Yanmar 6BY2 - Page 5

TABLE OF CONTENTS
12/05
BY Service Manual
v
© 2009 Yanmar Marine International
Measuring Instruments.................................................................. 5-12
Sealants and Compounds............................................................. 5-13
Tests and Adjustments.................................................................. 5-14
Test Compression ................................................................... 5-14
Repair............................................................................................ 5-15
Cylinder Head................................................................................ 5-16
Cylinder Head Components .................................................... 5-16
General Guidelines.................................................................. 5-17
Remove and Install Cylinder Head Cover ............................... 5-17
Remove and Install Glow Plugs............................................... 5-19
Remove Cylinder Head ........................................................... 5-19
Disassemble Cylinder Head .................................................... 5-22
Clean Cylinder Head Components.......................................... 5-24
Pressure Test the Cylinder Head ............................................ 5-24
Inspect Cylinder Head Components........................................ 5-24
Replace Valve Stem Seals...................................................... 5-25
Assemble Cylinder Head......................................................... 5-26
Determine Cylinder Head Gasket Thickness........................... 5-26
Install Cylinder Head ............................................................... 5-27
Pistons and Cylinders.................................................................... 5-31
Remove and Disassemble Piston and Connecting Rod.......... 5-31
Inspect Pistons and Piston Rings............................................ 5-32
Assemble Piston and Connecting Rod.................................... 5-33
Install Piston and Connecting Rod .......................................... 5-34
Flywheel and Flywheel Housing.................................................... 5-37
Remove and Install Flywheel Housing ................................... 5-37
Remove and Install Drive Coupling ......................................... 5-38
Remove Flywheel.................................................................... 5-39
Replace Rear Crankshaft Seal................................................ 5-40
Install Flywheel........................................................................ 5-41
Camshaft and Timing Gear Train.................................................. 5-42
Components ............................................................................ 5-42
Check and Adjust Camshaft Timing ........................................ 5-44
Remove and Install Vibration Damper - 4BY2......................... 5-46
Remove and Install Vibration Damper - 6BY2......................... 5-47
Remove Timing Case Cover ................................................... 5-48
Remove and Install Timing Chain............................................ 5-49
Install Timing Case Cover ....................................................... 5-49
Remove and Install Timing Chain Tensioner........................... 5-50
Remove Camshafts................................................................. 5-51
Install Camshafts..................................................................... 5-54
Cylinder Block and Crankshaft...................................................... 5-56
Components ............................................................................ 5-56
Remove Crankshaft................................................................. 5-58
Measure Oil Clearance............................................................ 5-59
Inspect Crankshaft................................................................... 5-61
Inspect Cylinder Block............................................................. 5-62