel fuel
• Oil leaks should be present. The level should be between
the upper (Figure 4-1, (4)) and lower limit lines
• Fuel leaks (Figure 4-1, (5)) on the dipstick.
• Coolant leaks
Engine Oil Capacity at a Rake Angle of 0°
• Damaged or worn parts
18.8 L (19.9 qt)
• Loose or missing bolts Figure 4-2

• Fuel, coolant hoses, cracked V-belts, loose

clamps and fasteners

Check the Fuel Level SAE 10W-30

Check the fuel and fill if necessary. SAE 15W-40

-4°F 14°F 32°F 50°F 68°F 86°F 104°F

(-20°C) (-10°C) (0°C) (10°C) (20°C) (30°C) (40°C)
0000005

Figure 4-2
2. If oil level is low, fill to the specified level through
the filler port. NOTICE: Avoid overfilling the
engine oil. Add oil to the upper limit line on the
dipstick. Overfilling may induce oil into the
combustion chamber and damage components.

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 Periodic Maintenance Procedures PERIODIC MAINTENANCE
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Seawater Outlet 3. Replenish engine with coolant. If the fluid level

1. Check for seawater discharge immediately after in the coolant recovery tank is lower than the
engine start. Shut down right away if no LOW mark, open the filler cap and check the
discharge water is present. Troubleshoot and coolant level in the engine coolant tank.
correct seawater discharge problems before WARNING! NEVER remove the coolant filler
operating engine. cap if the engine is hot. Steam and hot
engine coolant will escape and seriously
Check for: burn you. Allow the engine to cool before
• Leaks in the seawater pump and lines attempting to remove the filler cap.
Replenish the engine with coolant if the level is
• Seawater pump impeller (See Disassembling low.
the Seawater Pump on page 7-6.)
• Check the coolant level when the engine is
Check the Coolant Level cold.
1. Check fluid level in the coolant recovery tank. • Check the coolant recovery tank daily.
The fluid level of the coolant recovery tank Standard
should be between the upper and lower limit
lines. Engine and Engine Coolant Recovery Tank
Coolant Tank Capacity Capacity
2. Check the coolant level in the coolant recovery
tank (Figure 4-3, (4)). If the coolant level is 28 L (30 qt) 1.5 L (1.6 qt)
close to the LOW mark (Figure 4-3, (2)), open NOTICE: If coolant levels drop quickly or the
the coolant recovery tank cap (Figure 4-3, (1)) coolant tank depletes with the recovery tank
and replenish the coolant recovery tank with a unchanged, check for a fluid or air leak in the
50% mixture of LLC and 50% clean soft water system. Adding coolant to the recovery tank
to the FULL mark. (Figure 4-3, (3)). CAUTION! during operation is not abnormal. The increased
ALWAYS wear eye protection and rubber coolant in the coolant recovery tank returns to the
gloves when you handle LLC. If the coolant coolant tank when the engine cools. If the engine
comes in contact with the eyes or skin, flush coolant level is normal in the coolant recovery
eyes and wash immediately with clean tank but low in the engine coolant tank, check for
water. loose hose clamps, broken hoses or other leaks.
Figure 4-3

(1)
130
150

(4)

200
FU
(3) LL

LO
(2) W

0006160

Figure 4-3
1 – Coolant Recovery Tank Cap
2 – LOW Mark
3 – FULL Mark
4 – Coolant Recovery Tank

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 PERIODIC MAINTENANCE Periodic Maintenance Procedures

Check All Alarm Functions

Check all alarm functions before and after starting After Initial 50 Hours of Operation
the engine. Check to see that all alarm functions
operate normally. Failure of an alarm system can Be sure to check the following after initial
lead to major engine damage. Check the alarm 50 hours or one-month of operation, whichever
functions before and after starting the engine every comes first.
day.
• Replace the Engine Oil and Engine Oil Filter
When pushing the start switch to the ON position
before starting the engine, the alarm window • Check the Electronic Control System
appears with audible sound on the display for about Operation
3 seconds, then goes off. This alarm operation is • Adjust the Propeller Shaft Alignment
normal.
When the sensor detects a problem during
Replace the Engine Oil and Engine Oil Filter
operation, the alarm indicator comes on with During initial engine operation, oil is quickly
audible sound on the display. contaminated due to the break-in wear of internal
parts. Change the oil and filters.
Under normal conditions, the display shows the
engine information such as engine speed, oil Drain the lubricating oil while the engine is still
pressure, coolant (freshwater) temperature and so warm. CAUTION! If the engine oil must be
on. drained while it is still hot, stay clear of the hot
engine oil to avoid being burned. ALWAYS wear
Check for Engine Fluid Leaks eye protection.
Before and after starting the engine, check for 1. Remove the oil dipstick. Attach the rotary waste
coolant and seawater leaks. Also, check for engine oil pump (optional) and pump out the oil. For
oil and fuel leaks. easier draining, remove the oil filler cap (yellow)
(Figure 4-4, (1)) on top of the rocker arm cover.
Check the Electronic Control System Figure 4-4

Make sure that the control lever can be operated Lube oil(1)
filler cap

smoothly before starting the engine. If it feels heavy Lube oil filter
(full flow)
to manipulate or binds up in any way, consult your
Yanmar dealer or distributor.

Lube oil filter

(2)
(bypass)
Filter bracket (3)
(4) 007088-00E
0006161

Figure 4-4
1 – Oil Filler Cap
2 – Bypass Filter
3 – Oil Filter Mounts
4 – Full Flow Filter

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 Periodic Maintenance Procedures PERIODIC MAINTENANCE
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2. Remove the oil filters with an oil filter wrench. Adjust the Propeller Shaft Alignment
Turn counterclockwise. The flexible engine mounts compress slightly after
3. Clean the face of the oil filter mounts the initial engine operation. This may cause
(Figure 4-4, (3)). Replace the filters. Apply oil to misalignment between the engine and the propeller
the rubber seal of the filters and install by hand shaft.
until the rubber seal touches the sealing face of
the filter mount. 1. Check for unusual noise and vibration of the
engine / boat hull, while gradually increasing
4. Use a filter wrench and turn clockwise an and decreasing the engine speed.
additional 3/4 of a turn for the full flow filter
(Figure 4-4, (4)). Turn the filter wrench 2. If there is unusual noise and / or vibration,
clockwise an additional full turn for the bypass adjust the propeller shaft alignment.
filter (Figure 4-4, (2)).
5. Fill with new oil. See Inspect Before Starting on
page 4-6.
6. Start engine and check for oil leaks.
7. Wait 10 minutes after stopping the engine.
Remove the oil dipstick and check the oil level.
Add oil if level is below the upper limit line on
dipstick.

Check the Electronic Control System

The electronic governor of the engine and the
marine gear are connected to the control head,
switch panel and display through the Interface
Module by wiring harnesses and terminal
connectors.
The wiring terminals may become loose after long
hours of use. It is dangerous to operate under
these conditions. Check the wiring periodically.
1. Check the wiring harness and connectors for
the throttle control cable. Check for loose
wiring.
2. Check the wiring harness and connectors to the
control cable line for the marine gear. Check for
loose wiring.
Check that the shifting of the marine gear moves
smoothly and test it in the NEUTRAL, FORWARD
and REVERSE positions.

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 PERIODIC MAINTENANCE Periodic Maintenance Procedures

Drain the Fuel / Water Separator (Optional)

Every 50 Hours of Operation 1. Close the fuel cock at fuel tank.
2. Loosen the drain plug (Figure 4-6, (5)) at the
Be sure to check the following every bottom of the fuel / water separator and drain
50 hours or monthly, whichever comes first. off any water and dirt. NOTICE: If nothing drips
when the drain plug is opened, loosen the air
• Drain the Fuel Filter and Fuel Filter / Water
bleed bolt (Figure 4-6, (1)) on the top of the
Separator
fuel / water separator by turning
• Check the Battery Electrolyte Level counterclockwise 2 to 3 turns. After draining, be
sure to tighten the air bleed bolt. (Air may bleed
• Adjust the V-Belt Tension or Replace V-Belt back into the system because the
fuel / water separator position is higher than the
Drain the Fuel Filter and Fuel Filter / Water fuel level in the fuel tank.)
Separator Figure 4-6

(1)
Drain the Fuel Filter
1. Close the fuel cock of the tank.
(2)
2. Loosen the drain plug (Figure 4-5, (1)). Drain
off any water and dirt collected inside. (3)
Figure 4-5

(5) (4) 0006163

Figure 4-6
1 – Air Bleed Bolt
(1) 0006162 2 – Seal
3 – Element
Figure 4-5 4 – Center Bolt
5 – Drain Plug
1 – Drain Plug
3. Remove the center bolt (Figure 4-6, (4)) to
disassemble the fuel / water separator. Clean
the element (Figure 4-6, (3)) with clean fuel.
4. When an additional fuel filter or fuel / water
separator is provided on the hull, drain, clean or
replace the element in it as well.
5. After reassembly of the fuel / water separator,
be sure to bleed air from the fuel system.

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 Periodic Maintenance Procedures PERIODIC MAINTENANCE
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Bleeding Air from Fuel System Check the Battery Electrolyte Level
1. Check the fuel level in the tank and fill if WARNING! ALWAYS turn off the battery switch
necessary. or disconnect the negative (-) cable before
2. Loosen the air bleed bolt at the top of the inspecting the electrical system. Failure to do
fuel / water separator by turning it 2 to 3 turns. so could cause short-circuiting and fires.
Pump fuel with the fuel feed pump by moving Always disconnect the negative (-) battery cable
the knob on the top of the feed pump up and first. An accidental short circuit may cause
down. When no air bubbles come out of the bolt damage, fire and / or personal injury. ALWAYS
hole, tighten the air bleed bolt. connect the negative (-) battery cable (back
onto the battery) LAST.
3. Because the automatic air-bleed system is
used on the fuel filter, there is no air bleed bolt WARNING! Keep the area around the battery
on the fuel filter. Continue to pump fuel with the well-ventilated, paying attention to keep the
fuel feed pump by moving the knob on top of battery away from any fire source. During
the feed pump up and down. Stop pumping operation or charging, hydrogen gas is
when the knob becomes stiff. This completes generated from the battery and can be easily
the air bleeding of the fuel system. Try starting ignited.
the engine again.
WARNING! Make sure your eyes and skin do
4. After start-up, the automatic air-bleeding device
not come in contact with the fluid. The battery
will purge the air from the fuel system. No
electrolyte is dilute sulfuric acid and causes
manual air bleeding is required for normal
severe acid burns. If you come in contact with
engine operation.
electrolyte, wash and rinse it off immediately
with a large amount of fresh water and baking
soda.
Battery Parts
Figure 4-7

(1) (2)
(3)

(4)

(5)
(8) (6)

(7)
0006164

Figure 4-7
1 – Terminal
2 – Cap
3 – Cover
4 – Cathode Plate
5 – Separator
6 – Glass Mat
7 – Zinc Anode Plate
8 – Battery Case

6LY3 Service Manual 4-11

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 PERIODIC MAINTENANCE Periodic Maintenance Procedures

Checking the Electrolyte Level • Measuring Battery Charge With Battery Tester
• Check the level of fluid in the battery Figure 4-9

(Figure 4-8, (2)). When the amount of fluid nears

the lower limit (Figure 4-8, (1)), fill with battery
fluid (commercially available) to the upper limit
(Figure 4-8, (3)). If operation continues with
insufficient battery fluid, the battery life is
shortened and the battery may overheat and
explode.
• Battery fluid tends to evaporate more quickly in
the summer, and the fluid level should be
checked more often.
• If the engine cranking speed is so slow that the
engine does not start, recharge the battery.
(1) 0006166
• If the engine still will not start after charging,
replace the battery. Figure 4-9
1 – Battery Tester
• When parking, remove the battery and store in a
warm place if the vessel will be left in ambient Measurement with a Battery Tester
temperatures below -15°C (5°F).
When checking the battery with the battery tester,
Figure 4-8

connect the red clip of the tester to the positive (+)

battery terminal and black clip to the negative (-)
(4)
battery terminal. Read the battery charge indicator.
Green zone: Normal
Yellow zone: Slightly discharged
(3) Red zone: Defective or completely discharged
(1)
Measuring Battery Charge with a Hydrometer
When using a hydrometer, the measured specific
gravity must be corrected according to the
temperature at the time of measurement. The
specific gravity of battery electrolyte is defined
using 20°C (68°F) as the standard. Since the
specific gravity increases or decreases by 0.0007
when the temperature varies by 1°C (1°F), correct
(2) 0006165
the value according to the equation below.
Figure 4-8 S20 = St + 0.007 ( t - 20 )
1 – Lower Limit Electrolyte temperature
2 – Electrolyte Level at measurement
3 – Upper Limit Specific gravity at measurement
4 – Grease Converted specific gravity at 20 C
001348-01E
Testing Battery Charge
• Use a battery tester (Figure 4-9, (1)) or
hydrometer to check battery condition. If the
battery is discharged, recharge it.

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 Periodic Maintenance Procedures PERIODIC MAINTENANCE
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Hydrometer Parts
Specific Gravity and Remaining Battery Charge Figure 4-11

(1)
Specific Discharged Remaining
Gravity Quantity of Charge
(20°C) (68°F) Electricity (%) (%)
(2)
1.28 0 100
1.26 10 90
1.24 20 80
(3)
1.23 25 75

Check the Following Battery Items:

0006168

1. Terminals Figure 4-11

Clean if corroded or soiled.
1 – Rubber Bulb
2. Mounting Bracket 2 – Glass Tube
3 – Float
• Repair or replace if corroded.
How to Read a Hydrometer
• Tighten if loose.
Figure 4-12

3. Battery Appearance
• Replace the battery if cracked or deformed.
• Clean with fresh water if contaminated.
Figure 4-10

0006169

Figure 4-12
(1)

0006167

Figure 4-10
1 – Float

6LY3 Service Manual 4-13

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 PERIODIC MAINTENANCE Periodic Maintenance Procedures

Adjust the V-Belt Tension or Replace V-Belt Excessive belt tension will cause reduced belt life
Insufficient belt tension will cause the belt to slip, and possible damage to the bearing of the
reduce electrical output and diminish coolant freshwater pump and the alternator.
circulation. 1. Make sure engine is not running.
If there is not enough tension in the V-belts 2. Check the tension of the V-belts by pressing on
(Figure 4-13, (6)), they will slip and the freshwater the middle of a belt with your finger
pump (Figure 4-13, (1)) will fail to provide sufficient [approximately 98 N (22 lb)].
coolant flow. Engine overheating and seizure may
result. Specified V-Belt Deflection
8-10 mm
For Used V-Belt
Figure 4-13

(2) (3) (Approximately 3/8 in.)

(1)
6-8 mm
For New V-Belt
(Approximately 5/16 in.)

• New V-Belt refers to a V-Belt which has been

used less than 5 minutes on a running engine.
(4) • Used V-belt refers to a V-belt which has been
(6) (5) used on a running engine for more than
5 minutes.
3. If the V-belt deflection is out of limits, adjust the
V-belt tensions. Loosen the adjuster bolt
(Figure 4-13, (3)) and move the alternator
(Figure 4-13, (4)) to adjust the V-belt tension.
0006170 NOTICE: Be careful not to get any oil on the
Figure 4-13 V-belt. Oil on the belt causes slipping and
stretching. Replace the belt if it is damaged.
1 – Freshwater Pump
2 – Adjuster
3 – Adjuster Bolt
4 – Alternator
5 – Deflection 8-10 mm (Approximately 3/8 in.)
6 – V-Belt

4-14 6LY3 Service Manual

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 Periodic Maintenance Procedures PERIODIC MAINTENANCE
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Check the Fuel Injector Spray Pattern

Every 250 Hours of Operation NOTICE: This engine applies double spring
nozzles manufactured by DENSO. Testing,
Be sure to check the following items every modifications or repairs should be performed by
250 hours or after one year of operation, whichever your authorized YANMAR service center.
comes first.
WARNING!
• Check the Fuel Injector Spray Pattern (Initial
• Never point a fuel injector toward you. Since
250 Hours Only)
the fuel is ejected at high-pressure from the
• Adjust the Intake / Exhaust Valve Clearance nozzle, it may penetrate the skin, resulting in
(Initial 250 Hours Only) injury.

• Drain the Fuel Tank • Never inject fuel toward a fire source.
Atomized fuel is highly flammable and may
• Replace the Fuel Filter Element cause a fire or burn skin.
• Replace the Engine Oil and Engine Oil Filter CAUTION! ALWAYS wear eye protection when
• Check the Seawater Pump Impeller servicing the engine and when using
compressed air or high-pressure fuel. Dust,
• Replace the Zinc Anode flying debris, compressed air, pressurized fuel
may injure your eyes.
• Clean the Air Intake Silencer
• Clean the Exhaust / Water Mixing Elbow
• Clean the Turbocharger Blower
• Flush the Intercooler
• Check the Wiring Connectors
• Tighten All Major Nuts and Bolts
• Check or Replace the Flexible Engine Mounts
• Replace the Engine Coolant

6LY3 Service Manual 4-15

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 PERIODIC MAINTENANCE Periodic Maintenance Procedures

Fuel Injection Nozzle Parts

Figure 4-14

(9)
(8)
(7)
(6)
(5)
(2)

(3) (4)

(1)

(15)

(11)
(14)
(13)

(12)

(10) 0006171

Figure 4-14

1 – Nozzle Holder Retaining Nut 9 – No. 2 Pressure Spring

2 – Nozzle Assembly 10 – Adjusting Shim
3 – Nozzle Body 11 – No. 1 Pressure Spring Seat
4 – Needle Tip 12 – Pressure Pin
5 – Adjusting Shim 13 – No. 1 Pressure Spring
6 – Tip Packing 14 – Adjusting Shim
7 – Straight Pins 15 – Nozzle Holder Body
8 – No. 2 Pressure Spring Seat

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 Periodic Maintenance Procedures PERIODIC MAINTENANCE
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1. Injection Pressure Measurements (d) Read the pressure gauge when the injection
Check the No. 1 (lower) opening pressure for a pressure begins to decrease. If No.1
rough reference point. To measure and adjust the opening pressure is out of limits, measure it
No. 1 and No. 2 opening pressures precisely, precisely at an authorized FIE (Fuel Injection
specialized knowledge, techniques and Equipment) service shop or replace the
equipment are required. Consult your authorized nozzle. NOTICE: Only No. 1 opening
YANMAR marine dealer or distributor. pressure can be measured with this method.
Specialized equipment is required to
(a) Install the fuel injection nozzle to the nozzle measure No. 2 opening pressures precisely.
tester and bleed air from the union nut Consult your authorized YANMAR marine
(Figure 4-15, (1)). dealer or distributor.
Figure 4-15

No. 1 Opening Pressure

24.00-24.98 MPa
(3481-3623 psi)

(1)
(e) After the injection test, check that there are
no drops from the injection hole.
Figure 4-17

0006172

Figure 4-15
1 – Union Nut 0006174

(b) Pump the tester handle several times as Figure 4-17

quickly as possible to discharge foreign
matter from the injection hole.
Figure 4-16

0006173

Figure 4-16
(c) Slowly pump the tester handle and observe
the pressure gauge.

6LY3 Service Manual 4-17

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 PERIODIC MAINTENANCE Periodic Maintenance Procedures

2. Spray Pattern Inspection Adjust Intake / Exhaust Valve Clearance

Check the spray pattern. If the spray condition is Take measurements and make adjustments while
improper, have the nozzle cleaned at an the engine is cold.
authorized FIE (Fuel Injection Equipment)
service shop or replace the nozzle. 1. Valve clearance measurement
Figure 4-18
(a) Remove the rocker arm cover.
(b) Turn the crankshaft in the direction of normal
rotation to bring the piston of the No.1
cylinder to its compression top dead center
(TDC) while adjusting the index mark
(Figure 4-20, (2)) of the flywheel housing
(Figure 4-20, (1)) and the top mark of the
0006175 flywheel. (At compression TDC both intake
Figure 4-18 and exhaust valves are closed.) NOTICE:
The crankshaft should be turned clockwise
3. Leak Test as seen from the water pump end. The No. 1
Increase the pressure to near the specified cylinder position is on the opposite side of
injection pressure of 0.98 to 1.96 MPa the drive shaft housing. Since there is a
(142-284 psi). Check for fuel leakage from the clearance between the rocker arm and valve
injection hole and around the retaining nut. If bridge at compression, TDC can be checked
leakage occurs from the nozzle, replace, clean or by hand. Also, see that the top mark on the
overhaul the nozzle. NOTICE: If disassembly of flywheel aligns with the index mark on the
the nozzle holder retaining nut is necessary, flywheel housing. If there is no valve
have it done at an authorized FIE Service Center. clearance, disassemble and inspect the
valve seat area for abnormal or excessive
Figure 4-19

wear.
Figure 4-20

(1)

0006176

Figure 4-19 (2)

CAUTION! Never use a steel wire brush to clean

fuel injectors. Damage to the nozzle and other
components is likely to result.
0006177

Figure 4-20
1 – Flywheel Housing
2 – Index Mark

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 Periodic Maintenance Procedures PERIODIC MAINTENANCE
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(c) Insert a thickness gauge between the 2. Valve Clearance Adjustment

rocker arm and the valve bridge, and (a) Loosen the adjusting bolt of the valve bridge
record the measured valve clearance (Figure 4-22, (1)). Loosen the locknut of the
(Figure 4-21, (1)). (Use this data to estimate valve bridge adjusting bolt more than one
the state of wear.) turn to give clearance between the adjusting
bolt and valve. Check the valve for any
Figure 4-21

inclination of valve cap or wear.

(1) Figure 4-22

(1) (2)

0006178

Figure 4-21
1 – Valve Clearance 0006179

(d) Measuring Other Cylinders Figure 4-22

Turn the crankshaft 120° and make
adjustment for the No. 4 cylinder. Then 1 – Valve Bridge Adjusting Bolt
adjust the No. 2 cylinder according to the 2 – Rocker Arm Adjusting Bolt
firing order of the engine. The cylinder to be (b) Measure valve clearance temporarily. Insert
adjusted first does not have to be the No. 1 a thickness gauge between the rocker arm
cylinder. Select and adjust the cylinder with and the valve bridge, and adjust the valve
the piston nearest to top dead center (TDC) clearance by using the rocker arm adjusting
and make adjustments to other cylinders in bolt (Figure 4-22, (2)). Do not adjust the
the order of ignition by turning the crankshaft bridge adjusting bolt. Tighten the rocker arm
120° each time. NOTICE: Firing Order is adjusting bolt lightly (temporarily).
1-4-2-6-3-5.
Standard Valve Clearance
0.15-0.25 mm
Intake valve
(0.0059-0.0098 in.)
0.45-0.55 mm
Exhaust valve
(0.0177-0.0216 in.)

6LY3 Service Manual 4-19

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 PERIODIC MAINTENANCE Periodic Maintenance Procedures

(c) Tighten the bridge adjusting bolt gradually (e) Apply oil to both sides (valve and push rod,
while moving the thickness gauge, and contact surface) of rocker arm.
confirm the position where the movement of (f) Adjusting Other Cylinders
the thickness gauge becomes tight (the Turn the crankshaft 120° and adjust the No.
position where the adjusting bolt touches the 4 cylinder. Then adjust the No. 2 cylinder in
valve top). Then tighten the bridge adjusting the normal firing order. The cylinder to be
bolt 45° and lock the bolt with the locknut. adjusted first does not have to be the No. 1
cylinder. Select and adjust the cylinder
Figure 4-23

nearest to top dead center (TDC) and adjust

other cylinders in the firing order of the
engine by turning the crankshaft 120° each
time.

Drain the Fuel Tank

Open the drain cock of the fuel tank. Inspect for
water, dirt or other sediment. Drain (water, debris,
etc.) from the tank's bottom. Catch the fuel in an
0006180 approved container. Drain until clean fuel flows and
then close the drain cock.
Figure 4-23
Replace the Fuel Filter Element
(d) Loosen the rocker arm adjusting bolt and
readjust the valve clearance by using the When the engine is operated on light diesel fuel,
rocker arm adjusting bolt. NOTICE: If the replace the fuel filter element every 250 hours or
valve bridge has not been replaced or 1 year of operation.
moved to another cylinder, the above steps 1. Close the fuel cock on the fuel tank.
(a, b, and c) are not necessary.
2. Remove the center bolt (Figure 4-24, (10)) at
Standard Valve Clearance the bottom of the filter and take out the filter
element (Figure 4-24, (3)).
0.15-0.25 mm
Intake Valve 3. Replace the element, reinstall the bolt and
(0.0059-0.0098 in.)
0.45-0.55 mm tighten.
Exhaust Valve
(0.0177-0.0216 in.) 4. Bleed air from the fuel filter system.

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Figure 4-24

Fuel System Air Bleeding Procedures

(1)
1. Check the fuel level in the fuel tank. Fill if
necessary.
2. Loosen the air bleed bolt on the fuel filter by (2)
turning it 2 or 3 turns.
3. Pump fuel with the fuel feed pump by moving
the knob on the top of the feed pump up and
down. (3)
4. Allow the fuel and air bubbles to flow from the
air bleed bolt hole. When the fuel no longer
contains bubbles, tighten the air bleed bolt. This (4)
completes the air bleeding of the fuel system.
Start the engine. (5)
5. Repeat steps 1 through 4 if necessary.
6. After engine start-up, the automatic air-bleeding
(6)
device purges the air from the fuel system. No
manual air bleeding is required for normal
(7)
engine operation.
(8)

(9)

(10)

0006181

Figure 4-24
1 – Cover
2 – Gasket
3 – Filter Element
4 – Gasket
5 – Spring
6 – Case
7 – Gasket
8 – Drain Plug
9 – Gasket
10 – Center Bolt

6LY3 Service Manual 4-21

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 PERIODIC MAINTENANCE Periodic Maintenance Procedures

Replace the Engine Oil and Engine Oil Filter Clean the Air Intake Silencer
See Replace the Engine Oil and Engine Oil Filter Disassemble the intake silencer and clean the
on page 4-8. inside thoroughly.

Check the Seawater Pump Impeller 1. Remove the silencer by taking off the clamp.
See Disassembling the Seawater Pump on 2. Clean the element with a neutral detergent.
page 7-6. 3. Reassemble after it is completely dry.

Replace the Zinc Anode Clean the Exhaust / Water Mixing Elbow
The frequency for replacing the zinc anode plug The mixing elbow is attached to the turbocharger.
varies depending on the characteristics of the The exhaust gas is mixed with seawater in the
seawater and operational conditions. Inspect the mixing elbow.
zinc anode (Figure 4-25, (1)) at its scheduled
maintenance interval and remove the corroded 1. Clean dirt and scale out of the exhaust gas
area on the surface. Replace the zinc anode when passage. Clean and clear the seawater
it has decreased to less than 1/2 of the original passage in the mixing elbow.
size. If replacement of zinc anode is neglected, 2. Repair any cracks or damage to the mixing
seawater will corrode the coolant system. This will elbow by welding or replacement.
cause leaks and damage. NOTICE: Zinc anode 3. Inspect the gasket and replace if necessary.
plugs are identified with the label shown in
(Figure 4-25, (2)). Close the seacock before Clean the Turbocharger Blower
removing the plug.
Dirty fins on the turbocharger blower lead to engine
Figure 4-25

performance reductions. Clean the turbocharger

(1)
blower at its scheduled maintenance interval or
sooner if power output drops by 10%.
1. Prepare the cleaning agent, fresh water and a
(3)
(2) small pitcher.
0006184 2. Remove the M8 bolt and washer from
Figure 4-25 (Figure 4-27, (3)) the blower wash hole in the
silencer. Remove the drain plug (M8 bolt and
1 – Zinc Anode washer) from the intercooler.
2 – Zinc Anode Plug
3 – Identification Label
Figure 4-26

(2)
(1)

0006185

Figure 4-26
1 – Zinc Anode Location
2 – Heat Exchanger

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 Periodic Maintenance Procedures PERIODIC MAINTENANCE
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Figure 4-27 Flush the Intercooler

(1) Rust and scale buildup in the intercooler can
reduce engine performance by 10%.
Intercooler contamination causes the engine output
to fall. If a drop in engine output is noted (by about
10%), flush and clean the intercooler.
1. Remove the cover on the flywheel end of the
(3)
intercooler and inspect the inside of each tube
for rust or scale buildup from seawater.
(2)
0006186 2. If rust or scale is seen inside the tubes, remove
the intercooler from the engine.
Figure 4-27
3. Clean the tubes with a wire brush, if necessary.
1 – Turbocharger
4. Flush tubes with fresh water.
2 – Blower Wash Hole
3 – Air Silencer 5. Reinstall intercooler.
3. Run the engine at cruise power and inject about
Check the Wiring Connections
50 cc of cleaning agent in small amounts
through the hole in the silencer at about Check for loose wire connections.
10 second intervals as shown in Figure 4-27.
NOTICE: NEVER inject large quantities of fluid Tighten All Major Nuts and Bolts
into the blower all at once. Water hammer can Over time and with extended vibration, fasteners
damage the components of the turbocharger. If may come loose.
the air silencer (air cleaner) is removed from the
Check and retighten the following nuts, bolts and
turbocharger, decrease the amount of cleaning
fasteners, as applicable:
agent used to clean the turbocharger. Ensure
that all parts are dry and reassemble. 1. Flexible engine mount bolts
4. Wait 3 minutes while engine continues to run. 2. Shaft coupling bolts
5. Inject another 50 cc of fresh water in small 3. Exhaust flange bolts
amounts at about 10 second intervals.
4. Intake silencer fasteners
6. Run engine for about 10 minutes to dry the
5. Other nuts and bolts
turbocharger.
Retorque the major nuts and bolts below. See
7. Check engine power output. Repeat steps 4
Service Standards on page 14-3 for the tightening
through 7 until power output is satisfactory.
torques of the major parts.
8. Reinstall the M8 bolt and washer to the silencer
housing and the intercooler drain plug. 1. Cylinder head bolts
2. Crankshaft pulley bolts
3. Fuel injection nozzle set bolts
4. Fuel injection pipe joint nut
5. Rod bolts
6. Flywheel retainer bolts
7. Bearing cap bolts

6LY3 Service Manual 4-23

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 PERIODIC MAINTENANCE Periodic Maintenance Procedures
Figure 4-29

Check or Replace the Flexible Engine

(2)
Mounts (1)
The flexible engine mounts compress at initial
engine operation. This may cause misalignment of
the engine and propeller shaft. Check for cracks on
the rubber engine mounts. Replace the engine
mount(s) if damage or misalignment is found.

Replace the Engine Coolant

Be sure to replace the coolant every year. When (3)
the LLC is used, a replacement period of 2 years
can be obtained. (4)
(5) 0006188
Use clean soft water and add the LLC to the water
in order to prevent rust buildup and freezing. Figure 4-29
Cooling capacity drops when coolant is 1 – Freshwater Pump
contaminated with rust and scale. 2 – Coolant Tank
3 – Seawater Drain Cock
Even if antifreeze or antirust is added, the coolant 4 – Coolant Drain Cock
must be replaced periodically because it naturally 5 – Seawater Pump
degenerates. 3. Close the two coolant drain cocks. Be sure to
1. Place an approved container under the drain check that the two seawater drain cocks are
cocks. closed.
2. Open the two coolant drain cocks 4. Remove the coolant filler cap (Figure 4-30, (1))
(Figure 4-28) and completely drain all the on the coolant tank (Figure 4-30, (3)) by turning
coolant from the system. the cap counterclockwise 1/3 of a turn.
Figure 4-30
Figure 4-28

(1)

(2)

(1) (4) (3)

(2) 0006187 0006189

Figure 4-28 Figure 4-30

1 – Seawater Drain Cock 1 – Filler Cap

2 – Coolant Drain Cock 2 – Tabs
3 – Coolant Tank
4 – Notches
5. Pour coolant slowly into the coolant tank so that
air bubbles do not develop. Pour until the
coolant overflows from the filler port.

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6. After filling coolant, fit the filler cap and tighten it

firmly. To reassemble the cap, align the tabs Every 500 Hours of Operation
(Figure 4-30, (2)) on the bottom of the cap with
the notches (Figure 4-30, (4)) on the filler port
Be sure to check the following every 500 hours of
and turn clockwise 1/3 of a turn. WARNING!
operation or 2 years, whichever comes first.
ALWAYS tighten the coolant filler cap. If the
cap is loose, steam and hot engine coolant • Replace the Seawater Pump Impeller
will escape which may burn you.
• Adjust the Propeller Shaft Alignment
7. Remove the coolant recovery tank cap
(Figure 4-31, (1)) and fill with coolant mix to the • Check the V-Belt Tension
lower limit (Figure 4-31, (2)). Replace the cap
on the coolant recovery tank. • Inspect the Thermostat
Coolant recovery tank capacity: 1.5 L (3.2 pints) • Replace the Exhaust / Water Mixing Elbow
Figure 4-31

(1) • Adjust the No-load Minimum Speed

130
150 Replace the Seawater Pump Impeller
NOTICE: The impeller must be replaced
(4)
periodically (every 500 hours or 2 years, whichever
comes first).
200
(3)
FU
LL See Check the Seawater Pump Impeller on
page 4-22 for the procedure.
LO
(2) W

Adjust the Propeller Shaft Alignment

0006190 The flexible engine mounts deteriorate over time
and from extended vibration. This can lead to
Figure 4-31 increased vibration and misalignment of the
1 – Cap propeller shaft.
2 – Lower Limit
1. Check for unusual noise and vibration of the
3 – Upper Limit
4 – Coolant Recovery Tank engine and the hull while gradually increasing
and decreasing engine speed.
8. Check the rubber hose connecting the coolant
recovery tank (Figure 4-31, (4)) to the coolant 2. If necessary, adjust the propeller shaft
tank. Check that the hose is securely connected alignment. See Adjust the Propeller Shaft
and that it is not damaged. Alignment on page 4-9.

Check the V-Belt Tension

See Adjust the V-Belt Tension or Replace V-Belt on
page 4-14 for the procedure.

Inspect the Thermostat

See Inspecting the Thermostat on page 7-18.

Replace the Exhaust / Water Mixing Elbow

Replace the used mixing elbow with a new one,
even if no damage is found.

6LY3 Service Manual 4-25

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 PERIODIC MAINTENANCE Periodic Maintenance Procedures
Figure 4-32

Adjusting the No-load Minimum Speed

After warming up the engine, adjust and set the low SETUP MENU
idle speed by using the digital display as follows: MENUS POP UP
UNITS

1. Bring up the setup menu on the digital display. CONFIG/CAL

DAMPING
LANGUAGE
2. Select CONFIG / CAL, push the button under BEEPER OFF

the right arrow and the CONFIG / CAL screen BACK

will appear.
3. Select ENGINE SETTING, push the button
under the right arrow and the ENTER 0006195

PASSWARD screen appears. The ENGINE

SETTINGS screen will appear after entering the Figure 4-32
password “3124.”
TFX Password Input / Idle Change
Figure 4-33

i5601E Digital Display Alarms/Engine Diagnostic Codes

Performs the function indicated by a pop-up menu,
if present.
With no pop-up menu showing, briefly press to
display the Lighting & Contrast menu.

With no pop-up menu showing, press and HOLD

to display the MAIN MENU.

MAIN MENU

ALARMs / DIAGs

MONITOR SETTINGS
Idle speed
CALIBRATION

FACTORY SETTINGS
Configuration specified
(PORT/STBD specified change)
Password Protected

Buttons

“Down” Arrow moves menu selection down

“Up” Arrow moves menu selection up

“Right” Arrow acts on current menu item

BACK “Back” Moves back to previous menu

Engine Alarms/Diagnostic Codes

The ALARMs / DIAGs Screen Menu allows user to go to the Alarm or Diag Code Screen. This is very useful
in the HOT KEY Mode, as a dedicated hot key is not required to view these screens. Use can hold Right most
key down go into the menu mode and then via this menu access the desired screen.
0006196

Figure 4-33

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TFX Password Input / DTC Clear

Figure 4-34

Engine Alarms
The Alarm Screen will display the status of 20 defined alarms. A
flashing black background indicates unacknowledged alarm; a solid
black background indicates an acknowledged still in alarm state
status.

DTC Clear

Engine Diagnostic Codes

This screen displays the diagnostic code information. The title bar
indicates the number of diagnostic items.
Call to TFX about this procedure

Maintenance Warning
Based on startup issues, the maintenance timer will activate between 50 and 60 hours of operation. A maintenance
warning will be displayed on the digital display screen. To acknowledge this warning, press and hold the #5
(right most) button on the i5601E digital display for a few seconds until the main menu is displayed. Use the
down arrow button to move the cursor to “Calibration.” Press the right arrow button, then go to “User Setting”
menu. The arrow should be at the “Reset Maint. Time” selection. Press the right arrow key to reset. The warning
will go away. After an additional 250 hours of operation the maintenance warning will be displayed again, and
every 250 hours thereafter. This a reminder that periodic maintenance must be performed at these intervals.
0006197

Figure 4-34

4. Select ENTER IDLE rpm, push the button

under the right arrow and the IDLE rpm Low idle speed
SETTING screen will appear.
700 ± 25 rpm
5. The engine low idle speed can be set in 20 rpm
increments from 700 rpm to 800 rpm. Adjust the NOTICE: The high idle speed is fixed and cannot
low idle speed by using “+” or “-” button. Push be changed.
the SET button and a beep will sound.

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 PERIODIC MAINTENANCE Periodic Maintenance Procedures

Replace the V-Belt

Every 1000 Hours of Operation Replace the alternator drive belt every 1,000 hours
or 4 years, whichever comes first.
Be sure to check the following every 1,000 hours of
See Adjust the V-Belt Tension or Replace V-Belt on
operation or 4 years, whichever comes first.
page 4-14 for the procedure.
• Check the Fuel Injector Spray Pattern
Adjust the Intake / Exhaust Valve Clearance
• Clean and Check the Seawater and Coolant
Inspect and adjust intake / exhaust valve clearance.
Passages
See Adjust Intake / Exhaust Valve Clearance on
• Replace the V-Belt
page 4-18 for the procedure.
• Adjust the Intake / Exhaust Valve Clearance
Replace the Flexible Engine Mounts
• Replace the Flexible Engine Mounts The flexible engine mounts deteriorate over time
and extended use and vibration. This can lead to
Check the Fuel Injector Spray Pattern
increased vibration and misalignment of the
Adjust to ensure the best possible engine propeller shaft. Replace the flexible engine mounts
performance. every 1,000 hours or 4 years, whichever comes
See Check the Fuel Injector Spray Pattern on first.
page 4-15 for the procedure.

Clean and Check the Seawater and Coolant

Passages
Trash, scale, rust and other debris collected in the
coolant passages cause cooling capacity to
decline.
1. Check the rubber hoses and clamps and
replace if necessary.
2. If trash, scale or rust is found in heat
exchangers, clean them. (See Inspect the heat
exchanger and pressure cap. See Heat
Exchanger Components and Functions on
page 7-13. on page 4-30.)

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 Periodic Maintenance Procedures PERIODIC MAINTENANCE
12/05

1. Block the priming pump with your finger and

Every 2000 Hours of Operation check whether the pressed-in piston returns by
spring force. If the piston returns, the piston
does not have enough negative (-) pressure.
Replace every 2,000 hours or 2 years of engine
Replace the priming pump as a set.
operation, whichever comes first.
2. Check the piston spring for cuts, cracks, uneven
• Overhaul and Check the Fuel Feed Pump wear and rust.
• Clean the Engine Oil Cooler 3. If the piston, inter-spindle or tappet assembly is
extremely worn, replace the part.
• Clean the Seawater and Freshwater Systems
4. Check the contact surface of the valve and
• Replace the Rubber Fuel Hoses valve seat for defects.
• Replace the Thermostat 5. If there is play in a valve seat, which has been
cemented into the feed pump body, the whole
Overhaul and Check the Fuel Feed Pump fuel pump body must be replaced.
The fuel injection pump must be overhauled and See Fuel Injection Pump / Governor / Timer on
checked to ensure optimal engine performance. page 6-7 for the procedure of adjustment.

Disassembly of the Fuel Injection Pump NOTICE: Play in the valve seat hinders the opening
and closing of the valve, causing insufficient fuel
1. Remove the piston spring stopper plug and pull
supply and abnormal wear of the tappets and
out the piston and piston spring.
camshaft.
2. Remove the snap ring and pull out the tappet
assembly. Assemble the Fuel Feed Pump
3. Pull out the inter-spindle. 1. Install the O-ring.
4. Remove the priming pump. 2. Install the discharge valve spring stopper and
install the valve and spring from inside.
5. Remove the discharge valve spring stopper and
remove the valve and spring from inside. 3. Install the priming pump.
6. Remove the O-ring. 4. Push in the inter-spindle.
5. Install the snap ring and push in the tappet
Inspecting the Fuel Injection Pump
Figure 4-35
assembly.
(5) 6. Install the piston spring stopper plug and push
in the piston and piston and piston spring.
(1)

(4)
(2)

(3)

0006191

Figure 4-35
1 – Air Inlet Pressure
2 – Container Filled w / Light Oil
3 – Blocked
4 – Tappet
5 – Measuring Cylinder

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 PERIODIC MAINTENANCE Periodic Maintenance Procedures

Clean the Engine Oil Cooler Replace the Rubber Fuel Hoses
Rust and scale are deposited inside the seawater Rubberized fuel hoses tend to dry out and become
system during extended use. brittle after 2000 hours or 2 years of engine
operation (whichever comes first).
This lowers cooling performance, so it is necessary
to clean and maintain the oil cooler. See your authorized Yanmar marine dealer or
distributor to replace the rubber fuel hoses.
Internal contamination of the oil cooler reduces
cooling efficiency and accelerates the oil cooler Replace the Thermostat
degeneration.
See Thermostat Components and Functions on
1. Remove the oil cooler from the engine. page 7-17.
2. Flush and clean the inside (seawater passages)
of the cooler tubes with a nylon brush.
3. Clean the outside oil passages of the cooler
tubes.
4. When reassembling, install new O-rings and
separator packings.
5. Apply 0.2 MPa (29 psi) of pressure on the oil
passage and inspect for leaks.

Clean the Seawater and Coolant Systems

Rust and scale are deposited inside the seawater
and coolant systems during extended use. This
lowers coolant performance, so it is necessary to
clean and maintain the following parts in addition to
replacing the coolant.
1. Clean and inspect coolant rubber hoses.
• Remove the coolant hoses for the closed
coolant system and the seawater system.
• Check for dirt buildup and other obstructions.
Clean and clear if necessary.
• Check for cracks and deterioration of the
rubber hoses. If necessary, replace.
• Replace the used hose clamps, if necessary.
2. Inspect the heat exchanger and pressure cap.
See Heat Exchanger Components and
Functions on page 7-13.

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 Periodic Maintenance Procedures PERIODIC MAINTENANCE
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Testing Engine Operation Engine Test Run

Perform a test run of the engine after performing 1. Start the engine and idle at 700 to 900 rpm for
maintenance: about 5 minutes.
2. Check for any water, diesel fuel or oil leakage.
Preliminary Precautions Check for any abnormal vibrations or noises.
Before performing a test run, check the following: Check the oil pressure, coolant temperature
and exhaust gas color.
1. Remove any water from the fuel filter, water
separator and fuel tank. 3. Adjust the no-load minimum and maximum
speeds. (See Adjusting the No-load Minimum
2. Fill the diesel fuel, oil and coolant. Speed on page 4-26.)
3. Only use oil recommended by Yanmar. 4. Perform loaded operations as required.
4. Be sure to mix LLC with fresh water. 5. Shut the engine down after test running and let
5. Provide good ventilation in the engine room. stand for about 10 minutes. NOTICE: Check the
6. Allow the engine to warm up before making any oil and coolant levels again and add as
adjustments. required.

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 PERIODIC MAINTENANCE Periodic Maintenance Procedures

Check Points and Precautions During Running

Step Item Instructions Precautions

Make sure the seacock is open.
Make sure there is enough oil and Alarm indicator does not
Checks Before appear on the display.
1 coolant.
Operation
Operate the electronic control head and check if it
works properly.
Check the oil pressure and coolant temperature on
the display.
When the engine starts, check the following:
Fix leaks if any.
• There is no leakage of coolant, diesel fuel or oil.
Check the
No-load
• Exhaust gas does not leak. intake / exhaust valves, fuel
Operation;
2 injection nozzle and cylinder
Warm-up • There is no abnormal indication on the display. head.
Operation
• There is no abnormality in the seawater Do not raise the engine
discharge, engine vibration or engine sound. speed abruptly.
To warm up the engine, operate at low speed for
about 5 min., raise the speed to the no-load rated
speed and then to maximum speed.
Do not operate the engine at full load yet, but raise
the speed gradually for about 10 min. until it
reaches the rated speed.
Cruising (Load)
3 Make sure that the exhaust gas color and
Operation
temperature are normal.
Check the instrument panel and see if the coolant
temperature and oil pressure are normal.
Stopping the engine
Before stopping the engine, operate it at suddenly during high-speed
650 to 700 rpm for about 5 min. operation increases the
Stopping the temperature of engine parts.
4 Raise engine speed to 1,800 rpm just before
Engine
stopping the engine and idle the engine for about This procedure prevents
3 to 4 seconds. carbon from being deposited
on the valve seats.
Check for coolant and oil leaks.
Make sure no nuts and bolts are loose. Check the oil seal area.
Checks After
Close the seacock and fuel cocks. Check the engine installation
5 Stopping the
bolts.
Engine When the temperature is expected to fall below
freezing, drain the seawater. Drain the seawater pump.
Turn off the battery switch.

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 Periodic Maintenance Procedures PERIODIC MAINTENANCE
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Long-Term Storage 7. Select a well-ventilated location without

moisture and dust for storage.
Observe the following instructions when the engine
is to be stored for a long period of time: 8. Recharge battery once a month during storage
to compensate for self-discharge.
1. Drain seawater in the cold season or before the 9. When storing an engine for a long time, run the
long-term storage. NOTICE: NEVER drain engine periodically, according to the following
coolant in the cold season or before the procedure, because rust inside the engine, the
long-term storage. Failure to add antifreeze can rack agglutination of the fuel pump and so on
cause major damage to the engine. are likely to occur.
2. Clean the engine. (a) Replace the engine oil and the filter with new
3. Perform the nearest periodic inspection before ones before running the engine (See
storage. Replace the Engine Oil and Engine Oil Filter
4. Completely drain or completely fill the fuel tank on page 4-22).
to prevent condensation in the fuel tank. (b) Fill fuel tank if the diesel fuel was removed,
5. Disconnect the battery cable from the and bleed the fuel system.
negative (-) battery terminal. (c) Confirm that there is coolant in the engine.
6. Cover the silencer and electric parts with a (d) Operate the engine at idle speed for about
waterproof cover to prevent water and dirt from 5 minutes. Repeat monthly, if possible.
entering.

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 PERIODIC MAINTENANCE Periodic Maintenance Procedures

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 6LY3 Service Manual
Section 5

ENGINE
Page
Safety Precautions .......................................................................... 5-5
Introduction...................................................................................... 5-5
Disassembling the Engine and Components .................................. 5-6
Precautions Before Engine Disassembly .................................. 5-6
Special Tools ............................................................................. 5-7
Removing the Engine from the Vessel .................................... 5-18
Draining the Coolant................................................................ 5-18
Draining the Engine Oil............................................................ 5-18
Removing the Electrical Wiring................................................ 5-18
Removing the Fuel Filter and Fuel Hoses ............................... 5-19
Removing the Air Silencer ....................................................... 5-19
Removing the Mixing Elbow .................................................... 5-19
Removing the Turbocharger.................................................... 5-19
Removing the Coolant Hoses.................................................. 5-19
Removing the Intercooler ........................................................ 5-19
Removing the Starter Motor .................................................... 5-20
Removing the Alternator.......................................................... 5-20
Removing the Coolant Tank, Cooler and Pump ...................... 5-20
Removing the Seawater Pump................................................ 5-20
Removing the Oil Filter and Oil Cooler .................................... 5-20
Removing the Electronic Control Devices ............................... 5-20
Removing the Fuel Injection Lines .......................................... 5-20
Removing the Fuel Injection Nozzles ...................................... 5-21
Removing the Fuel Injection Pump.......................................... 5-21
Removing the Rocker Arm Shaft Assembly ............................ 5-21
Removing the Cylinder Head................................................... 5-21
Removing the Marine Gear ..................................................... 5-21
Removing the Crankshaft Damper and Pulley ........................ 5-21
Removing the Drive Shaft Housing Cover............................... 5-21
Removing the Flywheel and Flywheel Housing....................... 5-21
Turning the Engine Block Over................................................ 5-21
Removing the Oil Pan and Spacer .......................................... 5-21
Removing the Connection Rod End Caps............................... 5-21

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 ENGINE
Removing the Oil Pump .......................................................... 5-21
Removing the Main Bearing Bolts ........................................... 5-21
Disassembling the Crankshaft and Piston Assemblies ........... 5-21
Inspecting the Cylinder Block and Components............................ 5-22
Inspecting Oil Passages and Freeze Plugs............................. 5-22
Dye Penetrant Inspection Procedure ...................................... 5-22
Replacing Freeze Plugs .......................................................... 5-23
Fabricating a Freeze Plug Driver............................................. 5-24
Measuring the Cylinder Bores ................................................. 5-24
Cylinder Head Components and Functions............................. 5-26
Inspecting the Cylinder Head .................................................. 5-28
Inspecting the Pistons and Piston Pins ................................... 5-36
Inspecting the Connecting Rods ............................................. 5-41
Inspecting the Crankshaft........................................................ 5-44
Inspecting the Camshaft and Tappets..................................... 5-48
Inspecting the Tappets ............................................................ 5-50
Inspecting the Push Rods ....................................................... 5-51
Inspecting the Timing Gear ..................................................... 5-51
Inspecting the Idler Gear ......................................................... 5-51
Indexing the Gear Timing Marks ............................................. 5-52
Inspecting the Flywheel and Housing...................................... 5-53
Replacing the Ring Gear ......................................................... 5-53
Positioning Top Dead Center .................................................. 5-53
Inspecting the Intake / Exhaust System .................................. 5-54
Assembling the Engine and Components ..................................... 5-55
Precautions Before Assembling the Engine ............................ 5-55
Installing the Tappets .............................................................. 5-55
Installing the Piston Cooling Nozzles ...................................... 5-56
Installing the Camshaft Bearings............................................. 5-56
Installing the Crankshaft.......................................................... 5-57
Installing the Oil Pump ............................................................ 5-58
Installing the Drive Shaft Housing ........................................... 5-59
Installing the Camshaft............................................................ 5-59
Installing the Piston Assemblies.............................................. 5-59
Installing the Oil Pan Spacer ................................................... 5-60
Installing the Oil Intake and Delivery Tubes ............................ 5-60
Installing the Oil Pan ............................................................... 5-61
Installing the Flywheel Housing Oil Seal ................................. 5-61
Installing the Flywheel Housing............................................... 5-61
Installing the Seawater Pump.................................................. 5-62
Installing the Idler Gear ........................................................... 5-62
Installing the Oil Pressure Regulating Valve ........................... 5-63
Installing the Coolant Passage Cover ..................................... 5-63
Installing the Fuel Injection Pump ........................................... 5-63
Installing the Flywheel ............................................................. 5-63
Installing the Cylinder Head Assembly.................................... 5-64
Installing the Intercooler .......................................................... 5-65

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 12/05
ENGINE
Installing the Intake Manifold ................................................... 5-66
Installing the Marine Gear ....................................................... 5-66
Installing the Push Rod and Rocker Arm Shaft Assembly....... 5-66
Installing the Rocker Arm Cover.............................................. 5-66
Installing the Coolant Pump..................................................... 5-67
Installing the Drive Shaft Housing Cover................................. 5-67
Installing the Crankshaft V-Pulley and Damper....................... 5-67
Installing the Fuel Injection Nozzles ........................................ 5-68
Installing the Heat Exchanger.................................................. 5-70
Installing the Coolant Tank ...................................................... 5-70
Installing the Engine Oil Cooler ............................................... 5-71
Installing the Engine Oil Filters ................................................ 5-71
Installing the Engine Coolant Hoses........................................ 5-72
Installing the Engine Air Ducts................................................. 5-74
Installing the Engine Turbocharger.......................................... 5-74
Installing the Mixing Elbow ...................................................... 5-75
Installing the Oil Lines for the Fuel Injection Pump ................. 5-76
Installing the Alternator............................................................ 5-76
Installing the Starter Motor ...................................................... 5-76

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 ENGINE

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 Safety Precautions ENGINE
12/05

SAFETY PRECAUTIONS INTRODUCTION

Before servicing the engine, read the following This section of the Service Manual describes the
safety information and review the Safety Section on disassembly, inspection and reassembly of the
page 2-1. 6LY3 engines.

The safety message that follows has a

WARNING level hazard. The safety message
describes a hazardous situation which, if not
avoided, could result in death or serious injury.

ALWAYS ensure that all connections

are tightened to specifications after
repair is made to the exhaust system.
All internal combustion engines
create carbon monoxide gas during
operation and special precautions are required to
avoid carbon monoxide poisoning.

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 ENGINE Disassembling the Engine and Components

DISASSEMBLING THE ENGINE

AND COMPONENTS
Precautions Before Engine
Disassembly
• Diagnose the cause of the trouble, and
disassemble only those parts which are
necessary.
• Keep all disassembled parts in order.
• Have all required tools on hand.
• Clean parts with an approved cleaner in a
suitable location.
• Clear an adequate area for parts and prepare a
container.
• Drain coolant, seawater and oil.
• Close the seacock.

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 Disassembling the Engine and Components ENGINE
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Special Tools
The following tools are required when disassembling and reassembling the engine. Please use them as
instructed.

Part Name Part No.

FIC Lock Bolt 158908-51490
FIC Lock Bolt Collar 158908-51480

General Hand Tools

Name of the Tool Illustration Remarks

Size:
10 x 13
Wrench 12 x 14
17 x 19
0005719 22 x 24

Screwdriver —

0005720

Steel Hammer Local

0005721

Copper Hammer Local

0005722

Mallet Local

0005723

Nippers Local

0005724

Pliers Local

0005725

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 ENGINE Disassembling the Engine and Components

Name of the Tool Illustration Remarks

Offset Wrench Local (1 set)

0005726

Box Spanner Local (1 set)

0005727

Scraper Local
0005728

Lead Rod Local

0005729

File Local (1 set)

0005730

Local
Rod Spanner for Size:
Hexagon Socket Head 6 mm
Bolts 8 mm
0005731 10 mm

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 Disassembling the Engine and Components ENGINE
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Name of the Tool Illustration Remarks

S-0

O-Ring Pliers:
Hole type Local
Shaft type
H4 - H8

S = Hole type
H = Shaft type
0005732

Special Hand Tools

Name of the
Illustration Remarks
Tool

B C

A D

0005733
Piston Pin (Extraction of the piston pin.)
Insertion / A B C D
Extraction
Tool 11 mm 20 mm 80 mm 35 mm
(0.433 in.) (0.787 in.) (3.149 in.) (1.377 in.)

(Insertion of the piston pin.)

0005734

A D
E
Connecting
Rod Small B C
End Bushing
0005735
Insertion /
Extraction
A B C D E F
Tool
40 mm 37 mm
(-0.2 mm, (-0.45 mm, 5.8 ± 0.5
-0.5 mm) 86 mm 24 mm -0.48 mm) mm
10° ± 30° (Extraction)
(1.574 in.) (3.385 in.) (0.944 in.) (1.456 in.) (0.228 in.
0005736
(-0.007 in. (-0.017 in. ± 0.019 in.
-0.019 in.) -0.018 in.)

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 ENGINE Disassembling the Engine and Components

Name of the
Illustration Remarks
Tool

B C

Intake /
Exhaust A D
Valve Guide
Insertion / 0005733

Extraction
Tool A B C D
7.5 mm 20 mm 75 mm 11 mm
(0.295 in.) (0.787 in.) (2.952 in.) (0.433 in.)
0005737

Oil Filter
Wrench

0005738
0005739

Piston Ring
—
Compressor

0005740

Piston Ring
Tool (For
removal /
—
insertion of
the piston
ring.) 0005741

Valve
Lapping Tool
—
(Rubber Cap
Type)

0005742

Valve
Lapping —
Powder 0005743

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 Disassembling the Engine and Components ENGINE
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Name of the
Illustration Remarks
Tool

Feeler
Gauge

0005744

0005745

Pulley Puller

0005747
(Local)
0005746

Name of the
Illustration Remarks
Tool

d1 d2 d3 L1 L2 L3
16.2 mm 22 mm 13.5 mm 11.5 mm 65 mm 4 mm
Intake
(0.637 in.) (0.866 in.) (0.531 in.) (0.452 in.) (2.559 in.) (0.157 in.)
16.2 mm 22 mm 13.5 mm 9.5 mm 65 mm 4 mm
Exhaust
(0.637 in.) (0.866 in.) (0.531 in.) (0.374 in.) (2.559 in.) (0.157 in.)

L2

L1
Stem Seal
Insertion Tool
d1 —
(For inserting the d2 0005748
stem seal.)

L2
d3 L3
d1 L1
d2

0005749

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 ENGINE Disassembling the Engine and Components

Measuring Instruments
Tool Application

Name of the Tool Illustration Application

Vernier Calipers 0-150 mm (5.905 in.)

0005750

0-25 mm (0-1 in.)

25-50 mm (1-2 in.)
50-75 mm (2-3 in.)
Micrometer
75-100 mm (3-4 in.)
0005751
100-125 mm (4-5 in.)
125-150 mm (5-6 in.)

18-35 mm (0.708-1.377 in.)

Cylinder Gauge 35-60 mm (1.377-2.362 in.)
50-100 mm (1.968-4 in.)
0005752

Thickness Gauge 0.05-2 mm (0.001-0.078 in.)

0005753

0-343 N·m
Torque Wrench (0-35 kgf·m)
0005754 (0-252 lb-ft)

0-49 MPa
Nozzle Tester (0-500 kgf / cm2)
(0-7106 psi)

0005755

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Tool Usage

No. Name of the Tool Use Illustration

Measures shaft bending, distortions of

1 Dial Indicator
levelness and gaps.
0005756

Measures the narrow and deep places,

2 Test Indicator
which cannot be measured with a dial gauge.
0005757

3 Magnetic Stand Keeps the dial gauge firmly in position.

0006344

Measures the outer diameter of the

4 Micrometer
crankshaft, piston, piston pin, etc.
0006345

Measures the inner diameter of the cylinder

5 Cylinder Gauge
liner and rod bearings.
0006346

Measures the various outer diameter,

6 Vernier Calipers
thickness and width.
0006347

7 Depth Micrometer Measures the valve sink.

0005759

Measures the distortion in the position of the

8 Square
springs and squareness of parts.

0005760

9 V-Block Used in measuring shaft distortions.

0005761

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 ENGINE Disassembling the Engine and Components

No. Name of the Tool Use Illustration

Used to tighten bolts and nuts to the standard

10 Torque Wrench
torque.
0005762

Measures the distance between the ring and

11 Thickness Gauge ring groove and between the shaft and shaft
joint at the time of assembly.

0006342

12 Radiator Cap Tester Checks for leaks in the freshwater system.

0005763

Checks the density of antifreeze and

13 Battery Current Tester
charging condition of battery fluid.
0005764

Checks the shape and pressure of spray

14 Nozzle Tester emitted from the fuel injection valve at the
time of injection.

0006343

3 4
5
2 6

1 7
8

15 Digital Thermostat Measures the temperature of various parts.

DIGITAL

Float
0005765

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No. Name of the Tool Use Illustration

Measures the rotation speed by using a

Contact Type reflector seal, which is placed on the exterior
of the revolving shaft.
0005766

Revolving shaft

Measures the rotation speed by using a

Photoelectric Type reflector seal, which is placed on the exterior
of the revolving shaft.
Reflection mark
16 Tachometer 0005767

High pressure pipe

Measures the rotation speed without

High-Pressure Fuel
reference to the revolving shaft center or the
Pipe Clamp Type
exterior of the revolving shaft.

0005768

Circuit Tester Measures the resistance, voltage and

17
Volt Ohm Meter (VOM) continuity of the electric circuit.

0005769

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 ENGINE Disassembling the Engine and Components

Sealants, Adhesives, Lubricants and Cleaners

Items Usual Contents Features and Application

200 g (7 oz) Non-drying liquid gasket; solvent-less type, easy to remove,
Three Bond® No. 1
(1 kg (35 oz) also superior in seawater resistance, applicable to the various mating
TB1101
available) surfaces.
200 g (7 oz) Non-drying liquid gasket; easy to apply, superior in water
Three Bond® No. 2
(1 kg (35 oz) also resistance and oil resistance, especially superior in gasoline
TB1102
available) resistance.
Three Bond® No. 3 Drying film, low viscosity and forming of thin film, appropriate for
150 g (5 oz)
Sealant TB1103 the mating surface of precision parts.
200 g (7 oz) Semi-drying visco-elastic material, applicable to a non-flat
Three Bond® No. 4
(1 kg (35 oz) also surface having many indentations and protrusions, superior in
TB1104
available) heat resistance, water resistance and oil resistance.
Three Bond® No. 10 Solvent-less type silicone-based sealant, applicable to high
100 g (3.5 oz)
TB1211 temperature areas (-50° to 250°C (-58° to 482°F)).
Three Bond®
100 g (3.5 oz) Silicone-based, non-fluid type, thick application possible.
TB1212
Three Bond® Prevention of loose bolts, gas leakage and corrosion. Torque
200 g (7 oz)
TB1401 required to loosen bolt: 10 to 20% larger than tightening torque.
Adhesive Loctite®
SUPER 50 g (1.7 oz) Excellent adhesive strength locks the bolt semi-permanently.
TB1324
Sealing material for the threaded parts of various pipes.
5 m (16 ft)
Seal Tape Ambient temperature range:
round tape
-150° to 200°C (-238° to 392°F)
Brand Name
50 g (1.7 oz)
(LOWCOL PASTE) For assembly of engine cylinders, pistons, metals shafts, etc.
EP Lubricant Spray type facilitates application work.
Brand Name
(Molybdenum 330 g (12 oz)
(PASTE SPRAY)
Disulfate)
Brand Name Prevention of seizure of threaded parts at high temperature.
50 g (1.7 oz)
(MOLYPASTE) Applicable to the intake / exhaust valves (stem, guide, face)
1 box • The scale solvent removes scale in a short time (1 to 10
Scale Solvent (4 kg (8 lb) x 4 hours).
removers)
• Prepare the coolant (seawater is possible) in an amount that
1 box is about 10 times the weight of the solvent. Mix the solvent
Neutralizer
(2 kg (4 lb) x 4 with coolant.
(Caustic Soda)
neutralizers)
• Dipping the disassembled part into solvent removes scale. To
Scale Solvent shorten the removal time, stir the remover mixture.
• If the cleaning performance drops, replace the remover
mixture with a new remover mixture.
pH Test Paper —
• Neutralize the used mixture and dispose of it. To judge the
cleaning performance of the mixture, put pH test paper into
the mixture. If the test paper turns red, the remover mixture is
still effective.
Add antirust to the freshwater system at the cold area to operate
Antifreeze —
the engine.
• The cleaning agent removes substances, such as carbon,
adhering to disassembled parts.
Cleaning Agent —
• If a cleaning machine is used, prepare 4 to 6% mixture of 60°
to 80° to ensure more effective cleaning.

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 Disassembling the Engine and Components ENGINE
12/05

Items Usual Contents Features and Application

4 L (1 gal) x 4
18 L (5 gal) x 1 Special cleaning agent that requires no water, specially
Cleaning Agent for Turbocharger
designed for blower of turbocharger and intercooler.
15 sets: 1,
500 cc (1 pt) x 6

O-Ring Kit
Usual Contents Features and Application
Ø1.9 x 2 m: 1
(0.074 x 6.5 ft)
Ø2.4 x 2 m: 1
(0.09 x 6.5 ft)
Ø3.1 x 2 m: 1 O-ring of any size can be prepared, whenever required (including
(0.122 x 6.5 ft) adhesive, release agent, cutter and jig).
Ø3.5 x 2 m: 1
(0.137 x 6.5 ft)
Ø5.7 x 2 m: 1
(0.224 x 6.5 ft)

NOTICE: Three Bond® liquid gasket products are

Figure 5-1

(1)
the recommended sealants used for assembly.
Before providing service, observe the cautions
below:
1. Build up each sealant bead equally.
2. For bolt holes, apply the sealant to the inside
surface of each hole. (4)
3. Three Bond®
TB1104 (Gray) or Three Bond®
(2)
TB1102 (Yellow) is used with a gasket. The use
of either of these sealant bonds without a
gasket is not effective.
4. When gaskets are used, do not use sealant
Three Bond® TB1212.

(3) 0005770

Figure 5-1
1 – Oil Pan Mating Surface
2 – Inside of Oil Pan
3 – Bead of Three Bond® TB1212
4 – Outside

6LY3 Service Manual 5-17

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 ENGINE Disassembling the Engine and Components

Removing the Engine from the Draining the Coolant

Vessel 1. Open the two seawater drain cocks
For engines installed in the engine room of a (Figure 5-2, (1) and (3)) to drain the seawater.
vessel, remove the piping and wiring connecting 2. Open the two coolant drain cocks
them to the vessel. (Figure 5-2, (4) and (7)) to drain the coolant.
Figure 5-2

1. Disconnect the battery.

2. Disconnect the electronic control system.
3. Disconnect the wiring between the starting
motor and the battery.
4. Remove the exhaust rubber hose from the
mixing elbow.
5. Remove the rubber hose connecting the
coolant recovery tank to the filler cap.
6. Remove the seawater inlet hose from the
seawater pump. NOTICE: Remove the hose (7) (1) 0005771
after making sure the seacock is closed.
7. Remove the fuel inlet hose from the fuel feed (6) (2)
pump.
8. Remove the body fit (reamer) bolts and
disassemble the propeller shaft coupling and
thrust shaft coupling.
9. Disassemble the PTO coupling from the front of
the engine, if installed. (3)
10. Remove the flexible mount nuts. Lift the engine
and remove it from the engine base. (Leave the
flexible mount attached to the engine base.) (4)
(5) 0005772

Figure 5-2
1 – Seawater Drain Cock
2 – Coolant Tank
3 – Seawater Drain Cock
4 – Coolant Drain Cock
5 – Seawater Pump
6 – Coolant Pump
7 – Coolant Drain Cock

Draining the Engine Oil

Remove the dipstick guide retaining bolt and drain
the oil from the engine. NOTICE: If an oil supply /
discharge pump is used, install the hose in the
dipstick guide.

Removing the Electrical Wiring

Remove the wiring from the engine.

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 Disassembling the Engine and Components ENGINE
12/05

Removing the Fuel Filter and Fuel Removing the Mixing Elbow
Hoses 1. Remove the seawater hose connected to the
1. Remove the fuel feed pump hose mixing elbow (Figure 5-4, (4)).
(Figure 5-3, (3)), fuel pump hose 2. Remove the mixing elbow from the
(Figure 5-3, (4)) and the fuel nozzle turbocharger.
hose (Figure 5-3, (1)).
2. Remove the fuel filter from the engine.
Removing the Turbocharger
Figure 5-3
1. Remove the intake pipe (turbine-intake
manifold).
2. Remove the turbine oil return line from the oil
(1)
pan side of the engine that goes to the oil pan.
(2) 3. Remove the turbine oil line (oil cooler-turbine).
(6) (3) 4. Remove the turbine.

Removing the Coolant Hoses

(5) (4) 0005773
1. Remove the seawater hose between the
Figure 5-3 seawater pump and heat exchanger.
1 – Fuel Nozzle Hose 2. Remove the coolant hose between the coolant
2 – Fuel Filter Assembly pump, the heat exchanger and the exhaust
3 – Fuel Feed Pump Hose manifold.
4 – Fuel Pump Hose
5 – Drain Plug 3. Remove the coolant hose between the oil
6 – Hose to Fuel Pump cooler and coolant pump.

Removing the Air Silencer Removing the Intercooler

1. Remove the breather hose (Figure 5-4, (3)) 1. Remove the intake air hose.
from the air silencer (Figure 5-4, (2)). 2. Remove the seawater hoses.
2. Remove the air silencer from the turbocharger • Heat Exchanger
(Figure 5-4, (5)). • Intercooler (Figure 5-5, (3))
Figure 5-4

(1) • Oil Cooler (Figure 5-5, (1))

(5)
3. Remove the intercooler.
(4) Figure 5-5

(3)
(1)
(2) 0005774
(3)
(2) 0005775

Figure 5-4 Figure 5-5

1 – Intake Air Hose 1 – Oil Cooler
2 – Air Silencer 2 – Oil Filter
3 – Breather Hose 3 – Intercooler
4 – Mixing Elbow
5 – Turbocharger

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 ENGINE Disassembling the Engine and Components

Removing the Starter Motor Removing the Coolant Tank, Cooler

Remove the starter motor from the flywheel and Pump
housing. 1. Remove the coolant tank (Figure 5-7, (1)) and
gasket.
Removing the Alternator Figure 5-7

1. Loosen the alternator adjusting bracket

(Figure 5-6, (1)) and remove the V-belt
(1)
(Figure 5-6, (3)).
Figure 5-6

(1)
(2)

(3)
(4) (4) 0005777

Figure 5-7
1 – Coolant Tank
(2)
2 – Dipstick
3 – Heat Exchanger
(3) 0005776 4 – Seawater Pump
Figure 5-6 2. Remove the heat exchanger (Figure 5-7, (3)).
1 – Adjusting Bracket 3. Remove the coolant pump and gasket.
2 – Alternator
3 – V-Belt Removing the Seawater Pump
4 – Coolant Pump Remove the seawater pump (Figure 5-7, (4)).
2. Remove the adjusting bracket from the coolant
pump (Figure 5-6, (4)). Removing the Oil Filter and Oil
3. Remove the alternator (Figure 5-6, (2)) from Cooler
the drive shaft housing. 1. Remove the oil filter (Figure 5-5, (2)).
2. Remove the oil cooler (Figure 5-5, (1)).
3. Remove the oil dipstick and guide
(Figure 5-7, (2)).

Removing the Electronic Control

Devices
Remove the cover, the electronic control unit,
amplifier and fuse.

Removing the Fuel Injection Lines

1. Remove the fuel injection hose retainer.
2. Loosen the cap nuts on both ends of the fuel
injection hose and remove the fuel injection
hose.

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 Disassembling the Engine and Components ENGINE
12/05

Removing the Fuel Injection Nozzles Removing the Flywheel and Flywheel
NOTICE: If the fuel nozzle seat stays in the cylinder Housing
head, make a note of the cylinder number and 1. Loosen the flywheel bolts and remove the
remove it when disassembling the cylinder head. flywheel.
Removing the Fuel Injection Pump 2. Remove the flywheel housing. NOTICE: Avoid
scratching the ring gear.
See Removing the Fuel Injection Pump on
page 6-14 for the procedure. Turning the Engine Block Over
Removing the Rocker Arm Shaft Place wooden blocks on the floor. Set the mating
surface of the cylinder block on the wood. Keep the
Assembly positioning pins clear.
1. Remove the rocker arm cover.
2. Remove the bolts on the rocker arm shaft
Removing the Oil Pan and Spacer
support and remove the entire rocker arm shaft Remove the oil pan and spacer. NOTICE: Record
assembly as a unit. the location of each bolt.
3. Remove the push rods.
Removing the Connection Rod End
Removing the Cylinder Head Caps
1. Loosen the cylinder head bolts in the order 1. Loosen the rod bolts and remove the end cap.
shown in Figure 5-8. Remove the cylinder 2. Turn the crankshaft and remove the big end cap
head. for each connecting rod.
Figure 5-8

7 15 24 22 14 6
1 9 17 26 20 12 4 Removing the Oil Pump
(3) 1 2 3 4 5 6 (1) Remove the oil pump.
3 11 19 25 18 10 2
5 13 21 23 16 8
Removing the Main Bearing Bolts
(2)
1. Check the thrust clearance before
0005778
disassembling. See Inspecting the End Play of
Figure 5-8 the Crankshaft on page 5-46.
1 – Coolant Pump End 2. Loosen the main bearing bolts and remove.
2 – Operating Side 3. Remove the main bearing cap and lower main
3 – Flywheel End bearing insert. NOTICE: The thrust bearing
2. Remove the cylinder head gasket. (lower) is installed to the base main bearing
cap.
Removing the Marine Gear
Loosen the bolts for the gearbox case flange, and
Disassembling the Crankshaft and
remove the gearbox assembly. Piston Assemblies
Disassemble the crankshaft and piston assemblies.
Removing the Crankshaft Damper NOTICE: The thrust bearing (upper) is installed to
and Pulley the standard main bearing. Remove the main
Remove the crankshaft damper and the V-pulley. bearing insert (upper) from the cylinder block.
Remove the connecting rod and piston assembly.
Removing the Drive Shaft Housing
Cover
Loosen the drive shaft housing cover bolts and
remove the drive shaft housing cover from the drive
shaft housing.

6LY3 Service Manual 5-21

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 ENGINE Inspecting the Cylinder Block and Components

INSPECTING THE CYLINDER Dye Penetrant Inspection Procedure

BLOCK AND COMPONENTS The dye penetrant inspection kit consists of an
aerosol cleaner, penetrant and developer.
The cylinder block is a light alloy casting machined
with functionally designed ribs and support
Figure 5-10

structures. The side walls are shaped to maximize

rigidity, strength and quiet operation.
Perform a visual inspection for cracks on engines
that have been exposed to freezing temperatures,
have overturned or been subjected to undue stress.
Perform a dye penetrant inspection on any
suspected cracks. Replace the cylinder block if a 0005588
crack is not repairable.
Figure 5-10
Inspecting Oil Passages and Freeze
NOTICE: Always read the instructions included with
Plugs the dye penetrant kit before use.
Clear all oil passages of any obstructions and
1. Spray the cleaner directly on the surface to
ensure that all freeze plugs are secure.
soften heavily soiled areas or wipe the area
Figure 5-9

with a cloth moistened with cleaner.

(1)
2. When the surface is clean and dry, spray the
penetrant on the suspect area so it is
(9)
(2) completely covered and the penetrant liquid
No.1
(8) shows a smooth surface tension. Use enough
penetrant to maintain a wet appearance for at
(7)
No.6 least 10 to 15 seconds. Do not disturb for 5 to
10 minutes.
(6) 3. Spray the developer on a clean shop towel and
remove any excess dye penetrant.
(5) (3) 4. Spray a uniform thin film of developer on the
(4)
remaining penetrant and allow to develop for
0005587
several minutes. Cracks will appear as red dots
Figure 5-9 or a continuous red line on the surface being
inspected.
1 – 65 mm (2.559 in.) Plug
2 – 40 mm (1.574 in.) Plug
5. When finished, clean the surface with the
3 – 40 mm (1.574 in.) Plug cleaner.
4 – 16 mm (0.629 in.) Plug
5 – 35 mm (1.377 in.) Plug
6 – Flywheel End
7 – 40 mm (1.574 in.) Plug
8 – 16 mm (0.629 in.) Plug
9 – 40 mm (1.574 in.) Plug

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 Inspecting the Cylinder Block and Components ENGINE
12/05

Replacing Freeze Plugs

Step
Description Procedure Tool or Material Used
No.

(1)
(2)

Set the screwdriver at a slight angle in • Screwdriver

1
(3)
the upper portion of the plug. Tap lightly
(4) with a hammer and remove the plug. • Hammer

0005589

1 – Cylinder Block
2 – Hammer
3 – Screwdriver
4 – Plug

(1)

Wipe the cylinder block and plug • Thinner

opening clean. Apply an adhesive • Adhesive agent
2
agent (acrylic) on the outside surface of (or Three Bond®
the plug and cylinder block opening. 1386B)

0005590

1 – Clean and Apply Adhesive

(1)

Insert the plug using a driver and • Driver

3 hammer. (Drive the plug straight into
the opening.) • Hammer

0005591

1 – Jig

Do not add coolant to the cylinder block

4 —
for two hours after the plugs are set.

0005592

6LY3 Service Manual 5-23

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 ENGINE Inspecting the Cylinder Block and Components

Fabricating a Freeze Plug Driver

Figure 5-11

R2
R2
D2 D1 D3 D4 D2
R2
R2

L1 L4
L2 L3 L5
0005593

Figure 5-11

Plug Diameter D1 D2 D3 D4 L1 L2 L3 L4 L5
Ø16 12.0 mm 20.0 mm 10.0 mm 10.0 mm 2.5 mm 4.0 mm 20.0 mm 30.0 mm 150.0 mm
(0.63 in.) (0.472 in.) (0.787 in.) (0.393 in.) (0.393 in.) (0.098 in.) (0.157 in.) (0.787 in.) (1.181 in.) (5.905 in.)
Ø40 mm 36.0 mm 48.0 mm 34.0 mm 28.0 mm 8.5 mm 10.0 mm 20.0 mm 30.0 mm 150.0 mm
(1.574 in.) (1.417 in.) (1.889 in.) (1.338 in.) (1.102 in.) (0.334 in.) (0.393 in.) (0.787 in.) (1.181 in.) (5.905 in.)

Measuring the Cylinder Bores • Measure at 20 mm (0.8 in.) (Figure 5-13, (1))
below the top of the cylinder bore.
Clean the mating surface of the cylinder head, the
cylinder bores and all oil passages. Check the
Figure 5-13

following items after removing any carbon deposits (1) 20 mm (0.787 in.)
and / or gasket material residue.
(4)
• Check for any discoloration or cracks. If a crack is (2)
suspected, perform a dye penetrant inspection.
Clean and clear all oil passages.
(5)
• Measure the cylinder bore dimensions and (3)
compare the measurements to the allowable 20 mm
limits. Inspect the cylinder bore(s) for physical (0.787 in.) 0005595

damage and out-of-round conditions. Figure 5-13

Figure 5-12

1 – 20 mm (0.787 in.) Below Top of Cylinder Bar.

2 – Center of Piston Travel.
3 – 20 mm (0.787 in.) from Bottom of Piston
Skirt.
4 – Measure in Both Directions 4 at Points 1, 2
and 3.
5 – Measure in Both Directions 5 at Points 1, 2
and 3.
• Measure at the center of piston travel
(Figure 5-13, (2)).
• Measure at 20 mm (0.787 in.) (Figure 5-13, (3))
from the bottom of the piston skirt in directions 4
and 5 as shown in Figure 5-13.
0005594
NOTICE: Direction 4 is the crankshaft center line.
Figure 5-12

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 Inspecting the Cylinder Block and Components ENGINE
12/05

Measuring Cylinder Bores for Measuring Cylinder Bore Diameters

Out-of-Round: Measure the cylinder bore diameters and compare
Use a Dial Bore Gauge to measure the cylinder the values with the wear limits stated below.
bore diameters. Measure the cylinder bore twice at
right angles at positions 4 and 5 as shown in Cylinder Wear Limits
Figure 5-13.
Item Standard Limit
Record the following measurements: Cylinder Bore 105.900-105.930 mm 105.950 mm
Diameter (4.169-4.170 in.) (4.171 in.)
1. Two measurements at position 1 at the top of
0.03 mm (0.001 in.)
the cylinder bore. Cylinder Roundness —
or less
2. Two measurements at position 2 in the middle 0.02 mm (0.0007 in.)
of the cylinder bore. Cylindricity —
or less
3. Two measurements at position 3 at the bottom
of the piston ring travel in the cylinder bore.
This produces six different measurement values.
Calculate the average value of all the
measurements for each cylinder bore and compare
with the wear limits. See Measuring Cylinder Bore
Diameters on page 5-25.

6LY3 Service Manual 5-25

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 ENGINE Inspecting the Cylinder Block and Components

Cylinder Head Components and Functions

The head contains six cylinder bores and is installed with 26 head bolts. The valve seats are treated with a
special satellite alloy for superior resistance to heat and wear. The areas between the intake / exhaust valves
are cooled with internal circulating water.
Figure 5-14

(2)

(3)

(1)

(5) (4)

(6) (7)
(8) (9)
(13) (10)
(14)
(15)
(16)
(17) (12)
(11)
(18)

(22)

(19)

(21)
(20)
0005596

Figure 5-14

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 Inspecting the Cylinder Block and Components ENGINE
12/05

1 – Breather Return Hose 12 – Valve Bridge

2 – Breather Hose 13 – Valve Keepers
3 – Rocker Arm Cover 14 – Valve Retainer
4 – Breather Hose from Drive Shaft Housing 15 – Valve Spring
5 – Baffle Plate 16 – Valve Stem Seal
6 – Rocker Arm Shaft 17 – Valve Guide
7 – Exhaust Rocker Arm 18 – Bridge Guide
8 – Rocker Arm Spring 19 – Water Pump End
9 – Intake Rocker Arm 20 – Intake Valve
10 – Bridge Seat 21 – Exhaust Valve
11 – Rocker Arm Support 22 – Cylinder Head

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 ENGINE Inspecting the Cylinder Block and Components

Inspecting the Cylinder Head

Figure 5-16

The cylinder head is subjected to very severe

operating conditions with drastic and repeated
fluctuations of high pressure and high temperature.
Thoroughly remove all the carbon and dirt after
disassembling. Clean the cylinder head surface
and carefully inspect all of the parts.
Inspect the cylinder head for the following
conditions:
1. Check for distortion of the cylinder head mating
surfaces.
• Clean the cylinder head surface. 0005598

• Place a straight-edge along each of the four Figure 5-16

sides and each diagonal.
3. Check the intake and exhaust valve seats.
• Measure the clearance between the
Check the surface and width of the valve seats
straight-edge and mating surface with a feeler
(Figure 5-17). If the seat width is too wide, or if
gauge.
the surface is rough, correct to the following
standards:
Cylinder Head Distortion
Standard Wear Limit Seat Angle
0.05 mm 0.20 mm Intake 90°
(0.002 in.) or less (0.008 in.)
Figure 5-15
Exhaust 90°

Intake Seat Width

Standard Limit
1.07-1.24 mm 1.74 mm
(0.042-0.049 in.) (0.069 in.)

Exhaust Seat Width

Standard Limit
1.24-1.45 mm 1.94 mm
(0.049-0.057 in.) (0.076 in.)
0005597
Figure 5-17

Figure 5-15
2. Check for cracks in the cylinder combustion
surfaces.
• Remove the fuel injection nozzle, intake and
exhaust valve.
• Check for discoloration or distortion.
• Perform a dye penetrent inspection to check for
any cracks.
0005599

Figure 5-17

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 Inspecting the Cylinder Block and Components ENGINE
12/05

Figure 5-19

Correcting the Valve Seat Angles

Use a seat grinder (Figure 5-18) to correct
unevenness of the seat surface as follows:
Figure 5-18

(1)

(2)

0005601

Figure 5-19
1 – Valve Seat Width
2 – Valve Seat
0005600 3. Knead valve compound with oil and finish the
valve seat (Figure 5-19, (2)) with a lapping tool.
Figure 5-18 NOTICE: Use a rubber cap type lapping tool for
valves without a lapping tool groove slit.
1. Widen the valve seat width (Figure 5-19, (1))
using a 70° grinding wheel.
Figure 5-20

2. Grind the seat to the standard dimension

(45°) using a grinding wheel with a 15°
chamber.

Seat Angle Ø
Intake Valve 45°
Exhaust Valve 45°
0005718

Figure 5-20
NOTICE: When seat adjustment is necessary,
check the valve and valve guide. If the clearance
exceeds the tolerance, replace the valve or the
valve guide and grind the seat.

6LY3 Service Manual 5-29

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 ENGINE Inspecting the Cylinder Block and Components

4. Final finishing should be done with oil only. Inspecting Intake / Exhaust Valves and
• Clean the valve seat and cylinder head with Valve Guides
light oil or equivalent after valve seat lapping is
Check for Wear and Corrosion of Each Valve
completed.
Stem
• Make sure there is no grinding debris or Measure the outside diameter of valve
lapping compound remaining. (Figure 5-23) stem. Replace the valve if the stem is
• Measure the valve distortion after the valve excessively worn or corroded.
seat lapping has been completed.
• Replace the valve and valve seat if they exceed Intake Valve Stem Outside Diameter
tolerances. Standard Limit
Figure 5-21

7.960-7.975 mm 7.90 mm
(0.3133-0.3139 in.) (0.311 in.)

Exhaust Valve Stem Outside Diameter

Standard Limit
7.955-7.970 mm 7.90 mm
(0.3131-0.3137 in.) (0.311 in.)
Figure 5-22

55mm 55mm
(2.165 in.) (2.165 in.)
0005603

0005602
Figure 5-22
Figure 5-21 Figure 5-23

0005604

Figure 5-23

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 Inspecting the Cylinder Block and Components ENGINE
12/05

Check Valve Seat Wear and Contact Surface Check the Valve Guides
• Inspect the valve seat for scratches and Measure the inside diameter of the valve guide and
excessive wear. compare it to the Valve Guide Specifications Chart
below. Replace the valve guide if it exceeds the
• Check to make sure the contact surface is wear limit. NOTICE: The inside diameter standard
normal. dimensions are measured after the guide is
The seat angle must be checked and adjusted if installed in the cylinder head.
the valve seat contact surface is smaller than the
width of the valve seat. NOTICE: The intake and Valve Guide Specifications
exhaust valves have different diameters. Standard Limit
Check the Sink of the Valve Seat 8.010-8.025 mm 8.1 mm
Valve Guide Intake
(0.3153-0.3159 in.) (0.318 in.)
Over long periods of use and repeated lapping, Inside
combustion efficiency may drop. Measure the sink Diameter 8.015-8.030 mm 8.1 mm
Exhaust
(0.3155-0.3161 in.) (0.318 in.)
of the valve seat using a depth gauge.
0.035-0.065 mm 0.18 mm
Intake
Replace the valve and valve seat if the valve sink (0.0013-0.0025 in.) (0.007 in.)
(Figure 5-24, (2)) exceeds the tolerance. Clearance
0.045-0.075 mm 0.18 mm
Exhaust
(0.0017-0.0029 in.) (0.007 in.)
Intake Valve Sink
Replacing the Valve Guide
Standard Limit
Use the valve guide insertion tool (Figure 5-25, (1))
0.7-0.9 mm 1.2 mm
(0.027-0.035 in.) (0.047 in.) and tap valve guide (Figure 5-25, (2)) into the
cylinder head (Figure 5-25, (3)).
Figure 5-25

Exhaust Valve Sink

(1)
Standard Limit
1.2-1.4 mm 1.7 mm (2)
(0.047-0.055 in.) (0.066 in.) (3)
Figure 5-24

(1) (2)

(4)

0005605

Figure 5-24
1 – Cylinder Head
2 – Valve Sink
0005606

Figure 5-25
1 – Insertion Tool
2 – Tap Valve Guide
3 – Cylinder Head
4 – Tool

6LY3 Service Manual 5-31

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 ENGINE Inspecting the Cylinder Block and Components

Inspecting the Valve Guide Projection 5. Remove the tools and verify that the seal is
The valve guide should extend the specified against the top of the valve guide
distance above the top of the cylinder head (Figure 5-27, (5)).
Figure 5-27

(Figure 5-26).
(1)
Figure 5-26

(2)

(3)
7 +0.5
11.5

9+0.5
9.5

0
(4)

(5)

(6)

0005608

Figure 5-27
1 – Valve Stem Seal Installer
2 – Guide Pin
(1) (2) 0005607
3 – Seal Spring
4 – Valve Stem Seal
Figure 5-26
5 – Seal Against Top of Valve Guide
1 – Exhaust Valve 6 – Tool Stop
2 – Intake Valve
Checking the Valve Springs
Inspecting the Valve Stem Seals 1. Check the valve spring for scratches or
The valve stem seals on the intake / exhaust valve corrosion.
guides cannot be reused. Replace used seals with Figure 5-28

new ones.
Lubricate the valve stems before installing the new
stem seals on the intake (Figure 5-26, (2)) and
exhaust valves (Figure 5-26, (1)). Exhaust stem
seals are marked yellow. Intake stem seals are not
marked.

Installing the Valve Stem Seal 0005609

1. Place a tool stop against the cylinder head; over Figure 5-28
the valve stem (Figure 5-27, (1)).
2. Measure the free length of the spring.
2. Place the valve stem seal (Figure 5-27, (4)) on
the guide pin (Figure 5-27, (2)).
3. Place the guide pin and seal on the valve stem.
Check that the spring (Figure 5-27, (3)) is still
in position on the seal.
4. Use the valve stem seal installer tool to install
the seal. Tap the seal in position using a tool
stop (Figure 5-27, (6)) to prevent damage to
the valve stem seal.

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 Inspecting the Cylinder Block and Components ENGINE
12/05

3. Measure the valve spring inclination

Figure 5-30

(Figure 5-29, (1)).

Valve Spring Inclination Limit

1.2 mm (0.047 in.)
Figure 5-29

(1) (1)

(2)

0005663

0005611

Figure 5-30
1 – Spring Tension Tester
5. Assemble the valve springs. The side with the
smaller pitch (painted yellow) (Figure 5-31, (2))
should face down toward the cylinder head.
0005610 NOTICE: The pitch of this valve spring is not
even. Pay attention to the up-down direction of
Figure 5-29 the spring when assembling.
1 – Valve Spring Inclination Figure 5-31

(1)
2 – Valve Spring Free Length
4. Measure the valve spring free length
(Figure 5-29, (2)) and tension.

Valve Spring
Standard Limit (2)
53.0 mm 51.5 mm
Free Length
(2.086 in.) (2.027 in.)
(3) 0005612
K1 = 17.5 N / mm
(1.78 kgf / mm) — Figure 5-31
Tension at (62.9 ozf / 0.399 in.)
1 mm (0.039 in.) 1 – Top
Compression K2 = 22.9 N / mm 2 – Small Pitch Side (Yellow)
(2.33 kgf / mm) —
3 – Down Side
(82.3 ozf / 0.399 in.)

6LY3 Service Manual 5-33

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 ENGINE Inspecting the Cylinder Block and Components

Checking Spring Retainer and Spring Figure 5-32

Cotters (1) (2)

1. Inspect the inside face of the spring retainer.
2. Inspect the outside surface of the spring cotter.
3. Inspect the contact area of the spring cotter
inside surface and the notch in the head of the
valve stem.
4. Replace the spring retainer and spring cotters
when the contact area is less than 70%, or
when the spring cotters have worn excessively.

Inspecting the Injection Nozzle Sleeves

Lubricate the nozzle O-rings (Figure 5-32, (1)) with
clean engine oil. Insert the nozzle sleeve (4) (3) 0005613
(Figure 5-32, (2)) into the cylinder head and torque
to the value shown below.

Nozzle Sleeve Torque

57.8 ± 4.9 N·m
(5.89 ± 0.50 kgf·m)
(43 ± 3.6 lb-ft)

(2)
Part Name Part No.
Nozzle Sleeve 119578-11820
O-Ring (1AP22A) 24311-350220
Nozzle Sleeve Gasket 119578-11960

0005614

Figure 5-32
1 – O-Ring
2 – Nozzle Sleeve
3 – M13
4 – Gasket

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 Inspecting the Cylinder Block and Components ENGINE
12/05

Figure 5-34

Measuring Piston Top Clearance

• Place a high-quality fuse wire (Figure 5-33, (2))
(Ø1.2 mm (0.047 in.), 10 mm (0.393 in.) long in
four positions on the top of the piston
(Figure 5-33, (3)).
Figure 5-33

(1)

(2)
(3)
(1) 0005617

Figure 5-34
1 – Fuse Wire

0005616 Inspecting the Intake / Exhaust Rocker

Figure 5-33 Arms
Excessive wear of the rocker arm bearings and
1 – Cylinder Block
rocker arms will affect the duration and timing of the
2 – Fuse Wire
3 – Piston valve opening and closings. This will reduce engine
performance in direct proportion to the amount of
• Assemble the cylinder head and gasket to the wear.
cylinder block (Figure 5-33, (1)).
Figure 5-35

• Torque the head as previously described. (1)

• Turn the crank in the direction of engine rotation (2)
and press the fuse wire between the piston and (3)
head.
• Remove the head and take out the compressed
fuse wire.
• Measure the thickness of the compressed fuse
wire at four positions and calculate the average
top clearance for each piston.
(4)
0005618
Piston Top Clearance
0.78-0.98 mm Figure 5-35
(0.031-0.039 in.)
1 – Exhaust Rocker Arm
2 – Intake Rocker Arm
3 – Rocker Arm Support
4 – Rocker Arm Shaft Assembly

6LY3 Service Manual 5-35

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 ENGINE Inspecting the Cylinder Block and Components

1. Check the rocker arm shaft and rocker arm Inspecting the Pistons and Piston
bearing.
Pins
• Measure the outer diameter of the rocker arm
shaft. Pistons are made of a special light alloy with
Figure 5-36
superior thermal expansion characteristics. The top
of the piston forms a swirl-type combustion
chamber. The inside surface of the piston face is
cooled with oil-jet lubrication. NOTICE: Piston
shape differs among engine models. If an incorrect
piston is installed, engine performance will be
reduced. Check the applicable engine model
identification mark LY3 on the pistons for 6LY3
engines to ensure that the proper piston is being
used.
(1) 0005619
Figure 5-37

Figure 5-36 (1)

1 – Rocker Arm Hole Diameter

• Measure the inner diameter of the rocker arm (2)
bearing.
• Replace if wear exceeds the stated limits.
(3)
Rocker Arm Specification
Standard Limit
Inside Diameter of the
20.000-20.020 mm 20.090 mm (4)
Intake and Exhaust
(0.787-0.788 in.) (0.790 in.) (6)
Rocker Arm Bushing
(5)
Outside Diameter of the
19.970-19.990 mm 19.955 mm
Intake and Exhaust
(0.786-0.787 in.) (0.785 in.)
Rocker Arm Shaft
Clearance of the
0.010-0.050 mm 0.140 mm 0005620
Rocker Arm Shaft and
(0.0003-0.0019 in.) (0.0055 in.)
Bushing at Assembly Figure 5-37
• Replace the bearing if it moves in the rocker 1 – Top Compression Ring
arm. 2 – Middle Compression Ring
• Replace the entire rocker arm if there is no 3 – Oil Control Ring
tightening clearance. 4 – Piston Pin
5 – Circlip
2. Check the rocker arm spring and replace it if it 6 – Engine ID Mark
is corroded or worn.
3. Check the rocker arm and valve top retainer
wear. Inspect the contact surface of the rocker
arm and replace it if there is abnormal wear or
flaking.
4. Inspect the contact surface of the adjusting bolt
and push rod. Replace it if there is abnormal
wear or flaking.

5-36 6LY3 Service Manual

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 Inspecting the Cylinder Block and Components ENGINE
12/05

Measuring the Pistons

Piston Outside Diameter
Remove carbon deposits from the piston, taking
Clearance
care not to scratch the piston surface. Check the Piston
Between
combustion surface for any damage. ID Standard Limit
Piston and
Mark
Cylinder
Measure the outside diameter at the top of the
piston. 105.799-105.809 mm
L
(4.1653-4.1656 in.)
• Replace the piston if the outsides of the piston or 105.794-105.799 mm 105.780
ML 0.111-0.131 mm
ring grooves are worn. (4.1651-4.1653 in.) mm
(0.0043-0.0051
105.789-105.794 mm (4.1645
• Measure the outside diameter of the piston at a MS in.)
in.)
(4.1649-4.1651 in.)
right angle from the piston pin as shown in
Figure 5-38. 105.779-105.789 mm
S
(4.1645-4.1649 in.)
If the piston outside diameter exceeds the limit, Figure 5-38

replace the piston.

(1) 22 mm
(0.9 in.)

0005621

Figure 5-38
1 – Piston Skirt

Matching Pistons to Cylinder Sleeves

Pistons must be matched to cylinder sleeves according to the table below. The size mark of a piston is
shown on its top surface. The size mark of a cylinder sleeve is shown on the non-operating side of the
cylinder block. The serviceable matches of pistons and sleeves are as provided below.

Piston Outside Diameter,

D2
Below +0.005 Below 0
Tolerance
0 Minimum -0.005 Minimum
Size Mark ML MS
+0.030 maximum
L O X
+0.020 minimum
Cylinder Liner Inside
below +0.020
Diameter, M O O
+0.010 minimum
D1
below +0.010
S X O
0 minimum

Cylinder Liner Inside Diameter, D1 Piston Outside Diameter, D2

105.900 mm (4.1692 in.) 105.794 mm (4.1651 in.)

6LY3 Service Manual 5-37

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 ENGINE Inspecting the Cylinder Block and Components

Disassembling the Pistons Measure at positions a, b and c in directions A and

A floating-type piston pin is used in this engine. The B.
piston pin can be palm-pressed into the piston pin Figure 5-41

hole at room temperature (coat with oil to make it a b c

A
slide easily).
Figure 5-39

(1) 0005624

Figure 5-41
1 – Piston Pin Outside Diameter

Measuring the Piston Rings

There are two compression rings and one oil
0005622
control ring.
Figure 5-42

Figure 5-39
(1)
Measuring the Piston Pin
1. Measure the outside diameter of the piston pin
(Figure 5-41, (1)) as shown. (2)
2. Replace the pin if it is worn beyond the stated
limits.
(3)
Piston Pin
Standard Limit
Piston Pin Hole 37.025-37.040 mm 37.100 mm 0005625
Inside Diameter (1.457-1.458 in.) (1.460 in.)
Piston Pin Outside 36.994-37.000 mm 36.964 mm Figure 5-42
Diameter (1.4564-1.4566 in.) (1.4552 in.)
1 – Top Compression Ring
0.025-0.046 mm 0.110 mm
Clearance 2 – Middle Compression Ring
(0.0009-0.0018 in.) (0.0043 in.)
3 – Oil Control Ring
• Measure the thickness and width of the rings.
Figure 5-40

• Measure the ring-to-groove clearance after

installing the ring on the piston.
• Replace if wear exceeds stated limits.

0005623

Figure 5-40

5-38 6LY3 Service Manual

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 Inspecting the Cylinder Block and Components ENGINE
12/05

Measuring Piston Ring Gap

Piston Rings • Push the piston ring (Figure 5-44, (3)) into a
Standard Limit cylinder bore approximately 30 mm (1.2 in.)
(Figure 5-44, (4)) from the bottom of the cylinder.
Groove 2.626-2.646 mm 2.746 mm
Width (0.1033-0.1041 in.) (0.1081 in.) • Measure the piston ring gap (Figure 5-44, (5))
Top Ring
Ring Width
2.470-2.490 mm 2.450 mm with a feeler gauge.
(0.0972-0.0980 in.) (0.0964 in.)
Clearance — —
Piston Ring Gap
Groove 2.570-2.585 mm 2.140 mm
Standard Limit
Width (0.1011-0.1017 in.) (0.0842 in.)
0.30-0.50 mm 1.5 mm
Second 2.470-2.490 mm 1.950 mm Top Ring Gap
Ring Width (0.0118-0.0196 in.) (0.059 in.)
Ring (0.0972-0.0980 in.) (0.0767 in.)
0.50-0.70 mm 1.5 mm
0.080-0.115 mm 0.200 mm Second Ring Gap
Clearance (0.0196-0.0275 in.) (0.059 in.)
(0.0031-0.0045 in.) (0.0078 in.)
0.25-0.45 mm 1.5 mm
Groove 4.010-4.025 mm 4.130 mm Oil Ring Gap
(0.0098-0.0177 in.) (0.059 in.)
Width (0.1578-0.1582 in.) (0.1625 in.)
Figure 5-44

3.970-3.990 mm 3.950 mm
Oil Ring Ring Width
(0.1562-0.1570 in.) (0.1555 in.)
0.020-0.055 mm 0.150 mm (1)
Clearance
(0.0007-0.0021 in.) (0.0059 in.)
Figure 5-43

(2)

(3)

(4)

(5)
0005627

Figure 5-44

0005626 1 – Head Surface

2 – Cylinder Block
Figure 5-43 3 – Piston Ring
4 – Approximately 30 mm (1.2 in.)
5 – Piston Ring Gap

Replacing the Piston Rings

• Thoroughly clean the ring grooves when
replacing piston rings (Figure 5-44, (3)).
• The side with the manufacturer's mark
(Figure 5-45, (1)) must face up.
Figure 5-45

(1)

0005628

Figure 5-45

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 ENGINE Inspecting the Cylinder Block and Components

• After installing the piston ring, make sure it moves • Stagger the piston rings at 120° intervals, making
easily and smoothly. sure none of them line up on the piston.
• The oil control ring is equipped with a coil
Figure 5-46

expander.
(1)
• The coil expander joint (Figure 5-47, (2)) should
be opposite (staggered 180°) the oil ring gap
(2) (Figure 5-47, (1)).
Figure 5-47

(3)

(4)

(1) (2)
(6)

(5)
0005631

Figure 5-47
1 – Gap
2 – Joint of Coil Expander

0005629

(4)
12
0

(7)
120

(8)
(5)

0
12
(6) 0005630

Figure 5-46
1 – Top Compression Ring
2 – Middle Compression Ring
3 – Oil Control Ring
4 – Top Compression Ring Gap
5 – Oil Control Ring Gap
6 – Middle Compression Ring Gap
7 – Direction of Piston Pin
8 – Direction of Side Pressure

5-40 6LY3 Service Manual

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 Inspecting the Cylinder Block and Components ENGINE
12/05

Inspecting the Connecting Rods

Figure 5-49

100
mm
The connecting rod (Figure 5-48, (1)) is made of 100
mm
high-strength forged carbon steel. The large
crankshaft bearing is equipped with a bearing cap
and a 2-piece aluminum bearing insert assembly. (1)
The piston pin bearing (Figure 5-48, (2)) is a
non-serviceable copper alloy bushing that is
factory-installed. (3)
(2)
Figure 5-48

(2)

(1)
0005633

Figure 5-49
1 – Parallel Measurement
2 – Twist Measurement
(3) 3 – Mandrel
• Measure alignment.

(4) • Replace connecting rod if it exceeds the stated

limits.
(5)
Connecting Rod Twist
Standard Limit
Less than 0.05 mm
0005632 0.07 mm
(0.0019 in.)
(0.0027 in.)
Figure 5-48 (at 100 mm (3.936 in.))
Figure 5-50

1 – Connecting Rod
2 – Piston Pin Bearing
3 – Crank Pin Bearing Inserts
4 – Connecting Rod Cap
5 – Connecting Rod Cap Bolts

Inspecting the Connecting Rod Bearing

Alignment (1)

Ensure that the connecting rod is not twisted.

• Insert the appropriate mandrel
(Figure 5-49, (3)) into both ends of the
connecting rod.

(2) 0005634

Figure 5-50
1 – Connecting Rod Tool
2 – Twist Measurement Using a Rod Alignment
Tool

6LY3 Service Manual 5-41

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 ENGINE Inspecting the Cylinder Block and Components

Inspecting the Connecting Rod Side Measuring Crank Pin Oil Clearance
Clearance • Measure the crank pin outside diameter.
• Install the connecting rod to the crankshaft. • Measure the crank pin bearing inside diameter.
• Check the side clearance as shown in • Calculate the oil clearance from the difference of
Figure 5-51 and compare values with the stated the measured values. (See Measuring the Crank
limits. Pins and the Main Bearing Journals on page 5-46
for measuring the crank pin outside diameter.)
Connecting Rod Side Clearance
• Replace the crank pin bearing if the oil clearance
Standard Limit
exceeds the stated limits.
0.20-0.40 mm 0.45 mm
(0.0078-0.0157 in.) (0.0177 in.) • Correct the crankshaft by grinding to a uniform
Figure 5-51
undersized dimension (if available).
• Use an oversized bearing insert in the connecting
rod, if available (Figure 5-52). NOTICE: When
measuring the inside diameter of connecting rod
bearing inserts, install the bearing inserts
correctly and tighten the connecting rod cap bolts
to the standard torque.

Rod Bolt Torque

132.1-141.9 N·m
(13.5-14.5 kgf·m)
(1) (97.4-104.6 lb-ft)
0005635

Figure 5-51 Item Standard Limit

65.000-65.045 mm 65.100 mm
1 – Thickness Gauge Rod Bearing ID
(2.5590-2.5608 in.) (2.5629 in.)
64.952-64.964 mm 64.902 mm
Inspecting the Crank Pin Bearings Crank Pin O.D.
(2.5571-2.5576 in.) (2.5551 in.)
Check for flaking, melting or seizure on the contact Bearing 1.987-2.000 mm
surface of the crank pin bearings. —
Thickness (0.0782-0.0787 in.)
0.036-0.093 mm 0.160 mm
Clearance
(0.0014-0.0036 in.) (0.0062 in.)

An alternate procedure for measuring crank pin oil

clearance is to use a plastic gauge.

5-42 6LY3 Service Manual

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 Inspecting the Cylinder Block and Components ENGINE
12/05

Precautions for inspecting the crank pin

Figure 5-52

clearances:
• Wash the crank pin surface thoroughly.
• Clean the large end of the connecting rod and
install the crankshaft bearing inserts. Check that
(1) the bearing inserts fit properly.
• Match the alignment marks (Figure 5-54, (1)) on
the rod cap and connecting rod.
Figure 5-54

(1)
0005636
(2)
Figure 5-52
1 – Cylinder Gauge
• Lay the plastic gauge (Figure 5-53, (1)) on the
surface of the bearing insert in the connecting
rod.
Figure 5-53

0005638
(1)
Figure 5-54
1 – Alignment Mark
2 – Index Mark
• Coat the threads of the cap bolts with engine oil.
• Install the connecting rod to the crankshaft and
tighten the bolts to the specified torque.
If a torque wrench is not available, make index
0005637
marks (Figure 5-54, (2)) on the bolt heads and the
Figure 5-53 large end cap (to indicate the proper torque
position) and retighten the bolts to those positions.
1 – Plastic Gauge
• Make sure there is no sand, metal cuttings or
• Install the connecting rod on the crank pin and
other debris in the oil.
tighten to the standard torque.
• Make sure the crankshaft is not scratched.
• Remove the connecting rod and measure the
plastic gauge with measuring paper. • Clean and clear all oil holes.

6LY3 Service Manual 5-43

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 ENGINE Inspecting the Cylinder Block and Components

Inspecting the Piston Pin Bearing Inspecting the Crankshaft

Excessive wear to the piston pin bearing may result The crank pins and crank journals have been
in damage to the piston pin and / or the piston itself. induction-hardened for superior durability. The
• Measure the inside diameter of the piston pin crankshaft (Figure 5-56, (2)) is designed with
bearing. balance weights (Figure 5-56, (1)) for minimum
vibration.
• Measure the outside diameter of the piston pin
See Measuring the Piston Pin on page 5-38. The crankshaft main bearings (Figure 5-56, (3))
are the hanger type. The upper bearing insert
• Calculate the oil clearance from the difference of (cylinder block side) is designed with an oil groove.
the two values. There is no oil groove on the lower bearing insert
(bearing cap side). The main bearing on the
• Compare readings with the specifications given. flywheel end is equipped with a thrust bearing
(Figure 5-56, (9)), which supports thrust loads of
Piston Pin Bushing Inside Diameter the engine.
Standard Limit Figure 5-56

37.025-37.040 mm 37.100 mm (1)

(1.457-1.458 in.) (1.460 in.) (2)

Oil Clearance (3)

(4)
Standard Limit (9)
0.025-0.046 mm 0.110 mm
(0.0009-0.0018 in.) (0.0043 in.)
(5)
NOTICE: The piston pin bearing is a
non-serviceable copper alloy bushing that is (8)
factory-installed. The piston pin bearing comes
installed with the connecting rod assembly. (7)
Figure 5-55

(6) 0005641

Figure 5-56

(1) 1 – Balance Weight

2 – Crankshaft
3 – Main Bearing (Basic)
0005639 4 – Thrust Bearing
Figure 5-55 5 – Main Bearing (Intermediate)
6 – Main Bearing Cap (Intermediate)
1 – Cylinder Gauge 7 – Main Bearing Bolt
8 – Main Bearing Cap (Basic)
9 – Thrust Bearing (Flywheel End)

5-44 6LY3 Service Manual

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 Inspecting the Cylinder Block and Components ENGINE
12/05

Inspecting the Crankshaft Pins and Inspecting the Crankshaft Bend and
Bearings Deflection
• Perform a dye penetrant inspection of the • Support the crankshaft on V-blocks at both ends
crankshaft main bearing journals and the main bearing journals.
connecting rod pins (Figure 5-57).
• Rotate the crankshaft and measure the deflection
• Replace the crankshaft if any cracks or other (Figure 5-58, (1)) of the center journal with a dial
significant damage is found. indicator (Figure 5-59, (1)).
Figure 5-57 Figure 5-58

(2)

(1)

0005643

Figure 5-58
1 – Deflection
0005642 2 – Bend
Figure 5-59

1/2
Figure 5-57 1/2

(1)
0005644

Figure 5-59
1 – Dial Indicator
• Compare reading with specified limit.

Crankshaft Bend Limit

1/2 the Dial Gauge Reading
0.03 mm
(0.0011 in.)

6LY3 Service Manual 5-45

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 ENGINE Inspecting the Cylinder Block and Components

Measuring the Crank Pins and the Main

Bearing Journals Crank Pin
Standard Limit
• Measure the outside diameter, roundness and
taper at each crank pin and journal as shown in 64.952-64.964 mm 64.90 mm
Outside Diameter
(2.5571-2.5576 in.) (2.5551 in.)
Figure 5-60 and Figure 5-61.
0.036-0.093 mm 0.160 mm
Oil Clearance
(0.0014-0.0036 in.) (0.0062 in.)
Figure 5-60

Crank Journal
Standard Limit
74.952-74.964 mm 74.90 mm
Outside Diameter
(2.9508-2.9513 in.) (0.0062 in.)
0.036-0.093 mm 0.15 mm
Oil Clearance
(0.0014-0.0036 in.)) (0.0059 in.)

Inspecting the End Play of the Crankshaft

• Assemble the crankshaft to the engine block.
0005645
• Tighten the main bearing caps to the specified
Figure 5-60 torque.
Figure 5-61

• Move the crankshaft along its horizontal axis from

end to end.
• Install a dial indicator (Figure 5-62, (1)) on one
end of the crankshaft to measure crankshaft end
play.
Figure 5-62

(1)
0005646

Figure 5-61
• Resurface the crankshaft pins and main bearing
journals if measurements exceed the listed
specifications.
• Replace if the defect is excessive.

Crankshaft Pin and Main Bearing Journals

Item Limit (Diameter) 0005647

0.01 mm
Roundness / Taper Figure 5-62
(0.0003 in.)

NOTICE: To determine the oil clearance of the 1 – Dial Indicator

crank pin, measure the inside diameter of the • Replace the thrust bearing if it is worn beyond the
connecting rod crank pin bearing. stated limit.

Crankshaft Side Clearance

Standard Limit
0.132-0.223 mm 0.29 mm
(0.0051-0.0087 in.) (0.0114 in.)

5-46 6LY3 Service Manual

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 Inspecting the Cylinder Block and Components ENGINE
12/05

Inspecting the Main Bearings 6. Measure the inner diameter of the main bearing
1. Check each bearing insert for flaking material, inserts.
seizure or burning of the bearing surface.
Main Bearing Bolt Torque
2. Replace the bearings if any discrepancies are
245-265 N·m
found.
New Bolt (25.0-27.0 kgf·m)
3. Investigate the cause of any problems (180-195 lb-ft)
discovered with the main or connecting rod 225-245 N·m
bearings. Used Bolt (23.0-25.0 kgf·m)
(166-180 lb-ft)
4. Install the main bearing inserts.
Figure 5-63

(2)
Bearing Inside Diameter
(3)
(1) Standard Limit
75.000-75.045 mm
—
(2.9527-2.9545 in.)
(4)

(7) Bearing Thickness

Standard Limit
(6)
2.487-2.500 mm
—
(0.0979-0.0984 in.)

(5) 0005648 NOTICE: When assembling the bearing cap, keep

Figure 5-63 the following in mind:

1 – Thrust Bearing (Flywheel End) 1. The lower bearing insert (cap side) has no oil
2 – Main Bearing (Basic) groove.
3 – Thrust Bearing (Inboard) 2. The upper bearing insert (block side) has an oil
4 – Main Bearing (Intermediate) groove.
5 – Main Bearing Cap (Intermediate)
6 – Main Bearing Cap Bolt 3. Check the cylinder block alignment number.
7 – Main Bearing Cap 4. The “FW” on the cap must face the flywheel end
5. Tighten the cap to the specified torque. of the engine.

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 ENGINE Inspecting the Cylinder Block and Components

Inspecting the Camshaft and Tappets

Figure 5-65

(1)
The camshaft (Figure 5-64, (1)) is normalized. The (2)
cam lobes and bearing surfaces are surface
hardened and ground with a curve that minimizes
the repeated shocks on the valve seats and
maximizes valve seat life.
Figure 5-64

(2)
(1)

(3)
(4)
(5)
(6)
(3) 0005650

0005649
Figure 5-65
Figure 5-64 1 – Cam Gear
2 – Thrust Metal
1 – Camshaft 3 – Side Clearance
2 – Push Rod
3 – Tappet • Measure the height of each cam lobe as shown in
4 – Camshaft Bearing Figure 5-66.
5 – Thrust Bearing Figure 5-66

6 – Camshaft Gear

Inspecting the Camshaft Side Clearance

NOTICE: Measure the thrust clearance before
disassembling.
The cam gear (Figure 5-65, (1)) and camshaft are
assembled using a shrink-fit. Use caution when
replacing the cam thrust bearing.

Camshaft Side Clearance

Standard Limit
0.05-0.20 mm 0.29 mm 0005651
(0.0019-0.0078 in.) (0.0114 in.)
Figure 5-66
• Replace the cam if any lobes are worn beyond
the stated limit.

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 Inspecting the Cylinder Block and Components ENGINE
12/05

Inspecting the Camshaft for Straightness

Intake Cam Height • Support both ends of the camshaft on V-blocks.
Standard Limit
• Place a dial indicator at the central bearing area
49.435-49.565 mm 49.185 mm (Figure 5-67, (1)) and rotate the camshaft on the
(1.9462-1.9513 in.) (1.9364 in.)
V-blocks.
Figure 5-67

Exhaust Cam Height

Standard Limit
48.135-48.265 mm 48.110 mm
(1.8950-1.9001 in.) (1.9334 in.) (1)

Measuring the Camshaft Bearings

Measure the outside diameter of the camshaft
bearing with a micrometer.
The bearing oil clearance is calculated by
subtracting the measured camshaft outside
diameter from the inside diameter of the camshaft 0005652
bearing. The camshaft bearing at the water pump
end is measured with a cylinder gauge, after it is Figure 5-67
installed in the block. Replace if they exceed the
stated limits or are damaged in any way. 1 – Central Bearing
• Measure for variations.
Cam Shaft Bearing Specifications • Replace camshaft if it measures beyond the
Item Standard Limit stated limits. NOTICE: The reading on the dial
56.980-57.050 mm 57.130 mm indicator is divided by two to determine the
Bushing ID camshaft bend.
(2.2433-2.2460 in.) (2.2452 in.)
56.910-59.940 mm 56.880 mm
Camshaft OD
(2.2405-2.3598 in.) (2.2393 in.) Camshaft Bend Limit
0.040-0.140 mm 0.250 mm 0.02 mm (0.0007 in.)
Oil Clearance
(0.0015-0.0055 in.) (0.0098 in.)

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 ENGINE Inspecting the Cylinder Block and Components

Inspecting the Tappets • Measure the outer diameter of the tappet

(Figure 5-71).
The tappets are offset (Figure 5-68, (1)) to rotate
during operation and prevent uneven wear. • Replace if worn beyond the stated limits.
Figure 5-68

Tappet Specifications
Standard Limit
Tappet Stem Outside 14.218-14.233 mm 14.17 mm
(1) (1) Diameter (0.5597-0.5603 in.) (0.5578 in.)
Tappet Guide Hole
14.249-14.270 mm 14.30 mm
Inside Diameter
(0.5609 -0.5618 in.) (0.5629 in.)
(cylinder block)
0005654
0.016-0.052 mm 0.10 mm
Oil Clearance
Figure 5-68 (0.0006-0.0020 in.) (0.0039 in.)
Figure 5-71

1 – Offset
Figure 5-69

(1)

0005655

Figure 5-69
0005656

1 – Notches
Figure 5-71
NOTICE: When removing tappets, keep them
separate from each cylinder. The exhaust valve
tappet side has two notches (Figure 5-69, (1)) on
the top of the tappet. The tappet for the intake valve
has no notch.
• Check the contact area of each tappet.
• Replace if excessively or unevenly worn.
Figure 5-70

(1) (2) 0005653

Figure 5-70
1 – Abnormal Contact Area
2 – Normal Contact Area

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 Inspecting the Cylinder Block and Components ENGINE
12/05

Inspecting the Push Rods Inspecting the Idler Gear

• Measure the length and bend of the push rods as The idler gear bearing is a press-fit in the gear.
shown in Figure 5-72.
• Measure the bearing (Figure 5-73, (2)) inner
diameter.
Figure 5-72

• Measure the outer diameter of the idler gear shaft

(Figure 5-73, (3)).
• Replace the bearing and / or idler gear shaft if the
oil clearance exceeds the stated limit.
(1)
Idle Gear Specifications
0005657
Standard Limit
Figure 5-72
53.950-53.975 mm 53.88 mm
Idler Shaft Diameter
1 – Feeler Gauge (2.1240-2.1249 in.) (2.1212 in.)

• Replace if beyond the stated limits. Idler Gear Bushing Inside 54.000-54.025 mm 54.08 mm
Diameter (2.1259-2.1269 in.) (2.1291 in.)
0.025-0.075 mm 0.15 mm
Push Rod Specifications Oil Clearance
(0.0009-0.0029 in.) (0.0059 in.)
Standard Limit Figure 5-73

Less than 0.03 mm 0.3 mm

Push Rod Bend
(0.0011 in.) (0.011 in.)
Push Rod Diameter 10 mm (0.3936 in.) —

Inspecting the Timing Gear

The timing gear is a helical design for quiet
operation and is specially treated for high durability.
1. Inspect the gears and replace if the teeth are
damaged or worn.
(1)
2. Measure the backlash of all gears that mesh
and replace the gears as a set if wear exceeds (2)
the stated limit. NOTICE: If backlash is (3) 0005658

excessive, it will not only result in excessive

noise and gear damage, but also lead to bad Figure 5-73
valve and fuel injection timing and a decrease in 1 – Idler Gear
engine performance. 2 – Idler Gear Bearing
3 – Idler Gear Shaft
Timing Gear Backlash
Standard Limit
0.08-0.16 mm 0.25 mm
(0.0031-0.0062 in.) (0.0098 in.)

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 ENGINE Inspecting the Cylinder Block and Components

Indexing the Gear Timing Marks (1) (2)

Align the timing marks, as shown in Figure 5-74, (3)
on each gear when assembling the gear train
(“A”, “B” and “C”).
Figure 5-74

(1) (2)
(3)
(4)
(5)
B C
A

(4) (6)
(5)

(1)
(4)
(6)

0005660

(2) Figure 5-74

C

1 – Fuel Injection Pump Gear

2 – Camshaft Gear
(4) 3 – Seawater Pump Gear
4 – Idler Gear
5 – Crankshaft Gear
6 – Oil Pump Gear

(5)
0005659

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 Inspecting the Cylinder Block and Components ENGINE
12/05

Inspecting the Flywheel and Housing Replacing the Ring Gear

The function of the flywheel (Figure 5-75, (1)) is to • Heat the ring gear evenly at its circumference.
dampen the fluctuating torque loads delivered by
the crankshaft and deliver smooth crankshaft • Use a copper bar (Figure 5-75, (2)) or other soft
rotation. It does so by resisting intermittent metal and carefully tap the ring gear off the
rotational force during the power stroke and flywheel evenly around the whole circumference.
provides inertial momentum during the non-power
strokes. The flywheel is secured to the crankshaft Shrink Range of the Ring Gear
at the end opposite the drive shaft housing with six 0.21-0.45 mm
bolts. It is covered by the flywheel housing which is (0.0082-0.0177 in.)
bolted to the cylinder block. Figure 5-75

(1)
The damper disc is installed on the crankshaft side
of the flywheel. The rotation of the crankshaft is
transmitted through this disc to the input shaft of
the reduction and reversing gear. The reduction
and reversing gear is installed to the flywheel
housing.
The flywheel is balanced by holes drilled in its (4)
circumference.
The ring gear (Figure 5-75, (4)) is shrink fit to the (2)
circumference of the flywheel. The ring gear serves (3) 0005661
to start the engine by meshing with the starter
Figure 5-75
motor pinion.
1 – Flywheel
The stamped letter and line, which show top dead 2 – Copper Bar
center of each cylinder, are positioned on the 3 – Wooden Stand
flywheel circumference. By matching these marks 4 – Ring Gear
with the arrow mark at the hole of the flywheel
housing, the rotary position of the crankshaft can Positioning Top Dead Center
be ascertained in order to adjust tappet clearance
The top dead center is set by matching index marks
or fuel injection timing.
(Figure 5-76, (2)) on the flywheel in the hole of
flywheel housing (Figure 5-76, (1)).
Flywheel Specifications Figure 5-76

392 mm (1)
Outside Diameter of the Flywheel
(15.433 in.)
73.9 mm
Width of the Flywheel
(2.909 in.)
2.95 kgf·m2
GD2 Value
(21.337 lb-ft)
(2)
Pitch Circle Diameter 70 mm
of the Bolts (2.755 in.)
6-Ø16.5 mm
Fixing Part of No. of Thread Holes
(0.6496 in.)
the Crankshaft
95 mm 0005662
Fit Joint Diameter (+0.035, 0)
(3.7401 in.) Figure 5-76
387 mm 1 – Flywheel Housing
Center Diameter
Ring Gear (15.2361 in.) 2 – Matching Index Marks
No. of Teeth 129

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 ENGINE Inspecting the Cylinder Block and Components

Inspecting the Intake / Exhaust Exhaust System Components

System Exhaust gas (Figure 5-78, (4) and (5)) enters the
turbocharger (Figure 5-78, (6)) through the
Intake System Components exhaust manifold (Figure 5-77, (1)) (in the coolant
Air enters the intake silencer (Figure 5-77, (4)) tank) which is installed on the cylinder head
which is installed on the turbocharger (Figure 5-77, (2)). The exhaust gas flows to the
(Figure 5-77, (5)). It travels through the mixing elbow (Figure 5-78, (2)), through the
turbocharger and the intercooler turbocharger, and is discharged from the vessel
(Figure 5-77, (3)) and is fed to the intake manifold. along with seawater.
Figure 5-78

(2)
Figure 5-77

(1) (2)
Air
Exhaust gas
(1) (3)

(6)

(4)

(5) (3) (5) 0006315

(4)
0006314
Figure 5-78
Figure 5-77 1 – Exhaust Bend
2 – Mixing Elbow
1 – Exhaust Manifold 3 – Seawater Pipe
2 – Cylinder Head 4 – Exhaust Gas
3 – Intercooler 5 – Exhaust Gas
4 – Intake Silencer 6 – Turbocharger
5 – Turbocharger
When the inside of the intake manifold becomes Inspecting the Mixing Elbow
dirty, air resistance increases and reduces engine The mixing elbow is attached to the exhaust outlet
power. Check the inside of the intake manifold and of the turbocharger. After extended use, check and
the inlet of the air silencer at their scheduled clean the mixing elbow as outlined below:
inspection interval. Clean and clear, as necessary.
1. Clean any dirt and scale out of the gas and
Clean the mating surfaces of the intake manifold seawater lines.
and cylinder head when assembling. Ensure there 2. Repair cracks or other damage to welded parts.
is no air leak. Replace parts if needed.
NEVER operate an engine with the intake air 3. Inspect all gaskets and replace as necessary.
silencer removed.

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 Assembling the Engine and Components ENGINE
12/05

ASSEMBLING THE ENGINE AND

Figure 5-79

COMPONENTS
Precautions Before Assembling the
Engine
• Thoroughly clean and inspect all parts to be
assembled. (1)
0005779
• Coat sliding and rotating parts with new engine oil
when assembling. Figure 5-79

• Replace all gaskets and O-rings. 1 – Cylinder Block

• Use the proper sealing material as needed to Installing the Tappets

prevent oil / water leaks.
Check that each tappet (Figure 5-80, (1)) is
• Check the oil and thrust clearances of parts when installed in the appropriate cylinder and valve
assembling. (exhaust or intake). Apply a coat of engine oil to
each tappet before installation. After fitting, check
• Make sure to use the correct hardware and that each tappet operates freely and smoothly.
fasteners.
Figure 5-80

• Torque the main bolts and nuts to the specified (1)

torque value. Avoid over-tightening the aluminum (2)
alloy part retaining bolts.
• Align the index marks (if any) when assembling.
Make sure the correct part sets are used for
bearings, pistons and other assemblies where
required.
Clean all parts with an approved cleaning solvent,
diesel fuel or inspect all engine parts and compare
with stated wear limits. NOTICE: If dirt, shavings
and other debris are allowed to remain in the
engine, seizure, premature wear, intermittent 0005780
failures and poor engine performance may result.
Figure 5-80
Completely clean each oil hole. After cleaning,
check that no scaling remains anywhere on the 1 – Tappet
cylinder block (Figure 5-79, (1)). Place wooden 2 – Cylinder Block
blocks on the floor and set the cylinder block upside
down (with the cylinder head mounting surface
facing down). Keep the positioning pins clear of the
wooden blocks.

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 ENGINE Assembling the Engine and Components

Installing the Piston Cooling Nozzles Installing the Camshaft Bearings

1. Place each piston cooling nozzle 1. Apply oil to the outer surface of each bearing
(Figure 5-81, (1)). (Figure 5-82, (1)) and mounting surface of the
2. Ensure that the nozzle end is positioned on the cylinder block and then press the bearing into
piston head side. its position using a driving tool. Check the
position of each oil hole. More than 2/3 area of
3. Check that the cooling nozzle does not touch a hole should be aligned.
the cylinder block.
Forward: A=2
4. Install the piston cooling nozzles for each Middle: A=1.5
piston. Aft: A=0.5
Piston Cooling Nozzle Torque Figure 5-82

19.6 N·m (2.0 kgf·m) (14.4 lb-ft)

(1)

Figure 5-81

A
(1)

0005782

Figure 5-82
1 – Bearing
0005781 2. After installation, check each bearing for
Figure 5-81 distortion by measuring the inner diameter of
bearing.
1 – Piston Cooling Nozzle
Inner Diameter After Press-Fitting
57 + 0.05 / -0.02 mm
(2.2440 + 0.0019 / -0.0007 in.)

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 Assembling the Engine and Components ENGINE
12/05

Installing the Crankshaft 2. Lubricate each crank pin and crank journal. Set
each journal in the main bearing of the block.
1. Apply engine oil to each crank journal
(Figure 5-83, (1)) of the cylinder block 3. Lubricate both surfaces of each cap side main
(Figure 5-83, (2)) and each mating side of the bearing and install each main bearing insert to
main bearing inserts. Bearings with an oil the cap.
groove should be positioned on the upper side 4. Oil the bolt holes of each bearing cap. Install
(block side). Install thrust bearings so that oil bearing caps (Figure 5-85, (2)). Tighten each
grooves are positioned to the outside. cap bolt to the specified torque value. NOTICE:
Figure 5-83
Check that the arrow mark (Figure 5-85, (1)) on
(1) each bearing cap faces in the flywheel direction
and that the match mark on each cylinder is
correctly aligned.

Bearing Cap Bolt Torque

235 ± 10 N·m
M15, 14 Bolts (24 ± 1 kgf·m)
(173 lb-ft)
Figure 5-85

(2) (1) (2)

0005783

Figure 5-83
1 – Crank Journal
2 – Cylinder Block
Figure 5-84

0005785

Figure 5-85
1 – Arrow Mark
2 – Bearing Caps

0005784

Figure 5-84

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 ENGINE Assembling the Engine and Components

5. Check that the crankshaft rotates smoothly.

Figure 5-87

6. Set a dial indicator (Figure 5-86, (1)) on the

cylinder block and measure end play of the (1)
crankshaft.
Figure 5-86

(1)

0005787

Figure 5-87
1 – Oil Pump Idler Gear
2. Install the oil pump (Figure 5-88, (1)) with the
0005786 position pin. Secure the pump by tightening
three M10 x 55 mm bolts to the specified torque
Figure 5-86 value.
1 – Dial Indicator Figure 5-88

End Play of the Crankshaft (1)

0.132-0.223 mm
(0.0051-0.0087 in.)

Installing the Oil Pump

1. Set the oil pump idler gear (Figure 5-87, (1))
and shaft in the main bearing cap.

Oil Pump Idler Gear Specifications

0.10 - 0.30 mm
Side Clearance
(0.0039-0.0118 in.)
64 ± 2 N·m 0005788
Tightening Torque (6.5 ± 0.2 kgf·m)
(47 ± 1.4 lb-ft) Figure 5-88
1 – Oil Pump
3. Measure the gear backlash between the oil
pump and idler gear and compare to the value
specified below:

Gear Backlash
0.12 ± 0.04 mm
(0.0047 ± 0.001)

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 Assembling the Engine and Components ENGINE
12/05

Installing the Drive Shaft Housing 2. Place the thrust plate and secure it by
tightening the two M8 x 16 mm bolts.
Apply sealant gasket to the drive shaft housing and
fit the drive shaft housing to the cylinder body using 3. Check end play of the camshaft. NOTICE: If the
a dowel pin to position case. cam gear is removed from the camshaft, place
thrust bearing before installing the gear. Heat
Secure the drive shaft housing by tightening bolt the cam gear to between 180°C (356°F) and
listed below: 200°C (392°F) press it in place. Interference:
0.023 to 0.060 mm.
1. Four M8 x 45 mm bolts
2. Two M8 x 80 mm bolts Camshaft Side Clearance
Torque bolts to the specified value. 0.05-0.20 mm
Figure 5-89
(0.0019-0.0078 in.)

Installing the Piston Assemblies

1. The piston and connecting rod should be
(1) (1) assembled with the embossed connecting rod
(1) mark (Figure 5-91, (4)) and the stamped “FW”
(2) (1) mark (Figure 5-91, (3)) on the top of the piston
facing in the same direction as shown in
Figure 5-91. Install the piston and connecting
rod assembly with those marks facing the
(2) flywheel end of the engine.
0005789
Figure 5-91

Figure 5-89
(2)
1 – M8 x 45 mm bolts (1)
2 – M8 x 80 mm bolts

Installing the Camshaft

(3)
1. Apply oil to the bearings of the camshaft and
install the camshaft (Figure 5-90, (1)).
Figure 5-90

(4)

0005791

Figure 5-91
(1)
1 – Camshaft Side
2 – Fuel Injection Pump Side
3 – “FW” Mark
4 – Embossed Connecting Rod Mark
0005790
(Flywheel End)
2. Orient the connecting rod to each piston
Figure 5-90 (Figure 5-91). NOTICE: Coat all parts with
1 – Camshaft clean engine oil.

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 ENGINE Assembling the Engine and Components

3. Fit the piston rings and oil ring to each piston Installing the Oil Intake and Delivery
while checking that cutouts of rings are offset
120° from each other.
Tubes
4. Oil sleeve, outer surface of the piston and rod 1. Fit the flange end of the oil delivery pipe
bearings. (Figure 5-93, (2)) and install the other end into
the oil pan spacer.
5. Rotate the crankshaft pin of the corresponding Figure 5-93

piston to top position. (1)

6. Check the direction of the piston. (2)
7. Insert the piston into the cylinder using the
piston insertion tool.
8. Rotate the crankshaft while keeping the piston
rod seated on the crank pin until the piston is at
bottom dead center (BDC).
9. Install the rod cap. Apply oil to the bolt threads
while checking match marks and tighten the rod
cap bolts.
0005793

Rod Bolt Torque Figure 5-93

132.1-141.9 N·m
(13.5-14.5 kgf·m) 1 – Oil Intake Pipe
(97.4-104.6 lb-ft) 2 – Oil Delivery Pipe

10. Repeat this process for each piston. 2. Fit the oil intake pipe (Figure 5-93, (1)) into
position.
Installing the Oil Pan Spacer 3. Secure the flange ends with two M8 x 25 mm
Apply sealant to the oil pan spacer mating surface and two M8 x 16 mm bolts.
and then place the spacer (Figure 5-92, (1)) to the 4. Install the mounting bracket to the oil intake
cylinder block (Figure 5-92, (2)). Secure the spacer pipe and secure with two M8 x 25 mm bolts.
with two M8 x 35 mm bolts and two M8 x 30 mm 5. Torque all bolts to the specified values.
bolts. Torque bolts to the specified value.
Figure 5-92

(1)

(2)

0005792

Figure 5-92
1 – Spacer
2 – Cylinder Block

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 Assembling the Engine and Components ENGINE
12/05

Installing the Oil Pan Installing the Flywheel Housing Oil

1. Apply sealant bead to the mating surface of the Seal
oil pan (Figure 5-94, (1)). See Sealants, 1. Grease the outer circumference of the lip
Adhesives, Lubricants and Cleaners on portion of the oil seal (Figure 5-95, (2)).
page 5-16. Figure 5-95

Figure 5-94

(1)
(1)

(2)

0005795

Figure 5-95
1 – Cylinder Block
0005794
2 – Oil Seal
Figure 5-94 2. Install the oil seal into the flywheel housing.
1 – Oil Pan Installing the Flywheel Housing
2. Fit the pan to the oil pan spacer. 1. Use the two pilot pins as a guide, and fit the
3. Secure the oil pan with: flywheel housing to the engine block. Avoid
• Four M8 x 25 mm bolts damage to the oil seal.
• 26 M8 x 120 mm bolts 2. Secure the flywheel housing with nine
M10 x 30 mm bolts and five M10 x 35 mm bolts
• Two M8 x 10 mm bolts
as shown in Figure 5-96.
• Two M8 x 90 mm bolts
Spigot Joint Runout of the Flywheel Housing
0.25 mm
(0.0098 in.)
Figure 5-96

(1) (1)
(1)
(1) (1)
(1) (1)
(1)
(1)
(2)
(2)
(2) (2) (2)

0005796

Figure 5-96
1 – M10 x 30 mm bolts
2 – M10 x 35 mm bolts

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 ENGINE Assembling the Engine and Components

Installing the Seawater Pump 2. Secure the idler gear shaft with two
M8 x 25 mm bolts. Tighten bolts to the specified
Fit the seawater pump (Figure 5-97, (3)) to the torque values.
drive shaft housing (Figure 5-97, (1)). Secure the
pump with two M8 x 20 mm bolts and two M8 nuts. 3. Measure the side clearance and compare with
the following specified value.
Figure 5-97

(1)
(2) Idler Gear Side Clearance
0.12-0.22 mm
(0.0047-0.0086 in.)

4. Bring and hold the No. 6 piston (water pump

end) to top dead center (TDC).
5. Orient the idler gear (Figure 5-99, (3)) as
necessary to set the “A” (Figure 5-99, (2))
between the two embossed marks on the crank
gear and the “C” (Figure 5-99, (1)) between the
two embossed marks on the cam gear.
Figure 5-99

(3)

(3) (1)
0005797

Figure 5-97
1 – Drive Shaft Housing
2 – Cylinder Block
3 – Seawater Pump

Installing the Idler Gear

1. Align the oil hole (Figure 5-98, (3)) in the idler (2)
spindle shaft (Figure 5-98, (2)) with the oil hole
in the engine block. The positioning mark on the 0005799

spindle shaft should be on top Figure 5-99

(Figure 5-98, (1)).
Figure 5-98 1 – Adjusting Mark “C” for Cam Gear
(1) 2 – Adjusting Mark “A” for Cam Gear
3 – Idler Gear
6. Lubricate and secure the idler gear to its
(2) spindle with four M10 bolts.
7. Tighten bolts to the following specified torque
value.

(3)

0005798

Figure 5-98
1 – Positioning Mark
2 – Spindle Shaft
3 – Oil Hole

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 Assembling the Engine and Components ENGINE
12/05

Installing the Oil Pressure Regulating Installing the Fuel Injection Pump
Valve See Installing the Fuel Injection Pump on
Fit the oil pressure regulating valve assembly page 6-17.
(Figure 5-100, (1)) to the cylinder block and secure
with three M8 x 45 mm bolts and one M8 x 50 mm
Installing the Flywheel
bolt. 1. Use the pilot pin to orient the flywheel. NOTICE:
Figure 5-100
Use two M10 x 1.5 mm bolts to help guide the
(1) flywheel. Oil the threads and flanges.
2. Secure the flywheel with six M16 x 47 mm bolts.
Tighten the bolts to the following specified
torque in the order shown in Figure 5-102.

Flywheel Bolt Torque

294 ± 10 N·m
(30 ± kgf·m)
(216 ± 7 lb-ft)
Figure 5-102

0005800
1
4 6
Figure 5-100 2 3
5
1 – Oil Pressure Regulating Valve Assembly

Installing the Coolant Passage Cover 0005804

1. Apply sealant bead to the coolant passage Figure 5-102

cover (Figure 5-101, (1)).
Figure 5-101

(2)
(1)

0005801

Figure 5-101
1 – Coolant Passage Cover
2 – Cylinder Block
2. Secure with bolts.

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 ENGINE Assembling the Engine and Components

Installing the Cylinder Head

Figure 5-104

(4)
Assembly 26
20
18
12
10
3
1
5
7
13
15
21
23

NOTICE: Ensure that the mating surfaces of the (3) 1 2 3 4 5 6 (1)

cylinder head and the engine block are absolutely 24 16 8 2 9 17 25
clean of all dirt and any oil film. Inspect each 22 14 6 4 11 19
cylinder bore and remove any debris, lint and / or (2)
0005806
shavings of any kind.
Figure 5-104
1. Measure the flatness of the cylinder head and
1 – Coolant Pump End
the engine block to ensure dimensions are
2 – Operation Side
within the specified values. See Inspecting the 3 – Flywheel End
Cylinder Head on page 5-28. 4 – Non-Operation Side
2. Set a new, clean and dry head gasket 6. Set (do not drop) 13 M14 x 149 mm head bolts
(Figure 5-103, (1)) on the engine block using into the holes on the non-operation side
the pilot pins to guide gasket position. (Figure 5-104, (4)) of the engine
(Figure 5-104).
Figure 5-103

7. Finger tighten all of the head bolts.

(1) 8. Tighten the head bolts in the sequence shown
in Figure 5-104 in three stages. NOTICE: Use
the values for the new bolts or the used bolts.
9. Tighten all the head bolts to the specified
torque value shown in the 1st stage of the
following table. Use the proper torque sequence
as shown in Figure 5-104.

0005805 Cylinder Head Bolt Torque

Figure 5-103 1st Stage 2nd Stage 3rd Stage
1 – Head Gasket Used 108 N·m 167 N·m 206 ± 10 N·m
Head (11 kgf·m) (17 kgf·m) (21 ± 10 kgf·m)
3. Set the preassembled cylinder head gently on Bolts (79.6 lb-ft) (123.1 lb-ft) (144.5 lb-ft)
top of the head gasket using the pilot pins to
118 N·m 177 N·m 226 ± 10 N·m
position the cylinder head. New Head
(12.0 kgf·m) (18.0 kgf·m) (23 ± 1 kgf·m)
Bolts
4. Oil the threads and flanges of each head bolt. (87 lb-ft) (130.5 lb-ft) (159.3 lb-ft)

5. Set (do not drop) 13 M14 x 139 mm head bolts 10. Repeat this tightening sequence and bring all
into the holes on the operation side the head bolts to the torque value given in the
(Figure 5-104, (2)) of the engine 2nd stage.
(Figure 5-104).
11. Repeat the tightening sequence and bring all
the head bolts to the torque value given in the
3rd stage. NOTICE: Head identification No. is
marked on the upper surface on the flywheel
end.

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 Assembling the Engine and Components ENGINE
12/05

Installing the Intercooler

Figure 5-105

(1)
(2) 1. Apply silicone grease to the O-ring
(Figure 5-106, (1)). Fit the O-ring to the
flywheel end (Figure 5-106, (4)) of the cooler
core and insert the core into the cooler body.
NOTICE: Align marks of the core and the case
(Figure 5-107).
Figure 5-106

(1)

0005807 (4) (2)

Figure 5-105
1 – Torque Wrench 0005808
(3)
2 – Cylinder Head
Figure 5-106
1 – O-Ring
2 – Coolant Pump End
3 – Separator Packing
4 – Flywheel End
Figure 5-107

0005809

Figure 5-107
2. Apply silicone grease to the O-rings, fit two
O-rings to both sides of the cooler core and fit
the side covers to the cooler.
3. Fit the intercooler to the engine.

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 ENGINE Assembling the Engine and Components

Installing the Intake Manifold 6. Measure valve clearances and ensure they fall
within the following specifications.
Fit the intake manifold assembly and secure it by Figure 5-109

tightening the bolts. 20 12 3 5 13 21

26 18 10 1 7 15 23

Installing the Marine Gear (1) 1 2 3 4 5 6 (2)

Install the marine gear to the flywheel housing. 24 16 8 2 9 17 25

Refer to the Service Manual for the marine gear 22 14 6 4 11 19

procedure. (3) 0005615

Installing the Push Rod and Rocker Figure 5-109

Arm Shaft Assembly 1 – Flywheel End
1. Check the condition of each push rod. See 2 – Coolant Pump End
Inspecting the Push Rods on page 5-51. 3 – Operating Side

2. Install the push rods into each tappet. Standard Valve Clearance
3. Install the valve caps on top of each valve 0.15-0.25 mm
system. Intake Valve
(0.005-0.009 in.)
4. Position the rocker arm shaft assembly. 0.45-0.55 mm
Exhaust Valve
Figure 5-108 (0.017-0.021 in.)
(2)
(1) NOTICE: Be sure the opening and closing angles
for both intake and exhaust valves are checked
(3)
when timing gear is disassembled.
(4)
Intake Valve Open before TDC 26° ± 5°
Intake Valve Closed after BDC 56° ± 5°
Exhaust Valve Open before BDC 67° ± 5°
Exhaust Valve Closed after TDC 29° ± 5°

Installing the Rocker Arm Cover

0005810
1. Coat all of the rocker arm cover bolts
Figure 5-108 (M8 x 25 mm) with a liberal amount of clean
engine oil.
1 – Rocker Arm Shaft Assembly
2 – Exhaust Rocker Arm 2. Install the rocker arm cover.
3 – Rocker Arm Support 3. Install the lifting eye bolts to the drive shaft
4 – Intake Rocker Arm housing and to the flywheel ends of the rocker
5. Torque M8 bolts to the following specified arm cover.
values.

Rocker Arm Shaft Support Bolt Torque (M8)

26 ± 3 N·m
(2.6 ± 0.3 kgf·m)
(19.1 ± 2.2 lb-ft)

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 Assembling the Engine and Components ENGINE
12/05

Installing the Coolant Pump Installing the Drive Shaft Housing

1. Apply the correct sealant (See Sealants, Cover
Adhesives, Lubricants and Cleaners on 1. Apply the correct sealant to the mating surface
page 5-16) to both sides of the gasket of the drive shaft housing.
(Figure 5-110, (10)).
Figure 5-110
2. Use the pilot pins to position the cover.
(1) (2) 3. Secure the cover with nine M8 x 45 mm
(3) (washer-based) bolts (Figure 5-111, (1)) and
five M8 x 80 mm (washer-based) bolts
(Figure 5-111, (2)).
Figure 5-111

(2)

(1)
(4)
(5)

(6)

(10) (1)

(9) (1) 0005812

(7)
(8) Figure 5-111
0005811

1 – M8 x 45 mm
Figure 5-110 2 – M8 x 80 mm
1 – Thermostat
2 – O-Ring Installing the Crankshaft V-Pulley
3 – Cover and Damper
4 – Cylinder Head
5 – Flow from Cylinder Head 1. Position the V-pulley (Figure 5-112, (2)) on the
6 – Flow from Coolant Tank crankshaft. Install the M16 bolts and tighten the
7 – Coolant Pump bolts to the specified value. NOTICE: Keep the
8 – Flange groove of the V-pulley clean.
9 – O-Ring
10 – Gasket Crank Pulley Bolt (M16) Torque
2. Fit the coolant pump (Figure 5-110, (7)) to the 226 ± 10 N·m
mating surface of cylinder head (23 ± 1 kgf·m)
(Figure 5-110, (4)). (166.6 ± 7.3 lb-ft)

3. Install the O-ring (Figure 5-110, (2)) on the

coolant passage cover.
4. Install and tighten the bolts to the specified
torque value.

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 ENGINE Assembling the Engine and Components

Installing the Fuel Injection Nozzles

Figure 5-112

(1)
1. Fit the O-ring (Figure 5-114, (3)) to the fuel
injection nozzle (Figure 5-114, (2)) and apply
oil to outside of the O-ring. NOTICE: Replace
the O-ring every time the fuel injection nozzle is
disassembled.
Figure 5-114

(1)

(2)
(2)

0005813 (3)
Figure 5-112
(4)
1 – Engine
2 – V-Pulley
2. Install the fuel injection pump damper. If
necessary, install the caution labels on the 0005815

outside of the dampers as shown in

Figure 5-114
Figure 5-113.
Figure 5-113
1 – Fuel Nozzle Retainer
2 – Fuel Injection Nozzle
(1) 3 – O-Ring
4 – Nozzle Seat
2. Insert the nozzle seats (Figure 5-114, (4)) into
FUKOKU
the cylinder head.
3. Fit the fuel injection nozzle to the cylinder head.
NOTICE: Replace the nozzle seal every time
the fuel injection nozzle is disassembled.
(2) 4. Apply oil to the fuel nozzle retainer
(Figure 5-114, (1)) and the fuel nozzle bolt
(3) (Figure 5-115).
0005814

Figure 5-113
1 – Caution Label
2 – Damper (Crankshaft)
3 – Damper (Fuel Injection Pump)

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 Assembling the Engine and Components ENGINE
12/05

Figure 5-115 7. Insert the pipe seal (Figure 5-117, (1)) for the
(1) fuel injector line (Figure 5-117, (3)) into the
cylinder head and connect the fuel injector line
to the fuel injector nozzle (Figure 5-117, (2)).
(4) Figure 5-117

(1)
(2)

(3)
(2)
(4) (3)
0005816 0005818

Figure 5-115
(2)
1 – Bolt
2 – Washer
(1)
3 – Retainer
4 – Apply Oil
5. Fit the retainer and bolt to the fuel injection
nozzle.
6. Fasten the bolt by hand while shaking the
retainer back and forth and making the position
of the retainer stable. NOTICE: When installing
the retainer to the cylinder head, leave a gap of
at least 1.5 mm (0.059 in.) (Figure 5-116, (1))
between the retainer (Figure 5-116, (4)) and
the intake rocker arm (Figure 5-116, (5)) and at (4) 0005819
least 1 mm (0.039 in.) (Figure 5-116, (2))
between the fuel nozzle (Figure 5-116, (3)) and Figure 5-117
the retainer. 1 – Pipe Seal
Figure 5-116

2 – Fuel Injector Nozzle

(2)
(1) 3 – Fuel Injector Line
(3) 4 – Fuel Injector Line Nut
8. Tighten the fuel injector line nut
(Figure 5-117, (4)) to the following torque
value.

(4) Fuel Injector Line Nut Torque

24.5 ± 2 N·m
(2.5 ± 0.2 kgf·m)
(18 ± 1.4 lb-ft)

9. Tighten the retainer bolt for the fuel injector

(5) 0005817
nozzle to the following specified torque.
Figure 5-116 Retainer Bolt Torque
1 – 1.5 mm (0.059 in.) Gap 31.4 ± 2 N·m
2 – 1 mm (0.039 in.) Gap (3.2 ± 0.2 kgf·m)
3 – Fuel Nozzle (23.1 ± 1.4 lb-ft)
4 – Retainer
5 – Intake Rocker Arm

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 ENGINE Assembling the Engine and Components

Installing the Heat Exchanger Installing the Coolant Tank

1. Apply silicone grease to both of the O-rings 1. Fit the O-ring on the thermostat
(Figure 5-118, (2)) and install on both ends of (Figure 5-120, (2)) and insert the thermostat
the cooler core. into the coolant tank (Figure 5-120, (1)).
Figure 5-118 Figure 5-120

(2)
(1)

(2)

(1) (3)
0005823

Figure 5-120
(4)
0005820
2. Secure the coolant tank with bolts.
Figure 5-118 3. Tighten the bolts to the specified torque value.
1 – Coolant Pump End 4. Install the air line (Figure 5-121, (2)).
2 – O-Ring Figure 5-121

3 – Flywheel End (1)

4 – Separator Seal (2)
2. Insert the core into the cooler body.
3. Align the notch in the core
(Figure 5-119, (2)) with the centering hole
(Figure 5-119, (1)) in the cooler body.
Figure 5-119

(2)

(1)
(4)

(3) 0005824

Figure 5-121
1 – Coolant Plug
2 – Air Line
3 – Zinc Anode
4 – Brackets
5. Install the zinc anode
0005822
(Figure 5-121, (3)).
Figure 5-119 6. Install the brackets to the cylinder block
(Figure 5-121, (4)).
1 – Notch in Core
2 – Centering Hole
4. Fit the separator seal to both side covers (water
pump end and flywheel end). See
Figure 5-118.
5. Fit the side cover to the heat exchanger.

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 Assembling the Engine and Components ENGINE
12/05

Installing the Engine Oil Cooler 8. Install and tighten the oil tube.
1. Apply silicone grease to both of the O-rings Installing the Engine Oil Filters
(Figure 5-122, (1)) and install on both ends of
the cooler. 1. Apply a light coat of engine oil to the rubber
Figure 5-122
seal of both filters (Figure 5-124).
(1) Figure 5-124

(2)

(5) (3)

(4)
0005825 (3)
Figure 5-122 (1) (2)

1 – O-Ring 0005826

2 – Cooler Core
3 – Coolant Pump End Figure 5-124
4 – Separator Seal
1 – Full Flow Oil Filter
5 – Flywheel End
2 – Oil Filter Bracket
2. Insert the cooler core (Figure 5-122, (2)) into 3 – Bypass Oil Filter
the cooler body. 2. Turn the full flow oil filter (Figure 5-124, (1)) by
3. Align the marks on the cooler core with the hand until it makes contact with the sealing
marks on the body. surface.
3. Use a filter wrench and turn the full flow oil filter
Figure 5-123

an additional 3/4 turn.

4. Turn the bypass oil filter (Figure 5-124, (3)) by
hand until it makes contact with the sealing
surface.
5. Use a filter wrench and turn the bypass oil filter
an additional full turn.

(1)
0005893

Figure 5-123
1 – Core Alignment
4. Install the separator seal (Figure 5-122, (4)) to
the flywheel end (Figure 5-122, (5)) of the side
cover.
5. Install the end covers to the oil cooler.
6. Install the oil cooler to the engine.
7. Install the intercooler and the filter bracket to
the engine.

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 ENGINE Assembling the Engine and Components

Installing the Engine Coolant Hoses

Figure 5-125

1. Use the proper sealant and install hose elbow

“A” (Figure 5-126, (3)) to the heat exchanger
(Figure 5-125, (4)).
2. Use two hose clamps (Figure 5-125, (2)) on
each end of the hose and install the hose
between the seawater pump (Figure 5-126, (4))
and the heat exchanger. (1)
3. Use the proper sealant and install hose elbow
“B” (Figure 5-126, (8)) to the intercooler
(Figure 5-126, (6)). (2)
4. Use two hose clamps on each end of the hose (3)
and install the hose between the intercooler and
heat exchanger.
5. Install the hoses and clamps to the inlet and
outlet of the heat exchanger (Figure 5-126, (2))
and the oil cooler (Figure 5-126, (1)).
6. Install the hoses and clamps to the inlet and
outlet of the intercooler (Figure 5-126, (6))
and oil cooler (Figure 5-126, (1).

(4) 0005827

Figure 5-125
1 – Oil Cooler
2 – Hose Clamps
3 – Mixing Elbow
4 – Heat Exchanger

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 Assembling the Engine and Components ENGINE
12/05

Figure 5-126

(9)
(2)

(7)

(8)

(3)
(6)

(4)
(5)
(10)

(1)

0005828

Figure 5-126

1 – Oil Cooler 6 – Intercooler

2 – Heat Exchanger 7 – Flow from the Heat Exchanger
3 – Hose Elbow “A” 8 – Hose Elbow “B”
4 – Flow from the Seawater Pump 9 – Flow from the Marine Gear
5 – Flow to the Marine Gear 10 – Flow from the Intercooler to the Oil Cooler

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 ENGINE Assembling the Engine and Components

Installing the Engine Air Ducts Installing the Engine Turbocharger

1. Fit the air duct (Figure 5-127, (4)) to the outlet 1. Loosely assemble bracket “A”
of the turbine with a gasket (Figure 5-127, (3)) (Figure 5-128, (4)) to bracket “B”
and a V-clamp (Figure 5-127, (2)). (Figure 5-128, (5)) using two M10 x 18 bolts.
Figure 5-127 Figure 5-128

(1) (1)

(2)
(2)
(3)

(4)
(5)
(6)
(5)
(8)
(7)

(3)
0005829 0005830

Figure 5-127 (1) 1. Bolt, M10 x 22

1 – Turbocharger
2 – V-Clamp
3 – Gasket
4 – Air Duct
5 – Clamp (4)
6 – Hose
7 – Intercooler
2. Bolt, M10 x 18
8 – Air Flow from Turbocharger
3. Bolt, M10 x 18
2. Fit the air duct to inlet of the intercooler
(Figure 5-127, (7)) by using the hose (5)
(Figure 5-127, (6)) and the clamp
(Figure 5-127, (5)). (6)
0005831

Figure 5-128
1 – Turbocharger
2 – Mixing Elbow
3 – Air Silencer
4 – Bracket “A”
5 – Bracket “B”
6 – Flywheel Housing
2. Install and finger tighten the two M10 x 22 mm
bolts in the engine.
3. Install the turbocharger (Figure 5-128, (1)) with
its attached oil line and loosely install two
M10 x 18 mm bolts through bracket “A” and into
the turbocharger.

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 Assembling the Engine and Components ENGINE
12/05

4. Check the fit and alignment of all assemblies Installing the Mixing Elbow
and tighten in the sequence shown in
Figure 5-128. Install the mixing elbow (Figure 5-130, (4)) to the
turbocharger (Figure 5-130, (2)) with the gasket
NOTICE: NEVER allow oil or other lubricant to (Figure 5-130, (1)) and the V-band
remain on the mating surface of the silencer (Figure 5-130, (3)).
(Figure 5-129, (2)), hose or turbocharger
Figure 5-130

(Figure 5-129, (1)), as the assembly will come (1)

apart during engine operation. (2)
Figure 5-129

(1)

(2)
(4)

(3)
0005833

Figure 5-130
1 – Gasket
(3) 0005832 2 – Turbocharger
Figure 5-129 3 – V-Band
4 – Mixing Elbow
1 – Turbocharger
2 – Silencer
3 – Flanges
5. Thoroughly degrease the silencer flange, the
inside of the hose and the turbocharger flange.
6. Assemble the components and tighten the hose
bands to the following specified torque value.

Hose Band Torque

3 ± 0.5 N·m
(0.3 ± 0.05 kgf·m)
(2.2 ± 0.3 lb-ft)

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 ENGINE Assembling the Engine and Components

Installing the Oil Lines for the Fuel Installing the Alternator
Injection Pump 1. Install the adjuster (Figure 5-132, (2)) on the
1. Fit oil line “A” (Figure 5-131, (1)) between the coolant pump (Figure 5-132, (1)).
pressure regulating valve, timer and fuel
Figure 5-132

injection pump. (1) (2)

Figure 5-131
(3)
(1) (2)

(7) (6)
(4)

(5)

(3) 0005835
(4) 0005834

Figure 5-132
Figure 5-131
1 – Coolant Pump
1 – Oil Line “A” 2 – Adjuster
2 – Oil Line “B” 3 – Adjuster Bolt
3 – Overflow Valve 4 – Alternator
4 – Steady Brace and M8 Bolts 5 – Check Tension
2. Install the supporting brackets as shown in 6 – Deflection 8-10 mm (approximately 3/8 in.)
Figure 5-131. 7 – V-Belt

3. Apply seal washers to the pipe joint bolts. 2. Torque the adjuster bolts (Figure 5-132, (3)) to
the specified values.
4. Tighten the overflow valve (Figure 5-131, (3))
for oil line “A” and oil line “B” (Figure 5-131, (2)) 3. Install the alternator (Figure 5-132, (4)).
at the timer inlet. 4. Adjust the V-belt (Figure 5-132, (7)) tension as
shown in Adjust the V-Belt Tension or Replace
V-Belt on page 4-14 and tighten all the bolts to
the specified values.

Installing the Starter Motor

1. Install the starter motor to the flywheel housing.
2. Tighten the bolts to the specified torque value.

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 6LY3 Service Manual
Section 6

FUEL SYSTEM
Page
Safety Precautions .......................................................................... 6-3
Introduction...................................................................................... 6-4
Specifications .................................................................................. 6-5
Fuel Injection Pump / Governor / Timer .......................................... 6-7
Fuel Injection Pump Components ............................................. 6-8
Governor Components and Functions..................................... 6-10
Timer Components and Functions .......................................... 6-11
Removing the Fuel Injection Pump.......................................... 6-14
Installing the Fuel Injection Pump............................................ 6-17
Troubleshooting the Fuel Injection System ............................. 6-24
Fuel Injection Nozzle Components and Functions ........................ 6-26
Fuel Injection Nozzle Functions .............................................. 6-26
Fuel Feed Pump Components and Functions............................... 6-28
Fuel Feed Pump Components................................................. 6-29
Fuel Feed Pump Specifications............................................... 6-30
Disassembling the Fuel Feed Pump ....................................... 6-30
Inspecting the Fuel Feed Pump .............................................. 6-30
Assembling the Fuel Feed Pump ........................................... 6-30
Testing the Fuel Feed Pump ................................................... 6-31
Fuel Filter Components and Functions ......................................... 6-33
Inspecting the Fuel Filter ......................................................... 6-34
Electronic Control System ............................................................. 6-35
Engine Control System Diagram ............................................. 6-36
Sensors and Actuators ............................................................ 6-37
Injection Quantity Control Diagram.......................................... 6-38
Injection Timing Control Diagram ............................................ 6-39
Timer Phase Detection ............................................................ 6-40
ECU Control Data Management.............................................. 6-41
ECU Data Flow........................................................................ 6-43

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 FUEL SYSTEM

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 Safety Precautions FUEL SYSTEM
12/05

SAFETY PRECAUTIONS Piercing Hazard

Avoid skin contact with high-pressure
Before servicing the fuel system, read the following
diesel fuel spray caused by a fuel
safety information and review the Safety Section on
system leak such as a broken fuel
page 2-1.
injection line. High-pressure fuel can
penetrate the skin and result in serious
injury. If exposed to high-pressure fuel spray, obtain
The safety messages that follow have prompt medical treatment.
WARNING level hazards. These safety
messages describe a hazardous situation
NEVER check for a fuel leak with your hands.
which, if not avoided, could result in death or
ALWAYS use a piece of wood or cardboard.
serious injury.

Fire Explosion
Diesel fuel is flammable and explosive
under certain conditions. NEVER put
diesel fuel or other flammable material
near the engine during engine operation
or shortly after shutdown.

Never use a shop rag to catch the fuel.

ALWAYS put an approved fuel container under the

opening whenever removing any fuel system
component (such as changing the fuel filter).
Dispose of waste properly.

Wipe up all spills immediately.

6LY3 Service Manual 6-3

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 FUEL SYSTEM Introduction

INTRODUCTION
This section of the Service Manual describes the
procedures necessary to remove, install and adjust
the injectors and their associated system
components as used on the Yanmar 6LY3 engines.

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 Specifications FUEL SYSTEM
12/05

SPECIFICATIONS
Rotation Direction Clockwise Viewed From Drive Side
Injection Order 1-4-2-6-3-5-1
Interval 60° ± 0.5
General
Drive System Gear
Lubrication System Forced lubrication
Fuel Cut Method Cutting by stop solenoid
Cam Profile For Plunger AL12V220
Plunger Diameter / Lead Degree Ø11.0 mm (0.433 in.) / 55.35°
Lift to Port Close (No. 1 Plunger) 2.5 mm (0.098 in.) ± 0.05
Delivery Valve Retraction Volume 0 mm3 / st (CPV) (0 cu in.)
Adaptive Cutting 0 mm (0 in.)
Fuel
Injection Delivery Valve Opening Pressure 1.1 MPa (11.2 kgf / cm2) (159.441 psi)
Pump
Delivery Valve Spring Constant 24.8 N / mm (2.525 kgf / mm) (5.5 lb-ft)
Damping Valve —
Allowable Maximum Pump Speed 1850 rpm
Overflow Pressure 0.2 MPa (2.0 kgf / cm2) (29.007 psi)
Allowable Fuel Pressure 100 MPa (1020 kgf / cm2) (14503 psi)
Governor Governor Type Electronic control (PGS)
Cam Profile Type AL50DFP39
Fuel Delivery 7.6 cm3 / revolution (0.463 cu. in.)
Feed Pump
Delivery Pressure 0.23-0.37 MPa (2.3-3.8 kgf / cm2) (33.3-53.6 psi)
Suction Head 1.0 m (39.369 in)

6LY3 Service Manual 6-5

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 FUEL SYSTEM Specifications

Fuel System Diagram

Figure 6-1

(1)
(2)

(8)
(3)

(7) (4)
(5)

(6) 0005665

Figure 6-1

1 – Fuel Nozzle 5 – Fuel Feed Pump

2 – Fuel Return Line 6 – Fuel Line from Tank
3 – Fuel Filter 7 – Fuel Injection Pump
4 – Fuel Line to Tank 8 – Fuel Injection Line

6-6 6LY3 Service Manual

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 Fuel Injection Pump / Governor / Timer FUEL SYSTEM
12/05

FUEL INJECTION PUMP / Refer to the appropriate Service Manual for

disassembling, assembling and adjustment
GOVERNOR / TIMER procedures of the fuel injection pump
The 6LY3 engine is equipped with the YPES-AL II (Figure 6-2, (1)), governor and timer for 6LY3
fuel injection pump (Figure 6-2, (1)) with an engines.
electronic governor (Figure 6-2, (4)) and electro- NOTICE: The fuel injection pump and the rack
hydraulic timer (Figure 6-2, (2)). position sensor amplifier may only be disassembled
Figure 6-2
at an authorized FIE service center. See Figure 6-3
on page 6-8 for the location of the rack position
(1) amplifier.

(2)

(4)

(3)
0005664

Figure 6-2
1 – Fuel Injection Pump
2 – Electro-Hydraulic Timer
3 – Fuel Feed Pump
4 – Electronic Governor

6LY3 Service Manual 6-7

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 FUEL SYSTEM Fuel Injection Pump / Governor / Timer

Fuel Injection Pump Components

Figure 6-3

113

47
86

0005666
0

79.2
91.5
110
7°
38.0
(9)

(7)
(5)

(6)
(4)

+
32 32 27

No.1cyl

142
No.2cyl
200.5
59.8

200.5
(3)

232
No.3cyl
32 35

ST

376.2
No.4cyl

?10.7
No.5cyl
32
59.8

?14
No.6cyl

26 0.5
(8)
78.7
(2)
(1)

8
3

7
2

6
1

5
(10)

Figure 6-3

6-8 6LY3 Service Manual

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 Fuel Injection Pump / Governor / Timer FUEL SYSTEM
12/05

1 – Governor 6 – Rack Cover

2 – Fuel Inlet M14 x 1.5 7 – Timer Device
3 – Oil Inlet M8 8 – Fuel Feed Pump
4 – Rack Position Standard Surface 9 – Camshaft Key Position at FIC No. 1 Cylinder
5 – Overflow of Fuel Outlet 10 – Rack Position Sensor / Amplifier

6LY3 Service Manual 6-9

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 FUEL SYSTEM Fuel Injection Pump / Governor / Timer

Governor Components and The rack position sensor is linked to the control
rack (Figure 6-4, (3)) and detects the rack position.
Functions The governor solenoid is linked to the control rack
The electronic governor controls fuel injection and actuates it according to the rack position which
quantity and engine speed electronically. The rack is calculated by the ECU (Electronic Control Unit).
position sensor and governor solenoid are built into
the governor (Figure 6-4, (6)). This governor has a function of iso-chronous
control. Actual engine speed is feedback-controlled
to the target speed (throttle position). Engine speed
varies directly with throttle position.
Figure 6-4

(3)

(1) (2)
(4)

(8)

(7)

(6) (5)
0005667

Figure 6-4

1 – Fuel Decrease 5 – Fuel Injection Pump

2 – Fuel Increase 6 – Governor
3 – Control Rack 7 – Rack Position Sensor
4 – Timer 8 – Governor Solenoid (Rack Actuator)

6-10 6LY3 Service Manual

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 Fuel Injection Pump / Governor / Timer FUEL SYSTEM
12/05

Timer Components and Functions

Figure 6-5

Timer Components
The 6LY3 series engine utilizes an electro-hydraulic
timer. The timer consists of a piston, a cylinder and
a cam drive coupling. The piston has helical spline
outside and straight spline inside, as illustrated in
Figure 6-6. The cylinder (Figure 6-6, (6)) has 0005668

helical splines inside and oil passages to move the

Figure 6-5
piston. The cam drive coupling (Figure 6-6, (9))
has a straight spline outside and drives the pump
camshaft.
Figure 6-6

(1)

(2)
(9)

(3)
(4)

(5)
(8)

(7) (6)
0005669

Figure 6-6

1 – Electromagnetic Valve 6 – Cylinder

2 – Helical Spline 7 – Pump Drive Gear
3 – Piston 8 – Pump Camshaft
4 – Straight Spline 9 – Cam Drive Coupling
5 – Cam Tightening Nut

6LY3 Service Manual 6-11

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 FUEL SYSTEM Fuel Injection Pump / Governor / Timer

Timer Functions When advancing, the timer solenoid opens the

The electro-hydraulic timer advances or retards the advance port to the oil inlet side and opens the
fuel injection timing according to the timer phase retard port to the oil outlet side. The advance
control calculation by the ECU. The ECU calculates chamber is pressurized with oil and the oil in the
the optimum fuel injection timing depending on retard oil chamber (Figure 6-7, (5)) is pumped out
engine speed, load and coolant temperature. through the engine oil outlet (Figure 6-7, (9)). Then
the timer piston moves as a result of oil differential
The engine oil is fed to the electromagnetic valve pressure and rotates to the advance direction by
(timer solenoid), which controls the advance oil the helical spline. The opposite occurs in the
passage, retard oil passage and engine oil inlet / reverse.
outlet according to ECU indications.
Figure 6-7

(1)
(9) (2)

(3)

(4)

(8) (5)

(6)

(7) 0005670

Figure 6-7

1 – Electromagnetic Valve 6 – Piston

2 – Advance Oil Passage 7 – Advance Oil Chamber
3 – Retard Oil Passage 8 – Pump Camshaft
4 – Helical Spline 9 – Engine Oil Outlet
5 – Retard Oil Chamber

6-12 6LY3 Service Manual

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 Fuel Injection Pump / Governor / Timer FUEL SYSTEM
12/05

Advanced Position
Figure 6-8

(1)

(2)
(3)
(3)
(4)
(4)

(5)

(6)

(8)
(7) 0005671

Figure 6-8

1 – Timer Solenoid 5 – Damper Shaft

2 – Pump Drive Gear 6 – Drive Direction
3 – Cylinder 7 – Piston Movement
4 – Piston 8 – Rotating Cam and Piston

6LY3 Service Manual 6-13

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 FUEL SYSTEM Fuel Injection Pump / Governor / Timer

Removing the Fuel Injection Pump 4. Remove the damper (Figure 6-10, (3)) on the
fuel injection pump.
1. Set the crankshaft at 29° BTDC (Before Top Figure 6-10

Dead Center) on the compression stroke of the

No. 6 cylinder. NOTICE: Both intake / exhaust
values are closed on the compression stroke.
2. At 29° BTDC, the index marks on the V-pulley
(Figure 6-9, (2)) and drive shaft housing cover
(Figure 6-9, (1)) should align.
Figure 6-9

(2)

(1)

0005673
(3)

(1) (2) Figure 6-10

0005672
1 – Timer Cover
2 – Drive Shaft Housing Cover
Figure 6-9
3 – Damper
1 – Index Mark (Drive Shaft Housing Cover)
2 – Index Mark (V-Pulley)
3. Remove the fuel injection lines, supply lines
and cap the ends to keep dirt out.

6-14 6LY3 Service Manual

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 Fuel Injection Pump / Governor / Timer FUEL SYSTEM
12/05

5. Remove the timer cover (Figure 6-10, (1)) from 6. Before removing the fuel injection pump gear
the drive shaft housing cover (Figure 6-10, (2)). fasten an FIC (Fuel Injection Control) lock bolt
NOTICE: If the fuel injection pump gear and a collar through the FIC lock hole
(Figure 6-11, (1)) is to be removed without (Figure 6-12, (1)) of the fuel injection pump
setting the crankshaft to 29° BTDC No. 6, paint gear to lock the camshaft of the fuel injection
index marks on the idler gear (Figure 6-11, (2)) pump, before removing the fuel injection pump
and the fuel injection pump gear. Secure the gear gear. (The camshaft angle of this pump is in the
train and do not remove the idler gear. Align the same as factory default.) NOTICE: If the fuel
index marks when installing the pump gear. injection pump is removed without fastening an
FIC lock bolt, the pump camshaft angle may
Figure 6-11

change and the adjustment of the fuel injection

(2) timing will become difficult. In that case make
sure to ask the authorized FIE service shop to
adjust the FIC lock.
(1)
Part Name Part No.
FIC Lock Bolt 158908-51490
(4)
FIC Lock Bolt Collar 158908-51480

NOTICE: If the idler gear is to be removed,

ensure the index marks (Figure 6-11, (4)) on the
O
B

fuel injection pump gear align with the index mark

O

(3) “B” (Figure 6-11, (3)) on the idler gear. If they

0005674
don’t, rotate the crankshaft 360° until they do.
Figure 6-11 Figure 6-12

1 – Fuel Injection Pump Gear

2 – Idler Gear
3 – Adjusting Mark “B”
4 – Two Index Marks (1)

0005675

Figure 6-12
1 – FIC Lock Hole

6LY3 Service Manual 6-15

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 FUEL SYSTEM Fuel Injection Pump / Governor / Timer

7. Remove the damper shaft (Figure 6-13, (2)). 10. Remove the bolts for the governor bracket
Figure 6-13
(Figure 6-15, (6)).
Figure 6-15

(1)

(2)

(3)

(4)
(1) (6)
(2)
0005676 (5)
0005678

Figure 6-13 Figure 6-15

1 – Fuel Injection Pump Gear 1 – Pump Bracket “B”
2 – Damper Shaft 2 – Pump Bracket “A”
8. Remove the fuel injection pump gear 3 – Drive Shaft Housing
(Figure 6-13, (1)) from electro-hydraulic timer. 4 – Electromagnetic Valve
5 – Pump Bottom Bracket
9. Loosen (do not remove) the M8 x 25 (10T) bolts 6 – Governor Bracket
(Figure 6-14, (1)) for the timer housing (fuel
injection pump) from the drive shaft housing. 11. Remove the bolts for pump bracket “B”
Figure 6-14
(Figure 6-15, (1)).
12. Remove the bolts for pump bottom bracket
(Figure 6-15, (5)).
13. Remove the bolts for the timer housing and
remove the fuel injection pump assembly from
the drive shaft housing (Figure 6-15, (3)).
NOTICE: Use caution to avoid damaging the
electromagnetic valve when removing the fuel
injection pump. Keep the timer piston covered
to prevent dirt from settling on piston.

(1)
0005677

Figure 6-14
1 – M8 x 25 (10T) Bolts

6-16 6LY3 Service Manual

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 Fuel Injection Pump / Governor / Timer FUEL SYSTEM
12/05

Installing the Fuel Injection Pump

Figure 6-17

The fuel injection pump assembly is supported with (1)

several brackets to minimize vibration to the
electronic control parts of the injection control parts
in the injection pump. Improper installation of these
brackets may lead to a malfunction of the pump.
Install the brackets following the steps outlined
below:
1. Insert two spring pins (Figure 6-17, (1)) in the
flange of the timer housing of the fuel injection
pump. Assemble and install the retainer
(Figure 6-17, (27)) while adjusting knocking
holes.
Figure 6-16

(1) (2) 0005679

(2)
Figure 6-17
(3)
1 – Spring Pins, 4.0A x 10
2 – Retainer
2. Align the spring pins with the holes in the
retainer as shown in Figure 6-17.

(5)

(4) 0006199

Figure 6-16
1 – Pump Bracket “B”
2 – Pump Bracket “A”
3 – Drive Shaft Housing
4 – Pump Bottom Bracket
5 – Governor Bracket

6LY3 Service Manual 6-17

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 FUEL SYSTEM Fuel Injection Pump / Governor / Timer

3. Install the pump bottom bracket 4. Install the spring pins (Figure 6-19, (1)) and
(Figure 6-18, (2)) as shown in Figure 6-18 and guide bracket (Figure 6-19, (2)) into position.
tighten to the specified torque value. Figure 6-19

(1)
Bottom Bracket Bolt Torque (2)
49 ± 5 N·m
Tightening Torque (5.0 ± 0.5 kgf·m)
(36.1 ± 3 lb-ft)

Figure 6-18

(1)
(3)

0005681

Figure 6-19
1 – Spring Pins, 4.0A x 10
2 – Guide Bracket
3 – Nut, M8
5. Install nuts (Figure 6-19, (3)) and torque to the
specified value.

Guide Bracket Bolt Torque

25.5 ± 3 N·m
Tightening Torque (2.6 ± 0.3 kgf·m)
(18.8 ± 2 lb-ft)
(2)
6. Apply Three Bond® 1207C (Figure 6-20, (1)) to
0005680
the drive shaft housing mating surface of the
Figure 6-18 timer housing.
Figure 6-20

1 – M10 x 80 mm Bolts (4)

2 – Pump Bottom Bracket

(1)

0005682

Figure 6-20
1 – Apply Three Bond® 1207C

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 Fuel Injection Pump / Governor / Timer FUEL SYSTEM
12/05

7. Install the fuel pump assembly in the drive shaft

Figure 6-22

housing and initially tighten the bolts (Figure

6-21, (1)) for timer housing. Install two dummy 7
bolts (Figure 6-21, (2)).
NOTICE: NEVER damage the electromagnetic (1)
valve. Confirm that the timer of the fuel pump
assembly is in the most advanced position.
The piston (Figure 6-22, (1)) extends 7 mm
(0.276 in.) past the force of the timer flange (2)
(Figure 6-22, (2)).
0005685

Initial Torque Timer Housing Bolts Figure 6-22

4.0 ± 1 N·m
(0.4 ± 0.1 kgf·m) 1 – Piston
(2.9 ± 0.7 lb-ft) 2 – Timer Flange
8. Ensure the threads are clean and dry. Initially
tighten the bolts (Figure 6-23, (1)) on the pump
Figure 6-21

bottom bracket to the cylinder block.

Confirm that there is no gap between the bracket
and the cylinder block.

Initial Torque Pump Bottom Bolts

4.0 ± 1 N·m
M8 bolt (0.4 ± 0.1 N·m)
(2.9 ± 0.7 lb-ft)
4.0 ± 1 N·m
M10 bolt (0.4 ± 0.1 N·m)
(2.9 ± 0.7 lb-ft)

Figure 6-23

(1)
0005677

(2)

(1) (2) 0005686

Figure 6-23
0005986
1 – M8 x 25 Bolt
Figure 6-21 2 – M10 x 25 Bolt

1 – M8 x 25 (10T) Bolt
2 – M8 x 60 Dummy Bolt

6LY3 Service Manual 6-19

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 FUEL SYSTEM Fuel Injection Pump / Governor / Timer

9. Ensure the threads are clean and dry. Tighten 10. Tighten the bolts for the pump bottom bracket
the timer housing (fuel pump assembly) bolts (Figure 6-25) to the specified torque valve as
(Figure 6-24, (1)) to the drive shaft housing to shown.
the specified torque value.
Final Torque Pump Bottom Bracket Bolts
Final Torque Timer Housing Bolts 25.5 ± 3 N·m
35.3 ± 2 N·m M8 bolt (2.60 ± 0.31 kgf·m)
(3.6 ± 0.2 kgf·m) (18.8 ± 2.2 lb-ft)
(26.0 ± 1.5 lb-ft) 49.0 ± 5 N·m
M10 bolt (4.99 ± 0.51 kgf·m)
(36.1 ± 3.6 lb-ft)
Figure 6-24

Figure 6-25

(1)
0005687 (2)
(1)
0005688
Figure 6-24
Figure 6-25
1 – M8 x 25 (10T) Bolt
1 – M8 x 25 Bolt
2 – M10 x 25 Bolt
11. Remove the dummy bolts (Figure 6-26, (1)).
Figure 6-26

(1)

0005684

Figure 6-26
1 – Dummy Bolts

6-20 6LY3 Service Manual

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 Fuel Injection Pump / Governor / Timer FUEL SYSTEM
12/05

12. Install the pump bracket (Figure 6-27). Install 14. Install the governor bracket as shown in
the bolts (Figure 6-27, (1) and (2)) for the Figure 6-29. Tighten the bolts for the block
pump bracket and tighten to initial torque. (Figure 6-29, (1)) and bolts for pump
(Figure 6-29, (2)) to initial torque.
Initial Torque Pump Bracket Bolts
4.0 ± 1 N·m Initial Torque Governor Bracket Bolts
(0.40 ± 0.1 kgf·m) 4.0 ± 1 N·m
(2.9 ± 0.737 lb-ft) (0.40 ± 0.1 kgf·m)
(2.9 ± 0.737 lb-ft)
Figure 6-27

(1) Figure 6-29

(1)

(2)
0005690
(2)
0005692
Figure 6-27
1 – M8 x 50 Bolt Figure 6-29
2 – M8 x 20 Bolt
1 – M8 x 40 Bolt
13. Tighten the bolts to the final specified torque in 2 – M8 x 16 Bolt
the order shown in Figure 6-28. 15. Tighten the bolts to the final specified torque in
Final Torque Pump Bracket Bolts
the order shown in Figure 6-30.
25.5 ± 3 N·m Final Torque Governor Bracket Bolts
Final Torque (2.60 ± 0.31 kgf·m)
25.5 ± 3 N·m
(18.8 ± 2.2 lb-ft)
(2.60 ± 0.31 kgf·m)
Figure 6-28
(18.8 ± 2.2 lb-ft)

Figure 6-30

3 3

1 2
4

2
0005691 4
0005693
Figure 6-28
Figure 6-30

6LY3 Service Manual 6-21

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 FUEL SYSTEM Fuel Injection Pump / Governor / Timer

16. Install the pump gear (Figure 6-31, (1)) with the 17. Align the FIC lock bolt holes of the damper shaft
pump gear index marks (Figure 6-31, (4)) (Figure 6-32, (2)) with the fuel injection pump
around the idler gear index mark “B” gear (Figure 6-32, (1)). Tighten them together
(Figure 6-31, (3)). The pump drive gear and the while turning the pump gear counterclockwise
idler are machined to very close tolerances. to take up the gear lash. Tighten the bolts to the
NEVER attempt to drive gears into alignment following specified value.
with a hammer. Ensure there is no trash or dirt
attached to the timer piston. FIC Lock Bolt Torque
Figure 6-31 36.8 ± 2 N·m
(2) (3.8 ± 0.2 kgf·m)
(27.1 ± 1.4 lb-ft)

Figure 6-32

(1)

(4)
O
B
O

(3)
0005674 (3)

Figure 6-31
1 – Pump Gear
2 – Idler Gear (1)
(2) 0005695
3 – Idler Gear Index Mark “B”
4 – Pump Gear Index Marks Figure 6-32
1 – Fuel Injection Pump Gear
2 – Damper Shaft
3 – M10 Bolt
18. Remove the FIC lock bolt (Figure 6-33, (1)) and
collar.
Figure 6-33

(1)

0005675

Figure 6-33
1 – FIC Lock Bolt

6-22 6LY3 Service Manual

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 Fuel Injection Pump / Governor / Timer FUEL SYSTEM
12/05

19. Install a new oil seal (Figure 6-34, (2)) in the 20. Apply an even bead of Three Bond® 1207C
timer cover (Figure 6-34, (1)). NOTICE: When sealant (Figure 6-35, (3)) on the mating surface
removing an oil seal, replace it with a new one. of timer cover (Figure 6-35, (2)).
Figure 6-34 Figure 6-35

(1) (3)
(2)

(1)

(2)

(4)

0005697 (7) (5)

(6) 0005698
Figure 6-34
1 – Timer Cover Figure 6-35
2 – Oil Seal
1 – M8 x 85 mm Bolts
2 – Timer Cover
3 – Three Bond® 1207C Sealant
4 – M8 x 120 mm Bolts
5 – New Oil Seal
6 – M8 x 30 mm Bolts
7 – M8 x 65 mm Bolt

Bolt Torque
M8 x 85 mm 20.4 N·m (15.5 lb-ft)
M8 x 120 mm 35.5 N·m (26.1 lb-ft)
M8 x 30 mm 20.4 N·m (15.5 lb-ft)
M8 x 65 mm 20.4 N·m (15.5 lb-ft)

6LY3 Service Manual 6-23

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 FUEL SYSTEM Fuel Injection Pump / Governor / Timer

Troubleshooting the Fuel Injection Basic Checkpoints

System • Check for breaks or oil leaks throughout the fuel
system, from the fuel tank to the nozzle.
Complete repair means not only replacing defective
parts, but also finding and eliminating the cause of • Check the nozzle spray pattern.
the trouble. The cause of the trouble may not
necessarily be in the pump itself, but may be in the • Check the fuel delivery system operation. Loosen
engine or the fuel system. If the pump is removed the fuel pipe connection at the injection pump
prematurely, the true cause of the trouble may inlet and test the fuel feed pump.
never be known. Before removing the pump from
the engine, go through the basic inspection items
listed here.

Major Faults and Troubleshooting

Fault Cause Remedy

Engine won’t start. Fuel not delivered 1. No fuel in the fuel tank. 1. Fill Tank.
to injection pump. 2. Fuel tank cock is closed. 2. Open.
3. Fuel pipe system is clogged. 3. Clean and clear.
4. Fuel filter element is clogged. 4. Disassemble and clean,
or replace element.
5. Air is drawn into the fuel due to defective 5. Repair.
connection in the piping from the fuel tank to
the fuel pump.
6. Defective valve contact of the feed pump. 6. Repair or replace.
7. Piston spring of the feed pump is broken. 7. Replace.
8. Inter-spindle or tappets of the feed pump are 8. Repair or replace.
stuck.
No fuel delivered 1. Plunger is worn out or stuck. 1. Repair or replace.
to injection pump. 2. Delivery valve is stuck. 2. Repair or replace.
3. Control rack will not move. 3. Repair or replace.
Nozzle doesn’t 1. Nozzle valve doesn’t open or close normally. 1. Repair or replace.
work. 2. Nozzle seat is defective. 2. Repair or replace.
3. Injection nozzle starting pressure is too low. 3. Adjust.
4. Nozzle spring is broken. 4. Replace.
5. Fuel filter is clogged. 5. Repair or replace.
6. Excessive oil leaks from the nozzle sliding area. 6. Replace the nozzle
assembly.
Injection timing is 1. Camshaft is excessively worn. 1. Replace camshaft.
defective. 2. Roller guide was incorrectly adjusted or is 2. Adjust or replace.
excessively worn.
3. Plunger is excessively worn. 3. Replace plunger assembly.
Engine starts but immediately stops. 1. Fuel pipe is clogged. 1. Clean.
2. Fuel filter is clogged. 2. Disassemble and clean, or
replace the element.
3. Air is entering fuel lines. 3. Replace the packing repair
pipe.
4. Insufficient fuel delivery from the feed pump. 4. Repair or replace.

6-24 6LY3 Service Manual

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 Fuel Injection Pump / Governor / Timer FUEL SYSTEM
12/05

Fault Cause Remedy

Engine output is Defective injection 1. Knocking sounds caused by improper (too 1. Check the trouble code.
insufficient. timing and other advanced) injection timing.
failures. 2. Engine overheats or emits large amounts of 2. Check the trouble code.
smoke due to improper (too delayed) injection
timing.
3. Insufficient fuel delivery from the feed pump. 3. Repair or replace.
Nozzle is defective. 1. Defective injection nozzle performance. 1. Repair or replace nozzle.
2. Nozzle spring is broken. 2. Replace.
3. Excessive leaks from the nozzle. 3. Replace the nozzle
assembly.
Injection pump is 1. Plunger is worn. 1. Replace.
defective. 2. Injection amount is not uniform. 2. Adjust.
3. Injection timings of each cylinder are not even. 3. Adjust.
4. Delivery seal is defective. 4. Replace seal.
5. Delivery spring is broken. 5. Replace.
Idling is rough. 1. Movement of the control rack is defective. 1. Repair or replace.
Stiff plunger movement or sticking.
2. Uneven injection volume. 2. Adjust.
3. Injection timing is defective. 3. Check the trouble code.
4. Plunger is worn and fuel injection adjustment is 4. Replace.
difficult.
5. Feed pump can’t feed fuel at low speeds. 5. Repair or replace.
6. Fuel supply is insufficient at low speeds due to 6. Disassemble and clean, or
clogging of the fuel filter. replace the element.
Engine runs at high speeds but cuts out 1. The electric control system is defective. 1. Inspect and repair.
at low speeds. 2. Control rack is obstructed. 2. Inspect and repair.
Engine doesn’t reach maximum rpm. 1. Governor is defective. 1. Check trouble code.
2. Injection nozzle spray pattern is poor. 2. Repair or replace.
Loud knocking. 1. Injection timing is too fast. 1. Check the trouble code.
2. Injection from the nozzle is improper. 2. Repair or replace the
nozzle.
3. Fuel drips after each injection. 3. Repair or replace the
nozzle.
4. Uneven injection. 4. Adjust.
5. Engine overheats, or there is insufficient 5. Repair
compression.
Engine exhausts When exhaust 1. Injection timing is too slow. 1. Check the trouble code.
too much smoke. smoke is black: 2. The amount of injection is uneven. 2. Adjust.
3. Injection from nozzle is improper. 3. Repair or replace.
When exhaust 1. Injection timing is too fast. 1. Check the trouble code.
smoke is white: 2. Coolant mixed with the fuel. 2. Inspect the fuel system.

6LY3 Service Manual 6-25

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 FUEL SYSTEM Fuel Injection Nozzle Components and Functions

FUEL INJECTION NOZZLE

Figure 6-36

9.5
17
COMPONENTS AND
46
FUNCTIONS (2)
When the high-pressure diesel fuel reaches the (1)
injection nozzle, it pushes up the nozzle valve (held (3)
down by spring) and is injected into the combustion
chamber at high pressure.
The fuel is atomized by the nozzle to mix uniformly (7)
with the air in the combustion chamber. How well
the fuel is mixed with high temperature air directly
affects combustion efficiency, engine performance

159.2
(6)
and fuel economy.

94
(4)
Accordingly, the fuel injection nozzles must be kept
in top condition to maintain performance and
operating efficiency.
This engine uses double-spring nozzles

21.7
manufactured by DENSO.
NOTICE: NEVER disassemble the nozzle holder
(5) 0005699
retaining nut at a Yanmar workshop. Defer
maintenance to an authorized FIE service shop, Figure 6-36
which can maintain the DENSO fuel nozzles.
1 – Nozzle Body Holder
Fuel Injection Nozzle Functions 2 – M6 x 1.0 mm
3 – M12 x 1.5 mm
A double-spring type fuel nozzle is used with this
4 – M15 x 0.5 mm
engine. This allows each nozzle to inject fuel in two 5 – Nozzle Tip Spray Pattern
steps. 6 – No. 2 Spring
7 – No. 1 Spring
Fuel from the fuel injection pump passes through
the fuel port in the nozzle body holder and enters When diesel fuel reaches the specified No. 1
the nozzle body reservoir. pressure (lower), it pushes the nozzle valve up to
the pre-lift (held by the nozzle No. 1 spring
(Figure 6-36, (7))) and is injected through the small
holes on the tip of the nozzle body.
When the diesel fuel reaches the specified No. 2
pressure (higher), it pushes the nozzle valve up to
the full lift (held by the nozzle No. 2 spring
(Figure 6-36, (6))), and more diesel fuel is injected
at a higher pressure through the small holes.
After the diesel fuel is injected, the nozzle valve is
automatically pushed down by the nozzle spring
and closed.

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 Fuel Injection Nozzle Components and Functions FUEL SYSTEM
12/05

Fuel leaking between the nozzle valve and the

nozzle body goes to the hole on top of the nozzle
holder body and goes back through the return pipe
to the fuel tank.

Fuel Injection Nozzle Specifications

6LY3-STP
Engine Model 6LY3-ETP
6LY3-UTP
Nozzle ID Mark D DLLA155P913 D DLLA155P954
Spray Angle 155
No. of Injection Hole and Diameter 7-Ø0.26 mm (0.27 in.-0.010 in.)
No. 1 Pressure 24.00-24.98 MPa (245-255 kgf / cm2) (3480-3611 psi)
Nozzle Opening Pressure
No. 2 Pressure 36.96-38.34 MPa (377-391 (kgf / cm2) (5351-5554 psi)
Pre-Lift 0.24-0.30 mm (0.009-0.011 in.)
Nozzle Lift
Full Lift 0.33-0.38 (0.012-0.014 in.)
Body Mark D 8000 D 8090
Nozzle Holder Retaining Nut M15 39.2-49.0 N·m (400-500 kgf·cm) (28.9-36.1 lb-ft)
Tightening Torque High-Pressure Pipe Joint M12 22.5-26.5 N·m (229-270 kgf·cm) (16.5-19.5 lb-ft)
Fuel Return Pipe Joint M6 7.0-9.0 N·m (71-92 kgf·cm) (5.1-6.6 lb-ft)

NOTICE: The fuel injection nozzle for 6LY3-ETP is different in volume from that for the 6LY3-STP / -UTP.

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 FUEL SYSTEM Fuel Feed Pump Components and Functions

FUEL FEED PUMP

COMPONENTS AND
FUNCTIONS
The fuel feed pump consists of a priming pump,
which bleeds air from the fuel system and is used to
manually feed fuel while the engine is stopped. It
also consists of a feed pump, which supplies fuel
while the engine is running.
The fuel feed pump is driven by an eccentric cam
on the fuel camshaft.
When the cam pushes on the piston, via the roller
guide, the fuel in the piston chamber passes
through the discharge valve and flows behind the
piston. The suction valve closes under pressure
and prevents the fuel from flowing back to the tank.
When the cam is lowered, the piston is pushed
back by the piston spring and the fuel behind the
piston chamber is forced to the fuel pump. The
negative (-) pressure which develops in the piston
chamber makes the suction valve open and fills the
piston chamber with fuel.

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 Fuel Feed Pump Components and Functions FUEL SYSTEM
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Fuel Feed Pump Components

Figure 6-37

(1)

(2)

(17)
(16)
(15) (3)
(14) (4)
(5)

(13)
(12)
(11) (6)
(10) (7)
(8)
(9)
(18)

0005700

Figure 6-37

1 – Cover 10 – Roller Guide

2 – Priming Pump 11 – Roller Pin
3 – O-Ring 12 – Roller
4 – Priming Pump Valve Spring 13 – Retaining Ring
5 – Priming Pump Valve 14 – Discharge Valve
6 – Piston 15 – Discharge Valve Spring
7 – Piston Spring 16 – O-Ring
8 – O-Ring 17 – Plug
9 – Piston Spring Plug 18 – Inter-Spindle

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 FUEL SYSTEM Fuel Feed Pump Components and Functions

Fuel Feed Pump Specifications

Item Standard
Maximum Suction Head of Fuel Feed Pump 1.0 m (3.2 ft)
11.4 L / min. (3.001 gal.)
Maximum Discharge Volume of Fuel Feed Pump at camshaft speed 1500 rpm,
engine speed 3000 rpm
230-370 kPa (2.3-3.8 kgf / cm2) (33.3-53.6 psi)
Maximum Discharge Pressure of Fuel Feed Pump at camshaft speed 1500 rpm,
engine speed 3000 rpm

Disassembling the Fuel Feed Pump Assembling the Fuel Feed Pump
1. Remove the piston spring plug and pull out the 1. Position the discharge valve and spring in the
piston and piston spring. fuel feed pump housing. Lubricate and install a
2. Remove the retaining ring and pull out the roller new O-ring on the discharge valve plug. Install
guide, roller pin and roller. the discharge valve plug.
3. Pull out the inter-spindle. 2. Lubricate and install a new O-ring on the
priming pump. Install the priming pump.
4. Remove the priming pump.
3. Position the piston and piston spring in the fuel
5. Remove the discharge valve spring plug. feed pump housing. Lubricate and install a new
Remove the valve and spring. O-ring on the piston spring plug. Install the
6. Remove all O-rings. piston spring plug.
4. Install the inter-spindle.
Inspecting the Fuel Feed Pump
5. Position the roller guide, roller pin, and roller in
1. Block the priming pump with your finger and the fuel feed pump housing. Install the retaining
check whether the pressed-in piston returns by ring.
spring force.
6. When the pump has been reassembled,
2. If the piston returns, the piston does not have perform the air-tightness test. Apply 0.3 MPa
enough negative (-) pressure. Always replace
(3 kg / cm2) (43 psi) of air pressure
the priming pump as a complete set.
(Figure 6-37, (2)) to the discharge outlet of the
3. Check the piston spring for cuts, cracks, uneven pump and check for air leaks from the O-ring. If
wear and rust. air is leaking, replace the O-ring.
4. Replace the piston, inter-spindle or tappet if Figure 6-38

extremely worn. (1)

(2)
5. Check the contact surface of the valve and
valve seat for defects.
6. When there is play in a valve seat which has (5)
been sealed into the feed pump body, replace
(4) (3)
the entire pump body. NOTICE: Play in the
valve seat hinders the opening and closing of 0005701

the valve, causing insufficient fuel supply and

Figure 6-38
abnormal wear of the tappets and camshaft.
1 – Measuring Cylinder
2 – Air Pressure
3 – Container Filled with Light Oil
4 – Blocked (Plugged)
5 – Tappet

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 Fuel Feed Pump Components and Functions FUEL SYSTEM
12/05

Testing the Fuel Feed Pump Suction Test for the Priming Pump
1. Install the fuel feed pump onto the injection Loosen the handle of the priming pump and push
pump. the handle at 60-100 strokes / minute. If fuel comes
out of the delivery side of the feed pump
2. Run the fuel line directly from tank as shown in
(Figure 6-40, (4)) after about 30 strokes, the
Figure 6-39. Fuel piping should be provided
priming pump is normal. If it takes longer, replace
directly from the tank, not through the delivery
the priming pump as a set.
pump for this test.
Figure 6-39

Suction Test Specifications

Suction Head 1 m (3.2 ft)
Suction Pipe Within 30 strokes
Ø8 m (3.149 in.)
Diameter

Figure 6-40

(2)
(1)

(3)

0005702 (1)

(4)
0005704

Figure 6-40
(2)
1 – Valve “B”
2 – Pressure Gauge
3 – Valve “A”
0005703 4 – Feed Pump

Figure 6-39
1 – From Fuel Tank
2 – Fuel Delivery

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 FU EL SYSTEM Fuel Feed Pump Components and Functions

Maximum Fuel Feed Volume Test Delivery Test

The special equipment illustrated in Figure 6-41 1. Open Valve “A” (Figure 6-42, (2)).
will be needed for conducting maximum delivery 2. Operate the fuel injection pump at the specified
pressure and delivery volume tests. NOTICE: 1000 rpm.
NEVER run the engine for more than 5 minutes.
The fuel injection pump may be damaged if 3. Open Valve “B” (Figure 6-42, (1)) until the
operated in non-injection condition. pressure gauge indicator shows 0.1 MPa
(1 kg / cm2) (14.5 psi). Measure the delivery
rate for 1 minute.
Figure 6-41

(1) (2) Delivery Test Specifications

Volume: 1.8 L / min. (0.475 gal.)
Back pressure: 0.1 MPa (1 kg / cm2) (14.5 psi)
rpm: 1000

Figure 6-42

(2)
(1)
0005705

Figure 6-41
1 – Valve “B”
2 – Valve “A”
1. Operate the injection pump at the specified
600 rpm and read the pressure gauge indicator
when Valve “B” (Figure 6-41, (1)) is closed. 0005706

2. Tighten Valve “A” (Figure 6-41, (1)) so the Figure 6-42

pressure gauge indicator does not move when
pressure is applied. 1 – Valve “B”
2 – Valve “A”
Volume Pressure: 0.22-0.31 MPa (2.2-3.2 kg / cm2)
(31.9-44.9 psi)
rpm: 600

3. Replace the piston spring if it is defective.

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 Fuel Filter Components and Functions FUEL SYSTEM
12/05

FUEL FILTER COMPONENTS

Fuel Filter Specifications
AND FUNCTIONS Part No. 41650-550310
The fuel filter is installed between the fuel feed Filtering Method Filter paper element
pump and fuel injection pump, and removes Filtering Area 4000 cm2 (62 sq. in.)
dirt and foreign matter from the fuel pumped from Maximum 45 µ (1.7 mil)
the fuel tank. Element Pore Size
Average 35 µ (1.3 mil)

The filter element must be changed periodically. Figure 6-44

The fuel goes around the filter element. The fuel is 65

fed through the pores in the filter and discharged
from the center of the cover. Dirt and foreign matter 30°
in the fuel are deposited in the filter element.
Figure 6-43

(1)
(1)
(2)

(2)

(6) (3)

(5) (4)
0005707
216

Figure 6-43 ø90

ø102.8
1 – Return From Fuel Nozzle
2 – Fuel Filter Body
3 – Flow From Fuel Feed Pump
4 – Return From Fuel Pump (3)
5 – Drain Plug
6 – Flow to Fuel Pump
0005708

Figure 6-44
1 – M14 x 1.5 mm
2 – M14 x 1.5 mm
3 – M8 x 1.25 mm

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 FUEL SYSTEM Fuel Filter Components and Functions

Inspecting the Fuel Filter

The fuel strainer must be cleared occasionally. If
there is water or foreign matter in the strainer bowl,
disassemble the strainer and wash with clean fuel
to completely remove foreign matter. Replace
and / or clean at scheduled intervals.
Replace the filter if it is very dirty, deformed or
damaged.
Figure 6-45

(1) (2)
(4)
(3)
(5)

(6)
(8)

(9) (7)

0005709

Figure 6-45
1 – Attaching Hardware
2 – Fuel Filter Assembly
3 – Gasket
4 – Cover
5 – Filter Case
6 – Drain Plug
7 – Center Bolt
8 – Filter Element
9 – Rubber Pad

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 Electronic Control System FUEL SYSTEM
12/05

ELECTRONIC CONTROL
SYSTEM
The Electronic Control System (ECS) is used with
the 6LY3 series engines. In order to function, the
Engine Control Unit (ECU), the electronic governor
and electro-hydraulic timer are interconnected to
the fuel injection pump. The ECU controls the fuel
injection quantity and injection timing electronically.
This engine is also equipped with an engine control
unit, an engine interface module and other
electronic control equipment.

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 FUEL SYSTEM Electronic Control System

Engine Control System Diagram

The engine control system diagram is shown in Figure 6-46. The ECU controls the fuel injection quantity
and injection timing based on information such as engine operation (throttle, gear shift, control panel) and
engine condition (temperature, pressure, etc.).
Figure 6-46

Rocker switch panel YDT ECU +B

CAN
Throttle signal
Neutral signal

Emergency stop
Switch
Start Switch
Intake air heater
Ignition Switch Main relay

Backup throttle sensor Air heater relay

Intake air pressure sensor Rack actuator relay

Oil pressure sensor Timer solenoid advance

Timer solenoid retard

Water temperature sensor

Electronic governor

Oil temperature sensor

Rack position
amplifier Injection
Fuel injection pump nozzle
Crank angle sensor

Rack position
sensor
Camshaft speed
sensor
Fuel temperature sensor

Fuel feed pump Electro-hydraulic

timer
Oil pump

Fuel tank Oil sump

Fuel filter

0005710

Figure 6-46

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 Electronic Control System FUEL SYSTEM
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Sensors and Actuators

Sensors and actuators are devices used for engine control and monitoring. They are laid out on the engine
as shown in Figure 6-47. The oil pressure and the oil temperature sensors are installed for the purpose of
monitoring and warning the vessel operators.
Figure 6-47

Oil pressure sensor

(On oil filter)
Water temperature sensor
(On exhaust manifold)

Engine control unit

Crank speed sensor

(On flywheel housing)

Oil temperature sensor

(On oil cooler)

Boost pressure sensor

(On intake manifold)
Electronic governor

Timer solenoid
Rack position sensor
Injection pump (On hydraulic timer)
(On governor)

Pump speed sensor

(On governor) Fuel temperature sensor
(On injection pump)
0005711

Figure 6-47

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 FUEL SYSTEM Electronic Control System

Injection Quantity Control Diagram

The ECU (Engine Control Unit) controls the fuel injection quantity and injection timing. Injection quantity
control is done through the rack position control of the fuel injection pump. The injection quantity control
diagram by ECU is shown in Figure 6-48.
Figure 6-48

Input
Boost pressure
Fuel oil Target speed calculation Output
temperature
(Starting only) depend on throttle position
Coolant
temperature

Compensation
Engine speed Target governor position calculation
Throttle position

valve
target cal. basically depend on target speed and actual speed

Engine speed Rack position

Crank speed Rack actuator
governor cal. control cal.

Rack position
Rack position feedback calculation

4/4

3/4
Load

2/4
1/4
Idle

Speed 0005712

Figure 6-48

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 Electronic Control System FUEL SYSTEM
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Injection Timing Control Diagram

Injection timing is controlled as a timer phase, which is the torsion angle between the pump camshaft and
pump drive gear. The ECU injection timing control diagram is shown in Figure 6-49.
Figure 6-49

Rmax Input

Rack position
Coolant Output
temperature
Engine
load =100%
Rack position
Ridle

Engine load Speed

Crank speed
cal.

Timer solenoid
(Advance)
Timer phase Timer phase
target cal. control cal.
Timer solenoid
(Retard)

Timer phase
cal.

Cam speed 0005713

Figure 6-49

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 FUEL SYSTEM Electronic Control System

Timer Phase Detection

The timer phase is detected by two pulsar gears (Figure 6-50) and is calculated by the ECU from the
deviation of two pulses. The pulsar gear of crankshaft is located on the flywheel.
Figure 6-50

Timer phase detection

Pulsar gear

Crank gear
Cam gear

12 +1 pulse
12 pulse

Top pulse Top pulse Top pulse

Crank
pulse

Cam
pulse

-360° 0° 360°
Crank angle
0005714

Figure 6-50

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 Electronic Control System FUEL SYSTEM
12/05

ECU Control Data Management

In order to prevent the misuse or illegal operation of an engine’s control system, the control program and
data are managed by a production system. In addition, Yanmar’s production data management system can
provide the correct data for replacing an ECU and / or fuel injection pump when it is necessary.

ECU Control Data Management In Factory

The flow of ECU control data management in the factory is shown in Figure 6-51. Control program, data
map and data are assigned to a part number for each engine model. Engine production data and adjustment
data are specific for each engine and injection pump. The ECU control data for each engine is stored in the
factory server after running tests in the factory.
Figure 6-51

PRODUCTION DATA SERVER PRODUCTION

ORDER in factory SYSTEM

ENGINE MODEL
SERIAL NUMBER

PROGRAM / MAP

PRODUCTION DATA

ADJUSTMENT DATA

ECU
0005715

Figure 6-51

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 FUEL SYSTEM Electronic Control System

ECU Control Data Management in Service Shop

Figure 6-52 shows the ECU control data flow within a service shop when injection pump replacement is
required. In the case of replacing a fuel injection pump, the ECU of the engine must be rewritten by the
Pump Adjustment Data by using a YDT. The rewriting of the ECU control data is performed by Yanmar
authorized personnel when replacement of an ECU or its components is necessary.
NOTICE:
1. Data rewriting is permitted only by an authorized Yanmar technician.
2. Data rewriting is performed by using a YDT, which was originally developed by Yanmar. YDT consists of
PC-software, engine interface and connections.
3. YDT requires password access to handle this data.
Figure 6-52

YDT

PUMP IDENTIFICATION DATA

PUMP ADJUSTMENT DATA

PUMP DATA

PUMP with DATA

ECU

0005716

Figure 6-52

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 Electronic Control System FUEL SYSTEM
12/05

ECU Data Flow

Figure 6-53 shows the ECU control data flow when ECU replacement is required. When an ECU is ordered
from the factory, the ECU control data is selected according to the engine identification information such as
the engine serial number and pump serial number. Then an ECU is provided directly by the factory. The data
is stored in the production system network.
Figure 6-53

ORDER of ECU DATA SERVER PRODUCTION

for replacement in factory SYSTEM

ENGINE MODEL
SERIAL NUMBER

PROGRAM / MAP

PRODUCTION DATA

ENG & PUMP

ADJUSTMENT DATA

ECU
0005717

Figure 6-53

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 FUEL SYSTEM Electronic Control System

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 6LY3 Service Manual
Section 7

COOLANT SYSTEM
Page
Safety Precautions .......................................................................... 7-3
Introduction...................................................................................... 7-3
Coolant System Components and Functions .................................. 7-4
Coolant System Components.................................................... 7-5
Seawater Pump Components and Functions.................................. 7-6
Disassembling the Seawater Pump .......................................... 7-6
Inspecting the Seawater Pump ................................................. 7-7
Assembling the Seawater Pump .............................................. 7-8
Coolant Pump Components and Functions..................................... 7-9
Coolant System Components.................................................. 7-10
Disassembling the Coolant Pump .......................................... 7-11
Inspecting the Coolant Pump ................................................. 7-11
Heat Exchanger Components and Functions................................ 7-13
Heat Exchanger Components ................................................. 7-13
Disassembling the Heat Exchanger ........................................ 7-13
Inspecting the Heat Exchanger .............................................. 7-14
Pressure Cap Operation.......................................................... 7-14
Inspecting the Pressure Cap .................................................. 7-15
Coolant Recovery Tank Components and Functions.................... 7-16
Installing the Coolant Recovery Tank...................................... 7-16
Coolant Recovery Tank Precautions ....................................... 7-16
Thermostat Components and Functions ....................................... 7-17
Inspecting the Thermostat ...................................................... 7-18
Testing the Thermostat............................................................ 7-18
Seacock Components and Functions (Optional)........................... 7-19
Seacock Precautions.............................................................. 7-19
Inspecting the Seacock ........................................................... 7-19
Bilge Pump and Strainer Components and Functions (Optional).. 7-20

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 COOLANT SYSTEM
Bilge Pump Characteristics ..................................................... 7-21
Bilge Pump Insulation.............................................................. 7-21
Bilge Pump Durability .............................................................. 7-21
Bilge Pump Vibration Proof ..................................................... 7-21
Bilge Pump Precautions .......................................................... 7-21
Installing the Bilge Pump......................................................... 7-21
Troubleshooting the Bilge Pump ............................................. 7-23

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 Safety Precautions COOLANT SYSTEM
12/05

SAFETY PRECAUTIONS INTRODUCTION

Before servicing the coolant system, read the This section of the Service Manual describes the
following safety information and review the Safety procedures necessary to service the 6LY3 marine
Section on page 2-1. engine coolant systems.

The following safety message has CAUTION

level hazards. The safety message describes a
hazardous situation which, if not avoided, could
result in minor or moderate injury.

Coolant Hazard
Wear eye protection and rubber gloves
when handling Long Life Coolant (LLC).
If contact with the eyes or skin should
occur, flush eyes and wash immediately with clean
water.

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 COOLANT SYSTEM Coolant System Components and Functions

COOLANT SYSTEM The thermostat is closed when the coolant

temperature is low, immediately after the engine is
COMPONENTS AND started and during low load operation. Then the
FUNCTIONS coolant flows to the coolant pump inlet, and is
circulated inside the engine by passing the heat
The coolant system is an indirect seawater-cooled, exchanger.
coolant-circulation type. The cylinders, cylinder
head, turbocharger and exhaust manifold are When the temperature of the coolant rises, the
cooled with coolant. The heat exchanger, oil cooler thermostat opens, coolant flows to the heat
and intercooler are cooled with seawater. exchanger and is cooled by the seawater in the
tubes as it flows through the coolant pipe. The
Seawater is pumped in by the seawater pump and temperature of the coolant is kept within a constant
goes to the heat exchanger where it cools the range by the thermostat.
coolant. It is sent to the intercooler and then the oil
cooler. After going to the marine gear oil cooler,
seawater is sent to the mixing elbow and
discharged from the boat with the exhaust gas.
Coolant is pumped by the coolant pump from the
coolant tank to the cylinder jacket to cool the
cylinders, turbocharger and then the cylinder head.
The coolant pump body also serves as a discharge
passageway (line) at the cylinder head outlet and is
fitted with a thermostat.

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 Coolant System Components and Functions COOLANT SYSTEM
12/05

Coolant System Components

Figure 7-1

(1) (2) (3) (4)

(5)

(6)

(13)

(12)
(7)

(11)
(8)

(10) (9) 0006200

Figure 7-1

1 – Fuel Injection Pump 8 – Coolant Outlet

2 – Oil Cooler 9 – Heat Exchanger
3 – Bypass Oil Filter 10 – Seawater Inlet
4 – Full Flow Oil Filter 11 – Seawater Pump
5 – Intercooler 12 – Thermostat
6 – Marine Gear Oil Cooler 13 – Coolant Pump
7 – Mixing Elbow

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 COOLANT SYSTEM Seawater Pump Components and Functions

SEAWATER PUMP Disassembling the Seawater Pump

COMPONENTS AND 1. Remove the rubber hose from the seawater
pump outlet (Figure 7-3, (14)).
FUNCTIONS Figure 7-3

The seawater pump (Figure 7-2) has a rubber (1)

impeller. The seawater pump is installed to the
drive shaft housing and is driven by a gear.
Figure 7-2

(14)
(2) (5)
(3) (6)
(4)

(7)
(13) (8) (9)
(12)
(11)

(10)
0006201 0006202

Figure 7-2 Figure 7-3

1 – Heat Exchanger
Seawater Pump Performance Specifications 2 – O-Ring
Minimum 215 L / min. (57 gal) at 3 – Impeller
In = -0.4 bar (-6 psi) 4 – Mechanical Seal
Flow Out = 1.2 bar (17.5 psi) 5 – O-Ring
2933 rpm 6 – Seawater Inlet
after 100 hours of duty 7 – Pump Drive Gear
Maximum 10 seconds at 8 – O-Ring
suction head = 0.5 m (1.5 ft) 9 – Drive Shaft Housing
Self-Priming Ability
length of pipe = 0.6 m (1.9 ft) 10 – Pump Gear Nut
622 rpm 11 – Seawater Pump Body
4 bar water (58 psi) 12 – Wear Plate
Tightness Test Leakage from seal: 13 – End Cover
Maximum 0.03% 14 – Seawater Pump Outlet
2. Remove the seawater pump assembly from the
Seawater Pump Durability Specifications drive shaft housing (Figure 7-3, (9)).
Impeller
Minimum 1500 hours 3. Remove the seawater pump end cover
Maximum 10% after (Figure 7-3, (13)).
Flow Drop
1000 hours
Water Lip Seal Minimum 1000 hours
Wear Plate End Cover Minimum 1500 hours
Other Parts Minimum 3000 hours

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 Seawater Pump Components and Functions COOLANT SYSTEM
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4. Take out the O-ring (Figure 7-3, (2)) and Inspecting the Seawater Pump
impeller (Figure 7-3, (3)). Use the special tools
shown in Figure 7-4, (3) and (4). Rubber Impeller
If there is damage or wear on the impeller, replace
M24 x 2 M10-length 40 mm (1.6 in.)
it.
Figure 7-4

(1) Wear Plate

(2)
Replace the wear plate if the side surface is worn or
deformed.

Pump Housing
Replace the pump housing if there is excessive
wear on the inner surface of the housing or on the
sliding surface of the impeller.
(4) Mechanical Seal
(3)
Replace the mechanical seal if there is water
(1) leakage from the drain pipe (coolant leakage: less
0006203
than 3 cc (0.014 oz) / hr).
Figure 7-4
NOTICE: Be careful not to damage any sliding
1 – Pump Body surface while replacing. Coat the sliding surface of
2 – Impeller the mechanical seal with a small amount of
3 – Special Tool “A” high-quality silicon oil to prevent early leakage due
4 – Special Tool “B” to insufficient run-in. Coat the seal bore with liquid
5. Remove the wear plate (Figure 7-3, (12)) and sealant.
the mechanical seal (Figure 7-3, (4)).
Bearing
6. Insert pliers from the drive gear long hole and
remove the stop ring that holds the bearings. Inspect the bearing for wear and damage.
7. Lightly tap the pump shaft from the impeller
side and remove the pump shaft, bearings and
drive gear as a set.
8. Remove the lip seal and mechanical seal if
necessary.

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 COOLANT SYSTEM Seawater Pump Components and Functions

Assembling the Seawater Pump

Figure 7-6

(1)
1. When replacing the mechanical seal, coat the
sliding surface with a good quality silicon oil. Do
not scratch any surfaces.
2. Coat the lip seal with grease and insert.
3. Install the pump shaft, ball bearing and gear
assembly to the pump unit and secure the
bearing stop ring. NOTICE: Coat the shaft with
grease before installing.
4. Install the O-ring. (2)
5. Install the pump drive gear and retighten the 0006205
pump drive gear nut to the specified torque.
Figure 7-6
Pump Drive Gear Nut Torque
1 – Impeller Rotation
73-83 N·m (53-61 lb-ft) 2 – Impeller
6. After inserting the mechanical seal, install the 9. Install the O-ring between the pump body and
wear plate and impeller. end cover.
7. Coat the inside of pump body impeller housing
with grease.
8. Insert the impeller (Figure 7-6, (2)) into the
pump body. See Figure 7-6, (1) for impeller
rotation. Impeller threads are toward the cover.
Figure 7-5

(1)

0006204

Figure 7-5
1 – Cover

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 Coolant Pump Components and Functions COOLANT SYSTEM
12/05

COOLANT PUMP COMPONENTS The bearing unit assembled in the pump shaft uses
grease lubricated ball bearings and cannot be
AND FUNCTIONS disassembled.
The coolant pump is a centrifugal (volute) type and The totally enclosed mechanical seal spring
circulates coolant from the coolant tank to the presses the impeller seal installed on the impeller
cylinders and the cylinder head. side away from the pump body side. This prevents
The coolant pump consists of the pump body, coolant from leaking along the pump shaft.
impeller, pump shaft, bearing unit and mechanical The impeller and pulley flanges are a press fit and
seal (Figure 7-7, (1)). The V-pulley on the end of they cannot be disassembled.
the pump shaft is driven by two V-belts from the
crankshaft.
Coolant Pump Specifications
Figure 7-7

13200 L (3487 gal) / hr at

(2) Delivery Capacity pump speed 3350 rpm
(1) (3)
total head 13 m (46.2 ft)
(4)

(7)

(6)

(5)

0006206

Figure 7-7
1 – Mechanical Seal
2 – Impeller
3 – Seal
4 – Cover
5 – Casing
6 – Shaft Bearing
7 – Pulley Seat

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 COOLANT SYSTEM Coolant Pump Components and Functions

Coolant System Components

Figure 7-8

(2)
(1)
(3)

(7)
(6)

(5)

(10)
(4)

(8)
(9)

0006207

Figure 7-8

1 – Thermostat 6 – Coolant Pump Assembly

2 – Seal 7 – Gasket
3 – Hose Elbow 8 – Flange
4 – V-Belts 9 – O-Ring
5 – V-Pulley 10 – Cylinder Head

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 Coolant Pump Components and Functions COOLANT SYSTEM
12/05

Disassembling the Coolant Pump Inspecting the Coolant Pump

NEVER disassemble the coolant pump. Replace
when defective. Bearing Unit Inspection
Rotate the impeller. If the rotation is not smooth, or
When removing the coolant pump as an assembly an abnormal noise is heard or felt, replace the
from the cylinder and cylinder head, replace the pump as an assembly.
cylinder inlet pipe O-ring.
When the coolant pump body and cylinder inlet Impeller Inspection
flange and / or coolant pump and pump plate are Check the impeller blades. Replace if damaged,
disassembled, retighten pump mounting bolts to corroded or if the impeller blade is excessively worn
the specified torque. due to contact with the pump body.

Coolant and Bypass Lines

Coolant Pump Bolt Torque
Check the holes in the coolant and bypass lines,
6.9-10.0 N·m (0.7-1.1 kgf·m)
clean out any dirt or other foreign matter and repair
as needed.

Coolant Pump Replacement

Replace the pump as an assembly if there is
excessive coolant leakage due to mechanical seal
or impeller seal wear.

Inspect Coolant Pump

Inspect the coolant pump body and flange, and
clean off scale and rust. Replace if corroded.

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 COOLANT SYSTEM Coolant Pump Components and Functions

Measuring the Coolant Pump Clearances

Coolant Pump Clearances
1. Push the impeller all the way toward the
Standard Limit
pump body and insert a thickness gauge
(Figure 7-9, (1)) diagonally between the Clearance Between
0.3-1.1 mm 1.5 mm
impeller and the body to measure the clearance the Impeller and
(0.011-0.043 in.) (0.059 in.)
Pump Body
between the two.
Clearance Between 1.5 mm
Figure 7-9

—
the Impeller and Plate (0.059 in.)

(1) 0006208

Figure 7-9
1 – Thickness Gauge
2. Place a straightedge (Figure 7-10, (1)) against
the end of the pump body and insert a
thickness gauge (Figure 7-10, (2)) between the
impeller and the plate (pump body bracket) to
measure the clearance between the two.
Figure 7-10

(1)

(2) 0006209

Figure 7-10
1 – Straight Edge
2 – Thickness Gauge

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 Heat Exchanger Components and Functions COOLANT SYSTEM
12/05

HEAT EXCHANGER
Figure 7-11

(1)
COMPONENTS AND (2)
FUNCTIONS (3)
(4)
Heat Exchanger Components
The heat exchanger uses seawater to cool the
engine’s internal coolant system. The inside of the (9) (5)
(6)
heat exchanger consists of many small diameter
tubes and baffle plates. The coolant flows through
the maze formed by the baffle plates. Seawater
flows around these tubes and baffles and carries
(8)
away the heat of the engine. (7)
0006210

Reservoir
Figure 7-11
There is a reservoir in the upper part of the exhaust
manifold, which serves as the coolant tank. There 1 – Aft Cover
is a passageway for the exhaust gases in the 2 – O-Ring
reservoir, which forms a water-cooled exhaust 3 – Filler Cap
manifold. 4 – Seal
5 – Coolant Tube Core
Filler Cap 6 – Gasket
7 – Forward Cover
The filler cap (Figure 7-11, (3)) on top of the 8 – O-Ring
coolant tank has a pressure valve, which lets off 9 – Gasket
steam through the overflow pipe when pressure in
the coolant system exceeds the specified value. It Heat Exchanger Specifications
also takes in air from the overflow pipe when
No. of Tubes 214
pressure in the coolant system drops below the
normal value. 5.35 mm
Tube Inner Diameter
(0.210 in.)
687.5 mm
Core Length
(27.067 in.)
2641 mm2
Tube Surface Area
(4.10 sq. in.)

Disassembling the Heat Exchanger

WARNING! Allow engine to cool before working
on the heat exchanger.
1. Remove the heat exchanger from the cylinder
head.
2. Remove the forward and aft covers, O-rings,
gaskets and cooler core.
NOTICE: Replace the O-rings and gaskets with
new ones whenever the coolant tube core is
removed.

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 COOLANT SYSTEM Heat Exchanger Components and Functions

Inspecting the Heat Exchanger Heat Exchanger Body Leakage Test

Perform a leakage test on the heat exchanger.
Inspecting the Coolant Tubes
Fit rubber covers on the inlets and outlets of the
1. Inspect the inside of the tubes for rust or scale
heat exchanger. Submerge the heat exchanger in
buildup from seawater and clean with a wire
water. Pressurize the tank to the listed pressure
brush (Figure 7-12).
and check for leaks.
NOTICE: Disassemble and wash when the
coolant temperature reaches 85°C.
Test Pressure
Figure 7-12

0.2 MPa (29 psi)

Figure 7-13

(3)
(2)
(1)

(4)
(5)

(7) (6) 0006212

Figure 7-13
0006211
1 – Filler Cap
Figure 7-12 2 – Air Hose
3 – Pressure Gauge
2. Check the joints at both ends of the tubes for 4 – Coolant Tank
looseness or damage. Repair if loose. Replace 5 – Rubber Plug
if damaged or corroded. 6 – Heat Exchanger Body
3. Check the tubes and replace if leaking. 7 – Rubber Plug

4. Clean any scale or rust from the outside of the Pressure Cap Operation
tubes. When cleaning the inside of the tubes,
use a nylon brush which fits inside the tubes. The pressure cap, installed on the coolant filler
neck, incorporates a pressure control valve. The
Inspecting the Cooler Body cap is installed on the filler neck by placing it on the
locking tab and rotating. The top seal of the cap
1. Check the heat exchanger body and the end
seals the top of the filler neck and the pressure
covers for dirt and corrosion. Replace if
valve (Figure 7-14, (3)) seals the locking seat.
excessively corroded or cracked.
2. Inspect the seawater and coolant inlets and The pressure valve and vacuum valve
outlets, retighten any joints as necessary and (Figure 7-15, (2)) both seal when the pressure in
clean the insides of the hoses and lines. the coolant system is within the specified value of
0.11 MPa (16 psi). This seals the coolant system.

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 Heat Exchanger Components and Functions COOLANT SYSTEM
12/05

Figure 7-16

Pressure Valve Operation

Figure 7-14

(1) (1)

(2)

(3)
0006348 0006214

Figure 7-14 Figure 7-16

1 – Pressure Valve Spring 1 – Pressure Valve Identification
2 – Overflow Tube
3 – Pressure Valve Inspecting the Pressure Cap
Vacuum Valve Operation WARNING! NEVER open the pressure cap while
Figure 7-15
the engine is running or right after shutting
down because high temperature steam will be
blown out. Remove the cap only after the
coolant has had a chance to cool down.
1. Remove scale and rust, check the seat and
seat valve, etc. for scratches or wear and the
spring for corrosion or settling. Replace if
(2) (1) 0006349 necessary.
NOTICE: Clean the pressure cap with fresh
Figure 7-15
water.
1 – Vacuum Valve Spring
2 – Vacuum Valve
2. Fit the adapter of the tester to the pressure cap
(Figure 7-17).
When the pressure within the coolant system Figure 7-17

exceeds the specified value, the pressure valve

opens and steam is discharged through the
overflow pipe into the coolant recovery tank. When
the coolant cools and the pressure drops below the
normal value, atmospheric pressure opens the
vacuum valve and air is drawn in through the
overflow pipe.
The coolant recovery tank keeps the coolant level
from dropping due to discharge of steam when the
0006215
pressure valve opens.
Figure 7-17
Pressure Cap Specifications
3. Pump the tester until the pressure gauge is
Pressure Valve Open at 93-123 kPa (13-18 psi) within the specified pressure range 93 to
Vacuum Valve Open at 5 kPa (0.7 psi) or below 123 kPa (13 to 18 psi) and note the gauge
reading. The cap is normal if the pressure holds
NOTICE: The pressure cap for the 6LY3 is different
for 6 seconds. If the pressure does not rise, or
from the caps for the 6LYA and L6LY2A. The
drops immediately, inspect the cap and repair
pressure value 1.1 is punched on the top of the cap
or replace as necessary.
for 6LY3 as shown in Figure 7-16.

6LY3 Service Manual 7-15

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 COOLANT SYSTEM Coolant Recovery Tank Components and Functions

COOLANT RECOVERY TANK

Coolant Recovery Tank Specifications
COMPONENTS AND
Overall Capacity 3.4 L (0.90 gal)
FUNCTIONS Full Line Capacity 1.5 L (0.396 gal)
The pressure valve opens to discharge steam when Low Line Capacity 0.43 L (0.113 gal)
the steam pressure in the coolant tank exceeds 93
to 123 kPa (13 to 18 psi). This consumes coolant. Installing the Coolant Recovery Tank
The coolant recovery tank captures the discharge
of coolant. 1. The coolant recovery tank is installed at
approximately the same height as the pressure
The steam discharged into the coolant recovery cap on the coolant tank (allowable difference in
tank condenses and the coolant level in the coolant height: 300 mm (11.8 in.) or less).
recovery tank rises. 2. The overflow pipe should be less than
When the pressure in the coolant system drops 1000 mm (39.4 in.) long and installed so that it
below the normal value, the coolant in the coolant does not sag or bend.
recovery tank is drawn back into the coolant tank to NOTICE: Make sure the overflow pipe of the
raise the coolant level back to its original level. coolant recovery tank is not submerged in the
bilge. If the overflow pipe is submerged in the
The coolant recovery tank allows for long hours of bilge, water in the bilge will be siphoned into the
operation without coolant replacement and coolant tank when the water is being cooled.
eliminates the possibility of burns when the steam
is ejected from the filler neck because the pressure Coolant Recovery Tank Precautions
cap does not need to be removed.
Check the coolant recovery tank when the engine is
cool. Refill with coolant as needed to bring the
Figure 7-18

(1) (2) coolant level between the low and full marks.
Check the overflow line and replace if it is bent or
cracked. Clean out the pipe if it is clogged.

(3)

130
150

200
FU
LL

LO
W

0006216

Figure 7-18
1 – Filler Cap
2 – Coolant Tank
3 – Subtank

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 Thermostat Components and Functions COOLANT SYSTEM
12/05

THERMOSTAT COMPONENTS
AND FUNCTIONS No. Item Measurement
1 Date of Manufacture —
The thermostat opens and closes a valve according
to changes in the coolant temperature inside the 2 Jiggle Valve R21.5 or more
engine. This controls the volume of coolant flowing 3 Valve Open Temperature —
to the heat exchanger from the cylinder head and, 4 Adjustment Fittings Ø8 mm (0.314 in.)
in turn, maintains the coolant temperature in the
5 Stopper Ø14 mm (0.551 in.)
engine at a constant level.
6 Piston Ø6.4 mm (0.251 in.)
The thermostat is a bottom bypass type. It is 7 Pellet —
located in a position connected with the cylinder
8 Valve t0.8 mm (0.31 in.)
head outlet line at the top of the coolant pump unit.
9 Seat t1 mm (0.39 in.)
When the coolant temperature exceeds the
10 Attachment Frame t1 mm (0.39 in.)
opening temperature, the thermostat opens and a
portion of the coolant is sent to the heat exchanger 11 Spring Ø3 mm (0.118 in.)
and cooled by seawater. The other portion flows 12 Helper Springs Ø1.8 mm (0.070 in.)
from the bypass line to the coolant pump intake. 13 Bypass Valve t0.6 mm (0.023 in.)

The bypass line is closed off as the thermostat 14 Pipe Ø15 mm (0.590 in.)
valve opens and is completely closed when the 15 E-Snap Ring E9
coolant temperature reaches 81.5°C (179°F). The
The thermostat used in this engine is a wax pellet
valve lifts 4 mm (0.16 in.), sending all of the coolant
type, with a solid wax pellet located in a small
to the heat exchanger.
chamber.
Figure 7-19

(1) (2) When the coolant temperature rises, the wax melts
(3) and increases in volume. This expansion and
contraction is used to open and close the valve.

Thermostat Specifications
Opening Temperature 69-73°C (156-163°F)
(4) Full Open Temperature 85°C (185°F)
(5)
Valve Lift at Full Open 10 mm (0.393 in.)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15) 0006217

Figure 7-19

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 COOLANT SYSTEM Thermostat Components and Functions

Inspecting the Thermostat Testing the Thermostat

Remove the thermostat cover (Figure 7-20, (3)) 1. Place the thermostat (Figure 7-21, (2)) in a
on the side of the coolant tank and take out the beaker of fresh water and heat it on an electric
thermostat. stove. The thermostat is functioning normally if
it starts to open between 69 and 73°C
Clean off the scale and rust and inspect.
(156 and 163°F), and opens to 10 mm
Replace if the performance characteristics have (0.4 in.) or more at 85°C (185°F). Replace the
changed, or if the spring is broken, deformed or thermostat if it is not functioning normally.
corroded.
Figure 7-20
Thermostat Specifications
Valve Opening
(2) Full Open Lift
Temperature*
(1)
10 mm (0.4 in.) at
(3) 69-73°C (156-163°F)
85°C (185°F) or more
* Valve opening temperature is stamped on the
flange.
Figure 7-21

(1)

(2)

0006218

Figure 7-20
1 – Thermostat
2 – Gasket
3 – Thermostat Cover
0006198

Figure 7-21
1 – Thermometer
2 – Thermostat
2. The thermostat should be inspected every 500
hours of operation. It should be inspected
sooner if the engine temperature rises
abnormally or white smoke is emitted any time
during engine operation.
3. Replace the thermostat every year or 2000
hours of operation, whichever comes first.

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 Seacock Components and Functions (Optional) COOLANT SYSTEM
12/05

SEACOCK COMPONENTS AND Seacock Precautions

FUNCTIONS (OPTIONAL) Always close the seacock after each day of use and
confirm that it is open before the beginning of the
The seacock, installed on the bottom of the hull next day of operation.
(Figure 7-22, (2)), controls the intake of seawater
into the boat. The seacock serves to filter the If the seacock is left open, seawater will flow in
seawater so that mud, sand and other foreign reverse and the vessel will sink if trouble occurs
matter does not enter the seawater pump. with the water pump.
If the engine is operated with the seacock closed,
Figure 7-22

(2) coolant will not be able to get in, resulting in engine

and pump trouble.

Inspecting the Seacock

(3)
(1) When the seawater volume has dropped and the
(4)
water pump is normal, inspect the seacock. The
vessel must be removed from the water to check for
clogging and to inspect the seacock.
If water leaks from the seacock, disassemble and
inspect for wear. If any damage is found, repair or
replace the seacock.
(5)

(6)

(7)
0006219

Figure 7-22
1 – Suction Hose
2 – Hull
3 – Cock
4 – Seacock Cover
5 – Bolt
6 – Scoop Strainer
7 – Bolt
Numerous holes are drilled into the water side of
the seacock and a scoop strainer is installed to
prevent debris from entering the system.

6LY3 Service Manual 7-19

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 COOLANT SYSTEM Bilge Pump and Strainer Components and Functions (Optional)

BILGE PUMP AND STRAINER COMPONENTS AND FUNCTIONS

(OPTIONAL)
Bilge Pump and Strainer Components Specifications
Name Bilge Pump
Time 10 min.
Rotation Direction Right (viewed from the impeller side)
Negative Pressure Detector Diaphragm type
Temperature -30°C to 80°C (-22°F to 176°F)
Figure 7-23

(1)

(2)

(3)

(12)
(4)
(5)
(6)

(11)
(10)
(7)
(8)
(9)
0006220

Figure 7-23

1 – Motor Assembly 7 – Red (+) Cable

2 – Controller 8 – Battery
3 – White Connector 9 – White (-) Cable
4 – Green Connector 10 – Inlet
5 – Blue Connector 11 – Strainer
6 – Red Connector 12 – Outlet

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 Bilge Pump and Strainer Components and Functions (Optional) COOLANT SYSTEM
12/05

Bilge Pump Characteristics Bilge water that is left in the hoses, pickup strainers
and pumps will freeze in cold temperatures. Take
Discharge Capacity at 0 m lift: 20 L (5.2 gal) or care to ensure that all residual water is completely
more. discharged from the bilge pump system in
Automatic Feed Height: 1 to 2 m (3.2 to 6.4 ft) or temperatures below 0°C (32°F). If necessary, use a
more. steaming towel to thaw frozen lines and
components. The pump will require an additional 5
Automatic Feed Time: 2 to 5 seconds. to 10 seconds to operate in freezing temperatures.
(Limit for automatic feed time for a new pump in
primed condition: approximately 1 second.) The pump can be run continuously for a period of
10 minutes. After this time it must be shut off for a
Automatic Shut-Off: Air intake causes negative (-) period of 2 hours before reuse.
pressure triggering automatic shut-off.
NEVER use the pump for showering. If the pump
Bilge Pump Insulation outlet is modified for showering, the increase in
water pressure will cause the pump motor to seize.
Insulation resistance: 500V with a mega tester
when the difference between the continuity point NEVER use the pump to drain off rain water or
and the body is 1 MΩ or greater. large amounts of water.
Insulation proof stress: AC50 between the NEVER submerge the pickup strainer in bilge
continuity point and the body, or 60 Hz 500V for 1 sludge. Position the strainer about 20 mm (0.8 in.)
minute when impressed current leakage is 10 mA above the sludge. Clear the pump of all sludge
or lower. before shutting the bilge pump down.

Bilge Pump Durability Ensure that the battery is properly charged with a
specific gravity of 1.25 or more.
Rated voltage when there is 3% saltwater 60 L +
engine oil 3%, and operation is at 1800 cycles and Installing the Bilge Pump
there are no difficulties.
1. Select a dry place above the bilge water level.
Bilge Pump Vibration Proof 2. Select the location for the bilge pump, taking
• Amplitude 0.51 mm (0.02 in.) (one side of the into consideration the length of the switch cable,
amplitude) its attachment point and the position of the
battery.
• Vibration frequency of 10-55 Hz 3. Orient the pump at 45° with the impeller on the
• Sweep time 90 seconds low end and the nozzles facing up. Select a
position approximately 50 to 70 cm (20 to 28
• Direction of vibration each direction 4 hours in.) from the bottom of the boat.
• No difficulties after test period 4. Keep the cord terminal away from the water.
Water inside the terminal or switch may lead to
Bilge Pump Precautions damage. Use caution to avoid cuts or nicks in
the insulation of the cord to prevent water from
Never run the pump dry. Be sure the strainer is
entering.
submerged in the bilge water before activating. If no
water is being drawn up after a period of 10 Assembling the Switch
seconds, prime the pump. (Do not cavitate the
pump for longer than 10 seconds.) 1. Attach the switch in a dry place with easy
access.
When the pump has not been used for a long 2. Connect the pump to the battery. (No more than
period of time, the inside of the pump will loose its three lengths of the existing cable can be used
prime. Before reusing, clean the inside of the pump to extend the pump cables.)
and prime it to ensure that it is wet. Check that the
pump is discharging water correctly.

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 COOLANT SYSTEM Bilge Pump and Strainer Components and Functions (Optional)

Positioning the Strainer Installing the Strainer

1. Attach the strainer in the lowest position of the After testing the bilge pump, install the strainer in
bilge about 20 mm (0.8 in.) above any sludge. place with bolts. (Avoid damaging the hull.)
2. Attach the strainer with a 1.2 to 1.8 m (4 to 6 ft)
Replacing the Bilge Pump Impeller
length of hose and allow plenty of slack.
NOTICE: The bilge pump impeller should be
3. Secure the strainer so that it will not turn upside
replaced by an authorized YANMAR service center.
down or on its side. Use the supplied hose and
avoid thin vinyl hose and hose that is not heat “Bolt Lock” is applied to the threads of the impeller
resistant. plate mounting bolts. Use a hair dryer to soften the
4. Check the strainer operation before tightening lock on the threads.
its mounting hardware. (Avoid damaging the
1. Remove the four M4 bolts that secure the
hull.)
impeller plate on top of the diaphragm switch.
5. The strainer contains a weight and can be used
2. Clean the impeller, the impeller cavity and the
with the weight in place.
impeller plate.
6. Always keep the strainer clean.
3. Apply a light coat of grease to the impeller, the
Attaching the Bilge Pump Outlet Nozzle plate and the side-gap adjusting shim(s).
1. Install the outlet nozzle on the discharge side of 4. Insert the shim(s) first and then the impeller.
the pump. 5. Install the impeller plate.
2. Make a hole of 21 mm (0.8 in.) or less for
Adjusting the Bilge Pump Impeller Side Gap
attaching the nozzle. The hose attached at the
nozzle should be 1.8 m (6 ft) or less and should The impeller replacement kit includes one impeller
connect without strain. and three shims for adjusting the impeller side gap.
If the bilge pump has no output after replacing the
Attaching the Hoses
pump impeller, shim the impeller to obtain the
1. Use a regulation hose. NEVER use a thin vinyl specified pump characteristics.
hose or a non-heat resistant hose. Attach the
hose from the strainer to the pump inlet. Make Ensure that the pump is performing to capacity by
the hose as short as possible and avoid sharp checking the current flow during operation. Select a
bends. shim combination that provides for a 10A current
draw at 12VDC or a 5A current draw at 24VDC.
2. Attach the delivery nozzle hose to the nozzle
outlet. NOTICE: If too many shims are used, the electric
current will be too great and will blow a fuse.
Testing the Bilge Pump
1. Check for any problems with the hose or wiring.
Then, connect the battery.
2. Add water to the bilge.
3. Turn the pump switch to ON. Verify that the
water is drawn in and discharged properly. The
pump will stop automatically when there is no
water left.
4. If the pump cavitates for more than 10 seconds,
lift the strainer above the water level and stop
the pump. Prime the pump before running it
again.

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 Bilge Pump and Strainer Components and Functions (Optional) COOLANT SYSTEM
12/05

Troubleshooting the Bilge Pump

Refer to the following countermeasures for difficulties that arise.

Problem Cause Countermeasure

Pump does not turn. Faulty wiring. Check the wiring between the motor and
battery.
Faulty battery. Check to see if the specific gravity of the
battery fluid is greater than 1.25.
Recharge or replace the battery.
Faulty starter switch. Consult your local Yanmar Marine dealer.
Faulty pump. Consult your local Yanmar Marine dealer.
Pump turns, but does not draw up water. Draws up air. Check the hose connections.
Retighten the pump bolts.
Low voltage in the battery. Check to see if the specific gravity of the
battery fluid is greater than 1.25.
Recharge or replace the battery.
The distance between the pump and the Lower the pump. (Position the pump so
surface of the water is too great. that it is closer to the surface of the water.)
The pump is too high. Lower the pump. (Position the pump so
that it is 50-70 cm (20-28 in.) above the
bottom of the boat.)
The pump intake is weak. If the intake is still faulty after priming,
consult your local dealer.
Pump turns, but the amount of discharge Clogged strainer. Clean the strainer.
is low.
The hose is broken or damaged. Check for damage and repair. If the
incorrect hose has been used, replace
with the regulation type of hose.
Water leakage from the pump. There is water leakage from the seals. Retighten the pump bolts.
Faulty pump seal. Consult your local Yanmar Marine dealer.
Pump draws up bilge, but the motor stops Faulty diaphragm switch. Check for loose wiring in the diaphragm
when the hand is removed from the starter switch and correct.
switch.
Damaged diaphragm switch. Consult your local Yanmar Marine dealer.
Motor does not stop when there is no bilge Clogged strainer or hose. Clean the strainer or hose.
water left.
Damaged diaphragm switch. Check for continuity at the diaphragm
switch terminal. Consult your local
Yanmar Marine dealer if there is
continuity.

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 COOLANT SYSTEM Bilge Pump and Strainer Components and Functions (Optional)

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 6LY3 Service Manual
Section 8

LUBRICATION
Page
Safety Precautions .......................................................................... 8-3
Introduction...................................................................................... 8-3
Lubrication Components and Functions.......................................... 8-4
Oil Pump Components and Functions............................................. 8-5
Oil Pump Specifications............................................................. 8-5
Oil Pump Components .............................................................. 8-6
Removing the Oil Pump............................................................. 8-7
Inspecting the Oil Pump ............................................................ 8-7
Installing the Oil Pump............................................................... 8-7
Oil Pressure Control Valve Components and Functions ........... 8-8
Replacing the Oil Pressure Control Valve ................................. 8-8
Oil Filter Components and Functions .............................................. 8-9
Replacing the Oil Filter ............................................................. 8-9
Oil Cooler Components and Functions ......................................... 8-10
Inspecting the Oil Cooler ......................................................... 8-10
Rotary Waste Oil Pump Components and Functions (Optional) ... 8-10
Rotary Waste Oil Pump Components...................................... 8-11
Inspecting the Waste Oil Pump ............................................... 8-11

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 LUBRICATION

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8-2 6LY3 Service Manual

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 Safety Precautions LUBRICATION
12/05

SAFETY PRECAUTIONS INTRODUCTION

Before servicing the 6LY3 marine engine lubrication This section of the Service Manual describes the
system, read the following safety information and procedures necessary to service the 6LY3 marine
review the Safety Section on page 2-1. engine lubrication systems.

Indicates a situation which can cause damage to

the machine, personal property, the environment or
cause the equipment to operate improperly.

Only use the engine oil specified. Other engine oils

may affect warranty coverage, cause internal
engine components to seize and / or shorten
engine life. NEVER mix different types of engine oil.
This may adversely affect the lubricating properties
of the engine oil.

ALWAYS be environmentally
responsible.
Follow the guidelines of the EPA or
other governmental agencies for the
proper disposal of hazardous materials such as
engine oil, diesel fuel and engine coolant. Consult
the local authorities or reclamation facility.
NEVER dispose of hazardous materials by
dumping them into a sewer, on the ground or into
ground water or waterways.

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 LUBRICATION Lubrication Components and Functions

LUBRICATION COMPONENTS The oil, which flows in the main gallery, goes to the
crankshaft journals (Figure 8-1, (9)) and lubricates
AND FUNCTIONS the crank pins from the crankshaft journals.
The engine oil in the oil pan is pumped up through Oil for the fuel injection pump (Figure 8-1, (1)) is
the oil intake filter (Figure 8-1, (11)) and intake line sent by lines from the main gallery to the fuel
by the oil pump (Figure 8-1, (12)). The oil is injection pump (Figure 8-1, (1)).
pumped to the oil cooler (Figure 8-1, (2)) and the
filter assembly (Figure 8-1, (4)). The oil is sent to Oil for the turbocharger (Figure 8-1, (6)) is sent by
the oil pressure regulating valve (Figure 8-1, (10)), lines from the oil filter (Figure 8-1, (5)) to the
which controls the oil pressure. Then it goes turbocharger (Figure 8-1, (6)).
through the holes in the cylinder body and
dispersed to the parts to be lubricated. The oil pressure throughout the system is regulated
by the safety valve (Figure 8-1, (13)) and then by
the oil pressure regulating valve (Figure 8-1, (10)).
Figure 8-1

(3) (5)
(2)
(4)
(1)

(12)
(11)
(10)

(9)
(13)

(8) (7)

(14) (6)
0006221

Figure 8-1

1 – Fuel Injection Pump 8 – Cam Bearings

2 – Oil Cooler 9 – Main Bearings
3 – Bypass Oil Filter 10 – Oil Pressure Regulating Valve
4 – Filter Assembly 11 – Oil Intake Filter
5 – Full Flow Oil Filter 12 – Oil Pump
6 – Turbocharger 13 – Safety Valve
7 – Rocker Arm Shaft 14 – Heat Exchanger

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 Oil Pump Components and Functions LUBRICATION
12/05

OIL PUMP COMPONENTS AND Oil Pump Specifications

FUNCTIONS
Pump Test Performance
The gear-type oil pump is installed on the cylinder Theoretical Delivery 32.8 cc (1.1 oz) per
block (Figure 8-2, (1)). The pump is driven by the revolution
crankshaft gear through the idler gear
Delivery 94.5 L (25 gal) or more
(Figure 8-2, (2)). An oil pressure regulating valve
(Figure 8-2, (6)) is located on the cylinder block Delivery Pressure
0.8 MPa (116 psi)
(Safety Valve)
behind the oil cooler.
Pump Speed 3200 rpm
Figure 8-2

Engine Speed 3200 rpm

Specification of Drive Gear

(1)
Module 2.5
Angle of Pressure 20°

(2) Number of Teeth 24

(6)
Standard Pitch Diameter 66.203 mm (2.606 in.)

(5) (3)

(4)
0006222

Figure 8-2
1 – Cylinder Block
2 – Idler Gear
3 – Shims
4 – Oil Pump
5 – Intake Filter
6 – Oil Pressure Regulating Valve

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 LUBRICATION Oil Pump Components and Functions

Oil Pump Components

Figure 8-3

33
76
(3) (4) (5)
(2)
200 (6)
100 103
(1)
35 35
36.5
55

76.879
(14)
(13)
(12)

(43.758)
52 (7)
(11) (10) (9) (8)
0006223

Figure 8-3

1 – Direction of Rotation 8 – Gear

2 – Cover 9 – Washer
3 – Shaft 10 – Safety Valve Case
4 – Gear 11 – Seat
5 – Case 12 – Spring Pin
6 – Drive Gear 13 – Spring
7 – Shaft 14 – Ball

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 Oil Pump Components and Functions LUBRICATION
12/05

Removing the Oil Pump

Figure 8-5

(1)
1. Drain the engine oil while the engine is still
warm. WARNING! If the engine oil must be
drained while it is still hot, stay clear of the
hot engine oil to avoid being burned.
ALWAYS wear eye protection.
2. Remove the oil pan and spacer.
3. Remove the oil inlet and outlet tubes.
4. Remove the oil pump.
5. Dispose of used engine oil properly. NOTICE: (2)
0006225
ALWAYS be environmentally responsible.
Figure 8-5
Inspecting the Oil Pump
1 – Straight Edge
1. Remove the oil pump cover. 2 – Feeler Gauge
2. Measure the oil pump gear to oil pump body NOTICE:
clearance.
1. The oil pump should be disassembled only
NOTICE: If the measured value exceeds the
when oil pressure is insufficient even after
service limit, or if there is local wear, replace the
adjusting the oil pressure regulator valve.
oil pump assembly.
2. When assembling, make sure the oil pump
Oil Pump Specifications gears rotate smoothly.
Gear-to-pump 0.098 mm (0.0039 in.)
Installing the Oil Pump
Gear-to-cover 0.093 mm (0.0037 in.)
1. Install the oil pump on the main bearing cap.
3. Measure the oil pump gear-to-pump body 2. Make sure the surface of the oil pump drive
clearance. gear and the surface of the idler gear are flush.
Figure 8-4

Tighten the pump bolts temporarily.

3. Rotate the crankshaft so the engagement of the
teeth is parallel.
4. Tighten the pump bolts.
(1)
5. Check the backlash of the drive gear.
Drive Gear Backlash
0.08-0.26 mm (0.0032-0.01 in.)

6. Use new O-rings and attach the oil inlet and

0006224
outlet tubes.
Figure 8-4 7. Install the oil pan. See Installing the Oil Pan on
page 5-61.
1 – Feeler Gauge
8. Install all drain plugs.
4. Measure the oil pump gear-to-pump cover
clearance with straight edge and gauge 9. Fill with the recommended engine oil to the
(Figure 8-5). upper level.

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 LUBRICATION Oil Pump Components and Functions

Oil Pressure Control Valve

Figure 8-6

Components and Functions

Engine oil flows from the oil cooler to the oil filter
and is directed on to the main gallery of the cylinder
block. The oil pressure is regulated by the oil
pressure control valve just before the oil enters the
main gallery.
When the pressure of the oil entering the main
gallery of the cylinder block exceeds the standard,
(1)
the pressure control valve piston opens a pressure
outlet and allows excess oil to drain back to the oil
pan.

Regulating Pressure at 3300 rpm

0.40-0.50 MPa (58-73 psi)
(2)
Replacing the Oil Pressure Control
Valve (3)
(4)
The control valve was set at the factory, it should
not require adjustment. (5)
(6)
If the oil pressure control valve is disassembled due
to spring trouble, install a pressure gauge on the oil (7)
pressure sending unit mounting washer. Adjust the
pressure with adjustment shims until it is at the 0006226

specified value.
Figure 8-6

Thickness of Adjustment Shim 1 – Oil Pressure Control Valve

2 – Bracket
0.2, 0.5, 1.0 mm
3 – Valve
(0.008, 0.02, 0.04 in.)
4 – Spring
5 – Shim
6 – Seal
7 – Plug

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 Oil Filter Components and Functions LUBRICATION
12/05

OIL FILTER COMPONENTS AND

Figure 8-8

FUNCTIONS
The oil filter assembly is installed on top of the
intercooler.
It consists of a full flow oil filter and a bypass oil
filter. Both the full flow oil filter and bypass oil filter
have paper type components. These filters are
easy to remove.
(3)
To prevent seizure in the event of the filter clogging, (2)
a bypass circuit is provided. (1)
0006228
Figure 8-7

(1) (2) (3) (4) (5) Figure 8-8

1 – Full Flow Oil Filter
2 – Filter Bracket
3 – Bypass Oil Filter

Specifications
(7) Full-flow Bypass
0.03 MPa 3.4 L (3.6 qt) /
(6) (4.4 psi) or less minimum
Deferential press.
Pressure Loss In / out
50 L / min. 0.44 MPa
SAE#30 (4.5 kgf / cm2)
80°C (176°F) (64 psi)
SAE#30
0006227 80°C (176°F)
Figure 8-7 Relief Valve 0.18 ± 0.02 MPa
Pressure (Open) 1.8 ± 0.2 kgf/cm 2 —
1 – Cover Seal (26 psi)
2 – Cover Assembly
3 – Filter Element Filtration Area 5800 cm2 5700 cm2
(899 sq. in.) (884 sq. in.)
4 – Filter Case
5 – Set Spring Filtration (Nominal) 20 µ 1µ
6 – Caution Label
7 – Element Seal Replacing the Oil Filter
See Removing the Oil Filter and Oil Cooler on
page 5-20 and Installing the Engine Oil Filters on
page 5-71.

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 LUBRICATION Oil Cooler Components and Functions

OIL COOLER COMPONENTS ROTARY WASTE OIL PUMP

AND FUNCTIONS COMPONENTS AND
The engine oil flows through the oil cooler and is FUNCTIONS (OPTIONAL)
cooled by the coolant system.
A rotary waste oil pump (Figure 8-10), used to
Figure 8-9
pump out waste oil during oil changing, is available
(1) as an option. This is a vane-type pump. Turning the
(2) handle rotates the vanes and pumps out the waste
(3)
oil.
(4)
Figure 8-10

(5)
(6)
(7)

0006229
0006230

Figure 8-9
(1)
1 – Aft Oil Cooler Cover
2 – Gasket
3 – O-Ring
4 – Gasket
5 – Cooler Core
6 – O-Ring
7 – Forward Oil Cooler Cover

Inspecting the Oil Cooler 0006231

1. Clean the inside of the seawater tubes with a Figure 8-10

nylon brush to prevent scale buildup.
2. If the rubber hose connection or welds are 1 – Rubber Hose
corroded, repair or replace the cooler.
3. Apply the following water pressures to the
seawater and oil lines to check for any leaks.
Repair or replace the cooler if there are any
leaks.

Oil Cooler Test Pressure

Oil Circuit 0.8 MPa (116 psi)
Seawater Path 0.3 MPa (44 psi)

8-10 6LY3 Service Manual

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 Rotary Waste Oil Pump Components and Functions (Optional) LUBRICATION
12/05

Rotary Waste Oil Pump Components Inspecting the Waste Oil Pump
1. Disassemble the waste oil pump and check for
Rotary Waste Oil Pump Specifications spring (Figure 8-11, (5)) breakage or vane
Delivery Capacity of One
0.13 L (0.3 pt)
(Figure 8-11, (7)) damage when there is an
Stroke extreme drop in discharge volume. Replace
Delivery Pressure 0.15 MPa (22 psi) or below damaged components, if necessary.
Suction Head less than 1 m (39.4 in.) 2. Replace the oil seal (Figure 8-11, (3)) if there is
Figure 8-11 excessive oil leakage from the handle shaft
(8) (1) (Figure 8-11, (4)).
(2) 3. Replace the impeller if there is an excessive
gap between the impeller and the covers on
(3) both sides of the casing. This will cause a drop
(7) in discharge volume.
(4) 4. The hose coupling threads are coated with
adhesive when installed. It cannot be removed
(6) from the body.
(5)

0006232

Figure 8-11
1 – Body
2 – Cover
3 – Oil Seal
4 – Shaft
5 – Spring
6 – Spindle
7 – Vane
8 – Cover

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 LUBRICATION Rotary Waste Oil Pump Components and Functions (Optional)

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 6LY3 Service Manual
Section 9

TURBOCHARGER
Page
Safety Precautions .......................................................................... 9-3
Introduction...................................................................................... 9-3
Turbocharger Components and Functions...................................... 9-4
Turbine ...................................................................................... 9-5
Compressor ............................................................................... 9-5
Bearings .................................................................................... 9-5
Seal Structure of the Compressor Housing ............................... 9-5
Maintenance Standards .................................................................. 9-6
Standard Limits.......................................................................... 9-6
Torque Chart ............................................................................. 9-8
Turbocharger Periodic Inspections.................................................. 9-9
Inspection Intervals.................................................................... 9-9
Checking the Rotor Rotation ..................................................... 9-9
Checking the Rotor Axial Play ................................................. 9-10
Checking the Rotor Radial Play............................................... 9-11
Disassembling the Turbocharger .................................................. 9-12
Special Tools ........................................................................... 9-12
Inspecting the Turbocharger Before Disassembling................ 9-14
Disassembling the Turbocharger............................................. 9-14
Inspecting the Turbocharger ......................................................... 9-15
Inspecting Major Items ............................................................ 9-15
Cleaning the Turbocharger...................................................... 9-15
Inspecting the Turbocharger Components .............................. 9-16
Assembling the Turbocharger ....................................................... 9-19
Installing the Floating Bearings ............................................... 9-19
Installing the Turbine Rotor Shaft ............................................ 9-20
Installing the Thrust Bearing.................................................... 9-20

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 TURBOCHARGER
Installing the Seal Plate........................................................... 9-20
Installing the Compressor Impeller.......................................... 9-21
Installing the Turbine Housing................................................. 9-21
Installing the Compressor Housing ......................................... 9-21
Connecting the Boost Hose..................................................... 9-21
Post-Assembly Inspection ....................................................... 9-21
Handling the Turbocharger............................................................ 9-22
Precautions for Installing the Turbocharger to the Engine ...... 9-22
Troubleshooting the Turbocharger ................................................ 9-23
Black Smoke ........................................................................... 9-23
White Smoke ........................................................................... 9-24
Excessive Oil Consumption..................................................... 9-24
Reduced Engine Power........................................................... 9-24
Poor Follow-Up of the Turbocharger ....................................... 9-24
Unusual Sound or Vibration .................................................... 9-25

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 Safety Precautions TURBOCHARGER
12/05

SAFETY PRECAUTIONS INTRODUCTION

Before servicing the engine turbocharger, review This section of the Service Manual describes the
the Safety Section on page 2-1. procedures necessary to service the 6LY3 marine
engine turbocharger.

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 TURBOCHARGER Turbocharger Components and Functions

TURBOCHARGER COMPONENTS AND FUNCTIONS

The RHC7W turbocharger has been adapted for use on the 6LY3 engine as well as the 6LY2. This
compressor has a high-power output rating.
Figure 9-1

(18)
(15) (17)
(12)
(11)
(10)
(2) (16)
(9)
(3) (14)
(1) A
(2)
(13)

(28)
(8) (27)
A
(7) (26)
(6)
(24)
(22)
(20)

(5) (4)
(23) (25)

(21)
(19) 0006084

Figure 9-1

1 – Boost Hose 15 – Floating Bearing

2 – Clip 16 – Thrust Bushing
3 – Turbine Housing 17 – Thrust Bearing
4 – Wastegate Actuator 18 – TORX T (M3) Machine Screw
5 – TORX T (Flat Head) Machine Screw 19 – Oil Thrower
6 – E-Circlip 20 – Large Seal Ring
7 – Turbine Pressure Plate 21 – Small Seal Ring
8 – Turbine Hexagon Bolt 22 – Seal Plate
9 – Turbine Rotor Shaft 23 – TORX T (M4) Machine Screw
10 – Turbine Seal Ring 24 – Compressor Impeller
11 – Insulation Plate 25 – Turbine Rotor Shaft End Nut
12 – Bearing Housing 26 – Compressor Hexagon Bolt
13 – Floating Bearing “B” 27 – Compressor Pressure Plate
14 – Retaining Rings 28 – Compressor Housing

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 Turbocharger Components and Functions TURBOCHARGER
12/05

Turbine Bearings
Exhaust gases coming out of the engine are The thrust bearing (axial bearing) prevents the
accelerated through the nozzle and directed on the turbine shaft from shifting due to the constant thrust
blades of the turbine rotor. This adds rotational loads of the turbine. The radial bearings use double
torque to the turbine shaft. oil films on their inside and outside surfaces that
flow in the direction of bearing rotation. This
The body of the turbine provides seal rings and reduces frictional drag on the face of the bearing
housings designed to protect the bearings from the and contributes to the dynamic stability of the
hot exhaust gases. turbocharger.
Compressor Seal Structure of the Compressor
The impeller of the compressor is installed on the Housing
other end of the turbine shaft. As the turbine is
accelerated by engine exhaust gases, it transmits A dual-wall structure is incorporated into the
the additional torque through the turbine shaft to pressure bulkhead of the compressor housing. This
the compressor impeller. The impeller compresses prevents pressurized intake air and oil from
intake air and delivers it to the intake manifold. entering the turbine. It consists of a seal ring and
an oil deflection plate.

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 TURBOCHARGER Maintenance Standards

MAINTENANCE STANDARDS
Standard Limits
Figure 9-2

E G2

F B A C H1 H2

G1
K

0005895

Figure 9-2

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 Maintenance Standards TURBOCHARGER
12/05

Item Check Item Limit of Use Remarks

(A) Turbine shaft journal O.D. 12.280 mm (0.4835 in.) See Turbine Rotor
(E) Turbine-Side Seal Ring Groove Width 1.630 mm (0.0642 in.) Shaft on page 9-16
Turbine Rotor Shaft (G1) Compressor-Side Seal Ring Groove Width 1.750 mm (0.0689 in.)
(G2) Compressor-Side Seal Ring Groove Width 1.520 mm (0.0598 in.)
Turbine Rotor Shaft Runout 0.011 mm (0.0004 in.)
See Floating
(C) Floating Bearing I.D. 12.360 mm (0.4866 in.)
Bearings on
Bearings (D) Floating Bearing O.D. 16.980 mm (0.6685 in.)
page 9-17
(B) Floating Bearing Base I.D. 17.110 mm (0.6736 in.)

See Thrust Bearing

(J) Thrust Bearing Width 4.480 mm (0.1764 in.)
Thrust Bearings and Oil Thrower on
(K) Thrust Bushing Groove-to-Groove Dimension 4.680 mm (0.1845 in.)
page 9-16
(F) Turbine-Side (Bearing Housing) 18.550 mm (0.7303 in.) See Bearing Housing
Seal Ring Insertion Parts (H1) Compressor-Side Seal Plate (Large) 16.050 mm (0.6319 in.) on page 9-18
(H2) Compressor-Side Seal Plate (Small) 14.050 mm (0.5531 in.)
See Checking the
Rotor Radial Play on
page 9-11
Play in Rotor Axial Direction 0.110 mm (0.0043 in.) Maintenance
Standard
0.06 mm-0.09 mm
(0.002-0.003 in.)
See Checking the
Rotor Axial Play on
page 9-10
Play in Rotor Radial Direction 0.215 mm (0.0084 in.) Maintenance
Standard
0.11 mm-0.18 mm
(0.004-0.007 in.)

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 TURBOCHARGER Maintenance Standards

Torque Chart
Figure 9-3

(1) (2) (3) (4)





(6) (5) 0005896

Figure 9-3

Reference Item Torque Special Instructions

1 Turbine Housing Hex Bolts (M8) 28 ± 1 N·m (20.6 ± 0.7 lb-ft) Coat with seizure preventative
Seal Plate TORX T (M4) Machine
2 3.7 ± 0.3 N·m (2.7 ± 0.2 lb-ft) Apply Loctite #242
Screw
3 Compressor Housing Hex Bolts (M8) 23 ± 1 N·m (16.9 ± 0.7 lb-ft) NA
Sealing Surface of Compressor
4 NA Fluid sealant to be applied here
Housing and Seal Plate
Compressor Impeller Shaft End Nut
5 7.8 ± 0.5 N·m (5.7 ± 0.3 lb-ft) NA
(M8) (Left-Hand Thread)
Thrust Bearing TORX T (M3)
6 1.27 ± 0.1 N·m (11.27 ± 0.8 lb-in) Apply Loctite #242
Machine Screw

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 Turbocharger Periodic Inspections TURBOCHARGER
12/05

TURBOCHARGER PERIODIC INSPECTIONS

Inspection Intervals
Periodically check the turbocharger for damage and overall condition. The inspection interval may vary due
to operating conditions. Refer to the table below for a guideline of when to inspect items under normal
conditions.

Purpose of Use Checking Intervals

For Marine Use Every 6 months or Every 12 months or Every 24 months or
Check Item 1500 operating hours 3000 operating hours 6000 operating hours
Rotation of Rotor O — —
Rotor Play — O —
Disassembly, Cleaning and Checking
— — O
of Entire Turbocharger

Checking the Rotor Rotation

Inspect the turbine rotor shaft by listening for any
abnormal sounds during operation. Use a listening
rod to help diagnose any potential problems.
Position the tip of the bar firmly on the turbocharger
case and gradually increase engine rpm. If
high-pitched sounds are generated at intervals of
2 to 3 seconds, some type of abnormal operation is
present. Any such indication is cause for
turbocharger inspection, overhaul or replacement.

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 TURBOCHARGER Turbocharger Periodic Inspections

Checking the Rotor Axial Play 4. Move the turbine / impeller back and forth in an
axial direction (Figure 9-4, (6)) and measure
1. Remove the turbocharger from the engine. travel on the dial indicator.
2. Cover all inlet openings to prevent any ingestion 5. Compare readings with the maintenance
of debris. standard limits that follow:
3. Install a magnetic dial indicator as shown in
Figure 9-4. Rotor Axial Play
0.06-0.09 mm (0.002-0.003 in.)
Limit: 0.11 mm (0.004 in.)

Figure 9-4

(3)

(1)

(2)

(6) (4)

(5)

0005897

Figure 9-4

1 – Turbine Housing 4 – Dial Indicator

2 – Oil Outlet 5 – Oil Inlet
3 – Magnetic Base 6 – Move the turbine rotor shaft in an axial
direction.

9-10 6LY3 Service Manual

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 Turbocharger Periodic Inspections TURBOCHARGER
12/05

Checking the Rotor Radial Play 3. Measure the travel with the dial indicator.
1. Set the magnetic dial indicator to measure 4. Compare readings with the maintenance
movement of the floating bearing as shown in standard limits that follow:
Figure 9-5. Rotor Radial Play
2. Grasp both the turbine and impeller and move 0.11-0.18 mm (0.004-0.007 in.)
them back and forth evenly in a radial direction Limit: 0.215 mm (0.0084 in.)
(Figure 9-5, (3)).
Figure 9-5

(2)

(1)

(3)

(4)

0005898

Figure 9-5

1 – Dial Indicator 3 – Move the turbine rotor shaft back and forth
2 – Magnetic Base evenly in a radial direction.
4 – Oil Inlet

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 TURBOCHARGER Disassembling the Turbocharger

DISASSEMBLING THE TURBOCHARGER

Special Tools
When assembling and disassembling the turbocharger, the special tools shown below are necessary.

Name of Tool Purpose of Use Remarks

B
0006238

Bar For removing the thrust bearing.

A B
106 Ø10

Material: Copper or brass

Pliers For installing and removing the floating bearing retaining ring.

0006239

Pliers For installing and removing the seal ring.

0006240

Available in the market

Torque
Screwdriver for
For installing the seal plate 3.7 ± 0.3 N·m (2.6 lb-in) for M4.
TORX bolt
For installing the thrust bearing 1.27 + 1 N·m (11.2 lb-in) for M3.
(Universal type)
5-50 kg / cm 0006241

Type: Equivalent to TORX TT20

Available in the market

Torque Wrench For installing the turbine housing 28 + 1 N·m (20.6 lb-in) for M8.
(Single-purpose For installing the compressor housing 23 + 1 N·m (16.9 lb-in) for M8.
type) For tightening the shaft end nut 80 ± 5 kgf·cm (6.9 lb-in) for M8.
0006242

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 Disassembling the Turbocharger TURBOCHARGER
12/05

Name of Tool Purpose of Use Remarks

Box Wrench For installing the turbine shaft (14 mm x 12 spline).

0006243

Measurement of play in axial and radial directions.

H
(1)

G J
(2)

E
I

F
Measuring Probe B C D
A
0006244

1 – Put on the Rolette

2 – Set it to the Dial Gauge

A B C D E F G H I J
M26
8 80 11 24 1 15 5L 10 L Ø5
P0.45

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 TURBOCHARGER Disassembling the Turbocharger

Inspecting the Turbocharger Before Removing the Turbine Rotor Shaft

Disassembling 1. Press down lightly with your hand on the turbine
housing and pull out the turbine rotor shaft.
Before disassembling the turbocharger, check the
following: NOTICE: If removing the shaft becomes difficult,
tap it lightly with a wooden hammer on the
• Make sure the turbine rotor and the compressor compressor-side shaft end.
impeller do not interfere with the housing in any
way. 2. Remove the insulation plate.

• Ensure the turbine shaft rotates smoothly. Removing the Seal Plate
• Measure the rotor shaft play. 1. Loosen the seal plate retaining M4 TORX T
across-head machine bolt with a TORX
Play of Rotor in Axial Direction screwdriver.
Limit of Use: 0.110 mm (0.0043 in.) 2. Remove the seal plate.
NOTICE: Screw two M6 bolts into the bolt holes
Play of Rotor in Radial Direction used for removing the seal plate and use the
Limit of Use: 0.215 mm (0.0084 in.)
bolts as handles to lift out the plate.
NOTICE: Liquid gasket has been applied to the
Disassembling the Turbocharger seal plate and the bearing housing.
The exact “clocking” angles for the assembly of the
3. Remove the oil thrower from the seal plate.
turbine housing, the bearing housing and the
compressor housing are determined by your engine Removing the Thrust Bearing and Thrust
application. Mark all of the seams on the Bushing
turbocharger with index marks before disassembly.
1. Use a TORX screwdriver (TT20) to loosen the
Disconnecting the Boost Hose TORX T across-head machine bolt from the
thrust bearing and the thrust bushing.
1. Move the clip to the center of the boost hose.
2. Remove the thrust bearing and the thrust
2. Disconnect the boost hose from the
bushing with a copper punch.
compressor housing and the wastegate
actuator. Removing the Floating Bearing
3. Remove the M8 hexagon bolts and the 1. Remove the compressor-side floating bearing
compressor-side pressure plates. from the bearing housing.
4. Remove the compressor housing. 2. Remove the turbine-side retainer ring from the
NOTICE: Liquid gasket has been applied to the floating bearing of the bearing housing.
mounting surface of the compressor housing and 3. Remove the turbine-side floating bearings from
bearing housing. the bearing housing.
NOTICE: Avoid damaging the impeller when 4. Remove the turbine's far-side and the
disassembling the compressor housing. compressor’s far-side retainer rings from the
floating bearing in the bearing housing.
Removing the Compressor Impeller
1. Use a 14 mm box-end wrench on the turbine Removing the Seal Ring
end of the turbine rotor shaft and remove the 1. Remove the turbine-side seal ring from the
shaft end nut. NOTICE: The turbine rotor shaft turbine rotor shaft.
end nut has left-hand threads. 2. Remove the compressor-side seal rings (large
2. Remove the compressor impeller. and small) from the oil thrower.
3. Remove the M8 hexagon bolts and turbine-side
pressure plates.
4. Remove the turbine housing.

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 Inspecting the Turbocharger TURBOCHARGER
12/05

INSPECTING THE TURBOCHARGER

Before cleaning, carefully check the disassembled parts for any indication of seizure, wear, foreign matter or
carbon deposits. Correct the cause of the trouble at this point.

Inspecting Major Items

Inspection Item Position to Be Checked

Carbon Deposits 1. Turbine rotor shaft turbine-side seal ring and the turbine housing backside.
2. Mounts for the bearing housing, the turbine housing and the bearing housing inside
wall.
Lubrication 1. Turbine rotor shaft, floating bearings, thrust bushing and oil thrower.
(Wear, Seizure, Discoloration, etc.) 2. Floating bearings and the thrust bushing.
3. Bearing housing and the inner periphery of the floating bearing retainer rings.
Oil Leaks 1. Turbine housing inside wall.
2. Outer periphery of the bearing housing and the turbine housing mount.
3. Turbine rotor shaft, turbine-side seal ring and the turbine rotor backside.
4. Compressor housing inside wall.
5. Compressor housing backside.
6. Seal plate surface and the seal ring insertion grooves.

Cleaning the Turbocharger

When cleaning parts, keep the following points in mind.

Section Tools and Detergent Cleaning Procedure

Turbine Rotor Shaft Turbine rotor shaft tools: 1. Immerse the turbine shaft in the washing bucket
1. Washing bucket (500 x 500) and heat the solution.
2. Heat source: steam or gas burner 2. NEVER beat the turbine rotor to remove carbon
deposits.
3. Brush
3. Immerse the parts until dirt deposits become soft
Detergent:
by penetration of detergent.
Carbon Solvent
4. When the deposits get soft, remove them using a
plastic bristle brush. NEVER use a wire brush for
cleaning
5. Protect the bearing surface of the turbine rotor
shaft and the seal ring groove from damage during
cleaning.
6. Incomplete cleaning will leave residual deposits
which may cause imbalance.
Turbine Housing Tools: Same as for cleaning the turbine rotor 1. Apply cleaning fluid to heavily soiled parts of the
shaft turbine housing.
Detergent: Same as for cleaning the turbine rotor 2. Use a plastic scraper or a stiff natural bristle brush
shaft to clean.
Compressor Housing Tools:
1. Washing bucket (500 x 500) 1. Immerse the parts until dirt deposits become soft.
2. Brush 2. When the deposits get soft, remove them using a
Detergent: Carbon Solvent plastic bristle brush. NEVER use a wire brush.

Others Wash all the other parts with diesel fuel.

Clean the oil passages with compressed air.
When cleaning, avoid damaging the parts and allowing them to rust.

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 TURBOCHARGER Inspecting the Turbocharger

Inspecting the Turbocharger 3. Measure the seal ring groove width and the
turbine rotor shaft for runout. If it exceeds 0.011
Components mm (0.0004 in.), replace the rotor shaft
(Figure 9-6, (2)).
Compressor Housing
Inspect the compressor housing surface for any Seal Ring Groove Width
scratches, nicks or cracks which may be caused by Limit: 1.63 mm (0.064 in.)
contact with the compressor impeller. If any defect
is found, replace the compressor housing. Turbine Rotor Shaft Runout

Turbine Housing Limit: 0.011 mm

(0.0004 in.)
Inspect the turbine housing surface for any
scratches caused by contact with the turbine rotor, NOTICE: If any value is beyond the specified
oxidation, thermal deformation or cracks. If any limits, replace the turbine rotor shaft assembly as
defect is found, replace the turbine housing. a unit.
Compressor Impeller 4. Inspect the turbine housing inside surface for
Inspect the impeller for any scratches or evidence signs of interference, discoloration, corrosion or
of interference. If any defect is found, replace the cracks. If any defect is found, replace the
compressor impeller. turbine housing.

Turbine Rotor Shaft Thrust Bearing and Oil Thrower

1. Inspect the turbine rotor for any scratches, 1. Inspect the overall part for scratches and / or
interference with the housing, surface defects, discoloration. If any damage is found, replace
bearing flaws, thermal distortion and / or the component.
discoloration. Replace the turbine rotor shaft 2. Measure the width of the seal ring groove at K
assembly as a unit if any damage is found. (Figure 9-7).
2. Measure the outer diameter of the turbine rotor Thrust Bearing Seal Ring Groove
shaft bearing (Figure 9-6, (1)).
Limit: 4.68 mm (0.184 in.)
Turbine Shaft Journal Figure 9-7

Outside Diameter
(1) G1
Limit: 12.28 mm (0.483 in.)
G2
Figure 9-6

(2)
E
(1)
(2)
A
K
0006247

Figure 9-7
(3) 1 – Thrust Bearing
0006246
2 – Oil Thrower
Figure 9-6
1 – Turbine Shaft Journal Outside Diameter
2 – Seal Ring Groove Width
3 – V-Block

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 Inspecting the Turbocharger TURBOCHARGER
12/05

3. Measure the width of the seal ring grooves for NOTICE: If any of these dimensions is beyond
the oil thrower at G1 and G2 (Figure 9-7). the specified limits, replace the entire thrust
bearing.
Oil Thrower Seal Ring Grooves
Groove G1 Limit: 1.75 mm (0.068 in.) Floating Bearings
Groove G2 Limit: 1.52 mm (0.059 in.) 1. Inspect the floating bearing for any abnormal
wear patterns, scratches or discoloration.
4. Measure the width of the thrust bearing Replace the floating bearings if any
(Figure 9-8, (1)). discrepancies are found.
2. Measure the inside (Figure 9-9, (1)) and
Figure 9-8

(1)
outside (Figure 9-9, (2)) diameters. If worn
beyond limits, replace the bearings with new
ones.
Figure 9-9

(3)

(2)

(1)
0005900
(2)

Figure 9-9
1 – Inside Diameter
2 – Floating Bearing
3 – Outside Diameter

Floating Bearing
Inside Diameter Limit: 16.98 mm (0.668 in.)
Outside Diameter Limit: 12.36 mm (0.486 in.)

0005899

Figure 9-8
1 – Thrust Bearing Width
2 – Thrust Bearing

Thrust Bearing Width

Limit: 4.48 mm (0.176 in.)

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 TURBOCHARGER Inspecting the Turbocharger

Bearing Housing Bearing Housing

1. Check the bearing housing for any separation, Floating Bearing Base
Limit: 17.11 mm (0.673 in.)
nicks or cracks. If any damage is found, replace Inside Diameter
the bearing housing. Turbine-Side
Limit: 18.55 mm (0.730 in.)
Figure 9-10
Seal Ring Hole
(2)
Seal Plate
1. Check the seal plate (Figure 9-11, (1)) for any
evidence of interference, nicks or cracks. If any
damage is found, replace the seal plate.
Figure 9-11

(1)

(3) (2)

(6) (3)

(1)
0006249
(5) (4)
Figure 9-11
1 – Seal Plate
2 – Seal Ring Hole
3 – Seal Ring Hole
0005901
2. Measure the seal ring hole
Figure 9-10 (Figure 9-11, (2) and (3)). If it is greater than
the specified limit, replace the seal plate.
1 – Floating Bearing Base “B”
2 – Bearing Housing Seal Ring Hole
3 – Floating Bearing Inside Diameter Limit: 14.05 mm (0.553 in.)
4 – Compressor Side
5 – Turbine Side
6 – Turbine-Side Seal Ring Hole
2. Check the retaining ring for any breakage or
cracks. If any defect is found, replace the
retaining ring.
3. Measure the inside diameter of the floating
bearing (Figure 9-10, (3)) and the turbine-side
seal ring hole (Figure 9-10, (6)). If they are
found greater than the specified limits, replace
the bearing housing and / or the floating
bearing.

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 Assembling the Turbocharger TURBOCHARGER
12/05

Wastegate Actuator ASSEMBLING THE

1. Check the wastegate actuator for any evidence TURBOCHARGER
of overheating, cracks or physical distortion. If
any damage is found, replace wastegate NOTICE: Always replace M3 and M4 TORX T
actuator and turbine housing together as a unit. machine bolts when assembling a turbocharger
unit.
2. Gradually apply a stream of low-pressure air to
the boost hose fitting and observe for NOTICE: Always replace the following parts when
wastegate operation. If it fails to operate, hangs assembling an RHC7W turbocharger unit:
up or does not operate in a smooth manner in
any way, replace wastegate and turbine • Four compressor-side seal rings (small)
housing as a unit. • Five compressor-side seal rings (large)
Seal Rings • Four M3 TORX T Machine Screws (3 ea.)
Always use new seal rings when assembling a
• Four M4 TORX T Machine Screws (4 ea.)
turbocharger unit.

Bolts
Installing the Floating Bearings
Inspect all fasteners, bolts and other associated NOTICE: Install the rounded surface of the
hardware. Replace any damaged components. retaining ring toward the bearing.
1. Install the inner retaining rings in the floating
bearing groove.
2. Coat the bearing with oil and place the
turbine-side floating bearing into the bearing
housing.
Figure 9-12

(2)

(1)

(3)

(4)

(1)

0006250

Figure 9-12
1 – Oil Inlet
2 – Position the ring closest to the turbine side
as shown.
3 – Align at this point.
4 – Position all other rings as shown above.

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 TURBOCHARGER Assembling the Turbocharger

3. Install the turbine-side outer retaining rings into Installing the Seal Plate
the bearing housing.
1. Install the seal rings to the oil thrower.
4. Position the compressor-side floating bearing in
the groove in the bearing housing. 2. Set the oil thrower in the seal plate.
3. Adjust the gap in the seal rings to match
Installing the Turbine Rotor Shaft (Figure 9-13).
Keep all parts coated with clean engine oil when
Figure 9-13

(1)
assembling.
1. Position the seal ring on the turbine rotor shaft.
2. Position the turbine housing on the turbine rotor
side of the bearing housing.
Note: Set the retaining ring so its round side
faces the bearing. 45q

3. Insert the turbine shaft into the bearing housing (2)

from the turbine side. NOTICE: Avoid damaging 0006251

the floating bearing with the turbine rotor shaft. Figure 9-13
4. Face the slot of the seal ring toward the oil inlet 1 – Oil Inlet
and align the seal ring with the turbine rotor 2 – Position the ring closest to the compressor.
shaft.
4. Apply Three Bond® No. 1207 sealant to the
Installing the Thrust Bearing turbine-side flange face of the seal plate and
mount to the bearing housing.
1. Install the thrust bearing on the turbine rotor
shaft. 5. Apply Three Bond® No. 1207 to the spots
shown in Figure 9-13, (1).
2. Apply engine oil to the thrust bearing and place
the thrust bearing in the bearing housing. Thickness of Sealant
3. Use M3 TORX T machine bolts and tighten to 0.1 - 0.2 mm (0.003 - 0.007 in.)
the specified torque value.
Thrust Bearing Bolt Torque
13 ± 1 kgf·cm (6.1 lb-in)

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 Assembling the Turbocharger TURBOCHARGER
12/05

2. Position the turbine pressure plates and tighten

Figure 9-14

the M8 hexagon bolts to the specified torque

(1) value.
Turbine Housing Bolt Torque
285 ± 10 kgf·cm (24.7 lb-in)

Installing the Compressor Housing

1. Apply Three Bond® No. 1207 sealant to the
compressor-side flange face of the bearing
(2) housing.
Thickness of Sealant

(3) 0.1 - 0.2 mm (0.003 - 0.007 in.)

2. Align the index marks and join the compressor

housing to the bearing housing.
3. Make sure the oil inlet, oil outlet and air outlet
are in their correct positions.
0005902
4. Attach the compressor pressure plates and
tighten the M8 hexagon bolts to the specified
Figure 9-14 torque.

1 – Fluid Sealant Application Spots Compressor Housing Bolt Torque

2 – No Sealant 230 ± 10 kgf·cm (19.9 lb-in)
3 – Avoid allowing sealant to overflow in this
area. Connecting the Boost Hose
6. Place the seal plate on the bearing housing.
1. Place the clips to the center of the boost hose.
Secure the seal plate with TORX T machine
bolts and tighten to the specified torque value. 2. Install the boost hose from the compressor
housing to the wastegate actuator (Figure 9-1).
Seal Plate Bolt Torque
3. Install clips to the boost hose nipples.
38 ± 3 kgf·cm (32.9 lb-in)
Post-Assembly Inspection
Installing the Compressor Impeller 1. Measure the rotor axial play and compare to the
1. Place the compressor impeller on the turbine specified limits. If the rotor play exceeds the
rotor shaft. limits, disassemble and reassemble the
2. Tighten the turbine rotor shaft end nut to the turbocharger. See Checking the Rotor Axial
specified torque value. NOTICE: The turbine Play on page 9-10.
rotor shaft end nut has left-hand threads. Rotor Axial Limits
Turbine Shaft Nut Torque 0.06 - 0.09 mm (0.002 - 0.003 in.)
80 ± 5 kgf·cm (6.9 lb-in)
2. Measure the rotor radial play and compare to
the specified limits. If the rotor play exceeds the
Installing the Turbine Housing
limits, disassemble and reassemble the
NOTICE: ALWAYS align the index marks when turbocharger. See Checking the Rotor Radial
assembling the turbocharger unit. Play on page 9-11.
1. Make sure the oil inlet, oil outlet and air outlet Rotor Radial Limits
are in their correct positions. Maintenance Standard: 0.11 - 0.18 mm (0.004 - 0.007 in.)

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 TURBOCHARGER Handling the Turbocharger

HANDLING THE
TURBOCHARGER
NOTICE: Keep all dirt, foreign matter and debris
out of the turbocharger unit.

Precautions for Installing the

Turbocharger to the Engine
Lubrication System
1. Pour fresh oil into the filler port and turn the
turbine rotor shaft by hand to lubricate all
internal components.
2. Clean and clear the oil inlet and outlet lines.
3. Check the oil fittings to ensure tight and secure
connections.

Intake System
1. Make sure there is no rubbish or foreign matter
in the air intake components.
2. Install the turbocharger securely and avoid any
leaks in the air induction system.

Exhaust System
1. Make sure there is no rubbish or foreign matter
in the exhaust manifold, or any other
component that feeds into the turbocharger.
NOTICE: The exhaust system and turbine wheel
housing hardware, such as nuts and bolts, are
made of heat-resistant steel. NEVER use
ordinary hardware.
2. Ensure that there are no leaks in the exhaust
gas system.

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 Troubleshooting the Turbocharger TURBOCHARGER
12/05

TROUBLESHOOTING THE
TURBOCHARGER
When trouble develops with the turbocharger, it cannot perform as expected and the specified engine power
cannot be attained. Check that each engine system is functioning properly. When engine operation has been
confirmed, troubleshoot the turbocharger while referring to the following tables and take appropriate action.

Black Smoke
Insufficient Amount of Intake Air

Possible Cause Correction

Air cleaner element is clogged. Replace or clean the element.
Air inlet port is blocked. Remove the obstruction.
Air leaks at the pipe connection. Check and repair the pipe.

Turbocharger Does Not Operate

Possible Cause Correction

The impurities contained in the oil precipitate at seal of the Change the engine oil, disassemble and clean the turbocharger.
turbine and hamper smooth rotation of the turbine rotor shaft.
Bearing Seizure Disassemble and repair the turbocharger.
• Insufficient oil feed or clogging of pipe. Inspect the engine oil system. Change the oil.
Replace or repair the rotating part.
• Oil temperature is too high. Observe the operating precautions described in the Operator’s
Manual.
• Imbalance of the rotating part.
• Insufficient warm-up operation or abrupt stopping of the
operation under load (No-load operation).
Contact or Failure of Turbine Rotor or the Compressor Impeller Inspect each engine system and repair as required.
• Over-rotation. Inspect the wastegate operation. Disassemble the turbine rotor
shaft and the compressor impeller. Inspect all the components.
• Excessive rise of exhaust gas temperature. Check the air cleaner and the engine. Repair as required.
Disassemble and repair the turbocharger.
• Ingestion of debris.
Reassemble the turbocharger.
• Bearing wear.
• Improper assembly.

Turbocharger Low Rotational Speed

Possible Cause Correction

Rotating speed does not pick up because of an exhaust gas Check the exhaust system and repair as required.
leak in front of the turbocharger.
Turbocharger fails to increase its speed because of a deformed Repair or replace the exhaust system components.
or blocked exhaust gas pipe.

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 TURBOCHARGER Troubleshooting the Turbocharger

White Smoke

Possible Cause Correction

Oil flows into the compressor side or turbine side because of a Repair or replace the pipe.
clogged or deformed oil return line.
The seal ring is worn abnormally or is broken because of Disassemble and repair the turbocharger.
excessive bearing abrasion.

Excessive Oil Consumption

Possible Cause Correction

The seal ring is worn abnormally or is broken because of Disassemble and repair the turbocharger.
excessive bearing abrasion.

Reduced Engine Power

Possible Cause Correction

Gas leak in the exhaust gas system. Disassemble and repair exhaust system.
Air leaks at the discharge side of the compressor. Repair leak.
Clogging of the air cleaner element. Clean or replace the element.
Turbocharger is contaminated or damaged. Disassemble and repair or replace the turbocharger.

Poor Follow-Up of the Turbocharger

Possible Cause Correction

Carbon deposits stuck on the turbine side (seal ring) hampers Change the engine oil and, at the same time, disassemble and
smooth rotation of the turbine rotor shaft. clean the turbocharger.
Incomplete diesel fuel combustion. Check the engine combustion system and restore its
combustion state.

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 Troubleshooting the Turbocharger TURBOCHARGER
12/05

Unusual Sound or Vibration

Abnormal Sound

Possible Cause Correction

If the gas passage gets too narrow because of nozzle blockage Disassemble and clean the turbocharger.
in the turbine housing or gas flow speed is too fast, air
discharged from the compressor is blocked and it flows in
reverse. (This phenomenon is generally called surging.)
Rotating part is obstructed.
Interference of rotating part(s). Disassemble, repair or replace the turbocharger.

Abnormal Vibration

Possible Cause Correction

Connection between the turbocharger and the suction or Check installation state of the turbocharger and repair any loose
exhaust pipe or oil pipe is loosened. parts.
Turbine rotor shaft or compressor impeller is broken because of Disassemble, repair or replace the turbocharger. Clear debris
bearing failure, rotating part interference or entry of foreign from the turbocharger.
matter.
Imbalance in rotating part(s). Repair or replace the rotating part(s).

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 TURBOCHARGER Troubleshooting the Turbocharger

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 6LY3 Service Manual
Section 10

STARTER
Page
Safety Precautions ........................................................................ 10-3
Introduction.................................................................................... 10-3
Starter Components and Functions............................................... 10-4
Starter Specifications............................................................... 10-4
Starter Characteristics ............................................................. 10-5
Starter Components ................................................................ 10-6
Starter Operation ..................................................................... 10-8
Starter Wiring Diagram ............................................................ 10-8

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 STARTER

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10-2 6LY3 Service Manual

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 Safety Precautions STARTER
12/05

SAFETY PRECAUTIONS INTRODUCTION

Before servicing the starter motor, read the This section of the Service Manual describes the
following safety information and review the Safety procedures necessary to service the 6LY3 marine
Section on page 2-1. engine starter motor.

The safety messages that follow have

WARNING level hazards. These safety
messages describe a hazardous situation
which, if not avoided, could result in death or
serious injury.

Shock Hazard
ALWAYS turn off the battery switch (if
equipped) or disconnect the negative (-)
battery cable before servicing the
equipment.

ALWAYS check the electrical harnesses for cracks,

abrasions, and damaged or corroded connectors.
ALWAYS keep the connectors and terminals clean.

Indicates a situation which can cause damage to

the machine, personal property, the environment or
cause the equipment to operate improperly.

NEVER engage the starter motor while the engine

is running. Damage to the starter motor pinion and /
or ring gear will result.

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 STARTER Starter Components and Functions

STARTER COMPONENTS AND

FUNCTIONS
The starting motor turns the ring gear which is
installed on the engine flywheel. The pinion gear of
the starter overcomes compression pressure,
engine friction loss and starts the engine.

Starter Specifications
YANMAR Part No. 129940-77010
HITACHI Model No. S14-102
Nominal Power (kW) 3.0
Nominal Voltage (V) 12
Rating (seconds) 30
Direction of Rotation
Clockwise
(Looking from the pinion side)
Number of Pinion Teeth 9
Mass (kg) 6.5 (14.3 lb)
Terminal Voltage (V) 12
No Load Electric Current (A) 160 maximum
Revolutions rpm 3600 minimum
Terminal Voltage (V) 10.85
Electric Current (A) 300
Load
Torque (N·m) 6.9 minimum (5.0 lb-ft)
Revolutions rpm 2000 minimum

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 Starter Components and Functions STARTER
12/05

Starter Characteristics
Figure 10-1

(1) (2) (3) (4)

N·m

rpm

(5) 0006270

Figure 10-1

1 – Output (kW) 4 – Voltage (V)

2 – Torque (N·m) 5 – Current (A)
3 – Speed (rpm)

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 STARTER Starter Components and Functions

Starter Components
Figure 10-2

(2)

(1) (5)

(4) (6)

(3)
(7)

(8)

(9)
(10)
(19)
(11)

(17) (18)
(15)

(16)
(14)
(13)

(12) 0006603

Figure 10-2

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 Starter Components and Functions STARTER
12/05

1 – Flywheel Housing 11 – Pinion

2 – Starting Motor Assembly 12 – Armature
3 – Bearing Retainer 13 – Field Coil
4 – Drive Shaft Housing 14 – Yoke
5 – Shift Lever 15 – Brush Assembly (-)
6 – Magnetic Switch (Solenoid) 16 – Brush Holder
7 – Pinion Stop 17 – Brush Spring
8 – Clutch 18 – Rear Cover
9 – O-Ring 19 – Through Bolt
10 – Brush Assembly (+)

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 STARTER Starter Components and Functions

Starter Operation Starter Wiring Diagram

When the starting switch is turned on, the solenoid 1. When the starting switch is engaged, the core
extends and the pinion gear is pushed to engage of the switch is energized. This extends the
the teeth of the flywheel. At the same time, the contact end of the solenoid to close the circuit
starter motor spins. This rotates the flywheel of the between the battery and the starter motor. As
engine until it starts. the core extends to close electrical contacts on
Figure 10-3
one end, the other end of the solenoid core
(1) (2) moves a lever that pushes the pinion gear
(3) against spring pressure into engagement with
(4) the teeth of the flywheel ring gear.
2. With battery power being supplied to the
(5) armature of the starter motor, the pinion gear is
(13) (14) driven to rotate.
3. When the starting switch is released, the
solenoid returns to its normal state. This breaks
contact between the armature of the starter
motor and the battery, the pinion gear is
retracted by return spring pressure.
Figure 10-4

(12) (6) (1)

(7)
(11) (10) (9) (8) 0006304
(2)
Figure 10-3
S
1 – Magnetic Switch (Solenoid)
B
2 – Torsion Spring M
3 – Shift Lever
4 – Drive Shaft Housing Mag
5 – Pinion
6 – Clutch
Mag
7 – Shift Return Spring
8 – Bearing
9 – Pinion Stop (4) (3)
10 – Yoke 0006305
11 – Armature
12 – Rear Cover Figure 10-4
13 – Brush Assembly
14 – Field Coil 1 – Starting Switch
2 – Magnetic Switch
3 – Starting Motor
4 – Battery

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 6LY3 Service Manual
Section 11

ALTERNATOR
Page
Safety Precautions ........................................................................ 11-3
Introduction.................................................................................... 11-4
Alternator Components and Functions (12V / 80A)....................... 11-5
Alternator Specifications.......................................................... 11-5
Alternator Components............................................................ 11-6
Alternator Wiring Diagram ....................................................... 11-8
Alternator Characteristics ........................................................ 11-9
Inspecting the Alternator.......................................................... 11-9

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 ALTERNATOR

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 Safety Precautions ALTERNATOR
12/05

SAFETY PRECAUTIONS
Before servicing the alternator, read the following Indicates a situation which can cause damage to
safety information and review the Safety Section on the machine, personal property and / or the
page 2-1. environment or cause the equipment to operate
improperly.

These safety messages that follow have NEVER turn the battery switch off or disconnect the
WARNING level hazards. These safety battery leads from the battery while the engine is
messages describe a hazardous situation operating. Damage to the alternator will result.
which, if not avoided, could result in death or
serious injury.
NEVER reverse the positive (+) and negative (-)
Shock Hazard ends of the battery cable when connecting battery
cables. The alternator will be damaged.
ALWAYS turn off the battery switch (if
equipped) or disconnect the negative (-)
battery cable before servicing the NEVER use a high-pressure wash directly on the
equipment. alternator. Water will damage the alternator and
result in inadequate charging.
ALWAYS check the electrical harnesses for cracks,
abrasions and damaged or corroded connectors. ALWAYS disconnect the battery cables from the
ALWAYS keep the connectors and terminals clean. battery when charging the battery.

NEVER use a high-voltage insulation resistance

tester for tests.

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 ALTERNATOR Introduction

INTRODUCTION
This section of the Service Manual describes the
procedures necessary to service the 6LY3 marine
engine alternator.

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 Alternator Components and Functions (12V / 80A) ALTERNATOR
12/05

ALTERNATOR COMPONENTS
Figure 11-1

AND FUNCTIONS (12V / 80A) (1)

The alternator (Figure 11-1, (1)) creates electrical
energy and charges the battery(ies). It is installed
on the engine drive shaft housing and is operated
with twin V-belts that are driven by the engine
crankshaft. The alternator is equipped with an IC
regulator that is designed to deliver a constant
voltage throughout a wide range of engine speeds
and uses diodes to convert AC to DC.
0006272

Figure 11-1
1 – Alternator

Alternator Specifications
Part No. 119578-77210
Alternator Model L-X4447 (HITACHI)
Battery Voltage 12V
Nominal Output 12V / 80A
Polarity Negative (-) Ground
Direction of Rotation
Clockwise
(viewed from pulley end)
Weight 5.8 kg (12.7 lb)
Rated Speed 5000 rpm
Operating Speed 1200-9000 rpm
Speed for 13.5V at 20°C (68°F) 1200 rpm or less
Output Current for 13.5V 75A or more at 5000 rpm
Regulated Voltage 14.5 ± 0.3V (at 20°C (68°F), Voltage Gradient -0.01V / °C)

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 ALTERNATOR Alternator Components and Functions (12V / 80A)

Alternator Components
Figure 11-2

(6) (7)

(5)
(3) (4)
(8)

(9)
(2)
(1) (11)
(12)
(13)
(14)
(15)

(10)

(16)

0006273

Figure 11-2

1 – Pulley 9 – Through Bolts

2 – Fan 10 – Bracket Bolts
3 – Front Cover 11 – Condenser
4 – Bearing 12 – Rear Cover
5 – Bearing Retainer 13 – Regulator
6 – Rotor 14 – Brush
7 – Bearing 15 – Condenser
8 – Stator 16 – Diode

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 Alternator Components and Functions (12V / 80A) ALTERNATOR
12/05

Figure 11-3

(6) (7)
(5)
(4)
(3) (8)

(2)

85
(9)
(1)

(10)

90
(11)

(13) (12)
(14)
170
0006274

Figure 11-3

1 – Pulley Nut 8 – IC Regulator

2 – Pulley 9 – Ball Bearing
3 – Ball Bearing 10 – Rear Cover
4 – Bearing Retainer 11 – Insulating Bushing
5 – Front Cover Assembly 12 – Bolt
6 – Stator 13 – Spacer
7 – Rotor 14 – Through Bolt

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 ALTERNATOR Alternator Components and Functions (12V / 80A)

Alternator Wiring Diagram

Figure 11-4

P
BAT
R Key
Switch
Diode
L
Sub Coil Condenser
Battery
R Switch
Rotor
Coil L

Stator Coil F Battery

E
IC Regulator

Alternator 0006275

Figure 11-4

NOTICE:
• Make all connections carefully.
• Never attempt to remove connections while the
alternator is functioning.
• Turn battery switch off when engine is stopped.

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 Alternator Components and Functions (12V / 80A) ALTERNATOR
12/05

Alternator Characteristics Inspecting the Alternator

The standard output characteristics of this 1. Inspect both belts for any cracks, stickiness or
alternator are shown in Figure 11-5. visual signs of wear.
Figure 11-5
2. Check that there is clearance (Figure 11-6, (1))
100 between the bottom of the belts and the bottom
of the pulley grooves.
80 3. Check the belt tension.
4. Make sure all of the connections and terminals
60
(1) on the alternator are tight.
(3) 5. Verify that all wires terminate properly in their
connectors.
40
6. Rotate the alternator and listen for any unusual
sounds.
20 Figure 11-6

0
0 2 4 6 8 10 x 103
(2) 0006276

Figure 11-5
(1)
1 – 13.5V Constant
2 – Alternator Speed
3 – Output Current (A)
0006277

Figure 11-6
1 – Clearance

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 ALTERNATOR Alternator Components and Functions (12V / 80A)

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 6LY3 Service Manual
Section 12

ELECTRICAL
AND ECU
Page
Safety Precautions ........................................................................ 12-3
Battery Components and Functions .............................................. 12-3
Battery Capacity and Battery Cables....................................... 12-3
Inspecting the Battery.............................................................. 12-4
Charging the Battery................................................................ 12-5
Precautions for Battery Storage .............................................. 12-7
Wiring Diagram.............................................................................. 12-8
ECU Connector Pin Configuration........................................... 12-9
Sensor Locations................................................................... 12-10
Sensors for Oil Pressure and Boost Pressure....................... 12-12
Sensors for Water, Oil and Fuel Temperatures..................... 12-12
Air Heater Components and Functions ....................................... 12-13
Air Heater Operation.............................................................. 12-13
Fuse, Relay and Harness Components ...................................... 12-16
Fuse Chart............................................................................. 12-16
Digital Display........................................................................ 12-21
Rocker Switch Panel ............................................................. 12-23
Control Head (Shift and Throttle)........................................... 12-24

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 ELECTRICAL AND ECU

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 Safety Precautions ELECTRICAL AND ECU
12/05

SAFETY PRECAUTIONS Power is removed from the battery by connecting a

load across these two terminals (Figure 12-1, (1)).
Before servicing the electrical components, read
the following safety information and review the When the battery is discharging, an electric current
Safety Section on page 2-1. flows from the positive (+) plates to the negative (-)
plates. When the battery is being charged, electric
current is passed through the battery in the
opposite direction by an external power source.
BATTERY COMPONENTS AND
FUNCTIONS Battery Capacity and Battery Cables
See Checking the Electrolyte Level on page 12-4
Battery Capacity
for electrolyte level and battery charge.
Standard 12V-150Ah
The battery utilizes chemical action to convert
Cold Weather 12V-150Ah
chemical energy to electrical energy. This engine
uses a lead acid battery which stores a fixed Full Charged Specific Gravity 1.26
amount of power that can be used when required.
After use, the battery can be recharged and used Battery Cables
again. Battery cables should be selected with the correct
flow and length in mind. As a rule, thick cables are
As shown in Figure 12-1, a nonconductive kept to the minimum required length and should be
container is filled with dilute sulfuric acid electrolyte. used to connect the battery to the starter.
Lead dioxide positive (+) plates (Figure 12-1, (7))
and lead dioxide negative (-) plates Using wire other than those specified may cause
(Figure 12-1, (4)) separated by glass mats the following troubles:
(Figure 12-1, (6)) are stacked alternately in the Figure 12-2

electrolyte. The positive (+) and negative (-) plates Wire thinner than specified Single conductor wire
are connected to their respective terminals
Wire longer than specified
(Figure 12-1, (1)).
Figure 12-1

High wiring resistance

(1) (2) Open circuit caused
(3) by vibrations
Low current

(4) Faulty starting Faulty charging

0006350
(5)

(6)
Figure 12-2

(8) (7)
0006261

Figure 12-1
1 – Terminal
2 – Filler Cap
3 – Cover
4 – Negative Plate
5 – Separator Plate
6 – Glass Mat
7 – Positive Plate
8 – Battery Case

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 ELECTRICAL AND ECU Battery Components and Functions

Overall length of the cables between the battery Checking the Electrolyte Level
terminals and the starter terminals should be Check the electrolyte level every 7 to 10 days. The
determined according to the following table: electrolyte must always be 10 to 20 mm (0.4 to
0.8 in.) over the top of the plates.
Battery Cable Specifications Figure 12-4

Voltage a+b+c
Voltage Cross Section
Drop Length
20 mm2
3.5 m (11 ft)
(0.031 sq. in.)
12V 0.2V or less
40 mm2
7 m (23 ft)
(0.062 sq. in.)
0006263

High resistance in the key switch (Figure 12-3, (2))

circuit can cause weak starter pinion engagement. Figure 12-4
Figure 12-3
NOTICE:
(1) 1. The “LEVEL” line on a transparent plastic
a
battery case indicates the height of the
c electrolyte.
(2) S
B
2. Always use distilled water to replenish the
E electrolyte level.
b 3. If electrolyte leaks from the battery, replace the
(3)
(4) 0006351
battery.

Figure 12-3 Measuring Electrolyte Specific Gravity

1. Draw some electrolyte up into a hydrometer.
1 – Battery Switch
2 – Key Switch 2. Take the specific gravity reading at the top of
3 – Starter Motor the scale of the hydrometer.
4 – Battery Figure 12-5

Inspecting the Battery

The strength of the battery’s charge governs the
starting performance of the engine. Inspect the
battery routinely to ensure dependable starting
performance.

Visual Inspection
1. Inspect the case for cracks, damage and
electrolyte leakage.
2. Inspect the battery holder for tightness,
corrosion and damage.
3. Inspect the terminals for corrosion and check 0006264

the cables for damage. Figure 12-5

4. Inspect the caps for cracking, electrolyte 3. The battery is fully charged if the specific
leakage and clogged vent holes. Correct any gravity is 1.260 at an electrolyte temperature of
abnormal conditions that are found. Clean 20°C (68°F). The battery is discharged if the
corroded terminals with a wire brush before specific gravity is 1.200 (50%). If the specific
reconnecting the battery cable. gravity is below 1.200, recharge the battery.

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 Battery Components and Functions ELECTRICAL AND ECU
12/05

4. If the difference in the specific gravity among NOTICE: Repeat the test twice to make sure the
the cells of the battery is ± 0.01, the battery is meter indication remains the same.
OK.
Washing the Battery
5. Measure the temperature of the electrolyte.
Since the specific gravity changes with the 1. Wash the outside of the battery with a brush
temperature, 20°C (68°F) is used as the while running water over the battery. (Make
reference temperature. sure no water gets into the battery.)
2. If the terminals, or other metal parts, are
Reading the Specific Gravity at 20°C (68°F) corroded due to exposure to electrolyte
S20 = St + 0.0007(t-20) leakage, wash off all of the acid.
S20: Specific gravity at the standard temperature of 20°C 3. Check the vent holes of the caps and clean if
(68°F) clogged.
St: Specific gravity of the electrolyte at 20°C (68°F) 4. After washing the battery, dry it with
0.0007: Specific gravity change per 1°C (33.8°F) compressed air, connect the battery cable and
t: Temperature of the electrolyte coat the terminals with the grease.
NOTICE: NEVER coat the terminals before
Voltage Test connecting the cables, the grease will act as an
Using a battery tester, the amount of discharge can insulator.
be determined by measuring the voltage drop
which occurs while the battery is being discharged Charging the Battery
with a large current.
Charging Methods
1. Connect the tester to the battery. There are two methods for charging a battery:
Use a 12V battery tester (Figure 12-6, (1)). normal and rapid. Rapid charging should only be
Adjust the current. used in emergencies.
Figure 12-6

Normal Charging
Normal charging should be conducted at a current
of 1/10 or less of the indicated battery capacity
(10A or less for a 100Ah battery).

Rapid Charging
Rapid charging is conducted over a short period of
time at a current of 1/5 to 1/2 the indicated battery
capacity (20A to 50A for a 100Ah battery).
NOTICE: Rapid charging can increase the
electrolyte temperature. Exercise care when rapid
charging the battery.
(1) 0006265

Figure 12-6
1 – 12V Battery Tester
2. Connect the positive (+) lead of the tester to the
positive (+) battery terminal, and the negative
(-) tester lead to the negative (-) battery
terminal.
3. Push the TEST button, wait 5 seconds and read
the meter.

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 ELECTRICAL AND ECU Battery Components and Functions

Charging Procedure Charging Precautions

1. Check the specific gravity and adjust the 1. Remove the battery caps to vent the gas during
electrolyte level. charging.
2. Disconnect the battery cables. 2. The electrolyte temperature should not exceed
3. Connect the red clip of the charger 45°C (113°F) during charging.
(Figure 12-7, (1)) to the positive (+) battery
Figure 12-8

terminal and connect the black clip to the

negative (-) terminal.

Specific Gravity
Figure 12-7

Electrolyte Temperature
0006352

(2) Figure 12-8

(1)
0006266 3. Since an alternator is used on this engine when
charging with a charger, always disconnect the
Figure 12-7 battery cables to prevent destruction of the
1 – Battery Charger diodes in the alternator.
2 – Battery NOTICE: Disconnect the negative (-) cable first.
4. Set the current to 1/10 to 1/5 of the capacity
indicated on the outside of the battery
(Figure 12-7, (2)).
5. Periodically measure the specific gravity during
charging to make sure the specific gravity
remains at a high fixed value. Also check
whether gas is being generated.

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 Battery Components and Functions ELECTRICAL AND ECU
12/05

Precautions for Battery Storage An easy-to-use battery charger is available from

Yanmar. Take proper care of the battery by using a
The life of a battery depends on the way it is battery charger (Figure 12-10, (1)) and
handled. After about 2 years its performance will hydrometer.
deteriorate and replacement will be necessary.
Figure 12-10

A battery will discharge about 0.5% per day when

not in use. It must be charged one to two times a
month while in storage.
Figure 12-9
Discharge Per Day (%)

(1)
0006269

Figure 12-10
1 – Battery Charger
When the specific gravity drops to about 1.16,
charge the battery up to a specific gravity of 1.26
Number of Days After Charging (24 hours).
0006353
Before putting the battery in storage for long
Figure 12-9 periods, charge it for about 8 hours.
If charging with the engine alternator is insufficient
because of frequent starts and stops, the battery
will rapidly lose power. Charge the battery as soon
as possible when it is used under these conditions.

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 ELECTRICAL AND ECU Wiring Diagram

WIRING DIAGRAM
Figure 12-11

Figure 12-11

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 Wiring Diagram ELECTRICAL AND ECU
12/05

ECU Connector Pin Configuration

Figure 12-12

1 2 3 4 5 6 7 8 9 10

1 RA TARD TAAD AHR1 AHR2 CRK- CAM- ST STHS IGN2

10
11 12 13 14 15 16 17 18 19 20

11 G-P MNR STSW RAR B1 CRK+ CAM+ NTS IGN1 EMS 20

21 22 23 24 25 26 27 28 29 30

21 STR STHL CAMP SNS5 B2 CANL PLO THF STH RPS

30
31 32 33 34 35 36 37 38 39 40

31 OUT1 OUT2 G_P1 G_P2 G_S CANH THW AN1 THLO PBST
40

0006117

Figure 12-12

PIN Description PIN Description

1 Rack Actuator 21 Starter Check
2 Retard Timer Solenoid 22 Sub-Throttle Indicator
3 Advance Timer Solenoid 23
4 Air Heater Relay 1 24 5V Supply Voltage
5 Air Heater Relay 2 25 12V DC
6 Crank Speed Sensor Pulse - 26 i2 Communication CANL
7 Cam Speed Sensor Pulse - 27 Oil Pressure Sensor
8 Starter ON 28 Fuel Temperature Sensor
9 Sub-Throttle Switch 29 Throttle Position Sensor
10 2nd Station Key 30 Rack Position Sensor
11 ECU Power GND 31
12 ECU Main Relay 32
13 33 Ground
14 Actuator Relay 34 Ground
15 12V DC 35 Sensor GND
16 Crank Speed Sensor Pulse + 36 i2 Communication CANH
17 Cam Speed Sensor Pulse + 37 Coolant Temperature Sensor
18 Neutral Switch 38
19 1st Station Key 39 Oil Temperature Sensor
20 Emergency Stop 40 Boost Pressure Sensor

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 ELECTRICAL AND ECU Warning Devices

WARNING DEVICES
This engine is equipped with several electronic sensors. The engine data from these electronic sensors is
sent to the electronic control unit (ECU) and used for engine control and system monitoring.

Sensor Locations
Figure 12-13

(1)
(2)

(3) 0006278

Figure 12-13

1 – Boost air pressure sensor installed on the 3 – Coolant temperature sensor installed on the
intake manifold with sealant tape. heat exchanger with sealant tape.
Torque = 9.8 ± 1 N·m (7.2 ± 0.7 lb-ft) Torque = 19.6 ± 3 N·m (14.4 ± 2.2 lb-ft)
2 – Oil pressure sensor installed on the oil filter
bracket with sealant tape.
Torque = 9.8 ± 1 N·m (7.2 ± 0.7 lb-ft)

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 Warning Devices ELECTRICAL AND ECU
12/05

Figure 12-14

(1) (2) (3) (4)

0006279

Figure 12-14

1 – Oil temperature sensor installed on the oil 3 – Fuel injection pump rpm sensor installed on
cooler with sealant tape. the fuel injection pump.
Torque = 19.6 ± 3 N·m (14.4 ± 2.2 lb-ft) 4 – Crankshaft rpm sensor installed on the
2 – Fuel temperature sensor installed on the flywheel housing.
fuel injection pump.
Torque = 19.6 ± 3 N·m (14.4 ± 2.2 lb-ft)

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 ELECTRICAL AND ECU Warning Devices

Sensors for Oil Pressure and Boost Sensors for Water, Oil and Fuel
Pressure Temperatures
The oil pressure sensor is located on the oil filter The water temperature sensor is located on the
bracket and the boost sensor is located on the exhaust manifold near the thermostat.
intake manifold.
A water temperature switch is not used. Data from
An oil pressure switch is not used. Data from the oil the water temperature sensor is used by the ECU
pressure sensor is used by the ECU for alarm for alarm indications instead of a water temperature
indication instead of an oil pressure switch. switch.
The oil temperature sensor is located on top of the
Oil Pressure Sensor Specifications oil cooler. The fuel temperature sensor is located
Part No. 119578-91300 on the side of the fuel injection pump
Output DC 0.5-3.5V (Figure 12-17).
Operating Pressure 0-1 MPa (0-145 psi) Figure 12-17

Figure 12-15
59 mm (2.322 in.)

19 mm (0.748 in.)
(1) (2) (3)

M12 x 1.5 mm 0006282

Figure 12-17
(4)
(6)
(5)
0006280 Water, Oil and Fuel Temperature Sensors Specifications

Figure 12-15 Part No. 119254-44910

Rated Voltage DC 5V
1 – Diaphragm
2 – Cap Operating Temperature -30°C (-22°F)~ +120°C (248°F)
3 – R 1/8 19.6 N·m
Tightening Torque
4 – Connection (14.4 lb-ft)
5 – Pressure Sensitive Element
6 – Housing Body

Alarm Diagram for Oil Pressure

Figure 12-16

200 kPa
(29 psi)
Alarm OFF

Alarm ON
20 kPa
(2.9 psi)

1000 3000
rpm rpm
Alarm Diagram of Oil Pressure
0006297

Figure 12-16

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 Air Heater Components and Functions ELECTRICAL AND ECU
12/05

AIR HEATER COMPONENTS

AND FUNCTIONS
Air Heater Operation
Figure 12-18

(1) (2)

+ -

(4) (3) 0006285

Figure 12-18
1 – ECU
2 – Battery
3 – Air Heater “A”
4 – Air Heater “B”
Figure 12-19

Pre-Heat. Air Heater is on when the

coolant temperature is less than
10°C (50°F) (maximum 30 seconds) After Heat. Air Heater is on when the
while engine is running. coolant temperature is less than
45°C (113°F) (maximum 10 minutes,
Key On 7 minutes) while engine is running.

Air Heater “A” Time

Air Heater “B” Time

Engine Speed
Time
0006359

Figure 12-19

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 ELECTRICAL AND ECU Air Heater Components and Functions

Heater plugs (Figure 12-21, (1)) are available for

Figure 12-21

this engine as an aid to starting in cold weather.

The heater plugs are installed on top of the
intercooler (Figure 12-21, (3)) to heat the charging (1)
air and facilitate easier engine starting. The heater
plugs are automatically controlled by the ECU (2)
(Engine Control Unit) (Figure 12-18, (1)) through
the coolant temperature sensor.
When setting the starter switch to ENGINE ON, the
heater plug automatically turns on for 30 seconds
when the coolant temperature is 10°C (50°F) or
less.
After the engine starts, the heater plug stays on for
a maximum of 10 minutes or until the coolant
temperature reaches 45°C (113°F). The heater
plugs then cut off. (3)
0006284

Heater Plug Specifications Figure 12-21

Part No. 119575-77050 1 – Heater Plug
Rated Current 58A 2 – Seal
Rated Voltage DC 11V 3 – Intercooler
Tightening Torque 25 N·m (18.4 lb-ft) or less
Figure 12-20
Pre-Heat Time (seconds)

40

30

20

10

0
-5°C 0°C 5°C 10°C 15°C 25°C
(23°F) (32°F) (41°F) (50°F) (59°F) (77°F)
Coolant Temperature
0006355

Figure 12-20

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 Air Heater Components and Functions ELECTRICAL AND ECU
12/05

Heater Relay Heater Fuse

Figure 12-22 Figure 12-23

(1)

(2)

(3)
(4)
(1) (2)
(5)
(6)

(7)
0006287

0006286
Figure 12-23
Figure 12-22
1 – Cover
1 – Use TYCO: 2 – Nut
Connector Housing 282080-1 3 – Washer
Seal 281934-2 4 – Fuse
Terminal 282110-1 5 – Bolt
2 – Bolt Terminals M6 6 – Jam Nut
Torque = 5 N·m (44 lb-in) Maximum 7 – Base

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 ELECTRICAL AND ECU Fuse, Relay and Harness Components

FUSE, RELAY AND HARNESS

COMPONENTS
When a short-circuit occurs, the electrical system is
protected by a fuse. See Troubleshooting on
page 13-1. All the fuses for the 6LY3 are shown in
the table below.

Fuse Chart

No. Fuse Size Application Fuse Location Part No.

1 10A AUX POWER Fuse box 198535-52120
IGNITION PANEL
2 10A Fuse box 198535-52120
(Switch panel)
3 20A ECU Fuse box 198535-52140
IGNITION SIG
4 10A Fuse box 198535-52120
(Switch ON signal)
5 5A YDT Fuse box 198535-52110
6 250A Air Heater “A” Below exhaust manifold 119578-77150
7 250A Air Heater “B” Below exhaust manifold 119578-77150
8 150A ALTERNATOR Below exhaust manifold 119578-77090
9 50A STARTER RELAY Below exhaust manifold 119578-77080
IGNITION SIG 1st Station
10 5A Rocker switch panel (1st Station) 170203-91930
(Switch ON signal)
IGNITION SIG 2nd Station
11 5A Rocker switch panel (2nd Station) 170203-91930
(Switch ON signal)

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 Fuse, Relay and Harness Components ELECTRICAL AND ECU
12/05

Fuse and Relay Location Fuse Location Label for the Fuse Box
Figure 12-26
Figure 12-24

(1) (2) (3) (4) (5) (6) (7)

(2)
(3)
(4)

AUX POWER
(5)

IGN. PANEL
SPARE

IGN. SIG

S. TOOL
10A

10A

20A

10A
ECU

5A
(6) SPARE
(1)
SPARE

SPARE

0006290

Figure 12-26
(7)
1 – Spare
0006288 2 – 10A
3 – 10A
Figure 12-24 4 – 20A
5 – 10A
1 – Relay 1: ECU Main Relay 6 – 5A
2 – Relay 2: 1st Station Relay 7 – Fuse Puller
3 – Relay 3: 2nd Station Relay
4 – Relay 4: Rack Actuator Relay
5 – Relay 5: Starter Check Relay
6 – Rack Position Sensor Amplifier
7 – Fuse Box

Relay Assembly Under the Exhaust Manifold

Figure 12-25

(2)

(1)

(3)

(4)
(5) 0006289

Figure 12-25
1 – Starter Relay
2 – Air Heater Relays
3 – Alternator Fuse (150A)
4 – Air Heater Fuse (250A)
5 – Starter Fuse (50A)

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 ELECTRICAL AND ECU Fuse, Relay and Harness Components

Wire Harness Locations Harness (D): Starter / Air Heater (Connection

See Figure 12-27 and Figure 12-28. between starter relay, starter S terminal and heater
fuses A / B).
Harness (ENG): Harness assembly for engine
electric devices. Harness (E): Starter / Alternator (Connection
between starter B terminal and alternator fuse).
Harness (A): Alternator (Connection between
alternator B terminal and alternator fuse). Harness (F): Starter (Connection between starter
relay and starter S terminal fuse).
Harness (B): Air heater A / B (Connection between
heater relays A / B and heater fuses A / B). Harness (G): Air Heater (Connection between
heater relays A / B and heater A / B).
Harness (C): Starter (Connection between starter
relay and starter S terminal).
Figure 12-27

(2) (3) (4)

(1)

(5)

(6)

(7)
(10) (9) (8) 0006291

Figure 12-27

1 – Harness (G) Heater Relay - Heater 6 – Harness (D) Starter - Fuse (250A)
2 – Water Temperature Sensor 7 – Harness (F) Fuse - Starter Relay
3 – Harness (C) Starter Relay - Starter 8 – Harness (B) Fuse (250A) - Heater Relay
4 – Starter 9 – Harness (A) Alternator - Fuse (150A)
5 – Harness (E) Starter - Fuse 10 – Alternator

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 Fuse, Relay and Harness Components ELECTRICAL AND ECU
12/05

Figure 12-28

(1)
(2)

(11)
(3)
(10) (4)

(9)
(5)
(8)

(7) (6) 0006292

Figure 12-28

1 – Oil Pressure Sensor 6 – Fuel Temperature Sensor

2 – Harness (ENG) 7 – Pump Speed Sensor
3 – Harness (G) Heater Relay - Heater 8 – Fuse Box
4 – Alternator 9 – Oil Temperature Sensor
5 – Boost Pressure Sensor 10 – Crankshaft rpm Sensor
11 – Intake Air Heater

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 ELECTRICAL AND ECU Remote Control Electronic Control System (ECS)

REMOTE CONTROL ELECTRONIC CONTROL SYSTEM (ECS)

Note: Refer to the ECS Installation and Operation Manuals for more details.
The control equipment consists of the rocker switch panel (Figure 12-29, (1)), the digital display
(Figure 12-29, (4)), the interface module (Figure 12-29, (5)) and the control head (Figure 12-29, (3)), which
are connected by the wire harness to the engine (electrical governor and marine gear (Figure 12-29, (7)) for
remote control operation).
Figure 12-29

(1) (2)

(5)

(4)
(3)

(6)

(7)

(8) (8)
(9)
0006302

Figure 12-29

1 – 1st Station Rocker Switch Panel 6 – 8-Pin Connector to Engine

2 – 12-Pin Connector to Engine 7 – To Marine Gear
3 – Control Head (Shift and Throttle) 8 – Terminator
4 – Digital Display 9 – NMEA T-Connector
5 – Interface Module

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 Remote Control Electronic Control System (ECS) ELECTRICAL AND ECU
12/05

Figure 12-30 Alarm Indicators

The alarm window appears with audible alarms
when a fault is detected. A sample of the alarm
window is shown in Figure 12-32.
Figure 12-32

DUAL PORT
Alarms
(1) HOT ENGINE CHECK ENGINE
OVER REV EMERGENCY
(2)
OIL PRESSURE LOW VOLTAGE
TURBO BOOST ALTERNATOR
(3) GEAR OIL SEA WATER FLOW
0006293
ENG COM ERROR LOW COOLANT
MAINTENANCE WATER IN FUEL
Figure 12-30
NETWORK THROTTLE PROBLEM

1 – 6-Pin Connector for the YDT 0006295

2 – 8-Pin Connector for Interface Module

3 – 12-Pin Connector for Switch Panel Figure 12-32

Digital Display Alarm Log Screen

A sample alarm log screen is shown in
The multifunction digital display has the following
Figure 12-33.
functions.
Figure 12-33

Display Functions
Port Eng Alarms
Runtime Engine Data with Three Screens Alarm Log
061803 17:04 - COM ERROR Y 025
Tachometer, oil pressure, coolant temperature, oil P0120/FEB0 THROTTLE SENSOR

temperature, fuel temperature, boost pressure,

VALUE OUT OF RANGE.
CONTACT YANMAR DISTRIBUTOR
voltage, load factor, throttle value, fuel consumption
rate and gear shift (F / N / R) can be shown.
Figure 12-31
CLR EXIT
0006296

SINGLE OIL PRES

Figure 12-33
2 3 0 100
84 PSi
1 4
WTR TEMP
0 2615
X1000 RPM
100 250
11 4 Fah

0006294

Figure 12-31

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 ELECTRICAL AND ECU Remote Control Electronic Control System (ECS)

Alarm Indicators and Data Log

Alarm indicators and a buzzer comes on when sensors detect an abnormality during engine operation.
The alarm indicators are off during normal operation, but come on when an abnormality arises. (See the
table below.)

Item ON OFF
Oil Press (Logging *1) (See Figure 12-34)
Alarm 100°C (212°F) 95°C (203°F)
Coolant Temperature Engine protection *2
110°C (230°F) 105°C (221°F)
(Log *1)
Alarm 110°C (230°F) 105°C (221°F)
Oil Temperature
Log *1 120°C (248°F) 115°C (239°F)
Alarm 80°C (176°F) 75°C (167°F)
Fuel Temperature
Log *1 90°C (194°F) 85°C (185°F)
Boost press *1, *2
250 kPa (36 psi) 200 kPa (29 psi)
(Engine protection, Logging)
Over speed
3900 rpm —
(Engine stop, Logging *1)
*1 “Log” shows alarm and is also memorized in ECU.
*2“Engine Protection” shows the alarm and also limits the engine speed to 1800 rpm or less for engine
protection.

Alarm Diagram at Oil Pressure

Figure 12-34

200 kPa
(29 psi)
Alarm OFF

Alarm ON
20 kPa
(2.9 psi)

1000 3000
rpm rpm
Alarm Diagram of Oil Pressure
0006297

Figure 12-34

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 Remote Control Electronic Control System (ECS) ELECTRICAL AND ECU
12/05

Rocker Switch Panel 3. Sub-Throttle control

• If the main throttle control fails, the sub-throttle
1st Station Panel lamp (Figure 12-35, (1)) will flash. The engine
1. ON-OFF-START switch speed is then controlled by using the
(Figure 12-35, (5)). sub-throttle (Figure 12-35, (2)).
2. Emergency stop switch (Figure 12-35, (3)). • Engine speed increases when the sub-throttle
knob is turned clockwise.
The engine shuts down when the top of the
emergency stop switch is pushed. Push the • When the sub-throttle lamp flashes, turn the
bottom part of the switch after the engine has sub-throttle knob counterclockwise to the end
shut down and return the switch to the former and turn the knob clockwise gradually until the
setting. (Restarting the engine after using the sub-throttle lamp is steady.
emergency stop may be slower or difficult.) Use • Each engine is controlled by its own
this switch only in an emergency. sub-throttle controller.
Figure 12-35

(1) (2) 2nd Station Panel (Optional)

1. ON-OFF-START switch is wired to the 1st
station panel.
2. Able to start and stop the engine from the 2nd
Start station panel (Figure 12-36, (1)).
Eng ON Emergency
Stop
3. Emergency stop switch is wired in series with
OFF the 1st station panel.
Figure 12-36

(5) (4) (3) 0006298

Start
Eng ON Emergency
Figure 12-35 Stop
OFF
1 – Sub-Throttle Lamp
2 – Sub-Throttle
3 – Emergency Stop Switch
4 – Rocker Switch Panel (1) 0006312
5 – ON-OFF-START Switch
Figure 12-36
1 – 2nd Station Panel

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 ELECTRICAL AND ECU Remote Control Electronic Control System (ECS)

Control Head (Shift and Throttle) Single-Lever Head for Single Installation
Figure 12-38

The control head is designed to allow an operator

to select the various control functions of a vessel. It
provides indications of current selections and F
(1)
transfers helm control to alternate locations. -N-

R (2)
Control Head Button Functions N
(3)
SEL

• N (NEUTRAL Button) - When the lever is in the

neutral idle position, this button will engage or (4)
disengage the neutral throttle control. This allows
for throttle but no forward or reverse thrust. When 0006357

the lever is in a gear idle position, this button will

engage or disengage the split range throttle Figure 12-38
(SRT) (optional). 1 – NEUTRAL Lamp (Yellow)
2 – NEUTRAL Button
• SELECT or SEL (SELECT Button) -
3 – SELECT Button
This button allows the operator to activate or 4 – SELECT Lamp (Green)
deactivate the current location as helm control in
multiple control stations installations.
• SYNC - This button engages or disengages
Power Train Synchronization (PTS) (option - if
installed). This is an option that will synchronize
starboard and port engine rpm when the control
head levers are set to nearly the same positions.

Two-Lever Head for Twin Installation

Figure 12-37

(1)

F F

-N- -N-
(7) R R (2)
N N
SELECT SYNC

(6) (3)

(5) (4)
0006356

Figure 12-37
1 – NEUTRAL Button
2 – NEUTRAL Lamp (Amber)
3 – SYNC Lamp (Red)
4 – SYNC Button
5 – SELECT Button
6 – SELECT Lamp (Green)
7 – NEUTRAL Lamp (Amber)

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 6LY3 Service Manual
Section 13

TROUBLESHOOTING
Page
Safety Precautions ........................................................................ 13-3
Introduction.................................................................................... 13-3
Preparation Before Troubleshooting ............................................. 13-4
Teleflex Display Indications ..................................................... 13-4
Troubleshooting by Symptom........................................................ 13-5
Troubleshooting Fuses, Relays and Harnesses.......................... 13-21
Fuse, Relay and Harness ...................................................... 13-21
Fuse Burns Out ..................................................................... 13-21
Test Check ............................................................................ 13-21
Checking a Fuse.................................................................... 13-21
Troubleshooting Blown Fuses ............................................... 13-22
Electronic Control System ........................................................... 13-26
Engine Control System Diagram ........................................... 13-26
Troubleshooting by DTC Fault Codes ......................................... 13-28
TELEFLEX i5601E Display Alarm Screen Information.......... 13-28
Terms .................................................................................... 13-28
List of DTC (Diagnostic Trouble Codes)................................ 13-30
Troubleshooting the Temperature Sensor............................. 13-40
Troubleshooting the Pressure Sensor ................................... 13-77
Wiring Diagrams .................................................................... 13-81

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 TROUBLESHOOTING

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 Safety Precautions TROUBLESHOOTING
12/05

SAFETY PRECAUTIONS INTRODUCTION

Before servicing the 6LY3 marine engines, review This section contains information and diagnostic
the Safety Section on page 2-1. troubleshooting charts to accurately diagnose an
engine, starter or alternator problem.

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 TROUBLESHOOTING Preparation Before Troubleshooting

PREPARATION BEFORE Teleflex Display Indications

TROUBLESHOOTING DTC: Diagnostic Trouble Code
It is important to diagnose and correct the cause of FMI: Failure Mode Identifier
trouble symptoms early in order to prevent a major
engine failure. At the first sign of a problem Refer to the Electronic Control System Operation
investigate the cause, correct it and prevent any Manual for more information about the DTC screen.
recurrence.
Organize the available data in order to understand
the possible cause of the problem.
1. What is the exact symptom of the trouble?
2. Read the client control ledger and examine the
history of the engine.
3. Get the engine model and serial number.
4. Get the vessel model and serial number in
which the engine is installed.
5. When was the last time the engine was
serviced?
6. How many hours of operation since the last
service interval and what was done?
7. Has the problem ever occurred before and what
was the resolution?
8. When did the symptom or failure happen?
9. Did anything change or did anything unusual
happen before the occurrence?
10. Was it sudden or gradual?
After narrowing down the possibilities, use the most
appropriate troubleshooting guide from this
manual, isolate the cause and correct it.

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 Troubleshooting by Symptom TROUBLESHOOTING
12/05

TROUBLESHOOTING BY SYMPTOM
It is important to thoroughly understand each system and the function of all parts in these systems. A careful
study of the engine mechanisms will make this possible. When problems arise, it is important to carefully
observe and analyze the indications of trouble in order to save time in determining their cause. Begin by
checking the most easily identifiable causes of difficulty. Where the cause of the difficulty is not readily
apparent, make a thorough examination of the system from the easiest, proceeding until the cause of the
trouble can be determined. While experience is an important factor in pinpointing engine problems, careful
study and understanding of the engine mechanisms, combined with good common sense, will help you
rapidly become an expert at troubleshooting.

Trouble Symptom Causes Corrective Action Remarks

No power to the digital display Low battery voltage / no battery Check the electrolyte level and See Checking the Electrolyte
and the control head. voltage. the specific gravity of the Level on page 12-4.
battery liquid.
Charge the battery or replace. See Charging the Battery on
page 12-5.
Check the wiring circuit. See Alternator Wiring Diagram
on page 11-8.
Battery will not charge. Check the wires between the See Alternator Wiring Diagram
alternator and the battery. on page 11-8.
Check the tension of the V-belt. See Inspecting the Alternator
on page 11-9.
Check the alternator. See Alternator on page 11-1.
Control system wiring is Connect the control system See Alternator Wiring Diagram
disconnected. wires. on page 11-8.
Connectors are not closed. Close the connectors See Remote Control Electronic
according to the manual. Control System (ECS) on
page 12-20.
Contact failure of each Check each connector pin and See Remote Control Electronic
connector pin. confirm the continuity. Control System (ECS) on
page 12-20.
Fuse burned out. Replace the fuse. See Troubleshooting Fuses,
(AUX POWER: 10A) Relays and Harnesses on
page 13-21.
Contrast control is too low Adjust the contrast. See Digital Display Operation
Manual.

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 TROUBLESHOOTING Troubleshooting by Symptom

Trouble Symptom Causes Corrective Action Remarks

An engine data screen will not The battery voltage is low Check the electrolyte level and See Checking the Electrolyte
display. (Discharging battery). the specific gravity of battery. Level on page 12-4.
Charge the battery or replace. See Charging the Battery on
page 12-5.
Check for a short. See Alternator Wiring Diagram
on page 11-8.
Battery will not charge. Check the wires between the See Alternator Wiring Diagram
alternator and the battery. on page 11-8.
Check the tension of the V-belt. See Check the V-Belt Tension
on page 4-25.
Check the alternator. See Alternator on page 11-1.
Wiring of the control system is Connect the control system See Alternator Wiring Diagram
disconnected. wires. on page 11-8.
Connectors are not closed. Close the connector according See Remote Control Electronic
to the manual. Control System (ECS) on
page 12-20.
Contact failure of each Check each connector terminal See Remote Control Electronic
connector pin. and confirm continuity. Control System (ECS) on
page 12-20.
Fuse burned out. Replace the fuse. See Troubleshooting Fuses,
(IGN. PANEL: 10A) Relays and Harnesses on
page 13-21.
Fuse burned out. Replace the fuse. See Troubleshooting Fuses,
(ECU: 20A) Relays and Harnesses on
page 13-21.
Fuse burned out. Replace the fuse. See Troubleshooting Fuses,
(IGN. SIG: 10A) Relays and Harnesses on
page 13-21.
Fuse burned out. Replace the fuse. See Troubleshooting Fuses,
(IGN. 1st Station: 5A) Relays and Harnesses on
page 13-21.
Fuse burned out. Replace the fuse. See Troubleshooting Fuses,
(IGN. 2nd Station: 5A) Relays and Harnesses on
page 13-21.
Detecting error. ➝ DTC: See Troubleshooting by
(U0146 / 12) DTC Fault Codes on
page 13-28.

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 Troubleshooting by Symptom TROUBLESHOOTING
12/05

Trouble Symptom Causes Corrective Action Remarks

Starting trouble The battery switch is off. Turn on the battery switch. See Battery Cables on
The starting motor does not page 12-3.
rotate and the engine cannot
The battery voltage is low Check the electrolyte level and See Checking the Electrolyte
start.
(discharging battery). the specific gravity of battery. Level on page 12-4.
Charge the battery or replace. See Charging the Battery on
page 12-5.
Check for a short. See Alternator Wiring Diagram
on page 11-8.
Battery will not charge. Check the wires between the See Alternator Wiring Diagram
alternator and the battery. on page 11-8.
Check the tension of V-belt. See Check the V-Belt Tension
on page 4-25.
Check the alternator. See Alternator on page 11-1.
Fuse burned out. Replace the fuse. See Fuse Chart on page 12-16
(IGN. PANEL: 10A) and Troubleshooting Fuses,
Relays and Harnesses on
page 13-21.
Fuse burned out. Replace the fuse. See Fuse Chart on page 12-16
(ECU: 20A) and Troubleshooting Fuses,
Relays and Harnesses on
page 13-21.
Fuse burned out. Replace the fuse. See Fuse Chart on page 12-16
(STARTER RELAY: 50A) and Troubleshooting Fuses,
Relays and Harnesses on
page 13-21.
Fuse burned out. Replace the fuse. See Fuse Chart on page 12-16
(IGN. 1st Station: 5A) and Troubleshooting Fuses,
Relays and Harnesses on
page 13-21.
Fuse burned out. Replace the fuse. See Fuse Chart on page 12-16
(IGN. 2nd Station: 5A) and Troubleshooting Fuses,
Relays and Harnesses on
page 13-21.

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 TROUBLESHOOTING Troubleshooting by Symptom

Trouble symptom Causes Corrective action Remarks

The starting motor does not rotate Starter relay contact failure. Check the operation of the See Troubleshooting Fuses,
and the engine cannot start. starter relay with a YDT or Relays and Harnesses on
equivalent service tool and a page 13-21.
tester. If there is a
malfunction, replace it.
The pinion gear of the starter Magnet-switch terminal is Check the magnet-switch See Troubleshooting Fuses,
does not mesh. loose. terminal. If a malfunction is Relays and Harnesses on
found, repair or replace. page 13-21.
Magnet-switch contact
failure.
Coil failure.
Burr on the tooth. Repair or replace. See Battery Cables on
page 12-3.
Clearance between the Repair the clearance. See Battery Cables on
pinion and the ring gear. page 12-3.
The pinion gear meshes but Loose battery or loose Check the terminals. If See Battery Cables on
the starting motor does not starting motor terminals. trouble is found, repair. page 12-3.
rotate.
Starter coil failure. Replace or repair. See Starter on page 10-1.
The clutch slips. Replace or repair. See Starter Components on
page 10-6.
Battery cable resistance is Replace with the proper See Battery Cables on
too high. (The wire diameter cable. page 12-3.
is thin.)
The battery voltage is too low Check the electrolyte level See Checking the Electrolyte
(battery discharge). and the specific gravity. Level on page 12-4.
Charge the battery or See Charging the Battery on
replace. page 12-5.
Check the electric circuit See Alternator Wiring
wiring. Diagram on page 11-8.

Note: Starter relay operation on YDT

• Check the “Diagnostic Test Digital-Out”
• Check the “Manual”
• Enter the Password
• Enter the Engine Starter Inter Lock RL ON / OFF

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 Troubleshooting by Symptom TROUBLESHOOTING
12/05

Trouble symptom Causes Corrective action Remarks

The pinion gear meshes, but The battery voltage is too low Check the wiring between See Alternator Wiring
the starting motor does not (faulty charging). the alternator and the Diagram on page 11-8.
rotate. (continued) battery.
Check the V-belt tension. See Check the V-Belt
Tension on page 4-25.
Check the alternator. See Alternator on page 11-1.
The starting motor does not rotate Internal engine failure. Disassemble and inspect. See Disassembling the
and the engine cannot start. Repair or replace. Engine and Components on
(continued) page 5-6.
The control lever is not in the Shift the lever to NEUTRAL See Remote Control
NEUTRAL position. position. Electronic Control System
Starter Interlock (ECS) on page 12-20.
Emergency stop switch is Turn off the emergency stop. See Remote Control
pressed. Electronic Control System
(ECS) on page 12-20.
Crank speed sensor detects ➝ DTC: See Troubleshooting
overspeed (P0219). Fuses, Relays and
Harnesses on page 13-21.
Camshaft speed sensor ➝ DTC: See Troubleshooting
detects overspeed (P0219). Fuses, Relays and
Harnesses on page 13-21.
A disconnect and / or ➝ DTC: See Troubleshooting
short-circuit error (P0335 Fuses, Relays and
and P0340) of both speed Harnesses on page 13-21.
sensors are detected.
A disconnect and / or ➝ DTC: See Troubleshooting
short-circuit error (P1210) of Fuses, Relays and
a rack actuator is detected. Harnesses on page 13-21.
A rack movement error ➝ DTC: See Troubleshooting
(P1211) is detected. Fuses, Relays and
Harnesses on page 13-21.
A battery cable is not Connect the cables. —
connected.

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 TROUBLESHOOTING Troubleshooting by Symptom

Trouble symptom Causes Corrective action Remarks

The starting motor rotates but the engine will not start.
No fuel. The viscosity of the fuel is too Use the recommended fuel. See Fuel Selection on
high and the fuel does not page 3-6.
flow.
Fuel line is frozen. Warm up the fuel.
Air in the fuel system. Bleed air in the fuel system. See Fuel System on
page 6-1.
Fuel filter is clogged. Replace. See Fuel Filter Components
and Functions on page 6-33.
No fuel in the fuel tank. Refuel. See Check the Fuel Level on
page 4-6.
A fuel cock is closed. Open the fuel cock. See Check the Fuel Level on
page 4-6.
Clogged fuel system. Check the fuel system and See Fuel Filter Components
repair if necessary. and Functions on page 6-33.
Fuel feed pump. Check / repair or replace. See Basic Checkpoints on
page 6-24.
Faulty fuel injection nozzle. Valve seat. Check the fuel spray See Fuel Injection Nozzle
condition. If a malfunction is Components and Functions
Needle valve.
found, send to the FIE shop on page 6-26.
Wear of nozzle seat. for service or replace.
Clogged fuel nozzle hole(s).
Nozzle opening pressure.
Faulty fuel injection pump. Wear of plunger. Check. If a malfunction is See Troubleshooting the
found, send it to the FIE shop Fuel Injection System on
Plunger spring is broken.
for service or replace. (If page 6-24.
Plunger is stuck. measuring lag with a YDT,
Delivery valve spring is the movement of rack can be
broken. checked.)

Air in the fuel system. Bleed air in the fuel system. See Fuel System on
page 6-1.
Faulty fuel injection system. Injection timing. Check the pump fitting. See Troubleshooting the
Reassemble. Fuel Injection System on
page 6-24.
Loose fuel injection line. Retighten if necessary. See Troubleshooting the
Fuel Injection System on
Damaged fuel injection line. Replace if necessary.
page 6-24.
Air in the fuel injection line. Bleed air.

13-10 6LY3 Service Manual

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 Troubleshooting by Symptom TROUBLESHOOTING
12/05

Trouble symptom Causes Corrective action Remarks

The starting motor rotates, but the engine will not start. (continued)
Low compression. Compressed air leakage Lap the valve seat or replace See Inspecting the Cylinder
from intake / exhaust valves. the valve(s). Block and Components on
page 5-22.
No clearance of intake / Adjust the valve clearance. See Inspecting Intake /
exhaust valve. Exhaust Valves and Valve
Guides on page 5-30.
Faulty cylinder head gasket. Replace the head gasket. See Cylinder Head
Components and Functions
on page 5-26.
Wear on the top of the Disassemble, check and See Inspecting the Cylinder
cylinder. measure the dimension. If Block and Components on
wear is found, replace the page 5-22.
cylinder block.
Piston ring wear. Disassemble, check and See Replacing the Piston
measure the dimension. If Rings on page 5-39.
wear is found, replace.
Sticking of the piston ring(s). Disassemble and check. If See Replacing the Piston
sticking is found, clean or Rings on page 5-39.
replace.
Loose cylinder head bolts. Torque to specifications. See Cylinder Head
Components and Functions
on page 5-26.
Damaged valve spring. If damaged, replace. See Checking the Valve
Springs on page 5-32.
Air heater does not operate. Air heater terminal is Check the terminal. Repair. See Troubleshooting Fuses,
disconnected, loose or has Relays and Harnesses on
failed. page 13-21.
Air heater relay terminal is
disconnected, loosened or
has failed.
Faulty air heater. Remove and check the air See Air Heater on
heater. Replace if necessary. page 13-81.
Faulty air heater relay. Check operation of the relay. See Air Heater on
Replace if necessary. page 13-81.
Fuse burned out. Replace. See Troubleshooting Fuses,
(Air heater “A” or “B”: 250A) Relays and Harnesses on
page 13-21.
Clogged intake / exhaust Check. Replace if necessary. See Air Heater on
lines. page 13-81.

6LY3 Service Manual 13-11

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 TROUBLESHOOTING Troubleshooting by Symptom

Trouble symptom Causes Corrective action Remarks

The engine cannot be Main throttle station is inactive. Activate the station. Refer to the Operation Manual
controlled. Engine speed does of the Control Head.
not increase. (The engine
Faulty main throttle: ➝ DTC: See Troubleshooting by
speed is fixed at low idling.)
Detected error (P0120) DTC Fault Codes on
page 13-28.
Faulty main and sub-throttle: ➝ DTC: See Troubleshooting by
Detected error (P0120, P0220) DTC Fault Codes on
page 13-28.
Fuse (AUX POWER: 10A) Replace. See Fuse, Relay and Harness
burned out. on page 13-21.
Detected error (P0120)
Faulty control head. Check the input value of a Refer to the YDT Manual.
acceleration sensor with a
YDT. If an error is not detected
and a malfunction is found,
replace.
Communication error of the ➝ DTC: See Troubleshooting by
control module: DTC Fault Codes on
Detected error (0146) page 13-28.
The engine cannot be Crankshaft speed sensor error: ➝ DTC: See Troubleshooting by
controlled. Engine speed does Detected error (P0335) DTC Fault Codes on
not rise to more than page 13-28.
1800 rpm.
Camshaft speed sensor error: ➝ DTC: See Troubleshooting by
Detected error (P0340) DTC Fault Codes on
page 13-28.
Difference error of speeds: ➝ DTC: See Troubleshooting by
Detected error (P0335) DTC Fault Codes on
page 13-28.
Disconnect and short-circuit ➝ DTC: See Troubleshooting by
error of the rack position DTC Fault Codes on
sensor: page 13-28.
Detected error (P1201)
Disconnect and short-circuit ➝ DTC: See Troubleshooting by
error of the boost sensor: DTC Fault Codes on
Detected error (P0235) page 13-28.
Over-boost error: ➝ DTC: See Troubleshooting by
Detected error (P0234) DTC Fault Codes on
page 13-28.
Abnormal rise error of coolant ➝ DTC: See Troubleshooting by
temperature: DTC Fault Codes on
Detected error (P0118) page 13-28.
Disconnect and short-circuit ➝ DTC: See Troubleshooting by
error of the timer DTC Fault Codes on
electromagnetic valve: page 13-28.
Detected error (P1220 or
P1225)
Unachievable specified value ➝ DTC: See Troubleshooting by
error of timer: Detected error DTC Fault Codes on
(P0216) page 13-28.

13-12 6LY3 Service Manual

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 Troubleshooting by Symptom TROUBLESHOOTING
12/05

Trouble symptom Causes Corrective action Remarks

The engine cannot be Engine is overloaded. Check around the propeller —
controlled. Engine speed does and the boat hull.
not increase.
CAN communication error or Check the input value of the Refer to the YDT Manual. If a
main throttle error detected. acceleration sensor with a main throttle error is detected,
(Main throttle cannot be YDT. If an error is detected, engine speed goes to idle.
activated.) correct or replace the harness.
Faulty control head. (Main If error is not detected and a
throttle can be activated.) malfunction is found, replace
the control head.
Sub-throttle or wire harness Check the input value of Refer to the YDT Manual.
failed (in operation by acceleration sensor with a Refer to Figure 13-1 on
sub-throttle). YDT. If an error is not detected, page 13-14.
check the signal voltage of the
sub-throttle sensor. If failure is
found, correct or replace the
wire harness or sub-throttle
sensor.
The engine cannot be Faulty control head. (Main Check the input value of the Refer to the YDT Manual.
controlled. Engine speed is not throttle can be activated.) acceleration sensor with a If a main throttle error is
reduced. YDT. If an error is not detected detected, engine speed goes
and a malfunction is found, to idle.
replace the control head.
Sub-throttle or wire harness Check the input value of the Refer to the YDT Manual.
failed. (In operation by acceleration sensor with a Refer to Figure 13-1 on
sub-throttle.) YDT. If an error is not detected, page 13-14.
check the signal voltage of the
sub-throttle sensor. If failure is
found, correct or replace the
wire harness or sub-throttle
sensor.
Error of rack position sensor: ➝ DTC: See Troubleshooting by
Detected error (P1201). DTC Fault Codes on
page 13-28.
Fuel injection pump rack is Check the rack log with a YDT. Refer to the YDT Manual.
stuck. If a malfunction is found,
replace the fuel injection pump.
The engine cannot be The gearbox connector is Wire according to the manual. See Alternator Wiring Diagram
controlled. disconnected. on page 11-8.
The gearbox cannot be Faulty contact of the gearbox Check the connector terminal. See Alternator Wiring Diagram
engaged or disengaged. connector. Repair if necessary. on page 11-8.
Open circuit in the gearbox Check the harness. See Alternator Wiring Diagram
harness. on page 11-8.
Faulty electromagnetic valve Replace the electromagnetic Refer to the Gearbox Manual.
on the gearbox. valve.
Low gearbox oil. Check the oil level. If low, refill. Refer to the Gearbox Manual.
Faulty gearbox hydraulic oil Disassemble and check. Refer to the Gearbox Manual.
pump. Replace if necessary.
Worn clutch friction discs. Disassemble and check. Refer to the Gearbox Manual.
Replace if necessary.
The engine cannot be Seized clutch friction discs. Disassemble and check. Refer to the Gearbox Manual.
controlled. The shift position Replace if necessary.
cannot be changed.

6LY3 Service Manual 13-13

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 TROUBLESHOOTING Troubleshooting by Symptom
Figure 13-1

5.0
4.58
4.5
4.0
Single Voltage (V)

3.5
3.0
2.5
2.0
1.5
1.0
0.5
0.42
0.0
0 20 40 60 80 100 120 140 160 180
Rotation Angle (Degree) 0006110

Figure 13-1

13-14 6LY3 Service Manual

© 2007 Yanmar Marine International
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 Troubleshooting by Symptom TROUBLESHOOTING
12/05

Trouble symptom Causes Corrective action Remarks

Engine speed is not stable. If low idle hunting occurs, follow these individual steps and check the effect after each step.
1) Change the control gain pattern with a YDT.
2) Raise the low idle speed with 20 rpm step.
3) Check the following items. If a malfunction is found, repair or replace.
4) Replace the fuel injection pump.
NOTICE: In case of trolling issues, check the faulty trolling end or reduction gear end.
When the rotational fluctuation is not cyclic, the wire harness may be broken. The harness
can be checked by operating the engine with the harness for the test. (DTC can be
detected by coming off the output range of the harness.) The signal output line is
short-circuited with other lines fixed to a 3V. 5V line or the grounded line is short-circuited
with a 3V line and the output drops.
Malfunction of the fuel Faulty valve and / or seat. Check the fuel spray See Fuel Injection Nozzle
injection nozzle. Sticking needle valve. condition with a tester. If a Components and Functions
malfunction is found, send it on page 6-26.
Wear of seat.
to the FIE shop for service or
Clogged fuel injection replacement.
hole(s).
A decrease in fuel opening
pressure.
Uneven fuel injection Faulty movement of the fuel Check. If a malfunction is Refer to the YDT Manual.
volume. injection pump plunger. found, send it to the FIE shop
Damaged fuel injection pump for service or replacement.
plunger. (If measuring lag with a YDT,
the movement of the rack
Damaged plunger spring.
can be checked.)
Improper installation of the Reinstall according to the See Specifications on
fuel injection pump. Specifications on page 6-5. page 6-5.
Clogged fuel filter. Check and replace if See Fuel Filter Components
necessary. and Functions on page 6-33.
Clogged fuel system. Check and repair. See Fuel Filter Components
and Functions on page 6-33.
Air in the fuel system. Check and bleed air. See Fuel System on
page 6-1.
Faulty movement of the fuel Check and repair or replace See Inspecting the Fuel
feed pump. if necessary. Feed Pump on page 6-30.
Faulty actuation of the Check with a YDT. DTC: See Troubleshooting
hydraulic timer. DTC: See Troubleshooting by DTC Fault Codes on
by DTC Fault Codes on page 13-28.
page 13-28.
Engine is overloaded. Check around the propeller —
and boat hull.
Seized main moving part(s). Check and repair or replace See Engine on page 5-1.
if necessary.
Clutch slip. Check and repair or replace Refer to the Marine Gear
if necessary. Manual of another volume.

6LY3 Service Manual 13-15

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 TROUBLESHOOTING Troubleshooting by Symptom

Trouble symptom Causes Corrective action Remarks

The engine stops suddenly. Emergency stop switch on Turn off the emergency stop See Battery Components
switch panel was pressed. switch. and Functions on page 12-3.
Emergency stop switch is Check the continuity of the See Alternator Wiring
open. circuit. Replace the damaged Diagram on page 11-8.
harness.
Fuel supply stops. No fuel in the fuel tank. Refuel. See Check the Fuel Level on
Air in the fuel system. Bleed air. page 4-6.
Fuel and water in the tank. Drain the fuel tank.
Closed fuel cock(s). Open the cock(s).
Clogged fuel filter. Replace the filter. See Fuel Filter Components
and Functions on page 6-33.
Damaged fuel lines. Check the fuel system and See Fuel System Diagram
repair. on page 6-6.
Faulty fuel feed pump. Check the feed pump and See Fuel Feed Pump
repair or replace. Components and Functions
on page 6-28.
Seized main moving part(s). Repair or replace if See Engine on page 5-1.
necessary.
Clogged air cleaner. Clean or replace. See Fuel System on
page 6-1.
Engine does not stop. Fuel injection pump brackets Disassemble the fuel Refer to the YDT Manual for
are improper. injection pump brackets and lag check. Refer to the Pump
reassemble according to this Disassembly and
manual. NOTICE: After Reassembly Manual.
reassembling, check the lag
with a YDT to check the
movement of the rack.
Seized fuel injection pump Replace the fuel injection Refer to the YDT Manual.
plunger. pump. Then, check the lag
with a YDT to check the
movement of the rack.

13-16 6LY3 Service Manual

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 Troubleshooting by Symptom TROUBLESHOOTING
12/05

Trouble symptom Causes Corrective action Remarks

White exhaust smoke in cold weather.
Air heater does not work The battery voltage is low Check the electrolyte level See Checking the Electrolyte
well. See Air Heater on (battery discharge). and the specific gravity. Level on page 12-4.
page 13-81. Charge the battery or See Charging the Battery on
replace. page 12-5.
Check the electric circuit. See Fuse and Relay
Location on page 12-17.
The battery voltage is low Check the alternator and See Inspecting the Battery
(faulty charging). battery terminals. on page 12-4.
Check the V-belt tension. See Check the V-Belt
Tension on page 4-25.
Check the alternator See Alternator on page 11-1.
operation.
Loose or faulty connection Check around the terminal See Air Heater Operation on
on the air heater terminal. and repair if necessary. page 12-13.
Loose or faulty connection Check around the terminal See Fuse, Relay and
on the air heater relay and repair if necessary. Harness Components on
terminal. page 12-16.
Faulty air heater. Disassemble and check. See Air Heater Operation on
Replace if necessary. page 12-13.
Faulty air heater relay. Check the relay with a YDT See Fuse, Relay and
and tester. Replace if Harness Components on
necessary. page 12-16.
Fuse burned out. Replace. See Troubleshooting Fuses,
(Air heater A or B: 250A) Relays and Harnesses on
page 13-21.
Coolant temperature sensor ➝ DTC: See Troubleshooting
error (P0115) is detected. by DTC Fault Codes on
page 13-28.
Improper fuel. Low cetane number. Replace the fuel. See Additional Fuel
Requirements on page 3-6.
Excessive aromatics in the Replace the fuel. See Additional Fuel
fuel. Requirements on page 3-6.
Faulty fuel injection nozzle. Faulty valve and / or seat. Check the fuel spray See Fuel Injection Nozzle
Sticking needle valve. condition with a tester. If a Components and Functions
malfunction is found, send it on page 6-26.
Wear of seat.
to the FIE shop for service or
Clogged fuel injection replacement.
hole(s).
Decrease in fuel opening
pressure.

6LY3 Service Manual 13-17

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 TROUBLESHOOTING Troubleshooting by Symptom

Trouble symptom Causes Corrective action Remarks

White exhaust smoke from warm engine.
Faulty fuel injection nozzle. Faulty valve and / or seat. Check the fuel spray See Fuel Injection Nozzle
Sticking needle valve. condition with a tester. If a Components and Functions
malfunction is found, send to on page 6-26.
Wear of the seat.
an FIE shop for service or
Clogged fuel injection replacement.
hole(s).
Decrease in fuel opening
pressure.
Improper fuel. Low cetane number. Replace fuel. See Fuel Selection on
page 3-6.
Excessive aromatics in the Replace fuel. See Fuel Selection on
fuel. page 3-6.
Excessive amount of oil in Seized piston. Disassemble and check. See Inspecting the Pistons
the engine causing oil to Replace if necessary. and Piston Pins on
burn. page 5-36.
Wear of the piston rings. Check and replace. See Measuring the Pistons
on page 5-37.
Sticking piston rings. Check, clean and replace. See Measuring the Pistons
on page 5-37.
Scarring or wear of the Disassemble and check. See Inspecting the Cylinder
cylinder wall. Repair or replace if Block and Components on
necessary. page 5-22.
Insufficient amount of oil in Scarring or wear of the Disassemble, check and See Inspecting Intake /
the engine causing oil to intake / exhaust valves. measure the dimension. Exhaust Valves and Valve
burn. Repair or replace if Guides on page 5-30.
necessary.
Scarring or wear of the valve Disassemble, check and See Inspecting Intake /
guides. measure the dimension. Exhaust Valves and Valve
Repair or replace if Guides on page 5-30.
necessary.
Damaged stem seal. Replace if necessary. See Inspecting the Valve
Stem Seals on page 5-32.

13-18 6LY3 Service Manual

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 Troubleshooting by Symptom TROUBLESHOOTING
12/05

Trouble symptom Causes Corrective action Remarks

Black exhaust smoke.
Faulty fuel injection nozzle. Faulty valve seat. Check the fuel spray See Fuel Injection Nozzle
Sticking needle valve. condition with a tester. If a Components and Functions
malfunction is found, send it on page 6-26.
Wear of seat.
to the FIE shop for service or
Clogged fuel injection replacement.
hole(s).
Decrease in fuel opening
pressure.
Faulty combustion because Clogged air cleaner. Clean or replace. See Troubleshooting the
of insufficient intake air Fuel Injection System on
volume. page 6-24.
Decrease in intake air Check the turbocharger. See Turbocharger
pressure. Clean the blower of Components and Functions
turbocharger. on page 9-4.
Charging air temperature is Check the impeller of the See Seawater Pump
too high. seawater pump. Check for a Components and Functions
clogged seawater line and on page 7-6.
for dirt in the intercooler core.
Engine room is not Check the ventilation. —
ventilated.
Faulty combustion because No valve clearance. Readjust the valve See Service Standards on
of the blow-by gas and the clearance. page 14-3.
decreased compression air Faulty contact of the intake / Lap the valve and seat. See Inspecting Intake /
pressure. exhaust valves and seats. Replace valve if necessary. Exhaust Valves and Valve
Guides on page 5-30.
Seized main moving parts. Disassemble and check. See Engine on page 5-1.
Replace if necessary.
Wear of the piston ring. Check and replace. See Measuring the Piston
Rings on page 5-38.
Sticking piston ring. Check and clean or replace. See Measuring the Piston
Rings on page 5-38.
Miscellaneous. Engine overloaded. Check around propeller and —
boat hull.
The injection timing is Check the injection timing —
improper. control and condition. If the
timing is incorrect, reinstall or
replace the timer.

6LY3 Service Manual 13-19

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 TROUBLESHOOTING Troubleshooting by Symptom

Trouble symptom Causes Corrective action Remarks

Insufficient engine output.
(Reduced maximum engine speed, reduced boat speed.)
Engine is overloaded. Increased ship resistance Check around the propeller —
Reduction of maximum Excessive burden. and boat hull. Check the
speed is not because of deadweight of the boat.
output reduction.
Faulty fuel injection nozzle. Faulty valve and / or seat. Check the fuel spray See Fuel Injection Nozzle
Sticking valve. condition with a tester. If a Components and Functions
malfunction is found, send it on page 6-26.
Wear of seat.
to the FIE shop for service or
Clogged fuel injection replacement.
hole(s).
Decrease in fuel opening
pressure.
Insufficient fuel supply. The fuel tank valve is not Open the fuel tank valve See Handling Diesel Fuel on
opening sufficiently. fully. page 3-7.
Clogged fuel filter. Replace the fuel filter. See Fuel Filter Components
and Functions on page 6-33.
Faulty fuel feed pump. Disassemble and service. See Fuel Feed Pump
Components and Functions
on page 6-28.
Wear of the fuel injection Ask the FIE shop for See Fuel Injection Pump /
pump plunger. maintenance. Governor / Timer on
page 6-7.
Insufficient intake air volume. Clogged air cleaner. Clean or replace. See Troubleshooting the
Fuel Injection System on
page 6-24.
Decrease in intake air Check the turbocharger. See Turbocharger
pressure. Clean the blower of Components and Functions
turbocharger. on page 9-4.
Intake air temperature is too Check the impeller of the See Seawater Pump
high. seawater pump. Check for a Components and Functions
clogged seawater line and on page 7-6.
for dirt in the intercooler core.
Clogged exhaust gas Check the exhaust passage. See Inspecting Intake /
passage. Exhaust Valves and Valve
Guides on page 5-30.
Faulty ventilation in the Check the ventilation unit. —
engine room.
Faulty combustion because No valve clearance. Adjust the valve clearance. See Service Standards on
of blow-by and reduced air page 14-3.
compression pressure. Faulty contact between valve Lap the valve or replace. See Service Standards on
and seat. page 14-3.
Seized main moving parts. Disassemble and check. See Engine on page 5-1.
Replace if necessary.
Wear of piston ring. Check and replace if See Measuring the Piston
necessary. Rings on page 5-38.
Sticking piston ring. Check and clean or replace. See Measuring the Piston
Rings on page 5-38.

13-20 6LY3 Service Manual

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 Troubleshooting Fuses, Relays and Harnesses TROUBLESHOOTING
12/05

TROUBLESHOOTING FUSES, RELAYS AND HARNESSES

Fuse, Relay and Harness
When a harness short-circuits, in some cases, the fuse burns out. (A fuse never burns out under the usual
state of use.)
If the power supply of the peripheral device is taken from the engine harness without notice, the fuse may
burn out.
All of the fuses for the 6LY3 engine are shown in the table below.

No. Fuse Size Application Fuse Location Part No.

1 10A AUX POWER Fuse box 198535-52120
IGN. PANEL
2 10A Fuse box 198535-52120
(Switch panel)
3 20A ECU Fuse box 198535-52140
IGN. SIG
4 10A Fuse box 198535-52120
(Switch ON signal)
5 5A YSDT Fuse box 198535-52110
6 250A Air Heater “A” Below the exhaust manifold 119578-77150
7 250A Air Heater “B” Below the exhaust manifold 119578-77150
8 150A ALTERNATOR Below the exhaust manifold 119578-77090
9 50A STARTER RELAY Below the exhaust manifold 119578-77080
IGN. SIG 1st Station
10 5A Rocker switch panel (1st Station) 170203-91930
(Switch ON signal)
IGN. SIG 2nd Station
11 5A Rocker switch panel (2nd Station) 170203-91930
(Switch ON signal)

Fuse Burns Out

1. When the location of the short circuit on the harness is found or when the causes of the short circuit are
clarified, repair as a temporary solution and replace the fuse. It is recommended to replace the harness
because of the possibility of decreasing waterproof quality on the harness and connector.
2. If the cause is undetermined, replace the fuse. If the fuse burns out again, replace the harness.

Test Check
Check the continuity by touching the corresponding fuse terminal to the ground. In the case of a fuse on a
relay assembly, open the fuse cover and check the continuity by touching the corresponding fuse terminal to
ground.

Checking a Fuse
1. Remove the fuse.
2. Check between both terminals for continuity.
3. If continuity is indicated, the fuse is in good condition.

6LY3 Service Manual 13-21

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 TROUBLESHOOTING Troubleshooting Fuses, Relays and Harnesses

Troubleshooting Blown Fuses

Blown fuses, their respective circuits and corrective action are shown in the following table. If the fuse blows
again, replace the corresponding wire harness.

Trouble Symptom Key

No. Size Application Corrective Action
Engine Stop Engine Running Switch

1 10A AUX POWER The engine can Error (P0120 / 0) is Off Check the continuity between the negative
start. Error detected. The digital (-) side of the fuse and ground (engine
(P0120 / 0) is display is not turned body). In case of continuity, the engine
detected. The digital on. harness may have a short circuit. Replace
display will not turn it. (See Wire Harness Locations on
on. page 12-18.) In case of no continuity,
replace the fuse. If the fuse burns out again,
replace the harness.
2 10A IGN PANEL The engine will not The engine will shut Off Check the continuity between the negative
(Switch panel) start. ECU will not down. The engine (-) side of the fuse and ground. (See Wire
turn on. cannot start. Harness Locations on page 12-18.) In case
of continuity, replace the fuse. In case of no
continuity, the engine harness may have a
short circuit. Remove the harness 12-pin
connector above the fuel injection pump
and check for continuity again. (See Wire
Harness Locations on page 12-18.) In case
of continuity, the engine harness has a
short circuit. Replace it. In case of no
continuity, the TELEFLEX harness may
have a short circuit. Replace it.
3 20A ECU The engine will not The engine shuts — Replace the engine harness. (See Wire
start. ECU will not down. The engine Harness Locations on page 12-18.)
turn on. cannot start.
4 10A IGN. SIG The engine starts. Error (U0146) is On Check the continuity between the negative
(Switch ON Error (U0146) is detected. (-) side of the fuse and ground. (See Wire
signal) detected. Harness Locations on page 12-18.) In case
of continuity, engine harness may have a
short circuit. Replace it. (See Wire Harness
Locations on page 12-18.) In case of no
continuity, replace the fuse. If the fuse
burns out again, main harness may have a
short circuit. Replace it.
5 5A YDT Engine runs normal Engine runs normal. On Check the continuity between the negative
but the YDT is (-) side of the fuse and ground. (See Wire
inoperative. Harness Locations on page 12-18.) In case
of continuity, engine harness may have a
short circuit. Replace it. (See Wire Harness
Locations on page 12-18.) In case of no
continuity, replace the fuse. If the fuse
burns out again, main harness may have a
short circuit. Replace it.

13-22 6LY3 Service Manual

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 Troubleshooting Fuses, Relays and Harnesses TROUBLESHOOTING
12/05

Trouble Symptom Key

No. Size Application Corrective Action
Engine Stop Engine Running Switch

6 250A Air heater “A” As air heater “A” is As air heater “A” is not Off Check the air heater. If it is OK, check the
or “B” not turned on, the turned on, the white operation of the air heater relay. If it has
startability of the smoke may increase failed, replace it.
engine in low when the engine is
On Check the operation of the air heater relay.
temperature cold. With the air
If it is OK, check it for continuity. If it has
becomes worse. heater off, white
failed, replace the air heater relay.
With the air heater smoke increases
off, the engine is when cold. Off Check the continuity between the negative
hard to start. (-) side of the fuse and ground. (See Wire
Harness Locations on page 12-18.) In case
of continuity, harness (B) may have a short
circuit. Replace it. (See Wire Harness
Locations on page 12-18.) In case of no
continuity, remove the harness from the air
heater terminal and check continuity
between the harness and ground. In case of
continuity, main harness may have a short
circuit. Replace it. In case of no continuity,
replace the fuse. If the fuse burns out again,
the main harness may have a short circuit.
Replace it.
7 150A ALTERNATOR Engine runs normal. Engine runs normal. Off Check the continuity between the negative
Battery discharge. (-) side of the fuse and ground. (See Wire
Harness Locations on page 12-18.) In case
of continuity, harness (A) may have a short
circuit. Replace it. (See Wire Harness
Locations on page 12-18.) In case of no
continuity, replace the fuse and follow it. If
the fuse burns out again, the main harness
may have a short circuit. Replace it.
8 50A STARTER Engine will not start. Battery discharge. Off Check the continuity between the negative
RELAY With the starter (-) side of the fuse and ground. (See Wire
switch on, relay Harness Locations on page 12-18.) In case
snaps but engine of continuity, check the starter relay. In case
will not turn over. of no continuity, replace the fuse. If the fuse
Speed sensor error burns out again, check the starter relay.
is detected.
On Check the operation of the starter relay. If it
is OK, harness (F) may have a short circuit.
Replace it (See Wire Harness Locations on
page 12-18.). If it has failed, the relay may
be damaged and the harness (c) is shorted.
Replace them both. In case the fuse burns
out again, replace starter.

6LY3 Service Manual 13-23

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 TROUBLESHOOTING Troubleshooting Fuses, Relays and Harnesses

Trouble Symptom Key

No. Size Application Corrective Action
Engine Stop Engine Running Switch

9 5A IGN. SIG 1st Engine will not start. The engine shuts On Check the continuity between the negative
Station ECU inoperative down and will not start (-) side of the fuse and ground. (See Wire
from 1st station. Harness Locations on page 12-18.) In case
of no continuity, replace the fuse. If the fuse
burns out again, perform the following:
• Disconnect the 12-pin connector above
the fuel injection pump.
• Check continuity between Pin 1 and
Pin 9 and ground (Figure 13-2 on
page 13-25).
In case of continuity, the engine harness
may be shorted. Replace it. In case of no
continuity, remove the TELEFLEX
extension harness from the connector of
switch panel. Check the pins of the
TELEFLEX extension harness in the same
manner.
10 5A IGN. SIG 2nd Engine will not start. Engine shuts down On Check the continuity between the negative
Station ECU inoperative and will not start from (-) side of the fuse and ground. (See Wire
1st station. Harness Locations on page 12-18.) In case
of no continuity, replace the fuse. If the fuse
burns out again, perform the following:
• Disconnect the 12-pin connector above
the fuel injection pump.
• Check continuity between Pin 1 and Pin
3 and ground (Figure 13-2 on
page 13-25).
In case of continuity, the engine harness
may be shorted. Replace it. In case of no
continuity, check the pins of the TELEFLEX
extension harness in the same manner.

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12/05

Control Panel, 1st Station 12-Pin Connector

Disconnect the 12-pin connector
Figure 13-3

(Figure 13-2, (1)) above the fuel injection pump.

Check continuity between pins 1 and 3 and ground.
6 7
Figure 13-2

(1)
5 8
4 9
3 10
2 11
1 12

0006310

0006116
Figure 13-3

Figure 13-2 Connector

No. Remarks
Destination
1 – 12-Pin Connector
1 Blank Waterproof plug
Power supply for sub-throttle
2 5V sensor
sensor
3 1st station ON 12V energized by ON
4 Battery 12V 12V always (from the battery)
5 Emergency stop Emergency stop (Return)
6 Sub-throttle sig. Sub-throttle voltage
7 Sensor ground —
8 Reserved Unused, though there is a line
9 2nd station ON 12V energized by ON
10 Main relay Energizing when ECU ON
11 Start 12V energized by START
12 Sub-throttle Lamp (LED)

6LY3 Service Manual 13-25

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 TROUBLESHOOTING Electronic Control System

ELECTRONIC CONTROL SYSTEM

The 6LY3 series engine is equipped with an Electronic Control System (ECS). The ECS includes an Engine
Control Unit (ECU), an engine interface module, an electronic governor and an electro-hydraulic timer.
These components are attached to the fuel injection pump, control fuel injection quantity and injection timing
electronically.

Engine Control System Diagram

The ECU controls fuel injection quantity and injection timing by interpreting engine operating parameters
such as throttle positions, gear shift selections and control panel displays. It monitors engine conditions such
as temperature, pressure and flow rates.

Yanmar Diagnostic Tool (YDT)

Figure 13-4

0006306

Figure 13-4

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 Electronic Control System TROUBLESHOOTING
12/05

Engine Control System and YDT

Figure 13-5

2nd Helm 1st Helm

or or or

Helm ECU Helm ECU Helm ECU

YDT
NMEA 2000

J1939
E
Power C
Battery U Inboard
Fuel Tank
Neutral Safety Start SW
F-N-R Electrical Gear
Sub Throttle Sensor

YDT

J1939
E
Power C
Battery U Inboard
Fuel Tank
Neutral Safety Start SW
F-N-R Electrical Gear
Sub Throttle Sensor

0006318

Figure 13-5

6LY3 Service Manual 13-27

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 TROUBLESHOOTING Troubleshooting by DTC Fault Codes

TROUBLESHOOTING BY DTC FAULT CODES

The following failure information is displayed on the TELEFLEX display.

TELEFLEX i5601E Display Alarm Screen Information

HOT ENGINE CHECK ENGINE

OVER REV EMERGENCY STOP
OIL PRESSURE LOW VOLTAGE
TURBO BOOST ALTERNATOR
GEAR OIL SEAWATER FLOW
ENG COM ERROR LOW COOLANT
MAINTENANCE WATER IN FUEL
NETWORK MAIN THROTTLE
PWR REDUCTION SEC THROTTLE
NEUTRAL PROTECT SHUTTING DOWN

Terms
DTC: Diagnostic Trouble Code
FMI: Failure Mode Identifier

13-28 6LY3 Service Manual

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TFX Diagnostic Screen Display Procedure 1

Figure 13-6

When powered-up, the i5601E Digital Displays will initially display an introductory screen showing the software In the unlikely event that an engine fault occurs, a warning box appears in the
revision level. They will then display one of the following four screens: display showing the cause of the fault, and the action to take. “Press Any Key
To Continue.”

Pressing any key acknowledges the alarm and immediately switches the display to the Alarms screen. The
i5601E continues to beep until all alarm conditions (engine faults) have cleared. Unacknowledged alarms are
shown as flashing boxes. Press any key to acknowledge alarm boxes that may still be flashing, and they will then
change to a stready highlighted state.

Alarm blocks remain highlighted as long as the alarm condition (engine fault) remains and will automatically
reset to an un-highlighted state after the alarm condition has passed.

These screens show all of the key engine data and can be accessed by pushing a single button. The right-most
button allows the contrast and brightness to be set.

Engine Diagnostic Code Summary Screen

Note: The i5601E is an extremely versitle display. The four-left keys can be reconfigured to allow the user to
display whatever screens he or she desires. For additional operational details, refer to Appenbdix A and the
technical manual.

0006320

Figure 13-6

TFX Diagnostic Screen Display Procedure 2

Figure 13-7

i5601E Digital Display Setup i5601E Menu Navigation

The i5601E was set up at the factory with the keys assigned and locked as shown on page 6 of this manual. This Performs the function indicated by a pop-up menu,
mode is the default mode and allows start up and operation of the engine. It serves many applications quite well. if present.
The i5601E Digital Display unit has many additional features and capabilities. This section of the book shows With no pop-up menu showing, briefly press to
the use of some of these features. display the Lighting & Contrast menu.

Changing the basic set up is typically accomplished in one of two ways.

With no pop-up menu showing, press and HOLD
1. Go to the systems menu and alter basic selections.
to display the MAIN MENU.
2. Enable the right arrow key on the basic screens to allow changing of the data shown in the default
displays.

To enter the Main Menu press and hold key 5 until the menu appears. ALARMs / DIAGs
MAIN MENU Diag Codes
Alarms
ALARMs / DIAGs Network Status
MONITOR SETTINGS Network Modes
To move around the menus use the softkeys at the bottom of the screen.
The function of a particular softkey changes from screen to screen to CALIBRATION
MONITOR SETTINGS
whatever is most appropriate for the given screen. FACTORY SETTINGS HOT KEYS LOCK
Units Menu
Password Protected Language Menu USER SETTINGS
Keys 1 2 3 4 5 Tach Range 0-3000
Reset Main1 Time
SPEED
Docking Mode
Depth Offset
Default Monitor Fwd Throt Curv 1
NOTE : Any changes to the setup menus may require reconfiguring the i5601E HOT KEY SETUP. Beeper ON Rev Throt Curv 1
About Split Range
Prog Shift Delay 0.0
BACK Returns you to the previous menu or screen.
CALIBRATION Station Protect N

USER SETTINGS
Decreases the setting of a selected menu item. TROLLING TROLLING

Troll Mode SPLIT

Moves the cursor arrow down to select the Lever 40%
FACTORY SETTINGS
next menu item in a list. Max Throttle 50%
Eng Display: PORT
Valve CAL
EXIT
Exits the current menu and returns you to the Set idle rpm
prior screen. Sync: Pwr Train
Lead Eng Port SETUP TROLL VALVE

T Engage Dry 0.0 RPM ENGAGE 450

Increases the setting of a selected menu item.
Setup TROLL Valve Trans Type ZF
Fixed Shift Dry 0.0

MORE
Reveals additional keys and swaps them with Buttons SYSTEM SELECT
those currently shown.
“Down” Arrow moves menu selection down
ON Toggles the operational status of a currently
OFF
selected menu item. “Up” Arrow moves menu selection up

Moves the cursor arrow up to select the “Right” Arrow acts on current menu item
previous menu item in a list.
BACK “Back” Moves back to previous menu
0006316

Figure 13-7

6LY3 Service Manual 13-29

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 TROUBLESHOOTING Troubleshooting by DTC Fault Codes

List of DTC (Diagnostic Trouble Codes)

TFX Diagnostic Screen Display Procedure 3
Figure 13-8

i5601E Digital Display Alarms/Engine Diagnostic Codes

Performs the function indicated by a pop-up menu,
if present.
With no pop-up menu showing, briefly press to
display the Lighting & Contrast menu.

With no pop-up menu showing, press and HOLD

to display the MAIN MENU. Engine Alarms
The Alarm Screen will display the status of 20 defined alarms. A
flashing black background indicates unacknowledged alarm; a solid
MAIN MENU black background indicates an acknowledged still in alarm state
status.

ALARMs / DIAGs

MONITOR SETTINGS

CALIBRATION

FACTORY SETTINGS

Password Protected

Engine Diagnostic Codes

This screen displays the diagnostic code information. The title bar
indicates the number of diagnostic items.

Buttons

Down Arrow moves menu selection down

Up Arrow moves menu selection up

Right Arrow acts on current menu item

Maintenance Warning
BACK Back Moves back to previous menu Based on startup issues, the maintenance timer will activate between 50 and 60 hours of operation. A maintenance
warning will be displayed on the digital display screen. To acknowledge this warning, press and hold the #5
(right most) button on the i5601E digital display for a few seconds until the main menu is displayed. Use the
down arrow button to move the cursor to “Calibration.” Press the right arrow button, then go to “User Setting”
Engine Alarms/Diagnostic Codes menu. The arrow should be at the “Reset Maint. Time” selection. Press the right arrow key to reset. The warning
will go away. After an additional 250 hours of operation the maintenance warning will be displayed again, and
The ALARMs / DIAGs Screen Menu allows user to go to the Alarm or Diag Code Screen. This is very useful
every 250 hours thereafter. This a reminder that periodic maintenance must be performed at these intervals.
in the HOT KEY Mode, as a dedicated hot key is not required to view these screens. Use can hold Right most
key down go into the menu mode and then via this menu access the desired screen.
0006317

Figure 13-8

This information is also shown on the YDT.

Fault Code: Active DTC
Fault Code: Logged DTC

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NOTICE: The LEVEL column shows the hierarchy of the trouble.

Level 1: The message of the faulty part appears on the display.
Level 2: Only the ENGINE ALARM message appears on the display and the faulty part appears when
operating the display.
Level 3: The faulty part can be seen when switching to LEVEL 3.

DTC Level Description

P0115 2 Coolant Temperature Sensor
P0118 2 Coolant Temperature Too High
P0120 3 Main Throttle Position Sensor
P0180 2 Fuel Temperature Sensor
P0183 2 Oil Temperature Too High
P0195 2 Oil Temperature Sensor
P0198 2 Oil Temperature Too High
P0216 3 Injection Timing Control Device
P0219 1 Crank / Cam Over Revolution
P0220 2 Sub-Throttle Sensor
P0234 2 Over Boost
P0235 2 Boost Pressure Sensor
P0335/0 2 Cam / Crank Speed Incompatibility
P0335/4 2 Crank Speed Sensor
P0340 2 Cam Speed Sensor
P0520 2 Oil Pressure Sensor
P0522 2 Oil Pressure Too High
P0562 1 ECU Power Supply Voltage
P0605 3 EEPROM Error
P1202 2 Rack Position Sensor
P1210 2 Rack Actuator
P1211 3 Rack Actuator Mechanical Malfunction
P1220/1225 3 Advance / Retard Timer Actuator (Solenoid)
P1230 3 5V Sensor Voltage
P1240 3 ECU Power Supply Voltage Open
P1603 3 ECU Temperature Too High
U0146 3 i8320 Communication Error

6LY3 Service Manual 13-31

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 TROUBLESHOOTING Troubleshooting by DTC Fault Codes

Wiring Diagram
Figure 13-9

0006419

Figure 13-9

13-32 6LY3 Service Manual

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ECU Connector Pin Configuration

Figure 13-10

1 2 3 4 5 6 7 8 9 10

1 RA TARD TAAD AHR1 AHR2 CRK- CAM- ST STHS IGN2

10
11 12 13 14 15 16 17 18 19 20

11 G-P MNR STSW RAR B1 CRK+ CAM+ NTS IGN1 EMS 20

21 22 23 24 25 26 27 28 29 30

21 STR STHL CAMP SNS5 B2 CANL PLO THF STH RPS

30
31 32 33 34 35 36 37 38 39 40

31 OUT1 OUT2 G_P1 G_P2 G_S CANH THW AN1 THLO PBST
40

0006117

Figure 13-10

PIN Description PIN Description

1 Rack Actuator 21 Starter Check
2 Retard Timer Solenoid 22 Sub-Throttle Indicator
3 Advance Timer Solenoid 23
4 Air Heater Relay 1 24 5V Supply Voltage
5 Air Heater Relay 2 25 12V DC
6 Crank Speed Sensor Pulse - 26 i2 Communication CANL
7 Cam Speed Sensor Pulse - 27 Oil Pressure Sensor
8 Starter ON 28 Fuel Temperature Sensor
9 Sub-Throttle Switch 29 Throttle Position Sensor
10 2nd Station Key 30 Rack Position Sensor
11 ECU Power GND 31
12 ECU Main Relay 32
13 33 Ground
14 Actuator Relay 34 Ground
15 12V DC 35 Sensor GND
16 Crank Speed Sensor Pulse + 36 i2 Communication CANH
17 Cam Speed Sensor Pulse + 37 Coolant Temperature Sensor
18 Neutral Switch 38
19 1st Station Key 39 Oil Temperature Sensor
20 Emergency Stop 40 Boost Pressure Sensor

6LY3 Service Manual 13-33

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 TROUBLESHOOTING Troubleshooting by DTC Fault Codes

Troubleshooting With the DTC

P0115/3, 4 (Coolant Temperature Sensor)

DTC P0115/3, 4 Coolant Temperature Sensor

Sensor Specification Chart Electrical Circuit Chart

Figure 13-11 Figure 13-12

Temperature Sensor Characteristics

(1) ECU
Typical Resistance (K Ohms)

A 37
100

B 35

0006159
10

59

19
0.1
-40°C -20°C 0°C 20°C 40°C 60°C 80°C 100°C 120°C M12 x 1.5 0006119
(-40°F) (-4°F) (32°F) (68°F) (104°F) (140°F) (176°F) (212°F) (248°F)

Temperature 0006118
Figure 13-12

Figure 13-11 Part Code: 119254-44910

1 – Coolant Temperature Sensor

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DTC Fault Code

DTC / FMI 1. Condition, 2. Fault, 3. Time to Detect, 4. Display Check Point

1. Key switch ON
2. Input signal voltage is above 4.8V Wire harness
P0115/3
3. 0.5 seconds sensor
4. CHECK ENGINE on the TELEFLEX display
1. Key switch ON
2. Input signal voltage is below 0.2V Wire harness
P0115/4
3. 0.5 seconds sensor
4. CHECK ENGINE on the TELEFLEX display

Engine takes following coolant temperature as a default.

Fail Mode -15°C (5°F) at engine stop (for starting)
60°C (140°F) at engine running
Limited Operation No limited operation
Yes
Fail Release
When input signal voltage goes to normal range (0.2 - 4.8 V) for 0.5 seconds
White smoke increases in cold conditions.
Remarks
Black smoke may increase at starting.

Fault

DTC / FMI Probable Cause

1. Open circuit of wire harness (signal and ground) or short to high voltage over 5V
P0115/3 2. Sensor failure
3. ECU failure
1. Wire harness (signal) short to ground
P0115/4 2. Sensor failure
3. ECU failure

Corrective action: See Temperature Sensor Diagnosis Procedure on page 13-40.

6LY3 Service Manual 13-35

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 TROUBLESHOOTING Troubleshooting by DTC Fault Codes

P0118/0 (Coolant Temperature Too High)

DTC P0118/0 Coolant Temperature Too High

DTC Fault Code

DTC / FMI 1. Condition, 2. Fault, 3. Time to Detect, 4. Display Check Point

1. Key switch ON
2. Coolant temperature above 110°C (230°F) Coolant system
P0118/0 Seawater system
3. 0.5 seconds Sensor
4. HOT ENGINE, PWR REDUCTION on the TELEFLEX display

Fail Mode Engine over-heat condition results in limited operation.

Limited Operation Maximum engine speed is limited to 1800 rpm.
Yes
Fail Release
When coolant temperature got below 95°C (203°F)
Yes
Limited Operation Release
After fail released and also throttle position at low idle position
Remarks —

Fault

DTC / FMI Probable Cause

Seawater Pump Impeller
Seacock
Seawater System
Coolant Level
Coolant System
P0118/0
Contamination of Heat Exchanger
Thermostat
Coolant Pump
V-Belt
Faulty Coolant Temperature Sensor

Troubleshooting Procedure
1. Check the seawater pump impeller. 7. Check the thermostat.
2. Check the seacock. 8. Check the coolant pump.
3. Check the seawater system. 9. Check the V-belt driving the coolant pump.
4. Check the coolant level. 10. Check the coolant temperature sensor.
5. Check the coolant system. 11. Check the wire harness.
6. Check the contamination of the heat exchanger.

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P0120/0 (Main Throttle Position Sensor)

DTC P0120/0 Main Throttle Position Sensor

Fault Code

DTC / FMI 1. Condition, 2. Fault, 3. Time to Detect, 4. Display Check Point

1. Key switch ON
2. Teleflex i2 module (i832X) sends a message that indicates throttle malfunction
P0120/0 status Main throttle head
3. —
4. MAIN THROTTLE, CHECK ENGINE on the TELEFLEX display

Target engine slows to low idle speed and stays there until the sub-throttle gets activated.
Sub-throttle is selectable when the sub-throttle lamp is blinking.
Fail Mode If the sub-throttle is selected, the lamp turns on.
Once the sub-throttle is selected, the sub-throttle keeps working even if the main throttle would
go back to normal.
Yes
1. If the sub-throttle is selected: Sub-throttle is active.
Limited Operation
2. If the sub-throttle is inactive: Engine speed is fixed at low idle or 1000 rpm
(Idle in Neutral and 1000 rpm in Forward / Reverse).
Yes
Fail Release
When ECU receives data of no error status from i2 module
1. If the sub-throttle is active: No.
Limited Operation Release 2. If the sub-throttle is inactive: Yes.
After the main throttle failure is cleared
CAN communication error is stated as DTC U0146 “CAN communication gateway” not “Main
Remarks
throttle position sensor.”

Limited Operation —
Fail Release Yes (i2 module communication error)
This DTC comes from the communication between the i2 module and the ECU only. The TELEFLEX
control head malfunction will be detected as “Main Throttle Position Sensor Error.” The marine gear
transmission control (shift) function is independent of the throttle function. This means that shifting
Remarks function should be controlled as i2 module function. (If i2 module is not active, then U0146 occurs and
the shift function may become inactive.) Normal communication continues after receiving data from i2
module. If the sub-throttle is selected before communication gets back to normal, the main throttle will
stay inactive.

Fail Mode: • The marine gear transmission control (shift)

function is independent of the engine control,
• The sub-throttle will be selectable with the which means the shifting function should be
sub-throttle lamp blinking. controlled by the control head.
• Once sub-throttle is selected (activated), the NOTICE: Activate the sub-throttle: Move the
sub-throttle keeps working even if the main sub-throttle to full counterclockwise and then back it
throttle goes back to normal status. up slightly. Reset the sub-throttle fault code: Key
Off. See Rocker Switch Panel on page 12-23.

6LY3 Service Manual 13-37

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 TROUBLESHOOTING Troubleshooting by DTC Fault Codes

Fault

DTC / FMI Probable Cause

1. Teleflex wire harness in the throttle control head unit
P0120/0
2. Teleflex throttle head malfunction

Troubleshooting Procedure 2. Check the TELEFLEX i2 Module (i832X)

1. Check the wire harness and the connector of software.
the throttle control head unit. 3. Replace the TELEFLEX throttle control head.

P0180/3, 4 (Fuel Temperature Sensor)

DTC P0180/3, 4 Fuel Temperature Sensor

Sensor Specification Chart Electrical Circuit Chart

Figure 13-13 Figure 13-14

Temperature Sensor Characteristics (1) ECU

A 28

100
B 35
Typical Resistance (K Ohms)

0006121

59
10

19
1

0006122

Figure 13-14

0.1 Part code: 119254-44910

-40°C -20°C 0°C 20°C 40°C 60°C 80°C 100°C 120°C
(-40°F) (-4°F) (32°F) (68°F) (104°F) (140°F) (176°F) (212°F) (248°F) 1 – Fuel Temperature Sensor
Temperature
0006120

Figure 13-13

13-38 6LY3 Service Manual

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DTC Fault Code

DTC / FMI 1. Condition, 2. Fault, 3. Time to Detect, 4. Display Check Point

1. Key switch ON
2. Input signal voltage is above 4.8V Wire harness
P0180/3
3. 0.5 seconds sensor
4. CHECK ENGINE on the TELEFLEX display
1. Key switch ON
2. Input signal voltage is below 0.2V Wire harness
P0180/4
3. 0.5 seconds sensor
4. CHECK ENGINE on the TELEFLEX display

Engine takes the following fuel temperature as a default:

50°C (122°F)
Fail Mode
*Above value can be monitored with a YDT.
(Diagnostic Test › Analog Input.)
Yes
Fail Release
When the input signal voltage goes to normal range (0.2 - 4.8V) for 0.5 seconds
Limited Operation No limited operation
Remarks —

Fault

DTC / FMI Probable Cause

1. Open circuit of the wire harness or short to high voltage over 5V
P0180/3 2. Sensor failure
3. ECU failure
1. Wire harness short to ground
P0180/4 2. Sensor failure
3. ECU failure

Troubleshooting Procedure
See Troubleshooting the Temperature Sensor on page 13-40.

6LY3 Service Manual 13-39

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 TROUBLESHOOTING Troubleshooting by DTC Fault Codes

Troubleshooting the Temperature Sensor

Temperature Sensor Diagnosis Procedure

DTC FMI Content PIN# of ECU PIN# of ECU

P0115 3/4 Coolant Temperature Sensor 37 35
P0180 3/4 Fuel Temperature Sensor 28 35
P0195 3/4 Oil Temperature Sensor 39 35

Sensor Characteristics Wiring Diagram of Temperature Sensor

Figure 13-15 Figure 13-16

Temperature Sensor Characteristics THF:28

(1) ECU
100 THW:37
(2) A HLO:39
[ECU_TH**]

[ECU_G_S]
Typical Resistance (K Ohms)

(3) B 35
0006142
10

59

19
M12 x 1.5
0006143

0.1 Figure 13-16

-40 -20 0 20 40 60 80 100 120
Temperature (C°) 0006141
Part code: 119254-44910
1 – Temperature Sensor
Figure 13-15
2 – Temperature Output
3 – Sensor Ground

13-40 6LY3 Service Manual

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Figure 13-17

1. [Sensor]
Check sensor performance NG
(resistance)

OK

2. [Wire harness] NG
Check ECU output voltage
of harness.
**Use breakout box
(Disconnect the connector of sensor) 3. [Wire harness]
OK Check wire harness open/short
NG

4. [Wire harness] NG
Check sensor conductivity

OK
OK

Replace
Replace ECU or Replace Replace Replace
ECU sensor ECU wire harness sensor
0006144

Figure 13-17

6LY3 Service Manual 13-41

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 TROUBLESHOOTING Troubleshooting by DTC Fault Codes

Case 1: When the DTC is ACTIVE

To identify the cause (wire harness, sensor failure or connector)
1. Check the sensor performance using the following:
Measure the resistance between both terminals of the temperature sensor (with the sensor connector
disconnected).
Check if the resistance is within normal range. (See Sensor Specification Chart on page 13-34.)
Faulty Replace sensor.
OK Check ECU / wire harness output voltage.

NOTICE: If a known good sensor is available, unplug the connector from the sensor that is indicating an
active DTC fault code and reconnect to the known good sensor. See if an alarm goes off or not.

Alarm goes off? Contents

Yes Sensor failure. Replace the sensor.
No Check the ECU / wire harness output voltage.

The temperature is logged by the YDT.

2. Checking the ECU / wire harness output voltage:
• Unplug the connector from the temperature sensor. Leave the ECU connector connected to the ECU.
• Turn the key to ON and supply power to the ECU.
• Measure the voltage. Check the voltage between the terminals of the wire harness connector.

Terminals Value
Wire Harness Connector
5V
A-B

Failure Check the engine wire harness.

OK Check the sensor voltage output.

3. Checking the wire harness open / short circuit.

• Disconnect the ECU connector from the ECU and unplug the sensor connector.
• Use an electric tester to check for an open / short circuit in the wire harness (continuity).
C: 5V sensor supply

Terminals Continuity Status

Good OK: Normal
[ECU_TH] - A
Defective Failure: Open circuit
Good OK: Normal
[ECU_G_S] - B, ECU Pin #35
Defective Failure: Open circuit
Defective OK: Normal
[ECU_TH] - other terminal / ground
Good Failure: Short circuit
Good OK: Normal
[ECU_G_S] - ground / 11 / 33 / 34, ECU Pin #35
Defective Failure: Short circuit

13-42 6LY3 Service Manual

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Terminals Continuity Status

Defective OK: Normal
[ECU_G_S] - other terminal, ECU Pin #35
Good Failure: Open circuit

1. Check the wire harness.

Failure
2. Replace the wire harness.
OK Check the sensor voltage output (see the following).

4. Sensor output voltage

Check for open / short circuit.
Make sure all connectors (Sensor and ECU) are connected.
Measure the voltage between the sensor signal and ground ([ECU_TH] - [ECU_G_S]).

Voltage Status Action

1. Replace the wire harness.
[ECU_TH] Wire harness [ECU_TH] short to ground / ground
Defective
≤ 0.2V 2. Replace the temperature sensor.
Sensor failure
0.2V <
Normal Replace the ECU if DTC is still active.
[ECU_TH]
condition (See Sensor Specification Chart on page 13-34.)
< 4.8V
1. Replace the wire harness.
[ECU_TH] Wire harness [ECU_TH] short to ground
Defective
≥ 4.8V 2. Replace the temperature sensor.
Sensor failure

Figure 13-18

Failure 1. Check the wire harness.

2. Replace the wire harness. ECU
OK Replace the ECU.

Case 2: When the DTC is not active (logged

status), the ECU stores the past DTC information (1)
and the YDT indicates a logged DTC. If a connector
comes loose, it may be the reason for a logged
DTC. (2)
Checking the wire harness:
Check the wire harness between the sensor and (3) 0006149
the ECU. See if the alarm turns on or not.
Figure 13-18
Recommendation: Before starting this, it may be
easier to clear DTC information by the YDT, 1 – Breakout box is a branch harness and
because the counter goes to 0 and can easily connector from each pin of ECU. The tester
identify when an alarm has occurred. probe can be inserted here, and the voltage
and the waveform between each ECU pin
can be measured.
DTC Contents
2 – Breakout Box and Harness
Yes Check the connector terminal. Replace the wire 3 – Engine Harness
harness.
No No action

6LY3 Service Manual 13-43

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 TROUBLESHOOTING Troubleshooting by DTC Fault Codes

P0183/0 (Fuel Temperature Too High)

DTC P0183/0 Fuel Temperature Too High

DTC Fault Code

DTC / FMI 1. Condition, 2. Fault, 3. Time to Detect, 4. Display Check Point

1. Key switch ON
2. Fuel temperature is above 90°C (194°F) FO system
P0183/0
3. 0.5 seconds FO sensor
4. CHECK ENGINE on the TELEFLEX display

Fail Mode Fuel temperature exceeds the acceptable range for the fuel system.
Limited Operation No limited operation
Yes
Fail Release
When the fuel temperature goes below 85°C (185°F)
Normal fuel temperature is about 40°C (104°F) at the inlet port of the injection pump and about 52°C
Remarks
(125.6°F) at the outlet port.

Fault

DTC / FMI Probable Cause

1. Fuel cock (no fuel)
2. Fuel filter
P0183/0
3. Fuel system
4. Fuel temperature sensor

Troubleshooting Procedure
1. Check the fuel cock.
2. Check the fuel filter.
3. Check the fuel system.
4. Check the fuel temperature sensor.

13-44 6LY3 Service Manual

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P0195/3, 4 (Oil Temperature Sensor)

DTC P0195/3, 4 Oil Temperature Sensor

Sensor Specification Chart Electrical Circuit Chart

Figure 13-19 Figure 13-20

Temperature Sensor Characteristics

(1) ECU
100
A 39

B 35
Typical Resistance (K Ohms)

0006124
10

59

19
1

0006125

Figure 13-20

0.1 Part code: 119254-44910

-40°C -20°C 0°C 20°C 40°C 60°C 80°C 100°C 120°C
1 – Oil Temperature Sensor
(-40°F) (-4°F) (32°F) (68°F) (104°F) (140°F) (176°F) (212°F) (248°F)

Temperature
0006123

Figure 13-19

6LY3 Service Manual 13-45

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DTC Fault Code

DTC / FMI 1. Condition, 2. Fault, 3. Time to Detect, 4. Display Check Point

1. Key switch ON
2. Input signal voltage is above 4.8V
P0195/3 Wire harness sensor
3. 0.5 seconds
4. CHECK ENGINE on the TELEFLEX display
1. Key switch ON
2. Input signal voltage is below 0.2V
P0195/4 Wire harness sensor
3. 0.5 seconds
4. CHECK ENGINE on the TELEFLEX display

Engine takes the following oil temperature as a default:

Fail Mode
90°C (194°F)
Limited Operation No limited operation
Yes
Fail Release
When the input signal voltage goes to normal range (0.2 - 4.8V)
Remarks —

Fault

DTC / FMI Probable Cause

1. Open circuit on the wire harness or short to high voltage over 5V
P0195/3 2. Sensor failure
3. ECU failure
1. Wire harness short to ground
P0195/4 2. Sensor failure
3. ECU failure

Troubleshooting Procedure
See Troubleshooting the Temperature Sensor on page 13-40.

13-46 6LY3 Service Manual

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P0198/0 (Oil Temperature Too High)

DTC P0198/0 Temperature Too High

DTC Fault Code

DTC / FMI 1. Condition, 2. Fault, 3. Time to Detect, 4. Display Check Point

1. Key switch ON
2. Oil temperature is above 120°C (248°F) Oil system
P0198/0 Cooling seawater system
3. 0.5 seconds sensor
4. CHECK ENGINE on the TELEFLEX display

Fail Mode
Limited Operation No limited operation
Yes
Fail Release
When the oil temperature goes below 115°C (239°F) for 0.5 seconds
Remarks Normal oil temperature at rated speed is about 90°C (194°F).

Fault

DTC / FMI Probable Cause

1. Seawater pump impeller
2. Seacock
3. Seawater system
P0198/0
4. Oil cooler
5. Oil volume
6. Oil temperature sensor

Diagnosis Procedure
1. Check the seawater pump impeller.
2. Check the seacock.
3. Check the seawater system.
4. Check the oil cooler.
5. Check the oil level.
6. Check the oil temperature sensor.

6LY3 Service Manual 13-47

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 TROUBLESHOOTING Troubleshooting by DTC Fault Codes

P0216/7 (Injection Timer Device)

DTC P0216/7 Injection Timer Device

Figure 13-21

(1)

(2)
(9)

(3)
(4)

(5)
(8)

(7) (6)
0006126

Figure 13-21

1 – Electromagnetic Valve 6 – Cylinder

2 – Helical Spline 7 – Pump Drive Gear
3 – Piston 8 – Pump Camshaft
4 – Straight Spline 9 – Cam Drive Coupling
5 – Cam Tightening Nut

13-48 6LY3 Service Manual

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DTC Fault Code

DTC / FMI 1. Condition, 2. Fault, 3. Time to Detect, 4. Display Check Point

1. Engine running Timer device
2. Does not meet target value of the injection timer phase speed sensor
P0216/7 Oil system
3. 10 seconds
Timer solenoid (Adv / Ret)
4. PWR REDUCTION, CHECK ENGINE on the TELEFLEX display

Engine cannot control the injection timer.

Fail Mode
Injection timing will be fully retarded or may stick at fixed position.
Limited Operation Maximum engine speed is limited to 1800 rpm.
Fail Release No
ECU would detect DTC of P1220 or P1225 if the injection timing control solenoid (timer solenoid) has a
Remarks problem with the wire harness. White smoke or black smoke may increase more than usual because of
failure mode of the injection timing control.

Fault

DTC / FMI Probable Cause

1. Timer or hydraulic device
2. Timer mechanical problem
3. Oil volume (Leak flow > 0.2 kgf / mm2) (285 psi)
P0216/7
4. Check the oil pressure.
5. Check the timer electromagnetic valve.
6. Replace the timer electromagnetic valve.

Troubleshooting Procedure (b) If the injection timing is not changing, and

1. Check the crank and cam speed with a YDT remains in same position (except at the
and see if they are stable. retarded and advanced positions), replace
the fuel injection pump (FIP) and the timer
If they are not stable, check the speed sensor.
device. May have some mechanical
2. Check the performance of the timer device with problems within the injection timing device.
a YDT. Condition and procedure of YDT
operation:
• Engine condition: Running at low idle and gear
not engaged.
• YDT: Diagnostic Test ➝ Active Control
Check the MANUAL check box of the
Direct timer Position Control.
Click the DESIRED cell and change
valve.
(a) If the device remains in the retarded or
advanced position, check the wire harness
of the hydraulic timer solenoids and also
check the solenoid valve. (Replace the wire
harness or timer solenoids if something is
wrong.)

6LY3 Service Manual 13-49

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 TROUBLESHOOTING Troubleshooting by DTC Fault Codes

P0219/0 (Engine Over Rev.)

DTC P0219/0 Engine Over Revolutions

DTC Fault Code

DTC / FMI 1. Condition, 2. Fault, 3. Time to Detect, 4. Display Check Point

1. Engine running Injector
2. Engine speed of the cam or crank exceeds 3900 rpm. FIP
P0219/0 Crank / cam speed sensor
3. —
Pulsar (gear)
4. OVER REV on the TELEFLEX display Wire harness

Fail Mode Rack needs to be set at stop position.

Break rack actuator relay
Limited Operation Engine stop
Fail Release No
Remarks Require key off to reset fail mode

Fault

DTC / FMI Probable Cause

1. Speed sensor (crank or cam)
• wire harness
• contaminants on the sensor core
2. Rack position sensor
P0219/0
3. Rack actuator performance
4. Fuel injection pump
5. Injector
6. Fuel system

Troubleshooting Procedure 3. Check the fuel injection pump.

1. Check if there is / are any other DTC detected 4. Check the injection nozzle and fuel line.
such as RACK POSITION SENSOR or RACK 5. Check the fuel injection pump lag (rack actuator
ACTUATOR related DTC. performance).
If there is / are, repair the DTC first. If lag results in fault, replace the fuel injection
2. Check if the DTC is detected by actual pump (including position sensor amplifier).
over-revolution faults.
If it was not over the revolution check the speed
sensor. (Look for contaminants on the sensor
core, connector, wire harness, etc.)

13-50 6LY3 Service Manual

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P0220/3, 4 (Sub-Throttle Sensor)

DTC P0220/3, 4 Sub-Throttle Sensor

Electrical Circuit Chart

See Sub-Throttle Indicator, Emergency Throttle Position Sensor on page 13-84.

DTC Fault Code

DTC / FMI 1. Condition, 2. Fault, 3. Time to Detect, 4. Display Check Point

1. Key switch ON
2. Input signal voltage to the ECU from the sub-throttle sensor is above 4.8V
P0220/3 Wire harness sensor
3. 0.5 seconds
4. SEC THROTTLE on the TELEFLEX display
1. Key switch ON
2. Input signal voltage to the ECU from the sub-throttle sensor is below 0.2V
P0220/4 Wire harness sensor
3. 0.5 seconds
4. SEC THROTTLE on the TELEFLEX display

Remarks
*If the sub-throttle position sensor is replaced with YANMAR standard parts, check the specification of the
throttle potentiometer.

Fail mode will be different according to the position of the main throttle.
1. If the sub-throttle is active: Target engine speed slows to low idle speed. Target speed is set to low
Fail Mode idle in neutral and 1000 rpm in non-neutral condition.
2. If the sub-throttle is inactive (main throttle is active):
No fail mode happens to throttle control.
Limited Operation —
1. If the sub-throttle is active: No.
Fail Release
2. If the sub-throttle is inactive: Yes.
Remarks If sub-throttle is active, the key must be switched OFF and ON again to reset the fail mode.

Fault

DTC / FMI Probable Cause

1. Sub-throttle position sensor ground wire harness open.
P0220/3
2. Sub-throttle position sensor signal wire harness short to battery or 5V sensor.
1. Sub-throttle position SIGNAL wire harness open or short to ground.
P0220/4
2. Sub-throttle position 5V SENSOR wire harness open or short to ground.

Troubleshooting Procedure
1. Check the sub-throttle voltage by YDT.
2. Check the wire harness and connectors. If wire harness is at fault, replace wire harness.
3. Check the sub-throttle position sensor.

6LY3 Service Manual 13-51

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P0234/0 (Over Boost)

DTC P0234/0 Over Boost

DTC Fault Code

DTC / FMI 1. Condition, 2. Fault, 3. Time to Detect, 4. Display Check Point

1. Key switch ON
2. Boost pressure is above 250 kPa (36 psi) Turbocharger
P0234/0
3. 0.5 seconds boost pressure sensor
4. PWR REDUCTION, the TURBO BOOST on the TELEFLEX display

Fail Mode Turbocharger over boost condition.

Limited Operation Maximum engine speed is limited to 1800 rpm.
Yes
Fail Release
When boost pressure is below 200 kPa (29 psi)
Yes
Limited Operation Release
After failure is cleared and also when throttle position is at low idle position
Remarks —

Fault

DTC / FMI Probable Cause

1. Turbocharger / wastegate
P0234/0
2. Boost pressure sensor

Troubleshooting Procedure
1. Check the wastegate.
2. Replace the boost pressure sensor.

13-52 6LY3 Service Manual

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P0235/3, 4 (Boost Pressure Sensor)

DTC P0235/3, 4 Turbocharger Boost Pressure Sensor

Sensor Specification Chart Electrical Circuit Chart

Figure 13-22 Figure 13-23

(1) (5)
1 (2) 24
5V Pressure Sensor Characteristics
0 50 100 150
4
2 (3) 40

3.5
3 (4) 35
3
Sensor Output Voltage

0006128
2.5
Figure 13-23
2
1 – Boost Pressure Sensor
2 – Supply Voltage (5V)
1.5
3 – Signal
4 – Ground
1
5 – ECU
Figure 13-24

0.5

321
0
0 200 400 600 800 1000 1200
>PPS< 1
Pressure (kPa) ± 5% 0006127

Figure 13-22

(1) (2) (3)

0006129

Figure 13-24
Part code: 119578-91300
1 – Ground
2 – Signal Output
3 – 5V Sensor

6LY3 Service Manual 13-53

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DTC Fault Code

DTC / FMI 1. Condition, 2. Fault, 3. Time to Detect, 4. Display Check Point

1. Key switch ON
2. Input signal voltage is above 3.6V Wire harness
P0235/3
3. 0.5 seconds Boost pressure sensor
4. PWR REDUCTION, CHECK ENGINE on the TELEFLEX display
1. Key switch ON
2. Input signal voltage is below 0.2V Wire harness
P0235/4
3. 0.5 seconds Boost pressure sensor
4. PWR REDUCTION, CHECK ENGINE on the TELEFLEX display

Engine takes the following boost pressure as a default:

Fail Mode
0 kPa (0 psi)
Limited Operation Maximum engine speed is limited to 1800 rpm.
Yes
Fail Release
When the input signal voltage goes to normal range (0.5 - 3.6V)
Yes
Limited Operation Release
After failure is cleared and also when throttle position is at low idle position
Sensor supply voltage must be kept below 6V. Once the sensor supply voltage exceeds 6V,
Remarks damage occurs. Replace the pressure sensor. To check if voltage was exceeded, check the
status of the DTC 1230/0 (short to 12V).

Fault

DTC / FMI Probable Cause

1. SIGNAL wire harness open or short to ground
P0235/3 2. 5V sensor wire harness open
3. Sensor failure
1. SIGNAL wire harness open or short to ground
P0235/4 2. 5V sensor wire harness open
3. Sensor failure

Troubleshooting Procedure
See Troubleshooting the Pressure Sensor on page 13-77.

13-54 6LY3 Service Manual

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P0335/0 (Cam / Crank Speed Incompatibility)

DTC P0335/0 Cam / Crank Speed Incompatibility

DTC Fault Code

DTC / FMI 1. Condition, 2. Fault, 3. Time to Detect, 4. Display Check Point

1. Engine running
2. Difference between the cam and crank speed is more than 50 rpm Wire harness
P0335/0 Crank speed sensor
3. 0.5 seconds Cam speed sensor
4. PWR REDUCTION, CHECK ENGINE on the TELEFLEX display

Engine will keep controlling the engine speed with the cam signal.
(ECU uses crank speed as normal condition.)
Fail Mode
Engine cannot control the injection timer and have the failure code of the injection timer control
with the injection timing fully retarded.
Limited Operation Maximum engine speed is limited to 1800 rpm.
Yes
Fail Release
When the difference between cam and crank speed is within 15 rpm
Yes
Limited Operation Release
After failure is cleared and also when the throttle position is at low idle position
White smoke or black smoke may increase more than usual because of the failure mode of the
Remarks
injection timing control.

Fault

DTC / FMI Probable Cause

1. Crank and cam speed sensor
(contaminants, wire harness, poor connection of connector, attachment)
P0335/0
2. Bad flywheel sensor
3. Electrical noise

Troubleshooting Procedure
1. Check the crank and cam speed if they are stable with a YDT.
If it is not stable, check the wire harness sensor, attachment and contaminants of the sensor core.
2. Check the status of flywheel sensor detection hole.

6LY3 Service Manual 13-55

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 TROUBLESHOOTING Troubleshooting by DTC Fault Codes

P0335/4 (Crank Speed Sensor)

DTC P0335/4 Crank Speed Sensor

Electrical Circuit Chart Figure 13-26

Figure 13-25

(3) (4)
(1) (2) (1) (2)
B 16
CRK+ CRK+

(5)
(6)
A 6
CRK- CRK-
(7)
(9) (8)
0006130
0006331

Figure 13-25
Figure 13-26
1 – Crank Speed Sensor
2 – ECU Part Code: 158557-61720
1 – Core
2 – Magnet
3 – O-Ring
4 – Yoke
5 – Coil Bobbin Comp.
6 – Sensor Body
7 – Bushing
8 – Epoxy Tape
9 – Coil

13-56 6LY3 Service Manual

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DTC Fault Code

DTC / FMI 1. Condition, 2. Fault, 3. Time to Detect, 4. Display Check Point

1. Engine running
2. Crank speed detects 0 rpm when the starter is activated (key position at START) or Crank speed sensor
P0335/4 crank speed suddenly goes to 0 rpm while the engine is running. Starter
3. 1 second Wire harness
4. PWR REDUCTION, CHECK ENGINE on the TELEFLEX display

Engine will keep controlling the engine speed with the cam signal.
(ECU uses crank speed as normal condition.)
Fail Mode
Engine cannot control the injection timer and have the failure code of the injection timer control
with the injection timing fully retarded.
Limited Operation Maximum engine speed is limited to 1800 rpm.
Yes
Fail Release
When the difference between the cam and crank speed is within 15 rpm
Yes
Limited Operation Release After the fault has been cleared and also when the throttle position is at low idle position. If a
higher idle position is selected with the control head, limited operation status is not released.
White smoke or black smoke may increase more than usual because of the failure code of the
Remarks injection timing control. This error is also detected when the key position is in START and the
gear is in neutral but the starter is not running (when no battery cable is connected to starter).

Fault

DTC / FMI Probable Cause

1. Crank speed sensor wire harness open or shorted
P0335/4 2. Poor connection to the crank speed sensor connector
3. Bad flywheel condition

Troubleshooting Procedure
1. Check if the starter is turning.
2. Check the wire harness.
3. Check the connectors and terminals.
4. Check the state of the speed sensor attachment
(dust, e.g.).
5. Check the sensor output signal.

6LY3 Service Manual 13-57

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 TROUBLESHOOTING Troubleshooting by DTC Fault Codes

P0340/4 (Cam Speed Sensor)

DTC P0340/4 Cam Speed Sensor

Electrical Circuit Chart Figure 13-28

Figure 13-27 (3) (4)

FOP Cam (1) (2)
Speed Sensor ECU
B 17
CAM+ CAM+
(5)
(6)

A 7
CAM- CAM- (7)
(9) (8)
0006331
0006326

Figure 13-28
Figure 13-27
Part code: 158557-61720
1 – Core
2 – Magnet
3 – O-Ring
4 – Yoke
5 – Coil Bobbin Comp.
6 – Sensor Body
7 – Insert Bush
8 – Epoxy Tape
9 – Coil

13-58 6LY3 Service Manual

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DTC Fault Code

DTC / FMI 1. Condition, 2. Fault, 3. Time to Detect, 4. Display Check Point

1. Engine running
2. Crank speed detects 0 rpm when the starter is activated (key position at START) or Cam speed sensor
P0340/4 crank speed suddenly goes to 0 rpm while the engine is running. Starter
3. 1 second Wire harness
4. PWR REDUCTION, CHECK ENGINE on the TELEFLEX display

Engine will keep controlling engine speed with the crank signal.
Fail Mode Engine cannot control the injection timer during and injection failure code. The injection timing
will default to fully retarded.
Limited Operation Maximum engine speed is limited to 1800 rpm.
Yes
Fail Release
When the difference between cam and crank speed is within 15 rpm
Yes
Limited Operation Release
After the fault has been cleared and also when throttle position is at low idle position
White smoke or black smoke may increase more than usual because of the failure code of the
Remarks injection timing control. This error is also detected when the key position is in START and the
gear is in neutral but the starter is not running (when no battery cable is connected to starter).

Fault

DTC / FMI Probable Cause

1. Cam speed sensor wire harness open or shorted
P0340/4
2. Poor connection to the cam speed sensor connector

Troubleshooting Procedure
1. Check if the starter is running.
2. Check the wire harness.
3. Check the connectors and terminals.
4. Check the state of the sensor attachment (dust, e.g.).
5. Check the sensor output signal.

6LY3 Service Manual 13-59

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 TROUBLESHOOTING Troubleshooting by DTC Fault Codes

P0520/3, 4 (Oil Pressure Sensor)

DTC P0520/3, 4 Oil Pressure Sensor

Sensor Specification Chart Electrical Circuit Chart

Figure 13-29 Figure 13-30

(1) (5)
5V Pressure Sensor Characteristics 1 (2) 24
0 50 100 150
4
2 (3) 27
3.5

3 (4) 35
3
Sensor Output Voltage

2.5 0006133

2
Figure 13-30
1 – Oil Pressure Sensor
1.5 2 – Supply Voltage (5V)
3 – Signal
1 4 – Ground
5 – ECU
0.5 Figure 13-31

0 321
0 200 400 600 800 1000 1200
Pressure (kPa) ± 5%
0006132 >PPS< 1

Figure 13-29

(3) (2) (1)

0006134

Figure 13-31
Part code: 119578-91300
1 – 5V Sensor
2 – Signal Output
3 – Ground

13-60 6LY3 Service Manual

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DTC Fault Code

DTC / FMI 1. Condition, 2. Fault, 3. Time to Detect, 4. Display Check Point

1. Key switch ON
2. Input signal voltage is above 3.6V Wire harness
P0520/3
3. 0.5 seconds Sensor
4. CHECK ENGINE on the TELEFLEX display
1. Key switch ON
2. Input signal voltage is below 0.2V Wire harness
P0520/4
3. 0.5 seconds Sensor
4. CHECK ENGINE on the TELEFLEX display

Fail Mode —
Limited Operation No limited operation
Yes
Fail Release
When the input signal voltage goes to normal range (0.2 - 3.6V)
Oil pressure is monitored for engine diagnosis use only.
Sensor supply voltage must be kept below 6V. Once the sensor supply voltage exceeds 6V, sensor
Remarks
damage occurs. Replace the pressure sensor. To check if the voltage has been exceeded, check the
status of DTC 1230/0.

Fault

DTC / FMI Probable Cause

1. SIGNAL wire harness short to high voltage over 5V
P0520/3 2. Sensor ground wire harness for the oil pressure sensor open
3. Sensor malfunction
1. SIGNAL wire harness open or short to ground
P0520/4 2. 5V sensor wire harness open
3. Sensor malfunction

Troubleshooting Procedure
See Troubleshooting the Pressure Sensor on page 13-77.

6LY3 Service Manual 13-61

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 TROUBLESHOOTING Troubleshooting by DTC Fault Codes

P0522/1 (Oil Pressure Too Low)

DTC P0522/1 Oil Pressure Too Low

Figure 13-32

200 kPa
(29 psi)
Alarm OFF

Alarm ON
20 kPa
(2.9 psi)

1000 3000
rpm rpm
Alarm Diagram of Oil Pressure
0006297

Figure 13-32

DTC Fault Code

DTC / FMI 1. Condition, 2. Judgement, 3. Time to Detect, 4. Display Check Point

1. Key switch ON
2. Oil pressure is below the standard compared to the engine speed
P0522/1 20 kPa @ 1000 rpm (29 psi @ 1000 rpm), 200 kPa @ 3000 rpm (2.9 psi@ 3000 rpm) Oil system
3. 0.5 seconds
4. OIL PRESSURE on the TELEFLEX display

Fail Mode —
Limited Operation No limited operation
Yes
Fail Release
When the oil pressure goes over the normal value
Remarks May damage the engine if kept running with low oil pressure

Fault

DTC / FMI Probable Cause

Oil level
Oil pump
P0522/1 Oil system
Oil filter
Oil pressure sensor

13-62 6LY3 Service Manual

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Troubleshooting Procedure 4. Check the oil system.

1. Check the oil level. 5. Check the oil filter.
2. Check the oil pressure with a calibrated gauge. 6. Check the oil pressure sensor.
3. Check the oil pump.

P0562/0, 1 (ECU Power Supply Voltage)

DTC P0562/0, 1 ECU Power Supply Voltage

Electrical Circuit Diagram

See Main Relay, 1st Station Relay, 2nd Station Relay on page 13-86.

DTC Fault Code

DTC / FMI 1. Condition, 2. Fault, 3. Time to Detect, 4. Display Check Point

1. Key switch ON
2. ECU supply voltage is above 16V Battery
P0562/0 Alternator
3. 2.5 seconds Wire harness
4. CHECK ENGINE on the TELEFLEX display
1. Key switch ON
2. ECU supply voltage is above 9V Battery
P0562/1 Alternator
3. 2.5 seconds Wire harness
4. LOW VOLTAGE on the TELEFLEX display

Fail Mode —
Limited Operation No limited operation
Yes
Fail Release
When the input signal voltage goes to normal range (9.5 - 15.5V)
Remarks If the battery is connected backward, the ECU will not be damaged, but the alternator will be damaged.

Fault

DTC / FMI Probable Cause

1. Wrong battery installed (24V, e.g.)
2. Wrong battery wiring connection
P0562/0
3. Wire harness open or short (ECU - Batt, Alt - Batt)
4. Alternator malfunction
1. Poor battery power
2. Battery wiring connection
P0562/1
3. Wire harness open or short (ECU - Batt, Alt - Batt)
4. Alternator malfunction

Troubleshooting Procedure
1. Check the battery voltage.
2. Check the alternator output voltage.
3. Check the battery wiring.

6LY3 Service Manual 13-63

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 TROUBLESHOOTING Troubleshooting by DTC Fault Codes

P0605/12 (EEPROM Error)

DTC P0605/12 EEPROM Error

DTC Fault Code

DTC / FMI 1. Condition, 2. Fault, 3. Time to Detect, 4. Display Check Point

1. Key switch ON
2. ECU detects EEPROM device error.
P0605/12 ECU
3. —
4. CHECK ENGINE on the TELEFLEX display

Fail Mode —
Limited Operation No limited operation
Fail Release No
Other DTC and some engine information cannot be indicated while this DTC is occurring.
Remarks Example: Engine Run Hours
Require key off to reset the fail mode

Fault

DTC / FMI Probable Cause

ECU device malfunction
P0605/12
Unusual electrical shock

Troubleshooting Procedure
Replace the ECU.

13-64 6LY3 Service Manual

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P1202/0, 1 (Rack Position Sensor)

DTC P1202/0, 1 Rack Position Sensor

Electrical Circuit Chart

Figure 13-33

(1)

(7) (8)
(2)
(6)

(5)

(4)
(3) 0006136

Figure 13-33

1 – Control Rack 5 – Rack Position Sensor

2 – Timer 6 – Governor Solenoid
3 – Fuel Injection Pump 7 – Fuel Decrease
4 – Governor 8 – Fuel Increase

6LY3 Service Manual 13-65

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 TROUBLESHOOTING Troubleshooting by DTC Fault Codes

DTC Fault Code

DTC / FMI 1. Condition, 2. Fault, 3. Time to Detect, 4. Display Check Point

1. Key switch ON Injection pump
2. Rack position sensor logic failure (rack current - rack position response) Rack position sensor
P1202/0, 1
3. 0.32 / 0.16 seconds Rack actuator
Wire harness
4. PWR REDUCTION, CHECK ENGINE on the TELEFLEX display

Engine keeps running with rack control failure code.

Injection timing is controlled in rack control failure mode.
Fail Mode
*Target rack position and actual rack position will be indicated as 0 by the YDT.
*Engine load is indicated 0% on the TELEFLEX display and on the YDT.
Limited Operation Maximum engine speed is limited to 1800 rpm.
Fail Release No
White smoke or black smoke may increase more than usual because of a failure code of the injection
Remarks timing control. This DTC also can be detected by rack mechanical P1211/7 or rack actuator P1210/4
malfunction, so check the rack actuator performance as well.

Fault

DTC / FMI Probable Cause

1. Rack position sensor wire harness open or short
P1202/0, 1
2. Mechanical rack malfunction

Troubleshooting Procedure
1. Check the wire harness and connector at the rack position sensor. Look for an open or a short circuit.
2. Check the rack actuator wire harness and the rack actuator relay.

13-66 6LY3 Service Manual

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P1210/4 (Rack Actuator)

DTC P1210/4 Rack Actuator

Electrical Circuit Chart

See P1210/4 (Rack Actuator) on page 13-67 and Rack Position Sensor on page 13-83.

DTC Fault Code

DTC / FMI 1. Condition, 2. Fault, 3. Time to Detect, 4. Display Check Point

1. Key switch ON
2. Abnormally high engine speed (rpm)
Wire harness
P1210/4 3. Uncontrollable rack actuator
Rack actuator
4. 0.1 seconds
5. CHECK ENGINE on the TELEFLEX display

Engine stops because the rack position is set to the stop position.
Fail Mode
Turn off the rack actuator relay.
Limited Operation Engine stop
Fail Release No
Require key off to reset the fail mode
Remarks Turn the key OFF and ON again to reset the failure code.
FFD (Freeze Frame Data) is recorded and can be logged by the YDT.

Fault

DTC / FMI Probable Cause

P1210/4 Rack actuator related wire harness open or short.

Troubleshooting Procedure
1. Check the wire harness and the connector of the rack actuator and actuator relay.
2. Check the rack actuator lag performance. If at fault, replace fuel injection pump.

6LY3 Service Manual 13-67

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P1211/7 (Rack Actuator Mechanical Malfunction)

DTC P1211/7 Rack Actuator Mechanical Malfunction

Electrical Circuit Chart

See P1210/4 (Rack Actuator) on page 13-67 and Rack Position Sensor on page 13-83.

DTC Fault Code

DTC / FMI 1. Condition, 2. Fault, 3. Time to Detect, 4. Display Check Point

1. Key switch ON
2. Abnormal acceleration of engine speed is caused by a rack actuator malfunction Rack actuator
P1211/7 Fuel injection pump
3. 1 second Wire harness
4. CHECK ENGINE on the TELEFLEX display

Engine stops because the rack position is set to the stop position.
Fail Mode
Turn off the rack actuator relay.
Limited Operation Engine stop
Fail Release No
Require key off to reset the fail mode
Remarks Turn the key OFF and ON again to reset the failure code.
FFD (Freeze Frame Data) is recorded and can be logged by the YDT.

Fault

DTC / FMI Probable Cause

1. Wire harness
P1211/7
2. Rack actuator, fuel injection pump

Troubleshooting Procedure
1. Check the wire harness and connector at rack actuator and actuator relay.
2. Check the rack actuator lag performance. If at fault, replace fuel injection pump.

13-68 6LY3 Service Manual

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P1220/7, P1225/7 (Advance / Retard Timer Solenoid)

P1220/7 Advance Timer Solenoid

DTC
P1225/7 Retard Timer Solenoid
Figure 13-34

Figure 13-35

(1)
(1)

0006311
0006137

Figure 13-34 Figure 13-35

1 – Timer Solenoid 1 – Electromagnetic Valve

6LY3 Service Manual 13-69

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Electrical Circuit Chart

Figure 13-36

Battery

Fuse
20A

ECU
Main
Advance Timer Solenoid
Relay
B

ECU

A 3

Retard Timer Solenoid

A 2

0006138

Figure 13-36

13-70 6LY3 Service Manual

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DTC Fault Code

DTC / FMI 1. Condition, 2. Fault, 3. Time to Detect, 4. Display Check Point
1. Key switch ON
2. ECU diagnosis shows an open or short condition of the advanced / retarded
P1220/7 timer output circuit. Wire harness
P1225/7 Timer solenoid
3. —
4. PWR REDUCTION, CHECK ENGINE on the TELEFLEX display

Engine cannot control the injection timer during an injection timer control failure code. The injection timing
Fail Mode
will default to fully retarded.
Limited Operation Maximum engine speed is limited to 1800 rpm.
Fail Release No
Require key off to reset fail mode
White smoke or black smoke may increase more than usual because of a failure code of the injection
Remarks
timing control. This DTC is for open or short status of wire harness and timer solenoid. Timer device
malfunctions are logged by other DTC.

Fault
DTC / FMI Probable Cause
P1220/7 1. Timer actuator connector is disconnected
P1225/7 2. Timer actuator related wire harness open or short

Troubleshooting Procedure
Check the injection timer solenoid and solenoid wire harness.

P1230/0, 1 (5V Sensor Voltage)

DTC P1230/0, 1 5V Sensor Voltage

ECU Connector Pin Configuration

Figure 13-37

1 2 3 4 5 6 7 8 9 10

1 RA TARD TAAD AHR1 AHR2 CRK- CAM- ST STHS IGN2

10
11 12 13 14 15 16 17 18 19 20

11 G-P MNR STSW RAR B1 CRK+ CAM+ NTS IGN1 EMS 20

21 22 23 24 25 26 27 28 29 30

21 STR STHL CAMP SNS5 B2 CANL PLO THF STH RPS

30
31 32 33 34 35 36 37 38 39 40

31 OUT1 OUT2 G_P1 G_P2 G_S CANH THW AN1 THLO PBST
40

0006139

Figure 13-37

No. 24: +5V

No. 35: Sensor Ground

6LY3 Service Manual 13-71

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DTC Fault Code

DTC / FMI 1. Condition, 2. Fault, 3. Time to Detect, 4. Display Check Point

1. Key switch ON
2. 5V sensor voltage is above 5.5V Wire harness
P1230/0
3. 0.5 seconds (ECU)
4. PWR REDUCTION, CHECK ENGINE on the TELEFLEX display
1. Key switch ON
2. 5V sensor voltage is below 4.5V Wire harness
P1230/1 Sensor
3. 0.5 seconds (ECU)
4. PWR REDUCTION, CHECK ENGINE on the TELEFLEX display

Fail Mode ECU cannot get boost pressure value and defaults to limited operation condition.
Limited Operation Maximum engine speed is limited to 1800 rpm.
Yes
Fail Release
When the sensor voltage goes to normal range (4.5 - 5.5V)
5V sensor affects all pressure sensors and sub-throttles.
P1230/0 or 1 cannot detect an open circuit, in 5V sensor wire harness. P1230/0, 1 can only detect a short
Remarks to ground. An open circuit will be shown as low voltage at sensor as a different failure code.
Sensor supply voltage must be kept below 6V. If sensor voltage exceeds 6V, sensor damage occurs.
Replace the pressure sensor. To check if the voltage exceeds 6V, check status of the DTC 1230/0.

Fault

DTC / FMI Probable Cause

P1230/0 5V sensor wire harness short to battery voltage
P1230/1 5V sensor wire harness short to ground

Troubleshooting Procedure
1. Check the 5V sensor wire harness (short).
2. Check the sub-throttle sensor wire harness.
3. Check the pressure sensor (boost, LO), wire harness and pressure sensor for a malfunction.

13-72 6LY3 Service Manual

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P1240/0 (ECU Power Supply Voltage Open)

DTC P1240/0 ECU Power Supply Voltage Open

ECU Connector Pin Configuration

Figure 13-38

1 2 3 4 5 6 7 8 9 10

1 RA TARD TAAD AHR1 AHR2 CRK- CAM- ST STHS IGN2

10
11 12 13 14 15 16 17 18 19 20

11 G-P MNR STSW RAR B1 CRK+ CAM+ NTS IGN1 EMS 20

21 22 23 24 25 26 27 28 29 30

21 STR STHL CAMP SNS5 B2 CANL PLO THF STH RPS

30
31 32 33 34 35 36 37 38 39 40

31 OUT1 OUT2 G_P1 G_P2 G_S CANH THW AN1 THLO PBST
40

0006139

Figure 13-38

No. 15 and 25: Power +12V (These are connected in parallel in ECU.)
No. 33 and 34: Ground (These are connected in parallel in ECU.)
DTC Fault Code

DTC / FMI 1. Condition, 2. Fault, 3. Time to Detect, 4. Display Check Point

1. Key switch ON
2. ECU diagnostic logic for ECU supply voltage open
P1240/0 Wire harness (battery - ECU)
3. Every second time the ignition is turned on
4. CHECK ENGINE on the TELEFLEX display

Fail Mode —
Limited Operation No limited operation
Fail Release No
Remarks —

Fault

DTC / FMI Probable Cause

P1240/0 ECU power supply voltage open

Troubleshooting Procedure
Check the ECU power supply wire harness.

6LY3 Service Manual 13-73

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 TROUBLESHOOTING Troubleshooting by DTC Fault Codes

P1603/0 (ECU Temperature Too High)

DTC P1603/0 ECU Temperature Too High

DTC Fault Code

DTC / FMI 1. Condition, 2. Fault, 3. Time to Detect, 4. Display Check Point

1. Key switch ON
2. ECU temperature is higher than 85°C (185°F) Cooling freshwater / seawater system
P1603/0 Environment around the ECU (engine room
3. 0.5 seconds temperature)
4. CHECK ENGINE on the TELEFLEX display

Fail Mode —
Limited Operation No limited operation
Yes
Fail Release
After the fault has been cleared and also when the ECU temperature drops below 80°C (176°F)
Remarks Around 50°C (122°F) is the usual temperature at hot condition.

Fault

DTC / FMI Probable Cause

P1603/0 Poor ventilation in the engine room

Troubleshooting Procedure / Recommendations

If the DTC gets active often, please keep the engine room temperature below 60°C (140°F) at all times.
Example: Improve the ventilation and the temperature of the engine room.

13-74 6LY3 Service Manual

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U0146/12 (i2 Model (i83XX) Communication Error)

i2 module (i83XX) communication error

DTC U0146/12
i2 module communication error

Electrical Circuit Chart

Figure 13-39

Battery

Fuse
20A

ECU
Main
Relay
AUX Power /
Service Tool ECU

3 36
CANH CANH

6 26
CANL CANL

2
BAT+

8
BAT-

0006140

Figure 13-39

6LY3 Service Manual 13-75

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DTC Fault Code

DTC / FMI 1. Condition, 2. Fault, 3. Time to Detect, 4. Display Check Point

1. Key switch ON Wire harness (CAN
2. No throttle position data transmitted from i2 module (i83XX) communication cable)
U0146/12
3. 1 second i2 module
Wire harness
4. ENG COM ERROR on the TELEFLEX display

ECU receives the throttle position data from the i2 module (i832X) and then goes to the throttle
failure code if it loses i2 module communication. Target engine speed slows to low idle speed
and stays there until the sub-throttle is activated. Sub-throttle will be selectable with the
Fail Mode
sub-throttle lamp blinking. If the sub-throttle is selected, the lamp turns on. Once the sub-throttle
is selected, the sub-throttle keeps working even if the i2 module communication would go back
to normal.
Limited Operation Main throttle fail mode
Fail Release Yes (i2 module communication error)
Main throttle fail release
1. If the sub-throttle is active: No.
Limited Operation Release
2. If the sub-throttle is inactive: Yes.
After the U0146 failure is cleared
This DTC comes from communication between i2 module and ECU only. A TELEFLEX control
head malfunction will be detected as “Main Throttle Position Sensor Error.”
Marine gear transmission control (shift) function is independent of the throttle function. This
Remarks means that the shifting function should be controlled as an i2 module function. (If i2 module is
OFF, then a U0146 failure code occurs and the shift function may go inactive.)
If the sub-throttle is selected before communication goes back to normal, the main throttle will
stay inactive.

Fault

DTC / FMI Probable Cause

1. Wire harness (CAN) between ECU and Teleflex i2 module is open or the connector is not connected properly.
U0146/12
2. i2 module powered off or has a malfunction.

Troubleshooting Procedure
1. Check if the i2 module unit is working.
2. Check the CAN communication cable between ECU and i2 module.
3. Check if the 8320 is installed. Check for proper software and software settings.

13-76 6LY3 Service Manual

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Troubleshooting the Pressure Sensor

DTC FMI Content PIN# of ECU_VSEN PIN# of ECU_PRS* PIN# of ECU_G_S

P0235 3/4 Boost Pressure Sensor 24 (SNS5) 40 (PBST) 35 (G_S)
P0520 3/4 Oil Pressure Sensor 24 (SNS5) 27 (PLO) 35 (G_S)

Performance Wiring Diagram

Figure 13-40 Figure 13-41

Pressure Sensor Characteristics Pressure Sensor ECU

0 50 100 150 1 24
4 5 V Sensor [SNS5]

2 PLO:27 [ECU_P***]
3.5 Signal Output
PBST:40
3 35
Sensor Output Voltage (V)

3 Sensor Ground [ECU_S]

0006146
2.5
Figure 13-41
2
Figure 13-42

1.5
321

1
>PPS< 1

0.5

0
0 200 400 600 800 1000 1200
Pressure (kPa) ± 5% (3) (1)
0006145
(2)
Figure 13-40
0006147

Figure 13-42
Part code: 119578-91300
1 – Sensor (5V)
2 – Signal Output
3 – Ground

6LY3 Service Manual 13-77

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Figure 13-43

1. [Sensor 5V] NG
Checking sensor 5V output

OK
4. [Wire harness] NG
Checking sensor 5V wire harness
2. [Wire harness] NG open / short.
Checking wire harness open/short.
(S-5V, Prs. sig, S-GND)

OK
2.

3. [Sensor] NG OK
Checking sensor performance.
3. 3.

OK

Exchange Exchange Exchange Exchange Exchange

ECU sensor wire harness ECU wire harness
0006148

Figure 13-43

NOTICE: If the supply voltage exceeds 6V, the sensor will be damaged and should be replaced. This is true
for all the sensors on the same circuit.
NOTICE: Before replacing the wire harness, check all of the connectors and the ECU.

13-78 6LY3 Service Manual

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Case 1: When DTC is ACTIVE

To identify the cause (wire harness, sensor failure or connector):
1. Checking the 5V sensor output voltage:
• Unplug sensor.
• Measure the voltage between terminals A and C.

Terminals Voltage Status

OK: Normal
5V
Wire harness ➝ Go to 2 “Check wire harness for an open / short.”
connector 1 - 3 Failure:
not 5V
➝ Go to 4 “Check 5V sensor wire harness open / short.”

NOTICE:
[ECU_SNS5] short to ground is shown as P1230/1.
[ECU_SNS5] short to battery is shown as P1230/0.
2. Checking the wire harness for an open / short:
• Disconnect the ECU and unplug the sensor.
• Check for open / short in wire harness (continuity test).

Terminals Continuity Status

Good OK: Normal
[ECU_P***] - B
Defective Failure: Open circuit
Good OK: Normal
[ECU_SNS5] - C
Defective Failure: Open circuit
[ECU_G_S] - A / Good OK: Normal
ground / 11 / 33 / 34 Defective Failure: Open circuit
[ECU_P***] - A / C / Defective OK: Normal
other terminal /
ground / Battery + Good Failure: Short circuit

[ECU_SNS5] - A / B / Defective OK: Normal

other terminal /
ground / Battery + Good Failure: Short circuit

[ECU_S_G] - B / C / Defective OK: Normal

other terminal /
ground / Battery + Good Failure: Short circuit

➝ Replace the wire harness.

Defective
Check the wire harness for damage or incorrect wiring.
OK Go to 3 “Check Sensor Performance.”

3. Checking the sensor performance:

• Connect the ECU and plug in the sensor.
• Turn the key on and supply voltage to the ECU.
• Measure the voltage.
• Use the breakout box.

6LY3 Service Manual 13-79

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• Check the sensor signal output and the 5V sensor voltage.

Terminals Value
A - B (pressure sensor connector) 0.5V (engine stopped)
5V
A - C (pressure sensor connector)
Wire harness is already checked at 1.

Replace the pressure sensor.

Defective
Replace the ECU if the pressure sensor replacement does not make a difference.
OK Replace the ECU.

Comment: Sensor signal output range

Terminals Voltage Status
Failure:
Below 0.5V 1. Open circuit B- [ECU_P***]
Just below 0.5V may be
an error. 2. Open circuit C- [ECU-SNS5]
3. Short to ground circuit B- [ECU_P***]

Wire harness connector A - B 0.5V <

[ECU_P***] OK: Normal
V < 3.6V
Failure:
above 3.6V 1. Short to battery C- [ECU_SNS5]
2. Short to battery B- [ECU_P***]

4. Checking the 5V sensor wire harness:

• Disconnect the ECU and unplug the sensor connector.
• Check for an open / short circuit (continuity test).

Terminals Continuity Status

Good OK: Normal
[ECU_SNS5] - C
Defective Failure: Open circuit
[ECU_SNS5] - A / B / Defective OK: Normal
other terminal /
ground / Battery + Good Failure: Short circuit

Case 2: When the DTC is not active (logged status):

• ECU stores the DTC information and the YDT indicates a logged DTC. If a connector comes loose, it may
be the reason for a logged DTC.
• Clear the DTC information first, then it becomes easy to identify when the new DTC comes on.
• Check the wire harness around the pressure sensor and ECU. Check if DTC comes again.

DTC Contents
Check if the DTC comes on.
Yes Check the connector terminal and wire harness.
Replace the wire harness.
No action at this time
No
Wait and see if same DTC occurs.

13-80 6LY3 Service Manual

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Wiring Diagrams • Sub-Throttle Indicator, Emergency Throttle

Position Sensor
The following wiring diagrams are provided:
• Starter Interlock Relay, Starter, Alternator
• Air Heater
• Main Relay, 1st Station Relay, 2nd Station
• Rack Actuator, Rack Actuator Relay, Relay
Emergency Switch
• NEUTRAL Switch
• Rack Position Sensor

Air Heater
Figure 13-44

Battery

Air Heater Relay 1 ECU

1A 4
AHR1 AHR1

1B

Fuse
2B 250A

Air Heater 1
2A

Air Heater Relay 2

1A 5
AHR2 AHR2

1B

Fuse
2B 250A

Air Heater 2
2A

0006151

Figure 13-44

6LY3 Service Manual 13-81

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Rack Actuator, Rack Actuator Relay, Emergency Switch

Figure 13-45

Battery

Fuse
20A

Main
Relay

Emergency
Stop
FOP Actuator Relay Switch ECU

A 20
BAT EMS

C 14
RAR RAR

B
FOP Actuator

D B C 1
RA

0006152

Figure 13-45

13-82 6LY3 Service Manual

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Rack Position Sensor

Figure 13-46

Battery

Fuse
20A

Main
Relay

Rack Sensor Amplifier

H
BAT
ECU

E 30
RPS RPS

A 35
G_S G_S

FOP Sensor

J A

B H

G G

C F

D E

0006153

Figure 13-46

6LY3 Service Manual 13-83

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Sub-Throttle Indicator, Emergency Throttle Position Sensor

Figure 13-47

Battery

Fuse
20A

ECU
Main
Relay

10
B1/2

Sub-Throttle
Indicator
ECU

12 22
STHL STHL

2 24
SNS5 SNS5

Sub-Throttle 6 29
STH STH
Position Sensor

7 35
G_S G_S

0006154

Figure 13-47

13-84 6LY3 Service Manual

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Starter Interlock Relay, Starter, Alternator

Figure 13-48

Battery

Fuse
20 A

Fuse ECU
10 A Main
Relay
Starter Interlock Relay

A
BAT

Key
Switch
ECU

C 21
STR STR

B 8
ST ST

Alternator

Fuse
Starter Relay 120 A
B
1A

1B

(2) Starter
50 A
2A
B

2B
S

0006155

Figure 13-48

6LY3 Service Manual 13-85

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Main Relay, 1st Station Relay, 2nd Station Relay

Figure 13-49

Battery

Fuse
10 A
Fuse
10 A Fuse
Key 20 A
ECU Main Relay Switch 1
Key
BAT A
Switch 2

ECU

MNR C 12
MNR
B

D 15
B1

25
Fuse B2
1st Station Relay
5A
Key SW1 A 19
IGN1

G_P1/2 C

Fuse
2nd Station Relay
5A
Key SW2 A 10
IGN2

G_P1/2 C

0006156

Figure 13-49

13-86 6LY3 Service Manual

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Neutral Switch
Figure 13-50

ECU

2A 18
NTS NTS

1A
G_P1/2

0006157

Figure 13-50

6LY3 Service Manual 13-87

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13-88 6LY3 Service Manual

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 6LY3 Service Manual
Section 14

SERVICE STANDARDS
Page
Service Standards ......................................................................... 14-3
Engine ..................................................................................... 14-3
Cylinder Head.......................................................................... 14-4
Camshaft and Gear Train ........................................................ 14-5
Cylinder Block.......................................................................... 14-6
Piston and Ring ....................................................................... 14-7
Connecting Rod....................................................................... 14-9
Tightening Torque for Bolts and Nuts.......................................... 14-10
Main Bolt and Nut .................................................................. 14-10
Standard Bolts and Nuts (Without Oil)................................... 14-11

6LY3 Service Manual 14-1

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 SERVICE STANDARDS

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14-2 6LY3 Service Manual

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 Service Standards SERVICE STANDARDS
12/05

SERVICE STANDARDS
Engine

Reference
No. Inspection Item Standard Limit
Page
0.15-0.25 mm
Intake —
(0.0059-0.0098 in.)
1 Valve Clearance 4-18
0.45-0.55 mm
Exhaust —
(0.0177-0.0216 in.)
8-10 mm
Used Part —
V-belt Tension (Approximately 3/8 in.)
2 4-14
at 98 N (22 lb) force 6-8 mm
New Part —
(Approximately 5/16 in.)
24.00-24.98 MPa
No. 1 Press. (245-255 kgf/cm2) —
(3623 psi)
3 Fuel Opening Pressure 6-27
36.96-38.34 MPa
No. 2 Press. (377-391 kgf/cm2) —
(5560 psi)
Engine 28 L (7.4 gal) —
4 Coolant Capacity Coolant Recovery 7-4
1.5 L (0.4 gal) —
Tank
Oil Capacity (full)
5 Engine 18.8 L (5 gal) — 4-6
at a 0° rake angle
0.40-0.50 MPa
6 Oil Pressure (4.1-5.1 kgf/cm2) — 8-8
(58-72 psi)
1000 rpm 20 kPA or less (2.9 psi) —
7 Oil Pressure Alarm (ON) 200 or less kPa 4-8
3000 rpm —
(29 psi)
Valve Opening 69-73°C
—
Temperature (156-163°F)
8 Thermostat 8 mm or above 4-30
Full Opening Lift (0.314 in.) —
90°C (194°F)
ON 100°C (212°F) —
9 Coolant Temperature Alarm
OFF 95°C (203°F) —
ON 110°C (230°F) —
10 Oil Temperature Alarm 12-22
OFF 105°C (221°F) —
ON 80°C (176°F) —
11 Fuel Temperature Alarm
OFF 75°C (167°F) —
0.78-0.98 mm
12 Top Clearance — 5-35
(0.0307-0.0385 in.)

6LY3 Service Manual 14-3

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 SERVICE STANDARDS Service Standards

Cylinder Head
General

Inspection Item Standard Limit Reference Page

0.05 mm or less 0.20 mm
Combustion Surface Distortion 5-29
(0.0019 in.) (0.0078 in.)
0.7-0.9 mm 1.2 mm
Intake
(0.0275-0.0354 in.) (0.0472 in.)
Valve Sink 5-29
1.2-1.4 mm 1.7 mm
Exhaust
(0.0472-0.0551 in.) (0.0669 in.)
Intake 90°C (194°F) —
Valve Seat Angle 5-29
Exhaust 90°C (194°F) —

Intake / Exhaust Valve and Guide

Inspection Item Standard Limit Reference Page
8.010-8.025 mm 8.1 mm
Guide Inside Diameter
(0.3153-0.3159 in.) (0.3188 in.)
Valve Stem Outside 7.960-7.975 mm 7.90 mm
Intake
Diameter (0.3133-0.3139 in.) (0.3110 in.)
0.035-0.065 mm 0.18 mm
Clearance
(0.0013-0.0025 in.) (0.0070 in.)
5-30
8.015-8.030 mm 8.1 mm
Guide Inside Diameter
(0.3155-0.3161 in.) (0.3188 in.)
Valve Stem Outside 7.955-7.970 mm 7.90 mm
Exhaust
Diameter (0.3131-0.3137 in.) (0.3110 in.)
0.045-0.075 mm 0.18 mm
Clearance
(0.0017-0.0029 in.) (0.0070 in.)
9.0-9.5 mm
Intake —
Valve Guide (0.3543-0.3740 in.)
Projection 7.0-7.5 mm 5-32
Exhaust —
(0.2755-0.2952 in.)
Valve Guide Installation Method Cold-fitted —

Valve Spring
Inspection Item Standard Limit Reference Page
53.0 mm 51.5 mm
Free Length (Intake / Exhaust)
(2.0866 in.) (2.0275 in.)
5-32
1.2 mm
Inclination (Intake / Exhaust) —
(0.0472 in.)

Rocker Arm and Shaft

Inspection Item Standard Limit Reference Page
20.000-20.020 mm 20.090 mm
Arm Shaft Hole Diameter
(0.7873-0.7881 in.) (0.7909 in.)
19.970-19.990 mm 19.955 mm
Shaft Outside Diameter 5-35
(0.7862-0.7870 in.) (0.7856 in.)
0.010-0.050 mm 0.140 mm
Clearance
(0.0003-0.0019 in.) (0.0055 in.)

14-4 6LY3 Service Manual

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 Service Standards SERVICE STANDARDS
12/05

Camshaft and Gear Train

Camshaft

Inspection Item Standard Limit Reference Page

0.05-0.20 mm 0.29 mm
Side Clearance 5-48
(0.0019-0.0078 in.) (0.0114 in.)
0.02 mm
Bending (1/2 the dial gauge reading) —
(0.0007 in.)
49.435-49.565 mm 49.185 mm
Intake
(1.9462-1.9513 in.) (1.9364 in.)
Cam Height 5-48
48.135-48.265 mm 48.110 mm
Exhaust
(1.8950-1.9 in.) (1.8940 in.)
Bushing Inside 56.980-57.050 mm 57.130 mm
Diameter (2.2433-2.2460 in.) (2.2492 in.)
Camshaft Outside 56.910-59.940 mm 56.880 mm
Camshaft and Bearing 5-48
Diameter (2.2405-2.3598 in.) (2.2393 in.)
0.040-0.130 mm 0.240 mm
Clearance
(0.0015-0.0051 in.) (0.0094 in.)

Idler Gear Shaft and Bushing

Inspection Item Standard Limit Reference Page

53.950-53.975 mm 53.88 mm
Idle Shaft Diameter
(2.1240-2.1249 in.) (2.1212 in.)
54.000-54.025 mm 54.08 mm
Idler Gear Bushing Inside Diameter 5-51
(2.1259-2.1269 in.) (2.1291 in.)
0.025-0.075 mm 0.15 mm
Oil Clearance
(0.0009-0.0029 in.) (0.0059 in.)

Gear Train Backlash

Inspection Item Standard Limit Reference Page

0.08-0.16 mm 0.25 mm
Gear Train Backlash 5-51
(0.0031-0.0062 in.) (0.0098 in.)

6LY3 Service Manual 14-5

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 SERVICE STANDARDS Service Standards

Cylinder Block
General

Inspection Item Standard Limit Reference Page

105.900-105.930 mm 105.950 mm
Cylinder Inside Diameter
(4.1692-4.1704 in.) (4.1712 in.)
0.03 mm or less
Roundness — 5-25
(0.0011 in.)
Cylinder Bore
0.02 mm or less
Cylindricity —
(0.0007 in.)

Crankshaft

Inspection Item Standard Limit Reference Page

0.03 mm
Bending (1/2 the dial gauge reading) — 5-45
(0.0011 in.)
Bearing Inside 65.000-65.045 mm 65.100 mm
Diameter (2.5590-2.5608 in.) (2.5629 in.)
64.952-64.964 mm 64.902 mm
Pin Outside Diameter
(2.5571-2.5576 in.) (2.5551 in.)
Crank Pin
1.987-2.000 mm
Bearing Thickness —
(0.0782-0.0787 in.)
0.036-0.093 mm 0.160 mm
Clearance
(0.0014-0.0036 in.) (0.0062 in.)
5-42, 5-46
Bearing Inside 75.000-75.045 mm
—
Diameter (2.9527-2.9545 in.)
Journal Outside 74.952-74.964 mm 74.90 mm
Diameter (2.9508-2.9513 in.) (2.9488 in.)
Crank Journal
2.487-2.500 mm
Bearing Thickness —
(0.0979-0.0984 in.)
0.036-0.093 mm 0.15 mm
Clearance
(0.0014-0.0036 in.) (0.0059 in.)

Crankshaft Thrust Bearing

Inspection Item Standard Limit Reference Page
0.132-0.223 mm 0.29 mm
Crankshaft End Play Side Clearance 5-46
(0.0051-0.0087 in.) (0.0114 in.)

14-6 6LY3 Service Manual

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 Service Standards SERVICE STANDARDS
12/05

Piston and Ring

Piston
Inspection Item Standard Limit Reference Page
105.799-105.809 mm
L
(4.1653-4.1656 in.)
105.794-105.799 mm
Piston Outside Diameter ML
(4.1651-4.1653 in.) 105.780 mm
(Measure vertical to the piston
105.789-105.794 mm (4.1645 in.)
pin) MS
(4.11651-4.1653 in.)
5-37
105.779-105.789 mm
S
(4.1645-4.1649 in.)
0.111-0.131 mm
Clearance Between Piston and Cylinder —
(0.0043-0.0051 in.)
Piston Diameter Measure Position 22 mm
—
(Upward from the bottom end of the piston) (0.8661 in.)
37.025-37.040 mm 37.100 mm
Piston Pin Hole Inside Diameter
(1.4576-1.4582 in.) (1.4606 in.)
36.994-37.000 mm 36.964 mm
Piston Pin Outside Diameter 5-38
(1.4564-1.4566 in.) (1.4552 in.)
0.025-0.046 mm 0.110 mm
Clearance Between Piston Pin and Hole
(0.0009-0.0018 in.) (0.0043 in.)

6LY3 Service Manual 14-7

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 SERVICE STANDARDS Service Standards

Piston Ring
Inspection Item Standard Limit Reference Page
2. 626-2.646 mm 2.746 mm
Ring Groove Width
(0.1033-0.1041 in.) (0.1081 in.)
2.470-2.490 mm 2.450 mm
Ring Width
(0.0972-0.0980 in.) (0.0964 in.)
Top Ring
0.136-0.176 mm 0.250 mm
Side Clearance
(0.0053-0.0069 in.) (0.0098 in.)
0.30-0.50 mm 1.5 mm
Gap
(0.0118-0.0196 in.) (0.0590 in.)
2.570-2.585 mm 2.140 mm
Ring Groove Width
(0.1082-0.1017 in.) (0.0842 in.)
2.470-2.490 mm 1.950 mm
Ring Width
(0.0972-0.0980 in.) (0.0767 in.)
Second Ring 5-38
0.080-0.115 mm 0.200 mm
Side Clearance
(0.0031-0.0045 in.) (0.0078 in.)
0.50-0.70 mm 1.5 mm
Gap
(0.0196-0.0275 in.) (0.0590 in.)
4.010-4.025 mm 4.130 mm
Ring Groove Width
(0.1578-0.1584 in.) (0.1625 in.)
3.970-3.990 mm 3.950 mm
Ring Width
(0.1562-0.1570 in.) (0.1555 in.)
Oil Ring
0.020-0.055 mm 0.150 mm
Side Clearance
(0.0007-0.0021 in.) (0.0059 in.)
0.25-0.45 mm 1.5 mm
Gap
(0.0098-0.0177 in.) (0.0590 in.)

14-8 6LY3 Service Manual

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 Service Standards SERVICE STANDARDS
12/05

Connecting Rod
Rod Big End
Inspection Item Standard Limit Reference Page
0.20-0.40 mm 0.45 mm
Side Clearance 5-42
(0.0078-0.0157 in.) (0.177 in.)

Rod Small End

Inspection Item Standard Limit Reference Page
37.025-37.040 mm 37.100 mm
Piston Pin Bearing Inside Diameter
(1.4576-1.4582 in.) (1.4606 in.)
36.994-37.000 mm 36.964 mm
Piston Pin Outside Diameter 5-44
(1.4564-1.4566 in.) (2.4552 in.)
0.025-0.046 mm 0.110 mm
Clearance
(0.0009-0.0018 in.) (0.0043 in.)

Tappet
Inspection Item Standard Limit Reference Page
14.249-14.270 mm 14.30 mm
Tappet Guide Hole Inside Diameter
(0.5609-0.5618 in.) (0.5629 in.)
14.218-14.233 mm 14.17 mm
Tappet Stem Outside Diameter 5-50
(0.5597-0.5603 in.) (0.5528 in.)
0.016-0.052 mm 0.10 mm
Clearance
(0.0006-0.0020 in.) (0.0039 in.)

6LY3 Service Manual 14-9

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 SERVICE STANDARDS Tightening Torque for Bolts and Nuts

TIGHTENING TORQUE FOR BOLTS AND NUTS

Main Bolt and Nut

Lubricating Oil
Thread Application
No. Name Torque
Diameter x Pitch (thread portion and
seat surface)
1st: 118 N·m (12.0 kgf·m) (87lb-ft)
New Bolt 2nd: 177 N·m (18.0 kgf·m) (130 lb-ft)
Cylinder 3rd: 216-236 N·m (22.0-24.1 kgf·m) (159-174 lb-ft)
1 M14 x 1. 5 Coat with oil
Head Bolt 1st: 108 N·m (11.0 kgf·m) (80 lb-ft)
Used Bolt 2nd: 167 N·m (17.0 kgf·m) (128 lb-ft)
3rd: 196-216 N·m (20.0-22.0 kgf·m) (145-159 lb-ft)
2 Rod Bolt M12 x 1.25 Coat with oil 132.1-141.9 N·m (13.5-14.5 kgf·m) (97-105 lb-ft)
3 Flywheel Retainer Bolt M16 x 1. 5 Coat with oil 284-304 N·m (29.0-31.0 kgf·m) (209-224 lb-ft)

Bearing New Bolt 245-265 N·m (25.0-27.0 kgf·m) (181-195 lb-ft)

4 M15 x 1.5 Coat with oil
Cap Bolt Used Bolt 225-245 N·m (23.0-25.0 kgf·m) (166-181 lb-ft)
Crankshaft Pulley Bolt
5 M16 x 1.5 Coat with oil 216-236 N·m (22.3-24.1 kgf·m) (159-174 lb-ft)
(FC300 pulley)
6 Timer Housing Bolt M8 x 1.25 No oil 33.3-37.3N·m (3.4-3.8 kgf·m) (25-27 lb-ft)
7 Timer Gear Bolt M8 x 1.25 Coat with oil 34.8-38.8 N·m (3.5-4.0 kgf·m) (26-29 lb-ft)
8 Idler Gear Shaft Bolt M10 x 1.5 Coat with oil 62-66 N·m (6.3-6.7 kgf·m) (46-49 lb-ft)
9 Oil Pump Bolt M12 x 1.75 Coat with oil 98-118 N·m (10.0-12.0 kgf·m) (72-87 lb-ft)
Coat with Moly Coat
10 Turbocharger V-Band Bolt 1/4-28 UNF 5.4-7.4 N·m (0.55-0.75 kgf·m) (4-5 lb-ft)
on thread portion
11 Seawater Pump Gear Bolt M14 x 1.5 Coat with oil 73-83 N·m (7.4-8.5 kgf·m) (23-83 lb-ft)
12 Fuel Nozzle Sleeve M13 x 1.5 No oil 52.9-62.7 N·m (5.4-6.4 kgf·m) (22-25 lb-ft)
13 Nozzle Fastening Bolt M8 x 1.25 Coat with oil 29.4-33.4 N·m (3.0-3.4 kgf·m) (22-25 lb-ft)
Fuel Injection Pipe
14 M12 x 1.5 No oil 22.5-26.5 N·m (2.3-2.7 kgf·m) (17-19 lb-ft)
Joint Nut
15 Fuel Return Pipe Joint Bolt M6 x 1.0 No oil 7.0-9.0 N·m (0.7-0.9 kgf·m) (5-7 lb-ft)
Coat with oil on
16 Oil Filter (Full Flow) 1-12 UNF Hand-tighten then turn an additional 3/4 of a turn.
O-ring
Coat with oil on
17 Oil Filter (Bypass) M25 x 1.5 Hand-tighten then turn an additional one turn.
O-ring
Silencer Installation Hose
18 — — 2.5-3.5 N·m (0.25-0.36 kgf·m) (2-3 lb-ft)
Band

14-10 6LY3 Service Manual

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 Tightening Torque for Bolts and Nuts SERVICE STANDARDS
12/05

Standard Bolts and Nuts (Without Oil)

Name Bolt Diameter x Pitch Tightening Torque Remarks

M6 x 1 9.8-11.8 N·m (1.0-1.2 kgf·m) (7.0-9.0 lb-ft) Use 80% of the value at left
when tightening aluminum
M8 x 1.25 22.5-28.5 N·m (2.3-2.9 kgf·m) (17-21 lb-ft)
Hexagon Bolt (7T) parts.
and Nut M10 x 1.5 44-54 N·m (4.5-5.5 kgf·m) (32-40 lb-ft)
Use 60% of the value at left
M12 x 1.75 78.2-98.2 N·m (8.0-10.0 kgf·m) (58-72 lb-ft) for 4T bolts and locknuts.
1/8 9.8 N·m (1.0 kgf·m) (7.0 lb-ft)
1/4 19.6 N·m (2.0 kgf·m) (14 lb-ft)
PT Plug —
3/8 29.4 N·m (3.0 kgf·m) (22 lb-ft)
1/2 58.8 N·m (6.0 kgf·m) (43 lb-ft)
M8 12.7-16.7 N·m (1.3-1.7 kgf·m) (9.0-12 lb-ft)
M10 19.5-25.5 N·m (2.0-2.6 kgf·m) (14-19 lb-ft)
Pipe Joint Bolt M12 24.4-34.4 N·m (2.5-3.5 kgf·m) (18-25 lb-ft) —
M14 39.1-49.1 N·m (4.0-5.0 kgf·m) (29-36 lb-ft)
M16 48.9-58.9 N·m (5.0-6.0 kgf·m) (36-43 lb-ft)

6LY3 Service Manual 14-11

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 SERVICE STANDARDS Tightening Torque for Bolts and Nuts

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14-12 6LY3 Service Manual

© 2007 Yanmar Marine International
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