Manual de Peças - Hon

ME372STI
E ENGINE
SERVICE MANUAL
070031
N69-28197-ZJ-11
NOTICE
This manual has been prepared by Yamaha primarily for use by Yamaha dealers and
their trained mechanics when performing maintenance procedures and repairs to
Yamaha equipment. It has been written to suit the needs of persons who have a
basic understanding of the mechanical and electrical concepts and procedures
inherent in the work, for without such knowledge attempted repairs or service to the
equipment could render it unsafe or unfit for use.
Because Yamaha has a policy of continuously improving its products, models may
differ in detail from the descriptions and illustrations given in this publication. Use
only the latest edition of this manual. Authorized Yamaha dealers are notified
periodically of modifications and significant changes in specifications and
procedures, and these are incorporated in successive editions of this manual.
ME372STI
ENGINE SERVICE MANUAL
© 2006 Yamaha Motor Co., Ltd.
1st Edition, December, 2006
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd. is
expressly prohibited.
Printed in Japan
HOW TO USE THIS MANUAL
MANUAL FORMAT
This manual provides the mechanic with descriptions of the operations of disassembly, repair,
assembly and check, each of which is presented in a sequential, step-by-step procedure.
To assist you in finding your way around this manual, the section title and major heading is
given at the head of each page.
A table of contents is provided on the first page of each section.
ILLUSTRATIONS
Some illustrations in this manual may differ from the model you have. This is because a proce-
dure described may relate to several models, though only one is illustrated. (The name of the
model described will be mentioned in the description).
To help you identify components and understand the correct procedures of disassembly and
assembly, exploded diagrams are provided. Steps in the procedure are numbered: 1), 2), 3).
Parts shown in the illustrations are identified as: 1, 2, 3.
REFERENCES
These have been kept to a minimum. References to other sections of the manual include the
relevant page number.
IMPORTANT INFORMATION
In this Service Manual particularly important information is distinguished in the following ways.
⁄ The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
¡ WARNING
Failure to follow WARNING instructions could result in severe injury or death to the machine
operator, a bystander, or a person inspecting or repairing the machine.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to the ma-
chine.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
CONSTRUCTION OF THIS MANUAL
This manual consists of chapters for the main categories of subjects. (See “Symbols” on the
next page.)
1st title 1 : This is a chapter with its symbol on the upper right of each page.
2nd title 2 : This title appears on the top of the each page, to the left of the chapter symbol.
3rd title 3 : This title precedes the paragraphs describing the working procedure.
All the procedures in this manual are organized in a sequential, step-by-step order. The infor-
mation has been compiled to provide the mechanic with an easy-to-read, handy reference that
contains comprehensive explanations of all disassembly, check, repair, and assembly proce-
dures.
Important procedures including removing, checking, and assembling steps 4 are explained in
detail.
IMPORTANT FEATURES
¡ Important engine data and information about special tools framed in a box together with
an illustrative symbol 5.
¡ A circled numeral 6 indicates a part name. A circled lower case letter indicates data or an
alignment mark 7.
¡ An arrow 8 indicates the course of action required to remedy the started condition of a
component.
EXPLODED DIAGRAM
Each chapter begins with exploded diagrams which facilitate correct disassembly and assem-
bly.
1 ENG
OVER
TURBOCHARGER E ENG
OVER
CYLINDER BLOCK E
Turbocharger Removal Connecting Rod and Piston Pin Check

1. Remove: 1. Check:
¡ Turbocharger ¡ Connecting rod and rod cap
2 ¡ Connecting rod bending

Turbocharger removal steps
¡ Connecting rod twisting
1) Drain the coolant. ¡ Piston pin and connecting rod bush-
 2) Remove the air filter.

3) Remove the mixing elbow.
ing
¡ Piston pin to bushing clearance
3  4) Separate the coolant by-pass pipe 1 and
the oil pipe 2, then remove the gaskets.
Connecting rod and rod cap checking step 6
1  NOTE:
1) Check the connecting rod 1 and rod cap
2 for cracks, bending and/or damage.
 Place a rag under the coolant by-pass pipe

ends to avoid spilling the fluid.
1 Cracks/Bending/Damage → Replace the
connecting rod assembly.
2


2
7

5) Remove the oil drain pipe 1 and the gas-
ket 2. Connecting rod bending checking step
 a
1) Check the connecting rod bending A by
use of the rod aligner.
8

2
Out of specification → Replace the con-
necting rod assembly.
1
 Connecting rod bending:
5
4 
<Limit>
0.05 mm (0.0020 in.) per 100 mm (3.937 in.)
6) Loosen the clamps 1 of the joint hose
2
3
 2.
7) Remove the bolts 3 below the turbo-
 charger. Connecting rod twisting checking step

1 1) Check the connecting rod twisting A by

a Out of specification → Replace the con-

Connecting rod twisting:
 8) Remove the boost pipe 1. <Limit>

0.05 mm (0.0020 in.) per 100 mm (3.937 in.)
1
SYMBOLS
1 2 Symbols 1 to 9 are designed as thumb-tabs
GEN and indicate the content of a chapter.
SPEC
INFO 1 General information
3 4 2 Specifications
3 Periodic check and adjustment
CHK REM 4 Engine removal and installation
ADJ INST 5 Fuel system
5 6 6 Engine overhaul
7 Power steering system
ENG 8 Electrical system
FUEL OVER 9 Troubleshooting
7 8
Symbols 0 to F indicate specific data:
– +
STEER ELEC 0 Special tool
A Recommended fuel
9 0 B Lubricant
C Engine speed
TRBL D Tightening torque
E Specified value, service, limit
A B F Resistance (Ω), Voltage (V), Electric cur-
rent (A)
Symbols G to J in an exploded diagram in-

C D dicate grade of lubricant and location of lu-
brication point:
T.R
G Apply Yamaha marine diesel engine oil

H Apply molybdenum disulfide oil
E F I Apply water resistant grease
(Yamaha marine grease A)
J Apply corrosion resistant grease
(Yamaha marine grease D)
G H
Symbols K and L in an exploded diagram
E M indicate grade of sealing or locking agent,
and location of application point:
I J
K Apply LOCTITE® No. 243, 271, 572
A D
L Apply ThreeBond® TB-1207B, 1322, 1324
K L
LT
TB
CONTENTS
GENERAL INFORMATION GEN
INFO 1
SPECIFICATIONS
SPEC 2
PERIODIC CHECK AND
ADJUSTMENT CHK
ADJ 3
ENGINE REMOVAL AND
INSTALLATION REM
INST 4
FUEL SYSTEM
FUEL 5
ENGINE OVERHAUL ENG
OVER 6
POWER STEERING SYSTEM
STEER 7
– +
ELECTRICAL SYSTEM
ELEC 8
TROUBLESHOOTING
TRBL 9
GEN E
INFO
CHAPTER 1
GENERAL INFORMATION
ENGINE IDENTIFICATION ...................................................................................................... 1-1
ENGINE AND PROPELLER ROTATION .................................................................................. 1-1

1
SAFETY WHILE WORKING .................................................................................................... 1-2
Fire Prevention ................................................................................................................... 1-2
Ventilation ........................................................................................................................... 1-2
Self-protection ................................................................................................................... 1-2
Oils, Greases and Sealing Fluids ...................................................................................... 1-2
Good Working Practices .................................................................................................... 1-3
SPECIAL TOOLS ..................................................................................................................... 1-5
OTHER EQUIPMENT TOOLS ................................................................................................. 1-8
HANDLING OF LIQUID GASKET............................................................................................ 1-9

Sealant Application Points and Types of Sealant to Be Applied ................................... 1-9
STANDARD ABBREVIATIONS AND SYMBOLS ................................................................. 1-10

Measurement ................................................................................................................... 1-10
Color Codes ...................................................................................................................... 1-10
GEN ENGINE IDENTIFICATION /
E
INFO ENGINE AND PROPELLER ROTATION
ENGINE IDENTIFICATION
When servicing, inspecting or ordering the
spare part of the engine or marine gear, check
the identification number as follows.
NOTE:
Because of the identification number plate
is sticked with special method, the engine
number and the serial number will be invalid
when removed.
The model and serial number plate is at-

tached on the side of the exhaust manifold.
A The different models can be identified by
checking the model and serial number plate
and using the following table.
MODEL PREFIX VARIATION SERIAL NO.
B C D A B C D
N691 P ******
ME372STI P1
N692 P ******
ENGINE AND PROPELLER ROTA-

TION
DO NOT rely on propeller rotation to be in
the same direction as engine rotation.
Engine rotation is determined by looking at
the flywheel end of the engine. The Yamaha
engines covered in this manual rotate coun-
terclockwise to the left as viewed from the
flywheel.
1-1
GEN SAFETY WHILE WORKING E
INFO
SAFETY WHILE WORKING
The procedures given in this manual are
those recommended by Yamaha to be fol-
lowed by Yamaha dealers and their mechan-
ics.
Fire Prevention
When handling fuel, be sure to keep away
from any open flames or heated materials.
If spiIling fuel, wipe it off immediately.
Ventilation
Engine exhaust gases are harmful to health.
When test-running an engine indoors, main-
tain good ventilation.
Self-protection
Protect your eyes with suitable safety glasses
or safety goggles, when grinding or when
doing any operation which may cause par-
ticles to fly off. Protect hands and feet by
wearing safety gloves or protective shoes if
appropriate to the work you are doing.
Oils, Greases and Sealing Fluids

Use only genuine Yamaha oils, greases and
sealing fluids or those recommended by
Yamaha.
1-2
INFO
NOTE:
Under normal conditions or use, there should
be no hazards from the use of the lubricants
mentioned in this manual, but safety is all-
important, and by adopting good safety prac-
tices, any risk is minimized. A summary of
the most important precautions is as follows:
1. While working, maintain good standards
of personal and industrial hygiene.
2. Clothing which has become contami-
nated with lubricants should be changed
as soon as practicable, and laundered be-
fore further use.
3. Avoid skin contact with lubricants; do not,
for example, place a soiled wiping-rag in
your pocket.
4. Hands and any other part of the body
which have been in contact with lubri-
cants or lubricant-contaminated clothing,
should be thoroughly washed with hot
water and soap as soon as practicable.
5. To protect the skin, the application of a
suitable barrier cream to the hands be-
fore working, is recommended.
6. A supply of clean lint-free cloths should
be available for wiping purposes.
Good Working Practices

1. The right tools
1) Use the recommended special tools to
protect parts from damage. Use the right
tool in the right manner - do not impro-
vise.
2) When checking with a tester, make sure
that battery in the tester can supply suf-
ficient power.
2. Tightening torque
Follow the tightening torque instructions.
When tightening bolts, nuts and screws,
tighten the large sizes first, and tighten in-
ner-positioned fixings before outer-posi-
tioned ones.
3. Non-reusable items
Always use new gaskets, packings, O-rings,
split-pins, circlips, etc., on reassembly.
1-3
INFO
4. Disassembly and Assembly
1) Clean parts with compressed air when
disassembling.
2) Oil the contact surfaces of moving parts
before assembly.
3) After assembly, check that moving parts

operate normally.
4) Install bearings with the manufacturer’s

markings on the side exposed to view,
and liberally oil the bearings. Press the
bearing at the outer race when install-
ing it in the bearing case, and press it at
the inner race when installing it on the
shaft. Keep bearing parallel to the case
or the shaft during the press fitting.
5) When installing oil seals, apply a light
coating of water-resistant grease to the
lip and the outside diameter.
CAUTION:
When inspecting and servicing, stop the en-
gine except inspection or service is needed
immediately. And wait for the engine cool-
ing down.
1-4
GEN SPECIAL TOOLS E
INFO
SPECIAL TOOLS
The proper special tools are necessary for complete and accurate adjustment and assembly.
Using special tools will help avoid damage caused by the use of improper tools or incorrect
procedures.
(These special tools are recommended by Yamaha. The tool numbers indicated below are those of TOYOTA Motor
Corporation, except for the tools marked with *.)
ILLUSTRATION TOOL No. TOOL NAME REMARKS

09275-54011 Plunger stroke measur- To Check injection timing
ing tool
90890-07603 Compression gauge To measure compression

attachment
09213-58013 Crankshaft pulley To secure crankshaft pulley

holding tool
09223-56010 Crankshaft rear oil seal To install crankshaft rear oil seal
replacer
09223-78010 Crankshaft oil seal To install crankshaft front oil seal

replacer
09308-10010 Oil seal puller To remove crankshaft front oil seal
09330-00021 Companion flange To secure crankshaft pulley

holding tool
09032-00100 Oil pan seal cutter To remove oil pan
09201-10000 Valve guide bush re-

mover & replacer set
• 09201-01080 Valve guide bush remover To remove and install valve guide bush
& replacer 8
09202-70020 Valve spring compressor To remove and install valve
09214-76011 Crankshaft pulley To install injection pump drive gear oil

replacer seal
1-5
GEN SPECIAL TOOLS E
INFO
09222-58020 Connecting rod bush
remover & replacer
Remover & replacer To remove and install connecting rod

bush
Guide To install connecting rod bush
Base To remove and install connecting rod

bush
Cover & seal replacer To mount crankshaft timing gear and

pump drive shaft gear
09950-40011 Puller B set
• 09951-04010 Hanger 150 To remove camshaft timing pulley,

pump drive shaft gear, crankshaft tim-
ing gear, and injection pump drive gear
bearing
• 09952-04010 Slide arm To remove camshaft timing pulley,
bearing
• 09953-04020 Center bolt 150 To remove camshaft timing pulley,
bearing
• 09954-04010 Arm 25 To remove camshaft timing pulley,
bearing
• 09955-04011 Claw No. 1 To remove injection pump drive gear
bearing
• 09955-04061 Claw No. 6 To remove camshaft timing pulley,

bearing
• 09957-04010 Attachment To remove injection pump drive gear
bearing
1-6
GEN SPECIAL TOOLS E
INFO
09950-50013 Puller C set
• 09951-05010 Hanger 150 To remove crankshaft pulley and injec-

tion pump drive gear
• 09952-05010 Slide arm To remove crankshaft pulley and injec-

• 09953-05010 Center bolt 100 To remove injection pump drive gear
• 09953-05020 Center bolt 150 To remove crankshaft pulley
• 09954-05021 Claw No.2 To remove crankshaft pulley and injec-

*TCP-2TB Turbocharger pressure To check for leakage from nozzle leak-

(from BANZAI) gauge age pipe #1
09820-63010 Alternator wrench To remove and install alternator pul-

ley
09286-46011 Alternator bearing puller To remove alternator rectifier end fram

and starter motor armature bearing
09820-00021 Alternator bearing puller To remove alternator rotor bearing
09215-00100 Camshaft bearing To remove and install camshaft bear-

remover and replacer ing
1-7
GEN OTHER EQUIPMENT TOOLS E
INFO
OTHER EQUIPMENT TOOLS
TOOL NAME REMARKS
Vernier caliper
Outside micrometer 0 ~ 25 mm, 25 ~ 50 mm, 50 ~ 75 mm, 75 ~ 100 mm
V Block
Power wrench (4 times)
Cylinder gauge 50 ~ 150 mm
Battery hydrometer
Radiator cap tester
Compound (Red lead)
Valve lapping compound
Hand valve lapper
Piston ring tool
Piston oil heater
Piston vise
Piston ring compressor
Straight edge
Square gauge
Plasti gauge
Surface plate
Digital circuit tester
Oil pressure gauge 0 ~ 500 kPa
Thickness gauge (Filler gauge)
Torque wrench ~ 100 kgf/cm, ~ 450 kgf/cm, ~ 900 kgf/cm, ~ 1800 kgf/cm
Dial gauge
Magnetic base
Heater gun
Flat chisel
Diesel compression gauge set
Diesel tacho tester
Nozzle tester
Snap ring plier
Pin punch
Thermometer 100 °C
Power steering pump pulley remover
Power steering pump pulley replacer
1-8
GEN HANDLING OF LIQUID GASKET E
INFO
HANDLING OF LIQUID GASKET
Sealant Application Points and Types of Sealant to Be Applied
Sealant types to be Standing time Reference
Sealant application points required after
applied assembly page No.
Stiffening plate x Cylinder block 6-119
Plug x Cylinder block 6-162
Heat exchanger x Gasket 6-22
ThreeBond® TB-1207B 2 hours
Heat exchanger side plates x Gasket 6-22
Intercooler rear side x Gasket 6-34
Oil pan x Stiffening plate 6-119
Cylinder head x Tight plug –
ThreeBond® TB-1324 1 hour
Cylinder block x Tight plug –
®
Rear engine mount x Between the nut and bolt ThreeBond TB-1322 1 hour 4-5
2-stage rate coupling x Damper stud threads 6-6
LOCTITE® No. 271 2 hour
2-stage rate coupling x Nuts 6-6
Screw x Seawater pump 6-15
Heat exchanger x Bolt threads 6-22
®
Intercooler x Seawater sender threads LOCTITE No. 572 6 hour 6-33
Intercooler x Elbow joint threads 6-33
Intake pipe x Joint plug threads 6-55
Heat exchanger x Anodes 3-38
Intercooler x Anodes 3-38
Mixing elbow x Plug 6-61
®
Mixing elbow x Joint plug LOCTITE No. 243 1 hour 6-61
Oil cooler cover x Oil pressure switch 6-125
Thermostat housing x Thremo switch 6-25
Thermostat housing x Water temperature sensor 6-25
1-9
GEN STANDARD ABBREVIATIONS AND SYMBOLS E
INFO
STANDARD ABBREVIATIONS AND SYMBOLS
Measurement
m : meter ft or ’ : foot The following abbreviations and symbols are

used:
mm : millimeter in or ”: inch
L : liter gal : U.S. gallon
N·m : Newton meter lb·ft : pounds foot
Kgf·m : kilogram meter lb·in : pounds inch
m3 : cubic meter ft3 : cubic foot
Color Codes
B : Black P : Pink Wiring diagrams use the following standard

abbreviations:
Br : Brown Pu : Purple
For wires which use tracer stripes, the main
G : Green R : Red color is followed by a slash (or dash) and then
Gy : Gray Sb : Sky blue the tracer color.
L : Blue T : Tan For example:
Lg : Light green W : White R/G = Red wire with a green tracer stripe
O : Orange Y : Yellow Y/R = Yellow wire with a red tracer stripe
1-10
SPEC E
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS .................................................................................................. 2-1
MAINTENANCE SPECIFICATIONS ........................................................................................ 2-4
2
Engine ................................................................................................................................. 2-4
Fuel System ........................................................................................................................ 2-8
TIGHTENING TORQUE ........................................................................................................... 2-9

Joints and Gaskets for Engine Piping ............................................................................ 2-11
TORQUE SPECIFICATIONS .................................................................................................. 2-12

Tightening Torque Specifications for Standard Bolts and Nuts ................................... 2-13
Pre-coated Bolts (With Seal-locking Agent Applied on the Threads) .......................... 2-14
Plastic Region Tightening ................................................................................................ 2-15
SPEC GENERAL SPECIFICATIONS E
GENERAL SPECIFICATIONS
ME372STI
MODEL
ITEMS P1
UNIT
(N691, N692)
GENERAL:
Base engine DAIHATSU 14B
Engine type Water cooled-4-stroke, OHV diesel
Number of cylinders 4
Combustion chamber type Direct injection
Fuel type Grade 2-D ASTMD975 or EN590
Minimum cetane rating: 48
Max. output at flywheel end *1 kW (HP) r/min. 123 (165)/3400
Max. output at flywheel end *2 kW (HP) r/min. 120 (161)/3400
Max. output at propeller end *1 kW (HP) r/min. 118 (158)/3400
Max. output at propeller end *2 kW (HP) r/min. 115 (154)/3400
Bore mm 102
Stroke mm 112
Total displacement L 3.66
Compression ratio 16.5
Compression pressure (standard) kPa/r/min. 2844 ± 196/220
Compression pressure (maintenance limit) kPa/r/min. 2200/220
Injection order 1–3–4–2
Max. no-load speed r/min. 3800
Propeller matching speed r/min. 3470 – 3570
Engine idling speed r/min. 650 – 700
Engine dry weight kg 370
VALVE SYSTEM:
Driving mechanism OHV
Valve clearance IN mm 0.2 – 0.25
(hot engine) EX mm 0.36 – 0.4
FUEL SYSTEM:
Injection pump type Distribution injection (VE type)
Governor type Mechanical all speed type
Rotation direction
Clockwise
(viewed from drive gear)
Injection timing (static) degree/BTDC 18.5
Plunger stroke
mm (in.) 1.19 (0.03)
(with dial gauge)
Injector Type Multiport (long stem type)
Number of injection port 4
Valve opening 19.61 + 0.98
MPa
pressure – 0
Fuel filter Integrated with sedimenter
LUBRICATION SYSTEM:
Engine oil type API/SAE CD or CE/15W-40
Engine oil capacity (with oil filter) L Max. 5.7, Min. 3.7
Oil pressure at idling *3 kPa Min. 49
at 3400 r/min. *4 kPa Min. 294
Oil pump type Trochoid pump (5 lobes (inner rotor),
6 divisions (outer rotor))
Oil cooler Coolant multiplate type
Lubrication system Full flow type
Oil filter Full-flow, spin-on type
2-1
ME372STI
MODEL
ITEMS P1
UNIT
(N691, N692)
COOLING SYSTEM:
Cooling mechanism Indirect fresh water cooling type
Coolant capacity L 11.8
Heat exchanger Seawater cooling multipipe type
Seawater pump Rubber impeller type
Seawater pump max. discharge L/min. 94 ± 10
Coolant pump Centrifugal pump
Coolant cap opening pressure kPa 88
Coolant temperature (at max. output) °C 82 ± 3 *5
Thermostatic valve opening temperature °C 76.5 ± 2
INTAKE, EXHAUST SYSTEM:
Turbo charging system Exhaust turbo-supercharging
Turbocharger type Water cooled turbine
CT26AC (Aisan)
Charge air pressure (at max. output) kPa 125.5 ± 10
Intercooler Seawater cooling multipipe type
Air filter Air-purifying type
Exhaust back pressure (at max. output) kPa 25.3 ± 2.7
ELECTRICAL SYSTEM:
System voltage V 12
Recommended battery capacity AH 110 or more
Starter motor output kW 2.5
Alternator output A 80
Pre-heating system Glow plug
Pre-heating lamp turn-out time sec 4 ± 0.4
Oil pressure switch operating pressure kPa 29.4 ± 9.8
Water temperature switch
°C 100 ± 2
operating temperature
Fuse Trim motor A 100
Charging system A 100
Meter, Power trim switch A 20
2-2
ME372STI
MODEL
ITEMS P1
UNIT
(N691, N692)
OTHERS:
Power steering fluid Automatic Transmission Fluid (ATF) Dexron® Type II
Power steering fluid capacity L 0.7
Belt deflection Alternator
New mm 10.5 – 12.5 (per belt)
(with pressure
of 100 N (10 kg))*6
At service mm 13 – 15 (per belt)
Power New mm 19 – 20 (per belt)

steering
pump At service mm 21 – 23 (per belt)
NOTE:
*1: Output power at 25 °C fuel temperature: Power steering Tension pulley Circulation
pump pump
ISO 3046-1.
*2: Output power at 40 °C fuel temperature:
ISO 8665.
*3: Oil temperature at main gallery: 70 – 80 °C
*4: Oil temperature at main gallery: 110 –
120 °C. Checking point 2
*5: At seawater inlet temperature 28 °C.
*6: See the figure on the right for belt deflec-
tion checking point. Checking point 1
Checking point 1:
Midpoint of the belt between the circula-
tion pump pulley and the power steering
pump pulley
Checking point 2: Alternator
Crank pulley
Midpoint of the belt between the circula-
tion pump pulley and the alternator pul-
ley
2-3
SPEC MAINTENANCE SPECIFICATIONS E
MAINTENANCE SPECIFICATIONS
Engine
Model
Item Unit
ME372STI P1
Cylinder head:
Warpage Limit mm (in.) 0.20 (0.0079)
New Cylinder head gasket thickness
Cutout number “1.5” mm (in.) 1.5 (0.0591)
Cutout number “1.6” 1.6 (0.0630)
Cutout number “1.7” 1.7 (0.0669)
Cylinder:
Cylinder head surface warpage
Limit mm (in.) 0.20 (0.0079)
Cylinder bore diameter
STD Mark “1” 102.000 – 102.010 (4.0157 – 4.0161)
Mark “2” 102.010 – 102.020 (4.0161 – 4.0165)
Mark “3” 102.020 – 102.030 (4.0165 – 4.0169)
Limit STD 102.18 (4.0228)
Main journal bore diameter
(Reference) STD Mark “1” 75.000 – 75.012 (2.9528 – 2.9532)
Mark “2” 75.012 – 75.024 (2.9532 – 2.9537)
Piston/Piston ring:
Piston diameter
STD Mark “1” mm (in.) 101.83 – 101.84 (4.0091 – 4.0094)
Mark “2” 101.84 – 101.85 (4.0094 – 4.0098)
Mark “3” 101.85 – 101.86 (4.0098 – 4.0102)
Piston to cylinder clearance STD 0.16 – 0.18 (0.0063 – 0.0071)
Limit 0.25 (0.0098)
Piston ring groove clearance
Top 0.08 – 0.12 (0.0031 – 0.0047)
2nd 0.04 – 0.08 (0.0016 – 0.0031)
Oil 0.030 – 0.070 (0.0012 – 0.0028)
Piston ring end gap
Top 0.35 – 0.50 (0.0138 – 0.0197)
2nd 0.45 – 0.60 (0.0177 – 0.0236)
Oil 0.20 – 0.40 (0.0079 – 0.0157)
Limit Top 1.30 (0.0512)
2nd 1.40 (0.0551)
Oil 1.20 (0.0472)
2-4
Model
Item Unit
ME372STI P1
Camshaft:
Thrust clearance STD mm (in.) 0.06 – 0.13 (0.0024 – 0.0051)
Limit 0.30 (0.0118)
Journal oil clearance STD 0.025 – 0.066 (0.0010 – 0.0026)
Limit 0.10 (0.0039)
Journal diameter
#1 Journal STD 53.459 – 53.475 (2.1047 – 2.1053)
#2 Journal 53.209 – 53.225 (2.0948 – 2.0955)
#3 Journal 52.959 – 52.975 (2.0850 – 2.0856)
#4 Journal 52.709 – 52.725 (2.0752 – 2.0758)
#5 Journal 52.459 – 52.475 (2.0653 – 2.0659)
Runout Limit 0.04 (0.0016)
Cam lobe height
STD Intake 44.879 – 44.961 (1.7669 – 1.7701)
Exhaust 45.050 – 45.140 (1.7736 – 1.7772)
Limit Intake 44.45 (1.7500)
Exhaust 44.62 (1.7567)
Connecting rod:
Limit 0.40 (0.0157)
Connecting rod oil clearance STD 0.03 – 0.07 (0.0012 – 0.0028)
Limit 0.10 (0.0039)
Connecting rod bearing center wall thickness
Mark “2” 1.485 – 1.490 (0.0585 – 0.0587)
Rod bending
Limit per 100 mm (3.94 in.) 0.05 (0.0020)
Twist
Limit per 100 mm (3.94 in.) 0.05 (0.0020)
Bushing inside diameter Mark “1” 34.009 – 34.014 (1.3389 – 1.3391)
Mark “2” 34.014 – 34.019 (1.3391 – 1.3393)
Piston pin diameter Mark “1” 34.000 – 34.005 (1.3386 – 1.3388)
Mark “2” 34.005 – 34.010 (1.3388 – 1.3390)
Piston pin oil clearance: STD 0.004 – 0.014 (0.0002 – 0.0006)
Limit 0.05 (0.0020)
Big end inner diameter
Mark “2” 64.01 – 64.02 (2.5201 – 2.5205)
2-5
Model
Item Unit
ME372STI P1
Crankshaft:
Limit 0.30 (0.0118)
Main journal oil clearance
STD (Except #3 journal) 0.030 – 0.074 (0.0012 – 0.0029)
Limit 0.10 (0.0039)
STD (#3 journal) 0.060 – 0.104 (0.0024 – 0.0041)
Limit 0.15 (0.0059)
Main journal bearing center wall thickness
(reference) STD Mark “1” 2.408 – 2.485 (0.0948 – 0.0978)
Mark “2” 2.485 – 2.490 (0.0978 – 0.0980)
Main journal diameter STD
STD (Except #3 journal) 69.98 – 70.00 (2.7551 – 2.7559)
STD (#3 journal) 69.95 – 69.97 (2.7539 – 2.7547)
U/S 0.25 69.74 – 69.75 (2.7457 – 2.7461)
U/S 0.50 69.49 – 69.50 (2.7358 – 2.7362)
U/S 1.00 68.99 – 69.00 (2.7161 – 2.7165)
Crank pin oil clearance STD 0.030 – 0.070 (0.0018 – 0.0028)
Limit 0.10 (0.0039)
Crank pin diameter STD 60.98 – 61.00 (2.4008 – 2.4016)
U/S 0.25 60.74 – 60.75 (2.3913 – 2.3917)
U/S 0.50 60.49 – 60.50 (2.3815 – 2.3819)
U/S 1.00 59.99 – 60.00 (2.3618 – 2.3622)
Circle runout Limit 0.08 (0.0031)
Main journal taper and out-of-round
Limit 0.02 (0.0008)
Crank pin taper and out-of-round
Limit 0.02 (0.0008)
Valve, valve seat, valve guide:
Valve clearance (hot) Intake mm (in.) 0.2 – 0.25 (0.0079 – 0.0098)
Exhaust 0.36 – 0.4 (0.0142 – 0.0157)
Valve overall length
STD Intake 126.55 (4.9823)
Exhaust 126.42 (4.9772)
Limit Intake
126.05 (4.9626)
Exhaust
Valve face angle °(deg.) 44.5
Stem diameter Intake mm (in.) 8.968 – 8.984 (0.3531 – 0.3537)
Exhaust 8.954 – 8.970 (0.3525 – 0.3531)
Stem oil clearance
STD Intake 0.026 – 0.062 (0.0010 – 0.0024)
Exhaust 0.040 – 0.076 (0.0016 – 0.0030)
Exhaust 0.12 (0.0047)
2-6
Model
Item Unit
ME372STI P1
Margin thickness
STD Intake mm (in.) 1.3 – 1.5 (0.052 – 0.059)
Exhaust 1.7 – 1.9 (0.067 – 0.075)
Exhaust 1.3 (0.051)
Valve guide bushing
Inside diameter 9.01 – 9.03 (0.3547 – 0.3555)
Outside diameter 14.023 – 14.041 (0.5521 – 0.5528)
Valve seat
Refacing angle Intake
°(deg.) 30, 45, 60
Exhaust
Contacting angle °(deg.) 45
Contacting width Intake
mm (in.) 1.9 – 2.3 (0.0748 – 0.0906)
Exhaust
Valve spring:
Free length
Outer spring mm (in.) 50.73 (1.9972)
Inner spring 45.28 (1.7827)
Installed tension
at 41.69 mm (1.6413 in.) outer spring kgf (lbf, N) 28.3 (62.4, 277)
Limit 25.5 (56.2, 250)
at 38.19 mm (1.5035 in.) Inner spring kgf (lbf, N) 13.8 (30.4, 135)
Limit 12.4 (27.3, 122)
Spring tilt Limit mm (in.) 2.0 (0.075)
Valve lifter:
Lifter diameter mm (in.) 26.955 – 26.975 (1.0612 – 1.0620)
Cylinder block lifter bore diameter 27.01 – 27.03 (1.0634 – 1.0642)
Oil clearance STD 0.035 – 0.075 (0.0014 – 0.0030)
Limit 0.10 (0.0039)
Push rod:
Circle runout Limit mm (in.) 0.5 (0.0197)
Timing gear:
Idler gear inside diameter mm (in.) 45.000 – 45.025 (1.7717 – 1.7726)
Idler gear shaft diameter 44.935 – 44.955 (1.7691 – 1.7699)
Idler gear oil clearance STD 0.045 – 0.090 (0.0018 – 0.0035)
Gear backlash STD 0.06 – 0.16 (0.0024 – 0.0063)
Limit 0.30 (0.0118)
Idler gear thrust clearance STD 0.06 – 0.17 (0.0024 – 0.0067)
Limit 0.30 (0.0118)
2-7
Model
Item Unit
ME372STI P1
Oil pump:
Body clearance STD mm (in.) 0.06 – 0.15 (0.0024 – 0.0059)
Limit 0.20 (0.0079)
Side clearance STD 0.03 – 0.09 (0.0012 – 0.0035)
Limit 0.15 (0.0059)
Tip clearance STD drive 0.22 – 0.25 (0.0087 – 0.0098)
driven 0.15 – 0.21 (0.0059 – 0.0083)
Limit 0.30 (0.0018)
Fuel System
Model
Item Unit
ME372STI P1
Injection nozzle:
Nozzle type – DLL-P
Nozzle opening pressure kgf/cm2 (MPa) 200 – 210 (19.61 – 20.59)
Injection pump:
Direction of rotation – Clockwise as seen from drive side
Injection order – 1–3–4–2
2-8
SPEC TIGHTENING TORQUE E
TIGHTENING TORQUE
Tightening torque Reference
Part to be tightened Remarks
N·m kgf·m lbf·ft Page No.
ENGINE:
2-stage rate coupling and flywheel:
Damper joint nut 5.6 0.57 4.1 LT 271 6-6
Coupling - Outer member 67 6.8 49 6-6
Flywheel - Crankshaft 157 16 116 6-7
Flywheel - Coupling assembly 29 3.0 22 6-7
Rear-end plate 18 1.8 13 6-7
Timing gears:
Idler gear thrust plate 47 4.8 35 6-81
Timing gear cover (M8 bolt) 18 1.8 13 6-81
(M10 bolt) 37 3.8 27 6-81
Crankshaft pulley #1 294 30 217 6-82
Cylinder head:
Cylinder head cover (nut) 9.8 1.0 7.2 6-109
(bolt) 9.8 1.0 7.2 6-109
Rocker arm support 25 2.5 18 6-109
Cylinder head 49 N·m (5.0 kgf·m, 36 lbf·ft) + 6-108
Plastic region tightening (90° + 90°)
Exhaust manifold (nut) 43 4.4 31 6-62
Glow plug 13 1.3 9.4 6-109
Injection nozzle clamp holder(nut) 18 1.8 13 5-5
Cylinder block:
Check valve 34 3.5 25 6-131
Main bearing cap 196 20 145 6-165,6-155
Connecting rod cap 69 N·m (7.0 kgf·m, 51 lbf·ft) + 6-166, 6-158
Plastic region tightening (90°)
Oil seal retainer 18 1.8 13 6-168
Engine bracket - Cylinder block 113 11.5 83 6-168
Heat exchanger bracket - Cylinder block 113 11.5 83 6-168
LUBRICATION SYSTEM:
Relief valve plug 34 3.5 25 6-125
Timing gear case (M8 bolt) 18 1.8 13 6-118
(M10 bolt) 37 3.8 27 6-118
Oil strainer (nut) 18 1.8 13 6-119
(bolt) 18 1.8 13 6-119
Oil pan (nut) 25 2.6 19 6-119
(bolt) 25 2.6 19 6-119
Oil level gauge guide union bolt 34 3.5 25 6-119
Oil cooler cover 15 1.5 11 6-125
2-9
Tightening torque Reference

Part to be tightened Remarks
N·m kgf·m lbf·ft Page No.
FUEL SYSTEM:
Injector body - Nozzle retaining nut 69 7.0 51 –
Injection nozzle holder 18 1.8 13 5-5
Leakage pipe hollow bolt 25 2.5 18 5-5
Injection pipe flare nut 25 2.5 18 5-5
Pickup (tacho) sensor 21 2.1 15 5-12
Fuel cut solenoid 22 2.2 16 5-11
Fuel cut solenoid lead 1.7 0.17 1.2 5-11
Injection pump - Gear case 18 1.8 13 5-13
Injection pump - Pump stay 18 1.8 13 5-13
Fuel delivery pipe hollow bolt 25 2.5 18 5-14
COOLING SYSTEM:
Circulation pump - Cylinder head 25 2.5 18 6-67
Circulation pump pulley 20 2.0 14 6-68
Thermo switch 34 3.5 25 LT 572 8-52
Water temperature sensor 11 1.1 7.9 LT 572 8-51
Seawater pump driven gear 74 7.5 55 6-16
Seawater pump cover 1.9 0.2 1.4 6-18
Heat exchanger side plate 12 1.2 8.7 6-22
TURBOCHARGER SYSTEM:
Turbocharger:
Oil pipe hollow bolt 11 1.1 7.9 6-53
Coolant by-pass pipe hollow bolt 20 2.0 14 6-53
Intake pipe - Plug 9.8 1.0 7.2 6-55
Intercooler:
Seawater flow sender 50 5.1 37 LT 572 6-33
Side cover 11 1.1 7.9 6-34
ELECTRICAL SYSTEM:
Starter motor terminal 8.8 0.9 6.5 8-25
Alternator wrench “B” 39 4.0 29 8-33, 8-41
Alternator wrench “A” (drive pulley) 109 11 80 8-41
Alternator terminal 7.8 0.8 5.8 8-44
OTHER ITEMS:
Power steering hose (small fitting) 15 1.5 11 7-5
Power steering hose (large fitting) 34 3.5 25 7-5
RIGGING:
Rear engine mount 55 5.6 41 4-6
Drive unit assembly nut: 1st 29 N·m (3.0 kgf·m, 21 lbf·ft) + Self-locking 4-6
2nd 69 N·m (7.0 kgf·m, 51 lbf·ft) nut
Front engine mount bracket 137 14 101 4-4
2-10
Joints and Gaskets for Engine Piping

unit: N·m (kgf·m)
Seal type Metal seal type
Gasket seal type
Screw size Flared pipe Nipple connector
M8 13 (1.3)
M10 20 (2.0) 11 (1.1)
M12 25 (2.5) 20 (2.0)
M14 25 (2.5) 31 (3.2)
M16 29 (3.0) 39 (4.0)
M18 39 (4.0) 59 (6.0)
M20 *39 (4.0) 64 (6.5) 20 (2.0)
M24 69 (7.0)
M28 *127 (13.0)
Metal seal type

Gasket seal type Type A Type B
(with flared pipe) (with nipple connector)
Joint bolt
Flare pipe
Gasket Connector Sealing face: 3 places
Flare nut Nut
Joint bolt Connector
Sealing face: nipple
4 places
Integrated eye Gasket
Flared connector
joint with wing Gasket Sealing face: Gasket
Gasket 5 places
¡ Always check each seating face (matching part, pipe joint, gasket, etc) before assembly, so
that there is no dirt or burrs on it.
¡ Pipes have certain allowance to facilitate assembly, and seating faces tend to slant. To
prevent any leakage, temporarily tighten the joint at first, and then tighten it to the speci-
fied torque.
¡ Apply the regular pressure after tightening, and check for any leakage.
* Do not reuse the soft washer #4840FR-N (compressed aluminum + carbon) once it is loos-
ened or removed. Always use a new one.
2-11
SPEC TORQUE SPECIFICATIONS E
TORQUE SPECIFICATIONS
Torque figures indicated in this manual are
valid for non-greased or non-oiled threads
and heads unless otherwise specified.
Therefore, do not grease or oil cap screws
unless otherwise specified in this manual.
NOTE:
A variation of ± 10 % is permissible for all
torques indicated in the following charts.
¡ WARNING
Use only metric tools on metric hardware.
Other tools may not fit properly. They may
slip and cause injury.
NOTE:
Check tightness of cap screws periodically.
Torque values listed are for general use only.
Do not use these values if a different torque
value or tightening procedure is listed for a
specific application.
Tighten cap screws having lock nuts to ap-
proximately 50 % of amount shown in the
charts.
2-12
Tightening Torque Specifications for Standard Bolts and Nuts

Torque values indicated in the table below are valid for dry and clean ISO standard threads
under the room temperature. Torque values for special component part or assembly are indi-
cated in the applicable service manual. Where multiple bolts are used to install a component
part, tighten them in a crisscross pattern and in multiple passes until the applied torque reaches
the specified value, in order to prevent them from being distorted.
(1) How to determine the required tightening torque

1. Required tightening torque for bolts
Identify the class of bolt strength based on the table below, and choose the corresponding
torque value from the Required Tightening Torque Table shown in the following page of
this manual.
2. Required tightening torque for nuts
Follow the steps described in 1 above for the bolt to be fitted with the nut.
(2) How to identify the class of bolt strength

1. Identification by the actual bolt configuration
Configurations and marks Class Configurations and marks Class
Hexagon Protruding, or 4=4T Hexagon Three protruding 8T
head bolt stamped number 5=5T head bolt lines
on the bolt head 6=6T
7=7T Stud bolt No mark 4T
No mark 4T
Hexagon No mark 4T
flange Dimple(s) of 6T
bolt w/washer about 2 mm
hexagon bolt diameter on one
Hexagon Two protruding 5T or both of the bolt
head bolt lines on the bolt ends
head Welded 4T
Hexagon Two protruding 6T bolt
flange lines on the bolt
bolt w/washer head
hexagon bolt
2-13
Nominal Specified torque

Pitch
Class Diameter Hexagon head bolt Hexagon flange bolt
(mm)
(mm) N·m kgf·m lbf·ft N·m kgf·m lbf·ft
6 1 5 0.5 3.7 6 0.6 4.4
8 1.25 13 1.3 9.6 14 1.4 10.3
10 1.25 26 2.7 19.2 29 3.0 21.4
4T
12 1.25 48 4.9 35.4 54 5.5 39.8
14 1.5 76 7.8 56.1 85 8.7 62.7
16 1.5 115 11.7 84.8 – – –
6 1 7 0.7 5.2 8 0.8 5.9
8 1.25 16 1.6 11.8 18 1.8 13.3
10 1.25 33 3.4 24.3 36 3.7 26.6
5T
12 1.25 60 6.1 44.3 67 6.8 49.4
14 1.5 93 9.5 68.6 105 10.7 77.4
16 1.5 140 14.3 103.3 – – –
6 1 8 0.8 5.9 9 0.9 6.6
8 1.25 19 1.9 14.0 21 2.1 15.5
10 1.25 40 4.1 29.5 44 4.5 32.5
6T
12 1.25 73 7.4 53.8 81 8.3 59.7
14 1.5 110 11.2 81.1 125 12.8 92.2
16 1.5 175 17.9 129.1 – – –
6 1 11 1.1 8.1 12 1.2 8.9
8 1.25 26 2.7 19.2 29 3.0 21.4
10 1.25 53 5.4 39.1 59 6.0 43.5
7T
12 1.25 97 9.9 71.5 105 10.7 77.4
14 1.5 150 15.3 110.6 170 17.3 125.4
16 1.5 230 23.5 169.6 – – –
CAUTION:
A variation of ± 10 % is permissible for all torques indicated in the table above.
Pre-coated Bolts (With Seal-locking Agent Applied on the Threads)
(1) Do not use the pre-coated bolt as it is

when it is in any of the following condi-
tions.:
1. When a pre-coated bolt is removed.
2. When a pre-coated bolt is tightened as a
result of torque check.
SEAL-LOCKING AGENT NOTE:
Criteria of the torque check should be set at
the lower limit of the allowable tightening
torque range. Tighten the pre-coated bolt
again by the following procedure if it is tight-
ened during the check.
(2) How to reuse a pre-coated bolt

1. Clean up the bolt and the tapped hole. (Clean the tapped hole when a new part is used.)
2. Dry them completely by compressed air or other means.
3. Apply the specified seal-locking agent (LOCTITE® No. 572) on the bolt threads.
2-14
Plastic Region Tightening
CAUTION:
Plastic region tightening method is specified on some of the bolts on the engine. Follow the
steps described here, since this method is different from the conventional procedure.
1. Bolts for plastic region tightening

Cylinder head bolts
Connecting rod bearing cap bolts
2. Additional tightening procedures after
90° additional tightening
reaching the specified torque
Tighten by 90° One is to give additional tightening by
90°, and the other is by 180° (90° + 90°
Engine
tightening)
front
90° + 90° tightening

Tighten by 90°
Tighten by 90° (2nd)
(1st)
2-15
CHK E
ADJ
CHAPTER 3
PERIODIC CHECK AND ADJUSTMENT
PRE-DELIVERY INSPECTION ................................................................................................. 3-1

Engine Mounting Bolts Check........................................................................................... 3-1
Fuel System Check ............................................................................................................ 3-1
Alternator V-belt and Power Steering Pump V-belt Check ............................................. 3-2
Engine External Condition Check ..................................................................................... 3-3
Engine Oil Level Check ...................................................................................................... 3-3
Battery and Electrical Connections Check ....................................................................... 3-4
Engine Wiring Check ......................................................................................................... 3-4
RUNNING-IN ........................................................................................................................... 3-5

Points to Note for New Engine ......................................................................................... 3-5
Running-in Period .............................................................................................................. 3-5
INTRODUCTION...................................................................................................................... 3-6
Periodic Maintenance and Lubrication Interval Chart .................................................... 3-6
PERIODIC CHECKS AND ADJUSTMENTS .......................................................................... 3-12

Engine Oil Level Check .................................................................................................... 3-12
Engine Oil and Filter Replacement ................................................................................. 3-14
Oil Separator and Blow-by Gas Hose Check ................................................................. 3-17
Oil Separator and Blow-by Gas Hose Cleaning ............................................................ 3-17
Air Filter Check ................................................................................................................. 3-18
Valve Clearance Check..................................................................................................... 3-19
Valve Clearance Adjustment ........................................................................................... 3-21
Engine Idling Speed and Maximum Engine Speed (No Load) Check ......................... 3-23
Throttle Cable Adjustment .............................................................................................. 3-24
Compression Pressure Measurement ............................................................................ 3-25
Drive Belts Check ............................................................................................................. 3-27
Drive Belts Replacement ................................................................................................. 3-27
Engine Cleaning and Protection ..................................................................................... 3-29
Fuel System Check .......................................................................................................... 3-29
Fuel Line Check ................................................................................................................ 3-29
Injection Timing Check .................................................................................................... 3-30
Injection Timing Adjustment........................................................................................... 3-32
Fuel Filter Draining (Water) ............................................................................................. 3-34
Fuel Filter Replacement ................................................................................................... 3-34
CHK E
ADJ
Fuel System Air Bleeding ................................................................................................ 3-37

Seawater Strainer Cleaning ............................................................................................ 3-38
Anode Check .................................................................................................................... 3-38
Coolant Level Check ........................................................................................................ 3-39
Coolant Replacement ...................................................................................................... 3-41
Thermostat Check ............................................................................................................ 3-42
Coolant Filler Cap Check ................................................................................................. 3-43
Cooling Hose Check ......................................................................................................... 3-44
Cooling System Pressurize Check .................................................................................. 3-44
Seawater Pump Impeller Replacement ......................................................................... 3-45
Power Steering Fluid Level Check .................................................................................. 3-47
Battery Check ................................................................................................................... 3-49
3
Fuse Check ....................................................................................................................... 3-51
Fuse Replacement ........................................................................................................... 3-51
CHK PRE-DELIVERY INSPECTION E
ADJ
PRE-DELIVERY INSPECTION
Do the following inspections to prepare the
engine for delivery to the customer.
Engine Mounting Bolts Check

1. Check:
¡ Engine mounting bolts
Engine mounting bolts checking step

1) Check the proper tightening of the bolts.
Loose → Retightening.
Fuel System Check

1. Check:
¡Fuel system
Fuel system checking step

1) Check the connection of fuel pipes and
hoses.
Leakage → Retightening.
3-1
ADJ
Alternator V-belt and Power Steering
Pump V-belt Check
1. Check:
¡ Belt tension
Alternator V-belt and power steering pump

V-belt checking step
Power steering Circulation

1) To measure the belt deflection, apply ap-
Tension pulley
pump pulley pump pulley proximately 10 kgf pressing force at the
mid position on the belt using the spe-
cial tool.
Out of specification → Adjust/Replace.
NOTE:
Checking point 2
See the figure on the left for belt deflection
checking point.
Checking Point 1:
Checking point 1
Midpoint of the belt between the circulation
pump pulley and the power steering pump
pulley.
Checking point 2:
Midpoint of the belt between the circulation
pump pulley and the alternator pulley.
Alternator pulley
Crank pulley
Drive belts deflection under:
100 N (10 kgf, 22 lbf)
Alternator V-belt:
13 – 15 mm (0.51 – 0.59 in.)
[New belt: 10.5 – 12.5 mm (0.41 – 0.49 in.)]
Power steering pump V-belt:
21 – 23 mm (0.82 – 0.9 in.)
[New belt: 19 – 20 mm (0.74 – 0.78 in.)]
3-2
ADJ
Engine External Condition Check
1. Check:
¡ Engine external condition
Engine external condition checking steps

1) Touch-up with the specified paint in case
of scratches or other flaws on the coat-
ing.
2) Replace any component that has been
damaged during the transportation.
Engine Oil Level Check

1. Check:
¡ Engine oil level
Engine oil level checking step

1) Use genuine YAMAHA diesel engine oil
1
or API CD or CE grade oil, and fill it to
1
the upper limit mark A on the oil level
a gauge 1.
Low level → Fill to the proper level.
3-3
ADJ
Battery and Electrical Connections
Check
1. Check:
¡ Battery fluid level
¡ Battery charging
¡ Secure mounting
¡ Tight connection
Battery fluid level checking step

1) Check the battery fluid level.
Battery charging checking step

UPPER
LOWER
1) Check the battery charging condition
(specific gravity).
Low battery charge → Recharge.
Secure mounting checking step

1) Check the secure mounting of the bat-
tery.
Loose → Fix.
Tight connection checking step

1) Check the tight connection of battery
cables.
Loose → Retighten.
Engine Wiring Check

1. Check:
¡ Wiring connections
Engine wiring checking steps

1) Check that all the electrical wirings are
connected correctly and tightly.
2) Make sure that the engine operates cor-
rectly by the remote control.
Incorrect connection/Loose connection
→ Correct/Retighten.
3-4
CHK RUNNING-IN E
ADJ
RUNNING-IN
Give adequate advice to the customers so
that they are fully aware of the importance
of running-in for the engine.
Points to Note for New Engine

Initial handling of the new engine has a sig-
nificant influence on its life.
New engines While the engine is brand new, all sliding
should be run-in parts still lack a good fit to each other. Im-
for about 20 moderate operation during this period may
hours.
result in abnormal wear, or may give adverse
effect on the engine components.
Running-in Period
1) Through the running-in period, keep the
Keep the engine speed
engine at a speed at least 300 rpm lower
lower throughout the 20 than the full-load operation. Avoid jerky
hours of running-in period. acceleration and deceleration.
2) Following the engine start, let it warm
up for about 10 minutes.
3) Do not overload the engine (You can tell
the overloading by dark, smoky exhaust).
4) Idling the engine for 5 minutes or more
before stopping it (cooling-off operation).
5) Engine oil and engine oil filter must be
changed after the first 20 operating
hours.
6) Thereafter, change the engine oil and the
oil filter every 100 hours of operation.
CAUTION:
¡ Follow the instruction 2), 3), 4), and 6)
even after the first 20 operating hours.
¡ Lack of adequate running-in period will
substantially impair the engine durabil-
ity.
3-5
CHK INTRODUCTION E
ADJ
INTRODUCTION
This section includes all information necessary to perform the recommended periodic checks,
adjustments, maintenance and lubrication. If performed regularly and correctly, the following
checks and measures will ensure a more reliable operation and a longer engine life.
However, the following chart can only be considered as a guide to general maintenance and
lubrication. Depending on operating conditions and type of use (i.e., fishing, cruising, water
skiing, etc.), maintenance intervals may have to be reduced.
¡ WARNING
Always disconnect the negative (–) battery cable before working on the engine. This will help
prevent accidental start and electrical short-circuiting, reducing the risk of personal injury
and damage to electrical components.
Periodic Maintenance and Lubrication Interval Chart

Interval of maintenance operations may be adjusted according to the operating conditions.
The following table gives general guidelines.
The mark (¡) indicates the check-ups which you may carry out yourself. The mark (™) indi-
cates the work to be carried out by your Yamaha stern drive dealer.
Maintenance description from daily check to annual inspection
Before After first

Every 100 At least
starting 20 hours
Item Remarks hours or 6 once each
engine or 2
months year
each day months
FUEL SYSTEM
Fuel tank Check fuel level. ¡ ¡ ¡ ¡
Fuel filter Drain water. ¡* ¡* ¡* ¡*
Replace. ™ or ¡ ™ or ¡
Gauze filter Cleaning ™
Injection timing Inspection and adjustment. ™
Fuel pipe connections Check for looseness. Tighten if
™ or ¡
necessary.
LUBRICATION SYSTEM
Oil pressure lamp Check for proper operation. ¡ ¡ ¡ ¡
Engine oil Check oil level and oil leaks. ¡
Change (Warm up engine
™ or ¡ ™ or ¡ ™ or ¡
before draining).
Engine oil filter Replace. ™ or ¡ ™ or ¡ ™ or ¡
COOLING SYSTEM
Seawater strainer Check and cleaning ¡ ¡ ¡ ¡
Seawater pump Replace impeller ™ or ¡
Cooling system Check coolant water level. ¡ ¡ ¡ ¡
Replace coolant. ™ or ¡
Check coolant pressure. ™ or ¡
Anodes (Intercooler, Check for erosion. Replace if ™ or ¡
Heat exchanger) necessary. ™ or ¡ Every 100 hours
or 3 months (NOTE 1)
Water shutter Inspect pivot and shutter.
™
Replace if necessary.
3-6
CHK INTRODUCTION E
ADJ
Before After first
Every 100 At least
starting 20 hours
engine or 2
months year
each day months
ELECTRICAL SYSTEM
Meters and switches Check proper function. ¡ ¡ ¡ ¡
Warning lamp Check for proper operation. ¡ ¡ ¡ ¡
Drive belts (all) Check for cracks, weathering
and damage. Check drive belt
¡ ¡ ¡ ¡
for deflection. Adjust or
replace if necessary.
Pre-heating device Check proper function. ™ ™ ™
Battery Check electrolyte level. Add
¡ ¡ ¡ ¡
electrolyte if necessary.
Check specific gravity. Charge
™ ™
or replace if necessary.
Electrical system Check connections and
insulation. Retighten or ¡ ™ or ¡ ™ or ¡ ™ or ¡
replace if necessary.
ENGINE
Starting condition, Check, adjust if necessary.
idling speed, abnormal ¡ ™ or ¡ ™ or ¡ ™ or ¡
engine noise
Fuel, water, oil, exhaust Check for leaks.
¡ ™ or ¡ ™ or ¡ ™ or ¡
gas and intake air
Exhaust gas condition Check the color. ¡ ™ or ¡ ™ or ¡ ™ or ¡
Engine brackets Bolt retightening ¡ ™ or ¡ ™ or ¡ ™ or ¡
Rubber mount Check the rubber mount
¡ ™ or ¡ ™ or ¡ ™ or ¡
condition, and bolt retightening.
Crank pulley Bolt retightening. ™ ™ ™
Air filter Cleaning. ™ or ¡ ™ or ¡
Replace. ™ or ¡
Engine alignment Have a Yamaha stern drive dealer
™ ™
check the engine alignment.
3-7
CHK INTRODUCTION E
ADJ
Before After first
Every 100 At least
starting 20 hours
engine or 2
months year
each day months
OTHER ITEMS
Throttle cable Check fully open and fully
¡ ¡ ¡ ¡
closed operation. Lubricate.
Shift cable Check for proper operation
¡ ¡ ¡ ¡
(F⇔N⇔R). Lubricate.
Clutch system Check for proper operation
¡ ¡ ¡ ¡
(F⇔N⇔R).
Power steering system Check for proper operation. ¡ ™ or ¡ ™ or ¡ ™ or ¡
Check oil level of power
steering pump reserve tank, ¡ ™ or ¡ ™ or ¡ ™ or ¡
Add fluid if necessary.
Bolts and nuts (all) Check retightening. ¡ ™ or ¡ ™ or ¡ ™ or ¡
Hose bands and clamps Check retightening.
¡ ™ or ¡ ™ or ¡ ™ or¡
(all)
Hoses and bushings (all) Check for damage and loose-
ness. Replace or retighten if ¡ ™ or ¡ ™ or ¡ ™ or ¡
necessary.
Engine and drive unit Check and clean. Paint if
¡
exterior necessary and then apply
¡ Every 3 weeks
anticorrosion spray.
in boating season.
NOTE 1: In saltwater or mineral-laden water areas, twice as often as the specified period.
* : When the warning light is on.
3-8
CHK INTRODUCTION E
ADJ
Periodic maintenance and replacement items chart
Every Every 1000 Every 1200

Every 2
Item Remarks engine oil hours or hours or
years
change 3 years 6 years
FUEL SYSTEM
Hose clamps Check for leaks and
™ or ¡
looseness.
Hoses Check for leaks and
™ or ¡
damage.
Union gasket Check for leaks. ™ or ¡
Replace. ™
Water separator Check.
™ or ¡
(sedimenter)
Fuel filter Replace. ™ or ¡ Every year
Gauze filter Cleaning ™ Every year
Injection nozzle Check for valve-opening
pressure, spray condi- ™
tion, and dripping.
Injection timing Check, and adjust if
™ Every year
necessary.
LUBRICATION SYSTEM
Engine oil Change. ™ or ¡ Every 100 hours or 6 months (NOTE 1)
Engine oil filter Replace. ™ or ¡ Every 100 hours or 6 months (NOTE 1)
Replace. ™
INTAKE/EXHAUST SYSTEM
™ or ¡
looseness.
Hoses, bellows Check for leaks and
™ or ¡
damage.
Replace. ™
Turbocharger Check for shaft free play,
™
exhaust gas and oil leaks.
Air filter Cleaning ™ or ¡
Replace. ™ or ¡ Every year
Bolts and nuts Check for looseness.
™ or ¡ ™
Retighten if necessary.
Water shutter Check and replace if
™ Every year
necessary.
Exhaust manifold Check. ™
COOLING SYSTEM
™ or ¡
looseness.
Hoses Check for leaks and
™ or ¡
damage.
Replace. ™ ™
Replace. ™
Seawater drain plug Check for leaks. ™ or ¡
Replace. ™ ™
3-9
CHK INTRODUCTION E
ADJ

Every 2
years
Seawater pipes Replace. ™

Seawater pump Replace.
™ or ¡ Every year
impeller
Seawater pump oil seal Replace.
™ ™
and mechanical seals
Seawater pump and Replace.
™ ™
cover
Seawater strainer cover Replace. ™ ™
Mixing elbow Check. ™ ™
Anodes (Intercooler, Check, and replace if
™ or ¡ Every 100 hours or 3 months
Heat exchanger) eroded more than half.
Heat exchanger element Cleaning ™
Replace. ™
Intercooler element Cleaning ™
Replace. ™
Coolant Replace. (use Yamaha
coolant)
Cooling system Check.
™ Every year
pressure
ELECTRICAL SYSTEM
Insulation Check for damages. ™ or ¡ ™ or ¡
Connectors Check for looseness. ™ or ¡ ™ or ¡
Alternator Overhaul. ™
Starter motor Overhaul. ™
Warning sensors Replace. ™
Relays (all) Replace. ™
ENGINE
Drive belts (all) Check. ™ or ¡
Replace. ™ or ¡ ™ or ¡
Valve clearance Check, adjust if necessary. ™ ™
Engine alignment Check, adjust if
™ Every year
necessary.
Engine rubber mounts Replace. ™
Flywheel coupling Replace. ™
Engine bracket bolts Check.
(on the engine block)
Crank pulley bolt Check for looseness,
™
retighten if necessary.
Valve and valve seats Check (at the time of
™
engine overhaul).
Piston and piston rings Check (at the time of
™
engine overhaul).
Bearings (all) Check (at the time of
™
engine overhaul).
Crankshaft Check (at the time of
™
engine overhaul).
3-10
CHK INTRODUCTION E
ADJ

Every 2
years
Cylinder head Check (at the time of

™
engine overhaul).
Cylinder block Check (at the time of
™
engine overhaul).
Gears (all) Check (at the time of
™
engine overhaul).
OTHERS
Power steering oil Cleaning ™
cooler element Check. ™
Power steering pump Check. ™
Power steering cylinder Check. ™
Rubber and resin parts Replace.
™ or ¡
(all)
Hose clamps (all) Replace. ™ or ¡
Engine exterior Check, paint if necessary,
™ or ¡
and then apply
(NOTE 2)
anticorrosion spray.
NOTE 1: Every 50 hours if used for high-speed or heavy-duty operation.

NOTE 2: Every 3 weeks in boating season.
3-11
CHK PERIODIC CHECKS AND ADJUSTMENTS E
ADJ
PERIODIC CHECKS AND ADJUST-
MENTS
Engine Oil Level Check
1. Check:
¡ Engine oil level
NOTE:
Stop the engine if it is running, and wait at
least 5 minutes for the oil to drain back into
the oil pan.
Engine oil level checking steps

1) Pull out the dipstick 1, wipe it clean and
1
reinstall it all the way into the dipstick
1
tube end 2.
a
2) Oil level should be between the “F“ mark
A and the “L” mark B.
2
Out of specification → Add/Change Oil.
b
Contamination/Deterioration → Change
Oil.
CAUTION:
Be sure not to add oil above the specified
level. If the oil level is too high, oil may be
blown out through the breather pipe, result-
ing in the increased rotation resistance and
insufficient output power. Also, oil may en-
ter the combustion chamber to cause over-
heating. These problems could ultimately
lead to the engine damage.
Recommended engine oil:

15W 40 20W 40 20W 50 YAMAHA diesel engine oil
10W 40 10W 50 SAE 15W-40, API CD or CE
10W 30
5W 30 NOTE:
30 Refer to the chart and select the oil with ap-
20 propriate viscosity, which corresponds to the
–29 –18 –7 4 16 27 38 C temperature likely to be encountered before
the next oil change.
3-12
ADJ
CAUTION:
¡ The oil used should be the CD or CE class
according to the classification of the
American Petroleum Institute (API), and
should be of the appropriate viscosity.
¡ Do not neglect the oil changes. Be sure
to replace the engine oil and oil filter at
regular intervals.
¡ It is essential to change oil and filter af-
ter the first 20 hours of operation. Sim-
ply replenishing without changing the oil
will cause engine deterioration.
2. Addition:
¡ Engine oil
Engine oil addition steps

1) Remove the oil filler cap.
2) Add the recommended engine oil up to,

1 but not past, the mark A on the dipstick
1
1.
a
CAUTION:
Do not allow any foreign material to enter
into the engine.
3) Reinstall the dipstick and oil filler cap.

4) Start the engine and let it warm up for
several minutes.
5) Stop the engine and check the oil level
again.
NOTE:
Before checking the oil level, wait at least 5
minutes for the oil to drain back into the oil
pan.
¡ WARNING
Wipe off any oil spilled on the engine. Spilled
oil is a serious fire hazard.
3-13
ADJ
Engine Oil and Filter Replacement
1. Replace:
¡ Engine oil
¡ Oil filter
NOTE:
The oil filter should be replaced every time
the engine oil is changed.
Engine oil and filter replacement steps

1) Start the engine and let it warm up to
normal operating temperature.
NOTE:
Warm oil drains faster and more thoroughly
than cold oil, taking more impurities with it.
2) Stop the engine and wait at least 5 min-

utes for the oil to drain back into the oil
pan.
3) Remove the dipstick 1.
1
2
4) Drain the engine oil from crankcase
through the dipstick tube 1. Use a suc-
tion pump 2.
NOTE:
Remove the engine oil filler cap 3. This will
3
speed up the oil draining.
3-14
ADJ
5) Remove the oil filter 1 with oil filter
wrench.
1
CAUTION:
After stopping the engine, wait 5 minutes
before removing the oil filter. Otherwise, oil
will pour out of the filter opening.
¡ WARNING
Spilled oil is a serious fire hazard.
A small amount of oil may spill out when
the filter is removed. Hold a small container
or a rag under the filter while you remove it.
Hold the filter upright to avoid any spilling.
Wipe up any spilled oil with dry rags imme-
diately.
6) Clean and check the oil filter mounting

surface A.
7) Apply light coat of clean engine oil to the

O-ring 1 on the new filter 2.
1
8) Screw the filter by hand until the O-ring
just touches the mounting surface, then
2 tighten it half a turn by hand.
CAUTION:
DO NOT use a filter wrench for filter instal-
lation.
3-15
ADJ
9) Fill up the engine oil.
Refer to “Engine Oil Level Check” sec-
tion (P3-12.)

YAMAHA diesel engin oil
SAE 15W-40, API CD or CE
Engine oil capacity:

Without oil filter change
Max. 4.8 L, Min. 2.8 L
 Max. 4.2 lmp qt., Min. 2.5 lmp qt. 
 Max. 5.1 US qt., Min. 3.0 US qt. 
With oil filter change
Max. 5.7 L, Min. 3.7 L
 Max. 6.0 US qt., Min. 3.9 US qt. 
¡ WARNING
Wipe off any oil spilled on the cylinder block.
Spilled oil is a serious fire hazard.
10) Install the dipstick and oil filler cap.

11) Start the engine and check for leaks
around the filter. If leaks are found, stop
the engine immediately and reinstall the
oil filter.
12) Check the engine oil level.
CAUTION:
¡ If necessary, add the recommended oil up
to the proper level.
¡ Check the oil level regularly with the dip-
stick. Engine can get seriously damaged
if the oil level is below the minimum level.
3-16
ADJ
Oil Separator and Blow-by Gas Hose
Check
1. Check:
¡ Oil separator and blow-by gas hoses
Oil separator and blow-by gas hose check-

ing steps
1) Check the blow-by gas hoses 1 for
cracks and/or damage.
1
Cracks/Damage → Replace.
2) Check the oil separator 2 for cracks and/
2 or damage.
1
Oil Separator and Blow-by Gas Hose

Cleaning
1. Clean:
¡ Oil separator and blow-by gas hoses
Oil separator and blow-by gas hose clean-

ing steps
1) Remove the hoses, and then remove the
oil separator.
2) Replace any damaged part with a new
one.
3) Clean the oil separator and blow-by
hoses with cleaning solvent and dry
them with compressed air.
4) Reinstall all removed parts, making sure
that they are positioned correctly.
3-17
ADJ
Air Filter Check
1. Check:
¡ Air filter element and air filter frame
Air filter element and air filter frame check-

ing steps
1) Pull up the fasteners 2 on the air filter
1
2 3 cover 1.
2) Unscrew the bolt 3 and remove the air
filter cover 1.
3) Remove the air filter element 4.
CAUTION:
Never run the engine without the air filter
element. This could lead to the damage on
engine or turbocharger.
4 NOTE:
Once the air filter element 4 is removed,
5 check the air filter element 4 and the air fil-
ter frame 5 for damage.
Contamination/Damage → Clean/Replace.
4) Clean the air filter element 4.
NOTE:
Wash the air filter element with mild deter-
gent or fresh water, and dry it up before in-
stalling it on the frame.
5) Install the air filter element 4.
6) Install the air filter cover 1.
NOTE:
To attach the air filter cover to the air filter,
align the fasteners 2 with corresponding
holes, push them down until they snap into
place, and tighten the bolt 3.
1
3
Bolt (air filter cover):
1.8 N·m (0.18 kgf·m, 1.33 lbf·ft)
T.R
3-18
ADJ
Valve Clearance Check
1. Check:
¡ Valve clearance
NOTE:
¡ Make sure that the engine has been
warmed up adequately before the valve
clearance checks.
¡ To check or adjust the valve clearance,
piston in #1 cylinder must be at Top Dead
Center (T.D.C.).
Valve clearance checking steps

1) Disconnect the breather hose 1.
1
2) Remove the cylinder head cover 1 and

gasket.
1
3-19
ADJ
3) Turn the crankshaft pulley 1 clockwise,
2
and align the TDC mark A on the pulley
with the stationary mark B on the tim-
b
ing gear cover 2.
1
a
4) Check that the rocker arms on #1 cylin-

der are loose and rocker arms on #4 cyl-
IN EX IN EX
inder are tight. If not, turn the crankshaft
one full turn (360°) and realign the marks
as explained above.
#1 piston is now at TDC on the compres-
sion stroke.
#1 #2 #3 #4
FWD
5) Measure the valve clearance with a thick-

ness gauge 1 between the rocker arm
and the valve stem cap on the following
valves.
#1 Cylinder IN/EX valves
#2 Cylinder IN valve
#3 Cylinder EX valve
#4 Cylinder –
1
Standard valve clearance:
IN: 0.2 – 0.25 mm (0.007 – 0.009 in.)(hot)
EX: 0.36 – 0.4 mm (0.014 – 0.015 in.)(hot)
NOTE:
Adjust the valve clearance, if measurements
are out of specification.
6) Turn the crankshaft one full turn (360°),

and align the marks as explained in step
3).
Measure the valve clearance for other
valves.
3-20
ADJ
7) Measure the valve clearance with the
FWD
thickness gauge on the following valves.
EX IN IN EX #1 Cylinder –
#2 Cylinder EX valve
#3 Cylinder IN valve
#4 Cylinder IN/EX valves
#1 #2 #3 #4 8) Install the cylinder head cover with gas-
ket.
9) Connect the breather hose.
Valve Clearance Adjustment

1. Adjust:
¡ Valve clearance
NOTE:
Make sure that the engine has been warmed
up adequately before the valve clearance
adjustments.
Valve clearance adjustment steps
2
1) Turn the crankshaft pulley 1 clockwise,
and align the TDC mark A on the pulley
with the stationary mark B on the tim-
b ing gear cover 2.
1
a
2) Check that the rocker arms on #1 cylin-

der are loose and rocker arms on #4 cyl-
inder are tight. If not, turn the crankshaft
one full turn (360°) and realign the marks
as explained above.
#1 piston is now at TDC on the compres-
#1 #2 #3 #4 sion stroke.
FWD
3-21
ADJ
3) With the #1 piston positioned at TDC on
the compression stroke, adjust the #1
valve clearance using a thickness gauge.
The thickness gauge 1 should move
with a very slight pull.
#1 #2 #3 #4 CAUTION:
FWD Always loose the lock nut and raise the ad-
justing screws fully to the top. If the adjust-
ing screws are too low, the piston and valves
may strike each other during valve clearance
#1 cylinder adjustment.

IN: 0.2 – 0.25 mm (0.007 – 0.009 in.)(hot)
EX: 0.36 – 0.4 mm (0.014 – 0.015 in.)(hot)
4) Adjust other valves.

FWD
Turn the crankshaft by 180° counterclock-
wise viewed from the flywheel end. Ad-
just the valve clearance for each cylin-
der in the firing order.
NOTE:
#1 #2 #3 #4 ¡ Firing order: #1 – #3 – #4 – #2
¡ The cylinders are identified by the ascend-
ing numerals starting with #1 on the tim-
ing gear end cylinder.
3-22
ADJ
Engine Idling Speed and Maximum En-
gine Speed (No Load) Check
1. Check:
¡ Engine idling speed
¡ Maximum engine speed (no load)
NOTE:
¡ Warm up the engine.
¡ Check for any abnormal sound of the tap-
pets.
Engine idling speed checking steps

1) Set the shift in neutral, and make sure
3 that throttle cable returns to the neutral
position. Check that the adjusting lever
2 is in contact with the idling set screw
1
1 on the injection pump.
2) Check the engine idling speed.
Out of specification → Adjust.
2
Engine idling speed:
650 – 700 r/min.
3) Loosen the lock nut, and turn the idling

set screw 1 until the specified engine
idling speed is attained.
Maximum engine speed (no load) checking

steps
1) Check the maximum engine speed with
no load.
Out of specification → Adjust.
Maximum engine speed with no load:

3800 r/min. or lower
2) Remove the seal, and turn the maximum

speed set screw 3 to attain the speci-
fied speed.
3) Put the seal again.
3-23
ADJ
Throttle Cable Adjustment
1. Adjust:
¡ Throttle cable position
Throttle cable adjustment steps

1) Put the remote control lever in “NEU-
TRAL” .
2 mm
(0.08 in.) 2) Loosen the lock nut 1.
Flat face side
3) Check that the adjusting lever 2 touches

N the idling set screw 3.
4) Mount the adjuster nut at the throttle
cable end, maintaining approx. 2 mm
3
(0.08 in.) clearance with the throttle le-
ver end. Then, secure the adjuster nut
with the lock nut 1.
2
5) Move the remote control box lever to the

“FULL THROTTLE” , and check that the
adjusting lever 2 at the injection pump
4
end is abutted to the maximum speed
set screw 4.
6) If the adjusting lever 2 is not abutted to
the maximum speed set screw 4, repeat
2 the steps 3) to 5) above, and also check
the settings of remote control side.
3-24
ADJ
Compression Pressure Measurement
1. Measure:
¡ Compression pressure
NOTE:
Insufficient compression pressure will result
in performance loss and poor fuel economy,
or excessive oil consumption.
Compression pressure measurement steps

1) Start the engine, let it warm up, and stop.
2) Disconnect the injection pump connecter
1.
1
3) Remove all the injection nozzles.
Refer to “Injection Nozzle Removal” sec-
tion (P5-2).
4) Attach the compression gauge attach-

ment and the compression gauge.
Compression gauge attachment:

90890-07603
Nuts (compression gauge attachment):

18 N·m (1.8 kgf·m, 13.3 lbf·ft)
T.R
5) Crank the engine until the reading on the

compression gauge stabilizes.
Out of specification → Engine overhaul.
NOTE:
¡ Always use a fully charged battery to ob-
tain engine revolution of 220 r/min. or
more.
¡ This measurement must be done in as
short a time as possible.
Compression pressure:
Standard
2844 ± 196 kPa
(29.0 ± 2 kgf/cm2, 412 ± 28 psi)
Limit
2200 kPa (22.0 kgf/cm2, 319 psi)
Max. variation between cylinders
490 kPa (4.9 kgf/cm2, 70 psi) or less
3-25
ADJ
6) Repeat the measurement for other cyl-
inders.
NOTE:
If the compression pressure is low in one or
more cylinders, pour a small amount of en-
gine oil into the cylinder and measure the
compression pressure again.
Compression pressure
(with oil in the cylinder)
Reading Diagnosis
Higher than with- Piston rings and/or cyl-
out oil inder are worn or dam-
aged.
Same as without Valve is stuck or seating
oil improperly.
or:
Defective cylinder head
gasket, or piston.
7) Install the injection nozzles.

Refer to “Injection Nozzle Installation”
section (P5-5).
8) Joint the injection pump connector.
9) Air bleed the fuel feed system.
Refer to “Fuel System Air Bleeding” sec-
tion (P3-37).
3-26
ADJ
Drive Belts Check
1. Check:
¡ Drive belts
Drive belts checking steps

1) Check the drive belts 1 for cracks, wear
and/or damage.
Cracks/Wear/Damage → Replace.
1
2) Check the drive belts 1 on several spots;
twist it moderately to look at the side
faces and inner surface.
Drive Belts Replacement

1. Replace:
¡ Power steering pump V-belt
¡ Alternator V-belt
Power steering pump V-belt replacement

steps
1) Loosen the nut 1 of the adjusting pulley
3
2.
2) Turn the adjusting bolt 3 counterclock-
4 wise to ease the tension on the power
1 steering pump V-belt 4.
3) Remove the power steering pump V-belt
2
4.
4) Install the power steering pump V-belt
4. Check that it is seated properly in the
pulley groove.
5) Adjust the power steering pump V-belt
tension.
Drive belt deflection under:

100 N (10 kgf, 22 lbf)
Power steering pump V-belt:
21 – 23 mm (0.82 – 0.9 in.)
[New belt: 19 – 20 mm (0.74 – 0.78 in.)]
3-27
ADJ
Alternator V-belt replacement steps
1) Remove the power steering pump V-belt.
Refer to “Power steering pump V-belt re-
placement steps” section on the previ-
ous page.
2) Loosen the mounting bolt 2 and adjust-
ing bolt 3 on the alternator 1.
3) Push the alternator toward the engine to
ease the tension on the alternator V-belt
4.
3 4) Remove the alternator V-belt 4.
1
5) Install the new alternator V-belt 4. Check
4 that it is seated properly in the pulley
groove.
6) Adjust the alternator V-belt tension.
2
NOTE:
Pry the alternator 1 with suitable tool (rod,
or pipe) , and push it away from the engine.
Tighten the adjusting bolt 3 in this position.
Drive belt deflection under:

100 N (10 kgf, 22 lbf)
Alternator V-belt:
a
13 – 15 mm (0.51 – 0.59 in.)
[New belt: 10.5 – 12.5 mm (0.41 – 0.49 in.)]
CAUTION:
Pry only on the reinforced portions A of the
alternator housing.
3-28
ADJ
Engine Cleaning and Protection
1. Clean and protect:
¡ Engine
Engine cleaning and protection steps

1) Check the engine exterior.
2) Remove the peeling paint, and touch up
with proper paint.
3) Apply anti-rust lubrication spray.
(Yamaha Silicone Protectant or an
equivalent product)
Fuel System Check
¡ WARNING
When servicing the fuel system, pay particu-
lar attention to the following points:
¡ Make sure that the main switch is “OFF”.
¡ Diesel fuel is flammable and explosive un-
der certain conditions.
¡ DO NOT smoke, and never work close to
an open flame, a source of sparks, or in-
tense heat.
¡ Take care not to spill diesel fuel. If you
spilled some accidentally, wipe it up im-
mediately with dry rags. When the en-
gine is still hot from operation, spilled
diesel fuel could catch fire. Always allow
the engine to cool off completely before
starting to work.
Fuel Line Check
¡ WARNING
Fuel leakage from any part of the fuel sys-
tem is a fire hazard which can result in seri-
ous bodily injury or death. Careful periodic
check of the entire fuel system is mandatory.
After storage it should be even more thor-
ough. All fuel components, including fuel
tanks (whether plastic, metal or fiberglass),
fuel lines, fittings, and fuel filters should be
checked for leakage or deterioration such as
softening, hardening, swelling, or corrosion.
Any defective part must be replaced before
the engine can be used.
3-29
ADJ
Injection Timing Check
1. Check:
¡ Injection timing
Injection timing checking steps

1) Disconnect the negative (–) lead from the
battery terminal.
1 2) Loosen the injection pipe flare nuts 1
3 2 on cylinder #3 and #4, and move them
toward the engine rear.
3) Remove the distributive head bolt 2 and
the gasket 3.
4) Attach the plunger stroke measuring tool

1 and a dial gauge 2 to the distributive
head plug.
Plunger stroke measuring tool:

2 09275-54011
5) Align the crankshaft pulley markings to

set it at TDC (where the notch on the
crankshaft pulley is aligned with the in-
dicating line.).
Set the indicator to “0“ 6) Slowly turn the crankshaft counterclock-

Slowly turn when the reading of dial wise and set the indicator of the dial
counterclockwise. gauge attached to the gauge to “0” when its reading reaches
injection pump reaches its minimum.
its minimum.
CAUTION:
After setting the indicator to “0”, turn the
crankshaft back and forth a little and check
Crankshaft pulley Dial gauge that the needle really shows the minimum.
3-30
ADJ
7) Turn the crankshaft clockwise, and take
Turn clockwise. Take the reading
on the injection
the reading on the dial gauge at TDC
pump dial gauge. (where the notch on the crankshaft pul-
ley is aligned with the indicating line.).
If out of standard value, repeat the ad-
justment steps.
Standard value:
Crankshaft pulley Dial gauge 1.19 (± 0.03) mm (0.0469 (± 0.0012) in.)
CAUTION:
If the notch on the crankshaft pulley has
passed the indicating line on the cover, turn
back the crankshaft pulley largely by more
than 30 degrees. Then, try again to align the
center of the notch with the indicating line.
3-31
ADJ
Injection Timing Adjustment
1. Adjust:
¡ Injection timing
Injection timing adjustment steps

1) Loosen the 4 flare nuts on the injection
pump and another 4 flare nuts on the
injection nozzle to the extent that they
become substantially unfastened.
NOTE:
Do not remove the flare nuts on the injection
pump and those on the injection nozzle.
2) Loosen the injection pipe clamps to the

extent that they become substantially
unfastened.
CAUTION:
Without loosening the injection pipe clamps,
the stress exerted on the injection pipe will
cause the damage or the fuel leakage.
3) Loosen the 2 injection pump mounting

nuts 1, and the 2 injection pump stay
mounting bolts 2.
1
CAUTION:
Do not loosen the injection pump by more
2
than 1/4 turns.
3-32
ADJ
4) Remove the distributive head bolt and
the gasket. Attach the plunger stroke
measuring tool 1 and a dial gauge 2 to
the distributive head plug through the
space between the #3 cylinder and the
2 #5 cylinder.
5) Operate the injection pump body and ad-

just the injection timing.
a Standard value:
1.19 (± 0.03) mm (0.0469 (± 0.0012) in.)
NOTE:
b
If the stroke is shorter than the standard
value, tilt the pump toward the engine A. If
the stroke is longer than the standard value,
tilt the pump in the direction of B.
6) Tighten the injection pump mounting

nuts and the injection pump stay mount-
ing bolts, and repeat the injection tim-
ing check.
Nuts (injection pump mounting):

18 N·m (1.8 kgf·m, 13 lbf·ft)
T.R
Bolts (injection pump stay mounting):

18 N·m (1.8 kgf·m, 13 lbf·ft)
7) Remove the planger stroke measuring

tool 1 and the dial gauge 2 from the
injection pump.
3
8) Install the distributive head bolt with a
new gasket.
1
Distributive head bolt:

2 25 N·m (2.6 kgf·m, 18.4 lbf·ft)
T.R
9) Tighten the 4 injection pipe flare nuts 3

to the injection pump (2 flare nuts for
checking).
10) Tighten the 4 nuts on the injection pipe
clamps.
11) Connect the negative (–) lead to the bat-
tery terminal.
3-33
ADJ
Fuel Filter Draining (Water)
1. Drain:
¡ Water
Fuel filter draining (water) steps
NOTE:
When the water separator warning light goes
on, the water in the fuel filter must be
drained.
1 1) Remove the fuel filter cover bolts 1 and

the fuel filter cover 2.
2) Place a container under the drain screw

1.
3) Loosen the drain screw 1.
4) Drain all the water in the fuel filter.
5) Tighten the drain screw 1.
1
6) Bleed air from the fuel feed system.

tion (P3-37).
Fuel Filter Replacement

1. Replace:
¡ Fuel filter
Fuel filter replacement steps
1 1) Turn the main switch to “OFF”, and stop

the engine.
2) Turn off the fuel cock on the fuel tank.
3) Remove the fuel filter cover bolts 1 and
the cover 2.
3-34
ADJ
4) Remove the band 1.
5) Disconnect the coupler 2 (water level
sensor).
1
2
6) Remove the fuel filter 1 using the filter

wrench.
¡ WARNING
11 ¡ Fuel in the bilge is a serious fire hazard.
Hold a small container or rag under the
fuel filter while you remove it. Hold the
filter upright to avoid spilling fuel. Clean
up any spilled fuel immediately with dry
rags.
¡ Before throwing it away, pour the fuel in-
side the fuel filter into a glass and check
that there is no significant amount of
water mixed with the fuel. If there is,
water may be collecting in the boat's fuel
tank, in which case the fuel tank has to
be drained as well.
7) Remove the water level sensor 1 and

O-ring.
1
8) Check and clean the mating surfaces on

the water level sensor 1 and new fuel
filter 3.
9) Install a new O-ring 2 onto water level
3 sensor.
1
2
New
3-35
ADJ
10) Lubricate the O-ring 2 with a thin coat
of clean fuel.
1
2
11) Install the water level sensor 1.
12) Tighten the water level sensor by hand.
a 13) Clean and check the fuel filter mounting

New
surface A.
2 14) Install a new O-ring 2 onto the fuel filter
1.
1
15) Lubricate O-ring with a thin coat of clean
fuel.
16) Screw-in the fuel filter 1 until the O-ring

just touches the mounting surface, then
tighten it further by hand for another half
turn.
11
CAUTION:
¡ DO NOT over-tighten.
¡ DO NOT use a filter wrench.
17) Open the boat’s fuel tank cock.

18) Bleed air from the fuel system.
tion (P3-37).
19) Check the fuel leakage.
Leakage → Repair.
20) Install the fuel filter cover 1.

2
NOTE:
Attach a grommet where the fuel filter cover
bolts will be mounted.
1
21) Tighten the fuel filter cover bolts 2.
Bolts (fuel filter cover):

3.5 N·m (0.36 kgf·m, 2.58 lbf·ft)
T.R
3-36
ADJ
Fuel System Air Bleeding
NOTE:
¡ Bleed air from the fuel system after the
disassembly of the fuel system, after loos-
1
ening or disconnecting the fuel hose and
after replacing the fuel filter.
¡ Push the priming pump 1 on the fuel fil-
ter until it feels relatively heavy (with slow
move).
CAUTION:
It is not necessary to loosen the bleed plug
or any of the pipes in order to bleed air from
the fuel system. If the bleed plug is un-
screwed, complete air bleeding will not be
attained.
3-37
ADJ
Seawater Strainer Cleaning
1. Clean:
¡ Seawater strainer
Seawater strainer cleaning steps

1) Fully tilt up the drive unit.
2) Remove the strainer cap 1, inner plate
1
2 and strainer 3.
2
3) Check the strainer cap 1 and the inner
plate 2 for cracks and/or damage.
3
4
4) Check the strainer 3 and the sealing rub-
ber 4 for tearing, wear and/or damage.
Tearing/Wear/Damage → Replace.
5) Clean the strainer cap 1.
6) Clean the inner plate 2.
7) Clean the strainer 3 with the fresh wa-
ter.
8) Install the strainer 3, inner plate 2 and
a
2 strainer cap 1.
3 NOTE:
4 ¡ Make sure that the sealing rubber 4 is
seated properly in the strainer case 5.
5 ¡ The flap A must be on the upper side.
Anode Check
1. Check:
¡ Anode
Anode checking step

1) Check the excessive wear of anodes.
Excessive wear (when more than one-
New third is worn out) → Replace.
NOTE:
LT
¡ There are 4 anodes installed on the en-

24
Replace gine; two each on the heat exchanger and

on the intercooler.
¡ Apply LOCTITE® No. 243 on the threads
when mounting the anodes.
Anode:
16 N·m (1.6 kgf·m, 11.8 lbf·ft)
T.R
3-38
ADJ
Coolant Level Check
Filler cap
¡ WARNING
Do not remove the filler cap while the en-
gine is hot. Scalding hot coolant and its
steam may be blown out, causing serious
injury. Once the engine is cooled off, open
the filler cap in the following procedure:
Place a thick rag or a towel over the filler
cap. Slowly turn the cap counterclockwise.
This allows residual pressure to escape.
When the hissing sound ceased, press down
and turn the cap counterclockwise to remove
it.
Handling notes for coolant

Coolant is harmful and should be handled
with special care.
¡ WARNING
¡ If coolant splashes into your eyes:
Thoroughly wash your eyes with water
and see a doctor.
¡ If coolant splashes onto your clothes:
Quickly rinse it away with water and then
wash it with soap.
¡ If someone swallowed the coolant:
Quickly make him or her throw up, and
see a doctor.
1. Check:
WITHOUT OPTIONAL RESERVE TANK
¡ Coolant level
b a
Coolant level checking step
NOTE:
Check the coolant level while the engine is
cold.
1) Coolant level shall be kept between the

maximum A and minimum B levels.
WITH OPTIONAL RESERVE TANK
Low level → Add soft water (tap water)
to the proper level.
a
3-39
ADJ
High-quality ethylene glycol anti-

freeze containing corrosion inhibi-
tors for engines:
Coolant to water mixing ratio
30 % – 55 %
Total amount
11.8 L (10.4 lmp qt., 12.5 US qt.)
Reservoir tank capacity (optional
accessory)
1.5 L (1.3 lmp qt., 1.6 US qt.)
Difference between minimum
and maximum levels
1.0 L (0.88 lmp qt., 1.06 US qt.)
CAUTION:
¡ Hard water or seawater is harmful for
coolant passage. Use boiled or distilled
water if soft water is not available.
¡ Do not use water containing impurities
or oil.
¡ Take precautions against the coolant
splashing onto the engine. If it takes
place, wash it away with water immedi-
ately.
¡ Do not mix different types and brands of
coolant.
CAUTION:
If the boat will be operated in the area where
(°F) (°C)
the outdoor temperature drops below –10 °C
32 0
(14 °F), it is necessary to alter the coolant /
23 –5 water mixing ratio. As shown in the graph,
14 –10 the proportion of undiluted coolant must be
5 –15
increased from 30 % to 55 %, according to
the temperature range.
–4 –20
–13 –25 Proportion of undiluted coolant
–22 –30 Outdoor temperature
A Range of mixture ratios
–31 –35
–40 –40 NOTE:
–49 –45 Recheck the coolant level whenever it is re-
plenished.
–58 –50
a ¡ Start the engine and let it warm up for
0 10 20 30 40 50 60 70 (%) several minutes.
¡ Wait a few minutes until the coolant is
settled.
¡ Check the coolant level.
3-40
ADJ
Coolant Replacement
1. Replace:
¡ Coolant
Coolant replacement steps

1) Drain the coolant.
NOTE:
Draining points:
¡ Remove the hose 1 under the heat ex-
changer.
¡ Drain bolt (green color) 2 on the port side
1
of cylinder block.
¡ Drain bolt (green color) 3 under the tur-
bocharger.
2) Remove the coolant filler cap and drain.

3) Tighten the drain bolts and the hose.
2
Drain bolt (cylinder):

25 N·m (2.6 kgf·m, 18.4 lbf·ft)
T.R
3 Drain bolt (Turbocharger housing):

52 N·m (5.3 kgf·m, 38.4 lbf·ft)
WITHOUT OPTIONAL RESERVE TANK 4) Fill the coolant.
a
NOTE:
Coolant shall be filled to the maximum level
A.
WITH OPTIONAL RESERVE TANK
3-41
ADJ
5) Start the engine and let it warm up for
several minutes.
6) Stop the engine and check the coolant
level again.
NOTE:
Wait a few minutes to let the coolant settle,
before checking the coolant level.
Thermostat Check
1. Check:
¡ Thermostat (valve opening tempera-
ture)
¡ Thermostat (valve lift)
Thermostat (valve opening temperature)

checking steps
1) Insert a thread around the thermostat
valve.
2) Suspend the thermostat in the water.
3) Heat the water and monitor the tempera-
ture with a thermometer.
4) Measure the temperature at which the
thermostat drops.
Out of specification → Replace.
Thermostat valve opening tem-

perature:
76.5 ± 2 °C (169.7 ± 35.6 °F)
Thermostat (valve lift) checking step

1) Place the thermostat in the water and
heat it. Measure the valve lift when the
water temperature reaches 85 °C (185 °F).
Thermostat valve lift:

10 mm (0.39 in.) or more
Valve lift
3-42
ADJ
Coolant Filler Cap Check
1. Check:
¡ Coolant filler cap (visual inspection)
¡ Coolant filler cap (valve opening pres-
sure)
Coolant filler cap (visual inspection) check-

ing step
1) Check the gasket, sealing rubber and

Gasket locking tab of the coolant filler cap for
Sealing rubber wear, damage, warpage and/or cracks.
Locking tab Wear/Damage/Warpage/Cracks → Re-
place.
Coolant filler cap (valve opening pressure)

checking steps
1) Apply some coolant on the gasket and
the sealing rubber.
2) Mount the coolant filler cap on the cool-
ant filler cap tester.
3) Put specified pressure on the filler cap
for 10 seconds, and confirm that the pres-
sure is kept at the constant level.
4) Put the pressure in excess of specifica-
tion, and confirm that the valve opens at
the specified pressure.
Valve opening pressure:

88 ± 15 kPa
(0.9 ± 0.15 kgf/cm2, 12.8 ± 2.1 psi)
3-43
ADJ
Cooling Hose Check
1. Check:
¡ Cooling hose
¡ Exhaust joint
Cooling hose checking step

1) Check the cooling hose for cracks, wear
and/or damage.
Loose → Tighten the hose clamp.
Exhaust joint checking step

1) Check the exhaust joint 1 for cracks,
wear and/or damage.
1
Loose → Tighten the hose clamp.
Cooling System Pressurize Check

1. Check:
¡ Cooling system (pressurize)
Cooling system pressurize checking steps

1) Fill the cooling system with the coolant.
2) Mount the radiator cap tester.
3) Let the engine warm up, and then stop
it.
4) Put 100 kPa (1.0 kgf/cm2 ,14.5 psi) pres-
sure on the cooling system, and check if
any pressure drop is detected.
Pressure drop → Repair.
NOTE:
Check for external leakage from the follow-
ing locations if pressure drop takes place.
¡ Hose
¡ Coolant by-pass pipe
¡ Heat exchanger
¡ Circulation pump
¡ Thermostat case
¡ Coolant pipe
¡ Heater cock
Check the following locations if there is no
external leakage.
¡ Exhaust manifold
¡ Cylinder block
¡ Cylinder head
3-44
ADJ
Seawater Pump Impeller Replacement
1. Replace:
¡ Seawater pump impeller
Seawater pump impeller replacement steps
¡ WARNING
As soon as the seawater pump hose is dis-
connected, plug the seawater inlet to pre-
vent seawater from entering.
1) Remove the cover 1 and the O-ring 2.
2) Check the impeller 1 for wear, cracks

and/or damage.
Wear/Cracks/Damage → Replace.
3) Remove the impeller 1 (defective).
Pull it out with pliers.
4) Lubricate the impeller 1 with Yamaha

marine grease A.
5) Install the impeller 1.
NOTE:
When inserting the impeller 1 into the pump
body, turn it counterclockwise while push-
1
ing.
A
CAUTION:
Make sure that the impeller blades are
turned as shown in the illustration.
3-45
ADJ
6) Install a new O-ring 1 and the cover 2.
Bolts (cover):
1.9 N·m (0.2 kgf·m, 1.4 lbf·ft)
T.R
NOTE:
If the O-ring comes off, keep it in the ring
1 groove by use of Yamaha marine grease A.
2
3-46
ADJ
Power Steering Fluid Level Check
1. Check:
¡ Power steering fluid level
Power steering fluid level checking steps
CAUTION:
DO NOT operate the engine without cool-
ing water supplied to the lower unit. Dam-
age can occur from the engine overheating.
1) Run the engine until it reaches normal

operating temperature.
2) While operating the engine, turn the
steering lever all the way to both sides
for several times.
Turn the steering lever until the drive unit
is pointing straight back and is centered.
Stop the engine.
3) Remove the filler cap 1 from the reser-
voir tank 2 of the power steering pump
1
and wipe the dipstick with a clean cloth.
4) Reinstall the filler cap in the reservoir
tank, and remove the cap once again.
Check the level of fluid on the level gauge
of the filler cap.
2
Fluid level below the specified level →
Add recommended fluid.
When the engine is hot.

Fluid level should be between the “HOT”
mark and the ”ADD” mark on the oil level
gauge (range A).
When the engine is cold.
Fluid level should be between the “FULL
a
COLD” mark on the level gauge and the
b tip of the oil level gauge (range B).
3-47
ADJ
5) If the fluid level has dropped below the
specified level, add the recommended
fluid up to the specified level.
Recommended fluid:
Automatic Transmission Fluid
(ATF) Dexron® Type II.
CAUTION:
¡ Use the recommended power steering
fluid. Failure to use the proper fluid will
cause hose and seal damage and the sys-
tem will develop leaks.
¡ DO NOT add fluid above the indicated
level, as this will cause the fluid to over-
flow. If you fill the reservoir above the ap-
propriate “FULL” mark, draw off the ex-
cess with a mechanic’s syringe or a plas-
tic bellows pump.
¡ If the level of the fluid in the reservoir tank
has dropped so far that you cannot see
any fluid remaining, it is possible that
there is a fluid leak somewhere in the
power steering hydraulic system. Inspect
the power steering hydraulic system.
Refer to “DE-DHT STERN DRIVE SERVICE
MANUAL” or “DE-DHD STERN DRIVE
SERVICE MANUAL”.
6) Install the filler cap and start the engine.

After rotating the steering lever several
times all the way to both sides, set the
drive unit straight and stop the engine.
Reinspect the fluid level.
7) Bleed air from the power steering hy-
draulic system if necessary.
3-48
ADJ
Battery Check
1. Check:
¡ Battery fluid level
¡ Battery terminal
¡ Specific gravity
Battery fluid level checking step

1) Check the battery fluid level.
a
NOTE:
UPPER
LOWER Battery fluid level should be between the
upper limit mark A and lower limit mark B.
b
CAUTION:
Fill the distilled water only. Tap water con-
tains minerals which are harmful to a bat-
tery.
Battery terminals checking step

1) Check the battery terminals.
Dirt → Clean with wire brush.
Improper connection → Correct.
NOTE:
After cleaning, a thin coat of grease shall be
applied on each terminal.
Specific gravity checking step

1) Check the specific gravity.
If the specific gravity is 1.23 or lower,
charge the battery. If it does not revive
after the charging, replace the battery.
Specific gravity:
1.23 at 20 °C (68 °F)
NOTE:
Battery must be replaced when:
¡ Battery voltage stays low or bubbles do
not appear in the fluid even after many
hours of charging.
¡ Sulfating, as indicated by the whitening
of plates or sedimentation (dirt at the bot-
tom) is visible in one or more cells.
¡ Specific gravity becomes lower in one cell
than the others.
¡ Deformation due to the buckling of plates
or insulators is visible.
3-49
ADJ
CAUTION:
A new battery must be charged to the full
extent before use to ensure maximum per-
formance.
¡ WARNING
Battery electrolyte is dangerous; it contains
sulfuric acid which is poisonous and highly
caustic.
Always follow these preventive measures:
¡ Avoid bodily contact with electrolyte as
it can cause severe burns and permanent
eye injury.
¡ Wear protective eye gear when handling
or when working near the batteries.
Antidote (EXTERNAL)
¡ SKIN – Flush with water.
¡ EYES – Flush with water for 15 minutes
and get immediate medical attention.
Antidote (INTERNAL)
¡ Drink large quantities of water or milk,
followed with milk of magnesia, beaten
egg or vegetable oil. Get immediate
medical attention.
Batteries also generate explosive hydrogen
gas. Always follow the following safety mea-
sures:
¡ Charge batteries in a well-ventilated area.
¡ Keep batteries away from fire, sparks, or
open flames (e.g., welding equipment,
lighted cigarettes, etc.)
¡ DO NOT SMOKE when charging or han-
dling batteries.
KEEP BATTERIES AND ELECTROLYTE OUT
OF REACH OF CHILDREN.
3-50
ADJ
Fuse Check
CAUTION:
Always turn off the main switch when check-
ing or replacing a fuse. Otherwise, short-cir-
cuiting may occur.
1. Check:
¡ Fuse
Fuse checking steps

1) Use a circuit tester for checking the con-
tinuity.
2) If the tester indicates ∞, the fuse is blown
and it must be replaced.
Fuse Replacement
1. Replace:
¡ Blown fuse
Fuse replacement steps

1) Turn off the main switch.
2) Install a new fuse of proper amperage.
3) Turn on the switches to verify the opera-
tion of the related electrical device.
4) If the fuse blows again immediately,
check the electrical circuit.
Description Amperage Quantity

Trim motor 100 A 1
Charging system 100 A 1
Meter, Power trim 20 A 1
switch
¡ WARNING
Never use a fuse with a rating other than
specified. Never use other material in place
of a fuse. An improper fuse may cause ex-
tensive damage to the electrical system,
malfunction of lightning and main switch,
and may even cause a fire.
3-51
REM E
INST
CHAPTER 4
ENGINE REMOVAL AND INSTALLATION
ENGINE REMOVAL AND INSTALLATION ............................................................................. 4-1

Engine Removal ................................................................................................................. 4-1
Engine Mount Check ......................................................................................................... 4-4
Rear Engine Mount Rubber Assembly ............................................................................. 4-5
Engine Installation ............................................................................................................. 4-5
Engine Alignment Adjustment ....................................................................................... 4-10
4
REM ENGINE REMOVAL AND INSTALLATION E
INST
ENGINE REMOVAL AND INSTAL-
LATION
Engine Removal
1. Remove:
¡ Engine
Engine removal steps

1) Remove the drive unit assembly.
SERVICE MANUAL”.
2) Drain the coolant and seawater.
NOTE:
¡ When draining the coolant, cover all elec-
trical parts, accessory parts etc. with a
plastic sheet to protect them.
¡ If the boat is on land, remove the drain
bolt from the bottom of the boat after
draining the coolant and drain out any
coolant that has collected at the bottom
of the boat. If the boat is still in water, use
the bilge pump. Then rinse the bottom of
the boat thoroughly with clean water and
dry it.
¡ If possible raise the bow slightly, so that
the coolant will drain completely from the
cylinder block.
3) Turn off the fuel cock on the fuel tank.

4) Disconnect the fuel inlet hose 1 and the
return hose 2.
¡ WARNING
1
Fuel in the bilge is a serious fire hazard.
Hold a small container or rag under the hose
2
nipples to catch spilling fuel. Clean up any
spilled fuel immediately with dry rags.
NOTE:
Put marks on the fuel hoses so that they can
be reinstalled in their original positions.
4-1
INST
3 5 4 5) Disconnect the extension wireharness 6
pin coupler 1 and the extension
wireharness 16 pin coupler 2.
6) Disconnect the power trim and tilt mo-
2 tor “up” relay (blue lead) 3, the power
trim and tilt motor “down” relay (green
1 lead) 4 and the power trim and tilt mo-
tor ground wire (black lead) 5.
1
7) Disconnect the hydraulic hoses 1 from
power steering control valve 2.
2
NOTE:
¡ Hold the open hose end a container.
¡ Install caps and plugs on all open con-
nections to prevent dirt from entering the
hydraulic system.
8) Loosen the hose clamps 1.
9) Disconnect the ground wires 1 from the

stud 2 on the flywheel housing.
2
10) Disconnect the battery positive (+) lead
3 from the starter motor.
11) Disconnect the trim sender leads (black

and brown/white) 1, trim limit switch
leads (purple/white and blue/white) 2,
4 5
and trailer switch leads (green/white,
1
blue/white and red/purple) 3 from the
extension wireharness.
3
12) Disconnect the water inlet hose 4 from
seawater inlet tube 5 on the gimbal
2
housing.
4-2
INST
13) Disconnect the throttle cable.
14) Disconnect the shift cable to the remote

2 control 1, and the shift cable to the drive
unit 2.
15) Attach a suitable hoist to the lifting brack-

ets 1 of the engine.
1
Remove slack from chain or strap.
¡ WARNING
DO NOT attach lifting sling or chain to the
hanger 2 mounted on the cylinder head.
This hanger will not support the weight of
the engine and could break. The engine could
fall, causing personal injury or damage.
2
16) Remove the left and right screws 1, nuts

2 and the left and right washers 3.
3 17) Carefully lift the engine out of boat.
4-3
INST
Engine Mount Check
1. Check:
¡ Front engine mount brackets
¡ Front engine mounts
¡ Rear engine mounts
Front engine mount brackets checking steps

1) Check the front engine mount brackets
1 1 for cracks, bends and/or damage.
Cracks/Bends/Damage → Replace.
2) Tighten the engine mount bracket bolts
(left and right).
1
Bolt (engine mount bracket):
113 N·m (11.5 kgf·m, 83 lbf·ft)
T.R
Front engine mounts checking steps
1) Check the front engine mount bases 1
for cracks, wear and /or damage.
Cracks/Wear/Damage → Replace the en-
gine mount bases as a set.
2) Check the front engine mount rubbers
2 for cracks, wear and/or damage.
Cracks/Wear/Damage → Replace engine
1 2
1 2
mount rubbers as a set.
Rear engine mounts checking step

1) Check the rear engine mounts for cracks,
wear and/or damage.
SERVICE MANUAL”.
4-4
INST
Rear Engine Mount Rubber Assembly
1. Assemble:
¡ Rear engine mount rubber
Rear engine mount rubber assembly steps

1) Pour a little water over the mount rub-
ber 1.
5 2) Press the mount rubber into the transom
plate 2 until its lower flange A is
TB through the hole.
1322
3 6 3) Install the spacer collar 3 into the mount
4
rubber.
b 4) Install the stopper plates 4 with the rub-
1 ber side B facing to the transom plate.
5) Install the bolt 5 and tighten the nut 6
to the specified torque.
NOTE:
2
Apply ThreeBond® TB-1322 to the engaging
b part of the nut 6 and bolt 5 when tighten-
ing the nut.
4 a
Nut (rear engine mount):
55 N·m (5.6 kgf·m, 41 lbf·ft)
T.R
Engine Installation
1. Install:
¡ Engine
Reverse the “Engine Removal” pro-
cedure.
Note the following points.
Engine installation steps

1) Carefully lower the engine into the boat,
2
lining up the hole of the rear engine
mounts with mount studs on the tran-
som plate. As the engine is lowered, con-
nect the exhaust joint 1 and the mixing
elbow 2.
1
4-5
INST
2) Check the position of the nuts 1 on the
intermediate plate. Make sure that the
flats are parallel with the centerline of the
boat.
OK NG
If the flats are not parallel to the boat’s
centerline, they will not fit properly into
the recessed groove 2 on the flywheel
housing and proper engine installation
and alignment will not be attained.
1
NOTE:
The engine flywheel casing is set on the stop-
per plate with a guide of the rear mount nut.
1
If nut is not positioned correctly, the engine
cannot be installed.
a
3) Install the left and right washers 1 and
a
1 2 the left and right nuts 2 onto the rear
engine mount.
1 2
NOTE:
Check that the washers 1 for the rear en-
gine mount are properly centered in the
round engine mount recess A.
If they are not, use the hoist to move the en-
gine so that the washers are centered in the
slot. Attach the engine in that position.
4) Tighten the nuts 1.
Nuts (rear engine mount):

55 N·m (5.6 kgf·m, 41 lbf·ft)
T.R
4-6
INST
5) When the front mount bracket-to-boat
lag screws have been removed, apply
silicone sealant to the threads of the lag
screws.
Install and tighten the lag screws se-
curely.
6) Release the hoist tension and remove the

lifting strap or chain. Attach the hoist to
the setting hanger 1 mounted on the
cylinder head, then remove slack from
chain or strap.
1
7) Adjust the engine alignment.

Refer to “Engine Alignment Adjustment”
section (P4-10).
4-7
INST
8) Install the drive unit assembly.
SERVICE MANUAL”.
NOTE:
¡ Stud 1 does not use a washer as it has a
3 4 ground plate 2 attached already.
1
¡ Tighten the nuts in two passes in the tight-
2 1
ening sequence shown.
2
6 5 Nuts (drive unit assembly):

T.R
1st
29 N·m (3.0 kgf·m, 21 lbf·ft)
2nd
69 N·m (7.0 kgf·m, 51 lbf·ft)
Drive unit recommended oil:

Yamaha Stern Drive Gear Oil or
Hypoid Gear Oil (SAE 90) GL-4,
GL-5 or equivalent
Oil level plug:

18 N·m (1.8 kgf·m, 13 lbf·ft)
T.R
Oil drain plug:

7 N·m (0.7 kgf·m, 5.2 lbf·ft)
Bolt (upper case cover):
18 N·m (1.8 kgf·m, 13 lbf·ft)
4-8
INST
9) Connect the leads.
NOTE:
Match the color codes of the leads.
10) Connect the hydraulic hoses 1 to power

1
steering control valve 2.
3
2 4
Large fitting 3:
34 N·m (3.5 kgf·m, 25 lbf·ft)
T.R
Small fitting 4:
15 N·m (1.5 kgf·m, 11 lbf·ft)
11) Connect the fuel inlet hose 1 and the

return hose 2.
NOTE:
Be sure to reconnect fuel hoses in their origi-
nal positions.
1
12) Connect the battery leads.
CAUTION:
¡ Connect the positive (+) lead first, then
the negative (–) lead.
¡ Grease both battery terminals.
13) Fill the engine oil.

Refer to “Engine Oil and Oil Filter Re-
placement” section (P3-14).

Max. 4.8 L, Min. 2.8 L
 Max. 4.2 lmp qt., Min. 2.5 lmp qt.
 Max. 5.1 US qt., Min. 3.0 US qt. 
Max. 5.7 L, Min. 3.7 L
 Max. 5.0 lmp qt., Min. 3.3 lmp qt.
 Max. 6.0 US qt., Min. 3.9 US qt. 
4-9
INST
14) Adjust the shift cables to the drive unit
1 1 and to the remote control 2.
SERVICE MANUAL”.
15) Adjust the Idling speed.

Refer to “Throttle Cable Adjustment”
section (P3-24).
Engine idling speed:

650 – 700 r/min.
Engine Alignment Adjustment

1. Adjust:
¡ Engine alignment
Engine alignment adjustment steps

1) Insert the engine alignment tool 1
through the gimbal bearing 2 into the
crankshaft coupling.
1
NOTE:
¡ If the alignment tool slides in and out eas-
ily, the alignment is correct.
D
¡ If the tool is difficult to insert or remove,
2
the engine is not aligned. In this case, per-
form the following steps.
CAUTION:
Remove the alignment tool before raising or
lowering the front of the engine. Otherwise
the tool could get stuck and cause damage
to bearings, splines, or get damaged itself.
4-10
INST
2) Remove the hoist tension.
3) Remove the hoist from the setting
hanger.
4) Loosen the left and the right front mount
adjustment nuts 1 to the raised position.
5) Turn the left and the right adjustment

3 nuts 2 clockwise, one turn at a time, to
lower the bracket 3 gradually. Identify
the position where the load for pushing/
pulling the alignment tool becomes
heavier.
6) Turn the left and the right adjustment

3
nuts 2 counterclockwise, one turn at a
time, to raise the bracket 3 gradually.
Identify the position where the load for
pushing in/pulling out the alignment tool
becomes heavier.
7) Lower the engine bracket and fix it at the

center of the distance between the point
“B”
“A” where the alignment tool movement
Center became heavier while lowering the en-
“A” gine bracket, and the point “B” where
the alignment tool movement became
heavier while raising the engine bracket.
Here, check the correct engine alignment
again using the engine alignment tool.
4-11
INST
CAUTION:
¡ Pull out the alignment tool while lower-
ing and raising the engine by turning the
adjustment nuts. If the alignment tool is
kept inserted in these processes, the tool
can be clamped in the gap, or can hardly
be removed, resulting in the damage on
the bearing, the spline, or the tool.
¡ Correct alignment cannot be obtained
with the deformed mount rubber stop-
per (by the permanent set) of the rear
mount. The deformation is resulted from
the excessive tightening torque exerted
on the rear mount nut.
¡ Improper alignment of gimbal bearing
will result in the heavy load required for
pushing in/pulling out the alignment tool
in the course of engine alignment.
8) Tighten the front engine mount nuts 1.
Nuts (front engine mount):

137 N·m (14 kgf·m, 101 lbf·ft)
T.R
4-12
FUEL E
CHAPTER 5
FUEL SYSTEM
INJECTION NOZZLE ............................................................................................................... 5-1

Injection Nozzle Removal .................................................................................................. 5-2
Injection Nozzle Check ....................................................................................................... 5-4
Injection Nozzle Installation .............................................................................................. 5-5
INJECTION PUMP ................................................................................................................... 5-7

Injection Pump Removal ................................................................................................... 5-9
Injection Pump Check ...................................................................................................... 5-10
Injection Pump Installation ............................................................................................. 5-13
5
FUEL INJECTION NOZZLE E
INJECTION NOZZLE
2
3
No. Part name Q’ty Remarks

1 Nozzle holder nuts 8 18 N·m (1.8 kgf·m, 13 lbf·ft)
2 Leakage pipe hollow bolts 4 25 N·m (2.5 kgf·m, 18 lbf·ft)
3 Nozzle leakage pipe 1
4 Fuel return hose #1 1
5-1
¡ WARNING
When servicing the fuel system, pay particu-
lar attention to the following points:
¡ Make sure that the main switch is “OFF”.
¡ Diesel fuel is flammable and explosive un-
der certain conditions.
¡ DO NOT smoke, and never work close to
an open flame, a source of sparks or in-
tense heat.
¡ Take care not to spill diesel fuel. If you
spilled some accidentally, wipe it up im-
mediately with dry rags. When the en-
gine is still hot from operation, spilled
diesel fuel could catch fire. Always allow
the engine to cool off completely before
starting to work.
Injection Nozzle Removal

1. Remove:
¡ Injection nozzle
Injection nozzle removal steps

1) Disconnect the fuel hose.
2) Unscrew the nuts, and remove the glow
plug holder 1.
1
3) Loosen the nut 1 and unscrew the 3

bolts 2, and remove the injection pipe
clamps.
2
2
5-2
4) Loosen the 4 flare nuts on the nozzle, and

disconnect the injection pipes from the
nozzle.
5) Hold distribution joint end of the pump

with a wrench, unscrew the 4 flare nuts
on the pump and remove the 4 injection
pipes.
NOTE:
Put some identification mark on each injec-
tion pipe so that they can be reinstalled in
their original positions.
6) Unscrew the leakage pipe hollow bolts

3, and remove the nozzle leakage pipe
1 1.
3 7) Remove the gaskets 2 of the leakage
2 pipe hollow bolts 3.
1
8) Remove the nuts 1, and remove the in-
jection nozzles 2.
2
9) Remove the O-rings 3 from the cylin-
der head.
4
10) Remove the gaskets 4 from the cylin-
der head.
3
NOTE:
Identify the position of each injection nozzle
carefully, so that they can be installed in their
original place.
5-3
Injection Nozzle Check

1. Check:
¡ Injection pressure
¡ Spray pattern
¡ Fuel leak
CAUTION:
Injection nozzle disassembly and repair must
be performed by the service shop designated
by the injection nozzle manufacturer.
Injection pressure checking step

1) Use the injection nozzle tester. Pump the
tester lever with a speed of approx. 1
time per second to check the injection
pressure.
Out of specification → Replace or repair
the injection nozzle.
Injection pressure:
17.7 MPa (180 kgf/cm2, 2567 psi)
¡ WARNING
Do not hold your hand under the tip of the
nozzle.
Spray pattern checking step

1) Use the injection nozzle tester. Pump the
tester lever with a speed of approx. 1
time per second to check the spray pat-
tern.
Improper spray pattern → Replace the
injection nozzle.
No Yes No No No ¡ WARNING
Do not put your hand under the tip of the
nozzle during the spray check.
Fuel leak checking step

1) Use the injection nozzle tester. Apply
pressure which is lower than the normal
injection pressure by approx. 981 –
1961 kPa (10 – 20 kgf/cm2) to the nozzle.
The injection nozzle is normal if no fuel
leakage is detected during the test.
Leakage → Replace the injection nozzle.
Yes No
5-4
Injection Nozzle Installation

1. Install:
¡ Injection nozzle
NOTE:
Injection nozzles must be reinstalled in their
original positions.
Injection nozzle installation steps
3 1) Install a new O-rings 1 on the cylinder

head.
4
2) Install a new gaskets 2 on the cylinder
head.
2
3) Install the injection nozzles 4, and
tighten the nuts 3 temporary.
1
Nuts (nozzle holder) 3:
18 N·m (1.8 kgf·m, 13 lbf·ft)
T.R
4) Using new gaskets 1, put the nozzle

leakage pipe 2 through the hole on the
2 cylinder head.
3 5) Using 4 new gaskets, install the nozzle
1 leakage pipe with hollow bolts 3.
6) Connect the fuel return hose to the nozzle
leakage pipe.
Hollow bolts (leakage pipe):

25 N·m (2.5 kgf·m, 18 lbf·ft)
T.R
7) Temporarily tighten the flare nuts on the

nozzle, and then tighten the flare nuts on
the pump while holding delibery joint
end of the pump with a wrench.
Flare nuts (injection pipe):

25 N·m (2.5 kgf·m, 18 lbf·ft)
T.R
NOTE:
Fix the injection pipes following the sequence
below.
Injection order: 1 – 3 – 4 – 2
5-5
8) Install the glow plug holder 1, and

tighten the nuts.
1
9) Fill the fuel line in the system by the prim-

ing pump located on the fuel filter.
10) Loosen one of the flare nuts on the
nozzle.
11) Crank the engine with starter motor un-
til the fuel comes out of the loosened nut.
12) Tighten the flare nut.
13) Perform the steps 10) to 12) above for
the rest of the injection pipes.
5-6
FUEL INJECTION PUMP E
INJECTION PUMP
3
5 6
1
4

1 Injection pump mounting nuts 2 18 N·m (1.8 kgf·m, 13 lbf·ft)
2 Injection pump mounting bolts 4 18 N·m (1.8 kgf·m, 13 lbf·ft)
3 Fuel cut solenoid 1 22 N·m (2.2 kgf·m, 16 lbf·ft)
4 Pickup sensor 1 21 N·m (2.1 kgf·m, 15 lbf·ft)
5 Union bolt 1
6 Union bolt 1
5-7
1
2

1 Injection pipe flare nuts 8 25 N·m (2.5 kgf·m, 18 lbf·ft)
2 Pipe clamp mounting bolts 3
3 Pipe clamp mounting nut 1
5-8
Injection Pump Removal
NOTE:
Before removing the injection pump, check
for abnormal noises from the pump while the
engine is running.
1. Remove:
¡ Injection pump
Injection pump removal steps
1) Remove the injection pipes.
Refer to “Injection Nozzle Removal” sec-
tion (P5-2).
2) Remove the oil level gauge and the pipe

1.
1
3) Disconnect the boost compensator hose
2.
6
5 4) Disconnect the fuel return hose #1 3.
3
5) Disconnect the fuel return hose #2 4.
4
2 6) Disconnect the fuel hose #2 5.
7) Disconnect the throttle connecting rod
6.
8) Disconnect the injection pump coupler
1.
9) Remove the nuts and bolts, and remove

a the injection pump.
NOTE:
Put alignment marks A on the injection
pump and timing gear case before remov-
ing so that the injection pump can be rein-
stalled in exactly the same position.
5-9
10) Remove the O-ring 1.
Injection Pump Check

1. Check:
¡ Fuel cut solenoid
¡ Pickup (tacho) sensor
¡ Injection pump
Fuel cut solenoid checking steps

1) Pull back the dust cover 1 of the fuel cut
solenoid.
2 2) Disconnect the fuel cut solenoid lead 2.
3) Remove the fuel cut solenoid 1.

4) Remove the O-ring 2, spring 3, valve
1 4, fuel strainer 5 and washer 6.
2
5
6
5) Check the fuel cut solenoid.

Refer to “Fuel Cut Solenoid Valve Check”
section (P8-48).
6) Check the spring 1 and the fuel strainer

2 for damage.
Damage → Replace.
1 2
5-10
7) Use some cleaning solvent and blow dry

with compressed air to clean the fuel
strainer.
8) Check the rubber seal A (valve 1) for

wear and/or damage.
Wear/Damage → Replace the valve.
1
9) Install the washer 1, fuel strainer 2,

valve 3, spring 4 and a new O-ring 5.
6 10) Install the fuel cut solenoid 6.
5
4 Fuel cut solenoid:

22 N·m (2.2 kgf·m, 16 lbf·ft)
T.R
NOTE:
2
1 Apply some grease on the O-ring 5 of the
fuel cut solenoid.
11) Connect the fuel cut solenoid lead 1.
1
Bolt (fuel cut solenoid lead):
1.7 N·m (0.17 kgf·m, 1.2 lbf·ft)
T.R
2
12) Put the dust cover 2 on the fuel cut so-
lenoid.
5-11
Pickup (tacho) sensor checking steps
1
1) Pull out the pickup (tacho) sensor lead
2
1 from the lead clamp 2.
3
2) Remove the pickup (tacho) sensor 3.
3) Check the pickup (tacho) sensor.

Refer to “Pickup (tacho) Sensor Check”
section (P8-3).
4) Mount a new O-ring 1 on the pickup

3 (tacho) sensor.
2
5) Install the pickup (tacho) sensor 2.
1
Pickup (tacho) sensor:

21 N·m (2.1 kgf·m, 15 lbf·ft)
T.R
NOTE:
Apply some grease on the O-ring 1 of the
pickup (tacho) sensor.
6) Clamp the pickup (tacho) sensor lead 3.
5-12
Injection pump checking steps

1) Check the injection pump operation.
Abnormal noise/Malfunction → Replace
the injection pump.
Injection Pump Installation

1. Install:
¡ Injection pump
Injection pump installation steps

1) Mount a new O-ring 1 on the injection
E pump.
2) Install the injection pump.

b
NOTE:
¡ The large spline A on the pump drive
shaft must be fitted into the correspond-
ing groove on the pump drive gear C.
a ¡ Align the match marks B of the injection
c pump and the timing gear case.
3) Tighten the nuts and bolts.
Nuts (injection pump to gear case):

18 N·m (1.8 kgf·m, 13 lbf·ft)
T.R
Bolts (injection pump mounting):

18 N·m (1.8 kgf·m, 13 lbf·ft)
5-13
4) Check the injection timing and adjust it.

Refer to “Injection Timing Check” section
(P3-30) and “Injection Timing Adjust-
ment” section (P3-32).
5) Connect the injection pump coupler 1.
6) Install the throttle connecting rod 1, fuel

hose #2 2, fuel return hose #2 3, fuel
return hose #1 4 and boost compensa-
tor hose 5.
1
4 Hollow bolt (Fuel hose #2):
2 25 N·m (2.5 kgf·m, 18 lbf·ft)
T.R
3
5
NOTE:
Always use a new gasket.
7) Install the injection pipes.

section (P5-5).
8) Fill the coolant to the maximum level.
Refer to “Coolant Level Check” section
(P3-39).
9) Check the engine idling speed and the
maximum speed.
Refer to “Engine Idling Speed and Maxi-
mum Engine Speed (No Load) Check”
section (P3-23).
5-14
ENG E
OVER
CHAPTER 6
ENGINE OVERHAUL
2-STAGE RATE COUPLING AND FLYWHEEL ........................................................................ 6-1

2-stage Rate Coupling and Flywheel Removal ................................................................ 6-2
2-stage Rate Coupling Disassembly ................................................................................. 6-3
2-stage Rate Coupling and Flywheel Check .................................................................... 6-4
2-stage Rate Coupling Assembly ..................................................................................... 6-6
2-stage Rate Coupling and Flywheel Installation ............................................................ 6-7
SEAWATER PUMP .................................................................................................................. 6-9

Seawater Pump Impeller Removal ................................................................................. 6-11
Seawater Pump Removal ................................................................................................ 6-11
Seawater Pump Check .................................................................................................... 6-12
Seawater Pump Replacement ........................................................................................ 6-13
Seawater Pump Installation ............................................................................................ 6-17
Seawater Pump Impeller Installation ............................................................................. 6-18
HEAT EXCHANGER .............................................................................................................. 6-19

Heat Exchanger Removal ................................................................................................ 6-20
Heat Exchanger Disassembly ......................................................................................... 6-20
Heat Exchanger Check ..................................................................................................... 6-21
Heat Exchanger Cleaning ................................................................................................ 6-21
Heat Exchanger Assembly .............................................................................................. 6-22
Heat Exchanger Installation ............................................................................................ 6-23
Thermostat Removal ....................................................................................................... 6-23
Thermostat Check ............................................................................................................ 6-25
Thermostat Installation ................................................................................................... 6-27
INTERCOOLER ...................................................................................................................... 6-28

Intercooler Removal ........................................................................................................ 6-29
Intercooler Disassembly .................................................................................................. 6-31
Intercooler Check ............................................................................................................. 6-32
Intercooler Cleaning ........................................................................................................ 6-33
Intercooler Assembly ...................................................................................................... 6-34
Intercooler Installation .................................................................................................... 6-35
TURBOCHARGER ................................................................................................................. 6-37

Handling Precautions ...................................................................................................... 6-40
Turbocharger Removal .................................................................................................... 6-41
ENG E
OVER
Turbocharger Check ......................................................................................................... 6-42

Turbocharger Disassembly ............................................................................................. 6-44
Turbocharger Measurement ........................................................................................... 6-47
Turbocharger Assembly .................................................................................................. 6-49
Turbocharger Installation ................................................................................................ 6-52
Turbocharger Pressure Measurement ........................................................................... 6-54
MIXING ELBOW AND EXHAUST MANIFOLD .................................................................... 6-56

Mixing Elbow and Exhaust Manifold Removal ............................................................. 6-57
Exhaust Manifold Check .................................................................................................. 6-59
Filler Neck Replacement .................................................................................................. 6-60
Mixing Elbow Check ........................................................................................................ 6-61
Mixing Elbow and Exhaust Manifold Installation ......................................................... 6-62
CIRCULATION PUMP ............................................................................................................ 6-65

Circulation Pump Removal ............................................................................................. 6-66
Circulation Pump Check .................................................................................................. 6-67
Circulation Pump Installation ......................................................................................... 6-67
TIMING GEARS ..................................................................................................................... 6-69

Timing Gear Removal ...................................................................................................... 6-71
Timing Gear Check........................................................................................................... 6-76
Timing Gear Cover Check................................................................................................ 6-78
Oil Seal Replacement ...................................................................................................... 6-78
Timing Gear Installation .................................................................................................. 6-79
6
CYLINDER HEAD ................................................................................................................... 6-83
Cylinder Head Removal ................................................................................................... 6-87
Cylinder Head Disassembly ............................................................................................ 6-89
Piston and Cylinder Block Top Cleaning ........................................................................ 6-90
Cylinder Head Check ....................................................................................................... 6-91
Valve Stem and Valve Guide Clearance Check .............................................................. 6-92
Valve Guide Replacement ............................................................................................... 6-93
Valve Check ...................................................................................................................... 6-94
Valve Seat Check .............................................................................................................. 6-95
Valve Seat Refacing ......................................................................................................... 6-96
Valve and Valve Seat Lapping......................................................................................... 6-98
Valve Spring Check .......................................................................................................... 6-99
Rocker Arm and Push Rod Check ................................................................................. 6-100
Camshaft Bearing and Camshaft Check....................................................................... 6-101
ENG E
OVER
Intake and Exhaust Manifold Check ............................................................................. 6-104

Cylinder Head Assembly ............................................................................................... 6-105
Cylinder Head Gasket Selection ................................................................................... 6-106
Cylinder Head Installation ............................................................................................. 6-108
Camshaft and Rocker Arm Installation ........................................................................ 6-109
OIL PUMP ............................................................................................................................ 6-111

Oil Pump Removal ......................................................................................................... 6-112
Oil Pump Disassembly .................................................................................................. 6-114
Oil Pump Check .............................................................................................................. 6-115
Oil Strainer Check .......................................................................................................... 6-117
Oil Pump Assembly ....................................................................................................... 6-117
Timing Gear Case Installation ....................................................................................... 6-118
OIL COOLER ........................................................................................................................ 6-121

Oil Cooler Removal ........................................................................................................ 6-122
Oil Cooler Check ............................................................................................................ 6-123
Oil Cooler Installation .................................................................................................... 6-124
OIL NOZZLE ........................................................................................................................ 6-127

Oil Nozzle Removal ........................................................................................................ 6-128
Oil Nozzle Check ............................................................................................................ 6-128
Oil Nozzle Installation .................................................................................................... 6-129
CYLINDER BLOCK ............................................................................................................... 6-130

Cylinder Block Disassembly .......................................................................................... 6-134
Valve Lifter and Camshaft Bearing Disassembly ........................................................ 6-136
Connecting Rod and Piston Disassembly .................................................................... 6-137
Main Bearing Cap and Crankshaft Disassembly ......................................................... 6-138
Piston and Connecting Rod Disassembly .................................................................... 6-139
Piston and Cylinder Block Cleaning ............................................................................. 6-141
Valve Lifter Check........................................................................................................... 6-142
Piston and Cylinder Block Check .................................................................................. 6-144
Connecting Rod and Piston Pin Check ......................................................................... 6-149
Connecting Rod Bushing Replacement ....................................................................... 6-151
Crankshaft and Bearing Check ...................................................................................... 6-153
Crankshaft Oil Seal Retainer and Oil Seal Check ........................................................ 6-159
Crankshaft Oil Seal Replacement ................................................................................. 6-159
Cylinder Block Assembly .............................................................................................. 6-161
Valve Lifter and Camshaft Bearing Assembly ............................................................. 6-161
ENG E
OVER
Piston and Connecting Rod Assembly ......................................................................... 6-163

Piston and Connecting Rod Installation ....................................................................... 6-166
Crankshaft Oil Seal Retainer Installation ..................................................................... 6-168
6
ENG 2-STAGE RATE COUPLING AND FLYWHEEL E
OVER
2-STAGE RATE COUPLING AND FLYWHEEL
LT
271
LT
271
3
4
D
FW

1 Flywheel housing 1
2 Bolts 6 29 N·m (3.0 kgf·m, 22 lbf·ft)
3 2-stage rate coupling assembly 1
4 Bolts 8 157 N·m (16 kgf·m, 116 lbf·ft)
5 Flywheel 1
6 Bolt 1 18 N·m (1.8 kgf·m, 13 lbf·ft)
7 Rear end plate 1
6-1
OVER
2-stage Rate Coupling and Flywheel
Removal
1. Remove:
¡ 2-stage rate coupling and flywheel
2-stage rate coupling and flywheel removal

steps
1) Remove the starter motor.
Refer to “Starter Motor Removal” sec-
tion (P8-12).
2) Disconnect the earth leads 1.
3
3) Remove the bracket 1.
4) Remove the boost pipe 2 and the gas-
kets.
5) Remove the power steering oil cooler 3.
NOTE:
1
Place the open hose end of the oil cooler into
a container.
2
CAUTION:
Prevent the dirt from entering the power
4 steering system by installing caps and plugs
in all open connections.
6) Remove the flywheel housing 4.
7) Remove the 2-stage rate coupling assem-

bly 1.
6-2
OVER
8) Remove the flywheel 1 and the rear end
plate 2.
1
2
2-stage Rate Coupling Disassembly

1. Disassemble:
¡ 2-stage rate coupling
NOTE:
1 Put marks A on the coupling 1 and outer
member 2 before removing so that they can
be reinstalled in the original position.
2-stage rate coupling disassembly steps

1) Remove the bolts 1, coupling 2,
5 damper collars 3, large washers 4,
2 bearing 5, and small washers 6.
6 3 4
2) Remove the plate 1, damper joint 2,

1 2 3 4 and bearing 3 from the outer mem-
ber 4.
6-3
OVER
Check
1. Check:
¡ Rear end plate
¡ Flywheel and gear teeth
¡ Bearings and bearing contact surfaces
¡ Coupling assembly/splines and
damper rubber
¡ Damper collars and plate
¡ Outer member and damper joint
NOTE:
If damage has occurred to the flywheel and
coupling component parts, replace the fly-
wheel and coupling as an assembly.
Rear end plate checking step

1) Check the rear end plate 1 for cracks
and/or damage.
1 Cracks/Damage → Replace.
Flywheel and gear teeth checking steps

1) Check the flywheel 1 for cracks and/or
2 damage.
1
2) Check the gear teeth 2 for burns, chips
and/or roughness.
Burns/Chips/Roughness/Wear →
Replace the flywheel assembly.
Bearings and bearing contact surfaces check-

ing step
1) Check the bearings 1 and the bearing
1 contact surface on the outer member 2
for wear, cracks and/or pitting.
Wear/Cracks/Pitting → Replace the cou-
1 pling assembly.
6-4
OVER
Coupling assembly/splines (coupling) and
damper rubber checking steps
1) Check the coupling assembly 1 for
b Cracks/Damage → Replace the coupling
assembly.
2) Check the spline A for burns, wear and/
a or damage.
Burns/Wear/Damage → Replace the cou-
1 pling assembly.
3) Check the damper rubber B for wear,
Wear/Cracks/Damage → Replace the cou-
pling assembly.
Damper collars and plate checking steps

1) Check the damper collars 1 for wear,
2 1
pling assembly.
2) Check the plate 2 for cracks and/or dam-
age.
Cracks/Damage → Replace the coupling
assembly.
Outer member and damper joint checking

steps
1) Check the outer member 1 for cracks
1
and/or damage.
2 Cracks/Damage → Replace the coupling
assembly.
2) Check the damper joint 2 for wear,
pling assembly.
6-5
OVER
2-stage Rate Coupling Assembly
1. Assemble:
¡ 2-stage rate coupling
2-stage rate coupling assembly steps

1) Install the plate 1, damper joint 2, and
1 2 3 4 bearing 3 in the outer member 4.
1
2 NOTE:
¡ The holes A located on the plate 1 for
the coupling assembly bolts must be
3 aligned with the center (as seen from the
LT 4 outer member 4) of the oval cut-outs B
271 on the outer member.
¡ Apply LOCTITE ® No. 271 to each stud
thread.
a ¡ Tighten both nuts simultaneously.
b Nuts (damper joint):

5.6 N·m (0.57 kgf·m, 4.1 lbf·ft)
T.R
a 2) Install the bearing 1, damper collars 2,

1 a large washers 3, coupling 4, small
4 washers 6, and bolts 5.
Bolts (coupling):
67 N·m (6.8 kgf·m, 49 lbf·ft)
T.R
5
NOTE:
LT
6 2 3 ¡ Align the matching marks A of the cou-
271 pling and the outer member.
¡ Apply LOCTITE® No. 271 to nuts.
¡ Tighten the bolts in several passes in a
crisscross pattern.
¡ Slight rotation at the bearing 1 must be
4 felt when twisting the coupling 4 by
hand.
6-6
OVER
Installation
1. Install:
2-stage rate coupling and flywheel installa-

tion steps
1) Install the rear end plate 1.
Bolt (rear end plate):

18 N·m (1.8 kgf·m, 13 lbf·ft)
T.R
1
2) Install the flywheel 1 onto the crank-

shaft.
Bolts (flywheel):
157 N·m (16 kgf·m, 116 lbf·ft)
T.R
NOTE:
¡ Clean the contact surfaces of the flywheel
1 and crankshaft.
crisscross pattern.
3) Install the 2-stage rate coupling assem-

bly 1.
Bolts (2-stage rate coupling

1 assembly):
T.R
29 N·m (3.0 kgf·m, 22 lbf·ft)
NOTE:
2
crisscross pattern.
¡ The round edge A of the washer 2 must
face the flywheel 3.
a
3
6-7
OVER
2 4) Install the flywheel housing 1.
5 5) Install the power steering oil cooler 2.
6) Install new gaskets and the boost pipe
3.
7) Install the bracket 4.
4 8) Connect the earth leads 5.
9) Install the starter motor.

Refer to “Starter Motor Installation” sec-
tion (P8-25).
6-8
ENG SEAWATER PUMP E
OVER
SEAWATER PUMP
20
19
18
17
16
15
14
13
12
11
10
A
8
7 9
6
LT
572
4
A
5
3
F WD

1 Bolts 4 1.9 N·m (0.2 kgf·m, 1.4 lbf·ft)
2 Cover 1
3 O-ring 1
4 Impeller 1
5 Cam 1
6 Mechanical seal 1
7 O-ring 1
8 Center collar 1
9 Bolt 1
0 Pump housing 1
6-9
ENG SEAWATER PUMP E
OVER
20
19
18
17
16
15
14
13
12
11
10
A
8
7 9
6
LT
572
4
A
5
3
F WD

A Oil seal 1
B Bearing 1
C Circlip 1
D Bearing 1
E Circlip 1
F Pump shaft 1
G Key 1
H O-ring 1
I Driven gwar 1
J Nut 1 74 N·m (7.5 kgf·m, 55 lbf·ft)
6-10
ENG SEAWATER PUMP E
OVER
Seawater Pump Impeller Removal
1. Remove:
Seawater pump impeller removal step

1) Take off the 4 bolts 1, and remove the
cover 2 and the O-ring 3.
2
1
2) Remove the impeller 1.
CAUTION:
Take care not to damage the impeller 1.
Seawater Pump Removal
¡ WARNING
As soon as the seawater pump hose is dis-
connected, plug the seawater inlet on the
pump to prevent seawater from entering.
1. Remove:
¡ Seawater pump
Seawater pump removal steps

1) Drain the seawater.
2) Remove the inlet 1 and outlet 2 hoses.
6-11
ENG SEAWATER PUMP E
OVER
3) Remove the seawater pump assembly.
Seawater Pump Check

1. Check:
¡ Driven gear
¡ Cover and wear plate
¡ Housing
¡ Impeller
Driven gear checking step

1) Check the driven gear 1 for cracks and/
or damage.
Burrs/Chips/Cracks/Damage → Replace
1
the driven gear.
Cover and wear plate checking step

1) Check the cover and the wear plate for
wear, cracks and/or damage.
Wear/Crack → Replace.
Housing checking step

1) Check the housing 1 for wear, cracks
and/or damage.
Wear/Cracks/Damage → Replace the
1
housing.
Impeller checking step

1) Check the impeller for wear, cracks and/
or damage.
Wear/Cracks/Damage → Replace the im-
peller.
6-12
ENG SEAWATER PUMP E
OVER
Seawater Pump Replacement
1. Replace:
¡ Seawater pump
Seawater pump replacement steps

1) Clamp the driven gear 1 in a vise with
1 soft-jaws 2 to loosen the nut 3.
3
2 2) Remove the nut 3.
3) Remove the driven gear 1, then remove

the key 2.
1
NOTE:
Use a gear puller if necessary.
2 4) Check the key 2.

Replace it if necessary.
5) Check the bearing 1.

Clean and lubricate the bearing, then
rotate the pump shaft.
2
Roughness → Replace the pump assem-
bly.
6) Check the seawater pump housing 2.
1
Cracks/Damage → Replace the pump as-
sembly.
7) Remove the circlip 1.

1
6-13
ENG SEAWATER PUMP E
OVER
8) Press out the pump shaft 1 in the illus-
trated direction.
1
NOTE:
Put out the pump shaft 1 and the bearings
2
2 as a set.
9) Remove the bearings 1 with a bearing

3 separator and general bearing puller.
2 10) Remove the circlip 3 from the pump
shaft 2.
11) Using a suitable rod 1 and hammer, tap

1
4 off the oil seal 2 from the impeller hous-
ing side. Then remove the center collar
3 and O-ring 4.
3
CAUTION:
2
Always use a new O-ring, bearing and oil
seal.
12) Tap off the oil seal 1 from the other side.
13) Using a suitable tool, install the new oil
a seal 1 flush with the bottom line A of
the impeller housing.
impeller housing side
CAUTION:
1 Be sure to install the oil seal 1 with the seal
lips facing toward the impeller housing.
14) Apply Yamaha marine grease A to the

O-ring 2 and the center collar 1.
NOTE:
3
Be sure to install the center collar with the
2 A pins A facing toward the oil seal 3.
a
1
6-14
ENG SEAWATER PUMP E
OVER
15) Using a suitable tool, fit the new oil seal
1 against the center collar. Make sure
1 bearing side
the oil seal is parallel to the pump hous-
ing.
CAUTION:
a Be sure to install the Oil seal 1 with the seal
lips A facing toward the bearing.
A
16) Remove the screw 2, then remove the

cam 1.
2
17) Remove old adhesive from the impeller

housing bore and cam 1.
A
18) Clean the contacting surfaces of the im-
peller housing and new cam with sol-
vent.
1 contacting surfaces of the impeller hous-
ing and new cam 1 and let it to dry for
at least 5 minutes.
20) Install the cam 1 and the screw 2.

Tighten the screw securely.
2 LT
572 NOTE:
Before installing the screw 2, apply
1 LOCTITE ® No. 572 or equivalent to the
threads of the screw.
21) Thoroughly wipe off the excess adhe-

sive.
22) Install a new circlip into the groove of
3 the pump shaft 1.
1 23) Install new bearings 2 tight against the
circlip 3, using a suitable tool and press.
6-15
ENG SEAWATER PUMP E
OVER
24) Apply Yamaha marine grease to the oil
b seal lips.
a 25) Install the pump shaft and bearings.
Apply pressure to the bearing outer race
A to press the shaft into the pump hous-
ing until the bearing outer race is flush
with the inside edge of the circlip groove
B.
26) Install the new circlip 1.

1
27) Install the driven gear 1 onto the pump

shaft.
a 1
NOTE:
b
¡ Position the driven gear so that the flange
B faces towards the pump.
2
¡ Align the set key 2 with the key groove
A of the driven gear 1.
28) Clamp the driven gear 1 in a vise with

1 soft-jaws 2 and tighten the nut 3.
3
2
Nut (pump driven gear):
74 N·m (7.5 kgf·m, 55 lbf·ft)
T.R
6-16
ENG SEAWATER PUMP E
OVER
Seawater Pump Installation
1. Install:
¡ Seawater pump
Seawater pump installation steps

1) Apply Yamaha marine grease A to a new
O-ring 1 and install it on the seawater
pump.
2) Mount the seawater pump in the gear

case engaging the pump with the gear.
6-17
ENG SEAWATER PUMP E
OVER
Seawater Pump Impeller Installation
1. Install:
Seawater pump impeller installation steps

1) Set the wear plate in the housing.
2) Apply some Yamaha marine grease A to

the impeller 1 and push it into the hous-
ing while turning it counterclockwise.
NOTE:
When inserting the impeller 1 into the pump
body, turn it counterclockwise while push-
ing.
1 A
CAUTION:
Make sure that the impeller blades are
turned as shown in the illustration.
3) Install the cover 2 with a new O-ring 3

and tighten the bolts 1 to the specified
torque.
Bolts (cover):
1.9 N·m (0.2 kgf·m, 1.4 lbf·ft)
T.R
3 NOTE:
2
1
If the O-ring comes off, keep it in the ring
groove by use of Yamaha marine grease A.
6-18
ENG HEAT EXCHANGER E
OVER
HEAT EXCHANGER
2 3
LT
243
LT
572
TB
1207B
D
FW TB
1207B
LT
572

1 Side plate mounting bolts 2 12 N·m (1.2 kgf·m, 8.7 lbf·ft)
2 Drain bolt (seawater) 1
3 Anodes 2 16 N·m (1.6 kgf·m, 12 lbf·ft)
6-19
OVER
Heat Exchanger Removal
1. Remove:
¡ Heat exchanger
Heat exchanger removal steps

2) Disconnect the neutral switch coupler 1.
3) Remove the shift assist assembly 2 and
2
the bracket.
3
1 NOTE:
DO NOT disconnect the shift cables 3.
4) Remove the hoses 1.

3 1
5) Loosen the nuts 2 and remove the
clamps 3.
1
6) Remove the heat exchanger.
Heat Exchanger Disassembly

1. Disassemble:
¡ Heat exchanger
Heat exchanger disassembly step

1) Remove the left and right side plates,
gaskets and O-rings.
a
1
NOTE:
Anodes
Before removing the side plate 1 on the ther-
mostat side, put marks A so that it can be
assembled in its original position.
6-20
OVER
Heat Exchanger Check
1. Check:
¡ Side plates
¡ Heat exchanger unit
Side plates checking step
1) Check the side plates for cracks, rust,
corrosion and/or damage.
Cracks/Rust/Corrosion/Damage → Re-
place.
Heat exchanger unit checking step
1) Check the heat exchanger for damage
and/or clogging.
Cracks/Rust/Corrosion/Damage → Re-
place.
Clogged → Wash and clean.
Heat Exchanger Cleaning

1. Clean:
¡ Heat exchanger unit
Heat exchanger unit cleaning steps

1) Soak the heat exchanger in clean water
for 90 – 120 minutes so that deposits can
be removed easily.
2) After washing it with tap water, remove
1 all deposits inside the coolant paths A
a carefully using a hard rod 1.
3) Blow off any debris or deposits from sea-
water paths and dry them with com-
pressed air.
6-21
OVER
Heat Exchanger Assembly
1. Assemble:
¡ Heat exchanger
Heat exchanger assembly steps
1) Remove any old adhesive and clean the
surfaces of the side plate and the heat
exchanger in contact with the gasket.
2) Apply ThreeBond® TB-1207B to the sur-
1 TB
faces 1. Allow them to dry for at least 5
minutes.
1207B
3) Install new gaskets and O-rings 2, 4 and
the side plates 3, 5.
LT
572 Bolts (side plate):

2
12 N·m (1.2 kgf·m, 8.7 lbf·ft)
T.R
3
NOTE:
¡ Install the side plate 5 on the thermostat
end at the position indicated by marks A.
a ¡ Before installation, apply LOCTITE® No.
LT
LT
572 or equivalent to the bolt threads.
572
Anodes
1 TB
5 4 1207B
6-22
OVER
Heat Exchanger Installation
1. Install:
¡ Heat exchanger
Heat exchanger installation steps

1) Install the heat exchanger. Align the pro-
a trusion on the heat exchanger with the
hole on the bracket A.
2) Install the clamps 1 and tighten the nuts.

2
3) Connect the hoses 2.
4) Fill the coolant.
2 Refer to “Coolant Replacement” section
(P3-41).
NOTE:
1 Check for the leakage of coolant.
Thermostat Removal
1. Remove:
¡ Thermostat
Thermostat removal steps

Refer to “Coolant Replacement” section
(P3-41).
2) Remove the thermostat cover 1, then
1
remove the thermostat 2.
6-23
OVER
3) Remove the hollow bolt 1, the gaskets
2 and the coolant by-pass pipe 3.
3
4) Disconnect the thermo switch lead 1

(red/black).
5) Disconnect the water temperature sen-
sor lead 2 (brown/black).
1
2 6) Remove the thermostat housing 1 and

the gasket 2.
6-24
OVER
Thermostat Check
1. Check:
¡ Thermostat cover and the thermostat
housing
¡ Rubber gasket
¡ Thermostat operation
Thermostat cover and thermostat housing

checking step
1) Check the thermostat cover 1 and the
2
1
thermostat housing 2 for damage.
NOTE:
LT When replacing the thermo switch 3 or the
243 water temperature sensor 4, apply a layer
4 3
of LOCTITE® No. 243 or equivalent to two or
three threads before installation. Thoroughly
wipe off the excess adhesive after tighten-
ing.
Thermo switch:
34 N·m (3.5 kgf·m, 25 lbf·ft)
T.R
Water temperature sensor:

10.5 N·m (1.1 kgf·m, 7.7 lbf·ft)
Rubber gasket checking step

1) Check the rubber gasket for wear and/or
damage.
Wear/Damage → Replace the thermostat.
6-25
OVER
Thermostat operation checking steps
1) Place the thermostat in water and gradu-
ally heat the water. Check the thermo-
meter while constantly stirring the wa-
ter.
2) Check the valve opening temperature
and the valve lift.
Thermostat:
Valve opening temperature
74.5 – 78.5 °C (166.1 – 173.3 °F)
Valve lift A
a 90 °C (194 °F): 10 mm (0.39 in.) or more
3) Check that the valve spring is tight when

the thermostat is fully closed.
Replace the thermostat if the valve open-
ing temperature or valve lift is not as
specified.
6-26
OVER
Thermostat Installation
1. Install:
¡ Thermostat
Thermostat installation steps
2 1) Install a new gasket 2 and the thermo-

stat housing 1.
2) Connect the thermo switch lead 1 (red/

black).
3) Connect the water temperature sensor
lead 2 (brown/black).
1
4) Install the thermostat 1.

a
NOTE:
Install the thermostat with the jigger valve
A facing upward.
5) Install the thermostat cover 1 and the

1
hose 2.
(P3-41).
2 NOTE:
Check for the leakage of coolant.
6-27
ENG INTERCOOLER E
OVER
INTERCOOLER
LT
243 3
2
4
5
LT
572
TB
1207B
D
FW
5

1 Side cover mounting bolts 10 11 N·m (1.1 kgf·m, 7.9 lbf·ft)
2 Side cover mounting nuts 10 11 N·m (1.1 kgf·m, 7.9 lbf·ft)
3 Anodes 2 16 N·m (1.6 kgf·m, 12 lbf·ft)
4 Seawater flow dender 1 50 N·m (5.1 kgf·m, 37 lbf·ft)
5 Intercooler mounting bolts 4
6-28
ENG INTERCOOLER E
OVER
Intercooler Removal
1. Remove:
¡ Intercooler
Intercooler removal steps
1) Drain the seawater.
1
2) Remove the air filter 1.
3) Remove the boost pipe 2 and the sea-
a water hoses 3.
NOTE:
Disconnect the seawater flow sender leads
2 A.
3
4) Disconnect the resistor leads 1.

1
1 4 5) Remove the 5 bolts 1 and the oil level

pipe 2, loosen the hose clamp 3, and
remove the intake pipe 4.
6) Disconnect the control unit connector 1.
6-29
ENG INTERCOOLER E
OVER
7) Remove the 3 bolts below the intercooler.
8) Remove the bolt above the intercooler,

then remove the intercooler.
6-30
ENG INTERCOOLER E
OVER
Intercooler Disassembly
1. Disassemble:
¡ Intercooler
Intercooler disassembly steps

1) Remove the front side cover 1 and the
2
3 rubber gasket 2.
1
NOTE:
Remove the collars 3 from the rubber gas-
ket.
2) Remove the rear side cover 1, gasket 3

4
3 and wave washers 2 (four pieces, on the
2
1
four corners), and then pull out the in-
tercooler element 4.
3) Remove the seawater flow sender 1.
6-31
ENG INTERCOOLER E
OVER
Intercooler Check
1. Check:
¡ Anodes
¡ Intercooler housing and side covers
¡ Breather hose
¡ Intercooler element
¡ Element core
¡ Seawater flow sender
Anodes checking step

1) Check the excessive wear of anodes.
Refer to “Anode Check” section (P3-38).
Intercooler housing and side covers check-

ing step
1) Check the intercooler housing and the
side covers for damage.
Damage → Replace.
Breather hose checking step

1) Check the breather hose for cracks and/
or damage.
Intercooler element checking step

1) Check the intercooler element 1 for
1
Element core checking steps

1) Check the element core 1 for clogging
and/or dirt.
Dirty/Clogged → Remove by blowing the
compressed air.
a
1 2) Check the fins A for any deformation.
Flattening of fins → Repair or replace the
element.
Seawater flow sender checking step

1) Check the seawater flow sender.
Refer to “Seawater Flow Sender Check”
section (P8-50).
6-32
ENG INTERCOOLER E
OVER
Intercooler Cleaning
1. Clean:
¡ Intercooler element
Intercooler element cleaning steps

1) Soak the intercooler element 1 in clean
water for 90 – 120 minutes so that de-
posits can be removed easily.
1
2) After washing it with tap water, remove

all deposits inside the coolant paths care-
fully using a hard rod 1.
3) Blow off any debris or deposits from
coolant paths and dry them with com-
1 pressed air.
NOTE:
¡ Sodium hydrate may be used for easier
removal of rusting.
¡ When sodium hydrate is used for clean-
ing, thoroughly flush the element with tap
water after the cleaning.
4) Install the seawater flow sender 1 and

1
the elbow joint 2.
LT
LT 572
NOTE:
2
572 Before reinstalling the seawater flow sender
4
3
1 and the elbow joint 2 on the rear side
cover 3, apply a single coating of LOCTITE®
No. 572 or equivalent to the threads. Wipe
off any excess adhesive.
Seawater flow sender:

50 N·m (5.1 kgf·m, 37 lbf·ft)
T.R
CAUTION:
Always use a new gasket 4 for the seawa-
ter flow sender.
6-33
ENG INTERCOOLER E
OVER
Intercooler Assembly
1. Assemble:
¡ Intercooler
Intercooler assembly steps

1) Install a new gasket on the housing (rear
side), and apply ThreeBond® TB-1207B
over the range indicated in the illustra-
15mm
tion.
NOTE:
88mm
¡ Be careful that ThreeBond® TB-1207B
does not enter the sealing surface of the
gasket.
¡ Place a wave washers on the four corners.
TB
Gasket
1207B
Apply R
ThreeBond TB-1207B
2) Tighten the mounting bolts on the rear

side cover to the specified torque in two
passes in a crisscross pattern.
Nuts (rear side cover):

11 N·m (1.1 kgf·m, 7.9 lbf·ft)
T.R
3) Insert the intercooler element using a

new gasket 1.
1 4) Attach the collars on a new gasket 1,
then mount the side cover 2 on the
housing (front side).
Bolts (front side cover):

2
11 N·m (1.1 kgf·m, 7.9 lbf·ft)
T.R
6-34
ENG INTERCOOLER E
OVER
Intercooler Installation
1. Install:
¡ Intercooler
Intercooler installation steps

Reverse the “Removal” procedure.
Note the following points.
CAUTION:
Always use a new gasket.
1) Install the intercooler assembly 1.

1
2) Connect the control unit connector 1.
3) Install the intake pipe 1 and boost com-

pensator hose 2.
1
4) Connect the resistor leads 1.

1
6-35
ENG INTERCOOLER E
OVER
5) Install the boost pipe 1, seawater hoses
3
2, and air filter 3.
a
NOTE:
Connect the seawater flow sender leads A.
6-36
ENG TURBOCHARGER E
OVER
TURBOCHARGER
D
FW

1 Drain bolt (coolant) 1 33 N·m (3.4 kgf·m, 24 lbf·ft)
6-37
ENG TURBOCHARGER E
OVER
D
FW

1 Oil pipe union bolt 1 11 N·m (1.1 kgf·m, 7.9 lbf·ft)
2 Oil pipe union bolt 1 11 N·m (1.1 kgf·m, 7.9 lbf·ft)
3 Oil pipe 1
4 Oil drain pipe 1
6-38
ENG TURBOCHARGER E
OVER
20
17
16 18
15
19
13
14
13
12
18
Blower side 19
11
10 2
1
8
7
6
5
4
3

1 Compressor housing 1
2 O-ring 1
3 Impeller lock nut 1
4 Impeller 1
5 Spacer 1
6 Snap ring 1
7 Retainer 1
8 O-ring 1
9 Corer thrust 1
0 Thrust bearing 1
A Center housing 1
B Shelled wheel 1
C Floating bearings 2
D Sleeve 1
E Turbine wheel and shaft 1
F Ring seal 1
G Snap ring 1
H Plate clamps 3
I Bolts 6
J Turbine housing 1
6-39
ENG TURBOCHARGER E
OVER
Handling Precautions
CAUTION:
1. Do not stop the engine immediately af-
ter the high speed running. Let the en-
gine idling for about 5 minutes to cool
down.
2. Avoid sudden racing or acceleration im-
mediately after starting the cold engine.
3. If the turbocharger is defective and must
be replaced, first try to find the cause of
the defect by checking the following
items.
¡Engine oil level and quality
¡Oil lines leading to the turbocharger
¡Conditions under which the turbo-
charger was used
4. Use caution when removing and install-
ing the turbocharger assembly.
Do not drop it or bang it against anything
or grab it by easily-deformed parts, such
as the actuator rod.
5. Before removing the turbocharger, plug
the intake and exhaust ports and the oil
inlet to prevent entry of dirt or other ma-
terial.
6. When replacing the turbocharger, check
for the accumulation of sludge particles
in the oil pipes and, if necessary, replace
the oil pipes.
7. Completely remove the old gasket ad-
hered to the lubrication oil pipe flange
and turbocharger oil flange.
8. The new bolts and nuts used for the re-
placement shall be of the specified type
to prevent breakage or deformation.
9. When replacing the turbocharger, put 20
cc (1.2 cu. in.) of oil into the impeller
wheel by hand to distribute oil in the
bearing.
10. After the overhauling or engine replace-
ment, shut off the fuel supply and crank
the engine for 30 seconds to distribute
oil in the engine. Then let the engine
idling for 60 seconds.
11. If the engine is running without the air
cleaner, case cover and hose, entering
foreign particles will damage the compo-
nents of the turbine running at very high
speed.
6-40
ENG TURBOCHARGER E
OVER
Turbocharger Removal
1. Remove:
¡ Turbocharger
Turbocharger removal steps

2) Remove the air filter.
4) Separate the coolant by-pass pipe 1 and
the oil pipe 2, then remove the gaskets.
1
NOTE:
Place a rag under the coolant by-pass pipe
ends to avoid spilling the fluid.
2
5) Remove the oil drain pipe 1 and the gas-

ket 2.
6) Loosen the clamps 1 of the joint hose

2
3 2.
7) Remove the bolts 3 below the turbo-
charger.
1
8) Remove the boost pipe 1.
6-41
ENG TURBOCHARGER E
OVER
9) Loosen the nuts 1 (double nuts at four
places) and remove the turbocharger 2
1 and gasket 3.
Turbocharger Check
1. Check:
¡ Turbine wheels
¡ Turbine housing
¡ Turbine wheels rotation
¡ Axial play (turbine wheels)
¡ Radial play (turbine shaft)
¡ Oil pipe
Turbine wheels checking step

1) Check the turbine wheels 1 for damage.
1 Cracks/Damage → Replace.
Turbine housing checking step

1) Check the turbine housing 2 for dam-
age.
2
Turbine wheels rotation checking step

1) Turn the turbine wheels, and check if it
moves smoothly.
Roughness → Replace.
6-42
ENG TURBOCHARGER E
OVER
Axial play (turbine wheels) checking steps
1) Set the dial gauge at the exhaust end.
2) Check the axial play of the turbine shaft,
holding the turbine wheel by hand.
Axial play (turbine wheels):

Standard
0.050 – 0.125 mm (0.002 – 0.005 in.)
<Limit> 0.155 mm (0.006 in.)
Radial play (turbine shaft) checking steps

1) Set the dial gauge as shown in the illus-
tration.
2) Check the radial play of the turbine shaft
by moving the shaft by hand in radial
direction.
Out of specification → Replace the tur-
bocharger assembly.
Radial play (turbine shaft):

Standard
0.075 – 0.125 mm (0.003 – 0.005 in.)
<Limit> 0.165 mm (0.006 in.)
Oil pipe checking step

1) Check the oil pipe for damage.
6-43
ENG TURBOCHARGER E
OVER
Turbocharger Disassembly
1. Disassemble:
¡ Turbocharger
Turbocharger disassembly steps

1) Remove the 6 bolts 1 and the 3 plate
1
2 clamps 2.
2) Put matching marks A on the center

housing and the turbine housing, and re-
move the compressor housing assembly
1.
1
a CAUTION:
Pay attention that the turbine wheel does
not come in touch with the exhaust turbo-
charger housing.
3) Remove the snap ring 1, and remove

1 the center housing lightly tapping on the
periphery of the compressor housing 2.
CAUTION:
¡ Put your hands on the snap ring to stop
it from jumping out.
2
¡ Pay attention that the impeller does not
come in touch with the compressor hous-
ing.
NOTE:
Check in which way the tapered surface of
the snap ring faces.
6-44
ENG TURBOCHARGER E
OVER
4) Put matching marks A on the impeller
a
and the turbine shaft.
CAUTION:
Disassembly without putting the matching
marks will cause the rotational imbalance
after the reassembly.
5) Clamp the turbine housing with a vise

and set the bearing housing on it. Re-
move the lock nut on the compressor
wheel while locking the boss on the shaft
and turbine wheel.
CAUTION:
Before loosening the lock nut, put appropri-
ate marking to maintain the relative posi-
tioning of the compressor wheel and the
turbine wheel.
NOTE:
¡ Impeller lock nut is a left-handed screw.
¡ Do not knock the shaft end with a ham-
mer or the like.
6) Press the turbine wheel 1 by hand, and

2 remove the compressor wheel 2 by
turning it softly.
7) Remove the snap ring.
NOTE:
Check to which way the tapered surface of
the snap ring faces.
(The flat surface should face to the retainer
sub assembly.)
6-45
ENG TURBOCHARGER E
OVER
8) Pull out the ritainer without forceful ac-
tions.
1 9) Remove the O-ring 1 and take out the

thrust bearing 3, and the corer thrust 2.
2
10) Remove the ring seal 1.

1
11) Cleaning and visual inspection of each

part.
¡ Visually inspect the parts before
cleaning, to check any trace of seizure,
abrasion, foreign matters, and carbon
deposits.
¡ Clean the parts with light oil using a
soft brush or the like. Then, dry them
with compressed air.
CAUTION:
¡ Never use caustic detergent, since it
causes corrosion on the aluminum.
¡ DO NOT use a wire brush.
6-46
ENG TURBOCHARGER E
OVER
Turbocharger Measurement
1. Measure:
¡ Turbine shaft
¡ Center housing
¡ Corer thrust
¡ Floating bearing
¡ Thrust bearing
Turbine shaft measurement steps
B 1) Measure the outer diameter of the shaft

and turbine wheel journal A.
2) Set the dial gauge next to the shaft
threads and measure the runout B.
A
Turbine shaft diameter limit:
A : 11.986 mm (0.472 in.)
Turbine shaft runout limit:
B : 0.005 mm (0.0001 in.)
Center housing measurement step

1) Measure the inner diameter of the cen-
D
ter housing C, D.
Center housing inner diameter

C
limit:
C : 18.012 mm (0.713 in.)
D : 20.02 mm (0.778 in.)
Corer thrust measurement step

1) Measure the corer thrust height E.
Corer thrust height limit:

E
E : 5.075 mm (0.2 in.)
6-47
ENG TURBOCHARGER E
OVER
Floating bearing measurement steps
1) Measure the inner diameter of the float-
ing bearing.
2) Measure the outer diameter of the float-
ing bearing.
Floating bearing
Inner diameter limit:
12.04 mm (0.474 in.)
Outer diameter limit:
17.92 mm (0.705 in.)
Thrust bearing measurement step

1) Measure the thrust bearing thickness.
Thrust bearing thickness limit:

4.94 mm (0.194 in.)
6-48
ENG TURBOCHARGER E
OVER
Turbocharger Assembly
1. Assemble:
¡ Turbocharger
NOTE:
Pay close attention to the cleanliness. Even
a fine dust may cause serious trouble, be-
cause of the high rotational speed of the tur-
bocharger.
Turbocharger assembly steps

1) Clamp the exhaust turbine housing with
a vise.
NOTE:
Put some cushioning material between the
turbine housing and the vise jaws.
2) Install the ring seal 2 on the shaft and

2
turbine wheel 1.
NOTE:
¡ DO NOT use any deformed ring seal.
¡ Apply engine oil to the ring seal.
1
3) Assemble the shaft and turbine wheel to

the center housing.
NOTE:
¡ Take precautions not to scratch the ring
seal.
¡ If a ring seal is too tight to make easy in-
sert, do not drive it in. Replace the ring
seal with a new one.
4) Temporarily attach the center housing

and the coupling assembly to the turbine
1 housing, and assemble the floating bear-
ings 1 and the sleeve 2.
2
NOTE:
1
Apply engine oil to the floating bearings.
6-49
ENG TURBOCHARGER E
OVER
5) Apply some engine oil on both surfaces
of the thrust bearing 1. Mount the thrust
bearing, aligning the hole on the thrust
1 bearing with the knock pin. Tighten the
screws to the specified torque.
NOTE:
2
¡ Make sure that the notch on the thrust
Blower side bearing is aligned with the oil drain line
on the center housing.
¡ The chamfer on the corer thrust 2 must
face the center housing.
Screws:
1.75 N·m (0.18 kgf·m, 1.3 lbf·ft)
T.R
6) Set a new O-ring 1 and install the re-
tainer 2 on the center housing. Fix them
firmly with the snap ring 3.
3 NOTE:
The flat face of the snap ring must face the
retainer sub assembly.
1
2
7) Fix the center housing to the turbine

a housing, temporarily place the compres-
sor wheel, and tighten the impeller lock-
nut 1 to the specified torque.
NOTE:
¡ Align the matching marks A on the im-
peller and the turbine shaft at the time of
assembly.
¡ Impeller lock nut is a left-handed screw.
1
Impeller lock nut:

9.3 N·m (0.95 kgf·m, 6.83 lbf·ft)
T.R
6-50
ENG TURBOCHARGER E
OVER
8) Set the dial gauge at the end of shaft and
turbine wheel. Measure the play by mov-
ing the compressor wheel along the axis
by hand.
Roughness → Replace the ring seal.
NOTE:
Probable cause of the roughness or heavy
rotation is a deformed ring seal or a foreign
matter trapped in the bearing or the sealing
area. In any case, disassembly check must
be performed again.
9) Set a new O-ring 1 and install the com-

pressor housing 2 to the center hous-
a ing aligning the matching marks A. Fix
1
them with the snap ring 3.
2 CAUTION:
¡ Pay attention that impeller does not
come in touch with the compressor hous-
ing.
¡ Align the matching marks on the com-
pressor housing and the center housing.
NOTE:
3
The flat face of the snap ring 3 must face
the retainer sub assembly.
10) Install the center housing to the turbine

housing aligning the matching marks A.
Set the lock plate and tighten the bolts
to the specified torque.
Bolts (turbine housing):

a
22.5 N·m (2.3 kgf·m, 16.6 lbf·ft)
T.R
NOTE:
¡ Prevent free turning.
¡ Align the matching marks on the exhaust
turbocharger housing and the center
housing.
¡ Pay attention that impeller does not come
in touch with the exhaust turbocharger
housing.
6-51
ENG TURBOCHARGER E
OVER
11) Pour the engine oil into the impeller
wheel.
NOTE:
After replacing the turbocharger assembly,
pour approx. 20 cc of new oil into the oil in-
let and rotate the turbine wheels by hand to
splash oil onto the bearing.
Turbocharger Installation
1. Install:
¡ Turbocharger
Turbocharger installation steps

1) Install the turbocharger 2 using a new
gasket 1.
3 2) Tighten the nuts 3 (double nuts).
3) Install the boost pipe 4 using a new gas-

ket.
4) Tighten the bolts 1.

2
1 5) Set the joint hose 2 in position and
tighten the hose clamps 3.
6-52
ENG TURBOCHARGER E
OVER
6) Install the oil drain pipe 2 using a new
gasket 1.
7) Install the oil pipe 1 using a new gas-

ket.
2 Hollow bolt (oil pipe):

11 N·m (1.1 kgf·m, 7.9 lbf·ft)
T.R
8) Install the coolant by-pass pipe 2 using
1 a new gasket.
Hollow bolt (coolant by-pass pipe):

20 N·m (2.0 kgf·m, 14 lbf·ft)
T.R
9) Install the mixing elbow using a new gas-

ket 1.
1
NOTE:
As installed, the pressure bonding area of the
gasket must come to the illustrated position.
10) Install the air filter.

(P3-41).
NOTE:
6-53
ENG TURBOCHARGER E
OVER
Refer to “Engine Oil Level Check” sec-
tion (P3-12).

YAMAHA diesel engine oil
SAE I5W-40, API CD or CE
Turbocharger Pressure Measurement
NOTE:
¡ The pressure of the turbocharger should
be checked after disassembly or replace-
ment of turbocharger components.
¡ Before measuring the turbocharger pres-
sure, the proper maintenance should be
performed on the following systems.
1) Air Intake System
Check for leakage or clogging between
the air cleaner and the turbocharger inlet
and between the turbocharger outlet and
the cylinder head inlet.
Air cleaner clogged → Clean or replace
the element.
Leakage from a component → Repair or
replace.
Deformed or damaged component → Re-
pair or replace.
2) Exhaust System
Check for leakage or clogging between
the cylinder head and the turbocharger
inlet and between the turbocharger out-
let and the exhaust pipe.
Foreign material in flow path → Remove.
Leakage from a component → Repair or
replace.
Deformed or damaged component → Re-
pair or replace.
6-54
ENG TURBOCHARGER E
OVER
1. Measure:
¡ Turbocharger pressure
NOTE:
If the boost pressure is lower than the speci-
fication, check the air intake system includ-
ing the engine room air intake, air filter and
intercooler. If malfunction is not found in
these components, check the turbocharger
and engine body.
Turbocharger pressure measurement steps

1) Start the engine and allow it to warm up
to the normal operating temperature.
2) Remove the plug 1 from the inspection

1
port.
3) Install the adapter 1 and connect the

pressure gauge 2 to it.
2
4) Measure the turbocharger pressure at
1
the specified engine speed.
Standard pressure (at 3600 r/min.)

125.5 ± 10 kPa
(1.29 ± 0.1 kgf/cm2, 18.2 ± 1.5 psi)
5) Remove the turbocharger pressure

gauge 2 and adapter 1.
6) Apply LOCTITE® No. 572 or equivalent

1 to the threads of the joint plug 1.
LT
572 7) Attach the plug 1 to the inspection port.
Joint plug (Boost sender):

9.8 N·m (1.0 kgf·m, 7.2 lbf·ft)
T.R
6-55
ENG MIXING ELBOW AND EXHAUST MANIFOLD E
OVER
MIXING ELBOW AND EXHAUST MANIFOLD

1 Exhaust manifold mounting nuts (double nuts) 18 43 N·m (4.4 kgf·m, 32 lbf·ft)
6-56
OVER
Mixing Elbow and Exhaust Manifold
Removal
1. Remove:
¡ Mixing elbow and exhaust manifold
Mixing elbow and exhaust manifold removal

steps
(P3-41).
3) Remove the turbocharger.
Refer to “Turbocharger Removal” sec-
tion (P6-41).
4) Remove the bracket 1 with seawater
strainer assembly 2.
5) Remove the cooling hose 1.
6) Remove the cover of the electrical box,

then remove the stay (4 bolts).
6-57
OVER
7) Disconnect the shift cable 1 at the re-
4
mote control end.
2
8) Disconnect the shift cable 2 at the drive
unit end.
9) Disconnect the neutral switch coupler 3.
3 10) Remove the shift assist assembly 4.
11) Remove the hose holder under the ex-
1
haust manifold.
Refer to “Heat Exchanger Removal” sec-
tion (P6-20).
13) Disconnect the thermo switch lead 1

(red/black).
15) Remove the thermostat housing bolts 1

and the hose 2.
1
16) Remove the heat exchanger bracket 1.
6-58
OVER
17) Remove the exhaust manifold 1.
18) Remove the exhaust manifold gasket 1.

1
Exhaust Manifold Check

1. Check:
¡ Exhaust manifold
¡ Exhaust manifold warpage
¡ Filler neck
NOTE:
Before the inspection, remove the fractions
of old gasket remaining on the exhaust mani-
fold, and clean it with a non-residual solvent
and a soft brush.
Exhaust manifold checking step

1) Check the exhaust manifold for damage
by means of visible dye penetrant.
6-59
OVER
Exhaust manifold warpage checking step
1) Check the warpage on the contact sur-
faces of the exhaust manifold and the cyl-
inder head by use of a straight edge and
a thickness gauge.
Manifold warpage:
Or less 0.20 mm (0.0079 in.)
Filler neck checking steps

1) Check the contact surface 1 of the cool-
ant filler neck seal for damage and/or
1 cracks.
Damage/Cracks → Replace.
2) Check the coolant filler neck locking tab
2 for bending and/or damage.
2
Bending/Damage → Replace.
Filler Neck Replacement

1. Replace:
¡ Filler neck
Filler neck replacement steps

1) Remove the filler neck 1.
a
1 2) Remove the O-ring 2 from the filler neck.
3) Install the new filler neck 1 with a new
2 O-ring 2.
A
NOTE:
Breather pipe A must face rearward as in-
stalled.
6-60
OVER
Mixing Elbow Check
NOTE:
¡ Before the inspection, remove the frac-
tions of old gasket remaining on the mix-
ing elbow, and clean it with a non-residual
solvent and a soft brush.
¡ Be careful not to scratch the gasket con-
tact surface.
1. Check:
¡ Mixing elbow
¡ Water temperature sensor
¡ Thermo switch
Mixing elbow checking step

1) Check the mixing elbow 1 for cracks and
damage by means of visible dye pen-
etrant.
NOTE:
1
¡ Once the plug 2 is removed, apply
LOCTITE ® No. 243 before mounting it
again.
¡ Once the joint plug 3 is removed, replace
the O-ring with a new one, and apply
LOCTITE ® No. 243 before mounting it
3
LT
again. Mounting angle shall be 90° rela-
243
tive to the mixing elbow mounting sur-
face.
2 Plug 2:
10 N·m (1.0 kgf·m, 7.4 lbf·ft)
T.R
Water temperature sensor checking step

1) Refer to “Water Temperature Sensor
Check” section (P8-51).
Thermo switch checking step

1) Refer to “Thermo Switch Check” section
(P8-52).
6-61
OVER
Mixing Elbow and Exhaust Manifold
Installation
1. Install:
Mixing elbow and exhaust manifold instal-

lation steps
1) Install a new gasket 1 on the exhaust
a manifold.
NOTE:
Install the exhaust manifold gasket with the
gasket links A on the upper side.
2) Install the exhaust manifold 1.
1 Nuts (exhaust manifold):

43 N·m (4.4 kgf·m, 31 lbf·ft)
T.R
NOTE:
Tighten the nuts in a crisscross pattern start-
ing in the middle.
3) Install the heat exchanger bracket.
Bolts (bracket-heat exchanger):

117 N·m (12 kgf·m, 86 lbf·ft)
T.R
4) Connect the hose, thermo switch lead 1

(red/black) and water temperature sen-
6-62
OVER
5) Install a new gasket, thermostat housing
1, and hose 2.
1 6) Install the heat exchanger.
Refer to “Heat Exchanger Installation”
section (P6-23).
7) Install the turbocharger.
2
Refer to “Turbocharger Installation” sec-
tion (P6-52).
8) Install the shift assist assembly 1.

3 1 9) Connect the neutral switch coupler 2.
10) Connect the shift cable 3 at the drive unit
end.
11) Connect the shift cable 4 at the remote
2 control end.
12) Install the electrical box stay, electrical

box, and cover.
13) Install the cooling hose 1.
14) Install the bracket 1 and the seawater

strainer assembly 2.
6-63
OVER
15) Install the mixing elbow.
(P3-41).
NOTE:
6-64
ENG CIRCULATION PUMP E
OVER
CIRCULATION PUMP
1
3
FWD

1 Nuts 4 20 N·m (2.0 kgf·m, 14 lbf·ft)
2 Bolts 5 25 N·m (2.5 kgf·m, 18 lbf·ft)
3 Circulation pump assembly 1
6-65
OVER
Circulation Pump Removal
1. Remove:
¡ Circulation pump
Circulation pump removal steps

(P3-41).
2) Remove the drive belts.
Refer to “Drive Belts Replacement” sec-
tion (P3-27).
3) Remove the adjusting pulley.
4) Remove the circulation pump pulleys 1.

1
5) Remove the circulation pump 1 and the

gasket.
1
6-66
OVER
Circulation Pump Check
1. Check:
¡ Bearing (circulation pump)
¡ Circulation pump housing
Circulation pump bearing checking step

1) Turn the pulley to check the movement.
Roughness → Replace the circulation
pump assembly.
Circulation pump housing checking step

1) Check the circulation pump housing 1
for cracks and/or damage.
Cracks/Damage → Replace the circula-
tion pump assembly.
Circulation Pump Installation

1. Install:
¡ Circulation pump
Circulation pump installation steps

1) Install a new gasket and the circulation
pump 1.
1
Bolts (circulation pump):
25 N·m (2.5 kgf·m, 18 lbf·ft)
T.R
6-67
OVER
2) Install the circulation pump pulleys 1 in
take the illustrated orientation, and
tighten the pump pulley nuts 2 to the
1
specified torque.
2
Nuts (circulation pump pulley):

20 N·m (2.0 kgf·m, 14 lbf·ft)
T.R
3) Install the adjusting pulley.
4) Install the drive belts.

tion (P3-27).

(P3-41).
NOTE:
6-68
ENG TIMING GEARS E
OVER
TIMING GEARS
15
16 22 New
18
17 19
21
5 13
10 11
9
New
12
20
6
4
2
New
1
14
3

1 Crankshaft pulley #2 bolts 6 1.9 N·m (0.2 kgf·m, 1.4 lbf·ft)
2 Crankshaft pulley #2 1
3 Crankshaft pulley #1 bolt 1 294 N·m (30 kgf·m, 217 lbf·ft)
4 Crankshaft pulley #1 1
5 Timing gear cover bolts 18 M8 bolt: 18 N·m (1.8 kgf·m, 13 lbf·ft)
M10 bolt: 37 N·m (3.8 kgf·m, 27 lbf·ft)
6 Timing gear cover 1
7 Oil seal 1
8 Idler gear thrust plate bolts 2 47 N·m (4.8 kgf·m, 35 lbf·ft)
9 Thrust plate 1
0 Idler gear 1
6-69
ENG TIMING GEARS E
OVER
15
16 22 New
18
17 19
21
5 13
10 11
9
New
12
20
6
4
2
New
1
14
3

A Bushing 1
B Idler gear shaft hollow bout 1 9.8 N·m (1.0 kgf·m, 7.2 lbf·ft)
C Idler gear shaft 1
D Injection pump drive gear 1
E Camshaft thrust plate bolts 2 18 N·m (1.8 kgf·m, 13 lbf·ft)
F Thrust plate 1
G Camshaft drive gear bolt 1 37 N·m (3.8 kgf·m, 27 lbf·ft)
H Washer 1
I Camshaft drive gear 1
J Crankshaft timing gear 1
K Timing gear case bolts 8 M10 bolt: 18 N·m (1.8 kgf·m, 13 lbf·ft)
L Timing gear case 1
6-70
ENG TIMING GEARS E
OVER
Timing Gear Removal
1. Remove:
¡ Timing gear
Timing gear removal steps

tion (P3-27).
2) Remove the seawater pump assembly.
Refer to Seawater Pump Removal” sec-
tion (P6-11).
3) Remove the circulation pump pulley.
Refer to “Circulation Pump Removal”
section (P6-66).
4) Remove the crankshaft pulley #2 1.
5) Remove the crankshaft pulley #1 mount-

ing bolt.
6) Remove the plate washer using a crank-
2
shaft pulley holding tool 1 and compan-
ion flange holding tool 2.
NOTE:
Use a power wrench if necessary.
1
Crankshaft pulley holding tool:

09213-58013 or (90890-07501)
Companion flange holding tool:
09330-00021
6-71
ENG TIMING GEARS E
OVER
7) Remove the crankshaft pulley with the
puller C set 1 and the adapter.
Puller C set:
09950-50013
 09951-05010 
 09952-05010 
 
1
 09953-05020 
 09954-05021 
or (90890-0740A, 90890-07512)
Adapter:
09958-20010 or (90890-07511)
NOTE:
¡ Screw-in the two bolts of the puller by
more than 8 mm (0.31 in.).
¡ Always keep the tool body parallel to the
crankshaft pulley.
8) Remove the timing gear cover 1.

1
CAUTION:
Be careful not to damage the gear cover and
gear case matching surfaces.
9) Check the thrust clearance of the idler

gear 1 with a thickness gauge 2.
1
Out of specification → Replace the idler
gear thrust plate.
Idler gear thrust clearance:

0.06 – 0.17 mm (0.0024 – 0.0070 in.)
<Limit> 0.30 mm (0.0118 in.)
2
Replace the idler gear and/or idler gear
shaft if necessary.
6-72
ENG TIMING GEARS E
OVER
10) Check the timing gear backlash with a
dial gauge.
Out of specification → Replace the gears
as a set.
Timing gear backlash:

0.06 – 0.16 mm (0.0024 – 0.0063 in.)
<Limit> 0.30 mm (0.0118 in.)
NOTE:
Measure the timing gear backlash at the fol-
lowing points:
Injection pump x idler gear
Crankshaft x idler gear
Camshaft x idler gear
11) Remove the injection pump drive gear

1.
12) Remove the thrust plate 1 and the idler

gear 2.
1
2
6-73
ENG TIMING GEARS E
OVER
13) Remove the hollow bolt 1 and the idler
gear shaft 2.
2
1
14) Remove the camshaft thrust plate bolts.
15) Remove the camshaft with camshaft

drive gear 1.
NOTE:
The engine must be placed upside down
when removing the camshaft, because the
valve lifter will get stuck on the body.
1
16) Remove the bolt 1.

Use a pipe wrench.
CAUTION:
Do not clamp the journal or the cam with a
pipe wrench.
17) Remove the camshaft drive gear 1.

1
Use a universal puller set.
6-74
ENG TIMING GEARS E
OVER
18) Remove the crankshaft timing gear 1.
1 Use the pulley and gear puller set 2 and
2 the adapter.
Puller C set:
09950-50013
 09951-05010 
 09952-05010 
 
 09953-05020 
 09954-05021 
or (90890-0740A, 90890-07512)
Adapter:
09958-20010 or (90890-07511)
NOTE:
¡ Screw-in the puller by more than 8 mm
(0.31 in.).
¡ Always keep the tool body parallel with
the drive gear.
6-75
ENG TIMING GEARS E
OVER
Timing Gear Check
1. Check:
¡ Gears
¡ Contact surfaces
¡ Oil passages
¡ Idler gear to gear shaft clearance
¡ Injection pump drive bearing
Timing gears checking step

1) Check the gear for burrs, chips, cracks
and/or damage.
Burrs/Chips/Cracks/Damage → Replace.
Contacting surfaces checking step

1) Check the contact surfaces A of the idler
a gear and the shaft.
Pitting/Blue discoloration/Damage →
b Replace the gear and shaft as a set.
Oil passages checking step

1) Check the oil passage B.
Contamination → Wash and blow out the
oil passages.
6-76
ENG TIMING GEARS E
OVER
Idler gear to gear shaft clearance checking
steps
1) Measure the inner diameter of the idler
gear 1 with a cylinder gauge.
Idler gear inner diameter:

45.000 – 45.025 mm (1.772 – 1.773 in.)
1
2) Measure the diameter of the idler gear

shaft 2 with a micrometer.
Idler gear shaft diameter:

44.942 – 44.975 mm (1.769 – 1.771 in.)
2
3) Calculate the idler gear to gear shaft

clearance using the formula indicated
below.
Idler gear to gear shaft clearance =

Idler gear inner diameter –
Idler gear shaft diameter
If out of specification, replace the gear

and shaft as a set.
Idler gear to gear shaft clearance =

0.025 – 0.075 mm (0.001 – 0.003 in.)
<Limit> 0.20 mm (0.008 in.)
Injection pump drive bearing checking step

1) Clean and lubricate, then turn the bear-
ing outer race by hand.
Roughness → Replace injection pump
drive gear assembly.
6-77
ENG TIMING GEARS E
OVER
Timing Gear Cover Check
1. Check:
¡ Timing gear cover
¡ Crankshaft oil seal
Timing gear cover checking step

1) Check the timing gear cover 1 for cracks
and/or damage.
Crankshaft oil seal checking step

1) Check the crankshaft oil seal for wear
and/or damage.
Wear/Damage → Replace.
Oil Seal Replacement

1. Replace:
¡ Oil seal
Oil seal replacement steps

1) Tap out the oil seal 1 with a suitable tool
and a hammer.
6-78
ENG TIMING GEARS E
OVER
2) Using the crankshaft oil seal replacer,
tap-in a new oil seal until its surface is
flush with the edge of the timing gear
cover 1.
lip of the oil seal.
1 Crankshaft oil seal replacer:

09223-78010
Timing Gear Installation

1. Install:
¡ Timing gear
NOTE:
¡ Carefully clean all parts to be installed.
¡ Apply clean engine oil to all sliding and
rotating surfaces before installing parts.
Timing gear installation steps

1) Remove the fractions of old gasket re-
maining on the timing gear cover and the
timing gear case.
2) Clean the sealing surfaces of the timing
gear cover and the case with a non-re-
sidual solvent.
3) Install the set key on the crankshaft.
4) Install the crankshaft timing gear 1.
Tap-in the timing gear using the cover
and seal replacer 2 and a hammer.
Cover and seal replacer:

a 09223-00010
NOTE:
2 1
¡ Position the timing gear 1 so that the tim-
ing marks A face forward.
¡ Align the set key with the key groove of
the timing gear.
6-79
ENG TIMING GEARS E
OVER
5) Install the idler gear shaft 1.
1
6) Assemble the thrust plate 1 and timing

gear 2 with key 3 to the camshaft.
2 3
7) Install the camshaft drive gear 1 onto

the camshaft 2.
2 Bolt (camshaft drive gear):

38 N·m (3.8 kgf·m, 28 lbf·ft)
T.R
8) Install the idler gear 1 and the camshaft

drive gear 3 and camshaft.
3
NOTE:
¡ The engine must be placed upside down
when installing the camshaft, because the
1
2 ¡ Align the idler gear timing marks “1” and
“2” with the crankshaft timing gear 2
mark ”1” and the camshaft drive gear 3
timing mark “2” respectively, then mesh
the gears.
¡ Lubricate the face of the bearing with en-
gine oil.
6-80
ENG TIMING GEARS E
OVER
9) Install the camshaft thrust plate bolts.
Bolts (camshaft thrust plate):

18 N·m (1.8 kgf·m, 13 lbf·ft)
T.R
10) Install the thrust plate 1.
Bolts (thrust plate):

1
47 N·m (4.8 kgf·m, 35 lbf·ft)
T.R
11) Install the injection pump drive gear 1.

1
NOTE:
Align the idler gear timing mark “1” and “0”
with crankshaft timing gear 2 mark “1” and
injection pump drive gear 1 timing mark “0”
respectively, then mesh the gears.
2
1
12) Install the timing gear cover 1.
Bolts (timing gear cover):

M8: 18 N·m (1.8 kgf·m, 7.2 lbf·ft)
T.R
M10: 37 N·m (3.8 kgf·m, 27 lbf·ft)
NOTE:
Tighten the bolts in a crisscross pattern.
13) Install the set key and the crankshaft pul-

ley #1 1.
NOTE:
¡ Align the set key with the key groove on
the pulley.
¡ Using an appropriate tool 2 and a ham-
2 1 mer, tap-in the pulley.
6-81
ENG TIMING GEARS E
OVER
14) Install the crankshaft pulley bolt using
the companion flange holding tool 1
and the crankshaft pulley holding tool 2.
Crankshaft pulley holding tool:

2
09213-58013
Companion flange holding tool:
1 09330-00021
Bolt (crankshaft pulley):

294 N·m (30 kgf·m, 217 lbf·ft)
T.R
NOTE:
Lubricate the bolt with oil and tighten it.
15) Install the crankshaft pulley #2 1.
Bolts (crankshaft pulley #2):

25 N·m (2.5 kgf·m, 18 lbf·ft)
T.R
NOTE:
Tighten the bolts in a crisscross pattern.
16) Install the seawater pump assembly.

Refer to “Seawater Pump Installation”
section (P6-17).
17) Install the circulation pump pulley.
Refer to “Circulation Pump Installation”
section (P6-67).
tion (P3-27).
(P3-41).
NOTE:
6-82
ENG CYLINDER HEAD E
OVER
CYLINDER HEAD
7
3
8
2
9
E
11 10
12 14
13
15
16 4
17
29 18
New E
19 New
20
30
New
22
23
5
21
24 6
New 1
New
26
27
E
25
28
E

1 Intake manifold 1
2 Screw grommets 4
3 Glow plug holder 1
4 Glow plug 4 13 N·m (1.3 kgf·m, 9.4 lbf·ft)
5 Leakagepipe 1
6 Injection nozzle 4
7 Cylinder head cover 1
8 Rocker arm bolts 10 25 N·m (2.5 kgf·m, 18 lbf·ft)
6-83
ENG CYLINDER HEAD E
OVER
3
8
2
9
E
11 10
12 14
13
15
16 4
17
29 18
New E
19 New
20
30
New
22
23
5
21
24 6
New 1
New
26
27
E
25
28
E

9 Rocker arm shaft 1
0 Spring 4
A Rocker arm 8
B Rocker support 5
C Cylinder head bolts 18 49 N·m (5.0 kgf·m, 36 lbf·ft) +
Plastic region tightening (90°+ 90°)
D Caps 8
E Valve cotters 8
F Valve retainers 8
6-84
ENG CYLINDER HEAD E
OVER
3
8
2
9
E
11 10
12 14
13
15
16 4
17
29 18
New E
19 New
20
30
New
22
23
5
21
24 6
New 1
New
26
27
E
25
28
E

G Valve springs (inner) 8
H Valve springs (outer) 8
I Oil seals 8
J Spring seats 8
K Valves 8
L Valve guides 8
M Push rods 8
N Valve lifters 8
O Set key 1
6-85
ENG CYLINDER HEAD E
OVER
3
8
2
9
E
11 10
12 14
13
15
16 4
17
29 18
New E
19 New
20
30
New
22
23
5
21
24 6
New 1
New
26
27
E
25
28
E

P Plug 1
Q Camshaft 1
R Bearings 5
S Liftting bracket (front) 1
T Liftting bracket (rear) 1
6-86
ENG CYLINDER HEAD E
OVER
Cylinder Head Removal
1. Remove:
¡ Cylinder head
Cylinder head removal steps

1) Remove the following parts before re-
moving the cylinder head.
¡ Fuel filter housing and bracket
¡ Thermostat
¡ Intercooler
Refer to “Intercooler Removal” sec-
tion (P6-29).
¡ Turbocharger
Refer to “Turbocharger Removal”
section (P6-41).
¡ Exhaust manifold
Refer to “Mixing Elbow and Exhaust
Manifold Removal” section (P6-57).
¡ Power steering pump
Refer to “Power Steering Pump Re-
moval” section (P7-2).
¡ Timing gears
Refer to “Timing Gear Removal” sec-
tion (P6-71).
¡ Injection nozzles
Refer to “Injection Nozzle Removal”
section (P5-2).
1
2) Remove the breather hose 1.
1 3) Remove the 4 bolts 1 and 2 nuts 2, then

2
remove the cylinder head cover 3.
2 3 1
6-87
ENG CYLINDER HEAD E
OVER
4) Loosen the nuts 1 and adjusting screws
2.
2
1
5) Remove the 10 bolts 1, then remove the

1 1 rocker arm support with rocker arm and
push rods.
1 1
6) Loosen the cylinder head bolts evenly by

2 8 10 16 18 13 11 5 3
half a turn in the order of numbers in the
illustration.
4 6 12 14 17 15 9 7 1
7) Remove the cylinder head.
NOTE:
If it is difficult to separate the cylinder head
from the cylinder block. Insert a suitable tool
in between to pry off the cylinder head from
the cylinder block.
CAUTION:
Be careful not to damage the contact sur-
faces of the cylinder head and cylinder block.
8) Remove the dowel pins 1.
6-88
ENG CYLINDER HEAD E
OVER
Cylinder Head Disassembly
NOTE:
Check the area around the valve seats be-
fore removing the cylinder head parts.
1. Check:
¡ Area around the valve seats
Area around the valve seats checking steps

1) Pour clean solvent into the intake port
and exhaust port.
2) Check the area around the valve seats.
Leakage from valve seats → Check valve
face, valve seat and valve seat width.
NOTE:
There should be no leakage from the valve
seats.
2. Disassemble:
¡ Cylinder head
Cylinder head disassembly steps

1) Remove the valve cotters by use of the
valve spring compressor.
Valve spring compressor:

09202-70020
2) Remove the spring retainers 1, valve

springs (outer) 2, valves 3, valve
springs (inner) 4, and spring seats 5.
Put some identification to each part so
4
that they can be reinstalled in their origi-
1
2 3 nal positions.
6-89
ENG CYLINDER HEAD E
OVER
3) Remove the valve stem oil seals 1.
Piston and Cylinder Block Top Clean-

ing
1. Clean:
¡ Piston and cylinder block
Piston and cylinder block top cleaning steps

1) Turn the crankshaft and bring each piston
to top dead center (TDC). Remove all car-
bon deposits from the piston heads and
combustion chambers using a gasket
scraper.
2) Remove any fraction of old gasket re-
maining on the top of the cylinder block
and bolt holes.
NOTE:
Blow out carbon deposits and foreign mate-
rial with compressed air.
CAUTION:
Be careful not to scratch the surfaces.
¡ WARNING
Protect your eyes when using compressed
air.
6-90
ENG CYLINDER HEAD E
OVER
Cylinder Head Check
NOTE:
Before the inspection, remove the fractions
of old gasket remaining on the surfaces of
the cylinder head and the manifold, and clean
them with a soft brush and detergent.
CAUTION:
Be careful not to scratch the gasket contact
surface.
1. Check:
¡ Cylinder head damage
¡ Cylinder head warpage
Cylinder head damage checking step

1) Check the cylinder head for cracks and/
or damage by means of visible dye pen-
etrant.
Cylinder head warp checking step

1) Check the warpage of the cylinder head
by use of the straight edge and the thick-
ness gauge.
Cylinder head warp:

Or less 0.20 mm (0.008 in.)
6-91
ENG CYLINDER HEAD E
OVER
Valve Stem and Valve Guide Clearance
Check
NOTE:
Before the inspection, remove all carbon de-
posits from the valve and the valve guide
using a scraper, wire brush and solvent.
1. Check:
¡ Clearance between the valve stem
and the valve guide
Valve stem and valve guide clearance check-

ing steps
1) Measure the valve guide inner diameter
with a caliper gauge.
Valve guide inner diameter:

9.01 – 9.03 mm (0.355 – 0.356 in.)
2) Measure the valve stem diameter with a

micrometer.
Valve stem diameter:

IN: 8.968 – 8.984 mm (0.3531 – 0.3537 in.)
EX: 8.954 – 8.970 mm (0.3525 – 0.3531 in.)
3) Calculate the clearance between the

stem and the guide shaft using the for-
mula indicated below.
Stem-to-guide clearance =
Valve guide inner diamete – Valve stem diameter
If out of specification, replace the valve

guide and valve as a set.
Stem-to-guide clearance:
IN: 0.026 – 0.062 mm (0.0010 – 0.0024 in.)
<Limit> 0.1 mm (0.0039 in.)
EX: 0.040 – 0.076 mm (0.0016 – 0.0030 in.)
<Limit> 0.12 mm (0.0047 in.)
6-92
ENG CYLINDER HEAD E
OVER
Valve Guide Replacement
1. Replace:
¡ Valve guide
Valve guide replacement steps

1) Remove the valve guides using the valve
guide bushing remover and replacer set
along with the handle set.
Valve guide bushing remover and

replacer set:
09201-10000 (09201-01080)
Handle set:
09950-70010 (09201-07150)
2) Measure the valve guide bore diameter

3) Select a new valve guide from the table
below.
Valve guide bore diameter (mm, (in.)) Valve guide size
14.023 – 14.041 (0.552 – 0.553) Standard
NOTE:
If the valve guide bore diameter is greater
than 14.041 mm (0.553 in.), replace the cyl-
inder head.
4) Tap the new valve guide into the cylin-

der to the specified height using the
valve guide bushing remover and re-
placer set along with the handle set.
a
Valve guide height A :
19.2 – 19.8 mm (0.756 – 0.780 in.)
Valve guide bushing remover and

replacer set:
09201-10000 (09201-01080)
Handle set:
09950-70010 (09951-07150)
5) After installing the valve guide, bore out

the valve guide using the valve guide
1
reamer 1 to obtain the proper stem-to-
guide clearance.
6-93
ENG CYLINDER HEAD E
OVER
Valve Check
1. Check:
¡ Valve face
¡ Valve stem end
¡ Overall length
¡ Margin thickness
Valve face checking step

1) Check the valve face for pitting and/or
scratches.
Pitting/Scratches → Replace the valve.
Valve stem end checking step

1) Check the valve stem end for deforma-
tion.
Mushroom-shaped, or diameter larger
than the rest of the stem → Replace the
valve.
Valve overall length checking step

1) Check the overall valve length A.
Out of specification → Replace the valve.
Overall valve length A :

a
IN: 126.55 mm (4.9823 in.)
<Limit> 126.05 mm (4.9626 in.)
EX: 126.42 mm (4.9772 in.)
<Limit> 126.05 mm (4.9626 in.)
Margin thickness checking step

1) Check the margin thickness A of the
valve.
Margin thickness A :
IN: 1.3 – 1.5 mm (0.052 – 0.059 in.)
<Limit> 0.9 mm (0.035 in.)
a EX: 1.7 – 1.9 mm (0.067 – 0.075 in.)
<Limit> 1.3 mm (0.051 in.)
6-94
ENG CYLINDER HEAD E
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Valve Seat Check
1. Check:
¡ Valve seats
¡ Valve seat width
Valve seat checking step

1) Check the valve seat for pitting and/or
carbon deposits.
Pitting/Carbon deposits → Grind.
Use a 45 ° valve seat cutter.
NOTE:
¡ Remove the metal only to the extent of
cleaning the seats.
¡ Use a valve seat cutter with an ultra-hard
tip for the exhaust valve.
Valve seat width checking steps

1) Apply mechanic’s bluing dye (Dykem) A
to the valve face.
2) Install the valve into the cylinder head.
3) Press the valve through the valve guide
and onto the valve seat to make a clear
a
pattern. Do not rotate the valve.
4) Measure the valve seat width B. Where
the valve seat and valve face make con-
tact, bluing will be removed.
5) If the valve seat is too wide B, too nar-
row, or the seat is not in the middle, the
valve seat must be refaced.
Out of specification → Replace the valve
seat.
Valve seat width B :

b IN: 1.9 – 2.3 mm (0.748 – 0.091 in.)
EX: 1.9 – 2.3 mm (0.748 – 0.091 in.)
6-95
ENG CYLINDER HEAD E
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Valve Seat Refacing
1. Reface:
¡ Valve seat
Use 30°, 45° and 60° valve seat cut-
ters.
CAUTION:
When turning the cutter, keep an even down-
ward pressure (4 – 5 kg) to prevent chatter
marks.
Cut sections as follows:

Section Cutter
A 30 °
B 45 °
C 60 °
C
B
A
Valve seat rafacing steps

1) Reface the valve seat.
The valve seat is centered on the valve

face but is too wide.
Action: Aim:
First:
To reduce
30° cutter
Use valve seat
lightly width to
Second:
specification
60° cutter
The valve seat is centered on the valve

face but is too narrow.
Action: Aim:
To achieve a
Use uniform valve
45° cutter
lightly seat width to
specification
6-96
ENG CYLINDER HEAD E
OVER
Valve seat is too narrow and is near the
valve margin.
Action: Aim:
First: To center the
30° cutter seat and to
Use achieve the
Second: specified
45° cutter width
Valve seat is too narrow and is near the

bottom edge of the valve face.
Action: Aim:
First: To center the
60° cutter seat and to
Use achieve the
Second: specified
45° cutter width
6-97
ENG CYLINDER HEAD E
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Valve and Valve Seat Lapping
1. Lap:
¡ Valve faces and valve seats
NOTE:
The valve seat and the valve face should be
lapped after refacing the valve seat or after
replacing the valve and the valve guide.
Valve face and valve seat lapping steps

1) Apply a coarse lapping compound A to
the valve face.
CAUTION:
Be sure no compound enters the gap be-
a
tween the valve stem and the guide.
2) Apply molybdenum disulfide oil to the

valve stem.
3) Install the valve into the cylinder head.
4) Turn the valve until the valve face and
valve seat are evenly polished, then clean
off all compound.
M NOTE:
To obtain the best lapping effect, lightly tap
the valve seat while rotating the valve back
and forth between your hands.
5) Apply a fine lapping compound to the

valve face and repeat the above steps.
NOTE:
Be sure to clean off the lapping compound
from the valve face and the valve seat after
every lapping operation.
6) Measure the valve seat width. If the valve

seat width is out of specification, reface
and lap the valve seat again.
6-98
ENG CYLINDER HEAD E
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Valve Spring Check
1. Check:
¡ Valve spring
¡ Spring tilt
Valve spring checking step

1) Check the free length A of the valve
spring.
Free length (valve spring):

Outer: 50.73 mm (1.9972 in.)
Inner: 45.28 mm (1.7827 in.)
a
Valve spring tilt checking step

1) Check the valve spring tilt A.
a
a Out of specification → Replace.
Spring tilt limit:

2.0 mm (0.08 in.)
6-99
ENG CYLINDER HEAD E
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Rocker Arm and Push Rod Check
1. Check:
¡ Rocker arm shaft
¡ Push rods
Rocker arm shaft checking steps

1) Check the rocker arm shaft diameter A.
Rocker arm shaft diameter A :

18.472 – 18.493 mm
(0.727 – 0.728 in.)
2) Check the rocker arm bushing diameter

B.
Rocker arm bushing diameter B :

18.512 – 18.553 mm
(0.729 – 0.730 in.)

c rocker arm shaft and rocker arm bush-
ing using the formula indicated below.
Clearance = Rocker arm – Rocker arm

C bushing shaft
diameter B diameter A
Rocker arm shaft to bushing clearance:

0.020 – 0.060 mm
(0.0079 – 0.0024 in.)
<Limit> 0.1 mm (0.0039 in.)
Push rods checking step

1) Set the dial gauge and check the push
rod runout.
Runout (push rod):

Or less 0.5 mm (0.020 in.)
6-100
ENG CYLINDER HEAD E
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Camshaft Bearing and Camshaft Check
1. Check:
¡ Camshaft bearings
¡ Cam lobes
¡ Cam lobes height
¡ Camshaft and bearing clearance
¡ Journal outer diameter
¡ Camshaft thrust clearance
Camshaft bearings checking step

1) Check the camshaft for pitting, scratches
and/or damage.
Pitting/Scratches/Damage → Replace the
bearings. Replace the camshaft if neces-
sary.
Camshaft runout checking step

1) Set the dial gauge and check the cam-
shaft runout.
¡ Runout (camshaft)
Runout (camshaft):
Or less 0.10 mm (0.004 in.)
NOTE:
Set the dial gauge to abut on the central part
of the camshaft for the measurement.
Cam lobes checking step

1) Check the cam lobe for pitting, scratches
and/or heat discoloration.
Pitting/Scratches/Heat discoloration →
Replace.
6-101
ENG CYLINDER HEAD E
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Cam lobe height checking step
1) Check the cam lobe height A.
Out of specification → Replace the cam-
shaft.
a Cam lobe height:
IN: 44.879 – 44.961 mm (1.7669 – 1.7701 in.)
<Limit> 44.45 mm (1.7500 in.)
a
EX: 45.050 – 45.140 mm (1.7736 – 1.7772 in.)
<Limit> 44.62 mm (1.7567 in.)
Camshaft and bearing clearance checking

step
1) Clean the bearings and the camshaft
journals.
2) Check the camshaft to bearing clearance.
Out of specification → Measure journal
diameter (camshaft)
Camshaft to bearing clearance:

0.025 – 0.066 mm
(0.0010 – 0.0026 in.)
<Limit> 0.10 mm (0.0039 in.)
Journal diameter measurement step

1) Measure the diameter A of the camshaft
journal with a micrometer. If the mea-
sured value is not as specified below,
replace the camshaft.
a Camshaft journal diameter A

#1 53.459 – 53.475
#2 53.209 – 53.225
#3 52.959 – 52.975
#4 52.709 – 52.725
#5 52.459 – 52.475
#4 #5
#2 #3
#1
6-102
ENG CYLINDER HEAD E
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2) Measure the inner diameter B of the
camshaft journal bearing with a cylinder
b
gauge. If the measured value is not as
specified below, replace the bearing.
Camshaft journal bearing diameter B
#1 53.500 – 53.525
#2 53.250 – 53.275
#3 53.000 – 53.025
#4 52.750 – 52.775
#5 52.500 – 52.525
camshaft journal and the bearing. If it is
not as specified below, replace the cam-
shaft and the bearing.
Clearance = Camshaft – Camshaft

journal journal
bearing diameter A
diameter B
Camshaft to bearing clearance:

0.025 – 0.066 mm
(0.0010 – 0.0026 in.)
<Limit> 0.10 mm (0.0039 in.)
If necessary, replace the cylinder block.
Camshaft thrust clearance checking step

1) Check the camshaft thrust clearance us-
ing the thickness gauge.
Out of specification → Replace thrust
plate.
If necessary, replace the camshaft.
Camshaft thrust clearance:

0.06 – 0.13 mm
(0.0024 – 0.0051 in.)
<Limit> 0.30 mm (0.00118 in.)
6-103
ENG CYLINDER HEAD E
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Intake and Exhaust Manifold Check
1. Check:
¡ Intake and exhaust manifold
Intake and exhaust manifold checking steps

1) Check the intake and exhaust manifold
for cracks and/or damage.
2) Check the warpage on the contact sur-
faces of the intake and exhaust manifold
to the cylinder head by use of a straight
edge and a thickness gauge.
Manifold warpage:
Or less 0.40 mm (0.016 in.)
6-104
ENG CYLINDER HEAD E
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Cylinder Head Assembly
CAUTION:
¡ Thoroughly clean all parts to be as-
sembled.
¡ Apply clean engine oil to all sliding and
rotating surfaces before installation.
¡ Replace all gaskets and removed oil seals
with new parts.
1. Assemble:
¡ Cylinder head
Cylinder head assembly steps

1) Install a new stem seal to the valve stem
guide. Then, assemble the valve spring
seat, springs (inner and outer) and spring
retainer.
2) Install the valve cotters to the spring re-

tainers by use of the valve spring com-
pressor.
NOTE:
¡ Install the valve cotters while compress-
ing the valve spring with the valve spring
compressor.
¡ Secure the valve cotters to the valve stem
by gently tapping with a plastic-faced
hammer.
Valve spring compressor:

09202-70020
3) Install the valve stem cap 1.
NOTE:
¡ Apply engine oil to the valve.
¡ All valve lifters must be reinstalled in their
original positions.
6-105
ENG CYLINDER HEAD E
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Cylinder Head Gasket Selection
1. Select:
¡ Cylinder head gasket (new)
NOTE:
Check the amount of protrusion of each pis-
ton from the cylinder.
Cylinder head gasket selection steps

1) Thoroughly clean all piston heads and
the cylinder block gasket surface.
2) Set the piston at slightly before TDC prior
to the measurement.
3) Place a dial indicator on the cylinder
block, and set the dial indicator at 0 mm
(0 in.).
1
NOTE:
¡ Position the measuring tip 1 of the dial
2 indicator 2 as shown in the illustration.
¡ Make sure that the measuring tip is
square to the cylinder block gasket sur-
a
face and the piston head when making
the piston head protrusion A measure-
ments.
4) Find where the piston head protrudes

a most by slowly turning the crankshaft
clockwise and counterclockwise. If the
protrusion is not as specified, remove the
b piston and connecting rod assembly and
reinstall it correctly.
NOTE:
¡ Measure each cylinder at two places as
shown in the illustration, making a total
of eight measurements.
¡ Use the average of the two measure-
ments as the piston protrusion value of
each cylinder.
Piston protrusion:
0.535 – 0.985 mm (0.0211 – 0.0388 in.)
Turn the crankshaft to align BDC mark

A with the flange groove B.
6-106
ENG CYLINDER HEAD E
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5) Select the largest piston protrusion value
a from the measurements made, then se-
lect the appropriate cylinder head gas-
ket according to the table below.
NOTE:
There are three types of cylinder head gas-
ket. Select one of them when replacing the
gasket.
Gasket size
Piston protrusion mm (in.)
A
0.535 – 0.785 (0.0211 – 0.0309) Use “1.5“
0.785 – 0.885 (0.0309 – 0.0348) Use “1.6“
0.855 – 0.985 (0.0348 – 0.0388) Use “1.7“
6-107
ENG CYLINDER HEAD E
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Cylinder Head Installation
1. Install:
¡ Cylinder head
Cylinder head installation steps

1) Install the dowel pins 1 and set the se-
2
lected new cylinder head gasket 2.
1 NOTE:
Take care that the gasket is installed in the
correct direction.
2) Mount the cylinder head and set the new

cylinder head bolts.
CAUTION:
Always replace the cylinder head bolts with
new ones.
NOTE:
¡ Apply a light coat of engine oil to the
threads and under the heads of the bolts.
¡ Pay close attention not to damage the
gasket in the course of cylinder head in-
stallation.
3) Tighten the cylinder head bolts to the
17 11 9 3 1 6 8 14 16
specified torque in several passes in the
order of the numbers in the illustration.
Bolts (cylinder head):

49 N·m (5.0 kgf·m, 36 lbf·ft)
T.R
NOTE:
If any of the bolts do not reach the specified
15 13 7 5 2 4 10 12 18
torque, replace that bolt.
4) Mark the front of each bolt head with

First
paint.
Second
retightening 90˚ retightening 90˚
NOTE:
Put the paint mark as shown in the illustra-
tion to help identify the retightened angle.
Engine front
Paint mark 5) Retighten the cylinder head bolts by 90°
in the order of the numbers in the illus-
tration.
6) Further retighten the cylinder head bolts
by another 90 ° in the specified order.
Check that the paint marks are now at
the rear end of the cylinder head bolts.
6-108
ENG CYLINDER HEAD E
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Camshaft and Rocker Arm Installation
1. Install:
¡ Camshaft and rocker arm
Camshaft and rocker arm installation steps

1) Install the camshaft 1 with camshaft
drive gear (into cylinder block).
Refer to “Timing Gear Installation” sec-
tion (P6-79).
NOTE:
1 ¡ The engine must be placed upside down
when installing the camshaft, because the
¡ Lubricate the face of the bearings with en-
gine oil.
2) Install the push rods and rocker arm sup-

1 1 port.
3) Tighten the bolts 1 (rocker arm support).
Bolts (rocker arm support):

25 N·m (2.5 kgf·m, 18 lbf·ft)
T.R
1 1
4) Adjust the valve clearance.

Refer to “Valve Clearance Adjustment”
section (P3-21).

IN: 0.2 – 0.25 mm (0.007 – 0.009 in.)(hot)
EX: 0.36 – 0.4 mm (0.014 – 0.015 in.)(hot)
2
5) Install the cylinder head cover 1 and
1 breather hose 2.
Nuts (cylinder head cover):

9.8 N·m (1.0 kgf·m, 7.2 lbf·ft)
T.R
Bolts (cylinder head cover):

9.8 N·m (1.0 kgf·m, 7.2 lbf·ft)
6) Install the glow plugs.
Glow plugs:
13 N·m (1.3 kgf·m, 9.4 lbf·ft)
T.R
6-109
ENG CYLINDER HEAD E
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7) Install the following parts.
¡ Injection nozzles
section (P5-5).
¡ Timing gears
Refer to “Timing Gear Installation”
section (P6-79).
Refer to “Power Steering Pump Instal-
lation” section (P7-5).
¡ Exhaust manifold
Manifold Installation” section (P6-62).
¡ Turbocharger
Refer to “Turbocharger Installation”
section (P6-52).
¡ Intercooler
Refer to “Intercooler Installation” sec-
tion (P6-35).
¡ Thermostat
Refer to “Thermostat Installation”
section (P6-27).
¡ Fuel filter housing and bracket

(P3-41).
NOTE:
6-110
ENG OIL PUMP E
OVER
OIL PUMP
2
7
3
4 6

1 Timing gear case (oil pump assembly) 1
2 Plug 1
3 Gasket 1
4 Spring 1
5 Relief valve 1 34N·m (3.5 kgf·m, 25 lbf·ft)
6 Oil pump inner gear 1
7 Oil pump outer gear 1
8 Oil pump cover 1
6-111
ENG OIL PUMP E
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Oil Pump Removal
1. Remove:
¡ Oil pump
Oil pump removal steps

2) Drain the engine oil.
3) Remove the timing gears.
Refer to “Timing Gear Removal” section
(P6-71).
4) Remove the oil level gauge guide.
5) Take out the oil pan mounting bolts and
1
nuts, then remove the oil pan 1 by use
of the oil pan seal cutter 2.
Oil pan seal cutter:

09032-00100
NOTE:
Insert the oil pan seal cutter 2 between the
cylinder block and the oil pan. Cut through
the old gasket with the cutter to open up the
gap, and remove the oil pan.
CAUTION:
¡ Do not use the oil pan seal cutter on the
timing gear case side or on the rear oil
seal retainer.
2 ¡ Be careful not to damage the flange of
the oil pan.
6) Remove the oil strainer 1 and the pipe

1
2 (oil pump outlet).
6-112
ENG OIL PUMP E
OVER
7) Remove the stiffening plate 1.
1
NOTE:
Insert the oil pan seal cutter 2 betweeen the
stiffening plate 1 and the cylinder block, cut
2 through the old gasket and remove the plate
1.
CAUTION:
Be careful not to damage the flange of the
stiffening plate.
8) Remove the timing gear case 1.

1
NOTE:
Lightly tap out the timing gear case with a
plastic-faced hammer.
6-113
ENG OIL PUMP E
OVER
Oil Pump Disassembly
1. Disassemble:
¡ Plate
¡ Outer pump
Oil pump disassembly steps

1) Remove the plate 1.
2) Remove the outer rotor 1.
3) Loosen the plug 1 and remove the gas-

ket 2, spring 3, and relief valve 4.
4
3
2
1
6-114
ENG OIL PUMP E
OVER
Oil Pump Check
1. Check:
¡ Relief valve
¡ Movement of relief value
¡ Spring
¡ Rotor clearance
¡ Oil pump gear
¡ Oil pump rotation
Relief valve checking step

1) Check the relief valve for scratches, wear
and/or damage.
Scratches/Wear/Damage → Replace.
Movement of relief valve checking step

1) Lubricate the relief valve and the valve
hole with some engine oil. Check that the
relief valve goes down the valve hole
smoothly by its weight.
Sticking → Replace the relief valve.
NOTE:
Replace the oil pump assembly if necessary.
Relief valve spring checking step

1) Check the relief valve spring for wear,
Wear/Cracks/Damage → Replace.
Outer and inner rotors checking step

1) Check the outer and inner rotors for
6-115
ENG OIL PUMP E
OVER
Rotor clearance checking steps
1) Check the rotor body clearance by set-
ting a thickness gauge as illustrated in
.
2) Check the rotor side clearance by setting

a straight edge and a thickness gauge as
illustrated in .
3) Check the rotor tip clearance by setting

a thickness gauge as illustrated in .
Out of specification → Replace the oil
pump assembly.
Rotor body clearance:

0.14 – 0.22 mm (0.0055 – 0.0087 in.)
<Limit> 0.4 mm (0.0157 in.)
Rotor side clearance:
0.03 – 0.09 mm (0.0012 – 0.0035 in.)
<Limit> 0.15 mm (0.0059 in.)
Rotor tip clearance:
0.11 – 0.24 mm (0.0043 – 0.0094 in.)
<Limit> 0.3 mm (0.0118 in.)
Oil pump rotation checking step

1) Check the oil pump rotation.
Roughness → Replace the oil pump as-
sembly.
6-116
ENG OIL PUMP E
OVER
Oil Strainer Check
1. Check:
¡ Oil strainer
Oil strainer checking steps

1) Check the oil strainer 1 and the strainer
a net A for cracks and/or damage.
2) Check the oil passage.
Soiled → Clean and blow out the dirt with
1 compressed air.
Oil Pump Assembly
NOTE:
sembled.
¡ Apply clean engine oil to the oil pump
rotor before assembly.
1. Install:
¡ Outer rotor
Outer rotor installation steps

1) Install the outer rotor 1 on the pump
body with the mark A on the rotor fac-
ing the gear.
a
2) Install the plate 1.
6-117
ENG OIL PUMP E
OVER
3) Insert the relief valve 1 into the pump
body and check that the valve has been
inserted smoothly to the end of the valve
hole. Then, put the spring 2 in the hole
and gasket 3 and tighten the plug 4 to
1
3
2 the specified torque.
4
Plug:
41 N·m (4.2 kgf·m, 30.2 lbf·ft)
T.R
Timing Gear Case Installation
NOTE:
¡ Before starting the work, remove the frac-
tions of old gasket from the timing gear
case oil pan and clean the sealing areas
and the contact surfaces with a non-re-
sidual solvent.
¡ Do not use the solvent that may give ad-
verse effect to the coating.
1. Install:
¡ Timing gear case
Timing gear case installation steps
1
1) Set a new gasket.
2) Install the timing gear case 1 on the cyl-
inder block by tightening the bolts to the
specified torque in a crisscross pattern.
Bolts (timing gear case):

M8 bolt: 18 N·m (1.8 kgf·m, 7.2 lbf·ft)
T.R
3) Remove the old gasket from the cylin-

der block, stiffening plate and oil pan.
4) Clean the sealing surfaces of the cylin-
der block, stiffening plate and oil pan
with non-residue solvent.
6-118
ENG OIL PUMP E
OVER
5) Apply ThreeBond® TB-1207B A to the
a TB
stiffening plate as shown in the illustra-
1207B
tion.
6) Install the oil strainer 1 and the oil pipe

1
2 and a new gasket by tightening the
bolts and nuts to the specified torque.
a Nuts (oil strainer):
2
18 N·m (1.8 kgf·m, 13 lbf·ft)
T.R
Bolts (oil strainer):
18 N·m (1.8 kgf·m, 13 lbf·ft)
Bolt A (oil pipe):
45 N·m (4.5 kgf·m, 33 lbf·ft)
7) Apply ThreeBond® TB-1207B A to the oil
pan as shown in the illustration.
A B
A B a TB
1207B
8) Tighten the oil pan bolts and nuts evenly

in several passes, moving from the in-
side to the outside in a diagonal pattern.
Bolts (oil pan):

25 N·m (2.6 kgf·m, 19 lbf·ft)
T.R
Nuts (oil pan):

25 N·m (2.6 kgf·m, 19 lbf·ft)
9) Install the oil level gauge guide.
Union bolt:
34 N·m (3.5 kgf·m, 25 lbf·ft)
T.R
10) Install the timing gears.

Refer to “Timing Gear Installation” sec-
tion (P6-79).
Refer to “Engine Oil and Filter Replace-
6-119
ENG OIL PUMP E
OVER


Max. 4.8 L, Min. 2.8 L
 Max. 5.1 US qt., Min. 3.0 US qt. 
Max. 5.7 L, Min. 3.7 L
 Max. 6.0 US qt., Min. 3.9 US qt. 

(P3-41).
NOTE:
6-120
ENG OIL COOLER E
OVER
OIL COOLER
5
2
1
3
2
6
LT 8
243
FW
D

1 Oil cooler cover mounting bolts 10 18 N·m (1.8 kgf·m, 13 lbf·ft)
2 Oil cooler cover mounting nuts 2 18 N·m (1.8 kgf·m, 13 lbf·ft)
3 Oil cooler cover 1
4 Oil cooler mounting nuts 4 15 N·m (1.5 kgf·m, 11 lbf·ft)
5 Oil cooler 1
6 Oil pressure switch 1 7.8 N·m (0.8 kgf·m, 5.7 lbf·ft)
7 Oil filter bracket 1
8 Relief valve plug 1 34 N·m (3.5 kgf·m, 25 lbf·ft)
9 Relief valve 1
6-121
ENG OIL COOLER E
OVER
Oil Cooler Removal
1. Remove:
¡ Oil cooler
Oil cooler removal steps

(P3-41).
2) Drain the engine oil and remove the oil
filter.
Refer to “Heat Exchanger Removal” sec-
tion (P6-20).
4) Remove the oil filter bracket 1.
5) Remove the relief valve 1, spring 2,

plug 3 and gasket 4.
1
2
4
3
6) Remove the oil pressure switch 1.

7) Remove the oil cooler cover 2.
6-122
ENG OIL COOLER E
OVER
8) Remove the oil cooler 1.
Oil Cooler Check

1. Check:
¡ Relief valve
¡ Oil cooler
¡ Oil cooler cover
¡ Oil filter bracket
Relief valve checking step

1) Push the relief valve with a wooden stick
to check its movement.
Sticking → Replace.
Oil cooler checking step

1) Check the oil cooler for cracks, damage
and/or clogging.
6-123
ENG OIL COOLER E
OVER
Oil cooler cover checking step
1) Check the oil cooler cover for cracks and/
or damage.
Oil filter bracket checking step

1) Check the oil filter bracket for cracks and/
or damage.
Oil Cooler Installation
NOTE:
Thoroughly clean all parts to be assembled.
1. Install:
¡ Oil cooler
Oil cooler installation steps

1) Install the oil cooler 1 on the oil cooler
cover. (with a new gasket)
Nuts (oil cooler cover):

15 N·m (1.5 kgf·m, 11 lbf·ft)
T.R
6-124
ENG OIL COOLER E
OVER
2) Install the oil cooler cover. (with a new
gasket)
Nuts/bolts (oil cooler cover):

15 N·m (1.5 kgf·m, 11 lbf·ft)
T.R
1
3) Install the oil pressure switch 2.
2
LT
243 NOTE:
Apply LOCTITE® No. 243 on the threads when
installing the oil pressure switch 2.
4) Install the relief valve 1, spring 2, plug

3 and new gasket 4.
Plug (relief valve):

1
34 N·m (3.5 kgf·m, 25 lbf·ft)
T.R
2
4
3
5) Install the oil filter bracket 1. (with a new

gasket)
6) Install the heat exchanger

Refer to “Heat Exchanger Installation”
section (P6-23).
6-125
ENG OIL COOLER E
OVER


Max. 4.8 L, Min. 2.8 L
 Max. 5.1 US qt., Min. 3.0 US qt. 
Max. 5.7 L, Min. 3.7 L
 Max. 6.0 US qt., Min. 3.9 US qt. 

(P3-41).
NOTE:
6-126
ENG OIL NOZZLE E
OVER
OIL NOZZLE
14B

1 Oil nozzles 4
2 O-rings 4
6-127
ENG OIL NOZZLE E
OVER
Oil Nozzle Removal
1. Remove:
¡ Oil nozzle
Oil nozzle removal steps

1) Remove the injection pump.
Refer to “Injection Pump Removal” sec-
tion (P5-9).
2) Remove the intercooler.
Refer to “Intercooler Removal” section
(P6-29).
3) Install an M8 pitch 1.25 bolt A and
washer and remove the oil nozzles 1
using a slide hammer with three claws.
1
a
Oil Nozzle Check

1. Check:
¡ Oil nozzle
Oil nozzle checking steps

1) Check the oil nozzles 1 for damage and/
or clogging.
1
Damage → Replace.
Clogged → Blow out with compressed
air.
6-128
ENG OIL NOZZLE E
OVER
Oil Nozzle Installation
1. Install:
¡ Oil nozzle
Oil nozzle installation steps

1) Install the oil nozzles 1. (with a new O-
b a ring)
NOTE:
Align a corner A of the nozzle nut with the
1 point mark B on the cylinder. Using a brass
bar and a hammer, drive-in the oil nozzle un-
til the nut is settled on the cylinder block.
CAUTION:
Be careful not to damage the o-ring when
installing the oil nozzle.
2) Install the intercooler.

Refer to “Intercooler Installation” section
(P6-35).
3) Install the injection pump.
Refer to “Injection Pump Installation”
section (P5-13).
6-129
ENG CYLINDER BLOCK E
OVER
CYLINDER BLOCK
13
1
14B
LT
572
New
12
LT
E 572
11
8
New 9
New
New 10
New
New 5 7
TB
4 1207B
6
TB
1207B

1 Rear oil seal retainer mounting bolts 6 18 N·m (1.8 kgf·m, 13 lbf·ft)
2 Oil pan mounting nuts 7 25 N·m (2.6 kgf·m, 19 lbf·ft)
3 Oil pan mounting bolts 17 25 N·m (2.6 kgf·m, 19 lbf·ft)
4 Oil pipe mounting nuts 2 2 N·m (0.2 kgf·m, 1.4 lbf·ft)
5 Oil pipe mounting bolt 1 49 N·m (5.0 kgf·m, 36 lbf·ft)
6 Oil strainer mounting nuts 2 2 N·m (0.2 kgf·m, 1.4 lbf·ft)
7 Oil strainer mounting bolts 2 2 N·m (0.2 kgf·m, 1.4 lbf·ft)
6-130
OVER
13
1
14B
LT
572
New
12
LT
E 572
11
8
New 9
New
New 10
New
New 5 7
TB
4 1207B
6
TB
1207B

8 Drain plug (coolant) 1
9 Check valve 1 34 N·m (3.5 kgf·m, 25 lbf·ft)
0 Oil nozzle 4
A Main bearing cap bolts 10 196 N·m (20 kgf·m, 145 lbf·ft)
B Main bearing caps 5
C Oil pressure sender 1 24 N·m (2.4 kgf·m, 17 lbf·ft)
6-131
OVER
8
9
E
10
6 7
5
E 11
New 4
E
E
3
1
New
E
13
16
15
14
12

1 Connecting rod mounting nuts 8 69 N·m (7.0 kgf·m, 51 lbf·ft) +
Plastic region tightening (90°)
2 Connecting rod caps 4
3 Connecting rods 4
4 Connecting rod bushings 4
5 Circlips 8
6 Pistons 4
7 Piston pins 4
8 Top rings 4
6-132
OVER
8
9
E
10
6 7
5
E 11
New 4
E
E
3
1
New
E
13
16
15
14
12

9 2nd rings 4
0 Oil rings 4
A Thrust washers 16
B Connecting rod bearings 8
C Main bearings 10
D Set keys 2
E Oil pump drive gear 1
F Crankshaft 1
6-133
OVER
Cylinder Block Disassembly
1. Disassemble:
¡ Cylinder block
Cylinder block disassembly steps

1) Drain the engine oil.
(P3-41).
3) Remove the following parts before dis-
assembling the cylinder block.
¡ Cylinder head
Refer to “Cylinder Head Removal”
section (P6-87).
¡ Starter motor
Refer to “2-stage Rate Coupling and
Flywheel Removal” section (P6-2).
¡ Alternator
¡ Engine wireharness
¡ Thermostat cover
¡ Power steering oil pump
¡ Heat exchanger
Refer to “Heat Exchanger Removal”
section (P6-20).
¡ Seawater pump
Refer to “Seawater Pump Removal”
section (P6-11).
¡ Injection pump
Refer to “Injection Pump Removal”
section (P5-9).
¡ Timing gears
Refer to “Timing Gear Removal” sec-
tion (P6-71).
¡ Oil pan
¡ Oil strainer
¡ Timing gear case
Refer to “Oil Pump Removal” section
(P6-112).
¡ Oil cooler
Refer to “Oil Cooler Removal” section
(P6-122).
6-134
OVER
NOTE:
¡ Place the engine on an engine stand 1
during disassembly.
¡ Place the engine upside-down on the
stand.
4) Remove the engine brackets 1 and the

heat exchanger bracket 2.
6-135
OVER
Valve Lifter and Camshaft Bearing Dis-
assembly
1. Disassemble:
¡ Valve lifter
¡ Camshaft bearing
Valve lifter disassembly steps

1) Remove the valve lifters 1. Using exten-
sion bar A, insert the valve lifter from
the edge of the cylinder head to the edge
of the oil pan and remove the bolts 2.
2) Remove the plug 1.
3) Remove the camshaft bearings 1, using

1 the bearing remover and replacer.
Camshaft bearing remover and replacer:

09215-00100
6-136
OVER
Connecting Rod and Piston Disassem-
bly
1. Disassemble:
¡ Connecting rod and piston
Connecting rod and piston disassembly

steps
1) Remove the crankshaft oil seal retainer
1.
2) Remove the connecting rod caps.

1
NOTE:
Put an identifying mark A on each connect-
ing rod cap 1 and connecting rod 2 for cor-
rect reinstallation.
2
a
3) Pull out the piston and connecting rod

from the top of the cylinder block.
4) Remove the connecting rod bearings 1.

Carefully identify the position of each
1
bearing so that they can be reinstalled
in their original positions.
6-137
OVER
Main Bearing Cap and Crankshaft Dis-
assembly
1. Disassemble:
¡ Main bearing cap and crankshaft
Main bearing cap and crankshaft disassem-

bly steps
1) Loosen the main bearing cap bolts
4 8 10 6 2
evenly by making half a turn at a time in
the order of the numbers in the illustra-
tion.
3 7 9 5 1
2) Remove the thrust washers 1.

1
NOTE:
Carefully identify the position of each thrust
washer so that they can be reinstalled in their
original positions.
3) Remove the crankshaft 1.

1
4) Remove the bearings from the cylinder

block and the main bearing caps. Care-
fully identify the position of each bear-
ing so that they can be reinstalled in their
5 original positions.
4
3
2
1
6-138
OVER
Piston and Connecting Rod Disassem-
bly
1. Disassemble:
¡ Piston and connecting rod
Piston and connecting rod disassembly steps
NOTE:
Before disassembling the piston and the con-
necting rod, check for the connecting rod free
play by trying to slide it back and forth along
the piston pin.
1) Check the connecting rod free play.

Any free play along the piston pin → Re-
place the piston and piston pin as a set.
2) Remove the piston rings by use of the

piston ring expander.
3) Remove the oil ring spring.
NOTE:
Carefully identify the position of each ring
so that they can be reinstalled in their origi-
nal positions.
6-139
OVER
4) Remove the snap ring 1 and heat the
piston to approximately 80 °C (176 °F).
1
CAUTION:
Be careful of the burn injury.
5) While the piston is still hot, disassemble

the connecting rod by lightly tapping on
the piston pin with a hammer and a brass
rod.
NOTE:
Carefully identify the position of each piston,
piston pin and connecting rod so that they
can be reinstalled in their original positions.
#1 #2 #3 #4
6-140
OVER
Piston and Cylinder Block Cleaning
1. Clean:
¡ Piston and cylinder block
Piston and cylinder block cleaning steps

1) Eliminate the scratches and lacquer de-
posits on the side wall of the piston by
means of wet sand paper #600 to 800.
NOTE:
Sand in a crisscross pattern. Do not sand
excessively.
2) Eliminate the carbon deposits on the

piston crown by use of the suitable tool
1.
3) Eliminate the carbon deposits in the

piston ring grooves by the suitable tool
1 that fits in the grooves.
4) Thoroughly wash the piston in cleaning

solvent using a soft brush.
NOTE:
Do not use a wire brush.
6-141
OVER
5) Remove the fractions of old gasket re-
maining on the cylinder block surface.
Be careful not to scratch the gasket con-
tact surface.
6) Clean the cylinder block using a soft
brush and cleaning solvent.
Valve Lifter Check

1. Check:
¡ Valve lifter bore
¡ Valve lifters
Valve lifters checking step

1) Check the valve lifter for scratches, cracks
and/or damage.
Scratches/Cracks/Damage → Replace.
If necessary, replace the cylinder head.
NOTE:
a
Confirm that the roller A turns smoothly.
2) Check the valve liter bore diameter B

Out of specification → Replace the cylin-
der block.
Valve lifter bore diameter B :

b
27.01 – 27.03 mm
(1.063 – 1.064 in.)
3) Check the valve lifter diameter C with, a

micrometer.
Valve lifter diameter C :

26.955 – 26.975 mm
(1.061 – 1.062 in.)
c
6-142
OVER
valve lifter and the lifter bore using the
formula indication below.
Valve lifter to lifter bore clearance =

Valve lifter bore diameter B –
Valve lifter diameter C
Out of specification → Replace the lifter.
If necessary, replace the cylinder block.
Valve lifter to lifter bore clearance:

0.035 – 0.075 mm
(0.0014 – 0.0030 in.)
<Limit> 0.10 mm (0.0039 in.)
6-143
OVER
Piston and Cylinder Block Check
1. Check:
¡ Piston wall
¡ Cylinder walls
¡ Cylinder block
¡ Cylinder block warpage
¡ Piston-to-cylinder clearance
¡ Ring groove clearance
¡ Piston rings (into cylinder)
¡ End gap
Piston wall checking step

1) Check the piston walls for scratches and/
or damage.
Excessive vertical scratches/Damage →
Replace the piston.
NOTE:
Replace the pistons and the cylinder block
as a set if necessary.
Cylinder walls checking step

1) Check the cylinder walls for scratches
and/or damage.
Excessive vertical scratches/Damage →
Replace the cylinder block and pistons
as a set.
Cylinder block checking step

1) Check the cylinder block for cracks and/
or damage by means of visible dye pen-
etrant.
6-144
OVER
Cylinder block warpage checking step
1) Check the cylinder block warpage by use
of a straight edge and a thickness gauge.
Cylinder block warpage:

Or less 0.20 mm (0.0079 in.)
Piston-to-cylinder clearance checking steps

1) Measure the piston diameter A with a
c micrometer at the specified height B.
NOTE:
There are three sizes of standard piston di-
b ameter. They are identified by the marks 1,
a 2, and 3 C stamped on the piston top.
Measuring height B :
42.8 mm (2.5866 in.)
Piston diameter A :
Mark “1”
101.83 – 101.84 mm (4.0091 – 4.0094 in.)
Mark “2”
101.84 – 101.85 mm (4.0094 – 4.0098 in.)
Mark “3”
101.85 – 101.86 mm (4.0098 – 4.0102 in.)
6-145
OVER
2) Measure the cylinder bore A with a cyl-
inder gauge.
15 mm If out of specification, replace the cylin-
der and additionally replace the pistons
Middle and piston rings as a set.
15 mm NOTE:
Measure the cylinder bore A in parallel with
and at right angles to the crankshaft. Then
take the greater of the measurements.
3) If the difference between the maximum

value and the minimum value for a single
cylinder exceeds the specified value, re-
place the cylinder block. Also replace the
pistons and piston rings as a set.
NOTE:
#1 #2 #3 #4
b There are three sizes of standard cylinder
FWD
bores. They are identified by the marks 1, 2
and 3 B, stamped on the top face of the cyl-
inder block.
Cylinder bore diameter A :

Mark “1”
102.00 – 102.01 mm (4.0157 – 4.0161 in.)
Mark “2”
102.01 – 102.02 mm (4.0161 – 4.0165 in.)
Mark “3”
102.02 – 102.03 mm (4.0165 – 4.0169 in.)
<Limit>
Standard
102.18 mm (4.0228 in.)
6-146
OVER
4) Calculate the oil clearance between the
piston and the cylinder using the formula
indicated below.
Piston-to-cylinder clearance =
cylinder bore – piston diameter
If out of specification, replace the cylin-

der, and additionally replace the pistons
and piston rings as a set.
Standard piston-to-cylinder clearance:

Standard
0.16 – 0.18 mm (0.0063 – 0.0071 in.)
<Limit> 0.25 mm (0.0098 in.)
NOTE:
c When installing new pistons, install a piston
having the same number mark C as that on
the cylinder block.
Front mark
Ring groove clearance checking step

1) Check the ring groove clearance.
Out of specification → Replace the pis-
ton.
NOTE:
Install piston rings (top and second rings) and
oil ring on the piston. Measure the clearance
between the rings and the wall of the piston
ring grooves using a thickness gauge.
Ring groove clearance:

Top ring
0.08 – 0.12 mm (0.0031 – 0.0047 in.)
Second ring
0.04 – 0.08 mm (0.0016 – 0.0031 in.)
Oil ring
0.03 – 0.07 mm (0.0012 – 0.0028 in.)
6-147
OVER
Piston rings (into cylinder) checking steps
1) Insert each piston ring into the cylinder
bore by pushing it with a piston crown.
Place the piston ring at right angles to
the cylinder bore.
NOTE:
a Place the ring end gap at 150 mm (5.9 in.) A
from the cylinder block top surface.
2) Check the end gap of the piston ring

placed in the cylinder bore.
Out of specification → Replace the pis-
ton ring.
End gap:
Top ring
0.35 – 0.50 mm (0.0138 – 0.0197 in.)
<Limit> 1.30 mm (0.0512 in.)
Second ring
0.45 – 0.60 mm (0.0177 – 0.0236 in.)
<Limit> 1.40 mm (0.0551 in.)
Oil ring
0.20 – 0.40 mm (0.0079 – 0.0157 in.)
<Limit> 1.20 mm (0.0472 in.)
6-148
OVER
Connecting Rod and Piston Pin Check
1. Check:
¡ Connecting rod and rod cap
¡ Connecting rod bending
¡ Connecting rod twisting
¡ Piston pin and connecting rod bush-
ing
¡ Piston pin to bushing clearance
Connecting rod and rod cap checking step

1) Check the connecting rod 1 and rod cap
2 for cracks, bending and/or damage.
1 Cracks/Bending/Damage → Replace the
connecting rod assembly.
Connecting rod bending checking step

1) Check the connecting rod bending A by
a
Out of specification → Replace the con-
Connecting rod bending:

<Limit>
0.05 mm (0.0020 in.) per 100 mm (3.937 in.)
Connecting rod twisting checking step

1) Check the connecting rod twisting A by
a Out of specification → Replace the con-
Connecting rod twisting:

<Limit>
0.05 mm (0.0020 in.) per 100 mm (3.937 in.)
6-149
OVER
Piston pin and connecting rod bushing
checking step
1) Check the piston pin 1 and the connect-
ing rod bushing 2.
Heat discoloration/Wear/Damage → Re-
place the piston pin and the bushing as
1 a set.
Piston pin to bushing clearance checking

steps
1) Measure the piston pin outer diameter
A.
If out of specification, replace the piston
pin.
NOTE:
Check the pin diameter selection mark on the
piston before measuring the outer diameter
a A.
Piston pin outer diameter A :

34.000 – 34.010 mm (1.3386 – 1.3390 in.)
2) Measure the inner diameter B of the con-

necting rod bushing.
b Bushing inner diameter B :

34.009 – 34.019 mm (1.3389 – 1.3393 in.)
3) Calculate the clearance between the pis-

ton pin and the bushing using the for-
mula indicated below.
Piston pin to bushing clearance =

bushing inner diameter B –
piston pin outer diameter A
4) If out of specification, replace the con-

necting rod bushing.
Piston pin to bushing clearance:

0.004 – 0.014 mm (0.0002 – 0.0006 in.)
<Limit> 0.05 mm (0.0020 in.)
6-150
OVER
Connecting Rod Bushing Replacement
1. Replace:
¡ Connecting rod bushing
Connecting rod bushing replacement steps

1) Press out the bushing 1 with the re-
mover/replacer 2 and base 3.
2
Connecting rod bushing remover

1
and installer set:
09222-58020
3
2) Gently file off any roughness on the

small end of the connecting rod.
3) Install the bushing 1 in guide 2. Fit-in

1 the ball A of the guide to the oil hole B
b
of the bushing.
Connecting rod bushing remover

a
and installer set:
2 09222-58020
4) Press the bushing 1 into the small end

2 of the connecting rod using the remover/
replacer 2, guide 4 and base 3.
1
4
6-151
OVER
NOTE:
Align the oil holes A on the bushing and on
the connecting rod.
a
5) After installing the bushing, check that

the oil holes on the connecting rod and
the bushing are aligned, and that the gap
between the end of the bushing and the
connecting rod are equal on both sides.
6) Hone the bushing using a pinhole

grinder to obtain the specified clearance
between the piston pin and bushing.
Piston pin to bushing clearance:

0.004 – 0.014 mm (0.0002 – 0.0006 in.)
7) Lubricate the piston pin 1 with engine

oil and press it into the connecting rod.
Check for the play.
1
6-152
OVER
Crankshaft and Bearing Check
1. Check:
¡ Crankshaft runout
¡ Main journal, crank pin and bearing
surface
¡ Main journal and crank pin outer di-
ameter
¡ Taper and out-of-round (of main jour-
nals and crank pin)
¡ Main journal oil clearance
¡ Crank pin oil clearance
Crankshaft runout checking step

1) Check the crankshaft runout using a dial
gauge. (at the center journal A)
Crankshaft runout:
Or less 0.08 mm (0.0031 in.)
Main journal, crankpin and bearing surface

checking step
1) Check each surface for scratches, pitting
and/r damage.
Scratches/Pitting/Damage → Replace the
bearing.
NOTE:
Grind or replace the crankshaft if necessary.
Main journal and crankpin outer diameter

checking step
1) Check the outer diameters of the main
journal and the crank pin using a mi-
crometer.
Out of specification → Check oil clear-
ance.
Standard main journal diameter:

Except #3 journal
66.980 – 70.000 mm (2.7551 – 2.7559 in.)
#3 journal
69.950 – 69.970 mm (2.7539 – 2.7547 in.)
Standard crank pin diameter:
60.980 – 61.000 mm (2.4008 – 2.4016 in.)
6-153
OVER
Taper and out-of-round checking step
1) Check the main journal and the crank pin
for taper and out-of-round.
Out of specification → Replace the crank-
shaft.
Taper and out-of-round:

Or less 0.02 mm (0.0008 in.)
Main journal oil clearance checking steps

1) Check the main journal oil clearance.
Out of specification → Replace the bear-
ings.
NOTE:
Replace the crankshaft if necessary.
Main journal oil clearance:

Except #3 journal
0.030 – 0.074 mm (0.0012 – 0.0029 in.)
<Limit> 0.10 mm (0.0039 in.)
#3 journal
0.060 – 0.104 mm (0.0024 – 0.0041 in.)
<Limit> 0.15 mm (0.0059 in.)
CAUTION:
Do not interchange the bearings, cylinder
block or bearing caps. They must be rein-
stalled in their original positions. If not, the
correct oil clearance may not be obtained,
causing engine damage.
2) Clean each bearing cap and cylinder

block area corresponding to the locations
of main journal bearing.
3) Install the lower half of the bearings 1
a and the crankshaft 2 in the cylinder
block.
NOTE:
Align the protrusion A on the bearing with
2 the notch B on the cylinder block.
b
1
6-154
OVER
4) Place some Plastigage 1 on each main
journal in the axial direction.
NOTE:
Do not cover the oil holes on the main jour-
nals with the Plastigage.
5) Install the bearings 1 in the bearing cap

2
2 and assemble the bearing cap.
6) Tighten the bolts to the specified torque

7 3 1 5 9
following the order shown in the illus-
tration.
Bolts (main bearing cap):

196 N·m (20 kgf·m, 145 lbf·ft)
NOTE:
Do not turn the crankshaft while measuring
8 4 2 6 10
the clearance.
7) Remove the bearing cap and measure

the width of the Plastigage.
Main journal oil clearance:

Except #3 journal
0.030 N·m – 0.074 mm
(0.0012 – 0.029 in.)
<Limit> 0.10 mm (0.0039 in.)
#3 journal
0.060 N·m – 0.104 mm
(0.0024 – 0.0041 in.)
<Limit> 0.15 mm (0.0059 in.)
6-155
OVER
If oil clearance is out of specification, select
FWD a replacement bearing from the following
table.
Bearing Crankshaft
#1
Journal Bearing Identifi- journal outer
#2
number number cation diameter
#3
#4
color dimension (mm)
#5 Yellow or green 1 1 Yellow Standard
Mark 1 or 2 69.98 – 70.00
2 2 Green
*(69.95 – 69.97)
– U/S 0.25 – 69.74 – 69.75
– U/S 0.50 – 69.49 – 69.50
– U/S 1.00 – 68.99 – 69.00
* Only for #3 journal
NOTE:
¡ When the standard bearing is used, re-
place with one with the same number.
¡ There are two sizes of standard bearings
identified by the marks 1 and 2.
8) Remove the Plastigage.
6-156
OVER
Crank pin oil clearance checking steps
1) Check the crank pin oil clearance.
Out of specification → Replace the bear-
ings.
NOTE:
Replace the crankshaft if necessary.
Crank pin oil clearance:

0.030 – 0.070 mm (0.0012 – 0.0028 in.)
<Limit> 0.10 mm (0.0039 in.)
CAUTION:
Do not interchange the bearings or connect-
ing rods. They must be returned to their
original locations during reinstallation. If not,
the oil clearance may not be correct, caus-
ing damage to the engine.
2) Clean the bearings, crank pins and bear-

ing portions of the connecting rods.
3) Install the upper half 1 of the bearing in

2 the connecting rod 2, and install the
1 3
lower half 3 of the bearing in the con-
4
necting rod cap 4.
NOTE:
Align the bearing protrusion A on the bear-
ing with notch B on the cap and the con-
necting rod.
a
b
4) Place some Plastigage 1 on the crank

1 pin in the axial direction.
6-157
OVER
5) Install the connecting rod assembly on
a the crankshaft.
NOTE:
¡ Match the numbered connecting rod cap
with the appropriate connecting rod.
¡ Install the connecting rod cap with the
front mark A facing forward.
6) Tighten the nuts to the specified torque.
Nuts (connecting rod cap):

1st tightening
T.R
69 N·m (7.0 kgf·m, 51 lbf·ft)
2nd tightening
Turn 90°
NOTE:
Do not turn the crankshaft while measuring
the clearance.
7) Remove the connecting rod cap and

measure the width of the Plastigage.
Crank pin oil clearance:

0.030 – 0.070 mm (0.0012 – 0.0028 in.)
<Limit> 0.10 mm (0.0039 in.)
If the oil clearance is out of specification,

select a replacement bearing from the
following table.
Bearing Crankshaft
Bearing
Bearing Identifi- journal outer
cap
number cation diameter
number
color dimension (mm)
1 1 Yellow Standard
2 2 Green 60.98 – 61.00
– U/S 0.25 – 60.74 – 60.75
– U/S 0.50 – 60.49 – 60.50
Mark 1 or 2 Front mark
Yellow or green – U/S 1.00 – 58.99 – 60.00
NOTE:
¡ When the standard bearing is used, re-
place with one having the same number.
¡ There are two sizes of standard bearings
identified by the marks 1 and 2.
8) Remove the Plastigage.
6-158
OVER
Crankshaft Oil Seal Retainer and Oil
Seal Check
1. Check:
¡ Crankshaft oil seal retainer and oil
seal
Crankshaft oil seal retainer and oil seal

checking steps
1) Check the crankshaft oil retainer 1 for
2
2) Check the crankshaft oil seal 2 for wear
and/or damage.
Wear/Damage → Replace.
1
Crankshaft Oil Seal Replacement

1. Replace:
¡ Crankshaft oil seal
Oil Seal Replacement steps

When crankshaft oil seal retainer has been
removed from the cylinder block
1) Tap out oil seal 1 using the suitable tool
and hammer.
2) Tap in a new oil seal 1 using the crank-

shaft rear oil seal replacer until the sur-
1
face of the new oil seal is flush with the
edge of the oil seal retainer.
Crankshaft rear oil seal replacer:

09223-56010

lip of the new oil seal.
6-159
OVER
When crankshaft oil seal retainer is installed
in the cylinder block
1) Cut off the lip A of the oil seal using a
knife.
2) Pry off the oil seal 1 using a screwdriver.
CAUTION:
¡ Wrap the end of the screwdriver tip with
a tape.
1 ¡ Be careful not to scratch the crankshaft.

lip of the new oil seal.
4) Tap in a new oil seal using the crankshaft
rear oil seal replacer until the surface of
the new oil seal is flush with the edge of
the oil seal retainer.
Crankshaft rear oil seal replacer:

09223-56010
6-160
OVER
Cylinder Block Assembly
CAUTION:
sembled.
¡ Apply clean engine oil to all sliding sur-
faces and rotating surfaces before instal-
lation the parts.
¡ Replace all gaskets and oil seals with new
ones.
Valve Lifter and Camshaft Bearing As-

sembly
1. Assemble:
¡ Valve lifter and camshaft bearing
Valve lifter and camshaft bearing assembly

steps
1) Install the valve lifter 1.
1
NOTE:
The guide bolt B is inserted into the long
c hole C of the valve lifter and inserted from
b the edge of the oil pan to the edge of the cyl-
inder head using the extension bar A.
d
a
Guide bolt:
B M10
37 N·m (3.8 kgf·m, 27 lbf·ft)
D M8
18 N·m (1.8 kgf·m, 13 lbf·ft)
2) Install the camshaft bearings 1 using the

bearing remover and replacer.
1
Camshaft bearing remover and replacer:
09215-00100
6-161
OVER
a
3) Install the plug 1.
1
Distance from the edge of the shear-
ing block A to the plug as installed:
2.0 mm (0.079 in.)
NOTE:
Apply ThreeBond® TB-1207B to the outside
circumference of the block.
6-162
OVER
Piston and Connecting Rod Assembly
1. Assemble:
Piston and connecting rod assembly steps

1) Install the snap ring 1. (on one side of
a
the piston hole)
1
b NOTE:
Position the snap ring so that the snap ring
end A aligns with the notch, and then press
the snap ring into the piston groove starting
from the end B.
2) Gradually heat the piston to approxi-

mately 80 °C (176 °F). Apply some en-
gine oil to the piston pin, and join the
piston and the connecting rod.
NOTE:
¡ Align the front mark (arrow) of the piston
with the front mark (protrusion) of the
connecting rod.
¡ Each piston, connecting rod and piston
pin must be reinstalled in its original po-
sition.
Front mark
3) Install the snap ring. (onto the other side

of the piston pin hole)
4) Install the oil ring spring, and then the

oil ring to the piston.
6-163
OVER
NOTE:
b Check that the end gap A of the oil ring 1 is
1 on the opposite side of the spring joint B.
5) Install the second compression ring, and

Stamped
marks
then the top compression ring to the
#1
piston, with the stamped marks on each
ring facing upward.
#2
NOTE:
¡ Install each ring with the stamped mark
facing upward.
¡ Offset the piston ring end gaps as shown
in the illustration.
1 Compression ring (second ring)
2 Compression ring (top ring)
3 1 3 Oil ring
4 Spring joint (oil ring)
Front mark
2 4
6) Install the main bearings to the cylinder

a c block. Align protrusion A of each bear-
ing with the groove B in the cap and the
cylinder block.
NOTE:
¡ Align each of the oil holes C in the bear-
b ings and the cylinder block.
¡ All bearings must be reinstalled in their
original positions.
7) Apply a light coating of engine oil to the

main bearings and install the crankshaft
1.
1
6-164
OVER
8) Install the thrust washers 1 to the #3
1 main journal position on the cylinder
block. Make sure that the oil grooves
come to the outside on the thrust wash-
ers 1.
NOTE:
The tab of the thrust washers 1 should be
located as shown in the illustration.
9) Apply some engine oil to the thrust

washers before the installation of bear-
ing cap.
10) Install the main bearing cap on the cyl-
inder block and set the new bolts.
Main bearing
cap number
NOTE:
a ¡ Apply a light coating of engine oil to the
bolt threads and under the heads.
¡ Install the main bearing caps in the as-
FWD cending order of the cap numbers from
the front end. Make sure that the arrow
mark A is pointing forward.
11) Check the crankshaft thrust clearance.

Out of specification → Replace the thrust
washers as a set.
NOTE:
Measure the thrust clearance while prying
the crankshaft back and forth with a screw-
driver.
Crankshaft thrust clearance:

0.04 – 0.25 mm (0.0016 – 0.0098 in.)
<Limit> 0.30 mm (0.0118 in.)
12) Tighten the main bearing cap bolts in

7 3 1 5 9
several passes following the order
shown in the illustration.
Bolts (main bearing cap):

196 N·m (20 kgf·m, 145 lbf·ft)
T.R
NOTE:
8 4 2 6 10
If any of the bolts do not reach the specified
torque, replace that bolt.
6-165
OVER
Piston and Connecting Rod Installation
1. Install:
Piston and connecting rod installation steps

1) Attach the bearing to the connecting rod
b aligning the protrusion A with the
a groove B.
NOTE:
¡ Align the protrusion on the bearing with
the groove in the rod and cap.
¡ All bearings must be reinstalled in their
original positions.
2) Apply a light coating of engine oil to the

cylinder bore, push-in the piston into the
corresponding cylinder using the piston
ring compressor. The front mark A on
the piston must come to the forward.
a
NOTE:
Check that the piston ring ends are fitted in
the groove before installing the piston into
the cylinder.
a 3) Apply some engine oil to the bearings,

bolts, and bolt heads. Install the connect-
ing rod cap to the correct cylinder by
checking the mark on it.
NOTE:
Install the connecting rod caps with the front
mark A (protrusion) facing forward.
4) Tighten the connecting rod cap nuts in

several passes.
CAUTION:
Always replace the connecting rod bolts and
nuts with new ones.
Nuts (connecting rod cap):

69 N·m (7.0 kgf·m, 51 lbf·ft)
T.R
6-166
OVER
a 5) Mark the front of the connecting rod
holding nuts with paint A.
6) Tighten the holding nuts by an additional

a
90°.
7) Check that the paint mark A is now at a
90° 90° angle to the front.
8) Check that the crankshaft turns smoothly.
9) Check the connecting rod thrust clear-

ance using a dial gauge.
If out of specification, replace the con-
necting rod or crankshaft.
Connecting rod thrust clearance:

0.10 – 0.20 mm (0.004 – 0.008 in.)
<Limit> 0.30 mm (0.012 in.)
6-167
OVER
Crankshaft Oil Seal Retainer Installa-
tion
NOTE:
Before starting the work, remove the frac-
tions of old gasket from the oil seal retainer
and the cylinder block. Clean the sealing ar-
eas and the contact surfaces with a non-re-
sidual solvent.
1. Install:
¡ Crankshaft oil seal retainer
Crankshaft oil seal retainer installation steps

1) Install the crankshaft oil seal retainer 1
on the cylinder block and tighten the
1 bolts to the specified torque in a criss-
cross pattern.
Bolts (rear oil seal retainer):

18 N·m (1.8 kgf·m, 13 lbf·ft)
T.R
2) Install the heat exchanger bracket and

tighten the bolts to the specified torque.
Bolts (bracket - heat exchanger):

113 N·m (11.5 kgf·m, 83 lbf·ft)
T.R
3) Install the engine brackets and tighten

the bolts to the specified torque.
Bolts (engine bracket):

113 N·m (11.5 kgf·m, 83 lbf·ft)
T.R
6-168
OVER
4) Remove the engine assembly from the
engine stand 1, and install the follow-
ing parts:
¡ Oil strainer
¡ Timing gear case and oil pan
Refer to “Timing Gear Case Installa-
1
tion” section (P6-118).
¡ Oil cooler
¡ Timing gears
Refer to “Timing Gear Installation”
section (P6-79).
¡ Injection pump
Refer to “Injection Pump Installation”
section (P5-13).
¡ Circulation pump
¡ Seawater pump
¡ Power steering oil cooler
¡ Power steering oil pump
¡ Heat exchanger
Manifold Installation” section (P6-62).
¡ Engine wireharness
¡ Starter motor
¡ Alternator
Refer to “Alternator Installation” sec-
tion (P8-44).
Refer to “2-stage Rate Coupling and
Flywheel Installation” section (P6-7).
6-169
OVER
(P3-41).



Max. 4.8 L, Min. 2.8 L
 Max. 5.1 US qt., Min. 3.0 US qt. 
Max. 5.7 L, Min. 3.7 L
 Max. 6.0 US qt., Min. 3.9 US qt. 
6-170
STEER E
CHAPTER 7
POWER STEERING SYSTEM ................................................................................................. 7-1

Power Steering System Air Bleeding ............................................................................... 7-1
POWER STEERING PUMP ...................................................................................................... 7-2

Power Steering Pump Removal ....................................................................................... 7-2
Power Steering Pump Check ............................................................................................ 7-3
Power Steering Pump Pulley Replacement ..................................................................... 7-4
Power Steering Pump Installation .................................................................................... 7-5
POWER STEERING OIL COOLER ........................................................................................... 7-6

Power Steering Oil Cooler Removal ................................................................................ 7-6
Power Steering Oil Cooler Check ..................................................................................... 7-6
Power Steering Oil Cooler Installation ............................................................................. 7-7
POWER STEERING CYLINDER .............................................................................................. 7-7
POWER STEERING SYSTEM REMOVAL FOR TWIN INSTALLATIONS .............................. 7-8

Power Steering System Removal ..................................................................................... 7-8
7
STEER POWER STEERING SYSTEM E

Power Steering System Air Bleeding
1. Air bleed:
¡ Power steering system
Power steering system air bleeding steps
CAUTION:
DO NOT operate the engine without cool-
ing water supplied to the lower unit. Dam-
age can occur from the engine overheating.
NOTE:
If there are many bubbles in the reservoir
tank, allow the bubbles to disperse first.
1) Fill the power steering pump reservoir

with the recommended power steering
fluid. Refer to “Power Steering Fluid
Level Check” section (P3-47).
2) Run the engine until it reaches normal
operating temperature.
While operating the engine, turn the
steering lever all the way to both sides
for several times.
3) Turn the steering lever until the drive unit
is pointing straight back and is centered.
Stop the engine.
4) Remove the filler cap 1. Allow any foam
in the reservoir tank 2 to dissipate be-
1
fore checking the fluid level.
Add the power steering fluid until the
fluid level comes between the “HOT”
2 mark and the “ADD” mark on the oil level
gauge (range A).
DO NOT overfill.
5) If the power steering fluid is foamy in
step 4), repeat steps 2) to 4) until the fluid
stops forming and the level remains con-
stant.
7-1
STEER POWER STEERING PUMP E
POWER STEERING PUMP

Power Steering Pump Removal
1. Remove:
Power steering pump removal steps

1) Drain power steering fluid.
2) Disconnect the power steering feed hose
1 from the power steering oil cooler.
1
3) Disconnect the power steering high pres-

1
sure hoses 1 from the power steering
cylinder.
4) Disconnect the hose clamps.
5) Remove the power steering pump

mounting bolts, and remove the power
steering pump.
7-2
Power Steering Pump Check

1. Check:
Power steering pump checking step

1) Check the power steering pump for clog-
ging.
Clog → Wash and clean.
7-3
Power Steering Pump Pulley Replace-

ment
1. Replace:
¡ Power steering pump pulley
Power steering pump pulley replacement

steps
1) Remove the power steering pump pul-
ley using the power steering pump pul-
ley remover 1.
1 NOTE:
Set the claw of the power steering pump
pulley remover in the pulley groove.
2) Install the power steering pump pulley

using the power steering pump pulley
replacer 1.
NOTE:
Install the pulley so that the end face of the
pump shaft is in flush A with the end face of
the pulley.
3) Bleed air from the power steering sys-

tem.
Refer to “Power Steering System Air
Bleeding” section (P7-1).
4) Check the power steering fluid.
Leakage → Repair.
7-4
Power Steering Pump Installation

1. Install:
Power steering pump installation steps

1) Install the power steering pump.
2) Connect the power steering high pres-

1 sure hoses 1.
Power steering hose (small fitting):

15 N·m (1.5 kgf·m, 11 lbf·ft)
T.R
Power steering hose (large fitting):

34 N·m (3.4 kgf·m, 25 lbf·ft)
3) Connect the power steering feed hoses

1.
1
4) Connect the hose clamps.
7-5
STEER POWER STEERING OIL COOLER E
POWER STEERING OIL COOLER

Power Steering Oil Cooler Removal
1. Remove:
Power steering oil cooler removal steps

1) Drain the power steering fluid.
2) Remove the air filter assembly.
3) Remove the boost pipe.
4) Disconnect the power steering hose 1
1
2 coming from the power steering cylin-
der.
3 3
5) Disconnect the power steering hose 2
leading to the reservoir tank.
6) Disconnect the seawater hose 3.
4 7) Remove the power steering oil cooler 4.
Power Steering Oil Cooler Check

1. Check:
Power steering oil cooler checking step

1) Check the power steering oil cooler for
cracks, damage and/or clogging.
7-6
POWER STEERING OIL COOLER /
STEER POWER STEERING CYLINDER
E
Power Steering Oil Cooler Installation

1. Install:
Power steering oil cooler installation steps

1) Install the power steering oil cooler.
2) Connect the power steering hose 1 com-

1
2 ing from the power steering cylinder.
3 3 3) Connect the power steering hose 2 lead-
ing to the reservoir tank.
4) Connect the seawater hose 3.
5) Bleed air from the power steering sys-
tem. Refer to “Power Steering System
Air Bleeding” section (P7-1).
6) Check the power steering fluid.
Leakage → Repair.
POWER STEERING CYLINDER

MANUAL” or “DE-DHD STERN DRIVE SER-
VICE MANUAL”.
7-7
POWER STEERING SYSTEM REMOVAL FOR
STEER TWIN INSTALLATIONS
E

REMOVAL FOR TWIN INSTALLA-
TIONS
Power Steering System Removal
1. Remove:
¡ Power steering system
Power steering system removal steps

1) Drain the power steering fluid.
2) Remove the power steering pump 1.
1
Refer to “Power Steering Pump Re-
moval” section (P7-2).
3) Remove the adjusting pulley and bracket.
4) Cut one piece of 9.5 mm (3/8 in.) ID power

1 steering hose 1 having approximately
2
203 mm (8 in.) length.
Connect the ends of the hose to the ports
of the power steering oil cooler 2 and
clamp securely.
NOTE:
Make sure that the hose does not touch the
air filter, boost pipe or turbocharger.
7-8
– +
ELEC E
CHAPTER 8
ELECTRICAL SYSTEM
AUTO QUICK GLOW SYSTEM .............................................................................................. 8-1

Main Switch Check ............................................................................................................ 8-2
Neutral Switch Check ........................................................................................................ 8-3
Pickup (tacho) Sensor Check ............................................................................................ 8-3
Glow Relay Check .............................................................................................................. 8-4
Glow Plug Check ................................................................................................................ 8-5
Glow Control Box Check ................................................................................................... 8-6
Resistor Check .................................................................................................................... 8-7
STARTING SYSTEM ............................................................................................................... 8-8

Main Switch Check ............................................................................................................ 8-9
Neutral Switch Check ........................................................................................................ 8-9
Diode Check ....................................................................................................................... 8-9
Starter Relay Check ......................................................................................................... 8-10
STARTER MOTOR ................................................................................................................. 8-11

Starter Motor Removal .................................................................................................... 8-12
Starter Motor Disassembly ............................................................................................. 8-12
Starter Motor Check and Repair ..................................................................................... 8-15
Starter Motor Assembly .................................................................................................. 8-21
Starter Motor Operation Test .......................................................................................... 8-24
Starter Motor Installation ................................................................................................ 8-25
CHARGING SYSTEM ............................................................................................................ 8-26

Circuit Diagram ................................................................................................................ 8-26
Battery and Electrical Connection ON-Boat Check........................................................ 8-27
Drive Belts Check ............................................................................................................. 8-27
Charging Circuit Check .................................................................................................... 8-28
ALTERNATOR ........................................................................................................................ 8-30

Alternator Removal ......................................................................................................... 8-31
Alternator Disassembly ................................................................................................... 8-32
Alternator Check and Repair ........................................................................................... 8-35
Alternator Assembly ........................................................................................................ 8-40
Alternator Installation ...................................................................................................... 8-44
FUEL SYSTEM ...................................................................................................................... 8-45

Main Switch Check .......................................................................................................... 8-46
– +
ELEC E
Neutral Switch Check ...................................................................................................... 8-46

Pickup (tacho) Sensor Check .......................................................................................... 8-46
Glow Control Box Check ................................................................................................. 8-46
Water Separator Switch Check ....................................................................................... 8-47
Fuel Cut Solenoid Valve Check ....................................................................................... 8-48
OTHER COMPONENTS ........................................................................................................ 8-49

Oil Pressure Sender Check .............................................................................................. 8-49
Oil Pressure Switch Check .............................................................................................. 8-49
Seawater Flow Sender Check ......................................................................................... 8-50
Water Temperature Sensor Check .................................................................................. 8-51
Thermo Switch Check ..................................................................................................... 8-52
8
– +
ELEC AUTO QUICK GLOW SYSTEM E
AUTO QUICK GLOW SYSTEM
R R
14
15
3 20A 100A 8
R/Pu R R
2
R/Pu Pu Y/R
13
OFF
ON
START R
4
11
Y/R Y/R
Pu G/Y R
R B
9
6
Gy G/Br R
5
B R
1 R
B L/G
B/W
10 R 12
7 R
12V

1 Battery 1
2 Main switch 1
3 Fuse (20 A) 1
4 Neutral switch 1
5 Pickup (tacho) sensor 1
6 Glow control box 1
7 Glow light 1
8 Fuse (100 A) 1
9 Glow relay 1
0 Glow plug 1
A After glow relay 1
B Resistor 1
C Alternator 1
D Starter motor 1
E Terminal assembly 1
8-1
– +
NOTE:
Main glow relay control:
The glow relay is switched ON for 10 ± 1.5
seconds when the main switch is turned ON.
When the engine speed reaches 400 ± 50 r/
min., the relay is switched OFF.
The relay is also switched ON while the main
switch is held in the “START” position, and
stays ON for 1 ± 0.5 seconds after the main
switch returns to the ON position.
After glow relay control:
The after glow relay is switched ON for 60 ±
9 seconds when the main switch is turned to
ON and the engine speed reaches more than
400 r/min.
Glow lamp control:
The glow lamp is lit for 4 ± 0.4 seconds after
the main switch is turned ON.
When the engine speed reaches 400 ± 50 r/
min., the lamp goes off.
Main Switch Check

1. Check:
¡ Main switch
Main switch checking step
1) Check the continuity between the termi-
Terminal nals marked “ – ” in each position of
Switch
R/Pu Pu Y/R the main switch.
position If there is no continuity, replace the main
OFF switch.
ON
START
8-2
– +
Neutral Switch Check

1. Check:
¡ Neutral switch
Neutral switch checking steps

1) Disconnect the neutral switch coupler 1
from the wireharness.
2) Put the remote control lever in “NEU-
TRAL”.
3) Check the continuity between the termi-

nals marked “ – ” in each position of
Terminal the neutral switch.
A1 A2
Switch
If there is no continuity, replace the neu-
position Y/R Y/R G/L B tral switch.
FREE
PUSH
Pickup (tacho) Sensor Check

1. Check:
Pickup (tacho) sensor checking steps

1) Disconnect the pickup (tacho) sensor
coupler 1 from the wireharness.
1
2) Check the pickup (tacho) sensor for the
2
continuity between 1 and 2.
2 1 If there is no continuity, replace the
pickup (tacho) sensor.
8-3
– +
Glow Relay Check

1. Check:
¡ Main glow relay
¡ After glow relay
Main glow relay checking steps

1) Disconnect the main glow relay coupler
1 from the main glow relay.
3 2) Connect the battery (12 V) to 1 and 2

2
terminals of the main glow relay.
3) Using a circuit tester check the main glow
relay for continuity between 3 and 4
terminals.
4 1 Replace the main glow relay if there is
no continuity.
After glow realy checking steps

1) Disconnect the after glow relay coupler
1 from the after glow relay.
3 2) Connect the battery (12 V) to 1 and 2

2
terminals of the after glow relay.
3) Using a circuit tester check the after glow
terminals.
4 1
Replace the after glow relay if there is
no continuity.
8-4
– +
Glow Plug Check

1. Check:
¡ Glow plug
Glow plug checking steps

1) Remove the glow plug holder 1.
2) Using a circuit tester, check that there is

2
continuity between the glow plug termi-
nal 1 and ground 2.
If there is continuity, replace the glow
plug.
8-5
– +
Glow Control Box Check

1. Check:
¡ Glow control box
Glow control box checking step

1) Connect circuit tester leads to each ter-
1
minal of control box 1 on indicated
table.
Pu L/R L/G
G/Br Y/R
Gr
G/Y B
A NOTE:
B
Pu L/R L/G G/Br Gy Y/R G/Y B (*) marks indicate that because of the con-
15kΩ~ denser the circuit tester needle might keep
Pu ∞ 15kΩ
∞ ∞ ∞ ∞
~ ∞* 60kΩ oscillating for a few moments after the tester
L/R ∞ ∞ ∞ ∞ ∞ ∞ ∞ probes are connected to the terminals. Wait
until the needle stabilizes in order to get on
L/G ∞ ∞ ∞ ∞ ∞ ∞ ∞ accurate reading.
G/Br ∞ ∞ ∞ ∞ ∞ ∞ ∞ Circuit tester positive (+) probe

Circuit tester negative (–) probe
Gy ∞ ∞ ∞ ∞ ∞ ∞ ∞
Y/R ∞ ∞ 300kΩ ∞ ∞ ∞ 100kΩ

~∞* ~ ∞*
G/Y ∞ ∞ ∞ ∞ ∞ ∞ ∞
B ∞ ∞ 3kΩ~
∞ ∞ ∞ ∞
8kΩ
8-6
– +
Resistor Check
1. Check:
¡ Resistor
NOTE:
¡ Be careful not to damage the resistor
pipes as this could cause an open circuit
or shorten the life of the plug.
¡ Avoid contaminating the resistor with oil
or gasoline when cleaning.
¡ During inspection, be sure to wipe any oil
off the resistor terminal and bakelite
washer with a dry cloth.
¡ Be careful not to apply more than 11 volts
to the resistor as this could cause an open
circuit.
Resistor checking steps

1) Disconnect wire lead 1.
2) Check the resistor for continuity between

the resistor terminal 1 and ground 2.
If there is no continuity, replace the re-
sistor.
1
8-7
– +
ELEC STARTING SYSTEM E
STARTING SYSTEM
9
R R R
100A
7
2 R/Pu R/Pu
8
4 20A
R/Pu Pu Y/R
OFF
ON
R
START
M
Pu
3
Y/R
5
Y/R
1 6
Y/R Br
B
R

1 Battery 1
2 Starter motor 1
3 Starter relay 1
4 Main switch 1
5 Neutral switch 1
6 Diode 1
7 Fuse (20 A) 1
8 Alternator 1
9 Fuse (100 A) 1
8-8
– +
Main Switch Check

1. Check:
¡ Main switch
Refer to “Main Switch Check” section
(P8-2).

1. Check:
¡ Neutral switch
Refer to “Neutral Switch Check” sec-
tion (P8-3).
Diode Check
1. Check:
¡ Diode
Diode checking steps

1) Disconnect the diode from the lead cou-
pler 1.
1
2) Using an circuit tester, check the diode

for continuity between 1 and 2 termi-
nals.
Tester (+) lead → 1 terminal
2
Tester (–) lead → 2 terminal
1
3) Using an circuit tester, check the diode
for continuity between 2 and 1 termi-
nals.
Tester (+) lead → 2 terminal

Tester (–) lead → 1 terminal
4) Take the following action depending on
the results of checking in 2) and 3) above:
Replace the diode if there was continu-
ity in both 2) and 3).
Replace the diode if there was no conti-
nuity in neither 2) and 3).
8-9
– +
Starter Relay Check

1. Check:
¡ Starter relay
Starter relay checking steps

1) Disconnect the starter relay coupler 1
from the starter relay.
3 2) Connect the battery (12V) to 1 and 2

2
terminals of the starter relay.
3) Using an circuit tester check the starter
terminals.
4 1
Replace the starter relay if there is no
continuity.
8-10
– +
ELEC STARTER MOTOR E
STARTER MOTOR

1 End cover 1
2 Brush holder 1
3 Brush 1
4 Field frame 1
5 Bearings 2
6 Armature 1
7 Plate washer 1
8 Magnetic switch 1
9 Compression spring 1
0 Steel ball 1
A Armature 1
B Starter housing 1
C Idler gear 1
D Bearing 1
8-11
– +
Starter Motor Removal

1. Remove:
¡ Starter motor
Starter motor removal steps
1 1) Disconnect the negative (–) lead 1 from

the battery terminal.
UPPER
LOWER
2) Disconnect the battery positive (+) lead

2 1.
3) Disconnect the starter motor leads 2.
3
4) Disconnect the magnetic switch leads 3.
1
5) Remove the starter motor 4.
Starter Motor Disassembly

1. Disassemble:
¡ Starter motor
Starter motor disassembly steps

1) Disconnect the field coil lead 1.
1 2) Remove the bolts 2 and the field frame
3 with armature.
2 3
8-12
– +
3) Remove the felt washer 1 from the

starter housing.
1
4) Remove the screws 1 and the starter

housing 2 from the magnetic switch.
5) Remove the return spring 1, idler gear

A
4 2, bearing 3 and plate washer 4 from
5 the starter housing 5.
1 3
6) Remove the steel ball 1 from the clutch

shaft hole A using a magnetic rod 2.
a
7) Remove the end cover 1 from the field

frame.
1
8-13
– +
8) Remove the brushes 1 and the brush

holder 2.
NOTE:
Using a screwdriver, hold back the spring and
1 disconnect the brushes 1 from the brush
holders 2.
9) Remove the armature 1 from the field

frame 2.
8-14
– +
Starter Motor Check and Repair

1. Check and repair:
¡ Armature coil
¡ Field coil
¡ Brush holder assembly
¡ Gear teeth (Pinion/Idler/Clutch)
¡ Clutch operation
¡ Bearings
¡ Magnetic switch
Armature coil checking steps

1) Using an ohmmeter (Ω x 1), check that
there is continuity between the segments
of the commutator. (For open circuit )
If there is no continuity, replace the ar-
mature.
2) Using an megatester, check that there is

no continuity between the commutator
and armature coil core. (For ground )
If there is continuity, replace the arma-
ture.
3) Check the commutator 1 for dirt and/or

burns.
Dirty/Burns → Clean it with #600 grit
sandpaper or on a lathe.
8-15
– +
4) Check the commutator for run out using

a dial gauge and V-blocks.
Out of specification → Correct it on a
lathe or replace armature.
Runout limit:
0.05 mm (0.0020 in.)
5) Check the commutator diameter A.

Out of specification → Replace armature.
Commutator diameter:
36.0 mm (1.417 in.)
<Limit> 35.0 mm (1.378 in.)
6) Check the commutator under depth A.

Out of specification → Scrape the mica
a to proper depth with a hacksaw blade
that has been ground to fit.
Undercut depth:
0.7 – 0.9 mm (0.028 – 0.035 in.)
<Limit> 0.2 mm (0.008 in.)
NOTE:
Check that the undercut groove is clean, free
of foreign material and smooth on the edges.
Field coil checking steps

1) Using an ohmmeter (Ω x 1), check that
there is continuity between the lead wire
and the field coil brush lead. (For open
circuit)
If there is no continuity, replace the field
frame.
8-16
– +
2) Using an megatester, check that there is

continuity between the field coil end and
the field frame. (For ground)
If there is no continuity, replace the field
frame.
Brush holder assembly checking steps

1) Check the brush length A.
Out of specification → Replace the brush
holder and the field frame.
Brush length:
a
20.5 – 21.0 mm
(0.807 – 0.827 in.)
<Limit> 13.0 mm (0.512 in.)
2) Check the brush spring load.

Out of specification → Replace the
springs as a set.
Brush spring load:

32 – 40 N
T.R
(3.3 – 4.0 kgf, 7.2 – 8.9 lbf)
1
3) Check the brush holder insulation.
Continuity → Repair or replace.
2 2
NOTE:
Check that there is no continuity between the
positive (+) 1 and negative (–) 2 brush hold-
1
ers.
8-17
– +
Gear teeth checking step

1) Check the pinion/idler/clutch gear teeth
for burrs, chips, wear and/or damage.
Burrs/Chips/Wear/Damage →
Replace the gears and/or the clutch
assembly and check the flywheel ring
gear for wear or damage.
Clutch operation checking step

1) Check the clutch operation.
Damage → Replace the clutch assembly.
B NOTE:
A Rotate the pinion gear clockwise and check
that it turns freely. Try to rotate the pinion
gear counterclockwise and check that it
locks.
Clutch assembly replacement steps

1) Push down the pinion gear 1 and the
starter housing 2.
2) Using a plastic-faced hammer, tap in the
3
stopper collar 3.
3) Using a suitable tool, pry out the snap

1
ring 1.
8-18
– +
4) Remove the following parts.

¡ Stopper collar 1
¡ Pinion gear 2
8
¡ Retainer 3
7 3
2
1
¡ Compression spring 4
6
¡ Starter housing 5
¡ Starter clutch 6
5 4
¡ Compression spring 7
¡ Clutch shaft 8
5) Replace the damaged parts with new

ones.
A
6) Assemble the following parts.
¡ Clutch shaft 1
(with compression spring 2 and
1 starter clutch 3 into starter housing
2
4)
6
7
8 ¡ Compression spring 5
3
¡ Retainer 6
4
¡ Pinion gear 7
5
¡ Stopper collar 8
7) Push down the pinion gear 7 and the

starter housing 4.
8) Using the snap ring pliers, install the new
1
snap ring 1.
CAUTION:
Always use a new snap ring.
8-19
– +
9) Using a pair of pliers, compress the snap

ring.
Check that the snap ring fits correctly.
10) Using a plastic-faced hammer, tap the

clutch shaft and install the stop collar
onto the snap ring.
Bearings checking step

1) Check the bearing movement.
Turn each bearing while applying inward
force.
Bearing replacement steps

1) Using the bearing puller 1, remove the
1 bearings.
Alternator bearing puller:

09286-46011
2) Install a new bearing 1 (front) tightly

against the shoulder of the shaft.
8-20
– +
3) Using a suitable tool 1 press-in a new

bearing 2 (rear) tightly against the
1
shoulder of the shaft.
2
CAUTION:
Do not press the outer race or balls of the
bearing. Contact should be made only with
the inner race.
Magnetic switch checking steps

1) Pull-in coil (open circuit).
Check that there is continuity between
the positive (+) lead terminal 1 and the
field coil terminal 2.
No continuity → Replace the magnetic
switch.
2
2) Hold-in coil (open circuit).

Check that there is continuity between
the positive (+) lead terminal 1 and the
switch body 2.
No continuity → Replace the magnetic
switch.
2
1
Starter Motor Assembly

NOTE:
Apply grease to the armature bearings, and
insert the armature into the field frame.
1. Assemble:
¡ Starter motor
Starter motor assembly steps

1) Install the armature 1 into the field
frame 2.
8-21
– +
2) Install the brush holder 1 and the

brushes 2.
NOTE:
¡ Using a screwdriver, hold back the brush
2 spring, and insert the brush into the brush
holder.
¡ Make sure that the positive (+) leads are
1 not grounded.
3) Install the end cover 1.
4) Install the steel ball 1 into the clutch

shaft hole A.
a
5) Install the return spring 1 into the mag-

netic switch hole.
6) Install the plate washer 2.
2
7) Install the bearing 1 and the idler

A
gear 2.
8-22
– +
8) Install the starter housing 1 to the mag-

2
netic switch 2.
9) Install the new felt washer 1 to the ar-

1 mature.
10) Install the magnetic switch 1 onto the

2
1
field frame 2.
NOTE:
Align the setting point A and B.
a
11) Tighten the bolts 1.
3
12) Connect the field coil lead 2.
NOTE:
Securely fit the rubber cover 3 onto the seat
4.
4
1 2
8-23
– +
Starter Motor Operation Test
CAUTION:
This test must be performed within 3 to 5
seconds to avoid damaging the coil.
1. Test:
¡ Pull-in
¡ Hold-in
¡ Clutch pinion gear return
¡ No-load performance
Pull-in test steps

1) Disconnect the field coil lead 1 from the
switch terminal 2.
2) Connect the battery 3 to the magnetic
switch as shown in the illustration.
2
3) Check that the clutch pinion gear moves
outward.
1 If the clutch pinion gear does not move,
replace the magnetic switch assembly.
3
Hold-in test steps

1) While connected as above with the clutch
pinion gear positioned outward, discon-
nect the negative (–) lead 2 from the field
coil terminal 1.
2) Check that the pinion gear remains out-
ward.
If the clutch pinion gear returns inward,
2 1
Clutch pinion gear return test steps

1) Disconnect the negative (–) lead 1 from
the switch body.
1 2) Check that the clutch pinion gear returns
inward.
If the clutch pinion gear does not return,
8-24
– +
No-load performance test steps

1) Connect the battery 1 and the ammeter
2 to the starter as shown in the illustra-
tion.
2) Check that the starter rotates smoothly
2
and steadily with the pinion gear mov-
ing outward.
Check that the ammeter shows the speci-
fied current.
1
Does not move/out of specification →
Replace the starter motor.
Specified current:
180 A or less at 11 V
Starter Motor Installation

1. Install:
¡ Starter motor
Starter motor installation steps
1) Install the starter motor 1.
2 2) Connect the starter motor lead 2.
3) Connect the battery positive (+) lead 3.
4 4) Connect the magnetic switch lead 4.
3
Nut (terminal):
8.8 N·m (0.9 kgf·m, 6.5 lbf·ft)
T.R
1
5) Connect the negative (–) lead 1 to the
battery terminal.
UPPER
LOWER
8-25
– +
ELEC CHARGING SYSTEM E
CHARGING SYSTEM
Circuit Diagram
2
3
100A
R R
4
20A 5
R R/Pu
R/Pu
6
Br Br
1 R/Pu
12V
Br
12V
7
8
R/Pu Pu Y/R
OFF
B
ON
START
9
Y/R Y/R Br
Pu

1 Battery 1
2 Starter motor 1
3 Fuse (100 A) 1
4 Fuse (20 A) 1
5 Alternator 1
6 Charging system warning light 1
7 Main switch 1
8 Starter relay 1
9 Diode 1
8-26
– +
Battery and Electrical Connection ON-

Boat Check
1. Check:
¡ Battery
Refer to “Battery Check” section (P3-
49).
¡ Fuses
Refer to “Fuse Check” section (P3-51).
¡ Electrical connections
Refer to “ELECTRICAL SYSTEM WIR-
ING DIAGRAM” at the end of the
book.
Drive Belts Check

1. Check:
¡ Drive belts
Refer to “Drive Belts Check” section
(P3-27).
8-27
– +
Charging Circuit Check

1. Check:
¡ Charging system warning light circuit
¡ Charging circuit
Charging system warning light circuit check-

ing steps
1) Warm up the engine and then turn it off.
2) Turn off all accessories.
3) Turn the main switch to “ON”, check that
the charging system warning light comes
on.
4) Start the engine.
Check that the light goes out.
If the light does not operate as specified,
troubleshoot the charging system warn-
ing light circuit.
Refer to “TROUBLESHOOTING” section
CHAPTER 9.
Charging circuit checking steps
NOTE:
If a battery/alternator tester is available, con-
nect the tester to the charging circuit as per
manufacturer’s instructions.
If a special tester is not available, connect a
voltmeter and ammeter to the charging cir-
cuit as follows:
1) Disconnect the lead 1 from the termi-

4
nal “B” 2 of the alternator and connect
5
3
6
it to the negative (–) lead 3 of the am-
meter 4.
1 2) Connect the positive (+) lead 5 of the
ammeter to the terminal “B” 2 of the
alternator 6.
7
2 3) Connect the positive (+) lead 7 of the
8 9 voltmeter to the terminal “B” 2 of the
alternator 6.
4) Ground the negative (–) lead 9 of the
voltmeter 8.
8-28
– +
5) Without load check.

At engine speeds between idling and
2000 r/min., check the reading on the am-
meter and voltmeter.
Output amperage:
10 A or less
Output voltage:
14.0 – 15.0 V at 25 °C (77 °F)
13.5 – 14.3 V at 135 °C (275 °F)
If the voltmeter reading is more than the

specified voltage, replace the IC regula-
tor.
If the voltmeter reading is more than the
specified voltage, check the IC regulator
and alternator as follows;
¡ With the terminal “F” grounded, start
the engine and check the voltmeter
reading of the terminal “B”.
If the voltmeter reading is greater than
the specified voltage, replace the IC
regulator.
If the voltmeter reading is less than
the specified voltage, check the alter-
nator.
6) With load check.

At an engine speed of 2000 r/min., turn
on all accessories.
7) Check the reading on the ammeter.
Output amperage:
30 A or more
If the ammeter reading is less than the

specified amperage, repair the alterna-
tor.
Refer to “ALTERNATOR” on the next
page.
NOTE:
With the battery fully charged, sometimes the
indication will sometimes be less than the
standard amperage.
8-29
– +
ELEC ALTERNATOR E
ALTERNATOR
16
14 15
13
12
11
10
8
7
5
4
3
2
1

1 Nut 1 109 N·m (11 kgf·m, 80 lbf·ft)
2 Pulley 1
3 Drive end frame (stator) 1
4 Bearing 1
5 Bearing retainer 1
6 Rotor 1
7 Bearing 1
8 Bearing retainer 1
9 Bearing cover 1
0 Rectifier end frame 1
A Seal plate 1
B Rectifier holder 1
C IC regulator 1
D Brush holder 1
E Holder cover 1
F End cover 1
8-30
– +
ELEC ALTERNATOR E
Alternator Removal
1. Remove:
¡ Alternator
Alternator removal steps

1) Disconnect the negative (–) lead 1 from
1
the battery terminal.
UPPER
LOWER
2) Disconnect the alternator leads 1.

tion (P3-27).
4) Remove the alternator.
8-31
– +
ELEC ALTERNATOR E
Alternator Disassembly
1. Disassemble:
¡ Alternator
Alternator disassembly steps

1) Remove the nut 1 and the terminal in-
sulator 2.
1
2
2) Remove the end cover 1.
3) Remove the brush holder cover 1.
4) Remove the brush holder 1 and the IC

1
regulator 2.
8-32
– +
ELEC ALTERNATOR E
5) Remove the rectifier holder 1.
6) Remove the rubber insulators 1.

1
7) Remove the seal plate 1.
8) Hold the alternator wrench “A” 1 with

a torque wrench, and tighten the alter-
1
nator wrench “B” 2 clockwise to the
2 specified torque.
A Alternator wrench:
09820-63010 or (90890-07431)
Alternator wrench “B”:

39 N·m (4.0 kgf·m, 29 lbf·ft)
T.R
NOTE:
Check that the alternator wrench “A” is fit-
ted securely to the rotor shaft.
8-33
– +
ELEC ALTERNATOR E
9) Clamp the alternator wrench “C” 3 in a

vise, and install the alternator to the al-
B ternator wrench “C” as shown in the il-
lustration.
10) To loosen the pulley nut, turn the alter-
nator wrench “A” clockwise .
CAUTION:
3
To prevent damage to the rotor shaft, do not
loosen the pulley nut more than one-half of
a turn.
11) Remove the alternator from the alterna-

tor wrench “C”.
12) Remove the alternator wrench “A” and
“B”.
13) Remove the pulley nut 1 and pulley 2.
14) Remove the nuts 1 from the rectifier end

frame 2.
1
1
15) Use the alternator bearing puller 1 to

remove the rectifier end frame 2.

1
09286-46011
8-34
– +
ELEC ALTERNATOR E
16) Remove the wave washer 1.

1
17) Remove the rotor 1 from drive end

frame 2.
1
Alternator Check and Repair

1. Check:
¡ Rotor (open circuit and ground)
¡ Slip rings
¡ Stator (open circuit and ground)
¡ Brush
¡ Rectifiers (Positive side/negative side)
¡ Bearing (front)
¡ Bearing (rear)
Rotor checking steps
A 1) Using an ohmmeter 1 (Ω x 1), check that

2
there is continuity between the slip rings
1
2. (For open circuit )
If there is no continuity, replace the ro-
tor.
Rotor coil resistance:

2.7 – 3.1 Ω at 20 °C (68 °F)
8-35
– +
ELEC ALTERNATOR E
2) Using an megatester 1, check that there

2
1 is continuity between the slip ring 2 and
the rotor 3. (For ground )
Continuity → Replace rotor.
3
Slip rings checking steps

1) Check the slip ring for roughness and/or
scoring.
Roughness/Scoring → Replace the rotor
and brushes as a set.
2) Check the slip ring diameter A.
Out of specification → Replace the rotor.
a
Slip ring diameter:
14.2 – 14.4 mm
(0.559 – 0.567 in.)
<Limit>
12.8 mm (0.504 in.)
Stator checking steps

1) Using an ohmmeter 1 (Ω x 1), check that
2
2 there is continuity between the coil leads
1 2. (For open circuit )
No continuity → Replace the drive end
frame assembly.
2
2) Using an megatester 1, check that there
is continuity between each of the coil
1
leads 2 and the drive end frame 3. (For
ground )
No continuity → Replace the drive end
frame assembly.
8-36
– +
ELEC ALTERNATOR E
Brush checking step

1) Check the exposed brush length A.
brushes and the brush holder as a set.
Exposed brush length:

10.5 mm (0.413 in.)
<Limit>
1.5 mm (0.059 in.)
a
Rectifiers (positive side) checking steps

1) Connect one tester probe of the ohmme-
2
ter 1 (Ω x 1) to the positive (+) terminal
2 and the other to one of the rectifier
terminals 3. Read the ohmmeter.
3 2) Reverse the tester probes and read the
3 ohmmeter again.
1
3) One reading must show continuity, and
the other no continuity.
Continuity or no continuity → Replace
the rectifier holder.
4) Repeat steps 1) and 2) with each termi-
nal.
Rectifiers (negative side) checking steps

1) Connect one tester probe to one of the
2 rectifier terminals 1 and the other to the
rectifier negative (–) terminal 2.
Read the ohmmeter.
2) Reverse the tester probes and read the
1
ohmmeter again.
1 3) One reading must show continuity, and
the other no continuity.
Continuity or no continuity → Replace
the rectifier holder.
4) Repeat steps 1) to 3) for each terminal.
8-37
– +
ELEC ALTERNATOR E
Front bearing checking step

1) Check the front bearing 1 for roughness.
Front bearing replacement steps

1) Remove the bearing retainer 1.
2) Using a suitable tool 1, press out the

1
front bearing 2.
2
3) Using the suitable tool 1 and a press,

install a new bearing.
1
8-38
– +
ELEC ALTERNATOR E
4) Install the bearing retainer 1.
Rear bearing checking step

1) Check the rear bearing 1 for roughness.
1 Roughness → Replace.
Rear bearing replacement steps

1) Using the alternator bearing puller 1, re-
move the bearing cover 2 and the bear-
ing 3.
1

2 09820-00021
3
CAUTION:
Be careful not to damage the fan.
2) Using a suitable pipe 1 and a press, in-

1
stall a new bearing and bearing cover.
8-39
– +
ELEC ALTERNATOR E
Alternator Assembly
1. Assemble:
¡ Alternator
Alternator assembly steps

1) Install the rotor 1 into the drive end
1
frame 2 on the pulley 3.
NOTE:
Place the drive end frame 2 on the pulley 3.
2
2) Install the wave washer 1.

1
3) Install the rectifier end frame 1.
NOTE:
Using a plastic-faced hammer, lightly tap on
1
the end frame.
4) Tighten the nuts 1 to rectifier end frame

2.
NOTE:
Tighten the nuts in a crisscross pattern.
1
1
8-40
– +
ELEC ALTERNATOR E
5) Install the pulley 1 to the rotor shaft and

tighten the pulley nut 2 by hand.
6) Hold the alternator wrench “A” 1 with

a torque wrench, and tighten the alter-
1
nator wrench “B” 2 clockwise to the
2 specified torque.
A Alternator wrench:
09820-63010 or (90890-07431)
Alternator wrench “B”:

39 N·m (4.0 kgf·m, 29 lbf·ft)
T.R
NOTE:
Check that the alternator wrench “A” is se-
cured to the rotor shaft.
7) Clamp the alternator wrench “C” 3 with

a vise, and install the alternator to the
B alternator wrench “C” as shown in the
illustration.
8) To tighten the pulley nut, turn the alter-
nator wrench “A” counterclockwise .
Alternator wrench “A”:

3 109 N·m (11 kgf·m, 80 lbf·ft)
T.R
9) Remove the alternator from the alterna-

tor wrench “C”.
10) Remove the alternator wrenches “A” and
“B”.
11) Install the seal plate 1.
8-41
– +
ELEC ALTERNATOR E
12) Install the rubber insulators 1.

1
13) Install the rectifier holder 1.
a 14) Install the IC regulator 1 and the brush

holder 2 onto rectifier end frame.
2
NOTE:
¡ Be careful to install the holder in the right
A 2 way.
¡ Install the five screws so that there is a
1
clearance A of approximately 1.1 mm
(0.043 in.) between the brush holder and
the connector.
Upward
15) Install the brush holder cover 1.
8-42
– +
ELEC ALTERNATOR E
16) Install the end cover 1.
17) Install the terminal insulator 1 and the

nut 2.
2
1
18) Check the rotor rotation.

Unsmooth rotation → Repair or replace
the alternator.
8-43
– +
ELEC ALTERNATOR E
Alternator Installation
1. Install:
¡ Alternator
Alternator installation steps

1) Install the alternator.
tion (P3-27).
3) Connect the alternator leads 1.
Nut (terminal):
7.8 N·m (0.8 kgf·m, 5.8 lbf·ft)
T.R
4) Connect the negative (–) lead 1 to the

1
battery terminal.
UPPER
LOWER
8-44
– +
ELEC FUEL SYSTEM E
FUEL SYSTEM
3
R R R
100A
4
R/Pu R/Pu
2 6 5
20A
R/Pu Pu Y/R
OFF
ON
START
Pu Y/R 12V
8
R
Y/B
7
Pu/B Y/B
10
1
B
9
B
B

1 Battery 1
2 Starter motor 1
3 Fuse (100 A) 1
4 Fuse (20 A) 1
5 Alternator 1
6 Main switch 1
7 Control box 1
8 Water separator warning lamp 1
9 Water separator switch 1
0 Fuel cut solenoid valve 1
8-45
– +
ELEC FUEL SYSTEM E
Main Switch Check

1. Check:
¡ Main switch
Refer to “Main Switch Check” section
(P8-2).

1. Check:
¡ Neutral switch
Refer to “Neutral Switch Check” sec-
tion (P8-3).
Pickup (tacho) Sensor Check

1. Check:
Refer to “Pickup (tacho) Sensor
Check” section (P8-3).
Glow Control Box Check

1. Check:
¡ Glow control box
Refer to “Glow Control Box Check”
section (P8-6).
8-46
– +
ELEC FUEL SYSTEM E
Water Separator Switch Check

1. Check:
¡ Water separator switch
Water separator switch checking steps

1) Disconnect the water separator switch
coupler 1.
2) Remove the water separator switch 2
from the fuel filter.
2
3) Connect the circuit tester to the water
separator coupler.
4) Hold the switch upright , and check

that there is no continuity.
Continuity → Replace the switch.
B Y/B
5) Hold the switch upside down , and

check that there is continuity.
No continuity → Replace the switch.
B Y/B
8-47
– +
ELEC FUEL SYSTEM E
Fuel Cut Solenoid Valve Check

1. Check:
¡ Fuel cut solenoid valve
Fuel cut solenoid valve checking steps

1) Remove the solenoid valve 1 from the
injection pump.
1
Refer to “Injection Pump Check” section
(P5-10).
2) Connect the battery to the solenoid valve

body and the terminal.
Battery (+) terminal → solenoid valve terminal

Battery (–) terminal → solenoid valve body
3) Feel the operation of the solenoid valve

by connecting and disconnecting the
battery.
Replace the solenoid valve if it does not
operate properly.
8-48
– +
ELEC OTHER COMPONENTS E
OTHER COMPONENTS
Oil Pressure Sender Check
1. Check:
¡ Oil pressure sender
Oil pressure sender checking steps

1) Disconnect the oil pressure sender ter-
1
minals 1.
2) Connect the circuit tester at the oil pres-
sure sender terminals.
3) Start the engine, and measure the resis-
tance at the specified oil pressure.
Out of specification → Replace the oil
pressure sender.
Oil pressure Resistance
0 kPa (0 kgf/cm2, 0 psi) 5 – 13 Ω
200 kPa (2 kgf/cm2, 29 psi) 48 – 56 Ω
400 kPa (4 kgf/cm2, 58 psi) 84 – 92 Ω
600 kPa (6 kgf/cm2, 87 psi) 119 – 129 Ω
Oil Pressure Switch Check

1. Check:
¡ Oil pressure switch
Oil pressure switch checking steps

1) Disconnect the oil pressure switch lead
1 from the oil pressure switch 2.
2
1 2 2) Using an circuit tester, check the oil pres-

sure switch for continuity between the
switch terminal 1 and the cylinder body
2.
No continuity → Replace the oil pressure
switch.
8-49
– +
1 2 3) Warm up the engine and let it run at the

idling speed.
4) Using an circuit tester, check that there
is no continuity between the switch ter-
minal 1 of the oil pressure switch and
the cylinder body 2.
Continuity → Replace the oil pressure
switch.
Seawater Flow Sender Check

1. Check:
¡ Seawater flow sender
Seawater flow sender checking steps

1) Disconnect the seawater flow sender
leads 1.
2) Remove the seawater flow sender 2
from the intercooler.
1
2
3) Connect the circuit tester to the seawa-

ter flow sender leads.
4) Hold the seawater flow sender up-
right , and check that there is no conti-
nuity.
L/Y B Continuity → Replace the seawater flow
sender.
5) Hold the seawater flow sender upside

down , and check that there is conti-
nuity.
No continuity → Replace the seawater
flow sender.
L/Y B
8-50
– +
Water Temperature Sensor Check

1. Check:
¡ Water temperature sensor
Water temperature sensor checking steps

sor lead.
2) Remove the water temperature sensor 1
from the thermostat housing.
3) Immerse the water temperature sensor

in water.
Br/B
4) Using an ohmmeter, check the resistance
at the specified water temperatures.
Out of specification → Replace the wa-
ter temperature sensor.
Water temperature Resistance
50 °C (122 °F) 210 Ω
80 °C (176 °F) 63 – 77 Ω
100 °C (212 °F) 34 – 40 Ω
120 °C (248 °F) 21 Ω
5) Install the water temperature sensor 1

to the thermostat housing.
NOTE:
Apply LOCTITE® No. 572 on the threads when
1 installing the water temperature sensor 1.
LT
Water temperature sensor:
572
11 N·m (1.1 kgf·m, 7.9 lbf·ft)
T.R
8-51
– +
Thermo Switch Check

1. Check:
¡ Thermo switch
Thermo switch checking steps
1) Disconnect the thermo switch lead.
2) Remove the thermo switch 1 from the
thermostat housing.
1
3) Immerse the thermo switch in water.
While heating the water, check the con-
tinuity at the specified water tempera-
tures using an circuit tester.
Water temperature Continuity
0 – 98 °C (0 – 208.4 °F) No continuity
Over 98 °C – 102 °C (208.4 – 215.6 °F) Continuity
4) While cooling the water, check the conti-

nuity at the specified water temperatures
Br/B using an circuit tester.
thermo switch.
Water temperature Continuity
Over 102 °C (215.5 °F) Continuity
102 – 93 °C (215.6 – 199.4 °F) Continuity
Below 93 °C (199.4 °F) No continuity
5) Install the thermo switch 1 to the ther-

mostat housing.
1
LT NOTE:
572 Apply LOCTITE® No. 572 on the threads when
installing the thermo switch 1.
Thermo switch:
34 N·m (3.5 kgf·m, 25 lbf·ft)
T.R
8-52
TRBL E
CHAPTER 9
TROUBLESHOOTING
TROUBLESHOOTING DIAGRAM ........................................................................................... 9-1

How to Trouble-shoot ........................................................................................................ 9-1
ENGINE AND RELATED PARTS ............................................................................................. 9-2

Engine is Hard to Start ...................................................................................................... 9-2
Engine Output is Insufficient ............................................................................................ 9-8
Engine Knocks .................................................................................................................. 9-15
Excessive Amount of Fuel is Consumed........................................................................ 9-17
Excessive Amount of Engine Oil is Consumed ............................................................. 9-17
Engine Runs but Not Properly ........................................................................................ 9-18
Engine Stalls During Operation ...................................................................................... 9-19
Abnormal Vibration Occurs ............................................................................................ 9-20
Engine Gets Overheated ................................................................................................. 9-21
Starter Motor .................................................................................................................... 9-23
Alternator ......................................................................................................................... 9-25
Lubrication System .......................................................................................................... 9-26
TURBOCHARGER ................................................................................................................. 9-28

Excessive Amount of Exhaust Smoke Comes Out........................................................ 9-28
Exhaust Smoke is White ................................................................................................. 9-29
Oil Decreases Quickly ...................................................................................................... 9-29
Output Power Reduces .................................................................................................... 9-29
Follow-up of Turbocharger is Poor (Slow) ..................................................................... 9-29
Abnormal Noise, Abnormal Vibration ........................................................................... 9-30
9
TRBL TROUBLESHOOTING DIAGRAM E
TROUBLESHOOTING DIAGRAM
Trouble?
Basic checking Symptoms of trouble Repair or adjust
Check the equipment visually or by

operating according to pre-delivery
check or periodic check procedures.
Simulation test Symptoms of trouble is Locate the possible

evident cause of trouble
Repair of adjust
Discover the conditions
under which the equipment
went out of order, and
reproduce the same conditions.
Confirmatory test
End
How to Trouble-shoot
1) In case of trouble, first check the equipment according to the pre-delivery check and peri-
odic check procedures.
2) Conduct a test under the simulated conditions, and investigate the symptoms of trouble.
3) Repair the defect and conduct a confirmatory test to make sure that the cause of the trouble
has been removed.
4) When the symptom of trouble cannot be reproduced, set up conditions similar to those in
which the trouble occurred, and conduct a test again.
9-1
TRBL ENGINE AND RELATED PARTS E
ENGINE AND RELATED PARTS

Engine is Hard to Start
Engine turns over Exhaust smoke No fuel is supplied

No fuel in fuel tank Fill fuel.
but does not start. hardly comes out. to injection pump.
Remove
Clogged fuel pipe
and clean.
Air drawn into fuel Repair

pipe through and bleed
connections air.
Clogged strainer at
Remove
intake port of
and clean.
injection pump
Disassem-
Defective fuel
ble and
pump
check.
Clogged fuel filter Replace.
Air trapped in fuel

Bleed air.
system
Fuel is supplied to Check and

injection pump. Pump not driven repair or
replace.
Loose connection
Retighten.
of injection pipe
Malfunction of fuel Check and

cut solenoid of pickup repair or
(tacho) sensor replace.
Stuck injection
pump of leakage Check and
from delivery valve repair.
due to cut spring
NOTE:
When fuel is not injected, loosen the air bleed screw and operate the
priming pump to find out whether fuel is supplied or not.
9-2
A
A small amount of
exhaust smoke Air drawn into fuel system Bleed air.
comes out.
Injection pipe cracked or loose at its Retighten

connection or replace.
Check and
Stuck delivery valve, defective seat or broken
then repair
spring
or replace.
Check and
Worn or seized plunger of injection pump then repair
or replace.
Clogged strainer at intake port of injection Remove

pump and clean.
Clogged fuel pipe Remove

and clean.
Clogged fuel filter Replace.
Disassem-
Insufficient amount of oil fed by oil pump ble and
check.
Check and
Injection pump control lever is not fully opened
correct.
Check and
Excessively worm roller ring or cam plate of
repair or
injection pump
replace.
Loose set screw of injection pump control Check and

pinion retighten.
Change
Poor fuel flow because of high viscosity.
fuel.
Fuel leaking from nozzle in excessive amount Check and

and injected in small amount correct.
NOTE:
In case the amount of injected fuel is insufficient, investigate the cause
carefully.
B
9-3
B
Large amount of Loose set screw of
Injection timing is Check and
exhaust smoke injection pump
incorrect. retighten.
comes out. coupling.
Engine assembled Check and

incorrectly, resulting correct.
in incorrect timing.
Incorrect timing to
push down plunger
due to excessive
Replace.
wear of injection
pump roller ring or
cam plate.
Incorrect injection
timing due to
Replace
defective injection
or correct.
nozzle or incorrect
injection pressure.
Pre-heating by Defective heater

intake airheater Replace.
relay or control unit
relay is not done
properly.
Defective intake
airheater Replace.
Check and
Poor wiring connec-
correct or
tion or disconnection
replace.
Water is mixed in Change

Fuel is incorrect.
fuel. fuel.
Change
Unsuitable fuel
fuel.
Nozzle remaining
Nozzle injection open caused by Check and
condition is poor. nozzle body-to-nee- correct.
dle valve seizure
Fuel leakage due

to poor wear-in of Check and
nozzle valve seat correct.
Low injection
pressure due to Check and
incorrect injection then
pressure adjustment retighten.
Damaged nozzle
Replace.
hole
Clogged nozzle hole Check and

clean.
C
9-4
Temperature fails to
Excessive valve Check and
rise to ignition level
clearance correct.
because of insuffi-
cient compression
pressure of engine.
Broken valve
Replace.
spring
Valve kept open by Check and

valve lifter correct.
Insufficient engine
Change
speed due to
engine oil.
solidified engine oil
Worn cylinder or Correct or

stuck piston ring replace.
Valve stem stuck Correct or

with guide and kept replace.
open
Improper air-tight-
Correct or
ness due to poor
replace.
wear-in of valve seat
Cylinder and
Check and
cylinder head not
correct.
tightened enough
Insufficient engine Recharge

cranking due to or replace
discharged battery the battery.
NOTE:
In this case, the fuel injection quantity is enough but it is not ignited in
the combustion chamber. Investigate a possible cause carefully.
9-5
Engine fails to turn Engine can be Starter fails to turn Poor contact of Correct or
over. turned over over. engine switch replace.
manually.
Blown fuse Replace.
Disconnection in
Correct or
wiring or loose
replace.
terminal
Insufficient battery Recharge

capacity, discharge or replace.
Poor contact of
commutator due to Correct or
stuck, worn or replace.
broken starter crush
Disconnection in
engine magnet coil Correct or
or armature coil of replace.
starter
Defective diode in
the electrical Replace.
equipment box
Defective IC
Replace.
regulator
Defective starter
relay Replace.
Starter turns over Worn ring gear

but dose not Replace.
teeth
engage with
flywheel properly.
Starter's magnetic Correct or
switch is replace.
maladjusted
Starter's magnetic
Correct or
switch engagement
replace.
is maladjusted
Starter pinion and Insufficient battery Recharge

ring gear do not capacity, discharge or replace.
engage properly.
Incorrect
open/close timing Check and
of magnetic switch correct.
contact point
Worn ring gear

Replace.
teeth
D Starter pinion not

Correct.
jumping out.
9-6
Engine cannot be Starter pinion gets

Replace.
turned over engaged with ring
manually. gear but fails to
rotate.
Valve contacts piston because valve operation Disassem-

timing has been set incorrectly during engine ble and
assembly. correct.
Disassem-
ble and
Engine rotating or sliding parts seized.
correct or
replace.
Warm up
Solidified engine oil. or change
engine oil.
NOTE:
In case the engine fails to turn over, check the starter and rotating parts
for seizure.
9-7
Engine Output is Insufficient
Small amount of Repair

Insufficient fuel
exhaust gas comes Air drawn through fuel pipe and bleed
supply.
out. air.
Disassem-
ble and
Clogged fuel pipe clean or re-
place.
Disassem-
ble and
Clogged fuel filter
clean or re-
place.
Disassem-
Clogged strainer at intake port of injection ble and
pump clean or re-
place.
Check and
Cause lies in
Loose pipe connection then
injection pump.
retighten.
Correct or
Worn roller ring or cam plate
replace.
Correct or
Stuck or excessively worn plunger
replace.
Correct or
Broken plunger spring
replace.
Correct or
Defective delivery valve or broken spring
replace.
Decreased injection quantity due to weakened Correct or

spring replace.
Correct or
Excessive leakage from nozzle
replace.
Maladjusted injection quality Adjust.
Faulty connection of control cable (not fully Check and

opened) adjust.
E Fuel flow is poor due to high viscosity Change

fuel.
9-8
Rotating part is Rotating part other than exhaust valve apt to Correct or
seized. get seized and hard to rotate replace.
Correct
Timing out of adjustment due to error in and
engine assembly readjust
timing.
Incorrect timing to push up plunger due to Replace

excessive wear of injection pump roller ring or and
cam plate readjust.
NOTE:
In this case, fuel injection quantity is insufficient. Check the fuel system
carefully and check rotating parts for seizure.
Combustion is poor Check and

because engine Valve kept open by valve lifter
correct.
compression
pressure is not
sufficient. Valve kept open because valve stem stuck Correct or
with guide replace.
Improper air-tightness due to poor wear-in of Correct or

valve seat replace.
Broken valve spring Replace.
Excessive leakage of compression pressure Correct or

due to worn cylinder or stuck piston ring replace.
Lack of cylinder to cylinder head tightness Check and

correct.
Combustion is Change
Water mixed in fuel
faulty. fuel.
Correct
Timing is advanced Advanced timing due to error in engine
and
excessively. assembly
adjust.
NOTE:
Engine has insufficient power output, but can still be started: while the
engine is cold (first started) the exhaust smoke is white. After the engine
has warmed up, the exhaust smoke becomes black.
F
9-9
Spray condition
Nozzle kept open due to nozzle body-to- Check and
from nozzle is not
needle valve sticking correct.
good.
Correct or
Leakage due to poor wear-in of nozzle needle
replace.
Low injection pressure due to incorrect Check and

injection pressure adjustment correct.
Broken nozzle pressure spring Replace.
Clean or
Clogged nozzle injection hole
replace.
Combustion is not Check and

done properly Valve kept open by valve lifter correct.
because of
insufficient amount
of compressed air. Valve kept open due to valve stem to guide Correct or
sticking. replace.
Improper air tighteness due to poor wear-in of Correct or

valve seat replace.
Broken valve spring Replace.
Excessive compressed air leakage due to Correct or

worn cylinder or stuck piston ring replace.
Cylinder and cylinder head not tightened Check and

properly correct.
Amount of air reduced because engine is

overheated and intake air is expanded.
NOTE:
If fuel is injected unevenly among cylinders, combustion condition
deteriorates, causing the engine to operate unstably and its output to
reduce. Thus, the throttle is opened too much, resulting in a large
amount of black exhaust smoke accompanied by engine knocking.
9-10
Exhaust gas
contains much white Timing is retarded. Improper setting of injection pump timing Adjust.
smoke.
Loose timing adjusting bolt of coupling Retighten.
Correct or
Worn injection pump cam plate and roller ring
replace.
Adjust and
Loose adjusting bolt then
tighten.
Correct or
Compression is low. Excessively worn piston ring and liner
replace.
Correct of
Stuck piston ring
replace.
Poor contact of valve seat Make

wear-in.
Incorrect valve timing, broken valve spring or Adjust or

incorrect valve clearance replace.
Spray condition
Nozzle kept open due to nozzle body-to- Check and
from nozzle is not
needle valve sticking correct.
good.
Correct or
Leakage due to poor wear-in of nozzle needle
replace.
Low injection pressure due to incorrect Check and

injection pressure adjustment correct.
Broken nozzle pressure spring Replace.
Clean or
Clogged nozzle injection hole
replace.
9-11
Exhaust gas Timing is advanced

contains much black (with knocking Improper timing setting of injection pump Adjust.
smoke. noise).
Injection is not
Maladjusted injection quantity Adjust.
uniform.
Loose set screw of control pinion Retighten.
Broken plunger spring Replace.
Plunger apt to get seized Replace.
Defective seat of delivery valve Replace.
Nozzle fails to inject

Decreased injection pressure Adjust.
properly.
Broken nozzle spring Replace.
Correct or
Nozzle needle valve apt to get seized
replace.
Correct or
Improper spray condition
replace.
Insufficient air
Broken turbo
supply.
Clogged air filter
Contaminated A/C core
Contaminated or damaged air heater element
9-12
Excessive amount Faulty condition Piping arranged improperly (Air apt to get Correct or
of exhaust smoke exists in piping and trapped) replace.
comes out. related parts.
Clean or
Clogged pipe or fuel filter
replace.
Oil leakage from piping system Check and

correct.
Check
Fuel oscillating in pipe and
correct.
Injection pump is
Air mixed in pump Bleed air.
faulty.
Broken plunger spring Replace.

NOTE:
The color of the exhaust smoke can
be black or white depending on the
Worn plunger Replace.
engine and other circumstantial
conditions (e.g., engine temperature,
loads, etc.). Replace or
Delivery valve spring damaged, broken or
dust caught in it remove
dust.
Cracked or distorted delivery valve packing Replace.
Check and
Inconsistent injection quantity
adjust.
Inconsistent injection timing Check and

adjust.
NOTE:
The engine hunting occurs when the amount of
injected fuel or the injection timing is not constant.
Therefore, check the fuel system including the
injection pump and others to locate its cause.
G
9-13
Broken or weakened governor spring Replace.
NOTE:
The governor, being a precision part, should never
be serviced by yourself.
Worn oil ring Replace.
NOTE:
When engine oil rises up to the upper part of the
piston, check if the oil ring is defective and if the
engine oil level is too high, they are possible
causes.
Check and
Clogged intake air port
clean.
Check and
Clogged exhaust air port
clean.
Check
Interference to fuel flow due to engine
and
vibration
correct.
NOTE:
Check for any other causes for excessive exhaust smoke.
9-14
Engine Knocks
Engine is over- Immediately after engine start or while the

Engine knocks. water temperature is low, this occurs because
cooled.
compressed air at low temperature retards the
ignition timing. Normally knocking lessens as
the water temperature rises.
Defective thermostat Replace.
Injection timing is If excessively advanced, exhaust smoke

not correct. becomes blackish and knocking noise Adjust.
increases during the hard acceleration.
If excessively retarded, knocking noise is weak

Adjust.
and the exhaust smoke is white.
Fuel is not injected

from nozzle Fuel injection pressure too low for atomization Adjust.
properly.
Incorrect timing due to improper fuel injection Check and

pressure adjust.
Seized nozzle or broken nozzle spring Replace.
Correct or
After-dripping from nozzle
replace.
Incorrect timing to push down plunger due to

Replace.
excessively worn roller ring or cam plate
Excessively worn plunger Replace.
Stuck plunger or broken spring Replace.
Check
Loose set screw and
retighten.
Damaged delivery valve seat or broken spring. Replace.
Throttle operation not available because of

Replace.
worn tip of nozzle needle valve
9-15
H NOTE:
As speed increases, the injection period becomes shorter in inverse
proportion to the speed, but ignition time lag does not become shorter
as much. Thus combustion is not controlled and both the maximum
pressure and rate of explosion increase.
Amount of intake air

Maladjusted valve clearance Adjust.
is not sufficient.
Low cetane value fuel causes large ignition

Cetane value of fuel Change
delay, resulting in knocking with normal
in use is low. fuel.
ignition timing
Engine oil comes Seizure between piston or piston ring to

excessively high up Replace.
cylinder
to the upper part of
piston.
Insufficient oil scraping due to worn or stuck
piston ring or oil ring Replace.
Excessive clearance between cylinder and

Replace.
piston
Replace
Low engine oil viscosity
engine oil.
Excessive clearance of connecting rod

Engine is defective. Replace.
bearing or peeled
Loose tightening bolt of connecting rod

bearing Retighten.
Excessive clearance between cylinder and

piston (the lower the engine temperature, the Replace.
louder the knock noise of the piston)
Remove
Foreign matter in cylinder hit by piston. foreign
matter.
9-16
Excessive Amount of Fuel is Consumed
Excessive fuel Nozzle is defective. Incorrect injection pressure Adjust.

consumption.
Correct or
Faulty spray condition
replace.
Broken nozzle spring Replace.
Stuck nozzle Replace.
Injection timing is Refer to "Injection Timing Asjustment"

incorrect. section (P3-32).
Exhaust gas
Amount of injection Refer to "Exhaust gas contains much
contains much black
is not uniform. black smoke" section (P9-12).
smoke.
Correct or
Low compression
replace.
Adjust or
Over-cooled engine.
repair.
Excessive Amount of Engine Oil is Consumed
Check and
Excessive engine Oil leakage from oil seal or packing
correct.
oil consumption.
Lessen oil
Excessive amount of oil to specified
amount.
Change
Incorrect engine oil with speci-
fied oil.
Check and
Overheated or over-cooled engine
repair.
Worn, stuck or broken ring Replace.
Worn valve guide Replace.
Worn or broken valve stem seal Replace.
Check and
Low compression
correct.
9-17
Engine Runs but Not Properly
Injection pump is
Idling is rough. Idling sub-spring maladjusted Adjust.
defective.
Unequal amount of injection among cylinders Adjust.
Varied injection timing Adjust.
Nozzle is defective. Incorrect injection pressure Adjust.
Correct or
Faulty spray condition
replace.
Broken nozzle spring. Replace.
Stuck nozzle. Replace.
Compression pressure varies among cylinders excessively. Repair.
Replace
Leakage exists due to cracked or improperly tightened high pressure
or
pipe.
retighten.
Air has entered into fuel filter or injection pump. Bleed air.
Engine is over-cooled. Refer to "Engine Knocks"

section (P9-15).
Idling speed is too

Poor return of control cable Repair.
high.
Defect in governor Repair.
Engine fails to
operate properly at Improper movement of governor spring. Repair.
high speed.
Refer to above "Idling is rough" descriptions above for

countermeasures for other symptoms.
9-18
Engine Stalls During Operation
Engine stalls Fuel is not fed to

No fuel in fuel tank Fill tank.
during operation. injection nozzle.
Clogged ventilation device of fuel tank. Check and

clean.
Check and
Clogged fuel system
clean.
Check and
Injection pumps not operating
repair.
Fuel is fed to
Seized engine operation part Replace.
injection nozzle.
Insufficient compression Check and

correct.
Defective remote control box Replace.
Drain water
Water or air mixed in fuel system or bleed
air.
NOTE:
Possible causes for engine stop during operation are the failures in
feeding fuel and malfunctioning or seized propeller shaft. Check related
parts to determine the cause.
Idling speed is set at lower rpm.
Injection pump does not work properly.
9-19
Abnormal Vibration Occurs
Abnormal vibration Replace

Engine vibrates. Engine base is not strong enough
occurs. or correct.
Loose engine mounting bolts Check and

correct.
Loose flywheel nuts Check and

correct.
Improper engine alignment Check and

correct.
Check and
Loose 2-stage rate coupling mounting nuts
correct.
Check and
Defective 2-stage rate coupling
replace.
Check and
Unbalanced compression
correct.
Idling is rough
Resonance occurs
Check and
due to torsional
correct.
vibration.
NOTE:
Possible causes for vibration are loose engine mounting bolts,
resonance, defective shaft core, etc. Check related parts to determine
the cause.
Engine center position is incorrect.
9-20
Engine Gets Overheated
Engine gets
Insufficient coolant Replenish.
overheated.
Malfunctioning thermostat. Replace.
Blow by from cylinder head gasket Replace.
Adjust or
Loose or broken drive belt
replace.
Seized circulation pump bearing Replace.
Damaged or corroded circulation pump or vane Replace.
Clogged or grimed seawater passage.

· Seawater strainer
Clean.
· Oil cooler element
· Heat exchanger element
Replace
Leakage from seawater pump sealed section
seal.
Worn or damaged seawater pump impeller Replace.
NOTE:
Possible cause for overheating are clogging in seawater system and a
fault in each component. Check entire cooling system for the cause.
Contaminated or clogged seawater passage in the drive unit.
9-21
seawater is mixed Check and

Loose cap end hose
in coolant. retighten.
Clean or
Clogged element of heat exchanger
replace.
Broken pipe of heat exchanger element Replace.
NOTE:
Mainly check the part where seawater and coolant are adjacent to each
other.
No cooling water
Leakage from water pipe. Replenish.
comes out.
Check,
clean and
Dust caught in impeller
remove
dust.
Broken housing cover gasket Replace.
Damaged spline in impeller Replace.
9-22
Starter Motor
Starter fails to Repair or

operate even when Wiring Disconnected or short-circuited
replace.
starter main switch
is turned to "START"
position.
Loose terminal Retighten.
Remove dust
Poor continuity of terminal and tighten or
replace.
Battery Undercharged Recharge.
Even when starter Starter magnetic Disconnected, short-circuited or broken pull-in

switch is turned Replace.
switch coil
back, starter
magnetic switch fails
to operate and
pinion doesn't get Poor sliding condition or moving core Correct.
engaged.
Starter magnetic Correct or

switch operates and Pinion Tooth surface not finished properly
replace.
pinion moves
forward but fails to
get engaged with
ring gear. Correct or
Ring gear Tooth surface not finished properly
replace.
Starter magnetic Starter magnetic

switch operates and Contact point of main switch defective Repair.
switch
pinion gets engaged
properly but starter
fails to rotate. Readjust
Maladjusted main switch interval
timing.
Battery Undercharged Recharge.
Wiring Decrease in rotation force due to poor contact Correct.
Repair or
Starter Failure in motor section
replace.
9-23
Maximum speed
revolution starts Starter magnetic Readjust
Main contact point interval maladjusted
before starter gets switch timing.
fully engaged.
Starter remains Starter magnetic

engaged even after Seized main contact point Replace.
switch
engine has started.
Return spring Broken of deteriorated Replace.
Pinion/clutch Poor sliding Correct.
9-24
Alternator
Undercharged
alternator Drive belt Looseness Adjust.
Repair or
Stator coil Disconnected or short-circuited
replace.
Repair or
Rotor coil Disconnected or short-circuited
replace.
Alternator capacitor Defective Replace.
Transistor type
Defective Replace.
regulator
Add
Battery Improper electrolytic solution distilled
water.
Repair or
Short-circuited electrode
replace.
Diode Defective Replace.
Alternator is over- Transistor type

charged. Defective Replace.
regulator
Abnormal noise
Bearing Defective Replace.
from alternator.
Stator coil Grounded or short-circuited Replace.
NOTE:
When there is trouble in the electric system, it is necessary to check
parts in detail including the contact condition.
9-25
Lubrication System
Excessive lubricant Change

Lubricant viscosity Low
consumption. lubricant.
High Check and

Lubricant pressure
adjust.
Quantity of oil in oil Check and

Excessive quantity
pan adjust.
Correct or
Piston ring/oil ring Worn or stuck
replace.
Correct or
Piston and liner Excessive clearance
replace.
Correct or
Liner Deformed
replace.
Each joint and Lubricant leakage due to loose connection or Correct or

packing defective packing replace.
Piston ring and oil

Matching Correct.
ring
NOTE:
Possible cause for excessive consumption are a large gap at sliding part,
leakage and excessive amount of oil. Check each part of the lubrication
system carefully.
Oil pressure is Correct or

Metal clearance Excessive
slow to rise. replace.
Repair or
Oil filter Clogged
replace.
Oil pan suction Clean or

Clogged
strainer replace.
9-26
Cylinder head Adjusting screw maladjusted Readjust.
Sliding part of Correct or

Worn
engine. replace.
Oil Insufficient amount Replenish.
Improper viscosity (too high or too low). Change

oil.
Oil pressure fails to Check and

Oil pressure sender Defective switch or failure in electric circuit
rise. replace.
Repair or
Oil pressure gauge Defective
replace.
Repair or
Oil pump Defective pump or damaged gear
replace.
Relief valve Defective Replace.
Check and
Oil pump/oil filter Improper installation
retighten.
Clean or
Pipe Clogged or cracked
replace.
Oil in oil pan Insufficient amount Add oil.
NOTE:
Possible causes for failure in oil pressure rise are insufficient amount of
oil, clogged passage and defective oil pressure gauge. Check lubrication
circuit carefully.
9-27
TRBL TURBOCHARGER E
TURBOCHARGER
Trouble in the turbocharger hinder the engine from performing its functions fully and provid-
ing specified engine output. In such case, check each part of the engine first to make sure that
the engine itself is in good condition. Then check the turbocharger according to the following
flow chart to make proper judgement for the correcting measures.
Excessive Amount of Exhaust Smoke Comes Out
Amount of intake air Clean or

Clogged air filter element
is not sufficient. replace.
Close air intake port Correct.
Leakage from connection of intake air system Correct.
Turbocharger fails to Clean or

Impurities in oil collected at turbine seal causing frictional rotation of
rotate. change
turbine spindle
engine oil.
Repair or
Seized bearing Insufficient oil supply, clogged oil supply pipe
replace.
Check and
repair or
High oil temperature
change
engine oil.
Clean or
Unbalanced rotor
replace.
Carefully observe
precautions for
Not fully warmed up or sudden stop operation
from loaded operation described in
instruction manual.
Contacting or Check and

Over-revolution
broken turbine shaft repair.
or blower impeller
Check and
Excessive rise of exhaust gas temperature correct injec-
tion pump.
Remove foreign
matter and check
Entry of foreign matter and repair air
cleaner and
engine.
Check and
Damaged or worn bearing repair or
replace.
Incorrect assembly Reassemble.
9-28
TRBL TURBOCHARGER E
Exhaust Smoke is White
Exhaust smoke is Influence from Revolution speed fails to rise because of

Clean or
white. exhaust gas exhaust gas leakage before entering
replace.
resistance turbocharger
Revolution speed of turbocharger fails to rise

because of deformed or closed pipe of exhaust Correct.
system
Oil Decreases Quickly
Excessive engine oil Oil flowing out into blower and turbine due to Repair or
consumption. clogged oil return pipe replace.
Excessively worn or broken seal ring caused by Repair or

excessive wear of bearing replace.
Output Power Reduces
Output power Excessively worn or broken seal ring caused by Repair or

reduces. excessive wear of bearing replace.
Follow-up of Turbocharger is Poor (Slow)
Follow-up of Check each

turbocharger is poor Gas leakage from exhaust system part and
(slow). repair.
Check and
Air leakage from discharge side of blower
repair.
Clean or
Clogged air cleaner element
replace.
Repair or
Grimed or damaged turbocharger
replace.
Carbon collected at sealed section of turbine Clean or

causing frictional rotation of turbine spindle change
engine oil.
Check fuel
injection
Faulty combustion system and
adjust.
9-29
TRBL TURBOCHARGER E
Abnormal Noise, Abnormal Vibration
When nozzle of turbine casing is closed and gas passage is made

Abnormal noise. excessively narrow at acceleration, blower discharge air gets stuck and Clean.
flows back (surging).
Rotating parts contact. Repair or

replace.
Check and
Vibration occurs. Loose connections of turbocharger to intake/exhaust pipe and oil pipe
correct.
Failure in bearing itself and contact between its rotating parts and other Repair or
parts. replace.
Check and
Damaged blower impeller due to entry of foreign matter.
replace.
Repair or
Unbalanced rotor
replace.
9-30
YAMAHA MOTOR CO., LTD.
Printed in Japan
Dec. 2006-0.5 × 1
(ME372STI)
(E) Printed on recycled paper
ENGINE WIRING HARNESS CONNECTION
Clamp 2
To be secured firmly to the bracket with a clamp.
(Do not cut off the clamp after installation.)
Wireharness to the PT pump Clamp: 90465-13M30
(when equipped) Wireharness: 6TC-82590-2
Themo SW
Wire color: Red/Black
Thermo SW tightening torque:

34 N·m (3.5 kgf·m, 25 lbf·ft)
4-pin connector (black)
Apply LOCTITE® No. 243
To be connected to the neutral switch connector.
Thermo unit tightening torque: Clamp 6

10.5 N·m (1.07 kgf·m, 7.7 lbf·ft) After making connection to the alternator,
Apply LOCTITE® No. 243 bundle the wireharnesses with a clamp. Cut
off the extra length of the clamp after in-
stallation.
Clamp: 90465-13M36
Tighten the LA ter minal (1 plate) of the

wireharness onto the alternator B terminal (M6).
Tightening torque: 7.8 N·m (0.8 kgf·m, 5.8 lbf·ft)
Thermo unit wire color:

Blown/Black
2-pin connector (Black)

To be connected to the
extension lead wire for
reservoir tank.
Connect the wireharness 3-pin connector
to the alternator.
Tighten the LA terminals of the wires from the wireharness onto the two
terminals (M4) of the oil pressure sender. The wire colors are black and
light blue, which may be tightened to either of the terminals.
Clamp 5 Oil pressure sender fitting

To be secured firmly to the Tightening torque : 24 N·m (2.4 kgf·m, 17.7 lbf·ft)
bracket with a clamp. Apply LOCTITE® No. 243
(Cut off the extra length of the Tightening torque on oil pressure
clamp after installation.) switch fastener: Tightening the LA terminal from wireharness
Clamp: 90465-15M54 8.35 N·m (0.9 kgf·m, 6.2 lbf·ft) with the M4 screw of oil pressure switch.
Apply LOCTITE® No. 243 Tightening torque: 2 N·m (0.2 kgf·m, 1.5 lbf·ft)
Clamp 3
Secure the diode to the main wireharness.
Clamp 4 Cut off the extra length of the clamp after securing it.
Secure the wires from the two fuse holders to the main Clamp: 90465-13M36
wireharness. Secure the wires where they are protected with
tube. Cut off the extra length of the clamp after securing it. Clamp 1
Connect the wireharness 3-pin connectors (3) to Clamp: 90465-13M36 To be secured to the bracket with a clamp.
each relay assembly. Three connectors may be To glow plug Cut off the extra length of the clamp.
coupled to any of the relays. Clamp: 90465-11M10
Tilt relay (Up)
Connect the 2 bullet connector

wires (Blue/Yellow, Black) from
the water sender to the bullet
connector wires in the harness,
watching the wire colors.
n
Brow
Black
n/
Gree e Black
Whit
Brown
Black
Blue/White k
Blac
Tilt relay (Down)
Black
Connect to the harness

to the power trim pump. Grounding wire: 6TA-82519-0
Details of Electrical Box Area
3 bullet connector wires (Green/ Install M6 terminals of the wires

White, Blue/White, Red/Purple) Install M10 terminal of the wire. (green and blue).
(They are fastened to the harness Tightening torque: Tightening torque:
with locking tie.) 21 N·m (2.1 kgf·m, 15.5 lbf·ft) 3.6 N·m (0.4 kgf·m, 2.7 lbf·ft)
When used in combination with
the drive unit equipped with tilt
switch, remove these wires from
the harness and connect them to
the tilt switch on the drive unit. Tilt relay (Up)
Black
k
Blac
Blue/White
Black
2 bullet connector wires
k
ac
2 bullet connector wires
Bl
(Brown/White, Black)
(Brown/White, Purple/White)
Connect them to the trim
Blue
n
Connect them to the trim limit ee
Gr
ck
k
sender on the drive unit. ac
Bla
switch on the drive unit. Bl
Tilt relay (Down)

To be secured with a clamp after
connecting each wire.
(See discription for Clamp 6.)
From the power trim pump. Wires from the PT Pump (when equipped)
Avoid Interference
Route the wireharness under the flange
in the lower part of the throttle lever,
to prevent the interference with the Wireharness: 6TC-82590-2
throttle lever.
Route the wireharness properly to avoid

sharp bending of the hose.
Connect the 9-pin connector from the
control unit to the wireharness.
Connect the 2-pin connector of the fuel filter to

the wireharness. Then, secure the corrugated part Water sender (M26)
of the wireharness to the pipe with a clamp. Tightening torque: 52.5 N·m (5.4 kgf·m, 38.7 lbf·ft)
Clamp: 90465-13M36
Connect the wireharness to the 1-pin connector of

the starter motor 50 terminal.
Tighten the wireharness LA terminal (1 plate)

together by the starter motor mounting nut.
(See illustration below.)
Nut: 95227-14600
Plane washer: 92907-14600
Spring washer: 92907-14100
Connect the wireharness to the 3-pin

connector of injection pump. Clamp 7
Bundle the wireharnesses with a clamp.
Clamp: 90465-13M36
Tighten the LA terminal (2 plates) from

the wireharness together onto the
starter motor 30 terminal (M10).
Tightening torque: Flywheel housing
21 N·m (2.1 kgf·m, 15.5 lbf·ft)
Wireharness (LA terminal)
Nut 95337-14600
Starter motor
Washer, spring
92907-10100
Washer
92907-14600
Tighten the terminal of the wireharness onto the glow plug terminal (M4).
(wire color: Red)
Tightening torque: 3 N·m (0.3 kgf·m, 2.2 lbf·ft)
Collar
Nut
Tighten the LA205

terminal with a nut,
and then cover it Put the two LA 310 terminals together.
with a cap.
Register Wiring
Place the rubber-capped

terminals on the top.
Tighten the LA terminals of the wires from the

wireharness onto the two terminals (M4) of the boost
sender. The wire colors are black and yellow/white,
which may be tightened to either of the terminals.
Details of Terminal Assembly

Boost sender fitting
Tightening torque: 64 N·m (6.5 kgf·m, 47.2 lbf·ft)
ENGINE ELECTRICAL SYSTEM WIRING DIAGRAM
1 Battery
2 Water temperature sender
3 Water temperature switch
4 Seawater flow sender
5 Resistor
6 Starter motor
7 Oil pressure sender
8 Oil pressure switch
9 Tachometer pickup/fuel cut solenoid valve
0 Water separator sender
A Boost sender (O/P)
B Electrical equipment box
(PTT relays, 20 A x 1 fuse)
C Terminal assembly
D Alternator
E Neutral switch
F Fuse (100 A)
G Coolant reserve tank (O/P)
H Glow control box
I After glow relay
J Starter relay
K Glow relay
L Glow plug
To power trim/tilt system
COLOR CODE
B ........... Black
Br ......... Brown
Gy ........ Gray
Lg ......... Light green
Pu ......... Purple
R ........... Red
Sb ......... Sky blue
B/W ...... Black/White
Br/B ...... Brown/Black
Br/G ...... Brown/Green
Br/W ..... Brown/White
G/L ....... Green/Blue
G/W ...... Green/White
L/G ....... Blue/Green
L/W ....... Blue/White
L/Y ........ Blue/Yellow
Pu/B ..... Purple/Black
Pu/W .... Purple/White
R/B ....... Red/Black
R/G ....... Red/Green
R/Pu ..... Red/Purple
Y/B ....... Yellow/Black
Y/R ....... Yellow/Red
Y/W ...... Yellow/White
WIRING CONNECTION DIAGRAMS
Single Engine/Single Station (EXAMPLE) Without panel type With panel type
1 Engine shut-off switch (O/P) 1 Engine shut-off switch (O/P)
64D-82570-10 64D-82570-10
2 Main switch 2 Main switch
*2 *3 6YF-82570-40 6YF-82570-11
3 Tachometer 3 Tachometer
N64-83600-00 6YF-83600-00
4 Speedometer (O/P) 4 Speedometer (O/P)
N64-83600-10 6YF-83600-20
5 Voltmeter 5 Voltmeter
N64-83600-30 *2
6 Trim meter 6 Trim meter
N64-83600-50 *2
7 Water temperature meter 7 Water temperature meter
N64-83600-20 *3
8 Oil pressure meter 8 Oil pressure meter
N64-83600-40 *3
9 Fuel meter (O/P) 9 Fuel meter (O/P)
N64-83600-70 6YF-83600-E1
0 Boost meter (O/P) 0 Boost meter (O/P)
N64-83600-60 6YF-83600-D1
A Pilot light panel A Pilot light panel
6YF-83530-20 6YF-83530-10
B Wireharness assembly B Wireharness assembly
6YF-82580-C0 6YF-82580-C0
¡ C Wireharness ¡ C Wireharness
6YF-82580-B0 6YF-82580-B0
¡ D Resistor ¡ D Resistor
6YF-85370-10 6YF-85370-10
E Control box E Control box
6YF-85590-11 6YF-85590-11
F Extension wireharness F Extension wireharness
6YF-82586-61 6YF-82586-61
G Extension wireharness G Extension wireharness
6YF-8258A-71 6YF-8258A-71
H Wireharness H Wireharness
6YF-82580-D0 6YF-82580-D0
To PTT switch To PTT switch

To meter light switch To meter light switch
Free Free
To engine extension wireharness To engine extension wireharness
(6TA-82586-00) (6TA-82586-00)
To Fuel sender To Fuel sender
*1 These are colors of identification coat- *1 These are colors of identification coat-
ing on the wireharness. ing on the wireharness.
*2 The volt meter and the trim meter are
NOTE 1: Component parts are listed un- available as a set only.
der their assemblies and indi- Part No: 6YF-83600-C1
cated by bullets. *3 The water temperature meter and the
NOTE 2: This wiring connection diagram oil pressure meter are available as a
is an example only. The actual set only.
COLOR CODE combination of meters and Part No: 6YF-83600-B1
B ........... Black O .......... Orange switches may vary according to
L ........... Blue Lg ......... Light green the boat. NOTE 1: Component parts are listed un-
N .......... Natural B/Y ....... Black/Yellow der their assemblies and indi-
Y ........... Yellow R/Pu ..... Red/Purple cated by bullets.
W .......... White L/W ....... Blue/White NOTE 2: This wiring connection diagram
P ........... Pink G/W ...... Green/White is an example only. The actual
Br ......... Brown Pu/W .... Purple/White combination of meters and
Gy ........ Gray Lg/R ...... Light green/Red switches may vary according to
Pu ......... Purple Lg/B ...... Light green/Black the boat.
R ........... Red Pu/B ..... Purple/Black
Single Engine/Dual Station (EXAMPLE) Without panel type With panel type
1 Engine shut-off switch (O/P) 1 Engine shut-off switch (O/P)
64D-82570-10 64D-82570-10
2 Main switch 2 Main switch
6YF-82570-40 6YF-82570-11
3 Tachometer 3 Tachometer
N64-83600-00 6YF-83600-00 (with hour meter)
4 Speedometer (O/P) 4 Speedometer (O/P)
*3 *4 N64-83600-10 6YF-83600-20
5 Voltmeter 5 Voltmeter
N64-83600-30 *3
6 Trim meter 6 Trim meter
N64-83600-50 *3
7 Water temperature meter 7 Water temperature meter
N64-83600-20 *4
8 Oil pressure meter 8 Oil pressure meter
N64-83600-40 *4
9 Fuel meter (O/P) 9 Fuel meter (O/P)
N64-83600-70 6YF-83600-E1
0 Boost meter (O/P) 0 Boost meter (O/P)
N64-83600-60 6YF-83600-D1
A Pilot light panel A Pilot light panel
6YF-83530-20 6YF-83530-10
B Tacho meter B Tacho meter
N64-83600-00 6YF-83600-10 (without hour meter)
C Wireharness assembly C Wireharness assembly
6YF-82580-C0 6YF-82580-C0
¡ D Wireharness ¡ D Wireharness
6YF-82580-B0 6YF-82580-B0
¡ E Resistor ¡ E Resistor
6YF-85370-10 6YF-85370-10
F Control box F Control box
6YF-85590-11 6YF-85590-11
G Extension wireharness G Extension wireharness
6YF-82586-52 6YF-82586-52
H Extension wireharness H Extension wireharness
6YF-82586-02 6YF-82586-02
I Wireharness I Wireharness
6YF-82580-D0 6YF-82580-D0
J Wireharness assembly J Wireharness assembly
6YF-82580-E0 6YF-82580-E0
K Extension wireharness K Extension wireharness
6YF-8258A-02 6YF-8258A-02
L Start and stop switch (O/P) L Start and stop switch (O/P)
6YF-82570-50 6YF-82570-20
To PTT switch To PTT switch
To meter light switch To meter light switch
Free Free
To engine extension wireharness To engine extension wireharness
COLOR CODE (6TA-82586-00) (6TA-82586-00)
B ........... Black To Fuel sender To Fuel sender
L ........... Blue Main station Main station
N .......... Natural Sub station Sub station
Y ........... Yellow *1 These are colors of identification *1 These are colors of identification coating on the
W .......... White coating on the wireharness. wireharness.
P ........... Pink *2 Leave free. *2 Leave free.
Br ......... Brown If it is connected meter at main sta- If it is connected meter at main station may give
Gy ........ Gray tion may give wrong indication. wrong indication.
Pu ......... Purple *3 The volt meter and the trim meter are available as
O .......... Orange NOTE 1: Component parts are listed a set only.
R ........... Red under their assemblies and Part No: 6YF-83600-C1
G .......... Green indicated by bullets. *4 The water temperature meter and the oil pressure
B/Y ....... Black/Yellow NOTE 2: This wiring connection diameter are available as a set only.
R/Pu ..... Red/Purple gram is an example only. Part No: 6YF-83600-B1
L/W ....... Blue/White The actual combination of
G/W ...... Green/White meters and switches may NOTE 1: Component parts are listed under their as-
Pu/W .... Purple/White vary according to the boat. semblies and indicated by bullets.
Pu/B ..... Purple/Black NOTE 2: This wiring connection diagram is an ex-
ample only. The actual combination of meters
and switches may vary according to the boat.
ENGINE CONNECTIONS
A B C D E F H
L/Y Y/B (To ST. relay) Pu
Sb Lg Y/R Y/R Lg Y/R R B B
Br/B Y/W
R/B (From (To (To (To
B Pu/B (To FCV) key diode) starter glow
switch) motor) plug)
B/W
B Y/R
R/G Gy L/G G/L G/L B Br R/Pu (From neutral R Br/G R
switch)
I Gy J K L M R
G/W (Free)
Br/W Pu
L/G Gy B/W Y/R B R
Pu Y/B
R/Pu Br/G
Y/R
Pu/W L/W
12V Y/R Br
B/W B
Battery G/Y R Pu/B Br G/Y R
(Free)
Trim sender
B B
Br/W Br/W
Trim and tilt switch

R/Pu R/Pu
UP L/W L/W
R/Pu
DW. G/W G/W
Br/G
B/W
G/Y
Y/R
L/G
Gy
Pu
Pu/B
B/W
Y/B
Gy
B
Trim limit switch
I
R
Pu/W L/W L/W L/W K M
J
Seawater Starter
R
R
Y/W
flow sender motor
R
R
B
Pu/W Pu/W
G/Y
Y/R
L/G
G/Br
B/W
L/R
Gy
Pu
Glow relay
M
R
H
L/Y
R
Br/G B
Resistor Boost pressure sender Glow Fuel cut-off Tachometer pickup Water separator
control box solenoide water level switch
L/Y
valve (FCV)
R
PT/T relay R
Electrical
R
PTT relay (DOWN)
(UP) B B
box
Diode
B
Starter relay
Br
B
B/W
L
Br
B
B
B
R B L B B
Y/R
G
Br
F
R
Y/R
G/W
Y/R G/W Br
Glow plug
R
After glow relay
Br
R
R
R
R
20A
G/Y fuse
L/W
L/W
B
R/Pu
Y/W
Pu/W
Br/W
R/Pu
Pu/B
G/W
Br/B
B/W
L/W
R/G
Y/R
R/B
Y/B
L/G
L/Y
G/L
Gy
Pu
Sb
Lg
Br
B
B A
100A Fuse Oil pressure Oil pressure
(2 places) sender switch Terminal ASSY. Neutral switch
Connect to extension
wireharness
R
Power trim and tilt motor
R
G/L B
R
D
Alternator
Water temp. Water temp.
M switch sender R
Y/R
Y/R
R
R
L
G
B
R
R
B
R/G
Sb
B
Br/B Br/B
R/B R/B
R/Pu
Pu
Br
R
G/L
Y/R
Y/R
B
B
G/L
Y/R
Y/R
B
S T U
Lg (Free) (Free)
B
Y/R
E
S B
Y/R B B B
Y/R
B
Wire lead
N23-82521-XX
Fresh reservoir
tank water level switch
T U
Y/R B
B B
METER WIRING DIAGRAM · SINGLE STATION
33 L/Y Sb R/B 34 Y/B 35 Pu/B 36

R/G R/B
Br/B Pu/B Y/W Lg Pu Y/R L/Y
B
R/G Gy
Br/W
G/W
Pu/W
Pu B/W Gy
R/Pu B/W G/L B/Y Lg
Y/R Br L/W L/G (Free) Y/B
6YF-8258A-71 37 38 39
R/Pu Sb
Y/R L/R
Pu Br/W Br/B
B/Y L/B L
L/W
L/G Pu
Pu/W
(Free)
L B Pu
B L/R Y/W P (Free)
G/W L/B G/L Br
P
B Fuel sender
B/Y (Free)
Br/W
Sb
Br/B
Gy
Y/R
Pu
R/Pu
6YF-82580-D0 B
L/W 33
Trim / Tilt SW. Main SW. G/W
Pu/W
L/W Pu/W R/Pu G/W
Br Connect to
R/Pu Pu Y/R L/Y
Stop. SW. R/G extension wireharness
22 R/Pu Y/R G/W TILT OFF
B/Y
R/B
Pu Illml. SW. (Lanyard) W (6TA-82586-00)
B/Y UP ON Pu/B
G/L
Pu/W (Free) FREE START
L/G
Y/W
Y/B 34
DOWN Y/R Y/R Y/R Y/R Lg
B/W
B
L
L
B Pu Pu Pu Pu
TW. remote control
Pu/W
R/Pu R/Pu R/Pu R/Pu R/Pu
G/W
Pu/B
L/W
25 23
B/W
L/W
R/G
R/B
Y/R
Y/B
B/Y
L/Y
Gy
Pu
Lg
(Free) (Free) grounding terminal
B/Y B/Y
B B
23 25
L/W L/W
Y/R Pu Y/R G/W 22 37 G/W
Pu Pu/W Pu/W
36 35
Pu/W
R/Pu
B
G/W
L L
L/W
L/R 30 29
L/B
R/Pu R/Pu
Pu/B
B/W
Y/R
B/Y
R/G
R/B
Y/B
L/Y
Pu
Gy
Lg
B/W B/W
Pu/B R/W
Y/R Y/R
Pu 28 27 Pu
B/Y B/Y
BZ
Y
P
B/Y
6YF-82530-10/20 L/B
R/B
R/G
L/R
Pilot lump assy. L L L/Y
L/G L/G Pu
Lg
Or
R
Br Br
G/L 1 38 G/L Y/B
R/B Pu Pu
Water temp. B B Gy Y/R
Pu/B Pu
R/G
Lub. oil pressure
6YF/N64-82600-XX Gy R/W
Meter panel assy. L/Y

Seawater flow B/W
Water level Lg O/B

Fuel Volt Trim (FreshWater reservoir)
R/B
U Water level Y/B
U U (Water separator) Lg
R/G
E
Br/B Br/B Lg/R (Free)
E Grow
L/W Sb Sb
Br/W Br/W Lg/B
L/Y
Y/W 2 39 Y/W
I I I P P
Boost Lub. oil Charge
Br Lg
pressure pressure Water temp.
Y/B
Tacho Nutral G/L 32
Br/W
Pu
Pu
Pu
(Shift position)
B
L
P
B
L
B
L
U U U (with Hour) R
Pu
R/G
L/W
R/B
Y/B
G/L
L/Y
Pu
Lg
Br
Or
20 E 18
E 16
E U I1 Speedo
6YF-85370-10 11
I
9
I
7
I
Registor assy.
Pu/B
Pu/B
13
4
Br/W
E I2
Pu/B
Y
B
L
B
L
G
P
B
L
Y/W
Br/B
Pu
Sb
Pu
Pu
B
L
B
L
B
L
Pu
Pu
Pu
(Free)
R/G
G/L
R/B
O/B
L/Y
Y/B
L/G
Gy
Pu
Pu
Lg
Br
R
B
19 17
Pu
Pu
15
L
L
62
51
36
36
51
10 8 6
Pu/B
Pu/B
Pu/B
14
5
Or
Pu
W
27
G
Y/W
R
Sb
Or
W
B
B
L
R/W
Pu/B
Pu/B
Pu
L
Y/R
Br/B
R
B
L
Pu/B
O/B O/B
Gy
Pu
6YF-85590-1X
B
R/B R/B
21 R/G R/G
L/Y L/Y
12
Lg
3 31
Lg Control unit assy.
Y/B Y/B
B/W B/Y
Gy Gy (Free)
Pu/B
Or
W
G
Y
R
6YF-82580-B0 6YF-82586-61
1 L/R 2 3 Lg/W 4 (Free) (Free) O/B 5 6 7 8 9 10 11 32 28 29

Sb Pu/B Pu/B
Br/B L/Y R/G
Br/W Gy Pu/B R Br/W Y Sb W Pu/B B Y/W P G Y/R
L L/B Br/B Gy O/B (Free) R/B (Free) Or Pu Y/R Pu
Y/B Lg R/B O/B
Pu L/G L/Y R/B R/G Pu
Gy (Free)
L/Y
L/G
Pu/B B Lg Br/L (Free)
Y/W Lg Br (Free) (Free) B/W B/Y
G/L Y/B Pu B L B L B L B L L L B B/Y B/W
Br (Free) R/G Y/B B (Free)
P (Free) G/L (Free)
(Free) (Free)
12 13 (Free) (Free) R/B 14 15 16 17 18 19 20 21 30 31
Pu/B Or (Free) R/G (Free)
Or (Free)
Or Pu Pu Pu Br/W Pu Sb B Pu Pu Y/W Pu P Pu R/B L/Y
(Free) (Free) Gy Br/B O/B Gy
W
R (Free)
W R R Gy R/B L/Y
R/G
L/W
L/Y Y/B (Free)
Y/B (Free) (Free) Lg
Y G (Free) R B G Y R/B Lg
Br B B B L L L B L B L Lg Gy Y/B
(Hour) L L/Y (Free) R/G Y/B R/G
G/L (Free) Lg
METER WIRING DIAGRAM · DUAL STATION
Trim / Tilt SW.

6YF-82580-E0
L/W Pu/W R/Pu G/W
TILT Start. SW. Stop. SW. 48 47 46 45
UP (Free) R/Pu 33 L/Y Sb R/B 34 Y/B 35 Pu/B 36 38
Illml. SW. (Free) Gy R/G R/B
Sb Br/B O/B (Free) L/B Y/R Lg Y/R (Free)
Br/B Pu/B Y/W Pu L/Y
FREE Br/W Pu B (Free) L
L/Y Pu
R/B L/G B/Y R/G Gy
DOWN
Br
W
Y
B
L/W L/G Pu
Br/W
G/W
B
L
49 Y/W Pu/W
(Free) Lg B B B/W
(Free) Pu L/B Pu Gy B Pu
Y R/Pu Br P R/Pu B/W G/L B/Y Lg
Pu/W
R/Pu
G/W
L/W
L/G (Free) Y/B G/L
B/Y
Y/B R/G G/L Br Pu/W Y/R Br Br
Br
W
G/W L/W
Y
L/W B/Y TW. remote control
grounding terminal 37 39 41 42 43
R/Pu Sb (Free) Sb
Y/R R/Pu Br/W
G/W Pu Br/W Br/B Br/B
B/Y (Free) Y/R (Free) (Free)
L/W
Pu/W
B/Y B/Y
R/Pu
B/Y B/Y
G/W
L/W
L/W B/Y L/G
B
L Pu/W B Br Y/R Y/R Y/R Pu
Y Pu Pu Pu/W
B B B (Free)
L L/B L/B L (Free) (Free) (Free) B
L/W 49 45 L/W L/W 45 41 L/W Y/W
B Y/W P (Free) (Free)
Pu/W Pu/W Pu/W Pu/W
G/W (Free) (Free) Pu/W G/W G/L Br P
G/W G/W G/W G/W
R/Pu R/Pu R/Pu R/Pu
L/B L/B
Br Br Br
G/L G/L G/L
L/G L/G L/G
1 46 Pu Pu 46 42 Pu
B B B
Identical with meters and pilot lamp Pu Pu
harnesses at the CABIN end.

O/B O/B O/B
R/B R/B R/B
6YF/N64-83600-XX 6YF-83530-10/20 R/G
L/Y
R/G
L/Y
R/G
L/Y
2 47 Lg Lg 47 31 Lg P
Y/B Y/B Fuel sender
6YF-85370-10 6YF-82580-B0 Gy
Y/B
Gy Gy
B
B/Y (Free)
Br/B Br/B Br/B
Sb Sb Sb
Br/W Br/W Br/W
3 48 Y/W Y/W 48 43 Y/W
P P P
F/B Br/W
Sb
Br/B
Gy
Y/R
Pu
6YF-82586-02 R/Pu
L/W 33
G/W
Pu/W
Br
L/Y
Connect to
R/G
R/B
extension wireharness
Trim / Tilt SW. (6TA-82586-00)
Main SW. 6YF-82580-D0 Pu/B
CABIN L/W Pu/W R/Pu G/W R/Pu Pu Y/R
G/L
L/G
Y/W
22 R/Pu Y/R G/W TILT OFF Stop. SW. B/Y Y/B 34
Lg
Pu B/Y UP ON (Lanyard) W B/W
Illmi. SW.
Pu/W (Free) FREE START
Pu/B
B/W
R/G
R/B
Y/R
Y/B
B/Y
L/Y
Gy
Pu
Lg
DOWN
L B Y/R Y/R Y/R Y/R
B
L
Pu Pu Pu Pu
Pu/W
L/W
R/Pu
G/W
L/W
(Free) (Free) R/Pu 25 23 R/Pu R/Pu R/Pu

TW. remote control B/Y B/Y
23 25 grounding terminal B B 36 35
Y/R L/W L/W 30 29

Y/R Pu Pu G/W 22 37 G/W
Pu/W Pu/W
Pu/W
R/Pu
B
G/W
L/W
L L
Pu/B
B/W
Y/R
B/Y
R/G
R/B
Y/B
L/Y
Pu
Gy
Lg
R/Pu R/Pu
B/W B/W
Pu/B R/W
Y/R Y/R
Pu 28 27 Pu
B/Y B/Y
6YF-82530-10/20 BZ
Pilot lump assy. Y
P
R/B B/Y
R/G
L L L/Y
L/G L/G Pu
Lg
Or
R
Br Br
G/L 1 38 G/L Y/B
R/B Pu Pu
Water temp. B B Gy Y/R
Pu/B Pu
Gy
R/G
Lub. oil pressure
6YF/N64-82600-XX Gy R/W
Meter panel assy. L/Y

Seawater flow B/W
O/B
Water level Lg O/B
Fuel Volt Trim (FreshWater reservoir) R/B
R/B
U Water level Y/B
U U (Water separator) R/G Lg
R/G
E
Br/B
Sb
Br/B
Sb
Lg/R (Free)
E Grow
L/W L/Y
Br/W Br/W Lg/B
L/Y
Y/W 2 39 Y/W
I I I P P Lg
Boost Lub. oil Charge
Br Lg
pressure pressure Water temp. Y/B
Y/B
Tacho Nutral G/L 32
Br/W
Pu
Pu
Pu
(Shift position)
B
L
P
B
L
B
L
U U U (with Hour) R
Pu
R/G
L/W
R/B
Y/B
G/L
L/Y
Pu
Lg
Br
Or
20 E 18
E 16
E U I1 Speedo
6YF-85370-10 11
I
9
I
7
I
Registor assy.
Pu/B
Pu/B
13
4
Br/W
E I2
Pu/B
Y
B
L
B
L
G
P
B
L
Y/W
Br/B
Pu
Sb
Pu
Pu
B
L
B
L
B
L
Pu
Pu
Pu
(Free)
R/G
G/L
R/B
O/B
L/Y
Y/B
L/G
Gy
Pu
Pu
Lg
Br
R
B
19 17
Pu
Pu
15
L
L
62
51
36
36
51
10 8 6
Pu/B
Pu/B
Pu/B
14
5
Or
Pu
W
27
G
Y/W
R
Sb
Or
W
B
B
L
R/W
Pu/B
Pu/B
Pu
L
Y/R
Br/B
R
B
L
Pu/B
O/B O/B
Gy
Pu
6YF-85590-1X
B
R/B R/B
21 R/G R/G
L/Y L/Y
12
Lg
3 31
Lg Control unit assy.
Y/B Y/B
B/W B/Y
Gy Gy (Free)
Pu/B
Or
W
G
Y
R
6YF-82580-B0 6YF-82586-52
1 L/R 2 3 Lg/W 4 (Free) (Free) O/B 5 6 7 8 9 10 11 32 28 29

Sb Pu/B Pu/B
Br/B L/Y R/G
Br/W Gy Pu/B R Br/W Y Sb W Pu/B B Y/W P G Y/R
L L/B Br/B Gy O/B (Free) R/B (Free) Or Pu Y/R Pu
Y/B Lg R/B O/B
Pu L/G L/Y R/B R/G Pu
Gy (Free)
L/Y
L/G
Pu/B B Lg Br/L (Free)
Y/W Lg Br Lg R/B B/W B/Y
G/L Y/B Pu B L B L B L B L L L B B/Y B/W
Br (Free) R/G Y/B B (Free)
P (Free) G/L (Free)
Gy (Free)
12 13 (Free) (Free) R/B 14 15 16 17 18 19 20 21 30 31
Pu/B Or Or O/B R/G (Free)
Pu Br/W Pu Sb B Pu Pu Pu Y/B L/Y
Or (Free) (Free) Pu Gy Pu Br/B Pu Y/W P R/B O/B Gy
W
R (Free)
W R R Gy R/B L/Y
R/G
L/W
L/Y Y/B (Free)
Y/B L/Y (Free) Lg
Y G (Free) R B G Y R/B Lg
Br B B B L L L B L B L Lg Gy Y/B
(Hour) L L/Y R/G R/G Y/B R/G
G/L (Free) Lg

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ME372STI

Turbocharger Removal Connecting Rod and Piston Pin Check

2 ¡ Connecting rod bending

 2) Remove the air filter.

 Place a rag under the coolant by-pass pipe

 charger. Connecting rod twisting checking step

Connecting rod twisting:

 8) Remove the boost pipe 1. <Limit>

Symbols G to J in an exploded diagram in-

G Apply Yamaha marine diesel engine oil

ENGINE IDENTIFICATION ...................................................................................................... 1-1

ENGINE AND PROPELLER ROTATION .................................................................................. 1-1

SPECIAL TOOLS ..................................................................................................................... 1-5

OTHER EQUIPMENT TOOLS ................................................................................................. 1-8

HANDLING OF LIQUID GASKET............................................................................................ 1-9

STANDARD ABBREVIATIONS AND SYMBOLS ................................................................. 1-10

The model and serial number plate is at-

ENGINE AND PROPELLER ROTA-

Oils, Greases and Sealing Fluids

Good Working Practices

3) After assembly, check that moving parts

4) Install bearings with the manufacturer’s

ILLUSTRATION TOOL No. TOOL NAME REMARKS

90890-07603 Compression gauge To measure compression

09213-58013 Crankshaft pulley To secure crankshaft pulley

09223-78010 Crankshaft oil seal To install crankshaft front oil seal

09308-10010 Oil seal puller To remove crankshaft front oil seal

09330-00021 Companion flange To secure crankshaft pulley

09032-00100 Oil pan seal cutter To remove oil pan

09201-10000 Valve guide bush re-

09202-70020 Valve spring compressor To remove and install valve

09214-76011 Crankshaft pulley To install injection pump drive gear oil

Remover & replacer To remove and install connecting rod

Guide To install connecting rod bush

Base To remove and install connecting rod

Cover & seal replacer To mount crankshaft timing gear and

09950-40011 Puller B set

• 09951-04010 Hanger 150 To remove camshaft timing pulley,

• 09955-04061 Claw No. 6 To remove camshaft timing pulley,

• 09951-05010 Hanger 150 To remove crankshaft pulley and injec-

• 09952-05010 Slide arm To remove crankshaft pulley and injec-

• 09953-05010 Center bolt 100 To remove injection pump drive gear

• 09953-05020 Center bolt 150 To remove crankshaft pulley

• 09954-05021 Claw No.2 To remove crankshaft pulley and injec-

*TCP-2TB Turbocharger pressure To check for leakage from nozzle leak-

09820-63010 Alternator wrench To remove and install alternator pul-

09286-46011 Alternator bearing puller To remove alternator rectifier end fram

09820-00021 Alternator bearing puller To remove alternator rotor bearing

09215-00100 Camshaft bearing To remove and install camshaft bear-

m : meter ft or ’ : foot The following abbreviations and symbols are

B : Black P : Pink Wiring diagrams use the following standard

GENERAL SPECIFICATIONS .................................................................................................. 2-1

MAINTENANCE SPECIFICATIONS ........................................................................................ 2-4

TIGHTENING TORQUE ........................................................................................................... 2-9

TORQUE SPECIFICATIONS .................................................................................................. 2-12

Power New mm 19 – 20 (per belt)

Tightening torque Reference

Joints and Gaskets for Engine Piping

Metal seal type