What to do if Yanmar Engine starter motor brushes are worn out?
If the starter motor brushes are not worn, replace the armature assembly. Otherwise, inspect the brushes and replace them if they show signs of wear.
General| Number of Cylinders | 6 |
|---|---|
| Fuel System | Direct injection |
| Type | Diesel |
| Aspiration | Turbocharged |
| Compression Ratio | 17.5:1 |
| Cooling System | Freshwater cooled |
| Starting System | Electric Starter |
| Lubrication System | Forced Lubrication |
| Fuel Consumption | 210 g/kWh |
Information, illustrations, and specifications are based on latest data.
No part of this publication may be reproduced without written permission.
Indicates an imminently hazardous situation resulting in death or serious injury.
Indicates a potentially hazardous situation resulting in death or serious injury.
Indicates a potentially hazardous situation resulting in minor or moderate injury.
Indicates a potentially hazardous situation causing machine damage or improper operation.
Never remove coolant filler cap if engine is hot. Steam can cause severe burns.
Keep battery area ventilated. Hydrogen gas can ignite.
Use lifting eyes and equipment. Never stand under hoisted engine.
Never stand under hoisted engine. If hoist fails, engine can fall.
Keep fire extinguishers handy. Ensure proper type and readiness.
Never remove fuel cap with engine running. Diesel fuel is flammable.
Use approved containers for fuel. Avoid flammable vapors from rags.
Never use diesel fuel as a cleaning agent. Diesel fuel is flammable.
Never check battery charge by shorting terminals. Sparks can cause explosion.
Check for fuel leaks. Replace rubberized fuel hoses every 2 years/500 hrs.
Only use key switch to start. Never jump-start. Sparks can cause fire.
Only use diesel fuel. Never refuel with engine running. Avoid ignition sources.
Never jump-start engine. Sparks from battery shorting can cause fire or explosion.
Hot engine surfaces can ignite oil/grease. Ensure exhaust pipe is clean.
Never stand under hoisted engine. Engine can fall, causing death or serious injury.
Never operate engine under influence of alcohol/drugs or when feeling ill.
Keep body parts away from moving parts. Wear tight clothing, tie back hair.
Wear PPE like gloves, work shoes, eye/hearing protection.
To prevent eye injury, always wear safety glasses while servicing the engine.
Avoid skin contact with high-pressure fuel spray. Seek medical treatment if exposed.
Turn off battery switch or disconnect cable before electrical system service.
Stop engine before servicing. Never leave key in switch.
Stay clear of hot engine oil when draining to avoid burns. Always wear eye protection.
Wait for engine to cool before draining coolant. Hot coolant can splash and burn.
Shift marine gear to NEUTRAL when engine is idle. Sudden movement can cause injury.
Keep body parts away from hot engine surfaces like muffler/exhaust pipe.
Follow safety precautions on hazardous substance containers (cleaners, sealants).
Never operate engine in enclosed area without ventilation. CO gas is dangerous.
Battery fluid is sulfuric acid. Avoid contact with skin/eyes. Wear PPE.
Wear eye protection and gloves when handling coolant. Flush contact areas with water.
Always wear eye protection when using compressed air or high-pressure water.
Secure engine solidly to prevent injury or damage from falling during work.
Starter motor is heavy. Use care when removing it.
Use care not to catch fingers between belt and pulley when installing belt.
Take corrective action if any problem is noted during visual check before operating.
Never overfill engine oil. Keep level between upper and lower lines.
Only use specified engine oil. Other oils may affect warranty or cause seizure.
Only use specified coolant. Others may affect warranty or cause rust/scale.
Never engage starter motor while engine is running. May damage starter/ring gear.
Replace any defective part or part not meeting standard/limit.
Immediately cap or plug all openings to prevent system contamination.
Dimensional drawings for the 4BY Inboard Version (Borg Warner Flange).
Dimensional drawings for the 4BY Stern Drive Version.
Dimensional drawings for the 6BY Inboard Version (Borg Warner Flange).
Dimensional drawings for the 6BY Stern Drive Version.
Illustrates the fuel flow path through the engine system.
Illustrates the coolant flow path through the engine system.
Shows the location of informational labels on Yanmar BY marine engines.
Shows typical engine data and drive information labels.
Location of the engine block information label.
Lists diesel fuel specifications and compliance requirements.
Details fuel requirements like cetane number, sulfur content, and additives.
Illustrates typical boat fuel system installation and components.
Notes on fuel supply line diameter, drain cock, and filter installation.
Covers ACEA service categories and recommended engine oil viscosity.
Procedure for bleeding the fuel system under specific conditions.
Guidelines and classifications for engine oil, including service categories.
SAE Service Grade Viscosity Chart based on ambient temperature.
Cautions on using specified oil, preventing contamination, mixing, and overfilling.
Lists trade names and producers for LongLife 01 engine oils.
Refer to documentation for recommended marine gear or stern drive oil.
Refer to documentation for recommended power steering fluid.
Details specifications for engine coolant and mixture recommendations.
Never remove hot coolant filler cap. Steam can cause severe burns.
Wear eye protection and gloves when handling coolant. Flush contact areas with water.
Use specified coolant. Avoid mixing types and contamination.
Note: LLC is required for warranty in the U.S.
Add LLC to deionized water. Use proper concentrate amount.
Lists trade names and manufacturers for recommended engine coolants.
General, test, adjustment, and repair specifications for engines.
Models numbers with no suffix for marine gear, 'Z' suffix for stern drive.
Indicates In-Line 4 or In-Line 6 cylinder configuration.
15° inclined, water-cooled, DOHC, 4-stroke diesel.
Direct injection.
Turbocharged with charge air cooler.
Dimensions provided in mm and inches.
Engine displacement in liters and cubic inches.
Standard firing order for 4-cylinder and 6-cylinder engines.
16.5:1 for both 4BY and 6BY engines.
kW and metric hp at 4000 rpm for each model.
Mean effective pressure in MPa and psi.
Torque values in N·m and ft-lb for different engine models.
4600 rpm.
ECU-controlled idle speeds for warm engines.
ECU-controlled speed for cold start conditions.
ECU-controlled engine speed limit.
Engine speed at wide open throttle.
Counterclockwise when viewed from flywheel.
4 valves per cylinder.
Hydraulic self-adjusting.
MHI with pneumatic wastegate or HOLSET with pneumatic wastegate.
Seawater cooled.
12V system.
12V / 2 kW (2.7 hp).
12V / 150A.
12V / 74 Ah / 680 CCA.
Common rail (ECU-controlled).
Variable depending on rpm; 250-1600 bar.
Variable (ECU-controlled).
Specified backpressure limits for 4BY and 6BY.
Closed cooling system with seawater heat exchanger.
Approximate coolant capacity in liters and quarts.
Rubber impeller, belt-driven.
140 L/min (37 gpm) at 4000 engine rpm.
2000 mm (78.75 in.).
Seawater cooled.
Totally enclosed, forced lube system.
Engine coolant system.
Pressure range in bar and psi at rated speed.
Pressure range in bar and psi at 1000 rpm.
Oil capacity in liters and quarts.
Closed, with filter.
Stern Drive (Bravo-1, -2, -3) or Marine Gear (ZF45A; Kanzaki).
Continuous and peak angles for front-to-rear and left-to-right operation.
Height in mm and inches.
Length for Stern Drive and Marine Gear versions.
Total length in mm and inches.
Width in mm and inches.
Dry weight in kg and lb.
Weight with mixing elbow in kg and lb.
Guidance on applying correct torque to fasteners to avoid damage or failure.
Torque values for hexagon bolts and nuts by nominal diameter and grade.
Torque values for hose clamps. Reuse and retightening prohibited.
Lists common abbreviations and symbols used in the manual.
Alphabetical list of abbreviations used in the manual.
List of common symbols and their meanings.
Provides conversion factors for various units of measurement.
Table of unit prefixes with their symbols and powers.
Conversion factors for length units.
Conversion factors for volume units.
Conversion factors for mass units.
Conversion factors for force units.
Conversion factors for torque units.
Conversion factors for pressure units.
Conversion factors for power units.
Formulas for converting between Fahrenheit and Celsius.
Important safety precautions and considerations before starting maintenance.
Describes procedures for engine care and maintenance.
Explains benefits of maintenance: prevents downtime, extends engine life.
Guidance on carrying out periodic maintenance tasks.
Recommends using genuine Yanmar parts for longevity.
Essential maintenance for EPA compliance and optimum performance.
EPA emission regulation applicability and conditions for USA.
Conditions for meeting EPA standards: temperature, humidity, backpressure.
Never operate engine in enclosed area without ventilation. CO gas is dangerous.
Procedures for inspection and maintenance tasks.
Summary of maintenance items by intervals: daily, 50, 250, 500 hours.
Specific maintenance for EPA emission-related parts like turbocharger adjustment.
Detailed procedures for maintenance at specific intervals (50, 250, 500 hours).
Specific maintenance tasks to perform after the first 50 hours of operation.
Maintenance tasks to be performed every 50 hours or monthly.
Maintenance tasks to be performed every 250 hours or annually.
Maintenance tasks to be performed every 500 hours or every 2 years.
Keep battery area ventilated. Hydrogen gas can ignite.
Never check battery charge by shorting terminals. Sparks can cause explosion.
Never remove hot coolant filler cap. Steam can cause severe burns.
Check for fuel leaks. Replace rubberized fuel hoses every 2 years/500 hrs.
Use approved containers for fuel. Avoid flammable vapors from rags.
Never use diesel fuel as a cleaning agent. Diesel fuel is flammable.
Never remove fuel cap with engine running. Diesel fuel is flammable.
Only use key switch to start. Never jump-start. Sparks can cause fire.
Never start engine without air filter. Failure can cause injury or death.
Never stand under hoisted engine. Engine can fall, causing death or serious injury.
Keep body parts away from moving parts. Wear appropriate clothing.
Never operate engine in enclosed area without ventilation. CO gas is dangerous.
Keep body parts away from hot engine surfaces like muffler/exhaust pipe.
Always wear eye protection when using compressed air or high-pressure water.
Secure engine solidly to prevent injury or damage from falling during work.
Use specified oil. Avoid mixing types and overfilling.
Use specified coolant. Avoid mixing types and contamination.
Important safety precautions before starting engine disassembly or service.
Describes disassembly, inspection, and reassembly of 4BY and 6BY engines.
General, test, adjustment, and repair specifications for engines.
Specifications for cylinder head, valve guides, camshaft bearings, valve seats.
Specifications for camshaft thrust bearing width, radial runout, axial play.
Specifications for valve head diameter and stem diameter.
Specifications for crankshaft journals, bearing clearance, axial play.
Specifications for crankshaft thrust bearing dimensions.
Specifications for connecting rod journal dimensions and radial play.
Specifications for permitted radial and axial runout.
Specifications for piston ring side clearance, end gap, and piston-to-cylinder clearance.
Specifications for cylinder bore diameter, out-of-round, conicity, and wear.
Engine oil capacity for 4BY and 6BY engines.
Torque values for various engine components.
Torque values for main bearing cap, drain plug, clamping, and engine mount nut.
Torque values for torsional vibration damper to crankshaft.
Assembly and initial torque values for connecting rod bolts.
Torque values for cylinder head bolts and seal plug.
Torque values for camshaft sprocket and bearing cap bolts.
Torque values for oil drain plug and oil sump bolts.
Torque values for timing case cover bolts, guide rail pin, and plugs.
Torque values for main bearing cap bolts and oil pick-up bolts.
Torque values for oil pick-up to oil pump and reinforcement shell.
Torque values for coolant return fittings.
Torque values for intake manifold to cylinder head.
Torque values for turbocharger to exhaust manifold and oil supply line.
Torque values for wires, belt pulley, and mounting bolts.
Torque values for wiring harness to ground holder and DDE harness pick up.
Torque values for sprocket to pump and fuel measuring valve.
Torque values for fuel injector, line union nuts, pressure sensor, regulator, return rail.
Torque value for idler pulley to alternator bracket.
Torque value for coolant return pipe.
Torque value for glow plugs.
List of specialized tools for engine service.
Tool for compressing valve springs for removal/installation.
Tool for installing valve stem seals (OEM Part No. specified).
Tool for measuring cylinder compression pressure (OEM Part No. specified).
Tool for compressing piston rings during installation.
Tool for removing and installing piston rings.
List of instruments used for engine measurements.
Used for measuring shaft bend and end play.
Used for holding the dial indicator during measurement.
Used for measuring outside diameters of crankshaft, pistons, etc.
Used for measuring inside diameters of cylinder bores, bearing bores, etc.
Used for measuring outside diameters, depth, thickness, and width.
Used for measuring valve recession.
Used for measuring valve spring inclination and part straightness.
Used for tightening nuts and bolts to specified torque.
Used for measuring piston ring gaps and side clearance.
Procedures for testing and adjusting engine systems.
Procedure for checking cylinder compression using a tester.
General preliminary steps for engine disassembly.
Covers cylinder head components, removal, disassembly, cleaning, testing, and assembly.
Specifications for cylinder head, valve guides, camshaft bearings, valve seats.
Specifications for camshaft thrust bearing width, radial runout, axial play.
Specifications for valve head diameter and stem diameter.
Procedure for removing, disassembling, assembling, and installing pistons and connecting rods.
Procedure for removing and disassembling pistons and connecting rods.
Steps for assembling pistons and connecting rods.
Procedure for installing piston and connecting rod assemblies.
Steps for removing and installing flywheel housing, drive coupling, flywheel, and rear seal.
Steps for removing and installing the flywheel housing.
Procedure for removing and installing the drive coupling.
Steps for removing the engine flywheel.
Procedure for replacing the rear crankshaft seal.
Steps for installing the engine flywheel.
Covers components, checking/adjusting timing, and removing/installing related parts.
Illustration and list of camshaft and timing gear train components.
Procedure for checking and adjusting camshaft timing.
Procedure for removing and installing the vibration damper on 4BY engines.
Procedure for removing and installing the vibration damper on 6BY engines.
Steps for removing the timing case cover.
Procedure for removing and installing the timing chain.
Steps for installing the timing case cover with new gasket.
Procedure for removing and installing the timing chain tensioner.
Steps for removing the engine camshafts.
Procedure for installing the engine camshafts.
Covers components, crankshaft removal, oil clearance measurement, and inspections.
Illustration and list of cylinder block and crankshaft components.
Steps for removing the engine crankshaft.
Procedure for checking oil clearance of connecting rods and main bearings.
Inspect crankshaft for cracks, measure journals, check runout.
Inspect cylinder block for discoloration, cracks, measure bores.
Procedure for selecting and installing crankshaft bearings and journals.
Steps for removing and installing the intake manifold.
Steps for removing the intake manifold.
Procedure for installing the intake manifold.
Steps for removing and installing the exhaust manifold.
Steps for removing the exhaust manifold.
Procedure for installing the exhaust manifold.
Procedure for safely attaching the engine to a repair stand.
Never stand under hoisted engine attached to a repair stand. Engine can fall.
Important safety precautions before starting engine disassembly or service.
Stop engine before servicing. Never leave key in ignition. Avoid moving parts.
Keep body parts away from hot engine surfaces like muffler/exhaust. Surfaces can cause burns.
Follow safety precautions on hazardous substance containers (cleaners, sealants).
Always wear eye protection when using compressed air or high-pressure water.
Secure engine solidly to prevent injury or damage from falling during work.
Use specified oil. Avoid mixing types and overfilling.
Use specified coolant. Avoid mixing types and contamination.
Protect air cleaner, turbocharger, electricals from damage during cleaning.
Never hold key in START for longer than 10 seconds; starter motor will overheat.
Details engine model, cylinders, bore, stroke, displacement, compression ratio.
Specifications for cylinder compression test.
Torque values for various engine components.
List of specialized tools for engine service.
Tool for compressing valve springs for removal/installation.
Tool for installing valve stem seals (OEM Part No. specified).
Tool for measuring cylinder compression pressure (OEM Part No. specified).
Tool for compressing piston rings during installation.
Tool for removing and installing piston rings.
List of instruments used for engine measurements.
Used for measuring shaft bend and end play.
Used for holding the dial indicator during measurement.
Used for measuring outside diameters of crankshaft, pistons, etc.
Used for measuring inside diameters of cylinder bores, bearing bores, etc.
Used for measuring outside diameters, depth, thickness, and width.
Used for measuring valve recession.
Used for measuring valve spring inclination and part straightness.
Used for tightening nuts and bolts to specified torque.
Used for measuring piston ring gaps and side clearance.
Procedures for testing and adjusting engine systems.
Procedure for checking cylinder compression using a tester.
General preliminary steps for engine disassembly.
Covers cylinder head components, removal, disassembly, cleaning, testing, and assembly.
Specifications for cylinder head, valve guides, camshaft bearings, valve seats.
Specifications for camshaft thrust bearing width, radial runout, axial play.
Specifications for valve head diameter and stem diameter.
Procedure for removing, disassembling, assembling, and installing pistons and connecting rods.
Procedure for removing and disassembling pistons and connecting rods.
Steps for assembling pistons and connecting rods.
Procedure for installing piston and connecting rod assemblies.
Steps for removing and installing flywheel housing, drive coupling, flywheel, and rear seal.
Steps for removing and installing the flywheel housing.
Procedure for removing and installing the drive coupling.
Steps for removing the engine flywheel.
Procedure for replacing the rear crankshaft seal.
Steps for installing the engine flywheel.
Covers components, checking/adjusting timing, and removing/installing related parts.
Illustration and list of camshaft and timing gear train components.
Procedure for checking and adjusting camshaft timing.
Procedure for removing and installing the vibration damper on 4BY engines.
Procedure for removing and installing the vibration damper on 6BY engines.
Steps for removing the timing case cover.
Procedure for removing and installing the timing chain.
Steps for installing the timing case cover with new gasket.
Procedure for removing and installing the timing chain tensioner.
Steps for removing the engine camshafts.
Procedure for installing the engine camshafts.
Covers components, crankshaft removal, oil clearance measurement, and inspections.
Illustration and list of cylinder block and crankshaft components.
Steps for removing the engine crankshaft.
Procedure for checking oil clearance of connecting rods and main bearings.
Inspect crankshaft for cracks, measure journals, check runout.
Inspect cylinder block for discoloration, cracks, measure bores.
Procedure for selecting and installing crankshaft bearings and journals.
Steps for removing and installing the intake manifold.
Steps for removing the intake manifold.
Procedure for installing the intake manifold.
Steps for removing and installing the exhaust manifold.
Steps for removing the exhaust manifold.
Procedure for installing the exhaust manifold.
Procedure for safely attaching the engine to a repair stand.
Never stand under hoisted engine attached to a repair stand. Engine can fall.
Important safety precautions before servicing the fuel system.
Describes procedures for servicing fuel system components on 4BY and 6BY engines.
General specifications including test/adjustment and torque values.
Specifications for high-pressure fuel pump, feed pump, and return fuel pressure.
Torque values for fuel system components.
List of special tools required for fuel system service.
Illustrations and lists of fuel system components for 4BY and 6BY engines.
Diagram showing fuel system component locations for 4BY engines.
Diagram showing fuel system component locations for 6BY engines.
Illustrates the fuel flow path through the engine system.
Procedures for testing fuel system components.
Procedure for measuring fuel feed pump pressure.
Procedure for testing return fuel pressure.
Procedures for repairing fuel system components.
Steps for removing a fuel injector.
Procedure for cleaning fuel injector cavities.
Procedure for installing a fuel injector.
Procedure for removing and installing high-pressure fuel lines.
Procedure for replacing the fuel feed pump.
Procedure for removing and installing the high-pressure fuel pump.
Procedures for replacing fuel filters.
Procedure for replacing the fuel fine filter.
Procedure for replacing the fuel filter/water separator.
Procedure for removing and installing the fuel rail.
Procedure for replacing the injector return fuel line.
Procedure for bleeding the fuel system after maintenance or running out of fuel.
Important safety precautions before servicing the cooling system.
Describes servicing of the 4BY and 6BY marine engine cooling systems.
General, test/adjustment, repair specs, torque chart, and tools.
Pressure specifications for cooling system and filler cap at operating temperature.
Coolant capacity for 4BY and 6BY engines.
Torque values for charge air cooler bolt and zinc anode.
List of special tools for cooling system pressure testing and belt service.
Torque wrench for tightening nuts and bolts.
Illustrates coolant flow path through the engine cooling system.
Procedures for testing cooling system pressure, filler cap, and thermostat.
Procedure for pressure testing the cooling system and filler cap.
Procedure for testing thermostat opening temperature.
Procedures for repairing cooling system components.
Steps for preparing the engine for long-term storage.
Procedure for draining the seawater cooling system.
Procedure for inspecting and replacing zinc anodes.
Procedure for draining and filling the closed cooling system.
Procedure for disconnecting and connecting quick-connect fittings.
Procedure for removing and installing the hydraulic oil cooler.
Procedure for inspecting and cleaning the hydraulic oil cooler.
Procedure for removing and installing the charge air cooler.
Procedure for disassembling and assembling the charge air cooler.
Procedure for removing and installing the heat exchanger.
Procedure for disassembling and assembling the heat exchanger.
Procedure for removing and installing the coolant pump.
Procedure for removing and installing the thermostat.
Inspection/replacement of the seawater pump impeller and removal/installation.
Procedure for inspecting and replacing the seawater pump impeller.
Procedure for removing and installing the seawater pump.
Procedure for replacing the seawater pump belt.
Important safety precautions before servicing lubrication systems.
Describes servicing of the 4BY and 6BY lubrication systems.
General specifications including test/adjustment and torque values.
Oil pressure specifications at idle and 4000 rpm for 4BY and 6BY.
Torque values for oil filter cap, sump bolts, drain plug, and pickup bolts.
List of special tools for oil pressure testing.
Torque wrench for tightening nuts and bolts.
Procedures for testing engine oil flow and pressure.
Illustrates engine oil flow path and component locations.
Procedure for checking engine oil pressure.
Procedures for repairing lubrication system components.
Illustration and list of engine lubrication system components.
Procedure for replacing engine oil and oil filter element.
Procedure for removing and installing the engine oil cooler.
Procedure for removing and installing the oil filter housing.
Procedure for removing and installing the engine oil sump.
Information on oil pump replacement (as an assembly).
Steps for removing the engine oil pump.
Procedure for installing the engine oil pump.
Use specified oil. Avoid mixing types and overfilling.
Keep body parts away from hot engine surfaces like muffler/exhaust. Surfaces can cause burns.
Stop engine before servicing. Never leave key in ignition. Avoid moving parts.
Follow safety precautions on hazardous substance containers (cleaners, sealants).
Always wear eye protection when using compressed air or high-pressure water.
Follow EPA guidelines for hazardous material disposal. Do not dump irresponsibly.
Never stand under hoisted engine. Engine can fall, causing death or serious injury.
Important safety precautions before servicing the turbocharger.
Describes removal, inspection, and installation of turbochargers on 4BY and 6BY engines.
General specifications including boost pressure limits and torque chart.
Turbocharger boost pressure limits for different engine models.
Torque values for turbocharger mounting and oil lines.
List of special tools required for turbocharger service.
Procedures for measuring and adjusting charge pressure.
Procedure for measuring turbocharger charge pressure.
Procedure for adjusting charge pressure on 4BY engines via wastegate rod.
Procedures for turbocharger removal and installation.
Steps for removing the engine turbocharger.
Procedure for installing the engine turbocharger.
Hot engine surfaces can ignite oil/grease. Ensure exhaust pipe is clean.
Stop engine before servicing. Never leave key in ignition. Avoid moving parts.
Follow safety precautions on hazardous substance containers (cleaners, sealants).
Keep body parts away from hot engine surfaces like muffler/exhaust. Surfaces can cause burns.
Always wear eye protection when using compressed air or high-pressure water.
Replace any defective part or part not meeting standard/limit.
Important safety precautions before servicing the starter motor.
Covers servicing of starter motor on 4BY and 6BY engines.
General specifications for starter motors, including power, voltage, weight, and torque.
Lists nominal power, voltage, temperature, rotation, and weight.
Torque values for battery positive cable and solenoid primary wire.
Diagnostic chart for troubleshooting starter motor problems.
Procedure for removing and installing the starter motor.
Stop engine before servicing. Never leave key in ignition. Avoid moving parts.
Turn off battery switch or disconnect cable before electrical system service.
Follow safety precautions on hazardous substance containers (cleaners, sealants).
Always wear eye protection when using compressed air or high-pressure water.
Never hold key in START for longer than 10 seconds; starter motor will overheat.
Important safety precautions before servicing the alternator.
Describes servicing of the 4BY and 6BY charging systems.
General specifications and special torque chart for the alternator.
Lists manufacturer, model, voltage, output, temperature, rotation, and weight.
Torque values for alternator mounting bolts and positive cable nut.
Procedures for replacing alternator belt and removing/installing alternator.
Procedure for replacing the alternator belt.
Procedure for removing and installing the alternator.
Procedure for removing and installing the alternator belt tensioner.
Stop engine before servicing. Never leave key in ignition. Avoid moving parts.
Turn off battery switch or disconnect cable before electrical system service.
Follow safety precautions on hazardous substance containers (cleaners, sealants).
Always wear eye protection when using compressed air or high-pressure water.
Use care not to catch fingers between belt and pulley while installing belt.
Do not operate engine if alternator produces unusual sounds. Damage may result.
Do not use high-pressure wash directly on alternator. Water can cause damage.
Do not reverse battery cables. Diode and stator coil can be damaged.
Never operate engine with batteries disconnected. Damage to alternator will result.
Do not turn battery switch OFF while engine is operating. Damage to alternator will result.
Important safety precautions before servicing electrical system and ECU.
Describes operation and procedures for testing/replacing electrical system and ECU.
Special Torque Chart for fuel control valve, sensor, and regulator.
Torque values for fuel control valve, sensor, and regulator.
Describes engine management system operation and component locations.
Diagram showing component locations for the 4BY engine management system.
Diagram showing component locations for the 6BY engine management system.
Illustrates and lists components of the electrical panel (fuses, relays, ECU).
Procedures for testing various electrical and ECU components.
Describes function and failure results of relays (starter, fuel pump, main).
Explains operation and failure results of the start relay.
Explains operation and failure results of the main relay.
Explains operation and failure results of the fuel pump relay.
Describes function, results of failure, and test values for the oil pressure sensor.
Describes function, results of failure, and test values for fuel injectors.
Describes function, results of failure, and test values for coolant temp sensor.
Describes function, results of failure, and test values for fuel rail pressure control valve.
Describes function, results of failure, and test values for water-in-fuel sensor.
Describes function, results of failure, and test values for crankshaft speed sensor.
Describes system, function, pre/post heating, failure results, and test values.
Describes function, results of failure, and test values for fuel temperature sensor.
Describes function, results of failure, and test values for fuel volume regulator.
Describes function, results of failure, and test values for charge air temp sensor.
Describes function, results of failure, and test values for charge air pressure sensor.
Describes function, results of failure, and test values for fuel rail pressure sensor.
Describes function, results of failure, and test values for camshaft speed sensor.
Describes function, results of failure, and test values for throttle position sensor.
Procedures for replacing ECU, coolant temp sensor, and air pressure/temp sensors.
Procedure for replacing the engine control unit (ECU).
Procedure for replacing the engine coolant temperature sensor.
Procedure for replacing the charge air pressure sensor.
Procedure for replacing the charge air temperature sensor.
Procedure for replacing the crankshaft speed sensor.
Procedure for replacing the camshaft speed sensor.
Procedure for replacing the high-pressure fuel control valve.
Procedure for replacing the high-pressure fuel sensor.
Procedure for replacing the fuel temperature sensor.
Procedure for replacing the fuel volume regulator.
Procedure for removing and installing the oil pressure sensor.
Stop engine before servicing. Never leave key in ignition. Avoid moving parts.
Be sure boat is in open water before increasing RPM. Sudden movement can cause injury.
Follow safety precautions on hazardous substance containers (cleaners, sealants).
Avoid skin contact with high-pressure fuel spray. Seek medical treatment if exposed.
Follow EPA guidelines for hazardous material disposal. Do not dump irresponsibly.
Never hold key in START for longer than 10 seconds; starter motor will overheat.
Immediately cap or plug all openings to prevent system contamination.
Contains information and charts to diagnose engine, starter, or alternator problems.
Details fault modes, torque limitations, and substitute maps.
Describes torque reduction due to active electronic faults in sensors or actuators.
Describes torque reduction due to low boost pressure or high intake air temperature.
Provides solutions for common engine problems like starting, exhaust color, vibration, and power.
Diagnoses and provides actions for engine starting issues.
Diagnoses causes and actions for white, blue, or black exhaust smoke.
Diagnoses causes and actions for engine vibration when drive is disengaged.
Diagnoses causes and actions for engine vibration when drive is engaged.
Diagnoses causes and actions for engine knocking noises.
Diagnoses causes and actions for low engine power output.
Diagnoses causes and actions for engine overheating.
Diagnoses causes and actions for engine running too cold.
Diagnoses causes and actions for repeated low coolant level or coolant expulsion.
Troubleshooting for no display or defective diode V1 on helm panel.
Information on working procedure, diagnostic trouble codes, and their meanings.
Steps to diagnose problems by gathering symptoms and extracting trouble codes.
List of P-codes, their fail modes, conditions, and actions.
Reminds user to check and clear trouble codes after completing repairs.
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