TABLE OF CONTENTS 12/05 Measuring Instruments.................................................................. 5-12 Sealants and Compounds............................................................. 5-13 Tests and Adjustments.................................................................. 5-14 Test Compression ................................................................... 5-14 Repair............................................................................................ 5-15 Cylinder Head................................................................................ 5-16 Cylinder Head Components ....................................................
5-16 General Guidelines.................................................................. 5-17 Remove and Install Cylinder Head Cover ............................... 5-17 Remove and Install Glow Plugs............................................... 5-19 Remove Cylinder Head ........................................................... 5-19 Disassemble Cylinder Head .................................................... 5-22 Clean Cylinder Head Components.......................................... 5-24 Pressure Test the Cylinder Head ............................................ 5-24 Inspect Cylinder Head Components........................................
5-24 Replace Valve Stem Seals...................................................... 5-25 Assemble Cylinder Head......................................................... 5-26 Determine Cylinder Head Gasket Thickness........................... 5-26 Install Cylinder Head ............................................................... 5-27 Pistons and Cylinders.................................................................... 5-31 Remove and Disassemble Piston and Connecting Rod.......... 5-31 Inspect Pistons and Piston Rings............................................ 5-32 Assemble Piston and Connecting Rod....................................
5-33 Install Piston and Connecting Rod .......................................... 5-34 Flywheel and Flywheel Housing.................................................... 5-37 Remove and Install Flywheel Housing ................................... 5-37 Remove and Install Drive Coupling ......................................... 5-38 Remove Flywheel.................................................................... 5-39 Replace Rear Crankshaft Seal................................................ 5-40 Install Flywheel........................................................................ 5-41 Camshaft and Timing Gear Train..................................................
5-42 Components ............................................................................ 5-42 Check and Adjust Camshaft Timing ........................................ 5-44 Remove and Install Vibration Damper - 4BY2......................... 5-46 Remove and Install Vibration Damper - 6BY2......................... 5-47 Remove Timing Case Cover ................................................... 5-48 Remove and Install Timing Chain............................................ 5-49 Install Timing Case Cover ....................................................... 5-49 Remove and Install Timing Chain Tensioner...........................
5-50 Remove Camshafts................................................................. 5-51 Install Camshafts..................................................................... 5-54 Cylinder Block and Crankshaft...................................................... 5-56 Components ............................................................................ 5-56 Remove Crankshaft................................................................. 5-58 Measure Oil Clearance............................................................ 5-59 Inspect Crankshaft...................................................................
5-61 Inspect Cylinder Block............................................................. 5-62 © 2009 Yanmar Marine International BY Service Manual v