TABLE OF CONTENTS Install Crankshaft..................................................................... 5-62 Replace Front Crankshaft Seal ............................................... 5-64 Intake Manifold.............................................................................. 5-66 Remove................................................................................... 5-66 Install....................................................................................... 5-67 Exhaust Manifold........................................................................... 5-69 Remove...................................................................................
5-69 Install....................................................................................... 5-69 Fuel System ......................................................................................... 6-1 Safety Precautions .......................................................................... 6-3 Introduction...................................................................................... 6-3 Specifications .................................................................................. 6-4 Test and Adjustment Specifications .......................................... 6-4 Special Torque Chart ................................................................
6-4 Special Service Tools...................................................................... 6-5 Fuel System Components............................................................... 6-6 4BY2 Engines............................................................................ 6-6 6BY2 Engines............................................................................ 6-6 Fuel Flow Diagram .......................................................................... 6-7 Tests and Adjustments.................................................................... 6-9 Measure Fuel Feed Pump Pressure .........................................
6-9 Test Return Fuel Pressure ...................................................... 6-10 Repair............................................................................................ 6-11 Remove Fuel Injector .............................................................. 6-11 Clean Fuel Injector Cavities .................................................... 6-12 Install Fuel Injector .................................................................. 6-13 Remove and Install High-Pressure Fuel Lines ........................ 6-14 Replace the Fuel Feed Pump.................................................. 6-15 Replace High-Pressure Fuel Pump.........................................
6-15 Replace Fuel Filters ................................................................ 6-19 Remove and Install Fuel Rail .................................................. 6-20 Replace Injector Return Fuel Line........................................... 6-21 Bleed the Fuel System ............................................................ 6-22 Cooling System ................................................................................... 7-1 Safety Precautions .......................................................................... 7-3 Introduction......................................................................................
7-4 Specifications .................................................................................. 7-4 Test and Adjustment Specifications .......................................... 7-4 Repair Specifications................................................................. 7-4 Special Torque Chart ................................................................ 7-4 Special Service Tools...................................................................... 7-5 Measuring Instruments.................................................................... 7-5 Cooling Flow Diagram.....................................................................
7-6 vi BY Service Manual © 2009 Yanmar Marine International