YANMAR 6SY-STP2 6SY655 8SY-STP SERIES MARINE ENGINES SERVICE MANUAL 0BSYM-G00100 – PDF DOWNLOAD
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DESCRIPTION:
YANMAR 6SY-STP2 6SY655 8SY-STP SERIES MARINE ENGINES SERVICE MANUAL 0BSYM-G00100 – PDF DOWNLOAD
This manual gives specific instructions for the
proper repair of Yanmar SY series marine engines.
Please follow the procedures carefully to ensure
quality service.
Yanmar recommends that you read this Service
Manual completely before starting with repairs.
Along with standard tools, Yanmar recommends the
use of special tools, necessary to perform repairs
correctly.
Yanmar products are continuously undergoing
improvement. This Service Manual has been
checked carefully in order to avoid errors. However
Yanmar is not liable, for any misrepresentations,
errors of description or omissions. Contact an
authorized Yanmar marine dealer or distributor for
any questions you have regarding this Service
Manual.
TABLE OF CONTENTS:
YANMAR 6SY-STP2 6SY655 8SY-STP SERIES MARINE ENGINES SERVICE MANUAL 0BSYM-G00100 – PDF DOWNLOAD
Revision History 6
Revision Control Table 6
Safety Precautions 8
Safety Precautions 15
Engine Outline Drawings 16
6SY-STP2 X ZF325-1 16
8SY-STP X MG5114 IV 17
Engine Piping Diagrams 18
Location of Nameplates 21
Engine Nameplate (Typical) 21
Diesel Fuel 22
Diesel Fuel Specifications 22
Additional Technical Fuel Requirements 22
Diesel Fuel Lines 22
Filling the Fuel Tank 23
Bleeding the Fuel System 23
Engine Oil 24
Engine Oil Specifications 24
Service Categories 24
Definitions 24
Additional Technical Engine Oil Requirements: 24
Engine Oil Viscosity 24
Maximum Angles of Inclination During Operation 25
Selection of Marine Gear Oil 25
Engine Coolant 25
Engine Coolant Specifications 25
Coolant (Closed Cooling System) 25
Principal Engine Specifications 27
Engine Service Standards 29
Tightening Torques for Standard Bolts and Nuts 30
Tightening Fasteners 30
Abbreviations and Symbols 31
Abbreviations 31
Symbols 31
Unit Conversions 32
Unit Prefixes 32
Units of Length 32
Units of Volume 32
Units of Mass 32
Units of Force 32
Units of Torque 32
Units of Pressure 32
Units of Power 32
Units of Temperature 32
Introduction 35
The Importance of Periodic Maintenance 35
Performing Periodic Maintenance 35
Yanmar Replacement Parts 35
Required EPA Maintenance – USA Only 35
EPA Installation Requirements – USA Only 35
Periodic Maintenance Schedule 36
Inspection and Maintenance of EPA Emission-Related Parts 38
Periodic Maintenance Procedures 39
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EPA Requirements 42
Conditions to Ensure Compliance with EPA Emission Standards 42
Inspection and Maintenance 42
Safety Precautions 45
Introduction 46
Principal Engine Specifications 46
Adjustment Specifications 46
Cylinder Head Specifications 47
Cylinder Head and Valves 47
Camshaft and Timing Gear Train Specifications 48
Camshaft 48
Intermediate Gear and Bushing 48
Timing Gear Backlash 48
Crankshaft and Pistons Specifications 49
Crankshaft 49
Thrust Bearing 49
Cylinder Liner 50
Connecting Rod 50
Piston Ring 50
Special Torque Chart 51
Special Service Tools 53
Measuring Instruments 58
Tests and Adjustments 60
Adjust Valve and Unit Injector Clearances 60
Adjusting Unit Injectors 61
Digital Caliper Method: 62
Special Tool Method: 62
Repair 63
Cylinder Head 64
Cylinder Head Components 64
General Guidelines 65
Remove and Install Rocker Covers 65
Upper Rocker Cover 65
Lower Rocker Cover 66
Remove the Cylinder Head 68
Disassemble the Cylinder Head 69
Clean the Cylinder Head Components 69
Inspect the Cylinder Head Components 69
Inspection of Intake and Exhaust Valves 69
Replace the Valve Stem Seals 71
Replace the Valve Seat 71
Removal 71
Machine the Valves 72
Machine the Valve Seat Inserts 72
Specifications 72
Procedure 73
Replace the Valve Guides 75
Replace the Unit Injector Sleeves 75
Reassemble the Cylinder Head 76
Install the Cylinder Head 76
Pistons and Cylinder Liners 78
Remove and Disassemble Piston and Connecting Rod 79
Inspect the Connecting Rods 80
Replace the Wrist Pin Bushing 82
Inspect the Pistons and Piston Rings 83
Assemble the Piston and Connecting Rod 83
Remove the Cylinder Liners 84
Measure the Cylinder Liner Height 86
Install the Cylinder Liners 86
Install the Piston and Connecting Rod 87
Flywheel and Flywheel Housing 90
Flywheel Housing Components – 6SY Engines 90
Flywheel Housing Components – 8SY Engines 92
Remove the Flywheel 93
Flywheel Inspection and Repair 94
Support Bearing Replacement 94
Remove the Ring Gear 94
Replace the Rear Crankshaft Seal 94
Remove the Flywheel Housing 95
Install the Flywheel Housing 95
Install the Flywheel 96
Timing Gear Train 98
6SY Components 98
8SY Components 100
Check the Camshaft Timing 102
6SY Engines 102
8SY Engines 102
Remove the Front Gear Housing – 8SY 102
Install the Front Gear Housing – 8SY 104
Intermediate Gear 104
Remove 104
Bearing Replacement – 6SY 106
Bearing Replacement – 8SY 107
Intermediate Gear Installation 108
Camshaft Gear 109
Remove 109
Install 110
Crankshaft Gear 111
Remove 111
Install 111
Remove the Camshaft 112
Replace the Camshaft Bearings – 6SY 113
Replace the Camshaft Bearings – 8SY 117
Install the Camshaft 120
Cylinder Block and Crankshaft 124
Remove the Crankshaft 126
Measure the Oil Clearance 127
Inspect the Crankshaft 128
Recondition the Crankshaft 129
Checking and Grinding 129
Inspect the Cylinder Block 129
Reconditioning 129
Install Crankshaft 130
Replace the Front Crankshaft Seal 132
Exhaust Manifold 133
Replacing Gaskets 133
Make sure that all connections are tightened to specifications after repair is made to the exhaust system 133
Lifting the Engine 134
6SY Engines 134
8SY Engines 134
Attaching Engine to Repair Stand 135
Safety Precautions 139
Introduction 139
Specifications 140
Special Service Tools 141
Fuel System Components 142
Fuel Delivery Components 142
Fuel Injector Components 143
Tests and Adjustments 143
Adjust the Unit Injectors 143
Measure the Fuel Feed Pump Pressure 143
Procedure 143
Results 144
Test the Fuel Pressure Relief Valve 144
Procedure 144
Results 144
Repair 144
Remove the Unit Injector 144
Install the Unit Injector 147
Replace the Fuel Feed Pump 149
If the fuel feed pump refuses to prime: 150
Replace the Fuel Filter and Fuel Filter / Water Separator 150
Replace the Fuel Filter 150
Replace the Fuel Filter / Water Separator 151
Replace Return Fuel Line 151
6SY Engines 152
8SY Engines 153
Bleed the Fuel System 153
If the engine fails to start after bleeding: 154
Introduction 157
Specifications 158
Special Service Tools 159
Measuring instruments 160
Tests and Adjustments 161
Pressure Testing Cooling System and Filler Cap 161
Cooling System 161
Filler Cap 161
Testing the Thermostat 162
Repair 162
Drain, Flush and Fill the Engine with Engine Coolant 162
Venting the Cooling System – 8SY Engines Only 163
Coolant Pump Removal 164
Install Coolant Pump 165
Remove and Install Pulley 165
Change the Coolant Pump Seal 166
Remove and Install Thermostat 168
6SY Thermostat Removal 168
Thermostat Removal – 8SY 169
Thermostat Installation – All Engines 169
Remove and Install Fresh Water Charge Air Cooler 169
Remove and Install Seawater Charge Air Cooler – 6SY Engines Only 172
Remove and Install the Heat Exchanger 174
6SY Engines 174
8SY Engines 176
Seawater Pump 178
Replace the Impeller 178
Remove and Disassemble Seawater Pump 179
Inspect the Seawater Pump 180
Assemble the Seawater Pump 181
Check or Replace the Zinc Anodes 182
Introduction 187
Specifications 187
Special Service Tools 188
Tests and Adjustments 189
Check the Engine Oil Pressure 189
Repair 190
Remove and Install the Oil Cooler 190
6SY Engines 190
8SY Engines 191
Remove and Install Oil Cleaning Components 193
Replace the Engine Oil Filter – 8SY 195
Clean the Centrifugal Engine Oil Cleaner 195
Oil Pump 198
Removal of Oil Pump 199
Installation of Oil Pump 199
Introduction 203
General Information 203
Oil Leaks 203
Foreign Bodies 203
Air and Exhaust Leaks 203
Oil Filter 203
Cleaning the Compressor Wheel 203
Specifications 204
Special Service Tools 205
Component Location 206
6SY Engines 206
8SY Engines 207
Tests and Adjustments 208
Measuring Charge Pressure 208
Repair 208
If the Turbocharger Does Not Operate: 208
Remove Turbocharger 209
Inspect the Turbocharger 210
Cleaning the Compressor 210
Measure the Radial and Axial Clearance 210
Radial Clearance 211
Axial Clearance 211
Install the Turbocharger 212
Before You Begin Servicing 217
Introduction 218
Starter Motor Specifications 219
Starter Motor Troubleshooting 220
Remove and Install Starter Motor 221
Repair Starter Motor – Bosch JE 222
Components 222
Brush Replacement 224
Equipment Required 224
Repair 224
Replace Solenoid 225
Before You Begin Servicing 229
Introduction 230
Specifications 231
Calculating Alternator Capacity 232
Alternator and Charging System Troubleshooting 232
Test and Inspection 233
Output Test 233
Brush Length 234
Rotor 234
Slip Rings 234
Resistance 234
Repair 235
Replace Alternator Belt 235
Introduction 239
Specifications 239
Specifications 239
Special Service Tools 239
Function Description – Engine Management System (EMS S6) 240
General 240
Component Location 241
6SY Engines 241
8SY Engines 242
Engine Speed Sensors – T28 and T29 243
Charge Air Pressure and Temperature Sensor – T26 244
Charge Air Pressure Sensor 245
Charge Air Temperature Sensor 245
Coolant Temperature Sensor – T27 246
Oil Pressure Sensor – T25 247
EMS S6 Control Unit E44 248
Function of EMS S6 Control Unit 248
EMS S6 Control Unit Connections 249
EMS S6 Control Unit Pin Assignments 250
Repair 253
Replace the EMS S6 Control Unit 253
6SY Engines 253
Remove the EMS S6 Wiring 253
Installing EMS S6 Wiring 256
Wiring and Cable Duct – 6SY 256
Introduction 263
Troubleshooting Chart 263
Fault Codes 278
Working Procedure 278
After Troubleshooting or Repair 278
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