Mahula de Peças

ME432STI
E ENGINE
SERVICE MANUAL
070029
N64-28197-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.
ME432STI
ENGINE SERVICE MANUAL
© 2006 Yamaha Motor Co., Ltd.
1st Edition, July, 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.
INPORTANT 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 marine
vehicle operator, a bystander, or a person checking or repairing the Stern Drive.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to the Sterm
Drive.
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
TIMING BELT AND TIMING PULLEYS E ENG
OVER
CYLINDER BLOCK E
Timing Belt and Timing Pulley Installa- Connecting Rod and Piston Pin Check
tion 1. Check:
1. Install: ¡ Connecting rod and rod cap
¡ Timing belt and timing pulley ¡ Connecting rod bearing
¡ Connecting rod twisting
2 Timing belt and timing pulley installation
steps
¡ Piston pin and connecting rod bush-
ing
1) Install the set key on the camshaft. ¡ Piston pin to bushing clearance
2) Install the plate washer and the camshaft
timing pulley #1. Connecting rod and rod cap checking step
6
3) Install the camshaft timing pulley #1 bolt. 1) Check the connecting rod 1 and rod cap
2 for cracks, bending and/or damage.
NOTE:
3 Align the set key with the key groove on the
timing pulley.
1 Cracks/Bending/Damage → Replace the
connecting rod assembly.
4) Tighten the camshaft timing pulley #1

2
2 bolt.
7
1
NOTE:
Hold the camshaft 1 with a wrench 2 when
tightening the timing pulley bolt. Connecting rod bending checking step
Bolt (timing pulley #1):

1) Check the connecting rod bending A by
use of the rod aligner.
8
98 N·m (10.0 kgf·m, 72.3 lbf·ft) a Out of specification → Replace the con-
T.R
necting rod assembly.

5) Remove fraction of old gasket remain-
4 ing on the cylinder head and the cylin-
der head cover.
Connecting rod bending:
<Limit> 5
6) Clean the sealing surfaces of the cylin- 0.03 mm (0.001 in.) per 100 mm (3.937 in.)
der head and the cylinder head cover
with a non-residual solvent.
7) Apply ThreeBond® TB-1207B to the cyl-
Connecting rod twisting checking step
inder head sealing surface.
TB
TB a
1) Check the connecting rod twisting A by
1207B NOTE: use of the rod aligner.
1207B
The cylinder head cover must be installed
within 5 minutes of sealant application. If Out of specification → Replace connect-
more than 5 minutes have passed, the sealing rod assembly.
ant must be removed and reapplied.
Connecting rod twisting:
<Limit>
0.15 mm (0.006 in.) per 100 mm (3.937 in.)
6-66 6-154
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
SHTG 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 ................................................................................................. 1-9
HANDLING OF LIQUID GASKET.......................................................................................... 1-10

Sealant Application Points and Types of Sealant to Be Applied ................................. 1-10
STANDARD ABBREVIATIONS AND SYMBOLS ................................................................. 1-11

Measurement ................................................................................................................... 1-11
Color Codes ...................................................................................................................... 1-11
GEN ENGINE IDENTIFICATION E
INFO
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 located

on the header tank.
The different models can be identified by
A checking the model and serial number plate
and using the following table.
MODEL PREFIX VARIATION SERIAL NO.

A B C D
B C D N641 SP ******
ME432STI P1
N642 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
*TDG-13 Compression gauge To measure compression

(from BANZAI) attachment
*NO.44
(from IYASAKA)
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
09316-20011 Transfer bearing replacer To install injection pump 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
• 09201-01070 Valve guide bush remover To remove and install valve guide bush
& replacer 7
• 09201-01080 Valve guide bush remover To remove and install valve guide bush
& replacer 8
1-5
GEN SPECIAL TOOLS E
INFO
09202-70020 Valve spring compressor To remove and install valve
09214-76011 Crankshaft pulley To install injection pump drive gear oil

replacer seal
09222-17011 Connecting rod bush

remover & replacer
• 09222-05021 Remover & replacer To remove and install connecting rod

bush
• 09222-05031 Guide To install connecting rod bush
• 09222-05041 Base To remove and install connecting rod

bush
09223-00010 Cover & seal replacer To mount crankshaft timing gear and
pump drive shaft gear
09950-60010 Replacer set
• 09951-00190 Replacer 19 To remove oil pump drive shaft gear
• 09951-00340 Replacer 34 To install oil pump drive shaft gear
• 09951-00320 Replacer 32 To mount camshaft oil seal
• 09951-00500 Replacer 50 To mount camshaft oil seal
• 09951-00640 Replacer 64 To injection pump drive gear oil seal
• 09952-06010 Adapter To mount camshaft oil seal
1-6
GEN SPECIAL TOOLS E
INFO
09950-70010 Handle set
• 09951-07150 Handle 150 To install the camshaft oil seal
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
1-7
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
*PSG-6TB Power steering fluid To check power steering fluid pressure

(from BANZAI) pressure gauge set
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
1-8
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
1-9
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.
Timing belt cover x Timing belt cover gasket 6-70
Semi-circular plug joint area x Cylinder head cover gasket 6-66
Timing gear cover x Timing gear case (oil pump) 6-87
Cylinder head x Semi-circular plug 6-112
Camshaft oil seal retainer x Cylinder head 6-75
Camshaft oil seal retainer joint area x Cylinder head cover gasket 6-66
®
Camshaft oil seal retainer joint area x Timing gear cover ThreeBond TB-1207B 2 hours 6-70
Main bearing cap (rudder frame) x Cylinder block 6-172
Rear oil seal retainer x Cylinder block 6-176
Heat exchanger x Gasket 6-21
Heat exchanger side plates x Gasket 6-21
Inter cooler rear side x Gasket 6-30
Oil pan x Main bearing cap (rudder frame) 6-130
Cylinder head x Tight plug –
Cylinder head x Water by-pass pipe #3 –
Cylinder block x Tight plug –
ThreeBond® TB-1324 1 hour
Oil cooler cover x Drain cock –
Timing gear case (oil pump) x Tapered screw plug 6-129
Main bearing cap (radder frame) x Oil return pipe –
®
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
Heat exchanger x Bolt threads 6-21
Inter cooler x Seawater sensor threads 6-29
®
Inter cooler x Elbow joint threads LOCTITE No. 572 6 hour 6-29
Intake manifold x Joint plug threads 6-51
Power steering pump x Bolt threads 7-8
Heat exchanger x Anodes 3-37
Inter cooler x Anodes 3-37
Mixing elbow x Plug 6-57
®
Mixing elbow x Joint plug LOCTITE No. 243 1 hour 6-57
Cylinder block x Oil pressure switch joint 6-177
Exhaust manifold x Thremo switch 6-58
Exhaust manifold x Coolant temperature sensor 6-58
1-10
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
1-11
SPEC E
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS .................................................................................................. 2-1
MAINTENANCE SPECIFICATIONS ........................................................................................ 2-3
2
Engine ................................................................................................................................. 2-3
Fuel System ........................................................................................................................ 2-8
Injection Pump ................................................................................................................... 2-9
Cooling System .................................................................................................................. 2-9
Turbocharger System ........................................................................................................ 2-9
Electrical System ............................................................................................................. 2-10
TIGHTENING TORQUE ......................................................................................................... 2-11

Engine ............................................................................................................................... 2-11
Joints and Gaskets for Engine Piping ............................................................................ 2-14
TORQUE SPECIFICATIONS .................................................................................................. 2-15

Tightening Torque Specifications for Standard Bolts and Nuts ................................... 2-16
Pre-coated Bolts (With Seal-locking Agent Applied on the Threads) .......................... 2-17
Plastic Region Tightening ................................................................................................ 2-18
SPEC GENERAL SPECIFICATIONS E
GENERAL SPECIFICATIONS
ME432STI
MODEL
ITEMS P1
UNIT
(N641, N642)
GENERAL:
Base engine TOYOTA 1HD-FT
Engine type Vertical, 4-stroke, inline
Number of cylinders 6
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. 235 (315)/3600
Max. output at flywheel end *2 kW (HP) r/min. 220 (295)/3600
Max. output at propeller end *1 kW (HP) r/min. 225 (301)/3600
Max. output at propeller end *2 kW (HP) r/min. 210 (282)/3600
Bore mm 94
Stroke mm 100
Total displacement L 4160
Compression ratio 15.7
Compression pressure (standard) MPa/r/min. 2.7 ± 0.3/280
Compression pressure (maintenance limit) MPa/r/min. 1.96/280
Injection order 1–4–2–6–3–5
Max. no-load speed r/min. 4100 – 4200
Propeller matching speed r/min. 3670 – 3770
Engine idling speed r/min. 650 – 700
Engine dry weight kg 460
VALVE SYSTEM:
Driving mechanism OHC
Valve clearance IN mm 0.2 ± 0.03
(cold engine) EX mm 0.5 ± 0.03
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 21
Plunger stroke
mm (in.) 1.88 (0.074)
(with dial gauge)
Injector Type Multiport (long stem type)
Number of injection port 6
Valve opening 17.7 + 0.98
MPa
pressure: 1st stage – 0
Valve opening 22.6 + 0.98
MPa
pressure: 2nd stage – 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. 9.9, Min. 8.2
Oil pressure at idle *3 kPa Min. 98
at 3600 r/min. *4 kPa Min. 343
Oil pump type Trochoid pump (5 lobes (inner rotor),
6 divisions (outer rotor))
Oil cooler Fresh water multiplate type
Lubrication system Full flow type
Oil filter Full-flow, spin-on type
2-1
SPEC GENERAL SPECIFICATIONS E
ME432STI
MODEL
ITEMS P1
UNIT
(N641, N642)
COOLING SYSTEM:
Cooling mechanism Indirect fresh water cooling type
Coolant capacity L 13.0
Heat exchanger Seawater cooling multipipe type
Seawater pump Rubber impeller type
Seawater pump max. discharge L/min. 130 ± 10
Coolant pump Centrifugal pump
Coolant cap opening pressure kPa 88
Coolant temperature (at max. output) °C 85 ± 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 176 ± 10
Intercooler Seawater cooling multipipe type
Air filter Air-purifying type
Exhaust back pressure (at max. output) kPa 45 ± 5
ELECTRICAL SYSTEM:
System voltage V 12
Recommended battery capacity AH 140 Min.
Starter motor output kW 2.5
Alternator output A 80
Pre-heating system Intake airheater
Pre-heating lamp turn-out time sec 10 ± 0.3
Oil pressure switch operating pressure kPa 29.4 ± 9.8
Water temperature switch
°C 100 ± 2
operating temperature
Fuse Load on gauges A 20
Main A 100
Intake airheater control A 10
OTHERS:
Power steering fluid Automatic Transmission Fluid (ATF) Dexron Type II
Power steering fluid capacity L 0.8
Belt deflection Alternator
New mm 10 – 12 (per belt)
(with pressure
of 98 N (10 kg))*6
At service mm 12 – 14 (per belt)
NOTE:
*1: Output power at 25 °C fuel temperature:
ISO 3046-1. Checking point Circulation pump
*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. Alternator
*5: At seawater inlet temperature 28 °C.
*6: See the figure on the right for belt deflec-
Crank pully
tion checking point.
2-2
SPEC MAINTENANCE SPECIFICATIONS E
MAINTENANCE SPECIFICATIONS
Engine
Model
Item Unit
ME432STI P1
Cylinder head:
mm (in.)
Warpage Limit 0.20 (0.0079)
New Cylinder head gasket thickness
Numbers of cutout “1” 0.85 – 0.95 (0.0335 – 0.0374)
mm (in.)
“3” 0.95 – 1.05 (0.0374 – 0.0413)
“5” 1.05 – 1.15 (0.0413 – 0.0453)
Cylinder:
Cylinder head matching face warpage
Limit 0.20 (0.008)
Cylinder bore diameter
STD Mark “1” 94.000 – 94.010 (3.70079 – 3.70118)
Mark “2” 94.011 – 94.020 (3.70122 – 3.70157)
Mark “3” 94.021 – 94.030 (3.70161 – 3.70197)
Limit 94.23 (3.70984)
Main journal bore diameter
STD Mark “A” 71.0000 – 71.0009 (2.79528 – 2.79531)
Mark “B” 71.0010 – 71.0019 (2.79531 – 2.79535)
Mark “C” 71.0020 – 71.0029 (2.79535 – 2.79539)
Mark “D” 71.0030 – 71.0039 (2.79539 – 2.79543)
Mark “E” mm (in.) 71.0040 – 71.0049 (2.79543 – 2.79547)
Mark “H” 71.0050 – 71.0059 (2.79547 – 2.79551)
Mark “4” 71.0060 – 71.0069 (2.79551 – 2.79555)
Mark “5” 71.0070 – 71.0079 (2.79555 – 2.79559)
Mark “6” 71.0080 – 71.0089 (2.79559 – 2.79563)
Mark “7” 71.0090 – 71.0099 (2.79563 – 2.79567)
Mark “8” 71.0100 – 71.0109 (2.79567 – 2.79570)
Mark “9” 71.0110 – 71.0119 (2.79571 – 2.79574)
Mark “L” 71.0120 – 71.0129 (2.79575 – 2.79578)
Mark “M” 71.0130 – 71.0139 (2.79579 – 2.79582)
Mark “R” 71.0140 – 71.0149 (2.79583 – 2.79586)
Mark “S” 71.0150 – 71.0159 (2.79587 – 2.79590)
Mark “U” 71.0160 – 71.0169 (2.79591 – 2.79594)
Mark “X” 71.0170 – 71.0180 (2.79594 – 2.79598)
2-3
Model
Item Unit
ME432STI P1
Piston/Piston ring:
Piston diameter
STD Mark “1” 93.845 – 93.846 (3.69469 – 3.69472)
Mark “2” 93.855 – 93.856 (3.69508 – 3.69512)
Mark “3” 93.865 – 93.866 (3.69547 – 3.69551)
Piston to cylinder clearance STD 0.07 – 0.09 (0.0027 – 0.0035)
Limit 0.135 (0.0053)
Piston ring groove clearance
STD Top 0.070 – 0.110 (0.00276 – 0.00433)
mm (in.)
2nd 0.040 – 0.080 (0.00157 – 0.00315)
Oil 0.030 – 0.070 (0.00118 – 0.00276)
Piston ring end gap
STD Top 0.27 – 0.39 (0.1063 – 0.015)
2nd 0.40 – 0.55 (0.0158 – 0.0217)
Oil 0.20 – 0.40 (0.0079 – 0.0158)
Limit Top 0.85 (0.0335)
2nd 0.90 (0.0354)
Oil 0.88 (0.0356)
Camshaft:
Thrust clearance STD 0.10 – 0.20 (0.0039 – 0.0078)
Limit 0.30 (0.012)
Journal oil clearance
#1 journal STD 0.022 – 0.074 (0.00087 – 0.00291)
Limit 0.10 (0.00394)
Others STD 0.023 – 0.075 (0.00091 – 0.00295)
Limit 0.10 (0.0039)
Journal diameter mm (in.)
#1 Journal STD 34.969 – 34.985 (1.37673 – 1.37736)
Others STD 27.986 – 27.998 (1.10181 – 1.10228)
Runout Limit 0.10 (0.0039)
Cam lobe height
STD Intake 48.203 – 48.303 (1.89776 – 1.90169)
Exhaust 50.739 – 50.834 (1.99760 – 2.00134)
Limit Intake 47.703 (1.87807)
Exhaust 50.234 (1.97772)
2-4
Model
Item Unit
ME432STI P1
Connecting rod:
Limit 0.30 (0.0118)
Connecting rod oil clearance
STD 0.024 – 0.040 (0.0009 – 0.0016)
Limit 0.10 (0.0039)
Connecting rod big end bore diameter
STD Mark “1” 62.014 – 62.020 (2.44150 – 2.44173)
Mark “2” 62.021 – 62.026 (2.44177 – 2.44197)
Mark “3” 62.027 – 62.032 (2.44201 – 2.44220)
Connecting rod bearing center wall thickness
STD Mark “2” 1.486 – 1.489 (0.05850 – 0.05862)
Mark “3” 1.490 – 1.492 (0.05866 – 0.05874)
mm (in.)
Mark “4” 1.493 – 1.495 (0.05878 – 0.05886)
Mark “5” 1.496 – 1.498 (0.05890 – 0.05898)
Mark “6” 1.499 – 1.501 (0.05902 – 0.05909)
Rod bending
Limit per 100 mm (3.94 in.) 0.03 (0.0012)
Rod twist
Limit per 100 mm (3.94 in.) 0.15 (0.006)
Connecting rod bolt outer diameter
STD 8.300 – 8.400 (0.32677 – 0.33071)
Limit 7.95 (0.3130)
Piston pin bushing inside diameter 33.006 – 33.018 (1.29945 – 1.2992)
Piston pin diameter 33.000 – 33.012 (1.29921 – 1.29969)
Piston pin oil clearance STD 0.002 – 0.006 (0.00008 – 0.00024)
Limit 0.03 (0.0012)
2-5
Model
Item Unit
ME432STI P1
Crankshaft:
Limit 0.30 (0.012)
Thrust washer thickness STD 2.930 – 2.980 (0.11535 – 0.11732)
Main journal oil clearance
STD 0.030 – 0.042 (0.00118 – 0.00165)
Limit 0.10 (0.0039)
Main journal diameter
STD Mark “A” 66.9990 – 67.0000 (2.63776 – 2.63780)
Mark “B” 66.9980 – 66.9989 (2.63772 – 2.63775)
Mark “C” 66.9970 – 66.9979 (2.63768 – 2.63771)
Mark “D” 66.9960 – 66.9969 (2.63764 – 2.63767)
Mark “E” 66.9950 – 66.9959 (2.63760 – 2.63763)
Mark “H” 66.9940 – 66.9949 (2.63756 – 2.63760)
Mark “4” 66.9930 – 66.9939 (2.63752 – 2.63756)
Mark “5” 66.9920 – 66.9929 (2.63748 – 2.63752)
Mark “6” 66.9910 – 66.9919 (2.63744 – 2.63748)
Mark “7” 66.9900 – 66.9909 (2.63740 – 2.63744)
Mark “8” 66.9890 – 66.9899 (2.63736 – 2.63740)
Mark “9” mm (in.) 66.9880 – 66.9889 (2.63732 – 2.63736)
Mark “L” 66.9870 – 66.9879 (2.63728 – 2.63732)
Mark “M” 66.9860 – 66.9869 (2.63724 – 2.63728)
Mark “R” 66.9850 – 66.9859 (2.63720 – 2.63724)
Mark “S” 66.9840 – 66.9849 (2.63717 – 2.63720)
Mark “U” 66.9830 – 66.9839 (2.63713 – 2.63716)
Mark “X” 66.9820 – 66.9829 (2.63709 – 2.63712)
Crank pin oil clearance STD 0.009 – 0.024 (0.00035 – 0.00094)
Limit 0.10 (0.0039)
Crank pin diameter
STD Mark “1” 58.995 – 59.000 (2.32264 – 2.32283)
Mark “2” 58.989 – 58.994 (2.32240 – 2.32260)
Mark “3” 58.982 – 58.998 (2.32213 – 2.32276)
Circle runout Limit 0.06 (0.00236)
Main journal taper and out-of-round Limit 0.02 (0.00079)
Crank pin taper and out-of-round Limit 0.02 (0.00079)

Main bearing:
Main bearing cap bolt outer diameter
mm (in.)
STD 11.800 – 12.000 (0.46457 – 0.47244)
Limit 11.50 (0.45276)
2-6
Model
Item Unit
ME432STI P1
Valve, valve seat, valve guide:
Valve clearance (cold) Intake mm (in.) 0.17 – 0.23 (0.0067 – 0.0091)
Exhaust 0.47 – 0.53 (0.0185 – 0.0209)
Valve overall length
STD Intake 126.85 – 127.45 (4.9941 – 5.0177)
Exhaust 126.83 – 127.43 (4.9933 – 5.0169)
Valve face angle °(deg.) 44.5
Stem diameter Intake mm (in.) 6.970 – 6.985 (0.27441 – 0.2750)
Exhaust 6.960 – 6.975 (0.27402 – 0.27461)
Stem oil clearance
STD Intake 0.025 – 0.060 (0.00098 – 0.00236)
Exhaust 0.035 – 0.070 (0.00138 – 0.00276)
Margin thickness
STD Intake 1.65 (0.0650)
Exhaust 1.4 (0.055)
Limit Intake 1.1 (0.043)
Exhaust 1.2 (0.047)
Valve guide bushing
Inner diameter 7.001 – 7.003 (0.27563 – 0.27571)
Outer diameter 11.54 – 11.551 (0.4543 – 0.45476)
Projection height 17.5 – 17.9 (0.6890 – 0.7047)
Valve seat
Refacing angle Intake °(deg.) 30, 45, 60
Exhaust 30, 45, 60
Contacting angle °(deg.) 45
Contacting width Intake mm (in.) 1.4 – 1.8 (0.055 – 0.071)
Exhaust 1.6 – 2.0 (0.063 – 0.079)
Valve spring:
Free length mm (in.) 49.6 (1.953)
Installed tension at 37.0 mm (1.457 in.) kgf (lbf) 30.7 – 33.9 (67.7 – 74.7)
Spring tilt Limit mm (in.) 2.0 (0.079)
2-7
Model
Item Unit
ME432STI P1
Timing gear:
Idler gear inner diameter mm (in.) 45.000 – 45.025 (1.77165 – 1.77264)
Idler gear shaft diameter mm (in.) 44.942 – 44.975 (1.76937 – 1.77067)
Idler gear oil clearance STD mm (in.) 0.025 – 0.083 (0.00098 – 0.00327)
Limit 0.20 (0.0079)
Gear backlash STD mm (in.) 0.05 – 0.15 (0.0020 – 0.0059)
Limit 0.30 (0.0118)
Idler gear thrust clearance STD mm (in.) 0.02 – 0.10 (0.0008 – 0.0039)
Limit 0.30 (0.0118)
Idler pulley tension spring:
Free length mm (in.) 72.7 (2.862)
Installed spring load at 90.1 mm (3.55 in.) kgf (lbf) 23 – 28 (50.7 – 61.7)
Oil pump:
Body clearance STD mm (in.) 0.10 – 0.17 (0.0039 – 0.0067)
Limit 0.20 (0.0079)
Side clearance STD mm (in.) 0.03 – 0.09 (0.0012 – 0.0035)
Limit 0.15 (0.0059)
Tip clearance STD mm (in.) 0.08 – 0.16 (0.0032 – 0.0063)
Limit 0.21 (0.0083)
Fuel System
Model
Item Unit
ME432STI P1
Injection nozzle:
Nozzle type KBAL
Pre-lift size mm (in.) 0.095 – 0.096 (0.00374 – 0.00378)
Nozzle opening pressure
#1 opening pressure kgf/cm2 (kPa) 180 – 190 (1.8 – 1.9)
#2 opening pressure 230 – 240 (2.3 – 2.4)
Injection pump:
Direction of rotation Clockwise (viewed from the driven gear)
Injection sequence 1–4–2–6–3–5 (D–E–F–A–B–C)
2-8
Injection Pump
Injection pump type Bosch type, VE type (distribution type)
Yamaha part number YU2-21001-C4-40
Toyota part number 22100-1C440
Denso part number 196000-4631
Pump Specifications
Plunger diameter φ12 mm (0.47 in.)
Spill port 2–A A = 4.0
Cam profile ND0385 B
configuration B = 0.15
Cam lift 3.1 mm (0.12 in.)
Static oil delivery rate 21.3 mm3/1 ° (pump cam angle) Injection sequence A–B–C–D–E–F
Delivery valve CPV (valve opening pressure 8 MPa) Rotating direction Clockwise (viewed from driving side)
* Contact Denso Service Shop or Yamaha head office for injection pump adjustment data
sheet.
Cooling System
Model
Item Unit
ME432STI P1
Coolant filler cap:
Opening pressure STD kPa (kg/cm2) 74 – 103 (0.74 – 1.03)
2
Limit kPa (kg/cm ) 60 (0.6)
Thermostat:
Valve opening temperature °C (°F) 74.5 – 78.5 (166.1 – 173.3)
Max valve lift (at 90 °C (194 °F)) mm (in.) 10 (0.39) or more
Turbocharger System
Model
Item Unit
ME432STI P1
Turbocharger:
Turbocharging pressure at Max. output kPa 173 – 193
2
(kg/cm ,psi) (1.76 – 1.96, 25 – 28)
Impeller wheel axial play STD 0.05 – 0.125 (0.00197 – 0.00492)
Limit mm (in.) 0.155 (0.0061)
Impeller wheel radial play STD 0.075 – 0.125 (0.00295 – 0.00492)
Limit mm (in.) 0.165 (0.0065)
2-9
Electrical System
Model
Item Unit
ME432STI P1
Pre-heating system:
Light-up timing Second 10 ± 0.3
Starter motor:
Voltage and output power V, kW 12, 2.5
No-load characteristics:
Current (at 11.0 V) A 180 Amps or less
Revolution r/min. 3500 or less
Commutator outer diameter
STD mm (in.) 36.0 (1.417)
Limit 35.0 (1.378)
Undercut depth:
STD mm (in.) 0.7 – 0.9 (0.028 – 0.035)
Limit 0.2 (0.079)
Runout Limit mm (in.) 0.05 (0.0020)
Brush length STD mm (in.) 20.5 – 21.0 (0.807 – 0.826)
Limit 13.0 (0.512)
Spring installed load kgf (lbf) 3.2 – 4.0 (7.1 – 8.8)
Alternator:
Rotor coil resistance (at 20 °C (68 °F) Ω 2.7 – 3.1
Slip ring diameter: STD 14.2 – 14.4 (0.559 – 0.567)
Limit mm (in.) 12.8 (0.504)
Exposed brush length: STD 10.5 (0.413)
Limit 1.5 (0.059)
Alternator regulator:
Regulating voltage
(at 25 °C (77 °F)) V 14.0 – 15.0
(at 115 °C (239 °F)) 13.5 – 14.3
2-10
SPEC TIGHTENING TORQUE E
TIGHTENING TORQUE
Engine
Tightening torque Reference
Part to be tightened Remarks
N·m kgf·m lbf·ft Page No.
2-stage rate coupling and flywheel:
Damper joint nut 5.6 0.57 4.13 LT 271 6-6
Coupling - Outer member 67 6.8 49.4 6-6
Flywheel - Crankshaft 127 13.0 93.7 6-7
Flywheel - Coupling assembly 29 3.0 21.4 6-7
Rear-end plate 18 1.8 13.3 6-7
Timing pulleys:
Timing pulley #1 - Camshaft 98 10.0 72.3 6-66
Timing pulley #2 - Pump drive gear 31 3.2 22.8 6-67
Auto tensioner 13 1.3 9.6 6-69
Idler pulley 34.5 3.52 25.46 6-67
Timing gears:
Pulley drive gear - Injection pump 98 10.0 72.3 6-86
Idler gear thrust plate 68 6.9 50.2 6-86
Timing gear cover 19.6 2.0 14.46 6-87
Crankshaft pulley 430 43.9 317.3 6-88
Cylinder head:
3-19,5-7
Cylinder head cover 6.4 0.65 4.72
6-67
Camshaft bearing cap 25 2.6 18.5 6-106, 6-117

Valve bridge adjustable nut 19 1.9 14.0 3-20
Rocker arm adjustable nut 19 1.9 14.0 3-20
Cylinder head 70 N·m (7.1 kgf·m, 51.6 lbf·ft) + 6-115
Plastic region tightening (90 ° + 90 °)
Camshaft oil seal retainer 19.6 2.0 14.46 6-75, 6-108
Exhaust manifold (bolt) 39 4.0 28.8 6-58
(nut) 32 3.3 23.6 6-58
Cylinder block:
Check valve 26 2.7 19.2 6-178
Main bearing cap (M12 bolt) 105 N·m (10.7 kgf·m, 77.4 lbf·ft) + 6-160, 6-172
Plastic region tightening (90 °)
(M8 bolt) 18.1 1.85 13.36 6-173
Connecting rod cap 37.5 N·m (3.83 kgf·m, 27.68 lbf·ft) + 6-163, 6-175
Plastic region tightening (90 °)
Oil seal retainer 6.4 0.65 4.72 6-176
Heat exchanger bracket - Cylinder 117 11.9 86.3 6-176
Control Unit bracket - Exhaust manifold 58.5 5.97 43.17 6-59
Engine bracket - Cylinder 117 11.9 86.3 6-177
Bracket tension rod - Engine bracket 64 6.5 47.2 6-178
Rod tension - Bracket tension rod 211 21.5 155.6 6-179
Rubber mount adjustable nut 207 21.1 152.8 4-11
2-11

Lubrication System:
Relief valve plug 41 4.2 30.3 6-127
Timing gear case 19.6 2.0 14.46 6-128
Oil strainer 8.8 0.9 6.49 6-130
Oil pan 15.7 1.6 11.6 6-130
Turbo oil pipe - Cylinder block 24.5 2.5 18.1 –
Dipstick tube 34.3 3.5 25.31 6-131, 6-137
Oil cooler cover 19.6 2.0 14.46 LT 572 6-136
Oil cooler cover - Check valve 26 2.7 19.2 6-135
Oil cooler cover - Relief valve 39 4.0 28.8 6-136
Oil cooler cover - Oil cooler 15.7 1.6 11.59 6-136
Fuel System:
Injector body - Nozzle retaining nut 34 3.5 25.1 –
Capsule sub-assembly - Plug screw 2.5 0.26 1.85 –
Injection nozzle clamp holder 25 2.6 18.5 5-6
Leakage pipe hollow bolt 18 1.8 13.3 5-6, 5-7
Injection pipe fitting nut 19 1.9 14.0 –
Injection pipe mounting flare nut 24.5 2.5 18.07 5-8, 5-19
Injection pipe clamp 6.4 0.65 4.72 5-8
Pickup (tacho) sensor 21 2.1 15.5 5-16
Fuel cut solenoid 22 2.2 16.2 5-15
Fuel cut solenoid lead 1.7 0.17 1.25 5-15
Injection pump - Gear case 18 1.8 13.3 5-17, 6-129
Injection pump - Pump stay 69 7.0 50.9 5-18
Injection pump - Pump drive gear 98 10.0 72.3 5-18
Fuel delivery pipe hollow bolt 29 3.0 21.4 5-19
Cooling System:
Circulation pump - Cylinder 19.6 2.0 14.46 6-74
Circulation pump pulley 19.6 2.0 14.46 6-75
Water temperature switch 34 3.5 25.1 LT 572 6-58
Water temperature sensor 11 1.1 8.1 LT 572 6-58
Seawater pump driven gear 110 11.2 81.2 6-16
Seawater pump cover 2 0.2 1.5 6-16, 6-17
LT 572
Heat exchanger drain cock 20 2.0 14.8 3-40
Cooling pipe joint 20 2.0 14.8 LT 572 6-118
Heat exchanger side plate 12 1.2 8.9 6-21
Turbocharger System:
Turbocharger:
Oil pipe #1 hollow bolt 11 1.1 8.1 6-49
Fresh water bypass pipe hollow bolt 20 2.0 14.8 6-49
Intake manifold - Screw plug 10 1.0 7.4 6-51
Intercooler:
Seawater flow sensor 64 6.5 47.2 LT 572 6-29
Side cover 10 1.0 7.4 6-30
2-12

Electrical System:
Starter motor terminal 21 2.1 15.5 8-21
Alternator wrench “B” 40 4.1 29.5 8-30, 8-38
Alternator wrench “A” (drive pulley) 110 11.2 81.2 8-38
Alternator terminal 8 0.8 5.9 8-41
Other Items:
Power steering hose (small fitting) 15 1.5 11.0 –
Power steering hose (large fitting) 34 3.5 25.1 –
Power steering pump - Cylinder block 44 4.9 32.5 LT 572 7-8
Drive gear - Power steering pump 100 10.2 73.8 –
2-13
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.
2-14
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 tolls 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.
2-15
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 7T
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. Identification by the part number
Hexagon bolt Stud bolt
Part # example: 9 1 1 1 1 - 4 0 6 2 0 Part # example: 9 2 1 3 2 - 4 0 6 2 0
Nominal Length Nominal Bolt

diameter underhead diameter length
(mm) (mm)
Length Bolt length
underhead Nominal Nominal
diameter diameter
(mm) (mm)
Class of strength Class of strength
2-16
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 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.
2-17
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

90° additional tightening
Cylinder head bolts
Tighten by 90°
Connecting rod bearing cap bolts
Others
Engine
front
2. Additional tightening procedures after

90° + 90° tightening
reaching the specified torque
Tighten by 90°
Tighten by 90° (2nd) One is to give additional tightening by
(1st) 90°, and the other is by 180° (90° + 90°
tightening)
2-18
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-belts Check .................................................................................................... 3-1
Engine External Condition Check ..................................................................................... 3-2
Engine Oil Level Check ...................................................................................................... 3-2
Battery and Electrical Connections Check ....................................................................... 3-3
Engine Wiring Check ......................................................................................................... 3-3
RUNNING-IN ........................................................................................................................... 3-4

Points to Note for New Engine ......................................................................................... 3-4
Running-in Period .............................................................................................................. 3-4
INTRODUCTION...................................................................................................................... 3-5
Periodic Maintenance and Lubrication Interval Chart .................................................... 3-5
PERIODIC CHECKS AND ADJUSTMENTS .......................................................................... 3-11

Engine Oil Level Check .................................................................................................... 3-11
Engine Oil and Filter Replacement ................................................................................. 3-13
Oil Separator and Blow-by Gas Hose Check ................................................................. 3-16
Oil Separator and Blow-by Gas Hose Cleaning ............................................................ 3-16
Air Filter Check ................................................................................................................. 3-17
Valve Clearance Check..................................................................................................... 3-18
Valve Clearance Adjustment ........................................................................................... 3-19
Engine Idle Speed and Maximum Engine Speed (No Load) Check............................. 3-21
Throttle Cable Adjustment .............................................................................................. 3-22
Compression Pressure Measurement ............................................................................ 3-23
Drive Belts Check ............................................................................................................. 3-25
Drive Belts Replacement ................................................................................................. 3-25
Timing Belt Check ............................................................................................................ 3-26
Engine Cleaning and Protection ..................................................................................... 3-28
Fuel System Check .......................................................................................................... 3-28
Fuel Line Check ................................................................................................................ 3-28
Injection Timing Check .................................................................................................... 3-29
Injection Timing Adjustment........................................................................................... 3-31
Fuel Filter Draining (Water) ............................................................................................. 3-33
CHK E
ADJ
Fuel Filter Replacement ................................................................................................... 3-33
Fuel System Air Bleeding ................................................................................................ 3-36
Seawater Strainer Cleaning ............................................................................................ 3-37
Anode Check .................................................................................................................... 3-37
Coolant Level Check ........................................................................................................ 3-38
Coolant Replacement ...................................................................................................... 3-40
Thermostat Check ............................................................................................................ 3-41
Coolant Filler Cap Check ................................................................................................. 3-42
Cooling Hose Check ......................................................................................................... 3-43
Cooling System Pressurize Check .................................................................................. 3-43
Seawater Pump Impeller Replacement ......................................................................... 3-44
Power Steering Fluid Level Check .................................................................................. 3-46
3
Battery Check ................................................................................................................... 3-48
Fuse Check ....................................................................................................................... 3-50
Fuse Replacement ........................................................................................................... 3-50
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.
Alternator V-belts Check

1. Check:
¡ Belt tension
Alternator V-belts checking step

1) To measure the belt deflection, apply ap-
proximately 10 kgf pressing force at the
mid position on the belt using the spe-
cial tool.
Out of specification → Adjust/Replace.
Drive belts deflection under:

98 N (10 kgf, 22 lbf)
Alternator V-belts:
12 – 14 mm (0.47 – 0.55 in.)
[New belt: 10 – 12 mm (0.39 – 0.47 in.)]
3-1
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
the upper limit mark A on the oil level
gauge 1.
Oil level low → Fill to the proper level.
a 1
3-2
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.
Fluid level low → Fill to the proper 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 → Retightening.
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/Retight.
3-3
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) Idle the engine for 5 minutes or more be-
fore 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 every
100 hours and the engine 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.
3-4
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 proper activation. ¡ ¡ ¡ ¡
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 of seawater
™ or ¡
pump.
Cooling system Check coolant water level. ¡ ¡ ¡ ¡
Replace coolant. ™ or ¡
Pressure in freshwater Check the pressure.
™ or ¡
cooling system
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.
3-5
CHK INTRODUCTION E
ADJ
Before After first
Every 100 At least
starting 20 hours
engine or 2
months year
each day months
ELECTRICAL SYSTEM
Function of gauges and Check proper function.
¡ ¡ ¡ ¡
switches
Warning lamp Check proper activation. ¡ ¡ ¡ ¡
Drive belts (All) Check for cracks, weathering
and damage. Check drive
¡ ¡ ¡ ¡
belts for deflection. Adjust if
necessary.
Function of pre-heating Check proper function.
™ ™ ™
device
Battery Check electrolyte level. Add
¡ ¡ ¡ ¡
electrolyte if necessary.
Check specific gravity. Change
™ ™
or replace if necessary.
Electrical system Check connections and
insulation. Tighten or replace ¡ ™ or ¡ ™ or ¡ ™ or ¡
if necessary.
ENGINE BODY
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 bracket area Bolt retightening ¡ ™ or ¡ ™ or ¡ ™ or ¡
Rubber mount Check the rubber mount
¡ ™ or ¡ ™ or ¡ ™ or ¡
condition, and bolt retightening.
Crank pulley, damper Bolt retightening. ™ ™ ™
Air filter Cleaning air filter. ™ or ¡ ™ or ¡
Replace air filter. ™ or ¡
Engine alignment Check at Yamaha stern drive
™ ™
dealer.
OTHER ITEMS
Throttle cable Check fully open and fully
¡ ¡ ¡ ¡
closed positions.
Shift cable Check proper operation
¡ ¡ ¡ ¡
(F⇔N⇔R). Lubricate.
Clutch system Check proper operation
¡ ¡ ¡ ¡
(F⇔N⇔R).
Power steering system Check proper operation. ¡ ™ or ¡ ™ or ¡ ™ or ¡
Check oil level of power
steering pump, Correct if ¡ ™ or ¡ ™ or ¡ ™ or ¡
necessary.
Bolts and nuts at each Check and retightening.
¡ ™ or ¡ ™ or ¡ ™ or ¡
section
Hose bands and clamps Check and retightening.
¡ ™ or ¡ ™ or ¡ ™ or¡
at each section.
3-6
CHK INTRODUCTION E
ADJ
Before After first
Every 100 At least
starting 20 hours
engine or 2
months year
each day months
Hoses and bushes at Check for damage and tight-
each section ness. Replace or retighten if ¡ ™ or ¡ ™ or ¡ ™ or ¡
necessary.
Engine exterior Clean and inspect. Paint if
¡
necessary and then apply
¡ Every three 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.
3-7
CHK INTRODUCTION E
ADJ
Periodic maintenance and replacement items chart
Items for At every Every 1000 Every 1200

Every 2
maintenance/ Remarks engine oil hours or hours or
years
replacement change 3 years 6 years
FUEL SYSTEM
Hoses and clamps Check for leaks and/or
™ or ¡
loosening.
Hoses Check for leaks and/or
™ or ¡
damage.
Union gasket Check for leaks. ™ or ¡
Replace. ™
Water separator Check proper function.
™ 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)
Oil filter Replace. ™ or ¡ Every 100 hours or 6 months (NOTE 1)
Oil pressure sender Replace.
™ ™
piping
Replace. ™
INTAKE/EXHAUST SYSTEM
Hose clamps Check for loosening.
™ or ¡
(loosening)
Hoses, bellows Check for leaks and/or
™ or ¡
damages.
Replace. ™
Turbocharger Check the shaft free play,
™
gas/oil leaks, etc.
Air filter Cleaning ™ or ¡
Replace. ™ or ¡ Every year
Bolts and nuts related to Check, and retighten if
™ or ¡ ™
the exhaust system necessary.
Water shutter Check and replace any
™ Every year
deteriorated parts.
Exhaust manifold Check the integrity. ™
COOLING SYSTEM
Hoses and clamps Check for leaks and/or
™ or ¡
loosening.
Water supply hose Check for leaks and/or
™ or ¡
damages.
Replace. ™ ™
3-8
CHK INTRODUCTION E
ADJ

Every 2
years

Replace. ™
Seawater drain plug Check for leaks. ™ or ¡
Replace. ™ ™
Seawater hoses and Replace.
™
pipes
Seawater pump Replace.
™ or ¡ Every year
impeller
Seawater pump oil & Replace.
™ ™
mechanical seal
Seawater pump and Replace.
™ ™
cover
Seawater filter 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. ™
Inter-cooler element Cleaning ™
Replace. ™
Cooling fresh water Replace. (with genuine
LLC)
Cooling system Check pressure.
™ Every year
pressure inspection
ELECTRICAL SYSTEM
Insulation Check for damages. ™ or ¡ ™ or ¡
Loose connectors Check for loosening. ™ or ¡ ™ or ¡
Alternator Check. (at the time of
™
engine overhaul)
Starter motor Check. (at the time of
™
engine overhaul)
Warning sensors Replace. ™
Relays Replace. ™
ENGINE BODY
Drive belts (All) Check. ™ or ¡
Replace. ™ or ¡ ™ or ¡
Timing belt Replace. ™ ™
Valve clearance Check, adjust if necessary. ™ ™
Engine alignment Check, adjust if
™ Every year
(shaft core) necessary.
Engine rubber mount Replace. ™
Flywheel coupling Replace. ™
Engine bracket bolts Check.
(on the engine block)
Crank pulley bolt Check, retighten if
™
(loosening) necessary.
3-9
CHK INTRODUCTION E
ADJ

Every 2
years
Valve and valve seat Check (at the time of

™
engine overhaul).
Piston and piston ring Check (at the time of
™
engine overhaul).
Each bearing and Check (at the time of
™
bearing metal engine overhaul).
Crankshaft Check (at the time of
™
engine overhaul).
Cylinder head Check (at the time of
™
engine overhaul).
Cylinder block Check (at the time of
™
engine overhaul).
Gears Check (at the time of
™
engine overhaul).
OTHER ITEMS
Power steering oil Cleaning ™
cooler element Check. ™
Power steering oil pump Check. ™
Power steering cylinder Check. ™
All rubber and resin Replace.
™ or ¡
parts
All hose clamps Replace. ™ or ¡
Engine external appear- Check, apply paint/ ™ or ¡
ance antirust if necessary. (NOTE 2)
NOTE 1: Every 50 hours if used for high-speed or heavy-duty operation.
NOTE 2: Every 3 weeks in boating season.
3-10
CHK PERIODIC CHECKS AND ADJUSTMENTS E
ADJ
PERIODIC CHECKS AND ADJUST-
MENTS
Engine Oil Level Check
1. Check:
¡ Engine oil
Out of specification → Add/Change
Oil.
Contamination/Deterioration →
Change Oil.
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
tube end 2.
2) Oil level should be between the “F“ mark
2 A and the “L” mark B.
CAUTION:
b a 1
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 insufficient output power due to
the additional rotation resistance, or oil may
enter the combustion chamber, causing over-
heating. These problems could ultimately
lead to 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 for expected ambient tem-
–29 –18 –7 4 16 27 38 C peratures before the next oil change.
3-11
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 oil changes. Be sure to re-
place the engine oil and oil filter at regu-
lar intervals.
¡ It is essential to perform and oil and fil-
ter change after the first 20 hours of op-
eration. Simply replenishing without
changing the oil after those 20 hours will
cause engine deterioration.
Engine oil addition steps

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

1 but not past, the “F” mark A on the dip-
stick 1.
CAUTION:
Do not allow any foreign material to enter
a 1 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 engine. Spilled oil
is a serious fire hazard.
3-12
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.
4) Drain the engine oil from crankcase

2
through the dipstick tube 1. Use a suc-
tion pump 2.
NOTE:
Remove the engine oil filler cap 3. This will
speed up the oil draining.
1
3-13
ADJ
5) Remove the oil filter 1 with oil filter
1
wrench.
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 A,
2 then tighten it half a turn by hand.
CAUTION:
DO NOT use a filter wrench for filter instal-
lation.
3-14
ADJ
9) Fill up the engine oil.
Refer to “Engine Oil Level Check” sec-
tion (P3-11.)

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

Without oil filter change
Max. 9.2 L, Min. 7.5 L
 Max. 8.1 lmp qt., Min. 6.6 lmp qt.
 Max. 9.7 US qt., Min. 7.9 US qt. 
With oil filter change
Max. 9.9 L, Min. 8.2 L
 Max. 10.5 US qt., Min. 8.7 US qt. 
¡ WARNING
Wipe off any oil spilled on the engine 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.
¡ If the oil level is below the minimum level,
the engine can get seriously damaged.
Therefore, check the oil level with the dip-
stick regularly.
3-15
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 hose 1 for crack
2 and/or damage.
1 Crack/Damage → Replace.
1 2) Check the oil separator 2 for crack and/
or damage.
Crack/Damage → Replace.
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 air filter assembly.
2) Remove the hoses, and then remove the

oil separator.
3) Replace any damaged part with a new
one.
4) Clean the oil separator and blow-by
hoses with cleaning solvent and dry
them with compressed air.
5) Reinstall all removed parts, making sure
that they are positioned correctly.
3-16
ADJ
Air Filter Check
1. Check:
¡ Air filter element and air filter frame
Air filter element and air filter frame check-

ing steps
1
1) Pull up the fasteners 2 on the air filter
2 3 cover.
2) Unscrew the bolt 3 and remove the
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.
NOTE:
4 Once the air filter element 4 is removed,
check the air filter element 4 and the air fil-
5 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 air filter element 4.
6) Install 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.
Tightening torque:
1
3 1.8 N·m (0.18 kgf·m, 1.33 lbf·ft)
T.R
3-17
ADJ
Valve Clearance Check
1. Check:
Rocker arm
Rocker arm ¡ Valve clearance
adjusting screw
Valve bridge NOTE:

Rocker shaft
adjusting screw ¡ Valve clearance check and adjustment
shall be performed when the engine is
Valve bridge cool.
¡ Measure the clearance between the
rocker arm and the valve bridge with a
thickness gauge.
Spring
Retainer
Camshaft
Spring seat
Valve
Valve guide
Valve clearance checking steps

1) Turn the crankshaft clockwise until the
mark on the pulley is aligned with the
mark on the gear case cover so that the
#1 cylinder comes at compression top
dead center.
2) Check the valve clearance in the places

shown in the illustration.
Out of specification → Adjust.
Standard valve clearance:

IN: 0.17 – 0.23 mm (0.0067 – 0.0091in.)(cold)
EX: 0.47 – 0.53 mm (0.0185 – 0.0209 in.)(cold)
IN EX EX IN EX IN NOTE:
Turn the crankshaft clockwise for 360°, and
check the rest of the valve clearances.
3) If the valve clearance is out of specifica-

tion, adjust it in the places shown in the
illustration.
Refer to ”Valve Clearance Adjustment”
section (P3-19).
3-18
ADJ
4) Apply seal packing black at the positions
shown in the illustration before install-
ing the cylinder head cover.
Bolts (cylinder head cover):

6.4 N·m (0.65 kgf·m, 4.72 lbf·ft)
T.R
CAUTION:
Positions to apply ThreeBond® TB-1207B. ¡ Degrease the mounting face.
¡ Installation shall be done within 5 min-
utes of the application of seal packing
black.
5) Install the breather hose and the pipe.
Valve Clearance Adjustment

1. Adjust:
¡ Valve clearance
Valve clearance adjusting steps

1) Loosen the lock nuts on the rocker arm
and the bridge. Then, loosen the adjust-
ing screw until it is fully detached from
the valve stem.
CAUTION:
Hold valve bridge with the adjustable
wrench (150 mm) while loosening the lock
nuts.
2) Insert a thickness gauge between the

rocker arm and the valve bridge.
3) Adjust the clearance by means of the ad-
justing screw on the rocker arm, and
tighten the lock nut temporarily.
4) Keeping the thickness gauge at the in-

serted position, confirm that friction of
the thickness gauge does not feel to be
faded.
If the friction feels to be faded, repeat the
adjusting procedure from step 1) above.
3-19
ADJ
5) Gradually screw-in the adjusting screw
on the valve bridge. Tighten the lock nut
when the thickness gauge friction begins
to increase.
Valve bridge adjusting nut:

19 N·m (1.9 kgf·m, 14 lbf·ft)
T.R
CAUTION:
¡ Hold the valve bridge with the adjustable
wrench while tightening the lock nut.
¡ Do not apply the torque in excess of
specification to the lock nut on the valve
bridge.
6) Loosen the lock nut on the rocker arm to

recheck the valve clearance.
7) Tighten the lock nut on the rocker arm.
Rocker arm adjusting nut:

19 N·m (1.9 kgf·m, 14 lbf·ft)
T.R
8) Reconfirm the valve clearance.

9) Turn the crankshaft clockwise for 360 °.
10) Adjust the valve clearances in the places

shown in the illustration, applying the
same procedure described above.
Standard valve clearance:

IN: 0.17 – 0.23mm (0.0067 – 0.0091 in.)
(cold engine)
EX: 0.47 – 0.53mm(0.0185 – 0.0209 in.)
IN EX IN EX IN EX (cold engine)
3-20
ADJ
Engine Idle 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 idle set screw 1
1
on the injection pump.
2) Check the engine idle speed.
2
Engine idle speed:
650 – 700 r/min.
3) Loosen the lock nut, and turn the idle 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.
Maximum engine speed with no load:

4200 r/min.
2) Remove the seal, and turn the maximum

speed set screw 3 to attain the speci-
fied speed.
3) Put the seal again.
3-21
ADJ
Throttle Cable Adjustment
1. Adjust:
¡ Throttle cable position
Throttle cable position adjustment steps

1) Put the remote control lever in “Fully
closed” position.
2) Loosen the set bolts 1.
3) Confirm that the remote control lever is

1 at “Full close” position. Tighten the bolts
1 in the position where the adjusting le-
3 ver 2 touches the engine idle speed ad-
justing screw 3.
4) Put the remote control lever at “Full

4
throttle” position.
5) Check that the adjusting lever 2 touches
the maximum speed adjusting screw 4.
If the adjusting lever does not touch the
maximum speed adjusting screw 4, re-
peat the steps 1) to 5) and check the re-
2
mote control.
3-22
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 the cylinder head cover.
4) Remove all the injection nozzles.
5) Attach the compression gauge attach-
ment and the compression gauge.
Compression gauge attachment:

TDG-13 (Banzai)
No. 44 (Iyasaka)
Tightening torque:
18 N·m (1.8 kgf·m, 13.3 lbf·ft)
T.R
6) 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 250 r/min. or
more.
¡ This measurement must be done in as
short a time as possible.
Compression pressure:
Standard
2.7 MPa (27.5 kgf/cm2, 392 psi)
Limit
1.96 MPa (19.9 kgf/cm2, 284 psi)
Max. variation between cylinders
0.3 MPa (3.0 kgf/cm2, 43.5 psi) or less
3-23
ADJ
7) 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.
8) Install the injection nozzles and cylinder

head cover.
9) Joint the injection pump connector.
10) Fuel feed system air bleeding.
Refer to “Fuel System Air Bleeding” sec-
tion (P3-36).
3-24
ADJ
Drive Belts Check
1. Check:
¡ Drive belts
Drive belts checking steps

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

1. Replace:
¡ Drive belts
Drive belt replacement steps

1) Loosen the mounting bolt 2 and adjust-
ing bolt 3 on the alternator 1.
3
1 2) Push the alternator toward the engine to
ease the tension on the drive belts 4.
3) Remove the drive belts 4.
4) Install the new drive belts. Check that it
is seated properly in the pulley groove.
2
4 5) Adjust the drive belts tension.
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.

98 N (10 kgf, 22 lbf)
Alternator V-belts:
12 – 14 mm (0.47 – 0.55 in.)
[New belt: 10 – 12 mm (0.39 – 0.47 in.)]
CAUTION:
Pry only on the reinforced portions of the
alternator housing.
3-25
ADJ
Timing Belt Check
1. Check
¡ Timing belt
Timing belt checking steps
CAUTION:
¡ Do not bend, twist, or turn the timing belt
inside out.
¡ Do not allow the timing belt to come in
contact with oil, water, or steam.
¡ Be sure that the timing belt is not tight-
ened when installing or removing the
camshaft timing pulley mounting bolt.
1) Remove the timing belt cover.

Refer to “Timing Belt and Timing Pulley
Removal” section (P6-62).
Seal washer 2) Check the timing belt cover 1 and the

gasket for cracks, wear and/or damage.
1 Cracks/Wear/Damage → Repair.
NOTE:
¡ If the gasket is damaged slightly, seal it
by applying ThreeBond® TB-1207B.
¡ If the gasket is seriously damaged, install
Timing belt a new one. In this case, make sure that
no fraction of old gasket remains on the
timing belt cover or on the engine body.
¡ Peel off the parting paper from the adhe-
sive face of the gasket. Attach a new gas-
ket on the timing belt cover. As it is at-
tached, the gasket thickness must be kept
evenly, and the groove on the attaching
face must run in the middle of the gasket.
¡ No gap is allowed at the gasket joint area.
Cut off the excessive length.
If there is any gap at the joint area, fill it
with ThreeBond® TB-1207B.
3-26
ADJ
3) Check the timing belt for cracks, wear
and/or damage.
Installation” section (P6-66).
NOTE:
If the belt teeth are cracked or damaged,
make sure that the camshaft is not tightened
excessively.
NOTE:
If there are cracks or noticeable wear on the
belt face, make sure that there is no nick on
one side of the idler pulley lock.
NOTE:
If the belt is worn or damaged only on one
side, check the alignment of the pulleys.
NOTE:
If the belt teeth show signs of wear, check
the condition and installation of the timing
belt cover and the gasket.
Make sure that there is no foreign material
on the pulley teeth.
3-27
ADJ
Engine Cleaning and Protection
1. Clean and protect:
¡ Engine
Engine cleaning and protect steps

1) Check the engine exterior.
2) Remove the peeling paint, and touch up
with 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.
3-28
ADJ
Injection Timing Check
1. Check:
¡ Injection timing
Injection timing checking steps
1 1) Disconnect the negative (–) lead from the

B #3 #6 battery terminal.
A
2) Loosen the injection pipe flare nuts 1
C F on cylinder #3 and #5, and move them
#5 #2 toward the engine rear.
1 D E 3) Remove the distributive head bolt 2 and
1 the gasket 3.
3 2
#1 #4
2
4) Attach the plunger stroke measuring tool

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

09275-54011
2
1
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
that the needle really shows the minimum.
Crankshaft pulley Dial gauge
3-29
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 1.88 (± 0.03) mm (0.0740 (± 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.
3-30
ADJ
Injection Timing Adjustment
1. Adjust:
¡ Injection timing
Injection timing adjustment steps

1) Loosen the 6 flare nuts on the injection
pump and another 6 flare nuts on the
injection nozzle to the extent that they
become substantially unfastened.
NOTE:
Neither the flare nuts on the injection pump
nor those on the injection nozzle have to be
removed.
2) Loosen the 6 nuts on 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:
The injection pump mounting nuts shall not
be loosened by more than 1/4 turns.
3-31
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
#5 cylinder.
2
1
5) Operate the injection pump body and ad-

just the injection timing.
a Standard value:
1.88 (± 0.03) mm (0.0740 (± 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 bolt, and repeat the injection timing
check.
Nuts (injection pump mounting):

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

69 N·m (7.0 kgf·m, 50.9 lbf·ft)
7) Remove the planger stroke measuring 1

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

25 N·m (2.6 kgf·m, 18.4 lbf·ft)
T.R
2
1
9) Tighten the 6 injection pipe flare nuts 3

to the injection pump (2 flare nuts for
checking).
10) Tighten the 6 nuts on the injection pipe
clamps.
11) Connect the negative (–) lead to the bat-
tery terminal.
3-32
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) 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 (P3-36).
Fuel Filter Replacement

1. Replace:
¡ Fuel filter
Fuel filter replacement steps

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 bolt 1 and
the cover 2.
1
3-33
ADJ
4) Remove the band 1.
5) Disconnect the coupler 2 (water level
sensor).
6) Remove the fuel filter 1 using the filter

wrench.
¡ WARNING
1 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 up-
right to avoid spilling fuel. Clean up any
spilled fuel immediately with dry rags.
¡ WARNING
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 with

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

water level sensor 1 and new fuel filter
3.
9) Install the new O-ring 2 onto water level
3 sensor.
1
2
New
3-34
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 the new O-ring 2 onto 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.
1 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 (P3-36).
19) Check the fuel leakage.
Leak → Repair.
20) Install the fuel filter cover 1.
NOTE:
Attach a grommet where the fuel filter cover
bolts will be mounted.
2
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
3-35
ADJ
Fuel System Air Bleeding
NOTE:
1
¡ Bleed air from the fuel system after the
disassembly of the fuel system, after loos-
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.
3-36
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
3 plate 2 for cracks and/or damage.
4 Cracks/Damage → Replace.
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.
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 anode.
Excessive wear (when more than one-
New third is worn out) → Replace.
NOTE:
LT
¡ There are 4 anodes installed on the en-

3
24
gine; two each on the heat exchanger and

Replace
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
3-37
ADJ
Coolant Level Check
¡ WARNING
Filler cap
Filler cap
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.
WITHOUT OPTIONAL RESERVE TANK 1. Check:

a ¡ Coolant level
Coolant level checking step

b
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.
3-38
ADJ
High-quality ethylene glycol anti-

freeze containing corrosion inhibi-
tors for engines:
Coolant to water mixing ratio
30 % – 55 %
Total amount
13.0 L (11.4 lmp qt., 13.7 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.
3-39
ADJ
Coolant Replacement
1. Replace:
¡ Coolant
Coolant replacement steps

1) Drain the coolant.
NOTE:
Places for draining:
¡ Drain cock (green color) 1 under the heat
exchanger.
1 ¡ Drain bolt 3 under the turbocharger.
¡ Drain bolt 2 on the engine block, at the
back of oil pressure sensor.
2) Remove the coolant filler cap and drain.

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

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

3 52 N·m (5.3 kgf·m, 38.4 lbf·ft)
Drain cock (Heat exchanger):
15.7 N·m (1.60 kgf·m, 11.58 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
3-40
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 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 at 85 °C
(185 °F).
Thermostat valve lift:

Valve lift 10 mm (0.39 in.) or more
3-41
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 constant level.
4) Put the pressure in excess of specifica-
tion, and confirm that the valve opens at
the specified pressure.
Valve opening pressure:

89 ± 9.8 kPa
(0.9 ± 0.10 kgf/cm2, 12.9 ± 1.4 psi)
3-42
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.
Loose → Tighten the hose clamp.
Cooling System Pressurize Check

1
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
¡ Bypass 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
3-43
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

1 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.
1 5) Install the impeller 1.
NOTE:
A When inserting the impeller into the pump
body, turn it clockwise while pushing.
CAUTION:
Make sure that the impeller blades are
turned as shown in the illustration.
3-44
ADJ
6) Install the new O-ring 1 and the cover
2.
Bolts (cover):
2 N·m (0.2 kgf·m, 1.5 lbf·ft)
T.R
2
NOTE:
1 If the O-ring comes off, keep it in the ring
New groove by use of Yamaha marine grease A.
3-45
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 right and left
several times.
Turn the steering lever until the drive unit
is pointing straight back and is centered.
Stop the engine.
1 3) Remove the filler cap 1 from the reser-
voir tank 2 of the power steering pump
and wipe the dipstick with a clean cloth.
4) Reinstall the filler cap in the reservoir
2 tank, and remove the cap once again.
Check the level of fluid on the level gauge
of the filler cap.
Fluid level below the specified level →
Add recommended fluid.
When the engine is hot.

The fluid level should be on the “HOT”
a b
mark A on the level gauge.
When the engine is cold.
The fluid level should be on the “COLD”
mark B and the end of the level gauge.
3-46
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”
6) Install the filler cap and start the engine.

After rotating the steering lever several
times all the way to right and left, set the
drive unit straight and stop the engine.
Reinspect the fluid level.
7) Perform air bleeding of the power steer-
ing hydraulic system if necessary.
3-47
ADJ
Battery Check
1. Check:
¡ Battery fluid level
¡ Battery terminal
¡ Specific gravity
Battery fluid level checking step

1) Check the battery fluid level.
a
Fluid level low → Fill to the proper level.
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.
3-48
ADJ
¡ Deformation due to the buckling of plates
or insulators is visible.
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.
3-49
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 continu-
ity.
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
Charging system 100 A 1
Meters 20 A 1
Intake airheater 10 A 1
control
¡ 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.
3-50
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.
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
Fuel in the bilge is a serious fire hazard.
Hold a small container or rag under the hose
1 nipples to catch spilling fuel. Clean up any
spilled fuel immediately with dry rags.
NOTE:
2 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.
7) Disconnect the hydraulic hoses 1 from

power steering control valve 2.
1
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.

2
9) Disconnect the bypass hose 2 from the
mixing elbow.
10) Disconnect the ground wire 1 from the

stud 2 on the flywheel housing.
2 11) Disconnect the battery positive (+) lead
3 3 from the starter motor.
4-2
INST
12) 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
13) Disconnect the water inlet hose 4 from
seawater inlet tube 5 on the gimbal
2
housing.
14) Disconnect the throttle cable.
15) Disconnect the shift cable to the remote

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

ets 1 of the engine.
Remove slack from chain or strap.
1
¡ WARNING
2 DO NOT attach lifting sling or chain to the
hanger 2 mounted on the intake manifold.
This hanger will not support the weight of
the engine and could break. The engine could
fall, causing personal injury or damage.
4-3
INST
17) Remove the left and right screws 1, nuts
2 and the left and right washers 3.
3
18) Carefully lift the engine out of boat.
2
1
Engine Mount Check

1. Check:
¡ Front engine mount brackets
¡ Front engine mount
¡ Rear engine mount
Front engine mount brackets checking steps

1) Check the front engine mount brackets
1 for cracks, bends and/or damage.
Cracks/Bends/Damage → Replace.
2) Tighten the engine mount bracket bolts
(left and right).
1 1
Bolt (engine mount bracket):

117 N·m (11.9 kgf·m, 86.3 lbf·ft)
T.R
Front engine mount checking steps

1) Check the front engine mount base 1 for
cracks, wear and /or damage.
Cracks/Wear/Damage → Replace engine
mount bases as a set.
2) Check the front engine mount rubbers
1
2 for cracks, wear and/or damage.
1 Cracks/Wear/Damage → Replace engine
2 mount rubbers as a set.
2
Rear engine mount checking steps

1) Check the rear engine mounts for cracks,
wear and/or damage.
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
part of the nut 6 and bolt 5 when tighten-
b
ing the nut.
4 a
Nut (rear engine mount):
55 N·m (5.6 kgf·m, 40.6 lbf·ft)
T.R
Engine Installation
1. Install:
¡ Engine
Reverse the “Engine Removal” pro-
cedure.
Note the following points.
Engine installation steps

2
1) Carefully lower the engine into the boat,
lining up the hole of the rear engine
mounts with mount studs on the tran-
3 som plate. As the engine is lowered, con-
nect the exhaust joint 1 and bypass hose
3 to the mixing elbow 2.
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.
Nut (rear engine mount):

55 N·m (5.6 kgf·m, 40.6 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 front lifting brackets 1 and setting
2 hanger 2 mounted on the intake mani-
1
fold, then remove slack from chain or
strap.
7) Adjust the engine alignment.

Refer to “Engine Alignment Adjustment”
section (P4-10).
4-7
INST
8) Install the drive unit assembly.
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
30 N·m (3.1 kgf·m, 22.1 lbf·ft)
2nd
70 N·m (7.1 kgf·m, 51.7 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.
1
10) Connect the hydraulic hoses 1 to power
steering control valve 2.
3
2 4
Large fitting 3:
34 N·m (3.5 kgf·m, 25.1 lbf·ft)
T.R
Small fitting 4:
15 N·m (1.5 kgf·m, 11.1 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.
12) Connect the battery leads.
CAUTION:
¡ Connect the positive (+) lead first, then
the negative (–) lead.
¡ Grease both battery terminals.
13) Fill the crankcase.

Refer to “Engine Oil and Oil Filter Re-
placement” section (P3-13).
Total amount:
9.2 L (2.02 lmp qt., 2.43 US qt.)
4-9
INST
14) Adjust the shift cables to the drive unit
1 1 and to the remote control 2.
MANUAL”.
15) Adjust the Idle speed.

Refer to “Throttle Cable Adjustment”
section (P3-22).
Engine idle 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
2 ¡ If the tool is difficult to insert or remove,
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) Loose the front engine mount nuts 3.
3) Connect the hoist to the front lifting
bracket to raise or lower the front of the
3
engine.
4) Turn both front adjusting nuts 4 by the
4 same amount to align the engine: clock-
wise to lower it, counterclockwise to
raise it.
5) Lower the engine onto the adjusting nuts
and check the alignment again with the
alignment tool.
6) Repeat steps 3) and 4) until the alignment
tool can be inserted and removed eas-
ily.
7) Tighten the front engine mount nuts 3.
Nuts (front engine mount):

207 N·m (21.1 kgf·m, 152.8 lbf·ft)
T.R
4-11
FUEL E
CHAPTER 5
FUEL SYSTEM
INJECTION NOZZLE ............................................................................................................... 5-1

Injection Nozzle Removal .................................................................................................. 5-2
Injection Nozzle Check ....................................................................................................... 5-5
Injection Nozzle Installation .............................................................................................. 5-6
INJECTION PUMP ................................................................................................................... 5-9

Injection Pump Removal ................................................................................................. 5-12
Injection Pump Check ...................................................................................................... 5-14
Injection Pump Installation ............................................................................................. 5-17
5
FUEL INJECTION NOZZLE E
INJECTION NOZZLE
2
3
No. Part name Q’ty Remarks

1 Nozzle clamp holder bolts 6 25 N·m (2.5 kgf·m, 18.4 lbf·ft)
2 Nozzle leakage pipe #1 mounting nut 1 18.6 N·m (1.9 kgf·m, 13.7 lbf·ft)
3 Nozzle hollow bolts 6 17.6 N·m (1.8 kgf·m, 13.0 lbf·ft)
4 Nozzle leakage pipe #3 mounting bolt 1 19.6 N·m (2.0 kgf·m, 14.5 lbf·ft)
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 bolt 1, and remove the
nozzle leakage pipe #3 2.
1
3) Loosen the 6 nuts, and remove the in-

jection pipe clamps.
5-2
4) Loosen the 6 flare nuts on the nozzle, and

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

with a wrench, unscrew the 6 flare nuts
on the pump and remove the 6 injection
pipes.
NOTE:
Put some identification mark on each injec-
tion pipe so that they can be reinstalled to
their original positions.
6) Disconnect the ventilation hose.
7) Remove the 17 bolts with seal washers,

to take away the cylinder head cover.
8) Hold the nozzle leakage pipe #1 1 with

a wrench and remove the nut 2.
2
1
5-3
9) Unscrew the hollow bolts (6 places), and

remove the nozzle leakage pipe #1.
10) Remove 6 gaskets of the hollow bolts.
CAUTION:
Pay attention not to drop the gaskets.
11) Remove the nozzle seals (6 places) with

a suitable tool.
12) Remove nozzle clamp holder bolts and

the washers (each 6 pcs.) to take away
the nozzle holder.
NOTE:
Identify the cylinder number on each injec-
tion nozzle, so that they can be reinstalled in
their original positions.
13) Remove the O-ring on the nozzle holder.

14) Remove the nozzle seat with a suitable
tool.
5-4
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
Injection nozzle tester
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.
Leak → Replace the injection nozzle.
Yes No
5-5
Injection Nozzle Installation

1. Install:
¡ Injection nozzle
NOTE:
Injection nozzles must be reinstalled in their
original positions.
Injection nozzle installation steps

1) Install a new O-ring 1 on the nozzle
holder & nozzle set.
2) Install a new nozzle seat on the cylinder
head.
1
3) Install the injection nozzle and injection

nozzle clamp holder, and tighten the bolt
temporary (6 bolts with washers).
4) Insert a new nozzle seal to the extent that
it touches the cylinder head.
CAUTION:
Take care not to damage the oil seal area
with the threads at the end of the nozzle.
5) Tighten the 6 bolts of the injection nozzle

clamp holder.
Bolts (injection nozzle clamp holder):

25 N·m (2.5 kgf·m, 18.5 lbf·ft)
T.R
6) Using a new gasket, put the nozzle leak-

age pipe #1 through the hole on the cyl-
inder head.
7) Using 6 new gaskets, install the nozzle
leakage pipe #1 with 6 bolts.
Hollow bolts (leakage pipe #1):

18 N·m (1.8 kgf·m, 13.3 lbf·ft)
T.R
CAUTION:
Do not drop gaskets.
5-6
8) Hold the nozzle leakage pipe #1 in place

with a wrench, and tighten the nuts.
Nut (leakage pipe mounting):

18.6 N·m (1.9 kgf·m, 13.7 lbf·ft)
T.R
Hold
9) Pressurize the injection nozzle to 49 kPa

(0.5 kgf/cm2, 7.1 psi) with turbocharger
pressure gauge and hold the pressure for
about 10 seconds. Check that there is no
leakage (pressure drop).
Turbocharger pressure gauge:

TCP-2TB (from BANZAI)
CAUTION:
Fuel leakage from nozzle leakage pipe #1
cannot be checked after the engine start.
Always perform the fuel leakage check im-
mediately after the installation of nozzle
leakage pipe #1.
10) Check the valve clearance and adjust it if

necessary.
11) Degrease the points shown in the illus-
tration.
12) Apply seal packing black at the illustrated
points, and install the cylinder head
cover within 5 minutes of seal packing
application.
Points to apply ThreeBond® TB-1207B.
13) Mount the bolts (17 pcs.) with new seal

washers and tighten them to the speci-
fied torque.

6.4 N·m (0.65 kgf·m, 4.7 lbf·ft)
T.R
CAUTION:
Do not start the engine. Let it stand for 2
hours after assembly.
5-7
14) Install the ventilation hose.

#3 #6
B A
15) Temporarily tighten the flare nuts on the
nozzle side, and then tighten the flare
C F nuts (6 pcs.) on the pump side while
#5 #2 holding the delivery joint end of the
pump with a wrench.
D E
Flare nuts (injection pipe):
#1 #4 24.5 N·m (2.5 kgf·m, 18.07 lbf·ft)
T.R
16) Install the injection pipe clamp.
Nuts (injection pipe clamp):

6.4 N·m (0.65 kgf·m, 4.7 lbf·ft)
T.R
17) Install the nozzle leakage pipe #3 2 with

bolt 1.
1
Bolt (nozzle leakage pipe #3 mounting):
19.6 N·m (2.0 kgf·m, 14.5 lbf·ft)
T.R
18) Connect the fuel hose.

2
19) Fill the fuel in the system line by the prim-

ing pump located on the fuel filter.
20) Loosen one of the flare nuts on the
nozzle.
21) Crank the engine with starter motor un-
til the fuel comes out at the loosened nut.
22) Tighten the flare nut.
Flare nuts (injection pipe):

24.5 N·m (2.5 kgf·m, 18.07 lbf·ft)
T.R
23) Perform the steps 20) to 22) above for

the rest of the injection pipes.
5-8
FUEL INJECTION PUMP E
INJECTION PUMP
CAUTION:
¡ No one can break the fuel pump seal ex-
cept at the authorized service shop of
YAMAHA or at the pump manufacturer.
Breaking by anyone else will void the
warranty.
¡ If any abnormality is suspected on fuel
pump or governor, consult YAMAHA or
pump manufacturer’s authorized service
shop. The pump shall be sealed again af-
ter the required services are completed.
5-9
3 2
6
5
7 A

1 Fuel cut solenoid 1 22 N·m (2.2 kgf·m, 16.2 lbf·ft)
2 Union bolt 1 24.5 N·m (2.5 kgf·m, 18.1 lbf·ft)
3 Injection pump mounting nut 2 18 N·m (1.8 kgf·m, 13.3 lbf·ft)
4 Pickup (tacho) sensor 1 21 N·m (2.1 kgf·m, 15.5 lbf·ft)
5 Injection pump mounting bolt 1 69 N·m (7.0 kgf·m, 50.9 lbf·ft)
6 Union bolt 1 24.5 N·m (2.5 kgf·m, 18.1 lbf·ft)
7 Drive gear nut 1 98 N·m (10.0 kgf·m, 72.3 lbf·ft)
5-10

1 Injection pipe flare nuts 12 24.5 N·m (2.5 kgf·m, 18.1 lbf·ft)
2 Pipe clamp mounting nuts 6 6.4 N·m (0.65 kgf·m, 4.7 lbf·ft)
5-11
Injection Pump Removal

1. Remove:
¡ Injection pump
Injection pump removal steps
1) Drain the coolant (fresh water).
Refer to “Coolant Replacement” section
(P3-40).
2) Remove the timing belt and the pulley
#2 1.
1 Removal” section (P6-62).
3) Disconnect the boost compensator hose

1.
5 1 4) Disconnect the fuel return hose #1 2.
2 5) Disconnect the fuel return hose #2 3.
6) Disconnect the fuel hose #2 4.
4
3 7) Disconnect the throttle cable 5.
8) Disconnect the injection pump coupler

6.
6
9) Disconnect the intake airheater relay and

remove it together with bracket.
5-12
10) Loosen the nut (pump drive gear).
NOTE:
Hold the fuel pump drive gear using the com-
panion flange holding tool.
Companion flange holding tool:

09330-00021
11) Remove the nut and the O-ring.
12) Remove the injection pipes.
13) Loosen the nuts and bolts (injection

pump) by 2 – 3 mm (0.08 – 0.12 in.).
NOTE:
Put alignment marks A on the injection
pump and the timing gear cover before re-
moving them, so that the injection pump will
be reinstalled in exactly the same position.
a
14) Detach the injection pump using the

puller C set 1.
1
Puller C set:
09950-50013
 09951-05010 
 09952-05010 
 
 09953-05020 
 09954-05021 
or (90890-0740A, 90890-07512)
NOTE:
¡ Screw in the 2 bolts of the puller by more
than 8 mm (0.31 in.).
¡ Make sure that the tool body is in parallel
with the drive gear.
15) Take away the nuts and bolts and remove

the injection pump.
CAUTION:
Do not hold the injection pump at the ad-
justment lever.
5-13
16) Remove the O-ring 1 and the key 2.
2 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
1
2) Disconnect the fuel cut solenoid lead 2.
3) Remove the fuel cut solenoid 1.

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

Refer to “Fuel Cut Solenoid Valve Check”
section (P8-45).
6) Check the spring 1 ant the fuel strainer

2 for damage.
Damage → Replace.
1 2
5-14
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 new O-ring 5.
10) Install the fuel cut solenoid 6.
5 6
4 Fuel cut solenoid:

22 N·m (2.2 kgf·m, 16.2 lbf·ft)
T.R
2
1
11) Connect the fuel cut solenoid lead 1.
1 Bolt (fuel cut solenoid lead):

2 1.7 N·m (0.17 kgf·m, 1.25 lbf·ft)
T.R
12) Cover the fuel cut solenoid with the dust

cover 2.
5-15
Pickup (tacho) sensor checking steps

1) Pull out the pickup (tacho) sensor lead
1 from the lead clamp 2.
3
2) Remove the pickup (tacho) sensor 3.
1
3) Check the pickup (tacho) sensor.

Refer to “Pickup (tacho) Sensor Check”
section (P8-43).
4) Mount the new O-ring 1 on the pickup

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

3 21 N·m (2.1 kgf·m, 15.5 lbf·ft)
T.R
NOTE:
Apply some grease on the O-ring of the
pickup (tacho) sensor.
6) Clamp the pickup (tacho) sensor lead 3.
5-16
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 the new O-ring 1 on the injec-
tion pump.
2) Install the injection pump.
1 NOTE:
a ¡ Align the set key 1 on the drive shaft and
the groove A on the injection pump drive
gear.
¡ Align the march marks B of the injection
pump and the timing gear case.
Nuts (injection pump mounting) 2:

18 N·m (1.8 kgf·m, 13.3 lbf·ft)
T.R
5-17
3) Install the pump bracket 1.

2
Bolts (injection pump mounting) 2:

69 N·m (7.0 kgf·m, 50.9 lbf·ft)
T.R
1
CAUTION:
3
Before tightening the bolt to the standard
torque, check that the pump bracket 1
touches the pump stay 3. If there is a gap,
loosen the nut and set the pump bracket to
touch the pump stay.
4) Mount the new O-ring 1 onto the injec-

tion pump drive gear.
5) Tighten the nut (pump drive gear).
NOTE:
Hold the pump drive gear with the compan-
ion flange holding tool.

09330-00021
Nut (pump drive gear):

98 N·m (10.0 kgf·m, 72.3 lbf·ft)
T.R
6) Check the injection timing and adjust it.

Refer to “Injection Timing Check” section
(P3-29) and “Injection Timing Adjust-
ment” section (P3-31).
5-18
7) Connect the injection pump coupler 1.
8) Install the throttle cable 1, fuel hose #2

2, fuel return hose #2 3, fuel return hose
1
#1 4 and boost compensator hose 5.
5
4
Hollow bolt (Fuel hose #2):
29 N·m (3.0 kgf·m, 21.4 lbf·ft)
T.R
2
3
NOTE:
Always use a new gasket.
9) Install the injection pipe.
Injection pipe:
24.5 N·m (2.5 kgf·m, 18.07 lbf·ft)
T.R
10) Install the camshaft pulley #2 and tim-

ing belt.
11) Fill the coolant to the maximum level.
Refer to “Coolant Level Check” section
(P3-38).
12) Check the engine idle speed and the
maximum speed.
Refer to “Engine Idle Speed and Maxi-
mum Engine Speed (no load) Check”
section (P3-21).
5-19
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 Removal ................................................................................................ 6-11
Seawater Pump Impeller Removal ................................................................................. 6-11
Seawater Pump Check .................................................................................................... 6-12
Seawater Pump Replacement ........................................................................................ 6-13
Seawater Pump Assembly .............................................................................................. 6-17
Seawater Pump Installation ............................................................................................ 6-18
HEAT EXCHANGER .............................................................................................................. 6-19

Heat Exchanger Removal ................................................................................................ 6-20
Heat Exchanger Disassembly ......................................................................................... 6-20
Heat Exchanger Check ..................................................................................................... 6-20
Heat Exchanger Cleaning ................................................................................................ 6-21
Heat Exchanger Assembly .............................................................................................. 6-21
Heat Exchanger Installation ............................................................................................ 6-22
Thermostat Removal ....................................................................................................... 6-23
Thermostat Check ............................................................................................................ 6-23
Thermostat Installation ................................................................................................... 6-24
INTERCOOLER ...................................................................................................................... 6-25

Intercooler Removal ........................................................................................................ 6-26
Intercooler Disassembly .................................................................................................. 6-27
Intercooler Check ............................................................................................................. 6-28
Intercooler Cleaning ........................................................................................................ 6-29
Intercooler Assembly ...................................................................................................... 6-30
Intercooler Installation .................................................................................................... 6-31
TURBOCHARGER ................................................................................................................. 6-33

Handling Precautions ...................................................................................................... 6-36
Turbocharger Removal .................................................................................................... 6-37
ENG E
OVER
Turbocharger Check ......................................................................................................... 6-38

Turbocharger Disassembly ............................................................................................. 6-40
Turbocharger Measurement ........................................................................................... 6-43
Turbocharger Assembly .................................................................................................. 6-45
Turbocharger Installation ................................................................................................ 6-48
Turbocharger Pressure Measurement ........................................................................... 6-50
MIXING ELBOW AND EXHAUST MANIFOLD .................................................................... 6-52

Mixing Elbow and Exhaust Manifold Removal ............................................................. 6-53
Exhaust Manifold Check .................................................................................................. 6-55
Filler Neck Replacement .................................................................................................. 6-56
Mixing Elbow Check ........................................................................................................ 6-57
Mixing Elbow and Exhaust Manifold Installation ......................................................... 6-58
TIMING BELT AND TIMING PULLEYS ................................................................................ 6-61

Timing Belt and Timing Pulley Removal ........................................................................ 6-62
Timing Belt and Timing Pulley Check ............................................................................. 6-65
Timing Belt and Timing Pulley Installation .................................................................... 6-66
CIRCULATION PUMP ............................................................................................................ 6-72

Circulation Pump Removal ............................................................................................. 6-73
Circulation Pump Check .................................................................................................. 6-74
Circulation Pump Installation ......................................................................................... 6-74
TIMING GEARS ..................................................................................................................... 6-76

Timing Gear Removal ...................................................................................................... 6-77
6
Timing Gear Check........................................................................................................... 6-81
Injection Pump Bearing Replacement ............................................................................ 6-83
Timing Gear Cover Check................................................................................................ 6-83
Oil Seal Replacement ...................................................................................................... 6-84
Timing Gear Installation .................................................................................................. 6-85
CYLINDER HEAD ................................................................................................................... 6-89

Cylinder Head Removal ................................................................................................... 6-92
Cylinder Head Disassembly ............................................................................................ 6-94
Piston and Cylinder Block Top Cleaning ........................................................................ 6-95
Cylinder Head Check ....................................................................................................... 6-96
Valve Stem and Valve Guide Clearance Check .............................................................. 6-97
Valve Guide Replacement ............................................................................................... 6-98
Valve Check ...................................................................................................................... 6-99
Valve Seat Check ............................................................................................................ 6-100
ENG E
OVER
Valve Seat Refacing ....................................................................................................... 6-101

Valve and Valve Seat Lapping....................................................................................... 6-103
Valve Spring Check ........................................................................................................ 6-104
Camshaft Bearing and Camshaft Check....................................................................... 6-105
Cylinder Head Bolt Check .............................................................................................. 6-108
Camshaft Oil Seal Retainer and Oil Seal Check .......................................................... 6-109
Camshaft Oil Seal Replacement ................................................................................... 6-109
Intake and Exhaust Manifold Check ............................................................................. 6-110
Rocker Arm Check ......................................................................................................... 6-110
Cylinder Head Assembly ............................................................................................... 6-112
Cylinder Head Gasket Selection ................................................................................... 6-113
Cylinder Head Installation ............................................................................................. 6-115
Camshaft Installation ..................................................................................................... 6-116
Pulley and Timing Belt Installation ............................................................................... 6-117
OIL PUMP ............................................................................................................................ 6-120

Oil Pump Removal ......................................................................................................... 6-121
Oil Pump Disassembly .................................................................................................. 6-123
Oil Pump Check .............................................................................................................. 6-123
Oil Pump Replacement .................................................................................................. 6-126
Oil Strainer Check .......................................................................................................... 6-126
Oil Pump Assembly ....................................................................................................... 6-127
Timing Gear Case Installation ....................................................................................... 6-128
OIL COOLER ........................................................................................................................ 6-132

Oil Cooler Removal ........................................................................................................ 6-133
Oil Cooler Check ............................................................................................................ 6-134
Oil Cooler Installation .................................................................................................... 6-135
CYLINDER BLOCK ............................................................................................................... 6-138

Cylinder Block Disassembly .......................................................................................... 6-140
Connecting Rod and Piston Disassembly .................................................................... 6-142
Main Bearing Cap and Crankshaft Disassembly ......................................................... 6-143
Piston and Connecting Rod Disassembly .................................................................... 6-145
Piston and Cylinder Block Cleaning ............................................................................. 6-147
Piston and Cylinder Block Check .................................................................................. 6-148
Connecting Rod and Piston Pin Check ......................................................................... 6-154
Connecting Rod Bushing Replacement ....................................................................... 6-156
Crankshaft and Bearing Check ...................................................................................... 6-158
ENG E
OVER
Main Bearing Cap Bolt and Connecting Rod Cap Bolt Check .................................... 6-164
Crankshaft Oil Seal Retainer and Oil Seal Check ........................................................ 6-165
Oil Nozzle and Check Valve Check ................................................................................ 6-167
Cylinder Block Assembly .............................................................................................. 6-167
Piston and Connecting Rod Assembly ......................................................................... 6-168
Crankshaft and Main Bearing Cap Assembly .............................................................. 6-170
Piston and Connecting Rod Installation ....................................................................... 6-174
Crankshaft Oil Seal Retainer Installation ..................................................................... 6-176
6
ENG 2-STAGE RATE COUPLING AND FLYWHEEL E
OVER
2-STAGE RATE COUPLING AND FLYWHEEL
3
4
6 7
LT LT
5
271 271

1 Rear end plate 1
2 Bolt 1 18 N·m (1.8 kgf·m, 13.3 lbf·ft)
3 Flywheel 1
4 Bolts 8 130 N·m (13.3 kgf·m, 95.9 lbf·ft)
5 2-stage rete coupling assembly 1
7 Flywheel housing bracket (right) 1
8 Flywheel housing bracket (left) 1
9 Flywheel housing 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 (P8-9).
2) Disconnect the earth leads 1.
3) Remove the bracket 1.

4) Remove the boost pipe 2 and the gas-
2 3 1 kets.
5) Remove the power steering oil cooler 3.
NOTE:
Place the open hose end of the oil cooler into
a container.
CAUTION:
Prevent the dirt from entering the power
steering system by installing caps and plugs
4 in all open connections.
6) Remove the flywheel housing 4.
6-2
OVER
7) Remove the 2-stage rate coupling assem-
bly 1.
8) Remove the flywheel 1 and the rear end

plate 2.
1
2
2-stage Rate Coupling Disassembly
1
NOTE:
Put marks A on the coupling 1 and outer
member 2 before removing so that they can
be replaced in the original position.
2
1. Disassemble:
a ¡ 2-stage rate coupling
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 2, and

1 2 3 4 bearing 3 from the outer member 4.
6-3
OVER
Check
NOTE:
If damage has occurred to the flywheel and
coupling component parts, replace the fly-
wheel and coupling as an assembly.
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
Rear end plate checking step

1) Check the rear end plate 1 for cracks
and/or damage.
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 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 coupling
1 assembly.
6-4
OVER
Coupling assembly/splines (coupling) and
damper rubber checking steps
1) Check the coupling assembly 1 for
cracks and/or damage.
b Cracks/Damage → Replace coupling as-
sembly.
2) Check the spline A for burns, wear and/
a or damage.
Burns/Wear/Damage → Replace cou-
1 pling assembly.
3) Check the damper rubber B for wear,
Wear/Cracks/Damage → Replace 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 coupling as-
sembly.
Outer member and damper joint checking

steps
1) Check the outer member 1 for cracks
1
and/or damage.
2 Cracks/Damage → Replace coupling as-
sembly.
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.
NOTE:
¡ The holes A located on the plate 1 for
the coupling assembly bolts must be
aligned with the right side (as seen from
the outer member 4) of the oval cut-outs
LT
B on the outer member.
271
¡ Apply LOCTITE ® No. 271 to each stud
thread.
a
¡ Tighten both nuts simultaneously.
Nut (damper joint):

b
5.6 N·m (0.57 kgf·m, 4.13 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.
Bolt (coupling):
67 N·m (6.8 kgf·m, 49.4 lbf·ft)
T.R
5
NOTE:
LT
6 2 3 ¡ Align the matchmarks A of the coupling
271 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, 13.3 lbf·ft)
T.R
1
2) Install the flywheel 1 onto crankshaft.
Bolts (flywheel):
127 N·m (13.0 kgf·m, 93.7 lbf·ft)
T.R
NOTE:
¡ Clean the contact surfaces of the flywheel
and crankshaft.
1
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, 21.4 lbf·ft)
NOTE:
2
crisscross pattern.
¡ The round edge A of the washer 2 must
face the flywheel 3.
a
3
6-7
OVER
4) Install the flywheel housing 1.
5) Install the power steering oil cooler 2.
3 2 4
6) Install the new gaskets and the boost
pipe 3.
7) Install the bracket 4.
8) Connect the earth leads 5.
9) Install the starter motor.

Refer to “Starter Motor Installation” sec-
tion (P8-22).
6-8
ENG SEAWATER PUMP E
OVER
SEAWATER PUMP
3 4
1
2
10
14
13
5 New New
12
New 11
New
8 9 New
6 7
New
16
20
19
17
18
15 New New

2 Cover 1
3 Impeller 1
4 Wear plate 1
5 Circlip 1
6 Washer 1
7 Mechanical seal 1
8 V-ring 1
9 O-ring 1
0 Pump housing 1
A Bearing 1
B Circlip 1
C Spacer 1
D Bearing 1
E Pump shaft 1
F Key 1
G Circlip 1
6-9
ENG SEAWATER PUMP E
OVER
3 4
1
2
10
14
13
5 New New
12
New 11
New
8 9 New
6 7
New
16
20
19
17
18
15 New New

H Oil seal 1
I Driven gear 1
J Nut 1 110 N·m (11.2 kgf·m, 81.1 lbf·ft)
6-10
ENG SEAWATER PUMP E
OVER
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 coolant (seawater).
2) Remove the inlet 1 and outlet 2 hoses.
3) Remove the seawater pump assembly.
Seawater Pump Impeller Removal

1. Remove:
¡ Impeller
Seawater pump impeller removal step

1) Take off the 4 screws 1, and remove the
cover 2 and the O-ring 3.
3
2
6-11
ENG SEAWATER PUMP E
OVER
2) Remove the impeller 1.
1 CAUTION:
Take care not to damage the impeller 1.
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.
1 Burrs/Chips/Cracks/Damage → Replace
driven gear.
Cover and wear plate checking step

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

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

1) Check the impeller for wear, cracks and/
or damage.
Wear/Cracks/Damage → Replace impel-
ler.
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
3
soft-jaws 2 to loosen the nut 3.
2
2) Remove the nut 3.
3) Remove the driven gear 1 and then re-

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

Replace it if necessary.
5) Check the oil seal 1.

1
Wear/Damage → Replace oil seal.
2 6) Check the seawater pump housing 2.
Checks/Damage → Replace pump as-
sembly.
7) Remove the oil seal using a suitable tool.
NOTE:
Be careful not to damage the shaft.
6-13
ENG SEAWATER PUMP E
OVER
8) Remove the circlip.
9) Remove the circlip 1 and the washer 2.

1
10) Press out the pump shaft 1 in the illus-

trated direction.
1 NOTE:
Put out the pump shaft 1 and the bearings
2 as a set.
2
11) Remove the bearing 1.

4 12) Remove the bearing 4 after removing
3
1
2 the circlip 2 and the spacer 3.
13) Remove the mechanical seal 1 and the

1 V-ring 2 using a suitable tool.
2
6-14
ENG SEAWATER PUMP E
OVER
14) After inseting a new bearing 4 onto the
pump shaft 5, install the spacer 3,
4
2
3 circlip 2, and then install the bearing 1
1 until it contacts the circlip 2.
15) Install a new V-ring 2 on the housing.

16) Install the mechanical seal 1 so that the
sealing surface faces the V-ring.
2
NOTE:
¡ Position the V-ring 2 so that the cone is
1
facing to the mechanical seal.
¡ Press in the mechanical seal uniformly by
hand.
17) Install the pump shaft with bearing into

2 the housing using a hydraulic press.
1
NOTE:
¡ Insert the pump shaft with bearing into
the housing from the gear side. Be care-
ful not to curlup the V-ring.
¡ Press the outer race 1 of the bearing un-
til it aligns with the circlip groove 2.
6-15
ENG SEAWATER PUMP E
OVER
18) Install the circlip 1.
19) Place the oil seal 2 with the marking fac-
2 ing to the circlip and push it in by an ap-
1
propriate tool until it abuts on the circrip.
20) After installing the mechanical seal 5 on
the shaft from the impeller side, place
the washer 4 on the shaft and then in-
stall the circlip 3.
NOTE:
5
4 ¡ Install the mechanical seal with the spring
facing to the impeller.
6
¡ Do not apply oil to the seal parts.
3 ¡ Do not spread open the circlip more than
necessary.
7
21) Attach the wear plate 6 and then install
8 9 the impeller 7.
22) Install the O-ring 8 and the cover 9.
Bolts (cover):
2 N·m (0.2 kgf·m, 1.5 lbf·ft)
T.R
23) Install the driven gear.
Nut (driven gear):

110 N·m (11.2 kgf·m, 81.1 lbf·ft)
T.R
6-16
ENG SEAWATER PUMP E
OVER
Seawater Pump Assembly
1. Assemble:
¡ Seawater pump
Seawater pump assembly 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 clockwise.
A
1
NOTE:
When inserting the impeller 1 into the pump
body, turn it clockwise while pushing.
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
3
torque.
2
Bolts (cover):
2 N·m (0.2 kgf·m, 1.5 lbf·ft)
T.R
NOTE:
If the O-ring comes off, keep it in the ring
groove by use of Yamaha marine grease A.
6-17
ENG SEAWATER PUMP E
OVER
Seawater Pump Installation
1. Install:
¡ Seawater pump
Seawater pump installation steps

1) Apply Yamaha marine grease A to the
new O-ring 1 and install it on the sea-
1
water pump.
2) Mount the seawater pump in the gear
case engaging with the gear.
NOTE:
¡ Slots are provided to assure the gear en-
gagement at the time of seawater pump
mounting .
¡ Engage the gears by moving the pump in
the slot. Before tightening the mounting
nuts, turn the seawater pump clockwise
to the full extent as illustrated below
(wiewed from the engine front).
6-18
ENG HEAT EXCHANGER E
OVER
HEAT EXCHANGER
LT
572
LT
4
LT 243
TB
1207B
TB TB
1207B 1207B
2
1 4 3
LT
243
TB
LT
1207B
572

1 Side plate mounting bolts 2 12 N·m (1.2 kgf·m, 8.9 lbf·ft)
2 Drain bolt (seawater) 1 15.7 N·m (1.60 kgf·m, 11.58 lbf·ft)
3 Drain bolt (fresh water) 1 15.7 N·m (1.60 kgf·m, 11.58 lbf·ft)
4 Anodes 2 19 N·m (1.9 kgf·m, 14.0 lbf·ft)
6-19
OVER
Heat Exchanger Removal
1. Remove:
¡ Heat exchanger
Heat exchanger removal steps

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

1. Disassemble:
¡ Heat exchanger
Heat exchanger disassembly step

1) Remove the left and right side plates,
a gaskets and O-rings.
1 NOTE:
Before removing the side plate 1 on the ther-
mostat side, put marks A so that it can be
assembled in its original position.
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.
6-20
OVER
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
a all deposits from inside the coolant paths
1 A using a hard rod 1 carefully.
3) Blow off any debris or deposits from sea-
water paths and dry them with com-
pressed air.
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 contacting with the gasket.
2) Apply ThreeBond® TB-1207B to the sur-
TB
faces 1. Allow them to dry for at least 5
1
minutes.
1207B
3) Install a new gaskets 2, 4 and the side
4 plate 3, 5.
LT
2 572 Bolts (side plate):

12 N·m (1.2 kgf·m, 8.9 lbf·ft)
T.R
NOTE:
¡ Install the side plate 5 on the thermostat
end at the position indicated by marks A.
a
¡ Before installation, apply LOCTITE® No.
5 572 or equivalent to the bolt threads.
LT
572
TB
4
1207B
6-21
OVER
Heat Exchanger Installation
1. Install:
¡ Heat exchanger
Heat exchanger installation steps

1) Install the heat exchanger. Align the pro-
trusion on the heat exchanger with the
hole on the bracket A at the time of in-
stallation.
2) Install the clamps 1 and tighten the nuts.

3) Connect the hoses 2.
NOTE:
1 2
Make sure that the hose A is installed cor-
2
rectly. (longer straight part end B to the
thermo-cover, and shorter part end C to the
coolant inlet)

(P3-40).
NOTE:
Check for the leakage of coolant.
6-22
OVER
Thermostat Removal
1. Remove:
¡ Thermostat
Thermostat removal steps

(P3-40).
2) Remove the thermostat cover 1 and
2
then remove the thermostat 2.
1
Thermostat Check
1. Check:
¡ Thermostat cover
¡ Rubber gasket
¡ Thermostat operation
Thermostat cover checking step

1) Check the thermostat cover for damage.
Rubber gasket checking step

1) Check the rubber gasket for wear and/or
damage.
Wear/Damage → Replace thermostat.
6-23
OVER
Thermostat operation checking steps
1) Place the thermostat in water and gradu-
ally heat the water. Check the thermom-
eter while constantly stirring the water.
2) Check the valve opening temperature
and the valve lift.
Thermostat:
Valve opening temperature
a
74.5 – 78.5 °C (166.1 – 173.3 °F)
Valve lift 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.
Thermostat Installation
1. Install:
¡ Thermostat
Thermostat installation steps
1) Install the thermostat 1.
a
NOTE:
Install the thermostat with the jigger valve
A facing upward.
2) Install the thermostat cover 1 and hose

2.
1 2
(P3-40).
NOTE:
6-24
ENG INTERCOOLER E
OVER
INTERCOOLER
2
LT
4 243
5 LT
572
TB
1207B

1 Seawater flow sensor 1 65 N·m (6.5 kgf·m, 47.2 lbf·ft)
2 Anodes 2 19 N·m (1.9 kgf·m, 14.0 lbf·ft)
3 Side cover mounting bolts 10 10 N·m (1.0 kgf·m, 7.4 lbf·ft)
4 Side cover mounting nuts 10 10 N·m (1.0 kgf·m, 7.4 lbf·ft)
5 Intercooler mounting bolts 4
6-25
ENG INTERCOOLER E
OVER
Intercooler Removal
1. Remove:
¡ Intercooler
Intercooler removal steps
1) Drain the seawater.
2) Remove the air filter 1 and the oil sepa-
2 rator 2.
1
3) Remove the boost pipe 3 and the sea-
water hoses 4.
4
NOTE:
Disconnect the seawater sensor A wiring.
3
a
4) Remove the bolts 1 at 5 places, as well

as the nuts and washers 2 at 2 places
1 on the intake pipe.
2
5) Remove the throttle wire bracket 1 and

the oil pressure sender 2.
1
6) Remove the 3 bolts below the intercooler.
6-26
ENG INTERCOOLER E
OVER
7) Remove the bolt above the intercooler
and then remove the intercooler.
Intercooler Disassembly
1. Disassemble:
¡ Intercooler
Intercooler disassembly steps

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

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.
6-27
ENG INTERCOOLER E
OVER
Intercooler Check
1. Check:
¡ Intercooler housing and side covers
¡ Breather hose
¡ Intercooler element
¡ Element core
¡ Seawater flow sender
Intercooler housing and side cover checking

step
1) Check the intercooler housing and the
side cover 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
compressed air.
a
1
2) Check the fins A for any deformation.

Flattening of fins → Repair or replace the
element.
Seawater flow sender checking steps

1) Check the seawater flow sender.
Refer to “Seawater Flow Sensor Check”
section (8-47).
6-28
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 from inside the coolant paths
using a hard rod 1 carefully.
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 sensor 1 and

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

64 N·m (6.5 kgf·m, 47.2 lbf·ft)
T.R
CAUTION:
Always use a new gasket 4 for the seawa-
ter flow sensor.
6-29
ENG INTERCOOLER E
OVER
Intercooler Assembly
1. Assemble:
¡ Intercooler
Intercooler assembly steps

1) Insert the intercooler element using a
new gasket 1.
1 2) Attach the collars on the new gasket 1,
and then mount the side cover 2 on the
housing (front side).
Bolts (front side cover):

2
10 N·m (1.0 kgf·m, 7.4 lbf·ft)
T.R
3) Install a new gasket on the housing (rear
side), and apply ThreeBond® TB-1207B
over the range indicated in the illustra-
tion.
NOTE:
¡ Be careful that ThreeBond® TB-1207B
does not enter the sealing surface of the
90mm gasket.
¡ Place a wave washers on the four corners.
TB
Gasket
1207B
Apply R
ThreeBond TB-1207B
4) Tighten the mounting bolts of the rear

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

10 N·m (1.0 kgf·m, 7.4 lbf·ft)
T.R
6-30
ENG INTERCOOLER E
OVER
Intercooler Installation
1. Install:
¡ Intercooler
Intercooler installation step

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

2 1
NOTE:
Pass the drain hose 1 throught the hole in
the intercooler bracket 2.
2) Install the oil pressure sender 1 and

throttle wire bracket 2.
2
3) Install the boost pipe 1, seawater hoses

4 2, 3, oil separator 4, and air filter 5.
5
NOTE:
a Connect the seawater hose 2 longer end to
2
the intercooler seawater outlet A, and
shorter end to the power steering oil cooler
seawater inlet B.
6-31
ENG INTERCOOLER E
OVER
(P3-40).
NOTE:
6-32
ENG TURBOCHARGER E
OVER
TURBOCHARGER
NEW
NEW

1 Drain bolt 1 33 N·m (3.4 kgf·m, 24.3 lbf·ft)
6-33
ENG TURBOCHARGER E
OVER
3
4

1 Oil pipe union bolt 1 11 N·m (1.1 kgf·m, 8.1 lbf·ft)
2 Oil pipe union bolt 1 24.5 N·m (2.50 kgf·m, 18.07 lbf·ft)
3 Coolant pipe union bolt 1 20 N·m (2.0 kgf·m, 14.8 lbf·ft)
4 Coolant pipe union bolt 1 20 N·m (2.0 kgf·m, 14.8 lbf·ft)
6-34
ENG TURBOCHARGER E
OVER
20
17
16 18
15
19
13
14
13
12
18
Seal 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
6-35
ENG TURBOCHARGER E
OVER
Handling Precautions
CAUTION:
1. Do not stop the engine immediately af-
ter the high speed running. Let the en-
gine idle 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 idle
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.
6-36
ENG TURBOCHARGER E
OVER
Turbocharger Removal
1. Remove:
¡ Turbocharger
Turbocharger removal steps

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

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

2
3 7) Remove the bolts 3 below the turbo-
charger.
8) Remove the boost pipe 1.
6-37
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.
6-38
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):

STD
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 turbo-
charger assembly.
Radial play (turbine shaft):

STD
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.
6-39
ENG TURBOCHARGER E
OVER
Turbocharger Disassembly
1. Disassemble:
¡ Turbocharger
Turbocharger disassembly steps

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

ing and the turbine housing, and remove
the compressor housing assembly 1.
CAUTION:
1
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.
¡ Pay attention that the impeller does not
2 come in touch with the compressor hous-
ing.
NOTE:
Check in which way the tapered surface of
the snap ring faces.
6-40
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 rock 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.)
6-41
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 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.
6-42
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 : More than 11.986 mm (0.472 in.)
Turbine shaft runout limit:
B : Less than 0.005 mm (0.0001 in.)
Center housing measurement step

1) Measure the inner diameter of the cen-
D
ter housing C, D.
Bearing case inside diameter limit:

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

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

E
E : More than 5.075 mm (0.2 in.)
6-43
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
Inside diameter limit:
Less than 12.04 mm (0.474 in.)
Outside diameter limit:
More than 17.92 mm (0.705 in.)
Thrust bearing measurement step

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

More than 4.94 mm (0.194 in.)
6-44
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.
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 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.
6-45
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:
¡ Make sure that the notch on the thrust
2
Seal 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 the new O-ring 1 and install the re-
tainer 2 on the center housing. Fix them
firmly with 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 rock nut is a left-handed screw.
1
Impeller rock nut:

9.3 N·m (0.95 kgf·m, 6.83 lbf·ft)
T.R
6-46
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 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 the new O-ring 1 and install the com-

pressor housing 2 to the center hous-
ing aligning the matching marks. Fix
1
them with 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.
Set the lock plate and tighten the bolts
to the specified torque.
Bolts (turbine housing):

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.
6-47
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) Install the boost pipe 4 using a new gas-
ket.
3) Tighten the nuts 3 (double nuts).
4) Tighten the bolts 1.

2
1 5) Set the joint hose 2 in position and
tighten the hose clamps 3.
6-48
ENG TURBOCHARGER E
OVER
6) Install the oil drain pipe 2 using a new
gasket 1.
2
7) Install oil pipe using a new gasket.
1 Hollow bolt 1:
11 N·m (1.1 kgf·m, 8.1 lbf·ft)
T.R
8) Install coolant bypass pipe using a new
gasket.
Hollow bolt 2:
20 N·m (2.0 kgf·m, 14.8 lbf·ft)
T.R
9) Install mixing elbow using a new gasket

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

(P3-40).
NOTE:
6-49
ENG TURBOCHARGER E
OVER
12) Fill the engine oil.
Refer to “Engine Oil and Filter Replace-

SAE I5W-40, API CD or CE

Max. 9.2 L, Min. 7.5 L
 Max. 8.1 lmp qt., Min. 6.6 lmp qt. 
 Max. 9.7 US qt., Min. 7.9 US qt. 
Max. 9.9 L, Min. 8.2 L
 Max. 8.7 lmp qt., Min. 7.2 lmp qt. 
 Max. 10.5 US qt., Min. 8.7 US qt. 
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
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.
Deformed or damaged component → Re-
pair or replace.
6-50
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 (or remove the sender if optional
sender is installed).
3) Install the adapter and connect the pres-

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

176 ± 10 kPa
(1.79 ± 0.1 kgf/cm2, 25.5 ± 1.5 psi)
5) Remove the turbocharger pressure

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

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

10 N·m (1.0 kgf·m, 7.4 lbf·ft)
T.R
6-51
ENG MIXING ELBOW AND EXHAUST MANIFOLD E
OVER
MIXING ELBOW AND EXHAUST MANIFOLD

1 Exhaust manifold mounting bolts 8 39 N·m (4.0 kgf·m, 28.8 lbf·ft)
2 Exhaust manifold mounting nuts 4 32 N·m (3.3 kgf·m, 23.6 lbf·ft)
6-52
OVER
Mixing Elbow and Exhaust Manifold
Removal
1. Remove:
¡ Mixing elbow and exhaust manifold
Mixing elbow and exhaust manifold removal

steps
(P3-40).
2) Remove the mixing elbow.
3) Remove the turbocharger.
Refer to “Turbocharger Removal” sec-
tion (P6-37).
4) Remove the bracket 1 with seawater
strainer assembly 2.
1
2
5) Remove the cooling pipe 1 and the gas-

1 2
ket 2.
6) Remove the cover of the electrical box

and then remove the stay (4 bolts).
6-53
OVER
7) Remove the fuse stay assembly.
2 4 8) Disconnect the shift cable 1 at the re-

mote control end.
9) Disconnect the shift cable 2 at the drive
unit end.
10) Disconnect the neutral switch coupler 3.
11) Remove the shift assist assembly 4.
1
3
12) Remove the hose holder under the ex-
haust manifold.
13) Remove the thermostat hausing bolts 1.

14) Remove the bolt 2 and the clamp 3.
1
15) Disconnect the hose.

1
16) Disconnect the thermo switch lead 1
(red/black).
17) Disconnect the coolant temperature sen-
sor lead 2 (brown/black).
2
18) Remove the exhaust manifold 1.

1
6-54
OVER
19) Remove the exhaust manifold gaskets 1.
1
20) Remove the coolant temperature sensor

1.
2 21) Remove the thermo switch 2.
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.
6-55
OVER
Exhaust manifold warpage checking step
1) Check the warpage on the contact faces
of the exhaust manifold and the cylin-
der head by use of a straight edge and a
thickness gauge.
Manifold warpage:
Filler neck checking step

1) Check the filler neck 1 for cracks and/or
damage.
1 Refer to “Exhaust Manifold Check” sec-
tion (P6-55).
Filler Neck Replacement

1. Replace:
¡ Filler neck
Filler neck replacement steps

1) Remove the filler neck 1.
2 2) Remove the O-ring 2 from the filler neck.
a
3) Install the new filler neck 1 with a new
O-ring 2.
NOTE:
Position the breather pipe A so that it points
A
1
away from the engine.
6-56
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
¡ Coolant 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:
¡ Once the plug 2 is removed, apply
1
LOCTITE ® No. 243 before mounting it
again.
¡ Once the joint plug 3 is removed, replace
the O-ring with the new one, and apply
LOCTITE ® No. 243 before mounting it
3
again. Mounting angle shall be 90° rela-
LT
tive to the mixing elbow mounting face.
243
Screw plug 2:
2
10 N·m (1.0 kgf·m, 7.4 lbf·ft)
T.R
Coolant temperature sensor checking step

1) Refer to “Coolant Temperature Sensor
Check” section (P8-48).
Thermo switch checking step

1) Refer to “Thermo Switch Check” section
(P8-49).
6-57
OVER
Mixing Elbow and Exhaust Manifold
Installation
1. Install:
Mixing elbow and exhaust manifold instal-

lation steps
1) Install the coolant temperature sensor 1
and the thermo switch 2.
2
LT Coolant temperature sensor:
1
243 11 N·m (1.1 kgf·m, 8.1 lbf·ft)
T.R
LT
Thermo switch:
243
34 N·m (3.5 kgf·m, 25.1 lbf·ft)
2) Install the new gasket 1 of the exhaust

a
manifold.
1
a NOTE:
Install the exhaust manifold gasket with the
gasket links A placed on the upper side.
3) Install the exhaust manifold.

4
1
Bolts 1, 4:
39 N·m (4.0 kgf·m, 28.8 lbf·ft)
T.R
Nuts 2, 3:
32 N·m (3.3 kgf·m, 23.6 lbf·ft)
2 1
NOTE:
3 4 Tighten the bolts and nuts in a crisscross
pattern starting in the middle.
4) Connect the hose, thermo switch lead 1

1
(red/black) and coolant temperature sen-
sor lead 2 (brown/black).
6-58
OVER
5) Install the new gasket and the thermo-
stat housing 1.
6) Install the hose holders under the ex-
haust manifold.
1
3
7) Install the cramp 2 and the bolt 3.
8) Install the turbocharger.
Refer to “Turbocharger Installation” sec-
2 tion (P6-48).
3 1 9) Install the shift assist assembly 1.

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

box, and cover.
15) Install the new gasket 1 and the cooling

2 1
pipe 2.
6-59
OVER
16) Install the bracket 1 with the seawater
17) Install the mixing elbow.

18) Fill the engine coolant.
(P3-40).
NOTE:
6-60
ENG TIMING BELT AND TIMING PULLEYS E
OVER
TIMING BELT AND TIMING PULLEYS
3 4

1 Timing pulley #1 mounting bolt 1 98 N·m (10.0 kgf·m, 72.3 lbf·ft)
2 Idler pulley mounting bolt 1 34.5 N·m (3.5 kgf·m, 25.4 lbf·ft)
3 Auto-tensioner mounting bolts 2 13 N·m (1.3 kgf·m, 9.6 lbf·ft)
4 Timing pulley #2 mounting bolts 4 31 N·m (3.2 kgf·m, 22.9 lbf·ft)
6-61
OVER
Timing Belt and Timing Pulley Removal
1. Remove:
¡ Timing belt and timing pulley
Timing belt and timing pulley removal steps

(P3-40).
2) Remove the bracket 1 with seawater

2
1
1 2
3) Remove the cooling pipe 1 and the gas-
ket 2.
4) Remove the timing belt cover.
5) Turn the crankshaft pulley clockwise, and

3 align the grooves A on the pulley #1 1
1
and the pulley #2 2 with the BDC marks
b a B on the timing gear cover 3.
a b
CAUTION:
By positioning the #1 cylinder at the BDC,
interference between valves and pistons is
2
avoided in case the camshaft is rotated.
6-62
OVER
NOTE:
c
If the timing belt is reused, draw an arrow C
on the timing belt (in the direction of the en-
gine revolutions).
6) Remove the auto-tensioner.
NOTE:
¡ The auto-tensioner is a high-pressure hy-
draulic cylinder.
¡ When removing, the two bolts should be
loosened slowly and gradually.
7) Remove the timing belt 1.
8) Remove the idler pulley 1.
9) Remove the outer plate 1, camshaft tim-

3 2
1 ing pulley #2 2 and inner plate 3.
6-63
OVER
10) Disconnect the ventilation hose.
1 11) Remove the cylinder head cover 1.
3 12) Loosen the camshaft timing pulley #1

2 bolt 1 by three turns.
NOTE:
1
loosening the timing pulley bolt.
13) Remove the camshaft timing pulley #1

1 1 with the puller B set 2.
Puller B set:
2
09950-40011
 09951-04010 
 09952-04010 
 
 09953-04020 
 09954-04010 
 
 09955-04061 
or (90890-0741A)
14) Remove the camshaft timing pulley #1

1 and the plate washer.
15) Remove the set key from the camshaft.
6-64
OVER
Timing Belt and Timing Pulley Check
1. Check:
¡ Timing belt
¡ Idler bearing movement
¡ Pulley bolt movement (on pulley)
Timing belt checking step

1) Check the timing belt.
Refer to “Timing Belt Check” section (P3-
26).
Idler bearing movement checking step

1) Check the movement of the idler bear-
ing.
Roughness → Replace idler bearing as-
sembly.
Pulley bolt movement checking step

1) Check the movement of the pulley bolt.
(on pulley)
Unsmooth movement → Replace idler
bearing assembly and pulley bolt as a
set.
6-65
OVER
Timing Belt and Timing Pulley Installa-
tion
1. Install:
¡ Timing belt and timing pulley
Timing belt and timing pulley installation

steps
1) Install the set key on the camshaft.
2) Install the plate washer and the camshaft
timing pulley #1.
3) Install the camshaft timing pulley #1 bolt.
NOTE:
Align the set key with the key groove on the
timing pulley.
4) Tighten the camshaft timing pulley #1

2 bolt.
1
NOTE:
tightening the timing pulley bolt.
Bolt (timing pulley #1):

98 N·m (10.0 kgf·m, 72.3 lbf·ft)
T.R
5) Remove fraction of old gasket remain-

ing on the cylinder head and the cylin-
der head cover.
6) Clean the sealing surfaces of the cylin-
der head and the cylinder head cover
with a non-residual solvent.
7) Apply ThreeBond® TB-1207B to the cyl-
inder head sealing surface.
TB
TB
1207B NOTE:
1207B
The cylinder head cover must be installed
within 5 minutes of sealant application. If
more than 5 minutes have passed, the seal-
6-66
OVER
8) Install the cylinder head cover together
with the gasket.
NOTE:
Tighten the bolts in a crisscross pattern start-
ing from the inside and moving to the out-
side.

6.4 N·m (0.65 kgf·m, 4.72 lbf·ft)
T.R
9) Connect the ventilation hose.
10) Install the timing pulley #2 2, inner plate

1 1, and outer plate 3.
2
NOTE:
3 Align the knock pin A on the injection pump
drive gear with the knock pin hole B on the
a inner plate and the slot C on the camshaft
b timing pulley #2.
c
Bolts (camshaft timing pulley #2):

31 N·m (3.2 kgf·m, 22.9 lbf·ft)
T.R
11) Install the idler pulley 1.
Bolt (idler pulley):

34.5 N·m (3.52 kgf·m, 25.45 lbf·ft)
T.R
6-67
OVER
12) Carefully wipe off each pulley so that
3 there are no remnants of oil or water on
1
them.
b a 13) Align each BDC mark B on the timing
a b pulley cover 3 with grooves A on the
camshaft timing pulleys #1 1 and #2 2.
2 CAUTION:
Turning the crankshaft causes the valve
heads to hit the top of the pistons. Do not
turn the crankshaft more than necessary.
14) Install the timing belt 1.

1
NOTE:
2 ¡ Install the timing belt in the following or-
der:
3 1) Camshaft timing pulley #2 2
4 2) Camshaft timing pulley #1 3
3) Timing belt idler pulley 4
¡ If the timing belt is reused, the arrow A
is pointing in the direction of engine ro-
tation.
a
15) Retract the auto-tensioner using a press.
CAUTION:
Retract the auto-tensioner slowly. The auto-
tensioner may be damaged if retracted rap-
idly.
16) Align the locations of the holes on the

auto-tensioner and insert a hexagonal
wrench (width across flat: 1.27 mm
(0.05 in.)) into those holes to keep the
auto-tensioner in the retracted state.
6-68
OVER
17) Pull out the hexagonal wrench after the
auto-tensioner is mounted by tightening
the bolts to the specified torque.
Bolts (auto-tensioner):
13 N·m (1.3 kgf·m, 9.6 lbf·ft)
T.R
18) Turn the crankshaft clockwise and check
that each pulley is aligned with the tim-
ing marks (TDC marks) as shown in the
illustration. If they are not aligned, re-
move the timing belt and readjust.
19) Remove all the fractions of old gasket re-
maining on the timing gear cover and the
oil seal retainer.
20) Clean the sealing surfaces of the timing
gear cover and the oil seal retainer with
a non-residual solvent.
6-69
OVER
21) Check the gasket on the timing belt cover.
NOTE:
¡ If the gasket is damaged slightly, seal it
by applying ThreeBond® TB-1207B.
¡ If the gasket is seriously damaged, install
a new one. In this case, make sure that
a b no fraction of old gasket remains on the
timing belt cover or on the engine body.
Peel off the parting paper from the adhe-
sive face of the gasket. Attach the gasket
on the timing belt cover. As it is attached,
the gasket thickness must be kept evenly,
and the groove A on the attaching face
must run in the middle of the gasket.
No gap is allowed at the gasket joint
area B. Cut off the extra length.
If there is any gap at the joint area, fill it
with ThreeBond® TB-1207B.
REFERENCE:
Timing belt cover gasket:
11328-17040 (TOYOTA part number)
22) Apply ThreeBond ® TB-1207B to the oil

seal retainer and the timing gear cover.
NOTE:
TB TB
1207B
The timing belt cover must be assembled
1207B
23) Install the timing belt cover together with

the gasket.
Bolts (timing belt cover):

19.6 N·m (2.0 kgf·m, 14.46 lbf·ft)
T.R
6-70
OVER
2 1
24) Install the new gasket 1 and the cooling
pipe 2.
25) Install the bracket 1 with seawater

1 2

(P3-40).
NOTE:
6-71
ENG CIRCULATION PUMP E
OVER
CIRCULATION PUMP
2
1

1 Circulation pump mounting bolts 7 19.6 N·m (2.0 kgf·m, 14.46 lbf·ft)
2 Circulation pump mounting nuts 2 19.6 N·m (2.0 kgf·m, 14.46 lbf·ft)
3 Pulley mounting nuts 4 19.6 N·m (2.0 kgf·m, 14.46 lbf·ft)
4 Camshaft oil seal retainer mounting bolts 4 19.6 N·m (2.0 kgf·m, 14.46 lbf·ft)
6-72
OVER
Circulation Pump Removal
1. Remove:
¡ Circulation pump
Circulation pump removal steps

2) Remove the timing belt, idler pulley and
pulley #1.
3) Remove the camshaft oil seal retainer.
4) Remove the circulation pump pulley 1.
5) Remove the alternator stay 1.

1 6) Remove the circulation pump 2 and the
gasket.
6-73
OVER
Circulation Pump Check
1. Check:
¡ Bearing (circulation pump)
¡ Impeller
¡ Circulation pump housing
Circulation pump bearing checking step

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

1) Check the impeller 1 for cracks and/or
1
damage.
Cracks/Damage → Replace circulation
pump assembly.
2
Circulation pump housing checking step
1) Check the circulation pump housing 2
for cracks and/or damage.
Cracks/Damage → Replace circulation
pump assembly.
Circulation Pump Installation

1. Install:
¡ Circulation pump
Circulation pump installation steps
1
1) Install the new gasket and the circulation
2
pump 1.
2) Install the alternator stay 2.
Nuts/bolts (circulation pump):

19.6 N·m (2.0 kgf·m, 14.46 lbf·ft)
T.R
6-74
OVER
3) Install the circulation pump pulley to take
the illustrated orientation, and tighten
FWD the pump pulley nuts 1 to the specified
torque.
Nuts (circulation pump pulley):

1
19.6 N·m (2.0 kgf·m, 14.5 lbf·ft)
T.R
4) Apply ThreeBond® TB-1207B at the lo-
TB cations shown in the illustration, and in-
1207B stall the camshaft oil seal retainer with
in 5 minutes of application.
Bolts (camshaft oil seal retainer):

19.6 N·m (2.0 kgf·m, 14.5 lbf·ft)
T.R
NOTE:
Degrease the attaching surface.
5) Install the pulley #1, idler pulley and tim-

ing belt.

(P3-40).
NOTE:
6-75
ENG TIMING GEARS E
OVER
TIMING GEARS
1207B
1207B
1207B

1 Injection pump gear mounting nut 1 98 N·m (10.0 kgf·m, 72.3 lbf·ft)
2 Timing gear cover mounting bolts 12 19.6 N·m (2.0 kgf·m, 14.46 lbf·ft)
3 Idler gear thrust plate mounting bolts 4 68 N·m (6.9 kgf·m, 50.2 lbf·ft)
4 Crankshaft pulley mounting bolt 1 430 N·m (43.9 kgf·m, 317.2 lbf·ft)
5 O-ring 1
6-76
ENG TIMING GEARS E
OVER
Timing Gear Removal
1. Remove:
¡ Timing gear
Timing gear removal steps

1) Remove the drive belt.
2) Remove the timing belt and the timing
pulleys.
3) Remove the camshaft oil seal retainer.
Refer to “Camshaft Oil Seal Replace-
2 4) Remove the crankshaft pulley mounting
bolt.
5) Remove the plate washer with a crank-
shaft holding tool 1 and companion
flange holding tool 2.
1
Crankshaft pulley holding tool:
09213-58013 or (90890-07501)
09330-00021
6) 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.
¡ Always keep the tool body parallel to the
crankshaft pulley.
7) Remove the timing gear cover 1.
1 CAUTION:
Be careful not to damage the contact sur-
faces of the gear cover and the gear case.
6-77
ENG TIMING GEARS E
OVER
2 8) Check the thrust clearance of idler gear
1 with a thickness gauge 2.
Out of specification → Replace the idler
gear thrust plate.
Idler gear thrust clearance:

0.02 – 0.10 mm (0.001 – 0.004 in.)
1
<Limit> less than 0.30 mm (0.012 in.)
Replace the idler gear and/or idler gear
shaft if necessary.
9) Check the timing gear backlash with a

dial gauge.
Out of specification → Replace the gears
as a set.
Timing gear backlash:

0.05 – 0.15 mm (0.002 – 0.006 in.)
<Limit> less than 0.30 mm (0.012 in.)
NOTE:
Measure the timing gear backlash at the fol-
lowing points:
Injection pump x idler gear
Crankshaft x idler gear
Oil pump x oil pump drive gear
6-78
ENG TIMING GEARS E
OVER
10) Remove the oil pump drive gear with the
1 puller B set 1 and the adapter.
Puller B set:
09950-40011
 09951-04010 
 09952-04010 
 
 09953-04020 
 09954-04010 
 
 09955-04061 
or (90890-0741A)
Adapter:
09958-20010 or (90890-07511)
NOTE:
Make sure that the tool body is in parallel
with the drive gear.
11) Remove the idler gear thrust plate 1,

2 idler gear 2 and idler gear shaft.
12) Remove the injection pump drive gear

1 nut with the companion flange holding
tool 1.

09330-00021
13) Remove the O-ring.
6-79
ENG TIMING GEARS E
OVER
14) Remove the injection pump drive gear
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 puller by more than 8 mm
(0.31 in.).
¡ Always keep the tool body parallel with
the drive gear.
15) Remove the crankshaft timing gear with

the puller B set 1 and the adapter.
1 Puller B set:
09950-40011
 09951-04010 
 09952-04010 
 
 09953-04020 
 09954-04010 
 
 09955-04061 
or (90890-0741A)
Adapter:
09958-20010 or (90890-07511)
6-80
ENG E
OVER TIMING GEARS
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
b gear and the shaft.
a
Pitting/Blue discoloration/Damage →
Replace gear and shaft as a set.
Oil passages checking step

1) Check the oil passage B.
b
Contamination → Wash and blow out the
oil passages.
6-81
ENG TIMING GEARS E
OVER
Idler gear to gear shaft clearance checking
steps
1) Using a cylinder gauge, measure the in-
side diameter of the idler gear 1.
Idler gear inner diameter:

45.000 – 45.025 mm (1.772 – 1.773 in.)
1
2) Using a micrometer, measure the diam-

eter of the idler gear shaft 2.
Idler gear shaft diameter:

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

clearance with the following formula.
2
Idler gear to gear shaft clearance =

Idler gear inside 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 steps

1) Clean and lubricate, then turn the bear-
ing outer race by hand.
6-82
ENG TIMING GEARS E
OVER
Injection Pump Bearing Replacement
1. Replace:
¡ Injection pump drive gear
Injection pump drive gear checking steps

1) Remove the bearing using the puller B
set 1 and the replacer set 2.
1 Puller B set:
09950-40011
 09951-04010 
 09952-04010 
2  
 09953-04020 
 09954-04010 
 
 09955-04011 
or (90890-0741A)
Replacer set:
09950-60010
2) Press in the new bearing using the crank-

shaft pulley replacer and push it until the
bearing presses tightly against the shoul-
der of the drive gear.
Crankshaft pulley replacer:

09214-76011
Timing Gear Cover Check

1. Check:
¡ Timing gear cover
¡ Crankshaft oil seal and injection pump
drive gear oil seal
Timing gear cover checking steps

1) Check the timing gear cover 1 for cracks
and/or damage.
6-83
ENG TIMING GEARS E
OVER
Crankshaft oil seal and injection pump drive
gear oil seal checking step
1) Check the crankshaft oil seal 1 and in-
jection pump drive gear oil seal 2 for
wear and/or damage.
Wear/Damage → Replace.
2
1
Oil Seal Replacement

1. Replace:
¡ Oil seal
Oil seal replacement steps

1) Using a suitable tool and a hammer, tap
out the oil seal 1.
2) Using the crankshaft oil seal replacer, tap

in the new oil seal until its surface is flush
1 with the edge of the timing gear cover
1.
lip of the oil seal.
Crankshaft oil seal replacer:

09223-78010
Replacer set:
09950-60010 (09951-00640)
(09952-06010)
Replacer set No. 2:
09950-60020 (09951-00810)
Handle set:
09950-70010 (09951-07150)
6-84
ENG TIMING GEARS E
OVER
NOTE:
The crankshaft oil seal can also be removed
using the oil seal puller without taking off the
fiming gear cover.
Oil seal puller:

09308-10010
Timing Gear Installation

NOTE:
¡ Carefully clean all parts to be installed.
¡ Apply clean engine oil to all sliding and
rotating surfaces before installing parts.
1. Install:
¡ Timing gear
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.
a Tap on the timing gear using the cover
and seal replacer 2 and a hammer.
Cover and seal replacer:

09223-00010
NOTE:
1 2
¡ 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.
6-85
ENG TIMING GEARS E
OVER
5) Install the set key on the injection pump
drive shaft.
A
6) Install the injection pump drive gear 1
and the new O-ring 2.
NOTE:
drive gear.
1 2
7) Install the injection pump drive gear nut.

Hold the pump drive gear using the com-
panion flange holding tool 1.

09330-00021
1
Nut (pump drive gear):
T.R
98 N·m (10.0 kgf·m, 72.3 lbf·ft)
8) Install the idler gear shaft.
9) Install the idler gear.
NOTE:
Engage the gears aligning the matching
marks as shown in the illustration.
10) Install the idler gear thrust plate.
Bolts (idler gear thrust plate):

68 N·m (6.9 kgf·m, 50.2 lbf·ft)
T.R
6-86
ENG TIMING GEARS E
OVER
11) Install the oil pump drive gear 1.
Tap on the oil pump drive gear using the
cover and seal replacer 2 and a ham-
FWD
mer.
NOTE:
gear.
1 2
Cover and seal replacer:
09223-00010
12) Apply ThreeBond ® TB-1207B to the

a TB
1207B
groove on the sealing surface of the tim-
ing gear cover A.
NOTE:
The timing gear cover must be assembled
13) Install the timing gear cover 1.

1
Bolts (timing gear cover):
19.6 N·m (2.0 kgf·m, 14.46 lbf·ft)
T.R
NOTE:
Tighten the bolts in a crisscross pattern.
14) Install the set key and the crankshaft pul-

1
ley 1.
NOTE:
¡ Align the set key with the key groove on
the pulley.
¡ Tap on the pulley using an appropriate
tool and a hammer.
15) Install the O-ring and the plate washer.
6-87
ENG TIMING GEARS E
OVER
16) Install the crankshaft pulley bolt using
1 the companion flange holding tool 1
and the crankshaft pulley holding tool 2.
Crankshaft pulley holding tool:

09213-58013
09330-00021
2
Bolt (crankshaft pulley):

430 N·m (43.9 kgf·m, 317.2 lbf·ft)
T.R
17) Install the camshaft oil seal retainer.
18) Install the timing pulleys and the timing
belt.
(P3-40).
NOTE:
6-88
ENG CYLINDER HEAD E
OVER
CYLINDER HEAD
8 {0.8 , 5.9}
T.R
11.3 {1.15 , 8.33}
8
T.R
25 {2.6 , 18.4}
T.R
25 {2.6 , 18.4}
T.R
8.5 {0.87 , 6.27}
19 {1.9 , 14.0}
T.R
T.R
4 4
4
3
9 5
1
40 {4.1 , 29.5} B 0
T.R
G 40 {4.1 , 29.5}
T.R
F
98 {10.0 , 72.3}
T.R
34.5 {3.52 , 25.45} A

T.R
19.6 {2.0 , 14.46}

T.R
Tigntening torque [N·m {kgf·m, lbf·ft}]

1 Intake manifold 1
2 Intake manifold gaskets 1 Always use new parts.
3 Valve rocker shaft 1
4 Cam shaft bearing caps 7
5 Cylinder head bolts 26 Tightening torque (Refer to 6-115).
6 Cylinder head 1
6-89
ENG CYLINDER HEAD E
OVER
8 {0.8 , 5.9}
T.R
11.3 {1.15 , 8.33}
T.R
8
25 {2.6 , 18.4}
T.R
25 {2.6 , 18.4}
T.R
8.5 {0.87 , 6.27}
T.R
19 {1.9 , 14.0}
T.R
4 4
4
3
9 5
1
40 {4.1 , 29.5} B 0
T.R
G 40 {4.1 , 29.5}
T.R
F
98 {10.0 , 72.3}
T.R
34.5 {3.52 , 25.45} A

T.R
19.6 {2.0 , 14.46}

T.R

7 Cylinder head gasket 1 Always use new parts.
8 Cylinder head dowel pins 2
9 Spring retainers 24
0 Valve springs 24
A Valves 24
B Spring seats 24
6-90
ENG CYLINDER HEAD E
OVER
8 {0.8 , 5.9}
T.R
11.3 {1.15 , 8.33}
T.R
8
25 {2.6 , 18.4}
T.R
25 {2.6 , 18.4}
T.R
8.5 {0.87 , 6.27}
T.R
19 {1.9 , 14.0}
T.R
4 4
4
3
9 5
1
40 {4.1 , 29.5} B 0
T.R
G 40 {4.1 , 29.5}
T.R
F
98 {10.0 , 72.3}
T.R
34.5 {3.52 , 25.45} A

T.R
19.6 {2.0 , 14.46}

T.R

C Stem oil seals 24
D Cam shaft 1
E Cam shaft bearings 14
F Cam shaft oil seal retainer 1
G Oil seal 1
6-91
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 (P6-26).
¡ Turbocharger
Refer to “Turbocharger Removal”
section (P6-37).
¡ Exhaust manifold
Refer to “Mixing Elbow and Exhaust
Manifold Removal” section (P6-53).
¡ Timing belt and timing pulleys
Refer to “Timing Belt and Timing Pul-
ley Removal” section (P6-62).
¡ Camshaft oil seal retainer
Refer to “Camshaft Oil Seal Replace-
¡ Injection nozzles
Refer to “Injection Nozzle Removal”
section (P5-2).
1
2) Loosen the 8 nuts and remove the intake
manifold 1 and gasket.
3) Remove the cooling pipe joint.
6-92
ENG CYLINDER HEAD E
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4) Loosen the bolts evenly by half a turn in
the order of numbers in the illustration.
10 14 18 20 16 12 8
11 15 19 21 17 13 9
2 4 6 7 5 3 1
5) Remove the rocker shaft and the the

bearing cap.
638 mm NOTE:
This work can be performed more easily by
immobilizing the rocker arm with two rods
as shown in the illustration.
2 8 10 16 18 24 26 21 19 13 11 5 3 6) Loosen the cylinder head bolts evenly by

half a turn in the order of the numbers in
the illustration.
4 6 12 14 20 22 25 23 17 15 9 7 1
7) Remove the cylinder head.
NOTE:
If it is difficult to separate the cylinder head
from the engine block. Insert a suitable tool
between the cylinder and block to pry off the
cylinder head.
CAUTION:
faces of the cylinder head and engine block.
8) Remove the dowel pins 1.

1
6-93
ENG CYLINDER HEAD E
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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 2, valves 3, and spring seats
3
4
4. Put some identification to each part
2 so that they can be reinstalled at their
1 original locations.
6-94
ENG CYLINDER HEAD E
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3) Remove the valve stem oil seal 1.
Piston and Cylinder Block Top Clean-

ing
1. Clean:
¡ Pistons
¡ 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.
6-95
ENG CYLINDER HEAD E
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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:

Bottom
Intake
Exhaust
6-96
ENG CYLINDER HEAD E
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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
using a caliper gauge.
Valve guide inner diameter:

7.001 – 7.003 mm (0.2756 – 0.2757 in.)
2) Measure the valve stem diameter using

a micrometer.
Valve stem diameter:

IN: 6.970 – 6.985 mm (0.274 – 0.275 in.)
EX: 6.960 – 6.975 mm (0.274 – 0.275 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: 0.025 – 0.060 mm (0.001 – 0.002 in.)
<Limit> 0.08 mm (0.003 in.)
EX: 0.035 – 0.070 mm (0.001 – 0.003 in.)
<Limit> 0.10 mm (0.004 in.)
6-97
ENG CYLINDER HEAD E
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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.
NOTE:
Tap out the valve guide bushings from the
combustion chamber side at the locations in-
A A A A A A dicated with A in the illustration using an SST.
A Other than A
Valve guide bushing remover and
replacer set:
09201-10000 (09201-01080)
Handle set:
09950-70010 (09201-07150)
NOTE:
Tap out other valve guide bushings toward
the combustion chamber using an SST.

replacer set:
09201-10000 (09201-01070)
Handle set:
09950-70010 (09951-07150)
2) Measure the valve guide bore diameter

using a caliper gauge.
3) Select a new valve guide from the table
below.
Valve guide bore diameter (mm, (in.)) Valve guide size
11.504 – 11.525 (0.453 – 0.454 in.) STD
NOTE:
If the valve guide bore diameter is greater
than 11.525 mm (0.454 in.), machine the valve
guide bore to the following dimension and
install an oversize guide.
Valve guide bore after the machining:

11.554 – 11.575 mm (0.455 – 0.456 in.)
NOTE:
Replace the cylinder head if the valve guide
bore is greater than 11.575 mm (0.456 in.).
6-98
ENG CYLINDER HEAD E
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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 :
IN: 17.5 – 17.9 mm (0.69 – 0.71 in.)
EX: 14.5 – 14.9 mm (0.57 – 0.59 in.)

replacer set:
09201-10000 (09201-01070)
(09201-01080)
Handle set:
09950-70010 (09951-07150)
5) After installing the valve guide, bore out

the valve guide using the valve guide
reamer 1 to obtain the proper stem-to-
1
guide clearance.
Stem-to-guide clearance:
IN: 0.025 – 0.060 mm (0.001 – 0.002 in.)
EX: 0.035 – 0.070 mm (0.001 – 0.003 in.)
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 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
valve.
6-99
ENG CYLINDER HEAD E
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Valve overall length checking step
1) Check the overall valve length A.
Out of specification → Replace valve.
Overall valve length A :

a
IN: 126.85 – 127.45 mm (4.99 – 5.02 in.)
<Limit> 102.79 mm (4.05 in.)
EX: 126.83 – 127.43 mm (4.99 – 5.02 in.)
<Limit> 102.64 mm (4.04 in.)
Margin thickness checking step

1) Check the margin thickness A of the
valve.
Margin thickness A :
IN: 1.65 mm (0.065 in.)
EX: 1.4 mm (0.055 in.)
a
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 amount of
cleaning the seats.
¡ Use a valve seat cutter with an ultra-hard
tip for the exhaust valve.
6-100
ENG CYLINDER HEAD E
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Valve seat width checking steps
1) Apply mechanic's bluing dye (Dykem) B
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
b
pattern. Do not rotate the valve.
4) Measure the valve seat width A. Where
the valve seat and valve face make con-
tact, bluing will be removed.
5) If the valve seat is too wide A, 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 A :

a IN: 1.4 – 1.8 mm (0.055 – 0.071 in.)
EX: 1.6 – 2.0 mm (0.063 – 0.079 in.)
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
6-101
ENG CYLINDER HEAD E
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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
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
30° cutter seat and to
Use achieve the
Second: specified
45° cutter width
6-102
ENG CYLINDER HEAD E
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Valve and Valve Seat Lapping
1. Lap:
¡ Valve faces and valve seats
NOTE:
After refacing the valve seat or replacing the
valve and valve guide, the valve seat and
valve face should be lapped.
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.
LT
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.
6-103
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):

49.6 mm (1.95 in.)
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.)
6-104
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
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):
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.
Cam lobe height checking step

1) Check the cam lobe height A.
Out of specification → Replace camshaft.
a
Cam lobe height:
IN: 48.203 – 48.303 mm (0.323 – 1.902 in.)
<Limit>
47.703 mm (1.878 in.)
a
EX: 50.739 – 50.834 mm (1.998 – 2.001 in.)
<Limit>
50.234 mm (1.978 in.)
6-105
ENG CYLINDER HEAD E
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Camshaft and bearing clearance checking
steps
1) Clean the bearings and the camshaft
journals.
2) Place the lower bearing and the camshaft
on the cylinder head.
NOTE:
¡ #1 shaft bearing has different size. Be sure
1 to install the correct size bearing.
¡ Set the thrust plate 1 on #1 camshaft
journal.
3) Place some Plastigage® in the axial di-

rection on the top of each camshaft jour-
nal.
4) Install the bearing caps correctly, check-
ing the journal numbers and direction.
Bolts (bearing cap):

25 N·m (2.5 kgf·m, 18.4 lbf·ft)
T.R
14 NOTE:
10
2
6 9 13 ¡ Tighten the bearing cap bolts in a criss-
4 5
8 3 1 cross pattern moving from the inside to
12 7
11 the outside.
¡ Do not turn the camshaft while measur-
ing the clearance.
6-106
ENG CYLINDER HEAD E
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5) Remove the bearing caps and measure
the width of the Plastigage®.
6) Remove the Plastigage®.
Out of specification → Measure the jour-
nal diameter (camshaft).
Camshaft-bearing clearance:
#1 journal
0.022 – 0.074 mm (0.001 – 0.003 in.)
Other journals
0.023 – 0.075 mm (0.001 – 0.003 in.)
<Limit> 0.10 mm (0.004 in.)
Journal outer diameter checking step

1) Check the outer diameter A of the cam-
shaft journals.
Out of specification → Replace camshaft.
Within specification → Replace bearings
of camshaft.
NOTE:
a Replace the bearing caps and cylinder head
if necessary.
Journal outer diameter (camshaft):

#1 journal
Other journals
34.969 – 34.985 mm (1.3767 – 1.3774 in.)
Other journals
27.986 – 27.998 mm (1.1018 – 1.1023 in.)
#1 journal
6-107
ENG CYLINDER HEAD E
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Camshaft thrst clearance checking steps
1) Install the camshaft, bearings and bear-
10 14 ing caps.
2
6 9 13
4 5
8 3 1 NOTE:
12 7
11
Tighten the bearing cap bolts in a crisscross
pattern moving from the inside to the out-
side.
2) Measure the camshaft clearance using a

dial gauge while moving the camshaft
back and forth.
Out of specification → Replace idler gear
thrust plate.
NOTE:
Replace the camshaft if necessary.
Camshaft thrust clearance:

0.10 – 0.20 mm (0.004 – 0.008 in.)
<Limit> 0.30 mm (0.012 in.)
Cylinder Head Bolt Check

1. Check:
¡ Cylinder head bolts
¡ Cylinder head bolt outer diameter
Cylinder head bolts checking step

1) Check the cylinder head bolts for cracks,
scratches and/or damage.
Cracks/Scratches/Damage → Replace.
Cylinder head bolt outer diameter checking step

1) Measure the cylinder head bolt outer di-
ameter A using a caliper. Take the small-
est measurement within the specified
range B.
Out of specification →Replace all bolts
a as a set.
b Cylinder head bolt outer diameter A :
10.85 – 11.000 mm (0.427 – 0.433 in.)
<Limit> 10.55 mm (0.415 in.)
Measuring point B
Find the narrowest point over a
range of 40 mm (1.575 in.)
6-108
ENG CYLINDER HEAD E
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Camshaft Oil Seal Retainer and Oil Seal
Check
1. Check:
¡ Camshaft oil seal retainer and oil seal
Camshaft oil seal retainer and oil seal check-

ing steps
1) Check the camshaft oil seal retainer 1
for cracks and/or damage.
2
2) Check the camshaft oil seal 2 for wear
and/or damage.
Camshaft Oil Seal Replacement

1. Replace:
¡ Camshaft oil seal
Camshaft oil seal replacement steps

1) Tap out the oil seal 1 using a suitable
tool and a hammer.
1
2) Tap in a new oil seal 1 using a hammer

until the surface of the new oil seal is
flush with the edge of the oil seal retainer.
Replacer set:
09950-60010 (09951-00320)
1 (09951-00500)
(09952-06010)
Handle set:
09950-70010 (09951-07150)

lip of the oil seal.
6-109
ENG CYLINDER HEAD E
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Intake and Exhaust Manifold Check
1. Check:
¡ Intake and exhaust manifold
¡ Manifold warpage
Intake and exhaust manifold checking step

1) Check the intake and the exhaust mani-
fold for cracks and/or damage.
EX:
Manifold warp checking step
1) Check the warpage on the contact faces
of the manifold to the cylinder head by
use of a straight edge and a thickness
gauge.
Manifold warpage:
IN: Less than 0.40 mm (0.016 in.)
Rocker Arm Check

1. Check:
¡ Rocker arm oil clearance
¡ Rocker arm, adjusting screw and
roller
¡ Valve bridge
Rocker arm oil clearance checking steps

1) Measure the inner diameter of the rocker
arm using a caliper gauge.
Out of specification → Replace rocker
arm or rocker shaft.
Rocker arm inner diameter:

20.012 – 20.033 mm (0.788 – 0.789 in.)
6-110
ENG CYLINDER HEAD E
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2) Measure the outer diameter of the rocker
shaft using a micrometer.
Out of specification → Replace rocker
arm or rocker shaft.
Rocker shaft outer diameter:

19.972 – 19.993 mm (0.786 – 0.787 in.)
3) Calculate the clearance between the

rocker arm and the rocker shaft using the
formula indicated below.
Rocker arm - rocker shaft clearance =

Rocker arm inner diameter –
Rocker shaft outer diameter
Rocker arm - rocker shaft clearance:

0.019 – 0.061 mm (0.001 – 0.002 in.)
<Limit>
0.010 mm (0.0004 in.)
Rocker arm, adjusting screw and roller

checking step
1) Check the rocker arm, adjusting screw
and roller for damage.
Damage → Replace.
Valve bridge checking step

1) Check the valve bridge for damage.
Damage → Replace.
6-111
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) Apply ThreeBond® TB-1207B to the semi-
circular plug and install it on the cylin-
der head.
NOTE:
Degrease the semicircular plug on the
TB
mounting face to the cylinder head.
1207B
2) Install a new stem seal to the valve stem

guide. Then, assemble the valve spring
seat, spring and spring retainer.
3) Install the valve cotters to the spring re-

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

09202-70020
6-112
ENG CYLINDER HEAD E
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4) Install the valve bridge 1.
1
Cylinder Head Gasket Selection
NOTE:
Check the amount of protrusion of each
piston above the cylinder block.
1. Select:
¡ Cylinder head gasket (new)
Cylinder head gasket selection steps

1) Thoroughly clean all piston heads and
cylinder block gasket surfaces.
2) Position the piston to be measured
slightly before TDC.
3) Place a dial gauge on the cylinder block,
and set the dial gauge at 0 mm (0 in.).
NOTE:
¡ Position the measuring tip of the dial
gauge as shown in the illustration.
h
¡ Make sure that the measuring tip is
square to the cylinder block gasket sur-
face and piston head when making the
a
piston head protrusion A measurements.
4) Find the piston of biggest intrusion by

slowly turning the crankshaft clockwise
and counter-clockwise. If the amount of
protrusion A is not as specified, remove
the piston and connecting rod assembly,
and reinstall it correctly.
6-113
ENG CYLINDER HEAD E
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NOTE:
¡ Measure each cylinder at two locations
as shown in the illustration, making a to-
tal of twelve measurements.
¡ The average of the two measurements for
each cylinder shall be used as the amount
of piston protrusion for that cylinder.
Piston protrusion:
0.175 – 0.425 mm (0.007 – 0.017 in.)
5) Select the largest amount of piston pro-

trusion from the measured values. Then
1
select the appropriate cylinder head gas-
ket according to the table below.
1 cutout
NOTE:
When replacing the cylinder head gasket, in-
stall the one with the same numbers of cut-
3 2 1 out as the original gasket.
There are five types of gaskets (with 1 - 5 cut-
3 cutout outs) installed at the factory, but only three
types are provided as spare parts (1, 3, and 5
cutouts). Use “3 cutouts” gasket when the
original has 2 cutouts, and use “5 cutouts“
3 2 1 gasket when the original has 4.
4
5 cutout Piston protrusion mm (in.) Gasket size
5
0.175 – 0.225 (0.007 – 0.009 in.) Use “1 cutout“
0.226 – 0.325 (0.009 – 0.013 in.) Use “3 cutouts“
0.326 – 0.425 (0.013 – 0.017 in.) Use “5 cutouts“
6-114
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Cylinder Head Installation
1. Install:
¡ Cylinder head
Cylinder head installation steps

1) Turn the crankshaft pulley to align BDC
mark A of the timing gear cover with the
a
b 1 flange groove B of the camshaft timing
pulley #2 1.
2) Install the dowel pins 1 and set the se-

1 lected cylinder head gasket 2.
NOTE:
Take care that the gasket is installed in the
correct direction.
1
2
3) Mount the cylinder head and set the cyl-

inder head bolts.
NOTE:
¡ If any of the bolts are broken or deformed,
replace all of the bolts as a set.
¡ 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.
25 19 17 11 9 3 1 6 8 14 16 22 24 4) Tighten the cylinder head bolts to the

specified torque in several passes in the
order of numbers in the illustration.
Bolts (cylinder head):

70 N·m (7.1 kgf·m, 51.6 lbf·ft)
T.R
23 21 15 13 7 5 2 4 10 12 18 20 26 NOTE:
If any of the bolts do not reach the specified
torque, replace that bolt.
6-115
ENG CYLINDER HEAD E
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5) Mark the front of each bolt head with
First Second
paint.
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 6) Retighten the cylinder head bolts by 90°
in the order of numbers in the illustra-
tion.
7) 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.
Camshaft Installation
1. Install:
¡ Camshaft
Camshaft Installation steps

1) Assemble the camshaft bearing and the
idler gear thrust plate to the cylinder
#1 camshaft jornal Others head.
NOTE:
Note that the size of the #1 camshaft journal
is different from that of the others.
29 mm 20 mm
2) Install the camshaft on the cylinder head

with the key ways facing upward.
6-116
ENG CYLINDER HEAD E
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3) Set up the rocker shafts and install them
on the cylinder head.
638 mm
Bolts:
8.5 N·m (0.87 kgf·m, 6.27 lbf·ft)
T.R
NOTE:
This work can be performed more easily by
immobilizing the rocker arm as shown in the
illustration using two rods.
4) Apply some engine oil to the threads of

14 the bolts and tighten them to the speci-
10 13
6
2 9 fied torque in several passes in the or-
4 5 21
1 19 der of numbers in the illustration.
8 3 17
12 15 Bolts (bearing caps):
7
16
11 25 N·m (2.5 kgf·m, 18.4 lbf·ft)
T.R
18
20
Pulley and Timing Belt Installation

1. Install:
¡ Pulley and timing belt
NOTE:
Before starting the work, remove any frac-
tions of old gasket remaining on the cam-
shaft oil seal retainer, cylinder head and tim-
ing gear cover, and clean the sealing areas
and the contact faces with a non-residual sol-
vent.
Pulley and timing belt installation steps

1) Apply ThreeBond® TB-1207B to the cam-
shaft oil seal retainer at the positions
specified in the illustration.
NOTE:
The camshaft oil seal retainer must be in-
stalled within 5 minutes of sealant applica-
tion. If more than 5 minutes have passed, the
TB sealant must be removed and reapplied.
1207B
6-117
ENG CYLINDER HEAD E
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2) Set the dowel pins in the cylinder head
and mount the camshaft oil seal retainer
by tightening the bolts to the specified
torque.
Bolts (camshaft oil seal retainer):

19.6 N·m (2.0 kgf·m, 14.46 lbf·ft)
T.R
NOTE:
¡ Carefully wipe off any excess ThreeBond®
TB-1207B.
¡ When installing the camshaft oil retainer,
wrap the camshaft keyway with a tape to
protect the oil seal.
3) Install the timing pulleys and the timing

belt.
Installation“ section (P6-66).
4) Adjust the valve clearance.
Refer to “Valve Clearance Adjustment”
section (P3-19).
Valve clearance (when cold):

IN: 0.17 – 0.23 mm (0.007 – 0.009 in.)
EX: 0.47 – 0.53 mm (0.019 – 0.021 in.)
5) Install the intake manifold 2 and the

cooling pipe joint 1 inserting the new
gasket, and tighten the nuts to the speci-
fied torque.
Nuts (cooling pipe joint):

20 N·m (2.0 kgf·m, 14.8 lbf·ft)
T.R
6-118
ENG CYLINDER HEAD E
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6) Install the following parts.
¡ Injection nozzles
Refer to “Injection Nozzle Installation”
section (P5-6).
¡ Exhaust manifold
Manifold Installation” section (P6-58).
¡ Turbocharger
Refer to “Turbocharger Installation”
section (P6-48).
¡ Intercooler
Refer to “Intercooler Installation” sec-
tion (P6-31).
¡ Thermostat
Refer to “Thermostat Installation”
section (P6-24).
¡ Fuel filter housing and bracket

(P3-40).
NOTE:
6-119
ENG OIL PUMP E
OVER
OIL PUMP
1207B
1207B

1 Relief valve plug 1 41 N·m (4.2 kgf·m, 30.2 lbf·ft)
2 Timing gear case mounting bolts 7 19.6 N·m (2.0 kgf·m, 14.46 lbf·ft)
3 Timing gear cover mounting bolts 12 19.6 N·m (2.0 kgf·m, 14.46 lbf·ft)
6-120
ENG OIL PUMP E
OVER
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
(P6-77).
4) Remove the oil level gauge guide.
5) Remove the tension rod and flywheel
housing bracket (L, R).
6) Take out the oil pan mounting bolts and

remove the oil pan 1 by use of the oil
pan seal cutter 2.
Oil pan seal cutter:

09032-00100
1
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.
¡ Be careful not to damage the flange of
2 the oil pan.
6-121
ENG OIL PUMP E
OVER
7) Loosen the 4 bolts and remove the oil
strainer 1.
8) Remove the power steering pump.

Refer to “Power Steering Pump Re-
moval” section (P7-5).
9) Put a matching mark A on the injection

a
pump timing gear cover to indicate the
original mounting position. Then, re-
move the injection pump mounting nuts
1.
10) Take out the seven bolts and remove the

timing gear case 1 by lightly tapping it
with a plastic-faced hammer.
1
6-122
ENG OIL PUMP E
OVER
Oil Pump Disassembly
1. Disassemble:
¡ Outer pump
Oil pump disassembly steps

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

ket 2, spring 3, and relief valve 4.
4
3
2
1
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.
6-123
ENG OIL PUMP E
OVER
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 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.
Roter 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 .
6-124
ENG OIL PUMP E
OVER
3) Check the rotor tip clearance by setting
a thickness gauge as illustrated in .
Out of specification → Replace oil pump
assembly.
Rotor body clearance:

0.10 – 0.17 mm (0.004 – 0.007 in.)
<Limit> 0.20 mm (0.008 in.)
Rotor side clearance:
0.03 – 0.09 mm (0.001 – 0.004 in.)
<Limit> 0.15 mm (0.006 in.)
Rotor tip clearance:
0.08 – 0.16 mm (0.003 – 0.006 in.)
<Limit> 0.21 mm (0.008 in.)
Oil pump gear checking step

1) Check the oil pump gear for burrs, chips,
Burrs/Chips/Cracks/Damage → Replace
oil pump assembly.
Oil pump rotation checking step

1) Check the oil pump rotation.
Roughness → Replace oil pump assem-
bly.
6-125
ENG OIL PUMP E
OVER
Oil Pump Replacement
1. Replace:
¡ Oil pump
Oil pump replacement steps

1) Remove the oil pump drive gear and oil
pump shaft using the replacer set.
Replacer set:
09950-60010 (09951-00190)
2) Install a new oil pump shaft in the tim-

ing gear cover, and temporarily install
the oil pump drive gear with a plastic-
faced hammer.
3) Press in the oil pump drive gear using
the replacer set.
Replacer set:
09950-60010 (09951-00340)
Oil Strainer Check

1. Check:
¡ Oil strainer
Oil strainer checking steps

1) Check the oil strainer 1 and the strainer
1 net A for cracks and/or damage.
2) Check the oil passage.
a Soiled → Clean and blow out the dirt with
compressed air.
6-126
ENG OIL PUMP E
OVER
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
1
body with the mark A on the rotor fac-
ing the gear.
a
2) 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
1
and gasket 3 and tighten the plug 4 to
2 the specified torque.
3
4
Plug:
41 N·m (4.2 kgf·m, 30.2 lbf·ft)
T.R
6-127
ENG OIL PUMP E
OVER
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 faces with a non-residual
solvent.
¡ Do not use the solvent that may give ad-
verse effect to the coating.
1. Install:
¡ Timing gear case
Timing gear case installation step

1) Set a new gasket 1 to the position indi-
1 cated in the illustration.

groove on the sealing face of the timing
gear case.
NOTE:
The timing gear case must be assembled
a within 5 minutes of sealant application. If
TB ant must be removed and reapplied.
1207B
3) Install the timing gear case 1 on the en-

gine block by tighten the bolts to the
specified torque in a crisscross pattern.
1
Bolts (timing gear case):

19.6 N·m (2.0 kgf·m, 14.46 lbf·ft)
T.R
6-128
ENG OIL PUMP E
OVER
4) Align the matching marks A on the tim-
ing gear case and the injection pump and
tighten the injection pump mounting
a nuts to the specified torque.
Nuts (injection pump mounting):

18 N·m (1.8 kgf·m, 13.3 lbf·ft)
T.R
5) Install the power steering pump.
Refer to “Power Steering Pump Installa-
tion” section (P7-6).
6) Remove the tapered screw plug 1.
7) Pour approximately 10 cc (0.061 cu. in.)

of engine oil into the oil pump housing.
8) Apply ThreeBond® TB-1324 to the ta-

pered screw plug 1 and tighten it.
TB
1
1324
6-129
ENG OIL PUMP E
OVER
9) Install the oil strainer 1 using a new gas-
ket by tightening the bolts to the speci-
fied torque.
1
Bolts (oil strainer):
8.8 N·m (0.90 kgf·m, 6.49 lbf·ft)
T.R
10) Apply ThreBond® TB-1207B to the oil pan
as shown in the illustration.
A B
TB
A B a 1207B
11) Tighten the oil pan bolts evenly in sev-

eral passes, moving from the inside to
the outside in a diagonal pattern.
Bolts (oil pan):

15.7 N·m (1.60 kgf·m, 11.58 lbf·ft)
T.R
12) Install the tension rod and the flywheel

the housing bracket.
6-130
ENG OIL PUMP E
OVER
13) Install the oil level gauge guide.
Union bolt:
34.3 N·m (3.52 kgf·m, 25.45 lbf·ft)
T.R
14) Install the timing gears.
Refer to “Timing Gear Installation” sec-
tion (P6-85).


Max. 9.2 L, Min. 7.5 L
 Max. 9.7 US qt., Min. 7.9 US qt. 
Max. 9.9 L, Min. 8.2 L
 Max. 10.5 US qt., Min. 8.7 US qt. 

(P3-40).
NOTE:
6-131
ENG OIL COOLER E
OVER
OIL COOLER
3 2
A B B A B
A 4
B B 5
B
C
C
C 6
B B B B B CC

1 Check valve 1 26 N·m (2.7 kgf·m, 19.2 lbf·ft)
2 Relief valve 1 39 N·m (4.0 kgf·m, 28.8 lbf·ft)
3 Oil cooler mounting nuts 4 15.7 N·m (1.60 kgf·m, 11.58 lbf·ft)
4 Oil cooler cover mounting bolts 2 19.6 N·m (2.0 kgf·m, 14.46 lbf·ft)
7 Water temperature sensor 1
6-132
ENG OIL COOLER E
OVER
Oil Cooler Removal
1. Remove:
¡ Oil cooler
Oil cooler removal steps

(P3-40).
2) Drain the engine oil and remove the oil
filter.
3) Remove the injection pump.
Refer to “Injection Pump Removal” sec-
tion (P5-12).
4) Remove the oil level gauge guide.
5) Remove the oil cooler cover 1 together

1 with the oil cooler.
6) Remove the oil cooler 1 from the oil

1 cooler cover 2.
2
7) Remove the relief valve.
6-133
ENG OIL COOLER E
OVER
8) Remove the check valve.
9) Remove the water temperature sensor.
Oil Cooler Check

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

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

1) Push the check valve ball with a wooden
stick to check its movement.
6-134
ENG OIL COOLER E
OVER
Oil cooler checking step
1) Check the oil cooler for cracks, damage
and/or clogging.
Oil cooler cover checking step

1) Check the oil cooler cover for cracks and/
or damage.
Coolant temperature sensor checking step

1) Check the coolant temperature sensor.
Refer to “Coolant Temperature Sensor
Oil Cooler Installation

NOTE:
Thoroughly clean all parts to be assembled.
1. Install:
¡ Oil cooler
Oil cooler installation steps

1) Install the check valve. (with new gas-
ket)
Check valve:
26 N·m (2.7 kgf·m, 19.2 lbf·ft)
T.R
6-135
ENG OIL COOLER E
OVER
2) Install the relief valve. (with new gas-
ket)
Relief valve:
39 N·m (4.0 kgf·m, 28.8 lbf·ft)
T.R
3) Install the oil cooler 1 on the oil cooler
1
cover 2.
2
Nuts (oil cooler cover):
15.7 N·m (1.60 kgf·m, 11.58 lbf·ft)
T.R
4) Install the water temperature sensor.

(with new gasket)
5) Install the oil cooler cover. (with new

gasket)
Nuts/bolts (oil cooler cover):

19.6 N·m (2.0 kgf·m, 14.46 lbf·ft)
T.R
6-136
ENG OIL COOLER E
OVER
6) Install the oil level gauge guide 1.
Union bolt 2:
34.3 N·m (3.50 kgf·m, 25.30 lbf·ft)
T.R
1
7) Install the injection pump.

Refer to “Injection Pump Installation”
section (P5-17).


Max. 9.2 L, Min. 7.5 L
 Max. 9.7 US qt., Min. 7.9 US qt. 
Max. 9.9 L, Min. 8.2 L
 Max. 10.5 US qt., Min. 8.7 US qt. 

(P3-40).
NOTE:
6-137
ENG CYLINDER BLOCK E
OVER
CYLINDER BLOCK

1 Rear oil seal retainer mounting bolts 4 6.4 N·m (0.65 kgf·m, 4.72 lbf·ft)
2 Main bearing cap mounting bolts 14 Tightening torque (Refer to 6-172).
3 Main bearing cap M8 bolts 15 18.1 N·m (1.85 kgf·m, 13.35 lbf·ft)
4 Check valves 6 26 N·m (2.7 kgf·m, 19.2 lbf·ft)
5 Oil strainer mounting nuts 2 8.8 N·m (0.9 kgf·m, 6.5 lbf·ft)
6 Oil strainer mounting bolts 2 8.8 N·m (0.9 kgf·m, 6.5 lbf·ft)
7 Oil pan mounting bolts 2 15.7 N·m (1.6 kgf·m, 11.58 lbf·ft)
8 Oil pan mounting nuts 28 15.7 N·m (1.6 kgf·m, 11.58 lbf·ft)
6-138
OVER

1 Connecting rod bolts 12 Tightening torque (Refer to 6-175).
2 Flywheel mounting bolts 6 127 N·m (13 kgf·m, 93.7 lbf·ft)
6-139
OVER
Cylinder Block Disassembly
1. Disassemble:
¡ Cylinder block
Cylinder block disassembly steps

1) Drain the engine oil.
(P3-40).
3) Remove the following parts before dis-
assembling the cylinder block.
¡ Cylinder head
Refer to “Cylinder Head Removal”
section (P6-92).
¡ Starter motor
¡ Flywheel
¡ Rear end plate
¡ Alternator
¡ Engine wireharness
¡ Thermostat cover
¡ 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 (P5-12).
¡ Timing gears
Refer to “Timing Gear Removal” sec-
tion (P6-77).
¡ Oil pan
¡ Oil strainer
¡ Timing gear case
Refer to “Oil Pump Removal” section
(P6-121).
¡ Oil cooler
Refer to “Oil Cooler Removal” section
(P6-133).
6-140
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.
5) Remove the oil pressure sender 2 and

the oil pressure switch 1.
6-141
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 2) Remove the connecting rod caps.
NOTE:
1
Put an identifying mark A on each connect-
ing rod cap 1 and connecting rod 2 for cor-
a rect reinstallation.
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
at their original locations.
6-142
OVER
Main Bearing Cap and Crankshaft Dis-
assembly
1. Disassemble:
¡ Main bearing cap and crankshaft
Main bearing cap and crankshaft disassem-

bly steps
1) The main bearing cap bolts shown in the
illustration shall be removed in a criss-
cross pattern moving from outside to the
inside.
2) Loosen the main bearing cap bolts

evenly by making half a turn at a time in
the order of numbers in the illustration.
4 8 12 10 6 2
14
3 7 11 13 9 5 1
3) Remove the main bearing cap 1.

1
NOTE:
If the main bearing cap is difficult to remove,
insert a screwdriver between the main bear-
ing cap and the cylinder block to pry it off.
CAUTION:
faces of the main bearing cap and the cylin-
der block.
6-143
OVER
4) Remove the thrust washers 1.
1
NOTE:
Carefully identify the position of each thrust
washer so that they can be reinstalled at their
original locations.
5) Remove the crankshaft 1.

1
6) Remove the bearings from the cylinder

block and the main bearing cap. Care-
fully identify the position of each bear-
ing so that they can be reinstalled at their
7 original locations.
5 6
4
3
2
1
7) Remove the check valves 1 and oil

2 nozzles 2.
8) Remove the gasket 1. (oil path on the

cylinder block bottom face)
1 CAUTION:
Handle the gasket 1 with care and make
sure it can be reinstalled secrely is securely
reinstalled.
6-144
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 if the connecting rod has
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 ring 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 at their origi-
nal locations.
6-145
OVER
4) Remove the snap ring 1 and heat the
piston to approximately 80 °C (176 °F).
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 plastic-faced ham-
mer and a brass rod.
NOTE:
Carefully identify the position of each piston,
piston pin and connecting rod so that they
can be reinstalled at their original locations.
#1 #2 #3 #4 #5 #6
6-146
OVER
Piston and Cylinder Block Cleaning
1. Clean:
¡ Piston
¡ 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.
6-147
OVER
5) Remove the fractions of old gasket re-
maining on the cylinder block surface.
Be careful not to scratch the gasket con-
tact face.
6) Clean the cylinder block using a soft
brush and cleaning solvent.
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 to piston pin clearance
Piston wall checking step

1) Check the piston walls for scratches and/
or damage.
Excessive vertical scratches/Damage →
Replace 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 cylinder block and pistons as a
set.
6-148
OVER
Cylinder block checking step
1) Check the cylinder block for cracks and/
or damage by means of visible dye pen-
etrant.
Use a dye penetrant.
Cylinder block warpage checking step

1) Check the cylinder block warpage by use
1
of a straight edge and a thickness gauge.
Cylinder block warpage:

Piston-to-cylinder clearance checking steps

1) Measure the outer diameter of the piston
Front mark
at the specified height using a microme-
ter.
NOTE:
There are three standard pistons of different
63 mm
(2.48 in.) diameters. They are identified by the marks
1, 2 and 3, which are stamped on the piston
Measuring point top.
Measuring height
63 – 68 mm (2.48 – 2.68 in.)
Piston diameter
Mark “1“: 93.845 – 93.846 mm (3.69468 – 3.69472 in.)
Mark “2“: 93.855 – 93.856 mm (3.69507 – 3.69511 in.)
Mark “3“: 93.865 – 93.866 mm (3.69547 – 3.69550 in.)
6-149
OVER
2) Measure the cylinder bore A using a cyl-
inder gauge.
10 mm If out of specification, replace the cylin-
der and additionally replace the pistons
Middle and piston rings as a set.
NOTE:
10 mm
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 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:
#4 #5 #6
There are three sizes of standard cylinder
b bores. They are identified by the marks 1, 2
and 3 B, which are stamped in the upper left
rear corner of the cylinder block.
Cylinder bore diameter:

#1 #2 #3 Mark “1“
94.000 – 94.010 mm (3.7008 – 3.7011 in.)
Mark “2“
94.011 – 94.020 mm (3.7012 – 3.7016 in.)
Bore size Mark “3“
selection number
94.021 – 94.030 mm (3.7016 – 3.7020 in.)
Front mark
6-150
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:

STD
0.07 – 0.09 mm (0.003 – 0.004 in.)
<Limit>
0.135 mm (0.005 in.)
NOTE:
When installing new pistons, install a piston
having the same number mark as the stan-
dard bore diameter mark on the cylinder
block.
Ring groove clearance checking step

1) Check the ring groove clearance.
Out of specification → Replace piston.
NOTE:
Install new 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
0.070 – 0.110 mm (0.003 – 0.004 in.)
<Limit> 0.170 mm (0.007 in.)
Second ring
0.040 – 0.080 mm (0.002 – 0.003 in.)
<Limit> 0.130 mm (0.005 in.)
Oil ring
0.030 – 0.070 mm (0.001 – 0.003 in.)
<Limit> 0.120 mm (0.005 in.)
6-151
OVER
Piston rings (in the cylinder) checking steps
1) Insert each piston ring into the cylinder
bore by pushing it with a piston crown.
Place the piston ring at a right angles to
the cylinder bore.
NOTE:
a
Measuring piston of the ring end gaps A
shall be at 150mm from the cylinder block
top surface.
2) Check the end gap of the piston ring

placed in the cylinder bore.
Out of specification → Replace piston
ring.
End gap:
Top ring
0.27 – 0.39 mm (0.011 – 0.015 in.)
<Limit> 0.85 mm (0.033 in.)
Second ring
0.40 – 0.55 mm (0.016 – 0.022 in.)
<Limit> 0.90 mm (0.035 in.)
Oil ring
0.20 – 0.40 mm (0.008 – 0.016 in.)
<Limit> 0.88 mm (0.035 in.)
6-152
OVER
Piston to piston pin clearance checking steps
1) Measure the outer diameter of the piston
Piston pin pin using a micrometer.
bore mark
Piston pin outer diameter (20 °C (68 °F)):
Mark “A”: 33.000 – 33.004 mm (1.2992 – 1.2994 in.)
Front mark Mark “B“: 33.005 – 33.008 mm (1.2994 – 1.2995 in.)
Mark “C“: 33.009 – 33.012 mm (1.2996 – 1.2997 in.)
2) Measure the piston pin bore using a cali-

per gauge.
Piston pin bore (20 °C (68 °F)):

Mark “A“: 32.998 – 33.002 mm (1.2991 – 1.2993 in.)
Mark “B“: 33.003 – 33.006 mm (1.2993 – 1.2995 in.)
Mark “C“: 33.007 – 33.010 mm (1.2995 – 1.2996 in.)
3) Calculate the clearance between the pis-

ton and the piston pin using the formula
indicated below.
Piston to piston pin clearance =

Piston pin bore – piston pin outer diameter
Out of specification → Replace piston

and piston pin as a set.
Piston-to-piston pin clearance:

0.002 – 0.006 mm (0.0001 – 0.0002 in.)
NOTE:
Check that the piston pin can be pushed in
by hand when the piston pin is coated with
engine oil and inserted into the piston that
has been heated to approximately 80 °C
(176 °F). If the piston pin can be inserted eas-
ily into the piston at room temperature, re-
place the piston and the piston pin.
6-153
OVER
Connecting Rod and Piston Pin Check
1. Check:
¡ Connecting rod and rod cap
¡ Connecting rod bearing
¡ 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-
necting rod assembly.
Connecting rod bending:

<Limit>
0.03 mm (0.001 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 connect-
ing rod assembly.
Connecting rod twisting:

<Limit>
0.15 mm (0.006 in.) per 100 mm (3.937 in.)
6-154
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 (20°C (68 °F)):

Mark ”A”: 33.000 – 33.004 mm (1.2992 – 1.2994 in.)
Mark ”B”: 33.005 – 33.008 mm (1.2994 – 1.2995 in.)
Mark ”C”: 33.009 – 33.012 mm (1.2996 – 1.2997 in.)
2) Measure the inner diameter B of the con-

necting rod bushing.
3) Calculate the clearance between the pis-
b
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:

0.002 – 0.006 mm (0.0001 – 0.0002 in.)
<Limit> 0.03 mm (0.001 in.)
6-155
OVER
Connecting Rod Bushing Replacement
1. Replace:
¡ Connecting rod bushing
Connecting rod bushing replacement steps

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

1
and installer set:
09222-17011 (09222-05021)
3 (09222-05041)
2) Gently file off any roughness on the

small end of the connecting rod with a
file.
3) Install the bushing 1 in guide 2. Ball A

1 of the guide should fit into the oil hole
b B of the bushing at this time.
Connecting rod bushing remover

a
and installer set:
2 09222-17011(09222-05031)
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
6-156
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
gaps 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:

0.002 – 0.006 mm (0.0001 – 0.0002 in.)
7) Lubricate the piston pin 1 with engine

oil and press it into the connecting rod.
Check for the presence of play.
1
6-157
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 runput checking step

1) Check the crankshaft runout using a dial
gauge. (at the center journal A)
Crankshaft runout:
a
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
b journal A and the crank pin B using a
micrometer.
a
Out of specification → Check oil clear-
ance.
Standard main journal outer diameter:

STD: 66.982 – 67.000 mm (2.637 – 2.638 in.)
Standard crank pin outer diameter:
STD: 58.982 – 59.000 mm (2.322 – 2.323 in.)
6-158
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:
Main journal oil clearance checking steps

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

0.030 – 0.042 mm (0.001 – 0.002 in.)
<Limit>
0.10 mm (0.004 in.)
CAUTION:
Do not interchange the bearings, cylinder
block or bearing caps. They must be rein-
stalled to their original positions. If not, the
correct oil clearance may not be obtained,
causing engine damage.
2) Clean each bearing cap and part of the

cylinder block corresponding to the lo-
cations of main journal bearing.
3) Install the lower half of the bearings 1
a and the crankshaft 2 in the cylinder
block.
NOTE:
Align bearing protrusion A on the bearing
2 with notch B on the cylinder block.
b
1
6-159
OVER
4) Place some Plastigage® 1 on each main
journal in the axial direction.
NOTE:
Do not cover the oil holes provided in the
main journals of the crankshaft with the
1 Plastigage® .
5) Install the bearings 1 in the bearing cap

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

following the order shown in the illus-
tration.
Bolts (main bearing cap):

11 7 3 1st tightening
1 5 9 13
105 N·m (10.7 kgf·m, 77.4 lbf·ft)
12 8 4 6 10
2nd tightening
2 14
Turn 90°
NOTE:
Do not turn the crankshaft while measuring
the clearance.
7) Remove the bearing cap and measure

the width of the Plastigage® . If the oil
clearance is out of specification, select a
replacement bearing from the following
table.
6-160
OVER
Crankshaft marking
A B C D E H 4 5 6 7 8 9 L M R S U X
A 3 3 3 3 3 3 3 3 3 3 3 3 4 4 4 4 4 4
B 3 3 3 3 3 3 3 3 3 3 3 4 4 4 4 4 4 5
C 3 3 3 3 3 3 3 3 3 3 4 4 4 4 4 4 5 5
D 3 3 3 3 3 3 3 3 3 4 4 4 4 4 4 5 5 5
E 3 3 3 3 3 3 3 3 4 4 4 4 4 4 5 5 5 5
H 3 3 3 3 3 3 3 4 4 4 4 4 4 5 5 5 5 5
4 3 3 3 3 3 3 4 4 4 4 4 4 5 5 5 5 5 5
5 3 3 3 3 3 4 4 4 4 4 4 5 5 5 5 5 5 6
Main bearing cap 6 3 3 3 3 4 4 4 4 4 4 5 5 5 5 5 5 6 6
marking 7 3 3 3 4 4 4 4 4 4 5 5 5 5 5 5 6 6 6
8 3 3 4 4 4 4 4 4 5 5 5 5 5 5 6 6 6 6
9 3 4 4 4 4 4 4 5 5 5 5 5 5 6 6 6 6 6
L 4 4 4 4 4 4 5 5 5 5 5 5 6 6 6 6 6 6
M 4 4 4 4 4 5 5 5 5 5 5 6 6 6 6 6 6 6
R 4 4 4 4 5 5 5 5 5 5 6 6 6 6 6 6 6 6
S 4 4 4 5 5 5 5 5 5 6 6 6 6 6 6 6 6 6
U 4 4 5 5 5 5 5 5 6 6 6 6 6 6 6 6 6 6
X 4 5 5 5 5 5 5 6 6 6 6 6 6 6 6 6 6 6
Example:
#1 #2 #3 #4 #5 #6 #7 Main bearing cap (E) and crankshaft (7) →
Use bearing 4.
NOTE:
¡ If using a standard bearing, replace with
one with the same number. Sometimes,
2 or 7 are marked on the bearing as the
engine is shipped out from the factory. In
such cases, the bearing marked with 2
shall be replaced by the new one marked
with 3, and the bearing with marking 7
shall be replaced by the one with 6.
#1
#2 ¡ If the applicable bearing number cannot
#5 #3 be determined, refer to the table to select
#6 #4 the correct bearing based on the numbers
#7 marked on the main bearing cap and the
crankshaft.
¡ There are four sizes of standard bearing,
marked 3, 4, 5, and 6.
Mark
2, 3, 4, 5 or 6
6-161
OVER
Crank pin oil clearance checking steps
1) Check the crank pin oil clearance.
Out of specification → Replace bearings.
NOTE:
Replace the crankshaft if necessary.
Crank pin oil clearance:

0.009 – 0.024 mm (0.0004 – 0.0009 in.)
<Limit>
0.10 mm (0.004 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 possible 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

4 the connecting rod 2, and install the
3
1 lower half 3 of the bearing in the con-
2 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

pin in the axial direction.
6-162
OVER
5) Install the connecting rod assembly on
the crankshaft.
NOTE:
a ¡ 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 bolts to the specified torque.
Bolts (connecting rod cap):

1st tightening
T.R
37.5 N·m (3.83 kgf·m, 27.66 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® .
If the oil clearance is out of specification,
Mark
2, 3, 4, 5 or 6 Mark select a replacement bearing from the
1, 2 or 3 following table.
Marked number
Connecting rod 1 2 3
Crankshaft 1 2 3 1 2 3 1 2 3
Bearing 2 3 4 3 4 5 4 5 6
Example:
Connecting rod (2) and crankshaft (1) = Total
#1 #2 #3 of (3) → Use bearing 3.
NOTE:
¡ If using a standard bearing, replace with
one having the same number.
¡ If the number of the bearing cannot be
determined, select the correct bearing by
#4 #5 #6 adding together the numbers punched on
the crankshaft and the connecting rod,
then selecting a bearing with the same
number as the sum.
¡ There are five sizes of standard bearings,
marked 2, 3, 4, 5, and 6.
6-163
OVER
Main Bearing Cap Bolt and Connecting
Rod Cap Bolt Check
1. Check:
¡ Main bearing cap bolts and connect-
ing rod cap bolts
¡ Main bearing cap bolt outer diameter
and connecting rod cap bolt outer di-
ameter
Main bearing cap bolts and connecting rod

cap bolts checking step
1) Check the main bearing cap bolts and the
connecting rod cap bolts for cracks,
scratches and/or damage.
Cracks/Scratches/Damage → Replace.
Main bearing cap bolts and connecting rod

cap bolts outer diameter checking step
Main bearing cap bolts 1) Check the outer diameters of the main
bearing cap bolts and the connecting rod
cap bolts.
Out of specification → Replace bolts as
a set.
b
a Main bearing cap bolt outer diameter B :

11.800 – 12.000 mm (0.465 – 0.472 in.)
<Limit> 11.50 mm (0.453 in.)
Measuring location: Minimum di-
Connecting rod cap bolts ameter over a range of 30 mm A
(1.181 in.)
Connecting rod cap bolt outer diameter D :
d
8.300 – 8.400 mm (0.327 – 0.331 in.)
<Limit> 7.95 mm (0.313 in.)
Measuring location: Minimum di-
c ameter over a range of 25 mm C
(0.984 in.)
6-164
OVER
Crankshaft Oil Seal Retainer and Oil
Seal Check
1. Check:
¡ Crankshaft oil seal retainer
¡ Crankshaft 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.
1
6-165
OVER
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 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.
When crankshaft oil seal retainer has been

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.
¡ Be careful not to scratch the crankshaft.
1

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
6-166
OVER
Oil Nozzle and Check Valve Check
1. Check:
¡ Oil nozzle
¡ Check valve
Oil nozzle checking step

1) Check the oil nozzles 1 for clogging and/
or damage.
1 Damage → Replace.
Clogged → Blow out the clogging with
compressed air.
Check valve checking step

1) Check the movement of the check ball of
the check valves.
Press-in the valve ball with a wooden
stick to check its movement.
Cylinder Block Assembly
CAUTION:
sembled.
¡ Apply clean engine oil to all sliding sur-
faces and rotating surfaces before install-
ing the parts.
¡ Replace all gaskets and oil seals with new
ones.
6-167
OVER
Piston and Connecting Rod Assembly
1. Install:
¡ Piston
¡ Connecting rod
Piston and connecting rod assembly steps

1) Install the snap ring 1. (on one side of
a
the piston hole)
1 NOTE:
b
Position the snap ring so that end A of the
snap ring aligns with the notch, and then
press the snap ring into the piston groove
starting from 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.
6-168
OVER
NOTE:
b Check that the end gap A of the oil ring 1 is
1 facing in the opposite direction from spring
joint B.
5) Install the second compression ring, and

Stamped
marks
then the top compression ring to the
No.1
piston, with the stamped mars on each
ring facing upward.
No.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
6-169
OVER
Crankshaft and Main Bearing Cap As-
sembly
NOTE:
Every component part must be washed and
cleaned before the engine assembly.
1. Assemble:
¡ Crankshaft and main bearing
Crankshaft and main bearing cap assembly

steps
1) Install the gasket 1. (oil path, bottom of
the cylinder block)
1
2) Fit the projection A on the oil nozzle into

the hole B on the cylinder block, and
fasten the oil nozzles to the specified
torque.
Check valve:
26 N·m (2.7 kgf·m, 19.2 lbf·ft)
T.R
a
b
6-170
OVER
3) Install the main bearings to the cylinder
block 2 and to the bearing cap 1. Align
protrusion A of each bearing with
groove B in the cap and the cylinder
block.
NOTE:
¡ Align each of the oil holes C in the bear-
2 ings and the cylinder block.
1
¡ All bearings must be reinstalled at their
original locations.
a c
4) Apply a light coating of engine oil to the

main bearing and install the crankshaft
1
1.
5) Install the thrust washers 1 to the #4

1 main journal position on the cylinder
block. Make sure that the oil grooves
come to the outside on the thrust wash-
ers 1 faces outward.
NOTE:
The tab of the thrust washers 1 should be at
the location shown in the illustration.
6-171
OVER
6) Check the crankshaft thrust clearance.
Out of specification → Replace 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 – 0.24 mm (0.002 – 0.009 in.)
<Limit> 0.30 mm (0.012 in.)
Thrust washer thickness:
2.930 – 2.980 mm (0.115 – 0.117 in.)
7) Apply some engine oil to the thrust

washers before the installation of bear-
ing cap.
8) Check that the contact faces of the cylin-

der block and the bearing cap are not
contaminated. Apply ThreeBond ® TB-
1207B to the cylinder block A contact
face.
NOTE:
The main bearing cap must be installed
a TB
1207B
9) Install the main bearing cap on the cyl-

inder block and set the bolts.
NOTE:
¡ If any of the bolts are broken or deformed,
replace that bolts.
¡ Apply a thin coating of engine oil to the
bolt threads and under the heads.
10) Tighten the main bearing cap bolts in

several passes following the order
shown in the illustration.
Bolts (main bearing cap):

11 7 3 5 9 13 105 N·m (10.7 kgf·m, 77.4 lbf·ft)
1
T.R
12 8 4 6 10
NOTE:
2 14
torque, replace that bolts.
6-172
OVER
11) Mark the front A of the bolt heads with
a paint.
FWD
12) Retighten the cylinder head bolts by 90°

90°
in the order of numbers shown in the
above illustration.
13) Check that the paint mark is now at a 90°
angle to the front.
14) Check that the crankshaft turns smoothly.
15) Check the crankshaft thrust clearance.
16) Install the bearing cap holding bolts and

tighten.
M8 bolts (main bearing cap):

11 7 3 1
5 9 13
18.1 N·m (1.85 kgf·m, 13.35 lbf·ft)
T.R
12 8 4 2 6 10 14 NOTE:
Tighten the bolts in a crisscross pattern start-
ing from the center.
6-173
OVER
Piston and Connecting Rod Installation
1. Install:
¡ Piston and connecting rod
Piston and connecting rod installation steps

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

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

bolts, and bolt heads. Install the connect-
FWD
ing rod cap to the correct cylinder by

checking the mark on it.
a
NOTE:
Install the connecting rod caps with the front
mark A (protrusion) facing forward.
FWD
6-174
OVER
4) Tighten the connecting rod cap bolts in
several passes.
Bolts (connecting rod cap):

37.5 N·m (3.83 kgf·m, 27.66 lbf·ft)
T.R
NOTE:
torque, replace that bolt.
5) Mark the front of the connecting rod

FWD
a holding bolts with paint A.
6) Tighten the holding bolts by an addi-

90° tional 90°.
7) Check that the paint mark A is now at a
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.)
6-175
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 faces with a non-residual
solvent.
1. Install:
¡ Crankshaft oil seal retainer
Crankshaft oil seal retainer installation steps

groove A on the crankshaft oil seal re-
tainer.
NOTE:
The retainer must be installed within 5 min-
a utes of sealant application. If more than 5
TB minutes have passed, the sealant must be
1207B removed and reapplied.
2) Install the crankshaft oil seal retainer 1

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

1 6.4 N·m (0.65 kgf·m, 4.72 lbf·ft)
T.R
3) Install the heat exchanger bracket and

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

117 N·m (11.9 kgf·m, 86.3 lbf·ft)
T.R
6-176
OVER
4) Install the oil pressure switch 2 and the
oil pressure sender 3.
LT
NOTE:
1
243 Apply LOCTITE® No. 243 on the threads when
installing the oil pressure switch joint 1.
2
Oil pressure switch joint:
3 9.0 N·m (0.9 kgf·m, 6.6 lbf·ft)
T.R
5) Install the engine brackets and tighten
the bolts to the specified torque.
Bolts (engine bracket):

117 N·m (11.9 kgf·m, 86.3 lbf·ft)
T.R
6-177
OVER
6) Remove the engine assembly from the
engine stand 1, and install the follow-
ing parts:
¡ Oil strainer
¡ Oil pan
¡ Tension rod
1
Refer to the installation steps below.
¡ Oil cooler
¡ Timing gear case
Refer to “Timing Gear Case Installa-
¡ Timing gears
Refer to “Timing Gear Case Installa-
¡ Injection pump
Refer to “Injection Pump Installation”
section (P5-17).
¡ Water pump
¡ Seawater pump
¡ Power steering oil cooler
¡ Heat exchanger
Manifold Installation” section (P6-58).
¡ Engine wireharness
¡ Starter motor
¡ Alternator
Refer to “Alternator Installation” sec-
tion (P8-41).
Refer to “2-stage Rate Coupling and
Flywheel Installation” section (P6-7).
7) Install the tension rod bracket 1 at the

bottom of engine bracket 2 provided on
both sides of the engine unit.
Tightening torque:
64 N·m (6.5 kgf·m, 47.2 lbf·ft)
T.R
2 1
6-178
OVER
8) Tighten the nut at one end of the tension
bracket (either on the right or on the left)
14 mm
so that the tip of the tension rod pro-
(0.55 in.)
trudes from the nut face by approxi-
mately 14 mm (0.55 in.).
Tightening torque:
First, tighten the 211 N·m (21.5 kgf·m, 155.6 lbf·ft)
T.R
nuts at one end.
9) Adequately loosen the inner nut 1 at the

opposite end, and apply some oil on the
seating face and threads of the outer nut.
Then, temporarrily tighten the outer nut
2.
Tightening torque:
7.5 N·m (0.77 kgf·m, 5.53 lbf·ft)
T.R
2 1
10) Fully tighten the inner nut 1 on the ten-

sion rod by hands (without any tools)
until the nut comes in touch with the ten-
sion rod bracket.
11) Tighten the outer nut 2 on the tension
rod to the specified torque.
Tightening torque:
211 N·m (21.5 kgf·m, 155.6 lbf·ft)
T.R

(P3-40).



Max. 9.2 L, Min. 7.5 L
 Max. 9.7 US qt., Min. 7.9 US qt. 
Max. 9.9 L, Min. 8.2 L
 Max. 10.5 US qt., Min. 8.7 US qt. 
6-179
STEER E
CHAPTER 7
POWER STEERING SYSTEM ................................................................................................. 7-1

Power Steering System Air Bleeding ............................................................................... 7-1
Power Steering Fluid Pressure Check .............................................................................. 7-2
POWER STEERING PUMP ...................................................................................................... 7-5

Power Steering Pump Removal ....................................................................................... 7-5
Power Steering Pump Check ............................................................................................ 7-5
Power Steering Pump Installation .................................................................................... 7-6
POWER STEERING OIL COOLER ........................................................................................... 7-6

Power Steering Oil Cooler Removal ................................................................................ 7-6
Power Steering Oil Cooler Check ..................................................................................... 7-7
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 before
continuing.
1) Fill the power steering pump reservoir

with the recommended power steering
fluid. Refer to “Power Steering Fluid
Level Check” section (P3-46).
2) Run the engine until it reaches normal
operating temperature.
While operating the engine, turn the
several times.
3) Turn the steering lever until the drive unit
is pointing straight back and is centered.
Stop the engine.
1
4) Remove the filler cap 1. Allow any foam
2
in the reservoir tank 2 to dissipate be-
fore checking the fluid level. Add fluid to
bring the level up to the “HOT” mark A.
DO NOT overfill.
5) If the power steering fluid is foamy in
step 4), repeat steps 2) – 4) until the fluid
stops forming and the level remains con-
stant.
7-1
Power Steering Fluid Pressure Check

1. Check:
¡ Power steering fluid pressure
Power steering fluid pressure checking steps

1) Install the pressure gauge.
1
Power steering fluid pressure

gauge set (From BANZAI):
PSG-6TB
1
 PSG-FJL...1
 
2
 PSG-2ST...2
2 CAUTION:
Fully open the pressure gauge valve.
2) Bleed air from the power steering sys-

tem.
Refer to “Power Steering System Air
Bleeding” section (P7-1).
3) Start the engine and check for leaks.
Repair if necessary.
4) Run the engine until it reaches the speci-
fied temperature to warm-up power
steering fluid.
While operating the engine, turn the
several times.
Specified temperature:
100 – 110 °C (212 – 230 °F)
7-2
5) Inspect the hydraulic pressure generated

Power steering by the power steering pump.
Reservoir tank
cylinder
While the engine is at idle, fully close the
pressure gauge valve and measure the
hydraulic pressure.
CAUTION:
Power steering
pump
¡ Do not keep the pressure gauge valve
closed by more than 10 seconds.
¡ Pay attention that the fluid temperature
will not get too high.
Hydraulic pressure generated by

the power steering pump:
10.0 – 10.7 MPa
(102.0 – 109.1 kgf/cm2,
1450 – 1552 psi)
6) Inspect the hydraulic pressure with no

Power steering
cylinder
Reservoir tank load.
Measure the hydraulic pressure at en-
gine speeds of 1000 r/min. and 3000
r/min. Identify the difference in pressure.
If the difference exceeds the criteria, re-
place the flow control valve on the power
Power steering steering pump.
pump
CAUTION:
¡ Fully open the pressure gauge valve.
¡ Do not operate the steering lever.
Hydraulic pressure difference:

Less than 0.49 MPa (5 kgf/cm2,
71.1 psi)
7-3
7) Inspect the hydraulic pressure generated

Power steering by the power steering cylinder.
Reservoir tank
cylinder
While the engine is at idle, turn the steer-
ing lever all the way to right and left, and
measure the hydraulic pressure.
If the measurement exceeds the criteria,
recheck the steering cable stroke and the
Power steering steering cylinder attachment. Correct any
pump abnormality by making an adjustment or
replacement.
CAUTION:
Fully open the pressure gauge valve. Do not
keep the steering lever at fully turned posi-
tion by more than 10 seconds.
Hydraulic pressure generated by

the power steering cylinder:
Less than 0.49 MPa (5 kgf/cm2,
71.1 psi)
8) Remove the pressure gauge.

tem.
10) Inspect the fluid level of the power steer-
ing system.
Refer to “Power Steering Fluid Level
7-4
STEER POWER STEERING PUMP E
POWER STEERING PUMP

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

1) Drain power steering fluid.
2) Disconnect the power steering feed hose
coming from the reservoir tank.
3) Disconnect the power steering high pres-
sure hose leading to the power steering
cylinder.
4) Remove the power steering pump 1.
Power Steering Pump Check

1. Check:
Power steering pump checking step

1) Check the power steering pump for clog-
ging.
Clog → Wash and clean.
7-5
POWER STEERING PUMP /
STEER POWER STEERING OIL COOLER
E
Power Steering Pump Installation

1. Install:
Power steering pump installation steps

1) Install the power steering pump 1 with
a new gasket.
2) Connect the power steering feed hose.
3) Connect the power steering high pres-
sure hose.
tem.
5) Check the power steering fluid.
1 Leakage → Repair.
6) Check the power steering operation.
Abnormal noise/Malfunction → Replace
power steering pump.
POWER STEERING OIL COOLER

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

1) Drain power steering fluid.
2
2) Remove the air filter assembly.
3) Remove the boost pipe.
4) Disconnect the power steering hose 1
3
3 coming from the power steering cylin-
4 der.
5) Disconnect the power steering hose 2
1 leading to the reservoir tank.
6) Disconnect the seawater hose 3.
7) Remove the power steering oil cooler 4.
7-6
POWER STEERING OIL COOLER /
STEER POWER STEERING CYLINDER
E
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.
Power Steering Oil Cooler Installation

1. Install:
Power steering oil cooler installation steps

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

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

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 power steering oil.
2) Remove the power steering pump 1 and
the O-ring 2.
3) Remove the power steering hose clamp
bracket from the intercooler, and then re-
move hoses from the port engine.
4) Install the cylinder block side cover 3
and the gasket 4 to seal the cylinder
block.
2 Bolt (cover 3 – cylinder block) 5:

1
44 N·m (4.5 kgf·m, 32.5 lbf·ft)
T.R
NOTE:
Apply LOCTITE® No. 572 or equivalent to the
bolt threads before installation.
4
3 ¡ Cylinder block side cover 3
5 LT
572 Part No.: YU1-12716-70-20

¡ Cylinder block side cover gasket 4
Part No.: YU1-12731-70-10
5) Remove the power steering oil reservoir

assembly.
6) Cut one piece of 9.5 mm (3/8 in.) ID power
steering hose 1 having approximately
1
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 hose is clear of air filter, boost pipe
or turbocharger.
7-8
– +
ELEC E
CHAPTER 8
ELECTRICAL SYSTEM
INTAKE AIRHEATER SYSTEM ............................................................................................... 8-1

Main Switch Check ............................................................................................................ 8-2
Neutral Switch Check ........................................................................................................ 8-3
Intake Airheater Relay Check ............................................................................................ 8-3
Intake Airheater Check ...................................................................................................... 8-4
Water Temperature Sensor Check .................................................................................... 8-4
STARTING SYSTEM ............................................................................................................... 8-5

Main Switch Check ............................................................................................................ 8-6
Neutral Switch Check ........................................................................................................ 8-6
Diode Check ....................................................................................................................... 8-6
Starter Relay Check ........................................................................................................... 8-7
STARTER MOTOR ................................................................................................................... 8-8

Starter Motor Removal ...................................................................................................... 8-9
Starter Motor Disassembly ............................................................................................... 8-9
Starter Motor Check and Repair ..................................................................................... 8-12
Starter Motor Assembly .................................................................................................. 8-18
Starter Motor Operation Test .......................................................................................... 8-21
Starter Motor Installation ................................................................................................ 8-22
CHARGING SYSTEM ............................................................................................................ 8-23

Circuit Diagram ................................................................................................................ 8-23
Battery and Electrical Connection ON-Boat Check........................................................ 8-24
Charging Circuit Check .................................................................................................... 8-25
ALTERNATOR ........................................................................................................................ 8-27

Alternator Removal ......................................................................................................... 8-28
Alternator Disassembly ................................................................................................... 8-29
Alternator Check and Repair ........................................................................................... 8-32
Alternator Assembly ........................................................................................................ 8-37
Alternator Installation ...................................................................................................... 8-41
FUEL SYSTEM ...................................................................................................................... 8-42

Main Switch Check .......................................................................................................... 8-43
Neutral Switch Check ...................................................................................................... 8-43
Pickup (tacho) Sensor Check .......................................................................................... 8-43
Water Separator Switch Check ....................................................................................... 8-44
– +
ELEC E
Fuel Cut Solenoid Valve Check ....................................................................................... 8-45
OTHER COMPONENTS ........................................................................................................ 8-46

Oil Pressure Sender Check .............................................................................................. 8-46
Oil Pressure Switch Check .............................................................................................. 8-46
Seawater Flow Sender Check ......................................................................................... 8-47
Coolant Temperature Sensor Check ............................................................................... 8-48
Thermo Switch Check ..................................................................................................... 8-49
8
– +
ELEC INTAKE AIRHEATER SYSTEM E
INTAKE AIRHEATER SYSTEM
3 8
R/Pu R R
12
2 20A R 100A
11
R/Pu Pu Y/R
OFF
ON Br 13 10A
START
9
4 R/Pu
Y/R
Pu Br/G
Y/R
B
P 6
5
B
1 7 B
Pu L/G
10
B

1 Battery 1
2 Main switch 1
3 Fuse (20 A) 1
4 Starter relay 1
5 Water temperature sensor 1
6 Intake airheater control unit 1
7 Intake airheater lamp 1
8 Fuse (100 A) 1
9 Intake airheater relay 1
0 Intake airheater 1
A Alternator 1
B Starter motor 1
C Fuse (10 A) 1
8-1
– +
NOTE:
Intake airheater relay control:
The intake airheater relay is activated for 10
seconds when the main switch is turned to
“ON“ position, and the coolant temperature
is 20 °C (68 °F) or lower. The relay is switched
“OFF“ once the main switch is turned to
“START“ position.
When the coolant temperature is between –20 °C
and 35 °C (between –68 °F and 95 °F), the
relay is also activated after 3 seconds from
the engine start, and performs after-heating
for the required period of time.
Intake airheater lamp control:
After the main switch is turned to “ON“ po-
sition, the intake airheater lamp is switched
on for 10 seconds when the coolant tempera-
ture is 20 °C (68 °F) or lower, and 3 seconds
when the coolant temperature is above 20
°C (68 °F), and then the light is turned “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
R/Pu Pu Y/R the main switch.
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”.
Terminal A1 A2
Switch
position Y/R Y/R G/L B
FREE
PUSH
Intake Airheater Relay Check

1. Check:
¡ Intake airheater relay
Intake airheater relay checking steps

1) Pull out the intake airheater relay cou-
pler from the intake airheater relay.
2) Connect the battery (12V) to the Br/G ter-
minal of the intake airheater relay cou-
pler.
Ground the terminal B.
3) Check the intake airheater relay for con-
tinuity between the terminals 1 and 2.
If there is no continuity, replace the in-
1 take airheater relay.
8-3
– +
Intake Airheater Check

1. Check:
¡ Intake airheater continuity
Intake airheater continuity checking step

1) Using an circuit tester, check the
contiunity between the terminal 1 and
the body 2.
No continuity → Replace.
2
1
Water Temperature Sensor Check

1. Check:
¡ Water temperature sensor
Water temperature sensor checking steps

1) Remove the water temperature sen-
sor 1.
1
2) Soak the pick up part of water tempera-
ture sensor in water.
3) Check the resistance under the specified
water temperature.
Replace the water temperature sensor if
the measured resistance is out of speci-
fication indicated below.
Water temperature Resistance
20 °C (68 °F) 2.2 – 2.7 kΩ
80 °C (176 °F) 0.29 – 0.35 kΩ
8-4
– +
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
8-5
– +
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.
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).
8-6
– +
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
relay for continuity between 3 and 4
terminals.
4 1
Replace the starter relay if there is no
continuity.
8-7
– +
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
8-8
– +
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

1.
3) Disconnect the starter motor leads 2.
4
4) Disconnect the magnetic switch lead 3.
2
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.
2) Remove the bolts 2 and the field frame
1
3 with armature.
2 3
8-9
– +
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
8-10
– +
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.
8-11
– +
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.
8-12
– +
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:
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.)
a
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.
8-13
– +
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 brush
holder and 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 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.
8-14
– +
Gear teeth checking step

1) Check the pinion/idler/clutch gear teeth
for burrs, chips, wear and/or damage.
Burrs/Chips/Wear/Damage →
Replace gears and/or clutch assembly
and check the flywheel ring gear for
wear or damage.
Clutch operation checking step

1) Check the clutch operation.
Damage → Replace 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.
8-15
– +
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 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.
8-16
– +
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.
8-17
– +
3) Using a suitable tool 1 press-in a new

bearing 2 (rear) tightly against the
1
shoulder of the shaft.
CAUTION:
2
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 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 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.
8-18
– +
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 idle gear 2.

A
8-19
– +
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
8-20
– +
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
8-21
– +
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,
No-load performance test steps

1) Connect the battery 1 and the ammeter
2 to the starter as shown.
2) Check that the starter rotates smoothly
and steadily with the pinion gear mov-
2
ing outward.
Check that the ammeter shows the speci-
fied current.
1
Does not move/out of specification →
Replace 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) Connect the starter motor lead 2.
3) Connect the battery positive (+) lead 3.
1
4) Connect the magnetic switch lead 4.
2
3
Nut (terminal):
21 N·m (2.1 kgf·m, 15.5 lbf·ft)
T.R
1
5) Connect the negative (–) lead 1 to the
battery terminal.
UPPER
LOWER
8-22
– +
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
8-23
– +
Battery and Electrical Connection ON-

Boat Check
1. Check:
¡ Battery
Refer to “Battery Check” section (P3-
48).
¡ Fuses
Refer to “Fuse Check” section (P3-50).
¡ Electrical connections
Refer to “ELECTRICAL SYSTEM WIR-
ING DIAGRAM” at the end of the
book.
8-24
– +
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.
8-25
– +
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.
8-26
– +
ELEC ALTERNATOR E
ALTERNATOR
16
14 15
13
12
11
10
8
7
5
4
3
2
1

1 Nut 1 110 N·m (11.2 kgf·m, 81.1 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
8-27
– +
ELEC ALTERNATOR E
Alternator Removal
1. Remove:
¡ Alternator
Alternator removal steps
1
1) Disconnect the negative (–) lead 1 from
the battery terminal.
UPPER
LOWER
2) Disconnect the alternator leads 1.
3) Remove the drive belts 1.

4) Remove the alternator 2.
2
Refer to “Drive Belts Check” section (P3-
25).
8-28
– +
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.
8-29
– +
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)
T.R
Alternator wrench “B”:

40 N·m (4.1 kgf·m, 29.5 lbf·ft)
NOTE:
Check that the alternator wrench “A” is fit-
ted securely to the rotor shaft.
8-30
– +
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 .
NOTE:
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
8-31
– +
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)
Roter 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)
8-32
– +
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 )
If there is continuity, replace the rotor.
3
Slip rings checking steps

1) Check the slip ring for roughness and/or
scoring.
Roughness/Scoring → Replace rotor and
brushes as a set.
2) Check the slip ring diameter A.
Out of specification → Replace 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 )
If there is 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 )
If there is no continuity, replace the drive
end frame assembly.
8-33
– +
ELEC ALTERNATOR E
Brush checking step

1) Check the exposed brush length A.
Out of specification → Replace brushes
and 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.
If both show 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.
If both show continuity or no continuity,
replace the rectifier holder.
4) Repeat steps 1) to 3) for each terminal.
8-34
– +
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 socket wrench 1, press

1
out the front bearing 2.
2
3) Using the suitable tool 1 and a press,

install a new bearing.
1
8-35
– +
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.
8-36
– +
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
8-37
– +
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”:

40 N·m (4.1 kgf·m, 29.5 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”:

3 110 N·m (11.2 kgf·m, 81.1 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.
8-38
– +
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.
8-39
– +
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
alternator.
8-40
– +
ELEC ALTERNATOR E
Alternator Installation
1. Install:
¡ Alternator
Alternator installation steps

1) Install the alternator 1.
2) Install the drive belts 2.
1
Refer to “Drive Belts Check” section (P3-
25).

98 N (10 kgf, 22 lbf)
2
Alternator V-belts:
12 – 14 mm (0.47 – 0.55 in.)
[New belt: 10 – 12 mm (0.39 – 0.47 in.)]
3) Connect the alternator leads 1.
Nut (terminal):
8.0 N·m (0.8 kgf·m, 5.9 lbf·ft)
T.R
4) Connect the negative (–) lead 1 to the

1
battery terminal.
UPPER
LOWER
8-41
– +
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
8-42
– +
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:
¡ Pickup (tacho) sensor
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 1
continuity between 1 and 2.
2 1 If there is no continuity, replace the
pickup (tacho) sensor.
8-43
– +
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
2
from the fuel filter.
1
3) Connect the circuit tester to the water
separator coupler.
4) Hold the switch upright , and check

that there is no continuity.
If there is continuity, replace the switch.
B Y/B
5) Hold the switch upside down , and

check that there is continuity.
If there is no continuity, replace the
switch.
B Y/B
8-44
– +
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
(P5-14).
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.
8-45
– +
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-
minals 1.
2) Connect the circuit tester at the oil pres-
sure sender terminals.
1 3) Start the engine, and measure the resis-
tance at the specified oil pressure.
If the resistance is out of specifications
indicated below, 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 1 from the oil pressure switch 2.
2) Using an circuit tester, check the oil pres-

1 2
sure switch for continuity between the
switch terminal 1 and the cylinder body
2.
If there is no continuity, replace the oil
pressure switch.
8-46
– +
3) Warm up the engine and let it run at the

1 2
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.
If there is continuity, replace the oil pres-
sure switch.
Seawater Flow Sender Check

1. Check:
¡ Seawater flow sender
Seawater flow sender checking steps

1) Disconnect the seawater flow sender
leads 1.
2
2) Remove the seawater flow sender 2
from the intercooler.
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 If there is continuity, replace the sender.
5) Hold the seawater flow sender upside

down , and check that there is conti-
nuity.
If there is no continuity, replace the
sender.
L/Y B
8-47
– +
Coolant Temperature Sensor Check

1. Check:
Coolant temperature sensor checking steps

1) Disconnect the coolant temperature sen-
sor lead.
2) Remove the coolant temperature sen-
sor 1 from the thermostat housing.
3) Immerse the coolant temperature sensor

in water.
Br/B
4) Using an ohmmeter, check the resistance
at the specified water temperatures.
If the resistance is out of specifications
indicated below, replace the coolant tem-
perature 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
8-48
– +
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.
If the continuity is out of specifications,
replace the 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
8-49
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 (P3-31).
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
· Water cooler 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 water cooler element Replace.
NOTE:
Mainly check the part where seawater and fresh water 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 turbo-charger 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 Impurities in oil collected at turbine seal causing frictional rotation of Clean or
rotate. turbine spindle change
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
Jul. 2006-0.5 × 1
(ME432STI) Printed on recycled paper
(E)
Clamp 2
ENGINE WIRING HARNESS CONNECTION To be secured firmly to the
bracket with a clamp.
Cut off the extra length of the
clamp after installation.
Clamp 7 Clamp: 90465-15M54 Wire lead N64-82117-0
Bundle the wires with a clamp.
(Do not cut off the clamp after
installation.) Wire lead N64-82115-0
Clamp: 90465-13M30 Clamp 6 Clamp 9
To be secured firmly to the Bundle the two wireharnesses
Wireharness N64-82590-0
bracket with a clamp. with a clamp.
Thermo unit tightening torque: (Do not cut off the clamp Cut off the extra length of the
10.5 N·m (1.07 kgf·m, 7.74 lbf·ft) after installation.) clamp after installation.
Apply LOCTITE® No. 243. Clamp: 90465-13M30 Connect the wireharness 16 pin Clamp: 90455-13M36
connector to control unit.
Thermo unit Wireharness to the PT
Wire color: Brown/Black pump (when equipped)
Thermo SW tightening torque:

34 N·m (3.5 kgf·m, 25.1 lbf·ft)
Apply LOCTITE® No. 243.
Thermo SW
Wire color: Red/Black
Clamp 8
After making connection to the alternator, adjust the
connector wire routing to avoid interference with the
heat exchanger front cover, and bundle the
wireharnesses with a clamp. (See illustration below.)
Cut off the extra length of the clamp after securing it.
Alternator wireharness (82590) Alternator wire lead

(82117)
*Set the wire carefully Clamp:

to avoid interference 90465-13M36
LA terminal wire from

wireharness (82590)
Tighten the two LA terminals; one for the wireharness
(82590) and the other for the wire lead (82117); to-
gether to the alternator B terminal (M6).
First, attach the LA terminal for the wireharness (with-
out cover) in the manner that the crimp-on area of
the LA terminal is aligned to the locating groove on
the alternator B terminal, and then attach the LA ter-
minal for the wire lead (with cover).
[See illustration above.]
Tightening torque: 7.9 N·m (0.80 kgf·m, 5.83 lbf·ft)
Nut: 95317-06600
Spring washer: 92907-06100
Washer: 92907-06200
Clamp 10
After making connection to
the alternator and to the 4-pin connector (black).
neutral switch, bundle both To be connected to the neutral switch connec-
wires with a clamp. tor.
Clamp: 90465-13M36
2-pin connector (Black)

To be connected to the extension Wire lead: N64-82115-0 Connect the wireharness 3-pin connector
lead wire for reservor tank. (O/P) Always route this part on the outside to the alternator.
relative to the wire lead: N54-82117-0 . * Make connection before installing the
heat exchanger. The narrow space to the
Clamp 1 connector hinders the connection after
Attach the clamp to the clamp guide area on the wireharness, the installation of the heat exchanger.
and fasten the clamp to the engine block.
Clamp: 90461-10091
Bolt: 97027-08016
Washer: 90201-084K5
Clamp 5
Secure the wires from the two Clamp 4
fuse holders to the main Secure the diode to the main wireharness.
wireharness. Secure the wires Cut off the extra length of the clamp after
where they are protected with securing it.
tube. Cut off the extra length of Clamp: 90465-13M36
the clamp after securing it.
Clamp: 90465-13M36
Clamp 3
Clamp 11
To be secured to the
Secure the wireharness (N65-82590-0 ) and the wire
Install M6 terminals of the bracket with a clamp.
leads (N64-82115-0 , N64-82117-0 ) with a clamp.
wire lead: N64-82115-0 . Cut off the extra length of
(To be tightened together with the rear engine hanger.)
Tightening torque: the clamp.
Clamp: 90461-14102
3.6 N·m (0.37 kgf·m, 2.66 lbf·ft) Clamp: 90465-11M10
Washer: 92907-10200
Brown
Green/White
Tilt relay (UP)

Connect the 2 bullet connector
wires (Blue/Yellow, Black) from
the water sender to the bullet Black
connector wires in the harness,
matching the wire colors. Brown
Blue/White
Black
*Avoid interference Tilt relay (Down)
Black
Make adjustment so that the Grounding wire: 6TA-82519-0
wire to the relay will not
touch the stud bolt.
Details of Electrical Box Area
Install M10 terminal of the wire. Install M6 terminals of the wires

Tightening torque: (green and blue).
2.1 N·m (0.21 kgf·m, 1.55 lbf·ft) Tightening torque:
3.6 N·m (0.37 kgf·m, 2.66 lbf·ft)
Tilt relay (UP)
Blue
3 bullet connector wires (Green/White,
Blue/White, Red/Purple) (They are
fastened to the harness with locking tie.) Black Tilt relay (Down)
When used in combination with the drive Green
To be secured with a clamp after
unit equipped with tilt switch, remove
connecting each wire.
these wires from the harness and 2 bullet connector wires (Brown/White, Purple/White) (See description for <Clamp 6>)
connect them to the tilt switch on the Connect them to the trim limit switch on the drive unit.
drive unit.
2 bullet connector wires (Brown/White, Black)
Connect them to the trim sender on the drive unit. Connect to the harness to
the power trim pump.
Wires from the PT pump (when equipped)
Tighten the LA terminals of the wires
from the wireharness onto the two
terminals (M4) of the oil pressure sender.
Fasten the wire lead (8356N-1 ) LA The wire colors are black and light blue,
Clamp 13
terminal onto the airheater terminal (M6). which may be tightened to either of the
Secure the wire for the airheater onto
Tightening torque: terminals. Cut off the clamps (2 places),
the back of the bracket with a clamp.
15.7 N·m (1.60 kgf·m, 11.58 lbf·ft) Tightening torque: and connect the unfolded wire
Cut off the extra length of the clamp
Nut: 95317-06600 1.6 N·m (0.16 kgf·m, 1.18 lbf·ft) to the boost sender.
after securing it.
Clamp: 90465-13M36
Wireharness: N64-82590-0
Wire lead N57-8356N-1 A
Clamp 15
Connect the fuel filter 2-pin connec-
tor to the wireharness.
After the connection, tie the
wireharness into the suitable length.
(See illustration below.)
Cut off the extra length of the clamp. Wire lead: N64-82115-0
Clamp: 90465-13M36
Wire lead: N64-82117-0
Connect the wireharness

to the starter motor 1-pin
connector.
A (O/P)
Tighten one LA (for M12) terminal of

the wireharness together with the
starter motor mounting bolt.
Tightening torque on oil pressure

switch fastener:
16.7 N·m (1.70 kgf·m, 12.32 lbf·ft)
Apply LOCTITE® No. 243.
Tighten the LA terminal from Crimp-on area

wireharness with the M4 screw of Connect the wireharness to All of them must face upward
oil pressure switch. the 3-pin connector of (to the starter motor).
Tightening torque: injection pump. Starter motor
4 N·m (0.4 kgf·m, 3.0 lbf·ft)
Connect the wireharness 2-pin Tighten the three LA terminals of the three wire leads
connector to the water temperature (N64-82117-0 , N57-8356N-0 , and N64-82115-0 ) to-
Wire lead: N57-8356N-0
sensor.
gether to the main terminal (M10) of the starter motor.
Each terminal shall be tightened with the salient of its
Connect the wireharness to the 2-pin crimp-on area facing upward (facing to the starter mo-
connector of intake airheater relay. tor), to assure the firm connection of the battery cable. Battery cable
(See illustration on the right)
Tightening torque:
21 N·m (2.1 kgf·m, 15.5 lbf·ft)
Nut: 90170-10202
Tighten the LA terminals of the wires from
the wireharness onto the two terminals B (O/P)
(M4) of the boost sender. The wire colors
are black and yellow/white, which may be
tightened to either of the terminals.
Tightening torque:
0.8 N·m (0.08 kgf·m, 0.59 lbf·ft)
Route the wires below

the boost sender body.
(Refer to B.)
Avoid interference
Avoid interference Before securing the Wire lead: N64-82115-0
Route the wireharness under wireharness, adjust it properly Clamp 12 Starter motor Wire lead: N6 4-82117-0 Route them downwardly along the inner side
the flange in the lower part of so that the branching area of Secure the
Breather hose The wire from the wireharness of the starter motor.
the throttle lever, to prevent in- the wireharness will not hit the wireharness with a
terference of the wireharness to corner of the air cooler clamp. having one LA terminal (for M12).
the throttle lever. bracket. Clamp: 90461-08072
(The white tape on the Bolt: 97527-08516
Clamp 14 wireharness indicates the
Secure the wireharness with a securing position in general.)
clamp.
Securing position shall be at
about 20 mm from the branch-
ing position (at the end of INTAKE AIRHEATER RELAY CONNECTION (SUB-ASSEMBLY)
corrugated tube). Attach the two leads to the intake airheater relay. As the wire leads are
Cut off the extra length of the attached, close the cover firmly unit it clicks.
clamp.
Clamp: 90465-13M36 Remove the nuts and washer (M6) on intake airheater
relay terminal, and then fasten the lead wire.
Tightening torque: 4.5 N·m (0.46 kgf·m, 3.32 lbf·ft)
Intake airheater relay
Cover

ENGINE ELECTRICAL SYSTEM WIRING DIAGRAM
1 R 2
B
Br/ 1 Battery
3 2 Coolant temperature sender
4 3 Coolant temperature switch
R/B
Br/B 4 Seawater flow sensor
B 5 Starter motor
L/Y
R/B
5 7 6 Oil pressure sender
7 Intake airheater relay
B 8 Intake airheater
L/Y R 9 Coolant temperature sensor for pre-heating control
B
B
R 0 Oil pressure switch
B
B/W A Tachometer pickup/fuel cut solenoid valve
R
R 6 B Water separater sender
B b
C Boost sender (option)
B
R S
R D Electrical equipment box

B 8 10 (PTT relays, 20 A x 1 fuse, and 10 A x 1 fuse)
G/O 9 E Alternator
F Neutral switch
B
B
P Y/B G Fuse (100 A)
B
H Coolant reserve tank (option)
12 I Intake airheater control box
R/G
J Starter relay
R
R Y/R
Y/R 11 COLOR CODE
13 B ........... Black
20 B
Br ......... Brown
Y/W
Gy ........ Gray
B/W
/B Lg ......... Light green
u Pu
R/P
Pu G G/O R
Gy 14 Pu ......... Purple
L / Y/ B
19 P
Br
B
R ........... Red
Br /R Sb ......... Sky blue
Y
u /Pu
Lg R/P R /Y B/W ...... Black/White
R L R
B R/G b R/B Br/B ...... Brown/Black
S /B B
Br /B Gy Br/G ...... Brown/Green
Y/RB Pu /R Pu
R Y /B Br/W ..... Brown/White
Br Y B/W
R Y/W /G Lg G/L ....... Green/Blue
L
Y/R /L G/L
18 17
Y/R
B G
G/W ...... Green/White
Sb
L/G ....... Blue/Green
L/Y
R R
Y/B L/W ....... Blue/White

R
B
B Br/B R/B
L/Y ........ Blue/Yellow
R u
Br P
R
Y/W Lg B
/P
Pu/B
16 Pu/B ..... Purple/Black
u
R/G Gy
Pu/W .... Purple/White
B/W R/B ....... Red/Black
15 G/L
R/Pu
R/G ....... Red/Green
L/G Pu
Y/R Br R/Pu ..... Red/Purple
Y/B ....... Yellow/Black
Y/R ....... Yellow/Red
Y/W ...... Yellow/White
WIRING CONNECTION DIAGRAMS 1 Lanyard switch (option)
64D-82570-10
Single Engine/Single Station (EXAMPLE) 2 Main switch
6YF-82570-40
3 Tachometer
N64-83600-00
4 Speedometer (option)
N64-83600-10
5 Voltmeter
N64-83600-30
6 Trim meter
N64-83600-50
7 Coolant temperature meter
N64-83600-20
8 Oil pressure meter
N64-83600-40
9 Fuel meter (option)
N64-83600-70
0 Boost meter (option)
N64-83600-60
A Pilot light panel
6YF-83530-20
B Wireharness assembly
6YF-82580-C0
¡ C Wireharness
6YF-82580-B0
¡ D Resistor
6YF-85370-10
E Control box
6YF-85590-11
F Extension wireharness
6YF-82586-61
G Extension wireharness
6YF-8258A-71
H Wireharness
6YF-82580-D0
To PTT switch
To meter light switch
Free
To engine extension wireharness
(6TA-82586-00)
To Fuel sender
* These are colors of identification coat-
ing on the wireharness.
NOTE 1: Component parts are listed un-
der their assemblies and indi-
cated by bullets.
NOTE 2: This wiring connection diagram
is an example only. The actual
combination of meters and
switches may vary according to
the boat.
COLOR CODE
B ........... Black
L ........... Blue
N .......... Natural
Y ........... Yellow
W .......... White
P ........... Pink
Br ......... Brown
Gy ........ Gray
Pu ......... Purple
B/Y ....... Black/Yellow
R/Pu ..... Red/Purple
L/W ....... Blue/White
G/W ...... Green/White
Pu/W .... Purple/White
Single Engine/DUAL Station (EXAMPLE)
1 Lanyard switch (option)
64D-82570-10
2 Main switch
6YF-82570-40
3 Tachometer
N64-83600-00
4 Speedometer (option)
N64-83600-10
5 Voltmeter
N64-83600-30
6 Trim meter
N64-83600-50
7 Coolant temperature meter
N64-83600-20
8 Oil pressure meter
N64-83600-40
9 Fuel meter (option)
N64-83600-70
0 Boost meter (option)
N64-83600-60
A Pilot light panel
6YF-83530-20
B Wireharness assembly
6YF-82580-C0
¡ C Wireharness
6YF-82580-B0
¡ D Resistor
6YF-85370-10
E Control box
6YF-85590-11
F Extension wireharness
6YF-82586-52
G Extension wireharness
6YF-82586-02
H Wireharness
6YF-82580-D0
I Wireharness assembly
6YF-82580-E0
J Extension wireharness
6YF-8258A-02
K Start and stop switch (option)
6YF-82570-50
To PTT switch
To meter light switch
Free
To engine extension wireharness
(6TA-82586-00)
To Fuel sender
COLOR CODE Main station
B ........... Black Sub station
L ........... Blue * These are colors of identification coat-
N .......... Natural ing on the wireharness.
Y ........... Yellow ** Leave free.
W .......... White If it is connected meter at main station
P ........... Pink may give wrong indication.
Br ......... Brown NOTE 1: Component parts are listed un-
Gy ........ Gray der their assemblies and indi-
Pu ......... Purple cated by bullets.
B/Y ....... Black/Yellow NOTE 2: This wiring connection diagram
R/Pu ..... Red/Purple is an example only. The actual
L/W ....... Blue/White combination of meters and
G/W ...... Green/White switches may vary according to
Pu/W .... Purple/White the boat.
ENGINE CONNECTIONS
Battery
Pu/B
B/W
Y/B
Gy
B
G/O
K M
B
R
R
R
SeaWater
Y/W
R/G
Sb
B
J
B
flow sender
R
I H
R
B
L/Y
B
L/Y R
L/Y
B
Starter motor Oil pressure Coolant temp. Airheater Airheater Boost sender Oil pressure Fuel cut Pickup (tacho) Water separate
sender sensor for relay switch solenoid sensor switch A L/Y
pre-heating control valve Sb
Br/B R/B
B
Electrical equipment box Pu/B
R R Gy
R/G
B R
B G/W
Br/W
B/W PT/T relay B B PT/T relay
(UP) (DOWN) R/Pu Pu
Diode
B
L Pu/W L/W
Br
Br
L Y/R Br
Y/R
Br
G
B
B B Y/B C
B B Lg
Y/W Y/R Y/R
G/W
G/W Br
B/W
L/G G/L G/L B

R/Pu
R
D E
Br
10A x 1 fuse Pu
(black holder) Lg
R
20A x 1 fuse
L/W
L/W
B
(yellow holder) Br R/Pu
R/Pu F H
Y/R R G/O
Pu/W
Br/W
R/Pu
Pu/B
G/W
Br/B
Y/W
B/W
L/W
R/G
B
Y/R
R/B
G/L
Y/B
L/G
L/Y
Gy
Pu
Sb
Lg
Br
B
Y/R R
Coolant temp. B A
Thermal switch G
sender 100A x 2 fuse Newtral switch
To External harness
PT/T motor
R
G/L B
Br/B
D
Alternator
R/B
M Pu
Y/R
Y/R
R/Pu
R
Pu
Br
L
G
B B B Br Y/R P G/O L/G R/Pu
B
R
R
Br/B Br/B
R/B R/B
G/L
Y/R
Y/R
B
I J
P R
G/L
Y/R
Y/R
B
K L
Trim sender Gy B/W Y/R
B B B
Br
Pu/B
Br/W Br/W Br/W
M
Y/B
PT/T switch
R/Pu R/Pu
B
UP L/W L/W L/W
R/Pu
DW. G/W G/W G/W
N P (Free) R
(Free)
Trim limit switch Y/R
Lg
B
Y/R
Y/R
R
E
Pu/W L/W L/W L/W B
N Y/R B B B
F
R/Pu
G/O
Y/R
L/G
Pu
Br
P
B
B
Pu/W Pu/W
Y/R
B
G
Wire lead
Resorvoir switch
Airheater
control unit P R
Y/R B
B B
Starter relay
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 wire harness
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

Sea water 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 wire harness
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/W Pu Pu Pu Pu
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

Sea water 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 Br/B Lg/R (Free)
E Grow
L/W Sb Sb 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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ME432STI

4) Tighten the camshaft timing pulley #1

Bolt (timing pulley #1):

necting rod assembly.

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

HANDLING OF LIQUID GASKET.......................................................................................... 1-10

STANDARD ABBREVIATIONS AND SYMBOLS ................................................................. 1-11

The model and serial number plate is located

MODEL PREFIX VARIATION SERIAL NO.

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

*TDG-13 Compression gauge To measure compression

09223-78010 Crankshaft oil seal To install crankshaft front oil seal

09308-10010 Oil seal puller To remove crankshaft front oil seal

09316-20011 Transfer bearing replacer To install injection pump 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-

09214-76011 Crankshaft pulley To install injection pump drive gear oil

09222-17011 Connecting rod bush

• 09222-05021 Remover & replacer To remove and install connecting rod

• 09222-05031 Guide To install connecting rod bush

• 09222-05041 Base To remove and install connecting rod

09950-60010 Replacer set

• 09951-00190 Replacer 19 To remove oil pump drive shaft gear

• 09951-00340 Replacer 34 To install oil pump drive shaft gear

• 09951-00320 Replacer 32 To mount camshaft oil seal

• 09951-00500 Replacer 50 To mount camshaft oil seal

• 09951-00640 Replacer 64 To injection pump drive gear oil seal

• 09952-06010 Adapter To mount camshaft oil seal

• 09951-07150 Handle 150 To install the camshaft oil seal

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-

*PSG-6TB Power steering fluid To check power steering fluid pressure

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

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 ........................................................................................ 2-3

TIGHTENING TORQUE ......................................................................................................... 2-11