Manul de Peças H - Onda

ME422STI
ME422STI
ENGINE SERVICE MANUAL
E ENGINE
SERVICE MANUAL
YAMAHA MOTOR CO., LTD.
Printed in Japan
Nov. 2005-0.5 × 1
070026
（ME422STI）
（E）
Printed on recycled paper N60-28197-ZH-11
300902-
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.
ME422STI
© 2005 Yamaha Motor Co., Ltd.
1st Edition, November, 2005
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 appears only in the chapter “Periodic check and adjustment”.
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. Illustrations are sometimes labeled with an upper case letter 8.
¡ An arrow 9 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.
SYMBOLS
1 2 Symbols 1 to A are designed as thumb-tabs
GEN and indicate the content of a chapter.
INFO SPEC
1 General information
3 4 2 Specifications
3 Periodic check and adjustment
CHK REM 4 Engine removal and installation
ADJ INST 5 Engine
5 6 6 Fuel system
7 Exhaust system
ENG 8 Cooling system
OVER FUEL 9 Lubrication system
0 Turbocharger
7 8 A Power steering system
B Electrical system
EXHT COOL C Troubleshooting
9 0
Symbols D to J indicate specific data:
LUB TURB D Special tool
E Recommended fuel
A B F Lubricant
G Engine speed
– +
STEER ELEC H Tightening torque
I Specified value, service, limit
J Resistance (Ω), Voltage (V), Electric cur-
C D
rent (A)
TRBL Symbols K and L in an exploded diagram
indicate grade of lubricant and location of
E F lubrication point:
K Apply Yamaha gear-case lubricant

L Apply water resistant grease (Yamaha
G H marine grease A, Yamaha marine grease)
Symbols M and N in an exploded diagram
T.R
indicate grade of sealing or locking agent,

and location of application point:
I J
M Apply LOCTITE® No. 243, 271, 572
N Apply Three Bond® TB-1207B, 1322, 1324
K L
NOTE:
A Some of the above symbols may not appear
G
in this manual.
M N
TB
LT
CONTENTS
GENERAL INFORMATION GEN
INFO 1
SPECIFICATIONS
SPEC 2
PERIODIC CHECK AND
ADJUSTMENT CHK
ADJ 3
ENGINE REMOVAL AND
INSTALLATION REM
INST 4
ENGINE OVERHAUL ENG
OVER 5
FUEL SYSTEM
FUEL 6
EXHAUST SYSTEM
EXHT 7
COOLING SYSTEM
COOL 8
LUBRICATION SYSTEM
LUB 9
TURBOCHARGER
TURB 10
INDEX
POWER STEERING SYSTEM
STEER 11
– +
ELECTRICAL SYSTEM
ELEC 12
TROUBLESHOOTING TRBL
SHTG 13
GEN E
INFO
CHAPTER 1
GENERAL INFORMATION
ENGINE IDENTIFICATION ...................................................................................................... 1-1
PROPELLER AND ENGINE ROTATION .................................................................................. 1-1

1
SAFETY WHILE WORKING .................................................................................................... 1-2
Prepare for Emergencies ................................................................................................... 1-2
Handle Fuel Safety ............................................................................................................. 1-2
Prevent Battery Explosion ................................................................................................. 1-2
Wear Protective Clothing .................................................................................................. 1-2
Keep Work Area Clean ....................................................................................................... 1-3
Operate Stern Drive Safely ............................................................................................... 1-3
PRE-DELIVERY CHECK ........................................................................................................... 1-4

Check Engine Alignment ................................................................................................... 1-4
Check Drive Belts ............................................................................................................... 1-4
Check Engine Oil ................................................................................................................ 1-4
Check Fuel System ............................................................................................................ 1-4
Check Engine Exterior ....................................................................................................... 1-4
Check Battery and Electrical Connections ....................................................................... 1-4
Check Remote Control Operation ..................................................................................... 1-4
Perform Test Run ............................................................................................................... 1-5
OFF-SEASON STORAGE ........................................................................................................ 1-5

Engine ................................................................................................................................. 1-5
Drain Cooling System ....................................................................................................... 1-7
Preparation After Storage ................................................................................................. 1-8
CHECKS BEFORE LAUNCHING AND STARTING THE ENGINE .......................................... 1-9
INTERNATIONAL SYSTEM OF UNITS [SI] ......................................................................... 1-11

Description of “SI” Units in This Service Manual ......................................................... 1-11
SPECIAL TOOLS ................................................................................................................... 1-12
OTHER EQUIPMENT TOOLS ............................................................................................... 1-16

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

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

A B C D
N611 SP ******
ME422STIP1
N612 P ******
N601 SP ******
ME422STIP2
N602 P ******
PROPELLER AND ENGINE 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 counterclockwise (to the left) as viewed
from the flywheel.
1-1
GEN SAFETY WHILE WORKING E
INFO
SAFETY WHILE WORKING
Prepare for Emergencies
Be prepared for possible fires.
Keep the following items handy:
¡ First Aid Kit
¡ Fire Extinguisher
¡ Emergency Phone Numbers
Handle Fuel Safety

Use care when handling fuel; it is highly flam-
mable. DO NOT smoke or have open flames
or sparks nearby when handling fuel.
Always clean up spilled fuel oil and dispose
of cleaning materials properly.
Prevent Battery Explosion

Batteries produce explosive gases. Keep
sparks and flames away from batteries.
Check battery electrolyte level using a flash-
light.
Never check battery state of charge by con-
necting the battery posts with a conductor.
Use a voltmeter or hydrometer. Always dis-
connect the negative (–) cable first and re-
connect it last.
DO NOT charge a battery if the battery is fro-
zen. Allow the battery to warm up first.
Charge the battery in a well-ventilated area.
Battery electrolyte is poisonous and danger-
ous. It contains sulfuric acid and causes se-
vere burns. Avoid contact with skin, eyes or
clothing. If electrolyte gets in the eyes, flush
with water for 15 minutes and get prompt
medical attention.
Wear Protective Clothing

Wear safety equipment whenever necessary:
¡ Safety glasses or goggles
¡ Earmuffs or earplugs
¡ Safety shoes
¡ Gloves
¡ Respiratory protection
Avoid wearing loose clothing and jewelry.
1-2
GEN SAFETY WHILE WORKING E
INFO
Keep Work Area Clean
Properly ventilate your work area.
Keep the shop bench and floor clean and dry.
Cover all parts and part opening when they
are not being worked on, to prevent foreign
materials from entering and damaging the
engine.
Cleaning and protection of machined sur-
faces and friction areas are part of the repair
procedure; this is considered standard shop
practice.
Operate Stern Drive Safely

Remove the propeller.
DO NOT operate engine without cooling
water supplied to the water inlet ports on the
drive unit.
1-3
GEN PRE-DELIVERY CHECK E
INFO
PRE-DELIVERY CHECK
Perform the following checks to prepare the
engine for delivery to the customer.
Check Engine Alignment

¡ Use an engine alignment tool to check
engine alignment. Make any adjust-
ments as necessary. Refer to “Engine
Installation” on page 4-5.
¡ Make sure all engine mounting hardware
1 is tight.
Check Drive Belts
¡ Check the tension of the alternator and
circulation pump belts 2.
Check Engine Oil
¡ Make sure break-in oil is at the proper
level 3.
Check Fuel System
¡ Make sure all fuel lines and hoses are
connected and do not leak.
¡ If water separator warning light comes
on, drain the water from the water sepa-
rator 4.
Check Engine Exterior
¡ Touch-up any painted surfaces with
matching paint.
¡ Replace any parts damaged in shipping.
Check Battery and Electrical Connec-
tions
¡ Check the battery fluid level.
¡ Check if the battery is fully charged.
¡ Verify that the battery is securely at-
tached to the boat.
¡ Check that the battery cables are cor-
rectly and securely connected.
¡ Check all wire harness connections for
proper contact and tightness.
Check Remote Control Operation
¡ Make sure the engine can be controlled
properly with the remote control.
1-4
GEN PRE-DELIVERY CHECK / OFF-SEASON STORAGE E
INFO
Perform Test Run
¡ Be sure gear shifting and steering is
smooth.
¡ Check for leaks in the transom.
OFF-SEASON STORAGE
If the boat is kept unused for a long period,
internal parts of the engine or drive unit
might rust through of lack of lubrication and
protection. If the boat is stored in below-freez-
ing temperatures, seawater inside the sea-
water cooling system may freeze, causing
extensive engine damage.
Therefore precautions must be taken, to pre-
vent rusting and freezing.
Engine
¡ WARNING
When working in the engine compartment,
run the bilge blower if the boat has one. If
not, insure that the engine compartment is
sufficiently ventilated.
CAUTION:
¡ While running the engine, be sure to use
flushing gear or a water tank to provide
cooling water to the cooling system. Also
keep the engine speed at idling.
¡ While operating the engine, be sure the
water temperature and oil temperature
are kept within the proper range to pre-
vent engine overheating and subsequent
damage.
When carrying out the following storage

preparation, be sure to flush the cooling sys-
tem thoroughly. Refer to “Cooling System
Flushing” on page 3-42.
1) Warm up the engine to normal operat-

ing temperature.
2) Stop the engine, drain the engine oil and
replace the oil filter 1.
1-5
GEN OFF-SEASON STORAGE E
INFO
3) Tighten the drain bolt to the specified
torque, and add the indicated amount of
new engine oil. (Refer to “Engine Oil
Level Check” on page 3-7.)
4) Start the engine and run it at a speed be-
tween 1000 – 1200 r/min. Be sure no oil
leaks from the oil filter joint.
5) Stop the engine and check with an oil
level gauge whether the oil is at the
specified level. (Refer to “Engine Oil
Level Check” on page 3-7.)
6) Turn the fuel cock on the fuel tank side
to “OFF”.
7) Install a new filter 2 and filter cover. (Re-
fer to “Fuel Filter Replacement” on page
3-31.)
8) Drain all diesel fuel from the fuel tank,
or alternatively, fill the tank completely.
9) Clean the oil separator 3 and blow-by
hose 4, then reinstall it securely.
10) After turning off the main switch, turn
the battery switch “OFF” (if the boat is
equipped with one), or disconnect the
4 battery cables from the terminals.
3
CAUTION:
¡ DO NOT turn off the battery switch while
the ignition switch is still on.
This could damage the voltage regulator.
¡ When disconnecting the battery cables,
start with the (–) terminal.
11) Remove the battery and clean it. Add dis-

tilled water to the specified level and re-
charge the battery. Apply petroleum-
based grease to the terminals.
Store the battery in a cool, dry place.
CAUTION:
If the battery is stored without being prop-
erly charged, there is a danger that it will
freeze. A stored battery should be checked
once a month and appropriate maintenance
should be performed.
12) Lubricate the shift and throttle cables and

the linking mechanisms.
1-6
INFO
Drain Cooling System
To protect the cooling system from rust and
damage from freezing, drain coolant from the
cooling system completely.
CAUTION:
DO NOT store the engine with water left in
the cooling system.
NOTE:
¡ When draining coolant, cover all electri-
cal parts and accessories with a plastic
cover to prevent them from getting wet.
¡ After draining the coolant, remove the
drain bolt on the bottom of the boat to
drain any coolant that has collected in the
bilge (provided the boat is on land). If the
boat is in the water, use a bilge pump in-
stead. After draining, rinse thoroughly
with clean water and dry.
¡ If possible, lift the front of the engine
slightly, so that the coolant water drains
completely from the cylinder block.
1) Remove the drain cocks, plugs and hoses

located as shown, and drain the coolant.
Coolant:
¡ Drain plug 1 on the port side of the
cylinder block
¡ Drain plug 2 on the turbo charger
housing
¡ Hose 3 connected to the heat ex-
changer
Seawater:
¡ Drain cock 4 on the heat exchanger
¡ Seawater hose 5
2) Loosen clamps of the hoses in the loca-
tion described below then disconnected
the hoses.
¡ Heat exchanger 6
¡ Seawater pump 7
¡ Seawater strainer 8
NOTE:
¡ After removing the hoses, if necessary,
drain any remaining coolant and seawa-
ter by bending, lifting or shaking the hose.
¡ If sand or other dirt clogs up a drain hole,
use a needle or similar tool to free it.
1-7
INFO
3) When all coolant and seawater has been
drained, apply a sealant to the drain
plugs and tighten them to the specified
torque.
4) Check that the hoses are neither cracked
nor damaged and re-connect them. Be
sure to tighten the hose clamps securely.
Preparation After Storage

To prepare an engine after it has been stored
for a long time, perform the checks and the
maintenance described below, as well as
those described in “CHECKS BEFORE
LAUNCHING AND STARTING THE ENGINE”
(Refer to “CHECKS BEFORE LAUNCHING
AND STARTING THE ENGINE” on page 1-9.)
1) Tighten the drain plugs of the water cool-

ing system. Check the condition of the
cooling system hoses. Check if the hose
clamps are in good condition and tight-
ened securely.
2) Check the condition of the drive belts on
the alternator 1 and circulation pump
2. Adjust the tension of the drive belts
to the specified deflection.
3) Check that the engine mount, drive unit,
and power trim cylinder are securely at-
tached, that the steering and throttle
cables are properly connected, and that
the electrical system connectors are
firmly attached.
4) After engine check is completed, install
and securely connect a fully charged bat-
tery.
1-8
GEN OFF-SEASON STORAGE / CHECKS BEFORE
E
INFO LAUNCHING AND STARTING THE ENGINE
5) Check all the items listed under “CHECKS

BEFORE LAUNCHING AND STARTING
THE ENGINE”, and perform any neces-
sary maintenance.
6) Test run the engine on land or in the
water and make sure there are no prob-
lems of any kind.
CHECKS BEFORE LAUNCHING

AND STARTING THE ENGINE
The following items should be checked be-
fore starting the engine.
CAUTION:
¡ Make sure all periodic check, mainte-
nance, and periodic replacement of parts
have been performed. (Refer to “PERI-
ODIC CHECK AND ADJUSTMENT” on
page CHAPTER 3.)
¡ From time to time, check the water in-
take area of the drive unit. Make sure the
opening is not clogged with seaweed or
anything else.
¡ WARNING
Explosive battery fumes may collect in the
engine compartment. Before starting the
engine, ventilate the engine compartment.
If the boat has a bilge blower, let it run for at
least 3 minutes. If not, open the hatch and
ventilate for at least 5 minutes.
1) Check that no fuel is leaking from a fuel

line or connection. Also, verify that no
oil or fuel has leaked into the engine com-
partment. (Refer to “FUEL LINE CHECK”
on page 3-26.)
2) Check that the drain plugs of the cooling
system are securely tightened, and that
no water leakings into the bilge.
3) Check the battery fluid level (Refer to
“Battery Check” on page 3-43.)
Check that the battery terminals are not
loose, corroded, or damaged. Securely
fasten the battery to the boat.
1-9
GEN CHECKS BEFORE LAUNCHING AND STARTING THE ENGINE E
INFO
4) Check that the engine oil is at the speci-
fied level Refer to “Engine Oil Level
Check” on page 3-7.) and that there is
no water, metal gratings, or anything else
irregular in the oil. Check that no oil is
leaking from any part of the engine.
5) Check the oil level (Refer to “DE-DHD
STERN DRIVE SERVICE MANUAL”) in
the drive unit and make sure no oil is
leaking from the unit.
6) Check that the drive belts are not loose,
cracked, or damaged in any way.
(Refer to “Drive Belt Check” on page 3-
21.)
7) Check the oil level in the power steering
pump. (Refer to “DE-DHD STERN DRIVE
SERVICE MANUAL”)
1-10
GEN INTERNATIONAL SYSTEM OF UNITS [SI] E
INFO
INTERNATIONAL SYSTEM OF UNITS [SI]
The unit system currently applied in our daily life is called gravitational system of units. Both
gravitational system of units and International System of Units belong to the metric system of
measurement, and basically the same units are used in both systems, i.e. “meter” to indicate
length, “second” to indicate time, and “kilogram” to indicate mass.
Essential difference found in International System of Units in comparison with the gravita-
tional system is the clear distinction between the unit of “mass” and the unit of “force”.
In addition, the different units of “force” applied in the SI system results in the different units
of “amount” (e.g. amount of energy) related to the force.
The abbreviation “SI” stands for the French expression of International System of Units (Le
System International d’ Unites ).
Description of “SI” Units in This Service Manual

Both SI units and gravitational system of units are indicated in this service manual.
e.g.) Tightening torque 98 N·m (10 kgf·m, 71 lbf·ft)
Examples for major units
EQUIVALENT
OLD
ITEM SI UNIT (1 [FORMER UNIT] = X REMARKS
UNIT
[SI UNIT])
Force N kgf 1 kgf = 9.80665 N
Torque N·m kgf·cm 1kgf·cm = 0.0980665 N·m
Pressure Pa kgf/cm2 1 kgf/cm2 = 98.0665 kPa 10 kgf/cm2 = 980 kPa,
= 0.0980665 MPa 0.98 Mpa
100kgf/cm2 = 9.8 MPa
mmHg 1 mmHg = 0.133322 kPa
Rotational r/min rpm 1 rpm = 1 r/min
speed min–1 1 rpm = 1 min–1
Output power W PS 1 PS = 0.735499 kW 1 HP = 0.745 kW
1 HP = 1.01387 PS
W·h cal 1 kcal = 1.16279 W·h
Specific fuel g/W·h g/PS·h 1 g/PS·h = 1.3596 g/W·h
consumption
1-11
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

09248-64011 Valve clearance adjust- To valve clearance adjustment
ing tool (Page 3-14)
*TDG-7 Compression gauge To measure compression

(from BANZAI) attachment (Page 3-19)
*NO.30
(from IYASAKA)
09275-54001 Plunger stroke measur- To check injection timing

ing tool (Page 3-28)
09950-40011 Puller B set (Page 5-11, 5-20, 5-22, 5-23)
09951-04010 Hanger 150 To remove camshaft timing pulley, oil

pump drive gear, crankshaft timing
gear and injection pump drive gear
bearing
09952-04010 Slide arm To remove camshaft timing pulley, oil
bearing
09953-04010 Center bolt 150 To remove camshaft timing pulley, oil
bearing
09354-04010 Arm 25 To remove camshaft timing pulley, oil
bearing
09955-04060 Claw No.6 To remove camshaft timing pulley,
crankshaft timing gear and injection
pump drive gear
09955-04011 Craw No.1 To remove injection pump drive gear

bearing, oil pump drive shaft gear
09957-04010 Attachment To remove injection pump drive gear

bearing
1-12
GEN SPECIAL TOOLS E
INFO
09213-58013 Flange base To secure crankshaft pulley
(Page 5-18, 5-28)
09330-00021 Flange holder To secure crankshaft pulley

(Page 5-18, 5-21, 5-26, 5-28)
09950-50013 Puller C set (Page 5-19, 5-21, 6-20)
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
09954-05020 Claw No.2 To remove crankshaft pulley and injec-

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

replacer seal
(Page 5-24)
09223-78010 Oil seal replacer To install crankshaft front oil seal

(Page 5-24, 5-25)
09316-20011 Oil seal replacer To install injection pump oil seal

(Page 5-24, 5-25)
09223-00010 Cover and seal replacer To mount crankshaft timing gear and
oil pump drive gear
(Page 5-26, 5-27)
1-13
GEN SPECIAL TOOLS E
INFO
09202-70020 Valve spring compressor To remove and install valve
(Page 5-40, 5-57)
09201-10000 Valve guide bush re- (Page 5-43, 5-44)

mover and replacer set
09201-01080 Valve guide bush re- To remove and install valve guide bush
mover and replacer 8
09950-70010 Handle set (Page 5-43, 5-44)
09951-07200 Handle 200 To install camshaft oil seal
09032-00100 Oil pan seal cutter To remove oil pan

(Page 9-3)
09222-17011 Connecting rod bush (Page 5-85)

remover and replacer
09222-05021 Remover and 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
• 95093-10230 2-spring base To measure injection nozzle

(from DENSO) (Page 6-7, 6-8)
• 95093-10300 Attachment measure To measure injection nozzle

(from DENSO) (Page 6-7)
1-14
GEN SPECIAL TOOLS E
INFO
• 95093-10330 Master spring seat To measure injection nozzle
(from DENSO) (Page 6-11)
• PSG-6TB Power steering fluid To check power steering fluid pressure

(from BANZAI) pressure gauge set (Page 11-4)
09820-63010 Alternator wrench To remove and install alternator pul-

ley
(Page 12-29, 12-35)
09286-46011 Alternator bearing puller To remove alternator rectifier end fram

and starter motor armature bearing
(Page 12-17, 12-30)
09820-00021 Alternator bearing puller To remove alternator rotor bearing

(Page 12-34)
1-15
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
1-16
SPEC E
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS .................................................................................................. 2-1
MAINTENANCE SPECIFICATIONS ........................................................................................ 2-3
2
Engine ................................................................................................................................. 2-3
Fuel System ...................................................................................................................... 2-10
Cooling System ................................................................................................................ 2-12
Turbocharger System ...................................................................................................... 2-13
Electrical System ............................................................................................................. 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
HANDLING OF LIQUID GASKET.......................................................................................... 2-19

Types of Liquid Gasket .................................................................................................... 2-19
Remarks on Liquid Gasket Handling .............................................................................. 2-19
STANDARD ABBREVIATIONS AND SYMBOLS ................................................................. 2-21

Measurement ................................................................................................................... 2-21
Color Codes ...................................................................................................................... 2-21
ELECTRICAL SYSTEM WIRING DIAGRAM ......................................................................... 2-22

Engine Electrical System ................................................................................................. 2-22
Power Trim/Tilt System ................................................................................................... 2-24
ELECTRICAL PARTS COMPONENTS LOCATION ............................................................... 2-25
COOLING SYSTEM DIAGRAM ............................................................................................ 2-27

SPEC GENERAL SPECIFICATIONS E
GENERAL SPECIFICATIONS
Model ME422 STI
Unit
Item P1 P2
Model code number — N611, N612 N601, N602
Engine starting number — 000101 – 010101 –
Base engine — TOYOTA 1HD-T
Engine type — Water cooled-4-stroke, OHC diesel
Combustion chamber type — Direct injection
Valve mechanism — OHC
Bore x stroke mm (in.) 94.0 x 100.0 (3.70 x 3.94)
Cylinder layout & number — Inline, 6-cylinders
3
Displacement cm (cu·in.) 4163 (254)
Compression ratio — 15.3 : 1
Compression pressure (at 220 r/min): kPa (kgf/cm2, psi)
STD 2550±196 (26.0±2, 370±28.4)
Limit 2160 (22.0, 313)
Difference of pressure between 480 (4.9, 71)
cylinders
Maximum output (at crankshaft)*1 kW (HP) 205 (275) 183 (245)
@r/min @3800 @3800
Maximum output (at crankshaft)*2 kW (HP) 192 (257) 173 (232)
@r/min @3800 @3800
Engine idling speed r/min 600 – 650
Engine idling speed (in forward gear) r/min 535 – 585
Recommended operating range r/min 3880 – 3980
(full throttle propeller matching)
Maximum engine speed r/min 4200
Engine dimension:
Length x width x height mm (in.) 1167 (45.94) x 735 (28.94) x
732 (28.82)
Engine weight (dry) kg (lb) 450 (992)
Output coupling 2-stage rate rubber coupling
Engine mount system Rubber mount
Fuel system:
Fuel type — Grade 2-D ASTMD 975
Minimum cetane rating: 45
Fuel filter type Cartridge type
(Integrated with water separator)
Injection pump type — Distribution injection
(VE Type)
Injection timing Degree B.T.D.C. 26.0
Plunger stroke mm (in.) 1.65 – 1.69 (0.065 – 0.067)
Injection order — 1-4-2-6-3-5
Governor type Mechanical all speed type
Injection nozzle:type — KBAL
2-1
SPEC GENERAL SPECIFICATIONS E
Model ME422 STI

Unit
Item P1 P2
Cooling system: Two flow cooling system
Coolant capacity L (lmp qt, US qt) 12.4 (2.72, 3.28)
Fresh water (coolant) pump — Centrifugal pump
(resin impeller)
Seawater pump Circulating pump
(rubber impeller)
Thermostatic valve opening °C (°F) 76.5 ± 2 (170 ± 2)
temperature
Turbocharger system:
Turbocharging pressure at 3,800 r/min kPa (kgf/cm2, psi) 211±10 (2.15±0.1 , 30.6±1.5) 185±10 (18.9±0.1 , 26.5±1.5)
Electrical system:
Starter motor output V/kW 12/2.5
Alternator output V/Amps 14/80
Recommended battery capacity V/AH 12/110 or more
Pre-heating system Quick glow plug
Fuse:
Power trim and tilt motor Amps 100
Charging system Amps 100
Meter - Power trim switch Amps 20
Alternator drive belt diflection mm (in.) 12 – 14 (0.47 – 0.55)
(with pressure of 100 N (10 kgf, 22.0 lbf)) mm (in.) 10 – 12 (0.39 – 0.47) NEW belt
Lubrication system:
Oil pump type — Trochoid pump
Engine oil type — API CD or CE, SAE 15W-40
Engine oil capacity (without oil filter) L (lmp qt, US qt) 8.4 (1.85, 2.22)
Engine oil capacity (with oil filter) L (lmp qt, US qt) 9.2 (2.02, 2.43)
Oil pressure (at 3,800 r/min) kPa (kgf/cm2, psi) 343 (3.50, 49.7) or more
Other:
Power steering fluid — Automatic Transmission
Fluid (ATF) Dexron type II
Power steering pump — Vane type
NOTE:
*1: Output power at 25 °C (77 °F) fuel temperature: ISO 3046-1
*2: Output power at 40 °C (104 °F) fuel temperature: ISO 8665
2-2
SPEC MAINTENANCE SPECIFICATIONS E
MAINTENANCE SPECIFICATIONS
Engine
Model ME422 STI
Unit
Item P1 P2
Cylinger head:
Warpage Limit mm (in.) 0.20 (0.0079)
New cylinder head gasket thickness mm (in.)
Cutout number “1” 1.15 – 1.25 (0.0453 – 0.0492)
Cutout number “3” 1.25 – 1.35 (0.0492 – 0.0531)
Cutout number “5” 1.35 – 1.45 (0.0531 – 0.0571)
Cylinder:
Cylinder head surface warpage
Limit mm (in.) 0.20 (0.0079)
Cylinder bore diameter
STD Mark “1” 94.000 – 94.010 (3.7008 – 3.7012)
Mark “2” 94.010 – 94.020 (3.7012 – 3.7016)
Mark “3” 94.020 – 94.030 (3.7016 – 3.7020)
Limit 94.23 (3.7098)
Main journal bore diameter
(Reference) STD 71.000 – 71.018 (2.8046 – 2.8053)
Piston/Piston ring: mm (in.)
Piston diameter
STD Mark “1” 93.95 – 93.96 (3.6988 – 3.6992)
Mark “2” 93.96 – 93.97 (3.6992 – 3.6996)
Mark “3” 93.97 – 93.98 (3.6996 – 3.7000)
Piston to cylinder clearance
STD 0.04 – 0.06 (0.0016 – 0.0024)
Limit 0.14 (0.0055)
Piston ring groove clearance
Top 0.050 – 0.095 (0.0020 – 0.0037)
2nd 0.060 – 0.100 (0.0024 – 0.0039)
Oil 0.030 – 0.070 (0.0012 – 0.0028)
Piston ring end gap Top 0.27 – 0.54 (0.0106 – 0.0213)
2nd 0.40 – 0.62 (0.0157 – 0.0244)
Oil 0.20 – 0.52 (0.0079 – 0.0205)
Limit Top 1.34 (0.0591)
2nd 1.42 (0.0551)
Oil 1.32 (0.0520)
2-3
Model ME422 STI

Unit
Item P1 P2
Camshaft: mm (in.)
Thrust clearance STD 0.10 – 0.20 (0.0039 – 0.0079)
Limit 0.30 (0.0118)
Journal oil clearance
No.1 journal STD 0.022 – 0.074 (0.0009 – 0.0029)
Limit 0.10 (0.0039)
Others STD 0.030 – 0.066 (0.0012 – 0.0026)
Limit 0.10 (0.0039)
Journal diameter
No.1 journal STD 34.969 – 34.985 (1.3767 – 1.3774)
Others 27.986 – 27.998 (1.1018 – 1.1023)
Runout Limit 0.10 (0.0039)
Cam lobe height
STD Intake 54.440 – 54.460 (2.1433 – 2.1441)
Exhaust 54.940 – 54.960 (2.2024 – 2.2031)
Limit Intake 53.94 (2.1236)
Exhaust 55.44 (2.1827)
Connecting rod: mm (in.)
Limit 0.30 (0.0118)
Connecting rod oil clearance
STD 0.036 – 0.054 (0.0014 – 0.0021)
Limit 0.10 (0.0039)
Connecting rod bearing center
Wall thickness
(Reference) STD Mark “2” 1.486 – 1.489 (0.0585 – 0.0586)
Mark “3” 1.489 – 1.492 (0.0586 – 0.0587)
Mark “4” 1.492 – 1.495 (0.0587 – 0.0589)
Mark “5” 1.495 – 1.498 (0.0589 – 0.0590)
Mark “6” 1.498 – 1.501 (0.0590 – 0.0591)
Rod bending Limit per 100 mm 0.03 (0.0012)
(3.94 in.)
Twist Limit per 100 mm 0.15 (0.0059)
(3.94 in.)
Connecting rod bolt outer diameter
STD 8.300 – 8.400 (0.3268 – 0.3307)
Limit 7.95 (0.3130)
Bushing inside diameter 33.008 – 33.020 (1.2995 – 1.3000)
Piston pin diameter 33.000 – 33.012 (1.2992 – 1.2997)
Piston pin oil clearance STD 0.004 – 0.012 (0.0002 – 0.0005)
Limit 0.03 (0.012)
2-4
Model ME422 STI

Unit
Item P1 P2
Big end inner diameter
(Reference) STD Mark “1” 62.014 – 62.020 (2.4415 – 2.4417)
Mark “2” 62.020 – 62.026 (2.4417 – 2.4420)
Mark “3” 62.026 – 62.032 (2.4420 – 2.4422)
Crankshaft: mm (in.)
Limit 0.30 (0.0118)
Thrust washer thickness STD 2.930 – 2.980 (0.1154 – 0.1173)
Main journal oil clearance
STD 0.030 – 0.042 (0.0011 – 0.0016)
Limit 0.10 (0.0039)
Main journal diameter STD 66.982 – 67.000 (2.6371 – 2.6378)
Crank pin oil clearance STD 0.036 – 0.054 (0.0014 – 0.0021)
Limit 0.10 (0.0039)
Crank pin diameter STD 58.982 – 59.000 (2.3221 – 2.3228)
Circle runout Limit 0.06 (0.0024)
Main journal taper and out-of-round
Limit 0.02 (0.0008)
Crank pin taper and out-of-round
Limit 0.02 (0.0008)
Main bearing: mm (in.)
Main bearing cap bolt outer diameter
STD 11.800 – 12.000 (0.4646 – 0.4724)
Limit 11.50 (0.4528)
Valve, valve seat, valve guide: mm (in.)
Valve clearance (cold) Intake 0.15 – 0.25 (0.006 – 0.010)
Exhaust 0.35 – 0.45 (0.014 – 0.018)
2-5
Model ME422 STI

Unit
Item P1 P2
New valve adjusting shim thickness mm (in.)
Shim Shim
Thickness Thickness
No. No.
709 2.35 (0.0925) 45 2.85 (0.1122)
704 2.40 (0.0945) 21 2.90 (0.1142)
710 2.45 (0.0965) 46 2.95 (0.1161)
01 2.50 (0.0984) 26 3.00 (0.1181)
42 2.55 (0.1004) 47 3.05 (0.1201)
06 2.60 (0.1024) 31 3.10 (0.1220)
43 2.65 (0.1043) 48 3.15 (0.1240)
11 2.70 (0.1063) 36 3.20 (0.1260)
44 2.75 (0.1083) 49 3.25 (0.1280)
16 2.80 (0.1102) 41 3.30 (0.1299)
Valve overall length:
STD Intake 103.29 – 103.69 (4.0655 – 4.0823)
Exhaust 103.14 – 103.54 (4.0606 – 4.0764)
Limit Intake 102.79 (4.0468)
Exhaust 102.64 (4.0409)
Valve face angle Degree 44.5
Stem diameter Intake mm (in.) 7.975 – 7.99 (0.3140 – 0.3146)
Exhaust 7.960 – 7.75 (0.3134 – 0.3140)
Stem oil clearance
STD Intake 0.020 – 0.055 (0.0008 – 0.0022)
Exhaust 0.035 – 0.070 (0.0014 – 0.0028)
Exhaust 0.10 (0.0039)
Margin thickness
STD Intake 1.6 (0.063)
Exhaust 1.7 (0.067)
Exhaust 1.2 (0.047)
Valve guide bushing
Inside diameter 8.010 – 8.030 (0.3154 – 0.3161)
Outside diameter 13.004 – 13.025 (0.5112 – 0.5128)
Valve seat
Refacing angle Intake Degree 25, 45, 70
Exhaust 25, 45, 60
Contacting angle Degree 45
Contacting width Intake mm (in.) 1.5 – 1.9 (0.059 – 0.075)
Exhaust 1.8 – 2.2 (0.071 – 0.087)
2-6
Model ME422 STI

Unit
Item P1 P2
Valve spring:
Free length mm (in.) 46.20 (1.8189)
Installed tension at 37.0 mm (1.457 in.) N (kgf, lbf) 301 – 332 (30.7 – 33.9, 67.7 – 74.7)
Spring tilt Limit mm (in.) 2.0 (0.075)
Valve lifter: mm (in.)
Lifter diameter 40.892 – 40.902 (1.6099 – 1.6103)
Cylinder head lifter bore diameter 40.960 – 40.980 (1.6126 – 1.6134)
Oil clearance STD 0.058 – 0.083 (0.0023 – 0.0033)
Limit 0.10 (0.0039)
Timing gear: mm (in.)
Idler gear inside diameter 45.000 – 45.025 (1.7717 – 1.7726)
Idler gear shaft diameter 44.950 – 44.975 (1.7679 – 1.7707)
Idler gear oil clearance STD 0.025 – 0.075 (0.0010 – 0.0030)
Limit 0.20 (0.0079)
Gear backlash STD 0.05 – 0.15 (0.0020 – 0.0060)
Limit 0.30 (0.0118)
Idler gear thrust clearance
STD 0.05 – 0.15 (0.0020 – 0.0059)
Limit 0.30 (0.0118)
Oil pump: mm (in.)
Body clearance STD 0.10 – 0.17 (0.0039 – 0.0067)
Limit 0.20 (0.0079)
Side clearance STD 0.03 – 0.09 (0.0012 – 0.0035)
Limit 0.15 (0.0059)
Tip clearance STD 0.08 – 0.16 (0.0031 – 0.0063)
Limit 0.21 (0.0083)
2-7
Tightening torques
Tightening torque
Part to be tightened Remarks
N·m kgf·m lbf·ft
2-stage rate coupling and flywheel:
Damper joint nut 5.7 0.57 4.1 No. 271
LT
LT
Coupling – Outer member 68 6.9 49

Flywheel – Crankshaft 130 13.2 94
Flywheel – Coupling assembly 30 3.1 22
Rear end plate 18 1.8 13
Timing pulleys:
Timing pulley #1 – Camshaft 100 10.2 72
Timing pulley #2 – Pump drive gear 31 3.2 22
Auto tensioner 13 1.3 9
Idler pulley 35 3.6 26
Timing gears:
Power steering drive gear 100 10.2 72
Pump drive gear - Injection pump 100 10.2 72
Idler gear thrust plate 40 4.1 29
Timing gear cover 20 2.0 14
Crankshaft pulley #1 500 51.0 360
Cylinder head:
Camshaft bearing cap (# journal) 25 2.5 18
(others) 18 1.8 13
Cylinder head page 5-30
Camshaft oil seal retainer 20 2.0 14
Exhaust manifold (bolt) 40 4.1 29
(nut) 33 3.4 24
Glow plug 13 1.3 9.4
Injection nozzle clamp holder 39 4.0 28
Leakage pipe hollow bolt 12.5 1.25 9.0
Fuel pipe hollow bolt 30 3.1 22
Cylinder block:
Check valve 27 2.8 19
Main bearing cap page 5-88
Connecting rod cap page 5-91
Oil seal retainer 6.5 0.65 4.7
Heat exchanger bracket – Cylinder 117 11.9 85
Control unit bracket – Exhaust manifold 58.5 5.97 43
Engine bracket – Cylinder 117 11.9 85
Bracket tension rod – Engine bracket 63 6.4 46.4
Rod tension – Bracket tension rod 206 21 151.9
Rubber mount adjustable nut 206 21 151.9
2-8
Tightening torque
N·m kgf·m lbf·ft
Lubrication system:
Relief valve plug 42 4.3 30
Timing gear case 20 2.0 14
Oil strainer 9.0 0.9 6.5
Oil pan 10 1.0 7.2
Dipstick tube 20 2.0 14
Oil cooler cover drain cock 20 2.0 14
Oil cooler cover - Check valve 27 2.8 19 No. 572
LT
LT
Oil cooler cover - Relief valve 40 4.1 29

Oil cooler cover - Oil cooler 20 2.0 14
2-9
Fuel System
Model ME422 STI
Unit
Item P1 P2
Injection nozzle:
Nozzle type — KBAL
Pre-lift dimension mm (in.) 0.08 – 0.10 (0.0031 – 0.0039)
Nozzle opening pressure:
No.2 (Check pressure) MPa (kgf/cm2, psi) 29.91 ± 0.49
(305 ± 5, 4422 ± 72)
No.1 24.99 ± 0.49
(255 ± 5, 3697 ± 72)
Maximum lift adjusting shim mm (in.) 2.400 (0.0945)
thickness 2.425 (0.0955)
2.450 (0.0965)
2.475 (0.0974)
2.500 (0.0984)
Pre-lift adjusting spring seat
thickness 2.67 (0.1051)
2.68 (0.1055)
2.69 (0.1059)
2.70 (0.1063)
2.71 (0.1067)
2.72 (0.1071)
2.73 (0.1075)
2.74 (0.1079)
2.75 (0.1083)
2.76 (0.1087)
2.77 (0.1091)
2.78 (0.1094)
2.79 (0.1098)
2.80 (0.1102)
2.81 (0.1106)
2.82 (0.1110)
2.83 (0.1114)
2.84 (0.1118)
2.85 (0.1122)
2.86 (0.1125)
2.87 (0.1129)
#2 opening pressure adjusting
shim thickness 1.250 (0.0492)
1.275 (0.0502)
1.300 (0.0511)
1.325 (0.0522)
2-10
Model ME422 STI

Unit
Item P1 P2
mm (in.) 1.350 (0.0531)
1.375 (0.0541)
1.400 (0.0551)
1.425 (0.0561)
1.450 (0.0571)
1.475 (0.0581)
1.500 (0.0591)
1.525 (0.0600)
1.550 (0.0610)
1.575 (0.0620)
1.600 (0.0630)
1.625 (0.0640)
#1 opening pressure adjusting
shim thickness 1.250 (0.0492)
1.275 (0.0502)
1.300 (0.0511)
1.325 (0.0522)
1.350 (0.0531)
1.375 (0.0541)
1.400 (0.0551)
1.425 (0.0561)
1.450 (0.0571)
1.475 (0.0581)
1.500 (0.0591)
1.525 (0.0600)
1.550 (0.0610)
1.575 (0.0620)
1.600 (0.0630)
1.625 (0.0640)
1.650 (0.0650)
1.675 (0.0659)
1.700 (0.0669)
1.725 (0.0679)
1.750 (0.0689)
Injection pump:
Direction of rotation — Clockwise as seen drive gear side
Injection order — 1-4-2-6-3-5 (D-E-F-A-B-C)
2-11
Tightening torques
Tightening torque
N·m kgf·m lbf·ft
Injector body – Nozzle retaining nut 29 3.0 21
Injection nozzle clamp holder 39 4.0 28
Leakage pipe hollow bolt 12.5 1.25 9.0
Injection pipe fitting nut 25 2.5 18
Pickup (tacho) sensor 21 2.1 15
Fuel cut solenoid 22 2.2 16
Fuel cut solenoid lead 1.7 0.17 1.2
Injection pump – Gear case 18 1.8 13
Injection pump – Pump stay 70 7.1 50
Injection pump – Pump drive gear 100 10 72
Fuel delivery hose hollow bolt 30 3.1 22
Cooling System
Model ME422 STI
Unit
Item P1 P2
Coolant filler cap opening pressure
STD kPa (kgf/cm2, psi) 73 – 103 ( 0.74 – 1.03, 10.7 – 14.9)
Limit 60 (0.6, 8.5)
Thermostat:
Valve opening temperature °C (°F) 74.5 – 78.5 (166 – 173)
Valve lift (at 90 °C (194 °F)) mm (in.) 10 (0.39) or more
Tightening torques
Tightening torque
N·m kgf·m lbf·ft
Circulation pump – Cylinder 20 2.0 14
Circulation pump pulley 20 2.0 14
Thermo switch 35 3.6 25 No. 243
LT
LT
Water erature sensor 11 1.1 8 No. 243

LT
LT
Seawater pump drive gear 110 11.2 80

Seawater pump cover 2.0 0.2 1.4
Heat exchanger drain cock unit 20 2.0 14 No. 572
LT
LT
Joint 20 2.0 14 No. 572

LT
LT
Heat exchanger side plate 12 1.2 8.7

Anode 19 1.9 14 No. 243
LT
LT
2-12
Turbocharger System
Model ME422 STI
Unit
Item P1 P2
Turbocharger:
Turbocharging pressure 211 ± 10 185 ± 10
at 3800 r/min 2
kPa (kgf/cm , psi) (2.15 ± 0.1, (1.89 ± 0.1,
30.6 ± 1.5) 26.5 ± 1.5)
Impeller wheel axial play STD mm (in.) 0.05 – 0.125 (0.0020 – 0.0049)
Limit 0.155 (0.006)
Impeller wheel radial play
STD 0.075 – 0.125 (0.0030 – 0.0049)
Limit 0.0165 (0.0065)
Tightening torques
Tightening torque
N·m kgf·m lbf·ft
Turbocharger:
Oil pipe #1 hollow bolt 11 1.1 8.0
Bypass pipe hollow bolt 20 2.0 14
Intake manifold – screw plug 10 1.0 7.2
Inter cooler:
Seawater flow sensor 65 6.6 47 No. 572
LT
LT
Side cover 10 1.0 7.2
2-13
Electrical System
Model ME422 STI
Unit
Item P1 P2
Pre-heating system:
Light timing page 12-4
Starter motor:
Voltage and output power V/kW 12 V/2.5
No-load characteristic:
Current (at 11.0 V) Amps 180 or less
Revolution r/min 3500 or more
Commutator outer diameter:
STD mm (in.) 36.0 (1.417)
Limit 35.0 (1.378)
Undercut depth:
STD 0.7 – 0.9 (0.028 – 0.035)
Limit 0.2 (0.008)
Runout: Limit 0.05 (0.0020)
Brush length: STD 20.5 – 21.0 (0.807 – 0.827)
Limit 13.0 (0.512)
Spring installed load N (kgf, lbf) 32 – 40 (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 mm (in.) 14.2 – 14.4 (0.559 – 0.567)
Limit 12.8 (0.504)
Exposed brush length: STD 10.5 (0.413)
Limit 15 (0.059)
Alternator regulator:
Regulating voltage V
(at 25 °C (77 °F)) 14.0 – 15.0
(at 115 °C (239 °F)) 13.5 – 14.3
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
at 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 guide.
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
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 3.6 6 0.6 4.3
8 1.25 13 1.3 9.4 14 1.4 10
10 1.25 26 2.7 19 29 3.0 21
4T
12 1.25 48 4.9 35 54 5.5 39
14 1.5 76 7.8 55 85 8.7 61
16 1.5 115 11.7 85 – – –
6 1 7 0.7 5.1 8.0 0.8 5.8
8 1.25 16 1.6 11 18 1.8 13
10 1.25 33 3.4 24 36 3.7 25
5T
12 1.25 60 6.1 43 67 6.8 48
14 1.5 93 9.5 67 105 10.7 75
16 1.5 140 14.3 100 – – –
6 1 8 0.8 5.8 9 0.9 6.5
8 1.25 19 1.9 13 21 2.1 15
10 1.25 40 4.1 29 44 4.5 32
6T
12 1.25 73 7.4 53 81 8.3 59
14 1.5 110 11.2 80 125 12.8 90
16 1.5 175 17.9 125 – – –
6 1 11 1.1 8.0 12 1.2 8.7
8 1.25 26 2.7 19 29 3.0 21
10 1.25 53 5.4 38 59 6.0 43
7T
12 1.25 97 9.9 70 105 10.7 75
14 1.5 150 15.3 110 170 17.3 125
16 1.5 230 23.5 170 – – –
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® 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 at 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)
Engine
front
2-18
SPEC HANDLING OF LIQUID GASKET E
HANDLING OF LIQUID GASKET

Types of Liquid Gasket
The following types of liquid gasket are used on the engine.
Brand name Three Bond® TB-1207B: black
Three Bond® TB-1324
Remarks on Liquid Gasket Handling

1. Procedures of liquid gasket application and parts assembly
1) Thoroughly remove the fractions of old liquid gasket adhered on the matching surfaces of
the parts to be joined. Wipe off any oil, water, or dust from the matching surfaces with
clean rag.
When applying the liquid gasket, the layer of the gasket at the starting point of application
must be wrapped over with another layer at the end of application.
2) Matching parts shall be kept precisely in place at the time of assembly. In case of any
slippage, apply the liquid gasket again.
3) Assemble the parts within 5 minutes of liquid gasket application.
If 20 minutes or more has elapsed after the application, remove the gasket and apply it
again.
4) Do not start the engine for at least 2 hours after assembling the parts.
2. Removing the parts

When removing the part, do not try to lever it up at one position. Unclench the matching
face at multiple points alternately making use of gaps or ribs provided on the flange. Make
sure that any fraction of the removed gasket will not enter into the engine inside.
3. Application of the liquid gasket

When the liquid gasket comes in tubes, utilize the roll-up tool supplied with it. Liquid
gasket in cartridge shall be applied with application gun.
Roll-up tool Application gun

Liquid gasket in 150 g tube Liquid gasket in 300 g cartridge
For the liquid gasket in tubes, application width can be adjusted by cutting the nozzle tip at
the appropriate position.
2 1
1 : Approx. 2 mm (0.08 in.) width by

cutting the first step at the tip
2 : Approx. 5 mm (0.20 in.)width by
cutting the second step from the
tip
2-19
SPEC HANDLING OF LIQUID GASKET E
4. Sealant application points and types of sealant to be applied
Sealant types to be Standing time required

Sealant application points
applied after assembly
Timing belt cover x Timing belt cover gasket
Semi-circular plug joint area x Cylinder head cover gasket
Timing gear cover x Timing gear case (oil pump)
Cylinder head x Semi-circular plug
Camshaft oil seal retainer x Cylinder head
Camshaft oil seal retainer joint area x Cylinder head cover gasket
Three Bond® TB-1207B 2 hours
Camshaft oil seal retainer joint area x Timing gear cover
Main bearing cap (rudder frame) x Cylinder block
Rear oil seal retainer x Cylinder block
Heat exchanger x Gasket
Side plates x Gasket
Oil pan x Main bearing cap (rudder frame)
Cylinder head x Tight plug
Cylinder head x Water by-pass pipe No.3
Cylinder block x Tight plug
Three Bond® TB-1324 1 hour
Oil cooler cover x Drain cock
Timing gear case (oil pump ) x Tapered screw plug
Main bearing cap (rudder frame) x Oil return pipe
2-20
SPEC STANDARD ABBREVIATIONS AND SYMBOLS E
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
2-21
SPEC ELECTRICAL SYSTEM WIRING DIAGRAM E
ELECTRICAL SYSTEM WIRING DIAGRAM

Engine Electrical System
2-22
Connect to: Color Codes

1 Battery
2 Coolant temperature sender R : Red
3 Thermo switch
4 Seawater flow sensor O : Orange
5 Starter motor B : Black
6 Oil pressure sender
7 Oil pressure switch L : Blue
8 Pickup (tacho) sensor/Fuel cut solenoid valve Gy : Gray
9 Water separator switch
0 Boost sender (option) Br : Brown
A Electrical equipment box Sb : Sky blue
(PTT relays, 20 A Fuse)
B Alternator Lg : Light green
C Neutral switch Pu : Purple
D Fuse (100 A)
E Reservoir tank (option) R/B : Red/Black
F Glow control box R/G : Red/Green
G Starter relay
H Glow relay R/Pu : Red/Purple
I Glow plug
B/W : Black/White
J PTT relay (up)
K Diode L/R : Blue/Red
L Fuse (20 A)
M PTT relay (down)
L/Y : Blue/Yellow
L/W : Blue/White
To main wireharness (6TA-82586-00)
To main wireharness (6TA-82586-00)
L/G : Blue/Green
G/L : Green/Blue
G/W : Green/White
G/Br : Green/Brown
Y/R : Yellow/Red
Y/B : Yellow/Black
Y/W : Yellow/White
Br/B : Brown/Black
Br/W : Brown/White
Pu/W: Purple/White
2-23
Power Trim/Tilt System
Connect to: Color Codes

1 Trim limit switch
2 Trim sender R : Red
3 Power trim/tilt pump L : Blue
4 Power trim/tilt relay (Up) B : Black
5 Power trim/tilt relay (Down)
6 Trailer switch G : Green
7 Fuse (100 A) Br : Brown
8 Starter motor Gy : Gray
9 Battery (12 V)
Sb : Sky blue
Located at electrical equipment box Pu : Purple
From electrical equipement box (20 A Fuse) Y/R : Yellow/Red
R/B : Red/Black
R/G : Red/Green
R/Pu : Red/Purple
L/Y : Blue/Yellow
L/W : Blue/White
G/W : Green/White
Br/B : Brown/Black
Br/W : Brown/White
Pu/W: Purple/White
2-24
SPEC ELECTRICAL PARTS COMPONENTS LOCATION E
ELECTRICAL PARTS COMPONENTS LOCATION
Connect to:
1 Seawater flow sensor 0 Glow control box
2 Glow plug holder A Control box coupler
3 Boost sender (option) B For reservoir tank (option)
4 Glow plug lead C Water temperature sensor
5 Band D Thermo switch
6 Clamp E PTT harness
7 Neutral switch F Starter relay
8 Neutral switch coupler G Glow relay
9 Alternator
2-25
SPEC ELECTRICAL PARTS COMPONENTS LOCATION E
Connect to:
1 Ground earth 0 PTT relay (up)
2 To intermediate drive A Diode
3 Clamp B Fuse (20 A)
4 Oil pressure sender C PTT relay (down)
5 Starter motor D Fuel cut solenoid valve
6 Pickup (tacho) sensor/Fuel cut solenoid valve coupler E Pickup (tacho) sensor
7 Oil pressure switch
8 Band
9 Water separator sender coupler
2-26
SPEC COOLING SYSTEM DIAGRAM E
COOLING SYSTEM DIAGRAM
14
12
11
13
10 15
6
9
8 5
3
2
15
Coolant (freshwater) area Coolant flow Coolant draining point
Sea water area Sea water flow Sea water draining point
1 Drive unit 0 Warm water inlet

2 Seawater pump A Warm water outlet
3 Seawater filter B Reservoir tank (OP)
4 Inter-cooler C Thermostat
5 Power steering oil cooler D Mixing elbow
6 Heat exchanger E Anodes
7 Engine unit
8 Engine oil cooler
9 Circulation pump
2-27
CHK E
ADJ
CHAPTER 3
PERIODIC CHECK AND ADJUSTMENT
INTRODUCTION...................................................................................................................... 3-1
Periodic Maintenance/Lubrication Intervals Chart .......................................................... 3-1
ENGINE.................................................................................................................................... 3-7
Engine Oil Level Check ...................................................................................................... 3-7
Engine Oil and Oil Filter Replacement ............................................................................. 3-9
Oil Separator and Blow-by Hose Cleaning .................................................................... 3-11
Air Filter Cleaning ............................................................................................................ 3-12
Valve Clearance Adjustment ........................................................................................... 3-13
Engine Idle Speed and Maximum Speed Adjustment.................................................. 3-16
Engine Idle Speed Adjustment ....................................................................................... 3-17
Throttle Cable Adjustment .............................................................................................. 3-18
Compression Pressure Measurement ............................................................................ 3-19
Drive Belt Check ............................................................................................................... 3-21
Drive Belt Deflection Check and Adjustment ................................................................ 3-22
Timing Belt Check ............................................................................................................ 3-24
Engine Cleaning and Protection ..................................................................................... 3-26
FUEL SYSTEM ...................................................................................................................... 3-26

Fuel Line Check ................................................................................................................ 3-26
Injection Timing Adjustment........................................................................................... 3-28
Fuel Filter Draining (Water) ............................................................................................. 3-30
Fuel Filter Replacement ................................................................................................... 3-31
Fuel System Air Bleeding ................................................................................................ 3-34
COOLING SYSTEM ............................................................................................................... 3-34

Seawater Strainer Cleaning ............................................................................................ 3-34
Anodes Check .................................................................................................................. 3-35
Coolant Level Check ........................................................................................................ 3-36
Coolant Replacement ...................................................................................................... 3-37
Seawater Pump Impeller Replacement ......................................................................... 3-39
Cooling Hose Check ......................................................................................................... 3-40
Seawater Shutter Check .................................................................................................. 3-40
Cooling System Flushing ................................................................................................ 3-42
ELECTRICAL SYSTEM .......................................................................................................... 3-43

CHK E
ADJ
Battery Check ................................................................................................................... 3-43
Fuse Check ....................................................................................................................... 3-46
PERIODIC CHECKS AND ADJUSTMENT ............................................................................ 3-47

Thermostat Check ............................................................................................................ 3-47
Coolant Filler Cap Check ................................................................................................. 3-48
Cooling System Pressurize Check .................................................................................. 3-49
3
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 starts and electrical shorting, reducing the risk of personal injury and dam-
age to electrical components.
Periodic Maintenance/Lubrication Intervals Chart

¡ = Owner service item.
™ = Yamaha stern drive dealer service item.
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 Check and adjust. ™
Fuel pipe connections Check for looseness. Tighten if
™ or ¡
necessary.
LUBRICATION SYSTEM
Oil pressure warning light Check for proper operation. ¡ ¡ ¡ ¡
Engine oil Check oil level and oil leaks. ¡
Change (Warm up engine
™ or ¡ ™ or ¡ ™ or ¡
before draining).
Engine oil filter Replace. ™ or ¡ ™ or ¡ ™ or ¡
COOLING SYSTEM
Seawater strainer Check and clean. ¡ ¡ ¡ ¡
Seawater pump Replace impeller. ™ or ¡
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 3)
Seawater shutter Inspect pivot and shutter.
™
Replace if necessary.
3-1
CHK INTRODUCTION E
ADJ
Before After first
Every 100 At least
starting 20 hours
engine or 2
months year
each day months
ELECTRICAL SYSTEM
Meters and switches Check for proper operation. ¡ ¡ ¡ ¡
Warning lights Check for proper operation. ¡ ¡ ¡ ¡
Drive belts (All) Check for cracks, weathering
and damaged. Check drive
¡ ¡ ¡ ¡
belt for deflection. Adjust or
replace if necessary.
Pre-heating device Check for proper operation. ™ ™ ™
Battery Check electrolyte level. Add
¡ ¡ ¡ ¡
electrolyte if necessary.
Check specific gravity. Change
™ ™
or replace if necessary.
Electrical system Check connections and
insulation. Retighten or ¡ ™ or ¡ ™ or ¡ ™ or ¡
replace if necessary.
ENGINE
Engine idling and Check for unusual noises.
¡ ™ or ¡ ™ or ¡ ™ or ¡
starting Adjust if necessary.
Fuel, water, oil, exhaust Check for leaks.
¡ ™ or ¡ ™ or ¡ ™ or ¡
gas and intake air
Exhaust gas Check color of the gas. ¡ ™ or ¡ ™ or ¡ ™ or ¡
Engine bracket Bolt retightening. ¡ ™ or ¡ ™ or ¡ ™ or ¡
Engine rubber mount Check the rubber mount
¡ ™ or ¡ ™ or ¡ ™ or ¡
condition, and bolt retightening.
Crank pulley, damper Bolt retightening. ™ ™ ™
Air filter Clean. ™ or ¡ ™ or ¡
Replace. ™ or ¡
Engine alignment Yamaha stern drive dealer
™ ™
check engine alignment.
OTHERS
Throttle cable Check fully open and fully
¡ ¡ ¡ ¡
closed positions.
Power steering system Check for proper operation. ¡ ™ or ¡ ™ or ¡ ™ or ¡
Check oil level of power
steering pump reservoir. Add ¡ ™ or ¡ ™ or ¡ ™ or ¡
oil if necessary.
Bolts and nuts at each Check retightening.
¡ ™ or ¡ ™ or ¡ ™ or ¡
section
Hose bands and clamps Check retightening.
¡ ™ or ¡ ™ or ¡ ™ or¡
(All)
Hoses and bushes (All) Check for damage and loose-
ness. Replace or retighten if ¡ ™ or ¡ ™ or ¡ ™ or ¡
necessary.
3-2
CHK INTRODUCTION E
ADJ
Before After first
Every 100 At least
starting 20 hours
engine or 2
months year
each day months
Engine exterior Clean and inspect. Paint if
¡
necessary and then apply ¡
Every 3 weeks
anticorrosion spray.
in boating season.
NOTE 1: In saltwater areas, 50 hours of operation or 60 days (whichever comes first).

NOTE 2: Frequent maintenance is required, if used for high speed or heavy-duty operation.
NOTE 3: In saltwater or mineral-laden water areas, twice as often as the specified period.
* :When a warning light lights.
3-3
CHK INTRODUCTION E
ADJ
Periodic maintenance and replacement items chart
P1 & P2 P1 P2
At every
Items for Every Every Every
engine
maintenance/ Remarks Every 2 1000 1200 3000
oil
replacement years hours or hours or hours or
change
3 years 6 years 6 years
FUEL SYSTEM
Hoses 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.
™ or ¡
(sedimenter)
Fuel filter Replace. ™ or ¡ Every year
Gauze filter Clean. ™ Every year
Injection nozzle Check for valve-opening
pressure, spray condi- ™
tion, and dribbing.
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 leaks and
™ or ¡
looseness.
Hoses and bellows Check for leaks and
™ or ¡
damages.
Replace. ™
Turbocharger Check for the shaft free
™
play, gas/oil leaks.
Air filter Clean. ™ or ¡
Replace. ™ or ¡ Every year
Bolts and nuts related to Check, and retighten if
™ or ¡ ™
the exhaust system necessary.
Exhaust shutter Check and replace any
™ Every year
deteriorated parts.
Exhaust manifold Check the integrity. ™
COOLING SYSTEM
Hose clamps Check for leaks and
™ or ¡
looseness.
Hoses Check for leaks and
™ or ¡
damages.
Replace. ™ ™
3-4
CHK INTRODUCTION E
ADJ
P1 & P2 P1 P2
At every
engine
oil
change
Replace. ™
Seawater drain plug Check for leaks. ™ or ¡
Replace. ™ ™
Seawater pipes Replace. ™
Seawater pump Replace.
™ or ¡ Every year
impeller
Seawater pump oil and Replace.
™ ™
mechanical seal
Seawater pump cover Replace. ™ ™
Seawater strainer cover Replace. ™ ™
Mixing elbow Replace. ™ ™
Anodes (Intercooler, Check, and replace if
Heat exchanger) eroded by more than ™ or ¡ Every 100 hours or 3 months
half.
Heat exchanger element Clean. ™
Replace. ™
Inter-cooler element Clean. ™
Replace. ™
Coolant Replace. (use Yamaha
coolant)
Cooling system Check pressure.
™ Every year
pressure inspection
ELECTRICAL SYSTEM
Insulation Check for damages. ™ or ¡ ™ or ¡
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 (All) Replace. ™
ENGINE
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 cylinder block)
Crank pulley bolt Check, retighten if
™
(loosening) necessary.
3-5
CHK INTRODUCTION E
ADJ
P1 & P2 P1 P2
At every
engine
oil
change
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 (All) 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)
OTHERS
Power steering oil Clean. ™
cooler element Check. ™
Power steering pump Check. ™
Power steering cylinder Check. ™
Rubber and resin parts Replace. ™ or ¡
(All)
Hose clamps (All) Replace. ™ or ¡
Engine exterior Check, paint if necessary
™ or ¡ (NOTE 2)
and then apply anti-
corrrosion spray.
NOTE 1: Check every 50 hours in the case of frequent high-speed, heavy-load operations.
NOTE 2: Every three weeks in boating season.
3-6
CHK ENGINE E
ADJ
ENGINE
Engine Oil Level Check
1. Stop the engine if it is running, and wait
at least 5 minutes for the oil to drain back
into the oil pan.
2. Pull out the dipstick 1, wipe it clean and
reinstall it all the way into the dipstick
tube 2.
3. Remove:
¡ Dipstick 1
NOTE:
Note the level of oil left on the dipstick blade.
4. Check:
¡ Engine oil level
Oil level should be between the “F”
mark A and the “L” mark B.
Oil level low → Add recommended
engine oil to proper level.
CAUTION:
Be sure not to add oil above the specified
level. If the oil level is too high, oil may be
blown out through the breather pipe, out-
put may drop due to the increased rotation
resistance, or oil may enter the combustion
chamber, causing overheating. These prob-
lems could ultimately lead to engine dam-
age.
Recommended engine oil:

SAE 15W-40, API CD or CE
NOTE:
Refer to chart and select an oil with the
appropriate viscosity for expected ambient
temperatures between now and the next oil
change.
3-7
CHK ENGINE E
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 an oil and filter
change after the first 20 hours of opera-
tion. Simply replenishing without chang-
ing the oil after those 20 hours will cause
engine deterioration.
Engine oil addition steps

1) Remove the oil filler cap 1.
2) Add recommended engine oil up to, but
not past, the “F” mark A on the dipstick
2.
CAUTION:
Do not allow foreign material to enter the
crankcase.
3) Reinstall the dipstick and 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:
Wait at least 5 minutes for the oil to drain
back into the oil pan, before checking the oil
level.
¡ WARNING
Wipe off any oil spilled on engine block. Oil
in the bilge is a serious fire hazard.
3-8
CHK ENGINE E
ADJ
Engine Oil and Oil Filter Replacement
NOTE:
The oil filter should be replaced every time
the engine oil is changed.
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:
¡ Dipstick 1
4. Drain:
¡ Engine oil
(from crankcase through dipstick tube
1)
Use a suction pump 2.
NOTE:
Remove the engine oil filler cap 1. This will
speed up the oil draining.
5. Replace:
¡ Oil filter 1
Oil filter replacement steps

1) Remove the oil filter 1 using the oil fil-
ter wrench.
3-9
CHK ENGINE E
ADJ
NOTE:
After stopping the engine, wait 5 minutes
before removing oil filter. Otherwise oil will
pour out of the filter.
¡ WARNING
Oil in the bilge is a serious fire hazard.
A small amount of oil may be spilled 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 spilling oil.
Wipe up any spilled oil with dry rags imme-
diately.
2) Clean and check the oil filter installation

surface A.
3) Coat the O-ring 1 on the new filter 2
with a thin coat of clean engine oil.
4) Screw the filter by hand until the O-ring
just touches the cylinder block, then
tighten it half a turn by hand.
CAUTION:
DO NOT use a filter wrench.
6. Fill:
¡ Crankcase
¡ Refer to “Engine Oil Level Check” on
page 3-7.

Engine oil capacity

Without oil filter change:
8.4 L (1.85 lmp qt, 2.22 Us qt)
With oil filter change:
9.2 L (2.02 lmp qt, 2.43 Us qt)
¡ WARNING
Wipe off any oil spilled on the engine block.
Oil in the bilge is a serious fire hazard.
7. Install:
¡ Dipstick
¡ Oil filler cap
3-10
CHK ENGINE E
ADJ
8. Start the engine and check for leaks
around the filter. If leaks is found, stop
the engine immediately and reinstall the
oil filter.
9. Check:
¡ Engine oil level
Refer to “Engine Oil Level Check” on
page 3-7.
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
dipstick regularly.
Oil Separator and Blow-by Hose

3
Cleaning
1
1. Check:
¡ Blow-by hoses 1
2
¡ Oil separator 2
Clacks/Damage → Replace.
3
3 2. Clean:
2
¡ Blow-by hoses 1
4
¡ Oil separator 2
Replacement and cleaning steps

1) Loosen the hose clamps 3 and first re-
move the hoses 1, then the holder 4
3 and oil separator 2.
2) Replace any damaged part with a new
one.
3) Clean the oil separator and blow-by
1
hoses with cleaning solvent and dry
3 them with compressed air.
4) Reinstall all removed parts, making sure
they are positioned correctly.
3-11
CHK ENGINE E
ADJ
2 Air Filter Cleaning
1. Remove:
¡ Air filter cover 1
¡ Bolt 2
NOTE:
3 Pull the pins 3 of the air filter cover and re-
1
move the cover.
2. Remove:
¡ Air filter 1
CAUTION:
The engine should never be run without the
air filter, as this could lead to engine or turbo
charger damage.
3. Check:
¡ Air filter 1
¡ Air filter frame 2
2
Damage → Replace.
4. Clean:
¡ Air filter 1
1 NOTE:
Wash the air filter with mild detergent or
fresh water and dry up before installing it on
the frame.
¡ Air filter cover

(with a clean cloth)
5. Install:
1 ¡ Air filter 1
¡ Air filter cover 2
¡ Bolt 3
¡ Pins 4
NOTE:
To attach the air filter cover to the air filter,
align the pins 4 with the corresponding
holes A and push them down until they snap
into place.
Bolt (air filter cover):

2.0 N·m (0.2 kgf·m, 1.4 lbf·lt)
T.R
3-12
CHK ENGINE E
ADJ
Valve Clearance Adjustment
NOTE:
¡ The valve clearance should be adjusted
when the engine is cool.
¡ To check or adjust the valve clearance, pis-
ton in #1 cylinder must be at Top Dead
Center (T.D.C.).
1. Disconnect:
¡ Breather hose 1
2. Remove:
¡ Cylinder head cover 2
(with gasket)
3. Measure:
¡ Valve clearance
¡ Out of specification → Adjust.
Valve clearance (cold)

Intake valve:
0.15 – 0.25 mm
(0.006 – 0.010 in.)
Exhaust valve:
0.35 – 0.45 mm
(0.014 – 0.018 in.)
Checking steps
1) Turn the crankshaft pulley 1 clockwise,
and align the TDC mark A on the pulley
with the stationary mark B on the tim-
ing gear cover 2.
2) Check that the valve lifters on #1 cylin-
der are loose and valve lifters on #6 cyl-
inder are tight. If not, turn the crankshaft
one full turn (360°) and realign the marks
as explained above.
#1 piston is now at TDC on compression
stroke.
3-13
CHK ENGINE E
ADJ
3) Measure the valve clearance with a thick-
ness gauge 3 between the camshaft and
the lifter on the following valves.
#1 Cylinder IN/EX valves
#2 Cylinder EX valve
#3 Cylinder IN valve
NOTE:
Write down the valve clearance measure-
ments which are out of specification. They
will be used later to determine the required
replacement shim.
4) Turn the crankshaft one full turn (360°),

and align the marks as explained in step
1.
Measure the valve clearance for the other
valves.
5) Measure the valve clearance with the
thickness gauge on the following valves.
#6 Cylinder IN/EX valves
4. Adjust:
¡ Valve clearance
Adjustment steps
1) Turn the crankshaft clockwise until the
cam lobe A of the adjustment valve 1
points upwards.
2) Turn the valve lifter slots B to the ex-

haust manifold side.
3) Install the valve clearance adjusting tool
2 onto the valve lifter 3 and the cam-
shaft as shown in the illustration, and
press down the valve lifter.
Valve clearance adjusting tool:

09248-64011 or (90890-07710)
3-14
CHK ENGINE E
ADJ
4) Remove the shim 4 with a small screw-
driver 5 and magnetic rod 6.
5) Measure the thickness of the removed
shim 7 with a micrometer.
NOTE:
If the micrometer measures in inches, con-
vert the valve into millimeters (in. x 25.4 =
mm).
6) Determine the replacement shim thick-

ness either with the following formulas.
Intake N = T + (A – 0.20 mm)
Exhaust N = T + (A – 0.40 mm)
T: Thickness of used shim
A: Measured valve clearance
N: Thickness of new shim
New shim thickness mm (in.) Round off the calculated valve.

Shim Shim Last digit of
Thickness Thickness Rounded valve
No. No. calculated valve
709 2.35 (0.0925) 45 2.85 (0.1122) 0 to 3 0
704 2.40 (0.0945) 21 2.90 (0.1142) 4 to 6 5
710 2.45 (0.0965) 46 2.95 (0.1161) 7 to 9 10
01 2.50 (0.0984) 26 3.00 (0.1181)
42 2.55 (0.1004) 47 3.05 (0.1201) Example (intake): Unit: mm
06 2.60 (0.1024) 31 3.10 (0.1220) N = 2.80 + (0.29 – 0.20) = 2.89
The last digit “9” is rounded off to “10”, so
43 2.65 (0.1043) 48 3.15 (0.1240)
the rounded-off valve = 2.90.
11 2.70 (0.1063) 36 3.20 (0.1260)
N (Thickness of new shim) = 2.90 mm (0.1142
44 2.75 (0.1083) 49 3.25 (0.1280) in.), thus shim No. 21.
16 2.80 (0.1102) 41 3.30 (0.1299)
NOTE:
20 shim sizes are available, in increments of
0.05 mm (0.0020 in.) from 2.35 mm (0.0925
in.) to 3.30 mm (0.1299 in.).
7) Install the new shim on the valve

lifter.
NOTE:
¡ Apply engine oil to the new shim.
¡ The valve lifter must turn smoothly when
turned by hand.
3-15
CHK ENGINE E
ADJ
8) Remove the valve clearance adjusting
tool 2.
NOTE:
Turn the crankshaft clockwise several turns
so that the newly installed shims settle into
the right position.
9) Recheck the valve clearance. If the clear-

ance adjustment until the clearance is
correct.
5. Install:
(with gasket)
NOTE:
Tighten the bolts in a crisscross pattern start-
ing in the middle.
6. Connect:
¡ Breather hose 2
Engine Idle Speed and Maximum

Speed Adjustment
NOTE:
The valve clearance, injection timing and
throttle cable position must be correctly ad-
justed, before checking and adjusting the
engine idle speed.
CAUTION:
¡ Before performing this adjustment, turn
OFF all accessories.
¡ DO NOT operate the engine even mo-
mentarily without providing cooling wa-
ter. Either the seawater pump will be
damaged or the engine will overheat.
¡ When starting the engine out of the wa-
ter, be sure to install the flushing attach-
ment to feed cooling water.
¡ The engine should never be run without
air filter, as this could lead to engine or
turbo charger damage.
3-16
CHK ENGINE E
ADJ
Engine Idle Speed Adjustment
1. Put the remote control lever into “NEU-
TRAL”.
NOTE:
Check that the adjusting lever 1 touches the
idle speed adjusting screw 2 when the re-
mote control lever is in “NEUTRAL”.
2. Run the engine until it reaches normal

operating temperature, then stop it.
3. Check:
Engine idle speed
Out of specification → Adjust.
Engine idle speed:

600 – 650 r/min
Adjustment steps
1) Disconnect the throttle cable 1 from the
throttle lever 2.
2) Loosen the lock nut 3 of the idle speed

adjusting screw 4.
3) Turn the idle speed adjusting screw 4
in or out until the specified idle speed is
obtained.
Turning in Higher idle speed

Turning out Lower idle speed
4) Securely tighten the locknut, and recheck

the idle speed. Repeat the adjustment if
necessary.
5) Connect the throttle cable to the throttle
lever.
6) Check the position of the throttle lever.
Refer to “Throttle Cable Adjustment” on
page 3-18.
3-17
CHK ENGINE E
ADJ
Throttle Cable Adjustment
1. Adjust:
¡ Throttle cable position
Adjustment steps
1) Put the remote control lever in “NEU-
TRAL” .
2) Loose the adjuster locknuts 1.
3) Adjust engine idle speed refer to “Engine
Idle Speed and Maximum Speed Adjust-
ment” on page 3-16.
4) Attach an adjust nut to the throttle cable
end, providing 2 mm (0.79 in.) clearance
between the throttle lever end and the
adjust nut. Then, secure it with a lock
nut.
5) Check that the adjusting lever 2 touches

the idle speed adjusting screw 3.
6) Tighten the adjuster locknuts 1 on the
throttle cable end.
7) Put the remote control lever on “FULL

THROTTLE” .
8) Check that the adjusting lever 2 touches
the maximum speed adjusting screw 4.
If the adjusting lever does not contact the
maximum speed adjusting screw, turn in
the adjuster on the throttle cable and re-
peat steps 3) to 6) and check the remote
control side.
3-18
CHK ENGINE E
ADJ
Compression Pressure Measurement
NOTE:
Insufficient compression pressure will result
in performance loss and poor fuel economy
or excessive oil consumption.
1. Start the engine and let it warm up to

normal operating temperature, then stop
the engine.
2. Disconnect:
¡ Injection pump connecter 1
3. Remove:
¡ Glow plug 1
Refer to “CYLINDER HEAD” on page
5-30.
4. Attach:
¡ Compression gauge attachment 1
(to glow plug hole)
¡ Compression gauge 2
Compression gauge attachment:

TDG-7 or No.30 or (90890-07701)
5. Measure:
¡ Compression pressure
Out of specification → Repair.
Refer to “ENGINE OVERHAUL” on
page CHAPTER 5.
3-19
CHK ENGINE E
ADJ
Compression pressure (at sea level)

Standard:
2550±196 kPa
(26.0±2 kgf/cm2, 370±28.4 psi)
Minimum:
2160 kPa (22.0 kgf/cm2, 313 psi)
Max. variation between cylinders:
490 kPa (4.9 kgf/cm2, 70 psi) or less
NOTE:
If the cylinder compression in one or several
cylinders is low, pour a small amount of en-
gine oil through the glow plug hole into the
cylinder and measure the compression pres-
sure again.
Compression pressure
(With oil in the cyinder)
Reading Diagnosis
Higher than Piston rrings and/or cylin-
without oil der bore are worn or dam-
aged.
Same as with- Valve sticking, or seating
out oil improperly.
or:
Defective ring(s), cylinder
head gasket or piston.
Measurement steps
1) Crank the engine until the reading on the
compression gauge stabilizes.
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.
2) Repeat step 1 on the other cylinders.
NOTE:
The difference of compression pressure be-
tween the highest and lowest cylinder com-
pression readings should not exceed 490 kPa
(4.9 kgf/cm2, 70 psi).
3-20
CHK ENGINE E
ADJ
Drive Belt Check
1. Check:
¡ Drive belts 1
Cracks/Wear/Damage → Replace.
NOTE:
Check the belts on several spots; twist them
slightly to look at the sides and inner surface.
2 Water circulation pump relay

3 Alternator pulley
Drive belt replacement steps

¡ Alternator belts
1) Loosen the pivot bolt 1 and the adjust-
ing bolt 2 of the alternator 3.
2) Reduce the tension on the drive belts 4
by pushing the alternator towards the en-
gine.
3) Remove the drive belts.
4) Install the new drive belts. Check that
they seat properly in the pulley grooves.
5) Adjust the drive belt tension.
Refer to “Drive Belt Deflection Check and
Adjustment” on page 3-22.
Drive belt deflection under:

100 N (10 kgf, 22.0 lbf) pressure
Alternator belt:
10 – 12 mm (0.39 – 0.47 in.)
3-21
CHK ENGINE E
ADJ
Drive Belt Deflection Check and
Adjustment
¡ WARNING
Turn the main switch off, remove the key,
and wait until the engine has come to a com-
plete standstill before starting to check the
drive belt deflection.
CAUTION:
A badly tightened drive belt can lead to se-
vere damage in the electrical system, power
steering system, or engine unit. Make sure
the tension of the belt is within the speci-
fied range.
Too loose: The drive belt will slip and could
even come off the pulleys, causing faulty
operation of the water circulation pump, or
alternator. This would lead to overheating,
malfunction of electrical components, loss
of power steering or complete engine fail-
ure.
Too tight: Too much tension on a drive belt
will shorten its life and can cause it to break.
Excessive tension could also damage the
bearing.
1. Check:
¡ Drive belt tension
(alternator belts 1)
Out of specification → Adjust.

100 N (10 kgf, 22.0 lbf) pressure
Alternator belt:
12 – 14 mm (0.47 – 0.55 in.)
[New belt:
10 – 12 mm (0.39 – 0.47 in.) ]
NOTE:
For alternator belts 1:
Press with the hand on the belt at half way
between the alternator pulley 2 and the cir-
culation pump pulley 3.
3-22
CHK ENGINE E
ADJ
Belt tension adjustment steps
¡ Alternator belts
1) Loosen the pivot bolt 1 and the adjust-
ing bolt 2 of the alternator 3.
2) To obtain the correct drive belt tension,

pry the alternator 3 away from engine
with a suitable tool (i.e. rod, pipe) 4 and
tighten the adjusting bolt 2 in this posi-
tion.
CAUTION:
Pry only on reinforced portions A of the al-
ternator housing.
3) Tighten the pivot bolt 1.
3-23
CHK ENGINE E
ADJ
Timing Belt Check
CAUTION:
¡ Do not bend, twist, or turn the timing belt
inside out.
¡ Do not allow the timing belt to come into
contact with oil, water or steam.
¡ Be sure that the timing belt is not tight-
ened when installing or removing the
camshaft timing pulley mount bolt.
CAUTION:
When turning the crankshaft, the valve
heads will hit against the piston top.
1
Do not turn it more than necessary.
1. Remove:
¡ Timing belt cover 1
Refer to “TIMING BELT AND TIMING
PULLEYS” on page 5-8.
3
2. Check:
¡ Timing belt cover 1/Gasket 2
Cracks/Wear/Damage → Repair.
1
NOTE:
2 ¡ If the gasket is damaged slightly, seal it
by applying Three Bond® TB-1207B.
¡ If the gasket is seriously damaged, install
a new one. In this case, make sure that
no fragment of the 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 excessive length.
If there is any gap at the joint area, fill it
with Three Bond® TB-1207B.
Timing belt cover gasket:

11328-17030 (TOYOTA part No.)
3-24
CHK ENGINE E
ADJ
3. Check:
¡ Timing belt 3
NOTE:
If the belt teeth are cracked or damaged,
check if the camshaft is not excessively tight.
NOTE:
If there are cracks or noticeable wear on the
belt face, check if there is a nick on one side
of the idler pulley lock.
NOTE:
If the belt is only worn or damaged on one
side, check the alignment of the pulleys.
NOTE:
If belt teeth show signs of wear, check the
condition and installation of the timing belt
cover and gasket.
Check for foreign material on the pulley teeth.
4. Install:
¡ Timing belt cover
3-25
CHK ENGINE / FUEL SYSTEM E
ADJ
Engine Cleaning and Protection
1. Clean:
¡ Engine exterior
2. Remove peeling paint, and touch up with
paint.
3. Apply:
¡ Anti-rust lubrication spray
(Yamaha Silicone Protectant or an
equivalent product)
FUEL SYSTEM
¡ WARNING
When servicing the fuel system, pay particu-
lar attention to the following points:
¡ Be sure 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 do
accidentally spill some, wipe it up imme-
diately with dry rags. When the engine
is still hot from operation, spilled diesel
fuel could catch fire. Always allow the
engine cool off completely before start-
ing 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 like soft-
ening, hardening, swelling, or corrosion. Any
defective part must be replaced before the
engine can be used.
3-26
CHK FUEL SYSTEM E
ADJ
1. Check:
¡ Fuel pipe connections
Loose → Tighten.
Fitting nut 1 (fuel delivery pipe):

15 N·m (1.5 kgf·m, 11 lbf·ft)
T.R
Hollow bolt 2 (leakage pipe):
12.5 N·m (1.25 kgf·m, 9.0 lbf·ft)
Fitting bolt 3:
25 N·m (2.5 kgf·m, 18 lbf·ft)
T.R
4 Fuel inlet hose

5 Fuel delivery hose
6 Fuel return hose
3-27
CHK FUEL SYSTEM E
ADJ
Injection Timing Adjustment
1. Adjust:
¡ Injection timing
Measurement steps
1) Loosen the fitting nuts 1 of the #1 and
#5 cylinder injection pipes.
2) Remove the plug bolt 2 and gasket 3

from the injection pump distribution
head.
3) Install the plunger stroke measuring tool
4 and a dial indicator 5 to the plug bolt
hole.
Plunger stroke measuring tool:
09275-54001 or (90890-07720)
4) Slowly rotate the crankshaft pulley coun-

terclockwise and set the dial indicator to
“0” when the reaches its minimum.
5) Turn the crankshaft back and forth a little

and check that the needle really shows
the minimum.
NOTE:
It is essential that the dial indicator is set to
“0” correctly.
6) Measure the plunger stroke

(Dial indicator value).
Plunger stroke:
1.65 – 1.69 mm (0.065 – 0.067 in.)
3-28
CHK FUEL SYSTEM E
ADJ
Adjustment steps
1) Loosen the four remaining injection pipe
fitting nuts.
7 2) Disconnect the fuel hose #2 6 at fuel fil-

ter housing 7.
3) Loosen the bolt 0 and the two nuts A.
4) Adjust the plunger stroke by slightly tilt-

ing the injection pump body.
If the stroke is Tilt the pump to-
shorter than speci- wards the engine .
fied:
If the stroke is Tilt the pump away
longer than specifi- from the engine .
cation
5) Tighten the bolt 0 and two nuts A.
Bolt (injection pump – injection

pump stay):
70 N·m (7.1 kgf·m, 50 lbf·ft)
Nut (injection pump – gear case):
18 N·m (1.8 kgf·m, 13 lbf·ft)
3-29
CHK FUEL SYSTEM E
ADJ
6) Remove the plunger stroke measuring
tool 4 and the dial indicator 5.
7) Install the plug bolt 2 with a new gasket
3.
CAUTION:
Always use a new gasket for the plug bolt.
Plug bolt:
25 N·m (2.5 kgf·m, 18 lbf·ft)
T.R
8) Connect the injection pipes to the injec-
tion pump.
Fitting nut (injection pipe):

25 N·m (2.5 kgf·m, 18 lbf·ft)
T.R
7 9) Connect the fuel delivery hose 6 to the

fuel filter housing 7.
Hollow bolt (fuel delivery hose):
30 N·m (3.1 kgf·m, 22 lbf·ft)
T.R
10) Start the engine and check for leaks.

Repair if necessary.
6
Fuel Filter Draining (Water)

NOTE:
When the water separator warning light goes
on, the water in the fuel filter must be
drained.
1. Remove:
1
2 ¡ Fuel filter cover bolt 1
¡ Fuel filter cover 2
3-30
CHK FUEL SYSTEM E
ADJ
2. Place a container under the drain screw
1.
3. Loosen:
¡ Drain screw 1
Drain all the water in the fuel filter.
4. Tighten:
¡ Drain screw
5. Air bleed:
¡ Fuel feed system
¡ Refer to “Fuel System Air Bleeding”
on page 3-34.
Fuel Filter Replacement

1. Turn the main switch to “OFF”, and stop
the engine.
2. Shut the fuel cock on the fuel tank “OFF”.
3. Remove:
¡ Fuel filter cover bolt 1
1 ¡ Fuel filter cover 2
2
4. Remove:
¡ Band 2
5. Disconnect:
¡ Coupler 3 (water level sensor)
6. Remove:
¡ Fuel filter 1
Use the filter wrench.
3-31
CHK FUEL SYSTEM E
ADJ
¡ WARNING
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:
¡ Water level sensor 1
(with O-ring)
8. Check and clean mating surfaces on the

water level sensor 1 and new fuel filter
2.
9. Install:
¡ O-ring 3 (new)
(onto water level sensor)
10. Lubricate:
¡ O-ring 3
(with a thin coat of clean fuel)
11. Install:
¡ Water level sensor 1
12. Tighten the water level sensor by hand.
3-32
CHK FUEL SYSTEM E
ADJ
13. Clean and check the fuel filter mounting
surface A.
14. Install:
O-ring 2 (new)
(onto fuel filter 1)
15. Lubricate:
O-ring 2
(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 still by hand another halfturn.
CAUTION:
¡ DO NOT over-tighten.
¡ DO NOT use a filter wrench.
17. Open the boat’s fuel tank cock.

18. Air bleed:
¡ Fuel system
Refer to “Fuel System Air Bleeding”
on page 3-34.
19. Check:
¡ Fuel leakage
Leak → Repair.
20. Install:
¡ Fuel filter cover 1
NOTE:
Attach a grommet where the fuel filter cover
bolt will be mounted.
21. Tighten:
2
¡ Fuel filter cover bolt 2
1
Fuel filter cover bolt:
3.5 N·m (0.35 kgf·m, 2.53 lbf·ft)
T.R
3-33
CHK FUEL SYSTEM / COOLING SYSTEM E
ADJ
1 Fuel System Air Bleeding
NOTE:
¡ After disassembly of the fuel system, af-
ter loosening or disconnecting a fuel hose
and after replacing the fuel filter, the air
in the fuel system must be bled.
¡ 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
possible.
COOLING SYSTEM
Seawater Strainer Cleaning
1. Fully tilt up the drive unit.
2. Remove:
¡ Strainer cap 1
¡ Inner plate 2
¡ Strainer 3
3. Check:
¡ Strainer cap 1
¡ Inner plate 2
Cracks/Damage → Replace.
¡ Strainer 3
¡ Sealing rubber 4
Tearing/Wear/Damage → Replace.
4. Clean:
¡ Strainer cap
¡ Inner plate
¡ Strainer (with fresh water)
5. Install:
¡ Strainer 1
¡ Inner plate 2
¡ Strainer cap
NOTE:
¡ Make sure that the sealing rubber 3 is
seated properly onto the strainer case 4.
¡ The flap 3 must be on the upper side.
3-34
CHK COOLING SYSTEM E
ADJ
Anodes Check
1. Check:
¡ Anodes 1
Excessive wear (when more than one-
third is worn out) → Replace.
NOTE:
1
¡ Two anodes are provided on the heat ex-
LT
1
243 changer and on the inter-cooler respec-
tively.
¡ Apply LOCTITE® 243 on the threads when
installing the anodes.
NEW
Anodes:
19 N·m (1.9 kgf·m, 14 lbf·ft)
T.R
Must be replaced
3-35
ADJ
Coolant Level Check
¡ WARNING
Do not remove the filter cap when the en-
gine is hot. Scalding hot fluid and steam may
be blown out under pressure, causing severe
injury. When the engine has cooled, open the
filler cap as follows:
Place a thick rag or a towel over the filter
cap. Slowly rotate the cap counterclockwise
to the detent. This allows residual pressure
to escape. When the hissing sound has
stopped, press the cap down and turn coun-
terclockwise to remove it.
1. Remove:
Coolant filler cap 1
2. Check:
Coolant level
¡ The coolant level should be between
the maximum A and minimum B lev-
els.
Coolant level low → Add soft water
(tap water) to proper level.
Recommended coolant:
High quality ethylene glycol anti-
freeze containing corrosion in-
hibitors for engines
Coolant and water mix ratio:
30% – 55%
Total amount:
12.4 L (2.72 lmp qt, 3.28 US qt)
Reservoir tank capacity (option):
1.5 L (0.33 lmp qt, 0.40 US qt)
From MIN to MAX level:
0.2 L (0.04 lmp qt, 0.05 US qt)
CAUTION:
¡ Hard water or salt water is harmful to en-
gine parts. Use boiled or distilled water
if soft water is not available.
¡ Do not use water containing impurities
or oil.
¡ Take care that no coolant splashes onto
painted surfaces. If it does, wash it away
with water immediately.
¡ Do not mix different types and brands of
coolant.
3-36
ADJ
CAUTION:
If the boat will be used in temperatures that
could drop below –10 °C (14 °F), it is neces-
sary to change the coolant mixture ratio.
As shown in the graph, the proportion of
undiluted coolant must be increased from
30 % of the total volume to as much as 55 %,
according to the temperature range.
A Proportion of undiluted coolant

B Outdoor temperature
A Range of mixture ratios
Handling notes for coolant

Coolant is harmful and should be handled
with special care.
¡ WARNING
¡ If coolant splashes in your eyes:
Thoroughly wash your eyes with water
and see a doctor.
¡ If coolant splashes on your clothes:
Quickly wash it away with water and
then with soap.
¡ If coolant is swallowed:
Quickly make the patient vomit and take
him to a doctor.
3. Install:
¡ Coolant filler cap
4. Start the engine and let it warm up for
several minutes.
5. Stop the engine and check the coolant
level again.
NOTE:
Wait a few minutes to let the coolant settle,
before checking the coolant level.
Coolant Replacement
Place containers under the drain holes.
1. Disconnect:
¡ Coolant hose 1
(from the heat exchanger 2)
3-37
ADJ
3. Remove:
¡ Drain bolt 1
(on port side of cylinder)
¡ Drain bolt 2 (with gasket 3)
(on turbocharger housing 4)
Drain the coolant.
NOTE:
Remove the coolant filler cap 5 to speed up
draining of the coolant. However, remove the
drain bolts 1 and 2 first, as this will prevent
5 the coolant from spilling out.
4. Tighten:
¡ Drain bolts
Drain bolt (cylinder):

25 N·m (2.5 kgf·m, 18 lbf·ft)
T.R
Drain bolt
(turbo charger housing):
33 N·m (3.4 kgf·m, 24 lbf·ft)
CAUTION:
Always use a new gasket on the cylinder
drain bolt.
5. Connect:
¡ Coolant hose 1
(to heat exchanger 2)
6. Fill:
¡ Cooling system
(to maximum level A)
Refer to “Coolant Level Check” on
page 3-36.
7. Start the engine and let it warm up for
several minutes.
8. Stop the engine and check the coolant
level again.
NOTE:
Wait a few minutes to let the coolant settle,
before checking the coolant level.
3-38
ADJ
Seawater Pump Impeller Replace-
ment
4
3
¡ WARNING
As soon as the seawater pump hose is dis-
connected, plug the seawater inlet side to
prevent seawater from entering.
1. Remove:
¡ Cover 3
¡ O-ring 4
2. Check:
1 ¡ Impeller 1
Wear/Cracks/Damage → Replace.
3. Remove:
¡ Impeller 1 (defective)
Pull it out with pliers 2.
4. Lubricate:
¡ Impeller 1
(with YAMAHA Marine grease)
5. Install:
¡ Impeller 1
NOTE:
When inserting the impeller into the pump
body, turn it counterclockwise while push-
ing.
1
CAUTION:
Make sure that the impeller blades are
turned as shown in the illustration.
6. Install:
1 New ¡ O-ring 1 (new)
2 ¡ Cover 2
Bolt (cover):
2 N·m (0.2 kgf·m, 1.4 lbf·ft)
T.R
3-39
ADJ
Cooling Hose Check
1. Check:
¡ Cooling hoses 1
¡ Exhaust joint 2
Loose → Tighten the hose clamp.
Seawater Shutter Check

1. Ground the boat.
CAUTION:
Do not perform the shutter check on water,
because it may cause the water to flow back-
ward. Grounding of the boat is essential be-
fore carrying out of the shutter check.
2. Remove:
¡ Drain cock 1
(on heat exchanger)
¡ Hose clamp 2 (inlet hose)
3. Loosen:
¡ Clamps 5
4. Disconnect:
1
¡ Outlet hose 3 (seawater pump)
¡ Inlet hose 4 (seawater pump)
Drain the seawater.
NOTE:
3 ¡ After disconnecting a hose, shake, bend
or lift it up, to expel remaining seawater.
¡ If sand of dirt has clogged a drain hole,
5 use a needle or a similar tool to free it.
4 2
3-40
ADJ
5. Loosen:
¡ Clamps 1 (exhaust joint 2)
1 3
6. Disconnect:
¡ Cooling hose #5 3 (mixing elbow 4
to heat exchanger 5)
4 7. Remove:
¡ Mixing elbow 4
¡ Gasket
¡ Exhaust joint 2
1
1
1
8. Check:
¡ Seawater shutter 1
¡ Sealing rubber A
Unsmooth movement → Replace.
Refer to “EXHAUST COLLECTOR” on
page 7-9.
a
9. Install:
6 4 ¡ Exhaust joint 1
¡ Gasket 2 (new)
¡ Mixing elbow 3
2
New NOTE:
3
Install the gasket with the small holes A to
the side.
10. Connect:
6
¡ Cooling hose #5 4 (mixing elbow 3
1 to heat exchanger 5)
6 11. Tighten:
6
¡ Clamps 6
3-41
ADJ
12. Connect:
¡ Inlet hose 1 (seawater pump)
¡ Outlet hose 2 (seawater pump)
2
13. Install:
¡ Hose clamp 3 (inlet hose)
6
14. Tighten:
¡ Clamps 6
1 3
15. Install:
¡ Drain cock 1
Cooling System Flushing

1. Clean:
¡ Cooling system
Cooling system flushing steps

1) Remove the propeller (refer to “PROPEL-
LER SHAFT AND NUT INSPECTION” in
CHAPTER 3 of “DE-DHD STERN DRIVE
SERVICE MANUAL”), and fit the flush-
ing attachment 1 onto the cooling wa-
ter intake holes in the lower casing.
Connect the flushing attachment with a
garden hose 2 to a water tap.
CAUTION:
DO NOT operate the engine even briefly
without supplying cooling-water. It would
either damage the water pump or cause the
engine to overheat. Before starting the en-
gine, be sure to install the flushing attach-
ment and feed water.
¡ WARNING
Before flushing the engine, remove the pro-
peller. Keep yourself and others away from
the propeller shaft.
3-42
CHK COOLING SYSTEM / ELECTRICAL SYSTEM E
ADJ
2. Open the water tap just enough to allow
a low-pressure flow of water into the
flushing attachment.
CAUTION:
DO NOT open the water tap all the way to
avoid a high-pressure flow of water.
3. Shift into “NEUTRAL”, start the engine

and let it idle, to circulate water through
the cooling water passages. Let the en-
gine run until the discharged water is free
of dirt, contamination, and salt.
CAUTION:
While cooling system flushing, be sure to
keep the engine at idle speed.
Use a coolant temperature meter to moni-
tor the water temperature and make sure
the engine does not overheat.
4) When the water flow is clear, stop the

engine and turn off the water at the tap.
Disconnect the flushing attachment from
the lower casing.
5) Reinstall the propeller.
(Refer to “PROPELLER SHAFT AND NUT
INSPECTION“ in CHAPTER 3 of “DE-DHD
STERN DRIVE SERVICE MANUAL”)
ELECTRICAL SYSTEM
Battery Check
1. Check:
¡ Battery fluid level
Fluid level low → Fill to proper level.
NOTE:
Fluid level should be between the upper A
and the lower B mark.
CAUTION:
Refill with distilled water only; tap water
contains minerals harmful to a battery.
3-43
CHK ELECTRICAL SYSTEM E
ADJ
2. Check:
¡ Battery terminals
Terminal dirty → Clean with wire
brush.
Poor connection → Correct.
NOTE:
After cleaning the terminals, apply grease
lightly to the terminals.
3. Check:
¡ Specific gravity
Less than 1.280 → Recharge battery.
Specific gravity:
1.280 at 20 °C (68 °F)
The battery must be replaced when

¡ Battery voltage stays low or bubbles in
the fluid have not risen even after many
hours of charging.
¡ Sulfating, as indicated by the whitening
of plates, or sedimentation (dirt on the
bottom) is visible in one or more cells.
¡ Specific gravity after a long and slow
charge is significantly lower in one cell
than in the others.
¡ Warpage of buckling of plates or insula-
tors is visible.
CAUTION:
A new battery must be charged completely
before use to ensure maximum performance.
3-44
ADJ
¡ WARNING
Battery electrolyte is dangerous; it contains
sulfuric acid which is poisonous and highly
caustic.
Always follow these preventative 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 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 betteries 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.
3-45
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
Checking steps
1) Connect the digital multimeter to the fuse
and check it for continuity.
2) If the tester indicates ∞, the fuse is blown
and must be replaced.
1. Replace:
¡ Blown fuse
Replacement steps
1) Turn off the ignition.
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 immediately blows again,
check the electrical circuit.
No. Description Amperage
1 Meter 20 A
Power trim and tilt
2 100 A
motor
3 Charging system 100 A
¡ 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 ignition, and
possibly cause a fire.
3-46
CHK PERIODIC CHECKS AND ADJUSTMENTS E
ADJ
PERIODIC CHECKS AND
ADJUSTMENT
Thermostat Check
1. Check:
¡ Thermostat (valve opening tempera-
ture)
Out of specification → Replace.
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.
Thermostat valve opening temperature:

76.5 ± 2 °C (170 ± 2 °F)
2. Check:
¡ Thermostat (Valve lift)
NOTE:
Place the thermostat in the water and heat it.
Measure the valve lift when the water tem-
perature reaches at 85 °C (185 °F).
Thermostat valve lift:

10 mm (0.39 in.) or more
3-47
ADJ
Coolant Filler Cap Check
1. Check:
¡ Coolant filler cap (visual inspection)
Wear/Damage/Warpage/Cracks →
Replace.
NOTE:
Check for any wear, damage, warpage, or
cracks on gasket, sealing rubber, and lock-
ing tab of the coolant filler cap.
2. Check:
¡ Coolant filler cap (valve opening pres-
sure)
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 ± 0.15 kgf/cm2, 12.9 ± 1.4 psi)
3-48
ADJ
Cooling System Pressurize Check
1. Check:
¡ Cooling system (pressurize)
Pressure drop → Repair.
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 psi) pressure
on the cooling system, and check if any
pressure drop is detected.
NOTE:
Check for external leakage from the follow-
ing if pressure drop takes place.
¡ Hose
¡ Bypass pipe
¡ Heat exchanger
¡ Circulation pump
¡ Thermostat case
¡ Coolant pipe
¡ Heater cock
Check the following if there is no external
leakage.
¡ Exhaust manifold
¡ Cylinder block
¡ Cylinder head
3-49
REM E
INST
CHAPTER 4
ENGINE REMOVAL AND INSTALLATION
REMOVAL................................................................................................................................ 4-1
Drive Unit Removal ........................................................................................................... 4-1
Coolant and Seawater Draining ....................................................................................... 4-1
Hose and Lead Disconnection .......................................................................................... 4-1
Engine Removal ................................................................................................................. 4-3
CHECK ..................................................................................................................................... 4-4

Engine Mount ..................................................................................................................... 4-4
Mount Rubber Assembly Steps ........................................................................................ 4-5
INSTALLATION ....................................................................................................................... 4-5

Engine Installation ............................................................................................................. 4-5
Drive Unit Installation ........................................................................................................ 4-8
Hose and Lead Connections ............................................................................................. 4-9
4
REM REMOVAL E
INST
REMOVAL
Drive Unit Removal
1. Remove:
Drive unit assembly
Refer to “DRIVE UNIT REMOVAL” in
CHAPTER 4 of “DE-DHD STERN
DRIVE SERVICE MANUAL”.
Coolant and Seawater Draining

NOTE:
¡ When draining coolant cover all electri-
cal parts, accessory parts etc. with a plas-
tic 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 the water,
use the bilge pump. Then rinse the bot-
tom 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.
Hose and Lead Disconnection

1. Turn off the fuel cock on the fuel tank side
“OFF”.
2. Disconnect:
¡ Fuel inlet hose 1
¡ Return hose 2
¡ WARNING
Fuel in the bilge in a serious fire hazard.
Hold a small container or rag under the hose
nipples to catch spilling fuel. Clean up any
spilled fuel immediately with dry rags.
NOTE:
Put marks on the fuel hoses so that they can
be reinstalled in their original place.
4-1
REM REMOVAL E
INST
3. Disconnect:
¡ Extension wire harnesses
6 pin coupler ................................. 1
3 16 pin coupler ............................... 2
4. Disconnect:
5
¡ Power trim and tilt motor leads
Up relay (blue lead) ...................... 3
4
Down relay (green lead) .............. 4
1 2 Ground (black) .............................. 5
2 1 5. Disconnect:
¡ Hydraulic hoses 1
(from power steering control valve 2)
NOTE:
¡ Hold the open hose end into a container.
¡ Install caps and plugs on all open con-
nections to prevent dirt from entering the
hydraulic system.
6. Loosen:
¡ Hose clamps 1
(exhaust joint 2 – upper)
7. Disconnect:
¡ Ground wire 1
(from stud 2 on flywheel housing)
¡ Battery positive (+) lead 3
(from starter motor)
4-2
REM REMOVAL E
INST
8. Disconnect:
¡ Trim sender leads 1 (two)
¡ Trim limit switch leads 2 (two)
¡ Trailer switch leads 3 (three)
(from extension wire harness)
¡ Water inlet hose 4
(from seawater inlet tube 5 on gim-
bal housing)
9. Disconnect:
Throttle cable 1
10. Disconnect:
¡ Shift cable 1 (remote control side)
¡ Shift cable 2 (drive unit side)
Engine Removal
1. Attach a suitable hoist to the lifting brack-
ets 1 of the engine.
Remove slack from chain or strap.
¡ WARNING
DO NOT attach lifting sling or chain to
hanger 2 mounted on the joint pipe. This
hunger will not support the weight of the
engine and could break. The engine could
fall, causing personal injury or damage.
4-3
REM REMOVAL / CHECK E
INST
2. Remove:
¡ Screws 1 (left and right)
¡ Nuts 2
¡ Washers 3 (left and right)
3. Carefully lift the engine out of boat.
CHECK
Engine Mount
1. Check:
¡ Engine mount brackets 1 (front)
Cracks/Bends/Damage → Replace.
2. Tighten:
¡ Engine mount brackets (left and right)
Bolt (engine mount bracket):

117 N·m (11.9 kgf·m, 85 lbf·ft)
T.R
3. Check:
¡ Engine mount base 2 (front)
¡ Mount rubber 3
Cracks/Wear/Damage → Replace en-
gine mount base as a set.
4. Check:
¡ Engine mount (rear)
Refer to “GIMBAL HOUSING AND
TRANSOM PLATE” in CHAPTER 5 of
“DE-DHD STERN DRIVE SERVICE
MANUAL”.
4-4
REM CHECK / INSTALLATION E
INST
Mount Rubber Assembly Steps
¡ Pour a little water over the mount rub-
ber 1.
¡ Press the mount rubber into the transom
plate 2 until its lower flange A is
through the hole.
¡ Install the spacer collar 3 into the mount
rubber.
¡ Install the stopper plates 4 with the rub-
ber side B towards the transom plate.
¡ Install the bolt 5 and tighten the nut 6
to specification.
NOTE:
Apply Three Bond® TB-1322 to the engaging
part between the nut 6 and bolt 5 when
tightening the nut.
Nut (rear engine mount):

55 N·m (5.6 kgf·m, 40 lbf·ft)
T.R
INSTALLATION
Engine Installation
Reverse the “Engine Removal” procedure.
Note the following points.
1. Carefully lower the engine into the boat,
lining up the hole of the rear engine
mount with mount stud on the transom
plate. As the engine is lowered, connect
the exhaust joint 1 to the mixing elbow
2.
4-5
REM INSTALLATION E
INST
2. Check the position of the nuts 1 on the
intermediate plate to be sure that the flats
are parallel with the centerline of the
boat.
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 engine installation and
proper alignment will be impossible.
NOTE:
The engine flywheel casing is set on the stop-
per plate with a guide of the rear mount nut.
If nut is not positioned correctly, the engine
cannot be installed.
3. Install:
¡ Washers 1 (left and right)
¡ Nuts 2 (left and right)
(onto rear engine mount)
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:
¡ Nuts 2
Nut (rear engine mount):

55 N·m (5.6 kgf·m, 40 lbf·ft)
T.R
4-6
REM INSTALLATION E
INST
NOTE:
When the front mount bracket-to-boat lag
screws 1 have been removed, apply silicone
sealant to the threads of the lag screws.
Install and tighten the lag screws securely.
1 1
5. Release the hoist tension and remove the

lifting strap or chain. Attach the hoist to
the front lifting brackets 1 and steering
hanger 2 mounted on the joint pipe,
then remove slack from chain or strap.
6. Adjust:
¡ Engine alignment
Check and adjustment steps

¡ Insert the engine alignment tool 1
through the gimbal bearing 2 into the
crankshaft coupling.
NOTE:
¡ If the alignment tool slides in and out eas-
ily, the alignment is correct.
¡ 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.
4-7
REM INSTALLATION E
INST
1) Loose the front engine mount nuts 3.
2) Connect the hoist to the front lifting
bracket to raise or lower the front of the
engine.
3) Turn both front adjusting nuts 4 by the
same amount to align the engine: clock-
wise to lower it, counterclockwise to
raise it.
3 4
4) Lower the engine onto the adjusting nuts
and check the alignment again with the
alignment tool.
5) Repeat steps “3)” and “4)” until the
alignment tool can be inserted and re-
moved easily.
6) Tighten front engine mount nuts 3.
Front engine mount nut:

140 N·m (14.2 kgf·m, 100 lbf·ft)
T.R
Drive Unit Installation

1. Install:
¡ Drive unit assembly
Refer to “DRIVE UNIT REMOVAL” in
CHAPTER 4 of “DE-DHD STERN
DRIVE SERVICE MANUAL”.
NOTE:
¡ Stud 2 does not use a washer as it has
already a ground plate 3 attached.
¡ Tighten the nuts in two steps in the tight-
ening sequence shown.
Nut (drive unit assembly):

1st
T.R
30 N·m (3.1 kgf·m, 22 lbf·ft)

2nd
70 N·m (7.1 kgf·m, 50 lbf·ft)
Drive unit recommended oil:

Yamaha Gear Case Lube or
Hypoid Gearbox oil (SAE 90) GL-5
Oil level plug:

7 N·m (0.7 kgf·m, 5.2 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
REM INSTALLATION E
INST
Hose and Lead Connections
1. Connect:
¡ Leads
NOTE:
Match the color codes of the leads.
1 2. Connect:
2 4 3
¡ Hydraulic hoses
(to power steering control valve 2)
Large fitting 3:
34 N·m (3.5 kgf·m, 25 lbf·ft)
T.R
Small fitting 4:
15 N·m (1.5 kgf·m, 11 lbf·ft)
3. Connect:
¡ Return hose 2
NOTE:
Be sure to reconnect fuel hoses in their origi-
nal position.
1
4. Connect:
¡ Battery leads
CAUTION:
¡ Connect the positive lead first, then the
negative lead.
¡ Grease both battery terminals.
5. Fill:
¡ Crankcase
Refer to “Engine Oil and Oil Filter Re-
placement” on page 3-9.
Total amount:
9.2 L (2.02 lmp qt, 2.43 US qt)
4-9
REM INSTALLATION E
INST
6. Adjust:
¡ Shift cables
(drive unit 1 and remote control 2
side)
1 Refer to “SHIFT CABLE INSTALLA-
TION AND ADJUSTMENT” in CHAP-
TER 13 of “ENGINE INSTALLATION
MANUAL”.
2
7. Adjust:
¡ Idle speed
Refer to “Engine Idle Speed Adjust-
Engine idle speed:

600 – 650 r/min
4-10
ENG E
OVER
CHAPTER 5
ENGINE OVERHAUL
2-STAGE RATE COUPLING AND FLYWHEEL ........................................................................ 5-1

Removal .............................................................................................................................. 5-2
Disassembly ....................................................................................................................... 5-3
Check and Assembly ......................................................................................................... 5-3
Installation .......................................................................................................................... 5-6
TIMING BELT AND TIMING PULLEYS .................................................................................. 5-8

Removal .............................................................................................................................. 5-9
Check and Repair ............................................................................................................. 5-11
Installation ........................................................................................................................ 5-12
TIMING GEARS ..................................................................................................................... 5-17

Removal ............................................................................................................................ 5-18
Check and Repair ............................................................................................................. 5-22
Installation ........................................................................................................................ 5-25
CYLINDER HEAD................................................................................................................... 5-30

Removal ............................................................................................................................ 5-32
Disassembly ..................................................................................................................... 5-39
5
Check and Repair ............................................................................................................. 5-40
Assembly .......................................................................................................................... 5-56
Installtion .......................................................................................................................... 5-58
CYLINDER BLOCK................................................................................................................. 5-70

Removal ............................................................................................................................ 5-72
Disassembly ..................................................................................................................... 5-73
Check and Repair ............................................................................................................. 5-78
Assembly .......................................................................................................................... 5-94
Installation ...................................................................................................................... 5-102
ENG 2-STAGE RATE COUPLING AND FLYWHEEL E
OVER
2-STAGE RATE COUPLING AND FLYWHEEL
Connect to:
1 Rear end plate
2 Flywheel
3 2-stage rate coupling assembly
4 Flywheel housing bracket (right)
5 Flywheel housing
6 Flywheel housing bracket (left)
5-1
OVER
Removal
1. Remove:
¡ Starter motor
Refer to “STARTER MOTOR” on page
12-9.
2. Disconnect:
¡ Earth leads 1
3. Remove:
¡ Bracket 1
¡ Boost pipe 2
¡ Gaskets
¡ Power steering oil cooler 3
¡ Flywheel housing 4
¡ Flange
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
in all open connections.
4. Remove:
¡ 2-stage rate coupling assembly 1
5-2
OVER
5. Remove:
¡ Flywheel 1
¡ Rear end plate 2
Disassembly
NOTE:
Put marks A on the coupling 1 and outer
member 2 before removing so that they can
be replaced in the original position.
1. Remove:
¡ Bolts 1
¡ Coupling 2
¡ Damper collars 3
¡ Washers 4 (large)
¡ Bearing 5
¡ Washers 6 (small)
2. Remove:
1 2 3 4 ¡ Plate 1
¡ Damper 2
¡ Bearing 3
(from outer member 4)
Check and Assembly

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 1
5-3
OVER
2. Check:
¡ Flywheel 1
¡ Gear teeth 2
Burns/Chips/Roughness/Wear →
Replace flywheel assembly.
3. Check:
¡ Bearings 1
¡ Bearing contact surfaces
(on the outer member 2)
Wear/Cracks/Pitting → Replace cou-
pling assembly.
4. Check:
¡ Coupling assembly 1
Cracks/Damage → Replace coupling
assembly.
¡ Splines A (coupling)
Burrs/Wear/Damage → Replace cou-
pling assembly.
¡ Damper rubber B
Wear/Cracks/Damage → Replace cou-
pling assembly.
5. Check:
¡ Damper collars 1
pling assembly.
¡ Plate 2
assembly.
6. Check:
2 1 ¡ Outer member 1
assembly.
¡ Damper joint 2
pling assembly.
5-4
OVER
7. Install:
1 2 3 4 ¡ Plate 1
¡ Damper 2
¡ Bearing 3
(for outer member 4)
LT
271
NOTE:
4
¡ The holes A located on the plate 1 for
a the coupling assembly bolts must be
aligned with the right side (as seen from
the outer member 4) of the oval cut-outs
B on the outer member.
¡ Apply LOCTITE ® No. 271 to each stud
b
thread.
¡ Tighten both nuts simultaneously.
Nut (damper joint):

5.7 N·m (0.57 kgf·m, 4.1 lbf·ft)
T.R
¡ Bearing 1
¡ Damper collars 2
¡ Washers 3 (large)
¡ Coupling 4
¡ Bolts 5
¡ Washers 6 (small)
Bolt (coupling):
68 N·m (6.9 kgf·m, 49 lbf·ft)
T.R
NOTE:
¡ Align the matchmarks A of the coupling
and outer member.
¡ Tighten the bolts in several passes in a
crisscross pattern.
¡ Slight rotation at bearing 1 must be felt
when twisting coupling 4 by hand.
5-5
OVER
Installation
1. Install:
¡ Rear end plate 1
Bolt (rear end plate):
18 N·m (1.8 kgf·m, 13 lbf·ft)
T.R
2. Clean the matching surfaces of the fly-
wheel and crankshaft.
3. Install:
¡ Flywheel
(onto crankshaft)
Bolt (flywheel):
130 N·m (13.2 kgf·m, 94 lbf·ft)
T.R
NOTE:
Tighten the bolts in several passes in a criss-
cross pattern.
4. Install:
¡ 2-stage rate coupling assembly 1
Bolt (2-stage rate coupling

assembly):
T.R
30 N·m (3.1 kgf·m, 22 lbf·ft)
NOTE:
¡ Tighten the bolts in several passes in a
crisscross pattern.
¡ The round edge A of the washer 2 must
face the flywheel 3.
5-6
OVER
5. Install:
¡ Flywheel housing 1
¡ Gaskets (new)
¡ Boost pipe 3
¡ Bracket 4
6. Connect:
¡ Earth leads 5
7. Install:
¡ Starter motor
Refer to “STARTING SYSTEM” on
page 12-6.
5-7
ENG TIMING BELT AND TIMING PULLEYS E
OVER
TIMING BELT AND TIMING PULLEYS
35 N.m (3.6 kgf.m, 26 lbf.ft)
100 N.m (10.2 kgf.m, 72 lbf.ft)

10
3
2
1
8
7
31 N.m (3.2 kgf.m, 22 lbf.ft)

13 N.m (1.3 kgf.m, 9 lbf.ft)
Connect to:
1 Timing belt cover 7 #2 camshaft pulley
2 Camshaft timing pulley #1 8 Inner plate
3 Timing belt 9 Knock pin
4 Auto tensioner 0 Gasket
5 Timing belt idler pulley
6 Outer plate
5-8
OVER
Removal
1. Drain:
¡ Engine coolant
Refer to “Coolant and Seawater
Draining” on page 4-1.
2. Remove:
¡ Bracket 1
(with seawater strainer assembly 2)
¡ Cooling pipe #4 3
¡ Gasket 4
3. Remove:
b
4. Remove:
¡ Timing belt 1
2
a Removal steps
1) Turn the crankshaft pulley clockwise, and
1
4 align the grooves A on the #1 2 and #2
3 camshaft pulleys with the BDC marks
b B on the timing gear cover 4.
a 3
CAUTION:
By positioning the #1 cylinder at the BDC,
c interference between valves and pistons is
avoided, even if the camshaft is rotated.
NOTE:
d
If the timing belt is to be reused, draw a di-
d rection arrow C on the timing belt (in the
direction of the engine revolutions), and
make matching marks D on the pulleys and
timing belt.
5-9
OVER
2) Remove the auto-tensioner.
NOTE:
Auto-tensioner is a high-pressure hydraulic
cylinder.
Loosen the two bolts gradually and slowly
when removing it.
3) Remove the timing belt 1.
5. Remove:
¡ Idler pulley 1
1
6. Remove:
3
¡ Outer plate 1
a ¡ Camshaft timing pulley #2 2
¡ Inner plate 3
1
NOTE:
Make matching marks A on the outer plate
2 1 and timing pulley 2 for reference during
reinstallation.
7. Disconnect:
¡ Breather hose 1
8. Remove:
(with gasket)
5-10
OVER
9. Loosen:
¡ Bolt (camshaft timing pulley #1) 1
Loosen the bolt by three turns.
NOTE:
When loosing the timing pulley holding bolt,
hold the camshaft 2 with a wrench 3.
CAUTION:
Be careful not to damage the valve lifters
when holding the camshaft with the wrench
3.
10. Remove:
¡ Camshaft timing pulley #1 1
Use a universal puller. (Puller B set)
2.
NOTE:
Screw-in the pulley bolt 3 on the camshaft
by about three turns before use.
Puller B set:
09950-40011
 09951-04010 
 09952-04010 
 
 09953-04020 
 09954-04010 
 
 09955-04060 
or (90890-0741A)
¡ Bolt (camshaft timing pulley #1)

¡ Plate washer
¡ Set key
(from camshaft)
Check and Repair

1. Check:
¡ Timing belt 1
Refer to “Timing Belt Check” on page
3-24.
5-11
OVER
2. Check:
¡ Idler bearing movement
Unsmooth rotation → Replace idler
pulley assembly.
3. Check:
¡ Pulley bolt movement
(on the pulley)
Unsmooth operation → Replace idler
pulley assembly and pulley bolt as a
set.
Installation
1. Install:
¡ Set key
(to the camshaft)
¡ Plate Washer
¡ Bolt (timing pulley)
NOTE:
Align the set key with the key groove of the
timing pulley.
2. Tighten:
¡ Bolt (timing pulley)
NOTE:
When tightening the timing pulley holding
bolt, hold the camshaft with a wrench 2.
CAUTION:
Be careful not to damage the valve lifters
when holding the camshaft with the wrench
2.
Bolt (timing pulley #1):

100 N·m (10.2 kgf·m, 72 lbf·ft)
T.R
3. Remove any old gasket from the cylin-

der head and cylinder head cover.
4. Clean the sealing surfaces of the cylin-
der head and cylinder head cover with
non-residue solvent.
5-12
OVER
5. Apply:
¡ Three Bond® TB-1207B
(to cylinder head)
NOTE:
The cylinder head cover must be assembled
within 5 minutes of application, otherwise the
gasket material must be removed and reap-
plied.
6. Install:
(with gasket)
NOTE:
Tighten the bolts in a crisscross pattern from
the inside to outside.
7. Connect:
¡ Breather hose 2
8. Install:
¡ Inner plate 1
NOTE:
Align the knock pin A of the injection pump
drive gear with the knock pin hole B of the
inner plate and slot C of the camshaft tim-
ing pulley #2.
9. Install:
¡ Outer plate 1
NOTE:
Align the matchmarks A of the camshaft tim-
a
ing pulley #2 and outer plate.
1
Bolt (camshaft timing pulley #2):
31 N·m (3.2 kgf·m, 22 lbf·ft)
T.R
10. Install:
¡ Idler pulley 1
1
Bolt (idler pulley):
35 N·m (3.6 kgf·m, 26 lbf·ft)
T.R
5-13
OVER
b
11. Wipe off any trace of oil or water from
the pulleys, and keep them clean.
1
12. Align the grooves A on the camshaft tim-
a
ing pulleys #1 1 and #2 2 with the BDC
marks B on the timing gear cover 3.
3
b
CAUTION:
a 2 When turning the crankshaft, the valve
heads will hit against the piston top. Do not
turn it more than necessary.
13. Install:
1
¡ Timing belt 1
3
NOTE:
2 ¡ Install the timing belt in the following or-
4 der:
1) Camshaft timing pulley #2 2
2) Camshaft timing pulley #1 3
3) Timing belt idler pulley 4
c ¡ If reusing the timing belt , align with the
matching marks D made during removal,
and install the timing belt with the arrow
d
mark C pointing in the direction of the
engine revolution.
d
14. Install:
¡ Auto tensioner
Bolt (Auto tensioner):

13 N·m (1.3 kgf·m, 9 lbf·ft)
T.R
NOTE:
Retract the auto-tensioner before installation.
5-14
OVER
Installation steps
1) Retract the auto-tensioner with a press.
CAUTION:
Retract the auto-tensioner slowly. Damage
may result from the quick retraction.
2) Align the holes on the auto-tensioner,

and insert the hexagonal wrench (width
across flat: 1.27 mm (0.05 in.)) into it so
that it is kept retracted.
3) Secure the auto tensioner, and draw out
the hexagonal wrench.
15. Turn the crankshaft pulley clockwise and

check that each pulley aligns with the
timing marks (TDC mark) as shown in the
illustration.
If the marks do not align, remove the tim-
ing belt and readjust.
16. Remove any old gasket from the timing
gear cover and oil seal retainer.
17. Clean the sealing surfaces of the timing
gear cover and oil seal retainer with non-
residue solvent.
18. Check the gasket on the timing belt cover.
NOTE:
¡ If the gasket is damaged slightly, seal it
by applying Three Bond® TB-1207B.
¡ If the gasket is seriously damaged, install
a new one. In this case, make sure that
no fragment of the 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,
a
the gasket thickness must be kept evenly,
b 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 excessive length.
If there is any gap at the joint area, fill it
with Three Bond® TB-1207B.
Timing belt cover gasket:

11328-17030 (TOYOTA part No.)
5-15
OVER
19. Apply:
¡ Three Bond® TB-1207B A
a (to the oil seal retainer and timing
1207B
gear cover)
a
1207B
NOTE:
The timing belt cover must be assembled
within 5 minutes of application. Otherwise
the gasket material must be removed and
reapplied.
20. Install:
(with gasket)
21. Install:
¡ Gasket 1 (new)
22. Install:
¡ Bracket 1
23. Fill:
¡ Cooling system
Refer to “Coolant Replacement” on
page 3-37.
5-16
ENG TIMING GEARS E
OVER
TIMING GEARS
1
100 N.m(10 kgf.m,72 lbf·ft)
11
3
4
11
8
9
10
5
7
6
12
500 N.m(50 kgf.m,360 lbf·ft)
Connect to:
1 Camshaft oil seal retainer 7 Thrust plate
2 Injection pump drive gear 8 Crankshaft timing gear
3 Bearing 9 Oil pump drive gear
4 O-ring 0 Timing gear case cover
5 Idler gear shaft A Oil seal
6 Idler gear B Crankshaft pulley
5-17
ENG TIMING GEARS E
OVER
Removal
1. Remove:
¡ Drive belts
Refer to “Drive Belt Check” on page
3-21.
2. Remove:
¡ Timing belt
¡ Timing pulleys
3. Remove:
¡ Camshaft oil seal retainer
5-30.
4. Remove:
¡ Seawater pump
Refer to “SEAWATER PUMP” on page
8-12.
5. Remove:
¡ Power steering pump
Refer to “POWER STEERING PUMP”
on page 11-7.
6. Remove:
¡ Bolt (crankshaft pulley #1 1)
¡ Plate washer
Use the flange base 2 and the flange
holder 3.
NOTE:
Use a power wrench 4 if necessary.
Flange base:
09213-58013 or (90890-07501)
Flange holder:
09330-00021 or (90890-07451)
5-18
ENG TIMING GEARS E
OVER
7. Remove:
¡ Crankshaft pulley #1 1
Use the puller C set 2 and an adapter
3.
Pulley C set:
09950-50013
 09951-05010 
 09952-05010 
 
 09953-05020 
 09954-05020 
or (90890-0740A, 90890-07512)
Adapter:
09958-20010 or (90890-07511)
NOTE:
¡ Screw the two bolts of the puller more
than 8 mm (0.31 in.).
¡ Make sure the tool body is parallel with
the crankshaft pulley.
8. Remove:
1 ¡ Timing gear cover 1
Pry out timing gear cover.
CAUTION:
Be careful not to damage the gear cover and
gear case matching surfaces.
9. Check:
¡ Idler gear 1 thrust clearance
Use a thickness gauge.
Out of specification → Replace thrust
plate.
If necessary, replace the idler gear
and/or idler gear shaft.
Idler gear thrust clearance:

0.05 – 0.15 mm
(0.0020 – 0.060 in.)
<Limit>
Less than 0.30 mm (0.0118 in.)
5-19
ENG TIMING GEARS E
OVER
A 10. Check:
¡ Timing gear backlash
Use a dial indicator.
Out of specification → Replace gears
as a set.
Timing gear backlash:

0.05 – 0.15 mm
(0.0020 – 0.0060 in.)
<Limit>
B Less than 0.30 mm (0.0118 in.)
NOTE:
Measure the timing gear backlash at the fol-
lowing points:
Injection pump x idler gear
Crankshaft x idler gear
Oil pump x oil pump drive gear
11. Remove:
¡ Oil pump drive gear 1
Use the puller B set and the adapter
2.
Puller B set:
09950-40011
 09951-04010 
 09952-04010 
 
 09953-04020 
 09954-04010 
 
 09955-04060 
or (90890-0741A)
Adapter:
09958-20010 or (90890-07511)
NOTE:
Make sure the tool body is parallel with the
drive gear.
5-20
ENG TIMING GEARS E
OVER
12. Remove:
¡ Thrust plate 1
¡ Idler gear 2
¡ Idler gear shaft
13. Remove:
¡ Nut (injection pump drive gear)
Use the flange holder 1.
Flange holder:
09330-00021 or (90890-07451)
14. Remove:
¡ O-ring
15. Remove:
¡ Injection pump drive gear 1
Use the pulley C set 2 and the
adapter 3.
Puller C set:
09950-50013
 09951-05010 
 09952-05010 
 
 09953-05020 
 09954-05020 
or (90890-0740A, 90890-07512)
Adapter:
09958-20010 or (90890-07511)
NOTE:
than 8 mm (0.31 in.).
the drive gear.
5-21
ENG TIMING GEARS E
OVER
16. Remove:
¡ Crankshaft timing gear 1
Use the puller B set 2 and the adapter
3.
Puller B set:
09950-40011
 09951-04010 
 09952-04010 
 
 09953-04020 
 09954-04010 
 
 09955-04060 
or (90890-0741A)
Adapter:
09958-20010 or (90890-07511)
Check and Repair

1. Check:
¡ Gears
Burrs/Chips/Cracks/Damage →
Replace.
2. Check:
¡ Contacting surfaces A
(Idler gear 1 and idler gear shaft 2)
Pitting/Blue discoloration/Damage →
Replace gear and shaft as a set.
¡ Oil passages B
Contamination → Wash and blow out
oil passages.
3. Measure:
¡ Idler gear to gear shaft clearance
Measurement steps
1) Using a cylinder gauge, measure the in-
side diameter of the idler gear 1.
Idler gear inside diameter:

45.000 – 45.025 mm
(1.7717 – 1.7726 in.)
5-22
ENG TIMING GEARS E
OVER
2) Using a micrometer, measure the diam-
eter of the idler gear shaft 2.
Idler gear shaft diameter:

44.950 – 44.975 mm
(1.7697 – 1.7707 in.)
3) Calculate the idler gear to gear shaft

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

Idler gear inside diameter –
Idler gear shaft diameter
If out of specification, replace gear and
shaft as a set.
Idler gear to gearshaft:
clearance =
0.025 – 0.075 mm
(0.0010 – 0.0030 in.)
<Limit>
0.20 mm (0.0079 in.)
4. Check:
¡ Bearing 1
(injection pump drive gear)
Clean and lubricate, then turn the
bearing outer race with the finger.
Roughness → Replace.
Bearing replacement steps

1) Using the universal puller set 1 , remove
the bearing 2.
Puller B set:
09950-40011
 09951-04010 
 09952-04010 
 
 09953-04020 
 09954-04010 
 
 09955-04011 
or (90890-0741A)
Replacer set:
09950-60010
5-23
ENG TIMING GEARS E
OVER
2) Using an special tool 3 and press ma-
chine, press in a new bearing 2 tightly
against the shoulder of the drive gear 4.
Crankshaft pulley replacer:

09214-76011
5. Check:
¡ Timing gear cover 1
¡ Oil seal 2 (crankshaft)
¡ Oil seal 3 (injection pump drive gear)
Wear/Damage → Replace.
Oil seal replacement steps

(crankshaft front oil seal, injection pump
drive gear oil seal)
If the timing gear cover is removed from the

cylinder block.
1) Using a screwdriver and a hammer, tap
out the oil seal(s) 1.
2) Using a oil seal replacer 3, tap in the
new oil seal(s) until the oil seal surface
is flush with the edge of the timing gear
cover 2.
3) Apply marine grease to the oil seal lip.
Oil seal replacer:

09223-78010
Oil seal replacer:
09316-20011
5-24
ENG TIMING GEARS E
OVER
If the timing gear cover is installed on the
cylinder block.
1) Remove the oil seal(s) in the following
3 ways.
For the crankshaft oil seal and the drive
gear oil seal:
Use a screwdriver 3.
CAUTION:
Wind tape around the screwdriver’s tip and
take care not to scratch the crankshaft.

3) Using a oil seal replacer 1, tap in the
new oil seal(s) until the oil seal surface
is flush with the edge of the timing gear
cover.
Oil seal replacer:

09223-78010
Oil seal replacer:
09316-20011
Installation
NOTE:
¡ Thoroughly clean all parts to be as-
sembled.
¡ Before installing parts, apply clean engine
oil to all sliding and rotating surfaces.
1. Remove rests of old gasket from the tim-

ing gear cover and timing gear case.
2. Clean the sealing surfaces of the timing
gear cover and case with non-residue
solvent.
5-25
ENG TIMING GEARS E
OVER
3. Install:
¡ Set key
(to the crankshaft)
¡ Crankshaft timing gear 1
Use a cover, seal replacer 2, and a
hammer to tap in the timing gear.
Cover and seal replacer:
09223-00010
NOTE:
¡ Position the timing gear 1 so that the tim-
ing marks face A forward.
¡ Align the set key with the key groove of
the timing gear.
4. Install:
¡ Set key
(to injection pump drive shaft)
¡ Injection pump drive gear 1
¡ O-ring 2 (new)
NOTE:
drive gear.
5. Install:
¡ Nut (pump drive gear)
Use the flange holder 1 to hold the
pump drive gear.
Flange holder:
09330-00021 or (90890-07451)
Nut (pump drive gear):

100 N·m (10.2 kgf·m, 72 lbf·ft)
T.R
6. Install:
¡ Idler gear shaft 1
5-26
ENG TIMING GEARS E
OVER
7. Install:
¡ Idler gear 1
NOTE:
Align the idler gear timing marks “0” and “1”
with the crankshaft timing gear 2 mark “0”
and the injection pump drive gear 3 timing
mark “1” respectively, then mesh the gears.
8. Install:
¡ Thrust plate 1
Bolt (thrust plate):

40 N·m (4.1 kgf·m, 29 lbf·ft)
T.R
9. Install:
¡ Oil pump drive gear 1
Use a cover, seal replacer 2, and a
hammer to tap in the oil pump drive
gear.
NOTE:
gear.
Cover and seal replacer:

09223-00010
10. Apply:
(to groove of timing gear cover seal-
ing surface)
NOTE:
The timing gear cover must be assembled
within 5 minutes of application, otherwise the
material must be removed and reapplied.
5-27
ENG TIMING GEARS E
OVER
11. Install:
¡ Timing gear cover 1
Bolt (timing gear cover):

20 N·m (2.0 kgf·m, 14 lbf·ft)
T.R
1
NOTE:
Tighten the bolts in a crisscross pattern.
12. Install:
¡ O-ring 1 (new)
(in groove of crankshaft pulley #1)
13. Install:
¡ Set key
¡ Crankshaft pulley #1 1
NOTE:
¡ Align the set key with the key groove of
the pulley.
¡ Use an appropriate tool 2 and a hammer,
tap in the pulley.
14. Install:
¡ Plate washer
¡ Bolt (crankshaft pulley #1)
Use a flange holder 1 and a flange
base 2.
NOTE:
Use a power wrench 3 if necessary.
Flange base:
09213-58013 or (90890-07501)
Flange holder:
09330-00021 or (90890-07451)
Bolt (crankshaft pulley #1):

500 N·m (51.0 kgf·m, 360 lbf·ft)
T.R
5-28
ENG TIMING GEARS E
OVER
15. Install:
on page 11-7.
16. Install:
¡ Seawater pump
8-12.
17. Install:
5-30.
18. Install:
¡ Timing pulleys
¡ Timing belt
19. Install:
¡ Drive belts
3-24.
20. Fill:
¡ Cooling System
page 3-36.
5-29
ENG CYLINDER HEAD E
OVER
CYLINDER HEAD
Connect to:
1 Oil filler cap A Cylinder head K Valve lifter
2 Cylinder head cover B Screw grommets L Valve cotter
3 Gasket C Glow plug holder M Valve retainer
4 Camshaft D Glow plug N Valve spring
5 Set key E Leakage pipe O Spring seat
6 Camshaft bearing F Injection nozzle P Oil seal
7 Thrust plate G O-ring Q Valve
8 Lifting bracket (rear) H Gasket R Gasket
9 Valve guide I Clamp holder S Fuel return hose #2
0 Bearing cap J Shim
5-30
ENG CYLINDER HEAD E
OVER
Connect to:
1 Coolant filler cap A Throttle lever
2 O-ring B Throttle connecting rod
3 Exhaust manifold C Intake pipe
4 Gasket
5 Cooling pipe #4
6 Cooling pipe joint
7 Steering hanger
8 Intake manifold
9 Boost sender (option)
0 Boost compemsator hose
5-31
ENG CYLINDER HEAD E
OVER
Removal
1. Drain:
¡ Engine coolant
Mixing Elbow, Turbocharger and Variable

Boost Valve Assembly
1. Remove:
¡ Air filter assembly
¡ Mixing elbow
¡ Turbocharger
¡ Boost pipe
¡ Variable boost pipe assembly
Refer to “TURBOCHARGER” on page
10-1.
Fuel Filter Housing

1. Turn the main switch to “OFF”, and stop
the engine.
2. Shut the fuel cock on the fuel tank “OFF”.
3. Disconnect:
4. Remove:
¡ Band 2
5. Disconnect:
¡ Fuel delivery hose 2
6. Remove:
¡ Filter housing 3
(with fuel filter)
¡ Bracket 4
5-32
ENG CYLINDER HEAD E
OVER
Seawater Strainer and Cooling Pipe
1. Remove:
¡ Bracket 1
2. Remove:
¡ Cooling pipe 1
¡ Gasket 2
Intake Pipe and Inter Cooler

1. Loosen:
¡ Hose clamps 1
2. Remove:
¡ Intake pipe 2
¡ Gasket 3
¡ Hose 4
3. Install:
¡ Boost pipe 1
¡ Spacer 2
¡ Gaskets
4. Remove:
2 ¡ Bolt 1 (oil separator-clamp 2)
1 5. Disconnect:
¡ Seawater flow sensor leads 3
¡ Cooling hose 4
(from inter cooler)
3 ¡ Cooling hose 5
5
4
(from inter cooler)
5-33
ENG CYLINDER HEAD E
OVER
6. Remove:
¡ Inter cooler assembly 1
Injection Pipes and Intake Manifold

1. Remove:
¡ Injection pipes
¡ Leakage pipe
Refer to “INJECTION NOZZLES” on
page 6-1.
2. Disconnect:
¡ Boost compensator hose 1
¡ Throttle connecting rod 2
3. Remove:
¡ Nuts 1
¡ Seal washer 2
¡ Intake manifold 3
¡ Gaskets 4 (intake manifold)
5-34
ENG CYLINDER HEAD E
OVER
4. Remove:
¡ Steering hanger 1
¡ Cooling pipe joint 2
¡ Gasket 3 (cooling pipe joint)
Injection Nozzle and Glow Plug

1. Remove:
¡ Bolt 1
¡ Taper washer 2
¡ Nozzle holder 3
¡ Injection nozzle 4
¡ Gasket 5
NOTE:
Mark the injection nozzles carefully so that
they can later be reinstalled in their original
position.
2. Disconnect:
¡ Glow plug lead 1
3. Remove:
¡ Screw grommets 2
¡ Nuts 3
¡ Glow plug holder 4
4. Remove:
¡ Glow plug 1
5-35
ENG CYLINDER HEAD E
OVER
Exhaust Manifold
1. Remove:
¡ Cover 1 (starter relay)
2. Remove:
¡ Starter relay stay 1
3 3. Disconnect:
4
¡ Shift cable 1 (remote controller side)
¡ Shift cable 2 (drive side)
¡ Neutral switch coupler 3
1 4. Remove:
¡ Shift assist assembly 4
5. Remove:
¡ Turbocharger
10-1.
6. Remove:
¡ Bolt 1
¡ Thermostat housing 2
¡ Gasket 3
¡ Bolt 4
¡ Clamp 5
7. Remove:
¡ Heat exchanger
Refer to “HEAT EXCHANGER” on
page 8-18.
8. Remove:
¡ Power steering oil cooler
Refer to “POWER STEERING OIL
COOLER” on page 11-8.
5-36
ENG CYLINDER HEAD E
OVER
9. Remove:
¡ Exhaust manifold 1
¡ Bolt 2
¡ Joint 3
¡ Hose 4
10. Remove:
¡ Gaskets 1 (exhaust manifold)
¡ Power steering pump bracket 2
Cylinder Head Cover, Timing Belt and Pulley

1. Disconnect:
¡ Breather hose 1
2. Remove:
(with gasket)
3. Remove:
1
3 ¡ Timing belt 1
¡ Idler pulley 2
2 PULLEYS” on page 5-8.
4. Remove:
2 ¡ Bolts 1
1 3
¡ Camshaft oil seal retainer 2
(pry out the retainer from the cylin-
3 1
der head)
¡ Dowel pins 3
1 CAUTION:
1 Be careful not to damage the retainer and
cylinder head matching surfaces.
5-37
ENG CYLINDER HEAD E
OVER
Camshaft and Cylinder Head
1. Remove:
¡ Bolts 1
¡ Lifting bracket 2 (rear)
2. Remove:
¡ Bearing caps
NOTE:
¡ Loosen the bolts in the proper sequence.
Follow the numerical order shown in the
illustration.
¡ Start by loosing each bolt by half a turn
until they are all loose.
3. Remove:
¡ Bearings 1
(from #1 journal of cylinder head A
and #1 bearing cap 2)
¡ Thrust plate 3 (camshaft)
¡ Dowel pins
4. Remove:
¡ Bolts (cylinder head)
NOTE:
¡ Loosen the bolts in the proper sequence.
Follow the numerical order shown in the
illustration.
¡ Start by loosing each bolt by half a turn
until they are all loose.
5. Remove:
¡ Cylinder head 1
¡ Gasket (cylinder head)
¡ Dowel pins
NOTE:
If the cylinder head is difficult to lift off, pry
with a screwdriver between the cylinder head
and block.
5-38
ENG CYLINDER HEAD E
OVER
CAUTION:
Be careful not to damage the cylinder head
and cylinder block matching surfaces.
Disassembly
NOTE:
The valve seating should be checked before
removing the internal parts (valve, valve
spring, valve lifters etc.) of the cylinder head.
1. Remove:
¡ Valve lifters 1
¡ Shims 2
NOTE:
Identify the position of each valve lifter 1
and shim 2 very carefully so that they can
be reinstalled in their original places.
2. Check:
¡ Valve seating
Leakage at valve seat → Check the
valve face, valve seat and the valve
seat width.
Refer to “Valve Seat” on page 5-46.
Checking steps
1) Pour clean solvent into the intake and ex-
haust ports.
2) Check the valve seating.
¡ There should be no leakage at the
valve seat 1.
5-39
ENG CYLINDER HEAD E
OVER
3. Remove:
¡ Valve cotters 1
Valve spring compressor:

09202-70020
NOTE:
Attach the valve spring compressor 2 be-
tween the valve spring retainer and valve to
remove the valve cotters.
4. Remove:
¡ Spring retainer 1
¡ Valve spring 2
¡ Valve 3
¡ Spring seat 4
NOTE:
Identify the position of each part very care-
fully so that it can be reinstalled in its origi-
nal place.
5. Remove:
¡ Oil seal 1
Use needle-nose pliers.
Check and Repair

Piston and cylinder block top cleaning
1. Turn the crankshaft and bring each pis-
ton to top dead center (TDC). Using a
gasket scraper, remove all carbon from
the piston head and combustion cham-
bers.
2. Remove all the gasket material from the
top of the cylinder block and the bolt
holes.
NOTE:
Blow out carbon and foreign material with
compressed air.
CAUTION:
Be careful not to scratch the surfaces.
¡ WARNING
Protect your eyes when using compressed
air.
5-40
ENG CYLINDER HEAD E
OVER
Cylinder Head
1. Remove:
¡ Gasket material
(from cylinder head and manifold sur-
faces)
Use a gasket scraper.
CAUTION:
Be careful not to scratch the gasket contact
surface.
2. Wash the cylinder head thoroughly in

cleaning solvent using a soft brush.
3. Check:
¡ Cylinder head
Use dye penetrant.
Crack/Damage → Replace.
4. Measure:
¡ Cylinder head warpage
Use a straight edge and a thickness
gauge.
Cylinder head warpage:

5-41
ENG CYLINDER HEAD E
OVER
Valve and Valve Guide
1. Remove:
¡ Carbon deposit
(from valve)
Use a gasket scraper and wire brush.
2. Remove:
¡ Carbon deposit
(from valve guide inner surface)
Use a valve guide brush and solvent.
3. Measure:
¡ Stem to guide clearance
Measurement steps
1) Using a caliper gauge, measure the valve
guide inside diameter.
2) Using a micrometer, measure the valve

stem diameter.
Valve stem diameter

Intake:
7.975 – 7.990 mm
(0.3140 – 0.3146 in.)
Exhaust:
7.960 – 7.975 mm
(0.3134 – 03140 in.)
3) Calculate the stem to guide clearance

with following formula.
Stem to guide clearance =

Valve guide inside diameter –
Valve stem diameter
If out of specification, replace valve guide

and valve as a set.
5-42
ENG CYLINDER HEAD E
OVER
Stem to guide clearance

Intake:
0.020 – 0.055 mm
(0.0008 – 0.0022 in.)
<Limit> 0.08 mm (0.0031 in.)
Exhaust:
0.035 – 0.070 mm
(0.0014 – 0.0028 in.)
<Limit> 0.10 mm (0.0039 in.)
4. Replace:
¡ Valve guide
Replacement steps
1) Remove the valve guide using the valve
guide bushing remover and replacer set
1 and handle set.
2) Measure the valve guide bore diameter
using a caliper gauge 2.
3) Select a new valve guide from the fol-
lowing table.
Valve guide bush remover and re-

placer set:
09201-10000 (09201-01080)
or (90890-07601)
Handle set:
09950-70010 (09951-07200)
Valve guide bore

Valve guide size
diameter mm (in.)
13.004 – 13.025
Use STD
(0.5112 – 0.5128)
¡ If the valve guide bore diameter is larger

than 13.025 mm (0.5128 in.), machine the
valve guide bore to the following dimen-
sion and install an oversize guide.
Rebored valve guide bore:

13.054 – 13.075 mm
(0.5139 – 0.5148 in.)
¡ If the valve guide bore diameter is larger

than 13.075 mm (0.5148 in.), replace the
cylinder head.
5-43
ENG CYLINDER HEAD E
OVER
4) Tap a new valve guide 3 into the cylin-
der head to the specified height B, us-
ing the valve guide remover/installer 1.
Valve guide height B :

11.8 – 12.2 mm (0.465 – 0.480 in.)
Valve guide bush remover and re-

placer set:
09201-10000 (09201-01080)
or (90890-07601)
Handle set:
09950-70010 (09951-07200)
5) After installing the valve guide, bore the

valve guide using a valve guide reamer
4 to obtain proper stem to guide clear-
ance.
5. Check:
¡ Valve face
Pitting/Scratches → Grind the face.
Valve face angle:

44.5°
6. Check:
¡ Valve stem end
Mushroom shape or diameter larger
than rest of stem → Grind or replace.
CAUTION:
Do not grind off more than the minimum
overall length.
5-44
ENG CYLINDER HEAD E
OVER
7. Measure:
¡ Overall length A
Overall length
Intake:
103.29 – 103.69 mm
(4.0665 – 4.0823 in.)
<Limit>
102.79 mm (4.0468 in.)
Exhaust:
103.14 – 103.54 mm
(4.0606 – 4.0764 in.)
<Limit>
102.64 mm (4.0409 in.)
8. Measure:
¡ Margin thickness
Margin thickness
Intake:
1.6 mm (0.063 in.)
<Limit> 1.1 mm (0.043 in.)
Exhaust:
1.7 mm (0.067 in.)
<Limit> 1.2 mm (0.047 in.)
9. Measure:
¡ Runout (valve stem)
Runout limit:
0.01 mm (0.0004 in.)
NOTE:
¡ Always replace the guide if the valve is
replaced.
¡ Always replace the oil seal if the valve is
removed.
5-45
ENG CYLINDER HEAD E
OVER
Valve Seat
1. Check:
¡ Valve seat
Pitting/Carbon → Reface valve seat.
Use a 45° valve seat cutter.
NOTE:
Remove only enough metal to clean the
seats.
2. Measure:
¡ Valve seat width A
Out of specification → Reface valve
seat.
Valve seat width
Intake:
1.5 – 1.9 mm (0.059 – 0.075 in.)
Exhaust:
1.8 – 2.2 mm (0.071 – 0.087 in.)
Measurement 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
pattern. Do not rotate the valve.
4) Measure the valve seat width. Where the
valve seat and valve face make contact,
bluing will be removed.
5) If the valve seat is too wide, too narrow,
or the seat is not centered, the valve seat
must be refaced.
5-46
ENG CYLINDER HEAD E
OVER
3. Reface:
¡ Valve seat
Use 25°, 45°, 60°, and 70° valve seat
cutter.
CAUTION:
When turning the cutter, keep an even down-
ward pressure 40 – 50 N (4.1 – 5.1 kgf, 8.8 –
11.0 lbf) to prevent chatter marks.
Cut sections as follows:

Section Cutter
A 25°
B 45°
C IN: 70° EX:60°
Refacing steps
A The valve seat is centered on the valve

face but is too wide.
Action: Aim:
First:
To reduce
20° cutter
Use valve seat
lightly width to
Second:
specification
70°/60° cutter
B The valve seat is centered on the valve

face but it is too narrow.
Action: Aim:
To achieve a
Use uniform valve
45° cutter
lightly seat width to
specification
5-47
ENG CYLINDER HEAD E
OVER
C Valve seat is too narrow and is near the
valve margin.
Action: Aim:
First: To center the
25° cutter seat and to
Use achieve the
Second: specified
45° cutter width
D Valve seat is too narrow and is near the

bottom edge of the valve face.
Action: Aim:
First: To center the
70°/60° cutter seat and to
Use achieve the
Second: specified
45° cutter width
4. Lap:
¡ Valve face
¡ Valve seat
NOTE:
After refacing the valve seat or replacing the
valve and valve guide, the valve seat and
valve face should be lapped.
Lapping steps
1) Apply a coarse lapping compound A to
the valve face.
CAUTION:
Be sure no compound enters the gap be-
tween the valve stem and guide.
2) Apply molybdenum disulfide oil to the

valve stem.
4) Turn the valve until the valve face and
valve seat are evenly polished, then clean
off all compound.
5-48
ENG CYLINDER HEAD E
OVER
NOTE:
To obtain the best lapping result, 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 lapping compound from
the valve face and valve seat after every lap-
ping operation.
6) Apply mechanic's bluing dye (Dykem) B

to the valve face.
8) Press the valve through the valve guide
and onto the valve seat to make a clear
pattern.
9) Measure the valve seat width C. If the
valve seat width is out of specification,
reface and lap the valve seat again.
Valve Spring
1. Measure:
¡ Free length A (valve spring)
Free length (valve spring):

46.20 mm (1.8189 in.)
2. Measure:
¡ Installed tension A (valve spring)
Installed tension:
307 – 339 N
(31.3 – 34.5 kgf, 67.7 – 74.7 Ibf) at
37.0 mm (1.457 in.)
5-49
ENG CYLINDER HEAD E
OVER
3. Measure:
¡ Spring tilt A
Spring tilt limit:

2.0 mm (0.075 in.)
Valve Lifter
1. Check:
¡ Valve lifters
Scratches/Cracks/Damage → Replace.
If necessary, replace cylinder head.
2. Measure:
¡ Valve lifter bore diameter A
Use a caliper gauge.
Out of specification → Replace the cyl-
inder head.
Valve lifter bore diameter:

40.960 – 40.980 mm
(1.6126 – 1.6134 in.)
3. Measure:
¡ Valve lifter diameter B
Use a micrometer.
Valve lifter diameter:

40.892 – 40.902 mm
(1.6099 – 1.6103 in.)
5-50
ENG CYLINDER HEAD E
OVER
4. Calculate:
¡ Valve lifter to lifter bore clearance
(with following formula)
Valve lifter to lifter bore clearance
= Valve lifter bore diameter A –
Valve lifter diameter B
Out of specification → Replace lifter.

If necessary, replace cylinder head.
Valve lifter to lifter bore clearance:

0.058 – 0.083 mm
(0.0023 – 0.0033 in.)
<Limit>
0.10 mm (0.0039 in.)
Camshaft Bearing and Camshaft

1. Check:
¡ Camshaft bearings
Pitting/Scoring/Damage → Replace
bearings and cylinder head as a set.
If necessary, replace the camshaft.
2. Measure:
¡ Runout (camshaft)
Runout (camshaft):
3. Check:
¡ Cam lobes
Pitting/Scratches/Blue discoloration
→ Replace.
5-51
ENG CYLINDER HEAD E
OVER
4. Measure:
¡ Cam lobes height A
Cam lobes height

Intake:
54.440 – 54.460 mm
(2.1433 – 2.1441 in.)
<Limit> 53.94 mm (2.1236 in.)
Exhaust:
55.940 – 55.960 mm
(2.2024 – 2.2031 in.)
<Limit> 55.44 mm (2.1827 in.)
5. Measure:
¡ Camshaft to bearing clearance with
Plastigage®
Out of specification → Measure jour-
nal diameter (camshaft).
Camshaft to bearing clearance

#1 journal:
0.022 – 0.074 mm
(0.0009 – 0.0029 in.)
Other journals:
0.030 – 0.066 mm
(0.0012 – 0.0026 in.)
<Limit> 0.10 mm (0.0039 in.)
Measurement steps
1) Fit the camshaft bearings 1 to the #1
bearing cap 2 and #1 journal A of the
cylinder head.
NOTE:
Align the projection B on the bearing with
the notch C in the bearing cap and cylinder
head.
2) Clean the bearings and camshaft jour-

nals.
3) Place the camshaft on the cylinder head.
4) Position a strip of Plastigage® 3 on each
camshaft journal.
5) Install dowel pins and bearing caps.
Bolt (bearing cap) #1 journal:

25 N·m (2.5 kgf·m, 18 lbf·ft)
T.R
5-52
ENG CYLINDER HEAD E
OVER
NOTE:
¡ Tighten the bearing cap bolts in a criss-
cross pattern from the inner to the outer
caps.
¡ Do not turn the camshaft when measur-
ing the clearance.
6) Remove the bearing caps and measure

the width of the Plastigage®.
7) Remove the Plastigage®.
6. Measure:
¡ Journal diameter A (camshaft)
Out of specification → Replace cam-
shaft.
Within specification → Replace bear-
ings or camshaft.
If necessary, replace bearing caps and
cylinder head.
Journal diameter(camshaft)
No. 1 journal:
34.969 – 34.985 mm
(1.3767 – 1.3774 in.)
Others:
27.986 – 27.998 mm
(1.1018 – 1.1023 in.)
7. Measure:
¡ Camshaft thrust clearance
plate.
If necessary, replace camshaft.
Camshaft thrust clearance:

0.10 – 0.20 mm
(0.0039 – 0.0079 in.)
<Limit> 0.30 mm (0.0118 in.)
5-53
ENG CYLINDER HEAD E
OVER
Measurement steps
1) Install the camshaft.
Refer to “Camshaft” on page 5-61.
2) Using a dial indicator, measure the thrust

clearance while moving the camshaft
back and forth.
Cylinder head bolt

1. Check:
¡ Cylinder head bolt
Cracks/Scratches/Damage → Replace.
2. Measure:
¡ Cylinder head bolt diameter A
(at the narrower portion of the thread
– measuring point B)
Use verniel calipers.
Out of specification → Replace bolts
as a set.
Cylinder head bolt diameter:

10.800 – 11.000 mm
(0.4646 – 0.4724 in.)
<Limit> 10.55 mm (0.4154 in.)
5-54
ENG CYLINDER HEAD E
OVER
Camshaft Oil Seal Retainer and Oil Seal
2 1. Check:
¡ Oil seal 2 (camshaft)
1

If the camshaft oil seal retainer is removed
from the cylinder head.
1) Using a screwdriver and a hammer, tap
1
out the oil seal 1.
2) Using a suitable tool or removed oil seal

and a hammer, tap in a new oil seal until
its surface is flush with the oil seal re-
tainer edge.
If the camshaft oil seal retainer is installed

on the cylinder head.
1) Using a screwdriver, pry out the oil seal
1
1.
CAUTION:
¡ Take care not to scratch the camshaft 2.
2 ¡ Wind tape around the screwdriver tip.
2) Apply marine grease to a new oil seal

lip.
and a hammer, tap in the new oil seal
until its surface is flush with the oil seal
retainer edge.
5-55
ENG CYLINDER HEAD E
OVER
Intake and Exhaust Manifolds
1. Check:
¡ Intake manifold
¡ Exhaust manifold
Refer to “MIXING ELBOW AND EX-
HAUST MANIFOLD” on page 7-1.
2. Measure:
¡ Manifold warpage
(contacting surface to the cylinder
head)
gauge.
Manifold warpage:
A Exhaust ports side
B Intake ports side
Assembly
CAUTION:
sembled.
¡ Before installing the parts, apply clean en-
gine oil to all sliding and rotating sur-
faces.
¡ Replace all gaskets and removed oil seals
with new ones.
5-56
ENG CYLINDER HEAD E
OVER
Cylinder Head
1. Apply:
(to semicircular plug 1)
2. Install:
¡ Semicircular plug 1
(to cylinder head)
3. Install:
¡ Oil seal 1 (new)
¡ Valve 2
¡ Spring seat 3
¡ Valve spring 4
¡ Spring retainer 5
4. Install:
¡ Valve cotters 1
Valve spring compressor:

09202-70020
NOTE:
Install the valve cotters while compressing
the valve spring with the valve spring com-
pressor 2.
5. Secure the valve cotters onto the valve

stem by tapping lightly with a plastic-
faced hammer.
6. Install:
¡ Valve lifters 1
¡ Shims 2
NOTE:
¡ Apply engine oil to the valve lifters and
shims.
¡ All valve lifters and shims must be rein-
stalled in their original positions.
¡ The valve lifter must move smoothly
when rotated using a finger.
5-57
ENG CYLINDER HEAD E
OVER
Installtion
Cylinder Head Gasket Installation
1. Select:
¡ Cylinder head gasket (new)
Selection steps
Check the amount by which each piston pro-
trudes from the cylinder.
1) Thoroughly clean all the piston heads
and the cylinder block gasket surface.
2) Set the piston to be measured to slightly
before the TDC.
3) Place a dial indicator on the cylinder
block, and set the dial indicator at 0 mm
(0 in.).
NOTE:
¡ Position the measuring tip 1 of the dial
indicator 2 as shown in the illustration.
¡ Make sure that the measuring tip is
square to the cylinder block gasket sur-
face and piston head when making the
piston head protrusion A measurements.
4) Find where the piston head protrudes

most by slowly turning the crankshaft
clockwise and counterclockwise. If the
protrusion A is not as specified, remove
the piston and connecting rod assembly
and reinstall it correctly.
Refer to “CYLINDER BLOCK” on page 5-
70.
NOTE:
¡ Measure each cylinder at two places as
shown in the illustration, making a total
of twelve measurements.
¡ For the piston protrusion value of a cylin-
der, use the average of the two measure-
ments of each cylinder.
Piston protrusion:
0.475 – 00.725 mm
(0.0187 – 0.0285 in.)
5-58
ENG CYLINDER HEAD E
OVER
Select a new cylinder head gasket.
1) Select the largest piston protrusion value
from the measurements made, then se-
lect the appropriate cylinder head gas-
ket according to the table below.
NOTE:
There are five types of cylinder head gasket
(cutouts numbers 1 through 5) installed at
the factory, but only three types are supplied
as spare parts (cutouts numbers 1, 3 and 5).
When replacing the gasket select from one
of three types above.
Piston protrusion mm (in.) Gasket size

0.525 (0.0207) or less Use “1”
0.526 – 0.625
Use “3”
(0.0207 – 0.0246)
0.626 (0.0246) or more Use “5”
Cylinder Head
1. Turn the carnkshaft pulley, and align the
BDC mark A of the timing gear cover
with the flange groove B of the camshaft
timing pulley #2 1.
2. Install:
¡ Dowel pins 1
¡ Cylinder head gasket 2
NOTE:
Take care that the gasket is installed in the
correct direction.
3. Install:
¡ Cylinder head 1
NOTE:
¡ If any of the bolts are broken or deformed,
replace them as a set.
¡ Apply a light coat of engine oil on the
threads and under the heads of the bolts.
5-59
ENG CYLINDER HEAD E
OVER
4. Tighten:
Tightening steps
1) First, tighten the cylinder head bolts in
several passes in the sequence illus-
trated.
NOTE:
If any one of the bolts does not reach the
torque specification, replace the bolt.
2. Mark the front of the bolt head with paint

A.
3) Retighten the cylinder head bolts 90° in

the numerical order shown in above.
4) Retighten the cylinder head bolts an ad-
ditional 90° in the numerical order above.
Check that the painted mark is now fac-
ing rearward.
A Painted mark
Bolt (cylinder head)

1st:
T.R
70 N·m (7.1 kgf·m, 50 lbf·ft)

2nd:
turn 90°
3rd:
turn 90°
5-60
ENG CYLINDER HEAD E
OVER
Camshaft
1. Install:
¡ Thrust plate 1
¡ Camshaft bearings 2
(to #1 bearing cap 3 and #1 journal
A of the cylinder head)
NOTE:
Align the projection B of the bearings with
the notch C in the #1 bearing cap 3 and the
#1 journal A of the cylinder head.
2. Install:
¡ Camshaft
(onto cylinder head)
NOTE:
The key groove A should now face upward
.
3. Install:
¡ Dowel pins
¡ Bearing caps
NOTE:
The bearing caps are numbered from front
to rear.
4. Tighten:
¡ Bolt (bearing cap)
Bolt (bearing cap)

#1 journal:
T.R
25 N·m (2.5 kgf·m, 18 lbf·ft)

Others:
18 N·m (1.8 kgf·m, 13 lbf·ft)
5-61
ENG CYLINDER HEAD E
OVER
NOTE:
¡ Apply engine oil onto the bolt threads.
¡ Tighten the bolt in several passes in the
sequence illustrated.
5. Install:
¡ Lifting bracket 1 (rear)
(with engine harness holder 2)
Pulleys, Timing Belt and Cylinder Head

1. Remove any old packing material from
the camshaft oil seal retainer, cylinder
head and timing gear cover.
2. Clean the sealing and contact surfaces
of the retainer, cylinder head and timing
gear cover with non-residue solvent.
3. Apply:
(to camshaft oil seal retainer)
NOTE:
The retainer must be installed within 5 min-
utes of application, otherwise the material
a must be removed and reapplied.
1207B
4. Install:
2 ¡ Dowel pins 3
1 3
3 1 ¡ Bolts 1
Bolt (camshaft oil seal retainer):

1 20 N·m (2.0 kgf·m, 14 lbf·ft)
T.R
1 NOTE:
Carefully wipe off all excess TB-1207B.
5-62
ENG CYLINDER HEAD E
OVER
5. Install:
3
1 ¡ Idle pulley 2
¡ Timing belt 3
2 PULLEYS” on page 5-8.
6. Adjust:
¡ Valve clearance
Refer to “Valve Clearance Adjust-
Valve clearance (cold)

Intake valve:
0.15 – 0.25 mm
(0.006 – 0.010 in.)
Exhaust valve:
0.35 – 0.45 mm
(0.014 – 0.018 in.)
7. Install:
(with gasket)
8. Connect:
¡ Breather hose 2
Exhaust Manifold
1. Install:
¡ Gaskets 1 (new)
(exhaust manifold)
¡ Power steering pump bracket 2
NOTE:
Install the exhaust manifold gasket with the
gasket links A on the upper side.
5-63
ENG CYLINDER HEAD E
OVER
2. Install:
Bolt:
40 N·m (4.1 kgf·m, 29 lbf·ft)
T.R
Nut:
33 N·m (3.4 kgf·m, 24 lbf·ft)
NOTE:
Tighten the nut and bolt in two stages and in
a crisscross pattern.
¡ joint 2
3. Install
4. Install:
¡ Heat exchanger
page 8-18.
5. Install:
¡ Gasket 1 (new)
¡ Clamp 3
¡ Bolt 4
6. Install:
¡ Turbocharger
10-1.
3
4 7. Install:
¡ Hose holders
(Under the exhaust manifold)
1
8. Connect:
2 ¡ Shift cable 2 (drive side)
¡ Shift cable 1 (remote controller side)
9. Install:
5-64
ENG CYLINDER HEAD E
OVER
10. Install:
Injection Nozzle and Glow Plugs

1. Install:
¡ Glow plugs 1
Glow plug:
13 N·m (1.3 kgf·m, 9.4 lbf·ft)
T.R
2. Install:
¡ Glow plug holder 1
¡ Nuts 2
¡ Screw grommets 3
3. Connect:
¡ Glow plug lead 4
Nut (terminal):
3.0 N·m (0.3 kgf·m, 2.2 lbf·ft)
T.R
4. Install:
¡ Gasket 1 (new)
¡ Nozzle holder 3
¡ Taper washer 4
¡ Bolt 5
Injection nozzle:
39 N·m (4.0 kgf·m, 28 lbf·ft)
T.R
CAUTION:
Always use a new O-ring 1 for the injection
nozzle 2.
5-65
ENG CYLINDER HEAD E
OVER
NOTE:
Each injection nozzle must be reinstalled in
its original position.
Injection Pipes and Intake Manifold

1. Install:
¡ Gasket 1 (new)
¡ Cooling pipe joint 2
¡ Steering hanger 3
2. Install:
¡ Gasket 1 (new)
¡ Intake manifold 2
¡ Seal washer 3
¡ Nuts 4
NOTE:
If any of the seal washers are worn or dam-
aged, replace them.
Intake manifold:
20 N·m (2.0 kgf·m, 14 lbf·ft)
T.R
3. Connect:
5-66
ENG CYLINDER HEAD E
OVER
4. Install:
¡ Leakage pipe 2
¡ Gaskets 4 (new)
¡ Hollow bolts 3
Hollow bolt (leakage pipe):

12.5 N·m (1.25 kgf·m, 9.0 lbf·ft)
T.R
5. Connect:
¡ Fuel return hose 4
(to leakage pipe)
6. Install:
¡ Injection
Refer to “FUEL SYSTEM” on page
CHAPTER 6.
Intake Pipe and Inter Cooler

1. Install:
¡ Oil pressure sender bracket
2. Install:
2 ¡ Bolt 1 (oil separator clamp 2)
1 3. Connect:
¡ Cooling hose #3 5
(to inter cooler)
3 (to inter cooler)
5
4 ¡ Seawater flow sensor leads 3
4. Install:
¡ Gasket (new)
¡ Spacer 2
¡ Boost pipe 1
5-67
ENG CYLINDER HEAD E
OVER
5. Install:
¡ Hose 1
¡ Gasket 2 (new)
¡ Intake pipe 3
6. Tighten:
¡ Hose clamps 4
NOTE:
Put the hose clamps 4 in their original posi-
tion as shown in the illustration.
Seawater Strainer and Cooling Pipe #4

1. Install:
¡ Gasket 1 (new)
2. Install:
¡ Bracket 1
2
4 1 Fuel Filter and Housing
1. Install:
¡ Bracket 2
¡ Filter housing 1
(with fuel filter)
2. Connect:
3 ¡ Fuel inlet hose 3
5-68
ENG CYLINDER HEAD E
OVER
3. Connect:
4. Install:
¡ Band 2
Mixing Elbow, Turbocharger and Variable

Boost Valve Assembly
1. Install:
¡ Variable boost valve assembly
¡ Boost pipe
¡ Turbocharger
¡ Mixing elbow
CHAPTER 10.
2. Fill:
¡ Cooling system
page 3-36.
5-69
ENG CYLINDER BLOCK E
OVER
CYLINDER BLOCK
Connect to:
1 Spring A Rear end plate
2 Relief valve B Gasket
3 Timing gear case (oil pump assembly) C Oil strainer
4 Cylinder block D Oil pan
5 Main bearing cap E Oil nozzle
6 Oil pressure switch D Check valves
7 Oil pressure sender G Drain cock
8 Elbow joint H Orifice
9 Crankshaft oil seal retainer
0 Oil seal
5-70
OVER
Connect to:
1 Top ring A Bearing (connecting rod)
2 2nd ring B Set key
3 Oil ring C Crankshaft
4 Snap ring D Flywheel
5 Piston E Main bearing
6 Piston pin
7 Connecting rod bushing
8 Connecting rod
9 Connecting rod cap
0 Thrust washer
5-71
OVER
Removal
1. Drain:
¡ Engine oil
Refer to “Engine Oil and Oil Filter Re-
placement” on page 3-9.
2. Drain:
¡ Engine coolant
3. Before disassembling the cylinder block,
remove the following parts:
¡ Cylinder head
5-30.
¡ Starter motor
¡ Flywheel housing
¡ 2-stage rate coupling assembly
¡ Flywheel
¡ Rear end plate
Refer to “2- STAGE RATE COUPLING
AND FLYWHEEL” on page 5-1.
¡ Alternator
¡ Engine wire harness
Refer to “ELECTRICAL SYSTEM” on
page CHAPTER 12.
¡ Thermostat housing
¡ Heat exchanger
¡ Seawater pump
8-12.
¡ Injection pump
Refer to “INJECTION PUMP” on page
6-17.
¡ Timing gears
Refer to “Timing Gears” on page 5-
18.
¡ Timing gear case
¡ Oil cooler
¡ Tension rod
¡ Oil pan
¡ Oil strainer
Refer to “LUBRICATION SYSTEM” on
page CHAPTER 9.
5-72
OVER
4. The engine should be on an engine stand
1 for disassembly.
NOTE:
Place the engine upside down.
A B 5. Remove:
¡ Engine brackets 1
(left and right )
6. Remove:
¡ Oil pressure sender 1
¡ Oil pressure switch 2
¡ Gasket (oil pressure switch)
¡ Oil pressure switch joint 3
7. Remove:
¡ Bracket 1 (control unit)
¡ Bracket 2 (heat exchanger)
Disassembly
Connecting rod and piston
1. Remove:
Crankshaft oil seal retainer 1
5-73
OVER
2. Remove:
¡ Connecting rod caps 1
(With lower bearing)
NOTE:
Put identification marks A on each connect-
ing rod cap 1 and connecting rod 2 for ref-
erence during reinstallation.
3. Remove:
¡ Connecting rods 1
(with upper bearing and piston
through top of cylinder block)
4. Remove:
¡ Connecting rod bearings 1 (lower)
(from connecting rod cap 2)
¡ Connecting rod bearings 3 (upper)
(from connecting rod 4)
NOTE:
Identify the position of each bearing very
carefully so that the bearings can be rein-
stalled in their original positions.
Main Bearing Cap and Crankshaft

1. Remove:
¡ Holding bolts (main bearing cap)
NOTE:
Remove the main bearing cap holding bolts
in a crisscross pattern from the outside to
inside.
2. Remove:
¡ Bolts (main bearing cap)
NOTE:
¡ Loosen the bearing cap bolts, following
the numerical order shown in the illus-
tration.
¡ Start by loosing each bolt half a turn until
all are loose.
5-74
OVER
3. Remove:
¡ Main bearing cap 1
(with lower main bearings)
NOTE:
If the main bearing cap is difficult to lift off,
use a screwdriver to pry between the bear-
ing cap and the cylinder block.
CAUTION:
Be careful not to damage the main bearing
cap and cylinder block matching surfaces.
4. Remove:
¡ Thrust washers 1
NOTE:
Identify the position of each thrust washer
very carefully so that the washers can be re-
installed in their original positions.
5. Remove:
¡ Crankshaft 1
6. Remove:
¡ Main bearings 1 (upper)
(from cylinder block)
¡ Main bearings 2 (lower)
(from main bearing cap)
NOTE:
Identify the position of each bearing very
carefully so that the bearings can be rein-
stalled in their original position.
5-75
OVER
7. Remove:
¡ Check valves 1
¡ Oil nozzles 2
8. Remove:
¡ Gasket 1 (oil passage, bottom of cyl-
inder block)
¡ Oil passage orifice 2
(onto top of cylinder block)
CAUTION:
Be sure to handle the oil passage orifice care-
fully and reinstall it thoroughly.
Piston and Connecting Rod Disassembly

NOTE:
Before disassembling the piston and 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:
¡ Connecting rod free play
Any free play along the piston pin →
Replace the piston and piston pin as
a set.
2. Remove:
¡ Compression rings
¡ Oil ring
Use a piston ring expander.
5-76
OVER
3. Remove:
¡ Spring (oil ring)
NOTE:
Identify the position of each ring carefully so
that the rings can be reinstalled in their origi-
nal positions.
4. Remove:
¡ Snap rings 1
Use a small screwdriver.
5. Gradually heat the piston to approx

80 °C (176 °F).
6. Remove:
¡ Piston pin
¡ Connecting rod
NOTE:
¡ Using a plastic-faced hammer and brass
bar, lightly tap out the piston pin.
¡ Identify the position of each piston, pis-
ton pin and connecting rod very carefully
so that they can be reinstalled in their
original positions.
5-77
OVER
Check and Repair
Piston and Cylinder Block
1. Check:
¡ Piston wall
Excessive vertical scratches/Damages
→ Replace piston.
If necessary, replace pistons and cyl-
inder block as a set.
2. Remove:
¡ Score marks and lacquer deposits
(from sides of piston)
Use a 600 – 800 grit wet sandpaper.
NOTE:
Sand in a crisscross pattern. Do not sand
excessively.
3. Eliminate:
¡ Carbon deposits
(from piston crown and ring grooves)
Use a gasket scraper 1 and a broken
ring 2.
4. Thoroughly wash the cylinder head in

cleaning solvent using a soft brush.
CAUTION:
Do not use a wire brush.
5-78
OVER
5. Check:
¡ Cylinder walls
Excessive vertical scratches/Damage
→ Replace the cylinder block and the
pistons as a set.
6. Eliminate:
¡ Gasket material
(from the cylinder block surface)
NOTE:
surface.
7. Using a soft brush and solvent, clean the

cylinder block.
8. Check:
¡ Cylinder block
Use dye penetrant.
9. Measure:
¡ Cylinder block warpage
Use a straight edge 1 and a thickness
gauge.
Cylinder block warpage:
5-79
OVER
10. Measure:
¡ Piston to cylinder clearance
Measurement steps
First step
1) Using a micrometer, measure the piston
diameter A at the specified height B.
NOTE:
There are three sizes of standard piston di-
ameter, marked C 1, 2 and 3. The mark C is
stamped on the top of the piston.
Measuring height B :
67.5 mm (2.5866 in.)
Piston diameter
Mark “1”:
93.95 – 93.96 mm
(3.6988 – 3.6992 in.)
Mark “2”:
93.96 – 93.97 mm
(3.6992 – 3.6996 in.)
Mark “3”:
93.97 – 93.98 mm
(3.6996 – 3.7000 in.)
2nd step
1) Using a cylinder gauge, measure the cyl-
inder bore D.
If out of specification, rebore or replace
the cylinder, and replace the pistons and
piston rings as a set.
NOTE:
Measure the cylinder bore D in parallel to
and at right angles to the crankshaft. Then
take the greater of the measurements.
5-80
OVER
NOTE:
There are three sizes of standard cylinder
bore diameter, marked (E) “1”, “2” and “3”.
The mark E is stamped on the upper left rear
of the cylinder block.
Cylinder bore diameter E

67.5 mm (2.5866 in.)
Mark “1”:
94.000 – 94.010 mm
(3.7008 – 3.7012 in.)
Mark “2”:
94.010 – 94.020 mm
(3.7012 – 3.7016 in.)
Mark “3”:
94.020 – 94.030 mm
(3.7016 – 3.7020 in.)
<Limit>
STD: 94.23 mm (3.7098 in.)
3rd step
1) Calculate the piston to cylinder clearance
with the following formula:
Piston to cylinder clearance =

Cylinder bore D – Piston diameter A
If out of specification, rebore or replace

the cylinder, and replace the pistons and
piston rings as a set.
Piston to cylinder clearance

STD:
0.04 – 0.06 mm
(0.0016 – 0.0024 in.)
<Limit>
NOTE:
When installing a standard piston, install one
with the same number mark F as the stan-
dard bore diameter mark on the cylinder
block.
5-81
OVER
Piston Ring
1. Measure:
¡ Ring groove clearance A
Out of specification → Replace piston.
NOTE:
Install new piston rings (top 1 and 2nd 2)
and oil rings on the piston. Using a thickness
gauge 3, measure the clearance between the
ring and wall of the piston ring groove.
Ring groove clearance

Top ring:
0.050 – 0.095 mm
(0.0020 – 0.0037 in.)
2nd ring:
0.06 – 0.10 mm
(0.0024 – 0.0039 in.)
Oil ring:
0.03 – 0.07 mm
(0.0012 – 0.0028 in.)
2. Position:
¡ Piston ring
(into cylinder)
NOTE:
Push the ring with the piston crown so that
the ring is at right angles to the cylinder bore.
A 150 mm (5.91 in.)
3. Measure:
¡ End gap
5-82
OVER
End gap
Top ring:
0.27 – 0.54 mm
(0.0106 – 0.0213 in.)
<Limit>
1.34 mm (0.0591 in.)
2nd ring:
0.40 – 0.62 mm
(0.0157 – 0.0244 in.)
<Limit>
1.42 mm (0.0551 in.)
Oil ring:
0.20 – 0.52 mm
(0.0079 – 0.0205 in.)
<Limit>
1.32 mm (0.0520 in.)
Connecting Rod and Piston Pin

1. Check:
¡ Connecting rod 1
¡ Connecting rod cap 2
Cracks/Bends/Damage → Replace
connecting rod assembly.
2. Measure:
¡ Connecting rod bend A
Use rod aligner.
Out of specification → Replace con-
necting rod assembly.
Connecting rod bend:

<Limit>
0.03 mm (0.0012 in.) per
100 mm (3.94 in.)
3. Measure:
¡ Connecting rod twist A
Use rod aligner.
Out of specification → Replace con-
necting rod assembly.
Connecting rod twist:

<Limit>
0.15 mm (0.0059 in.) per
100 mm (3.94 in.)
5-83
OVER
4. Check:
¡ Piston pin 1
¡ Connecting rod bushing 2
Blue discoloration/ Wear/Damage →
Replace piston pin and bushing as a
set.
5. Measure:
¡ Piston pin to bushing clearance
Measurement steps
1) Measure the piston pin diameter A.
If out of specification, replace the piston
pin.
Piston pin diameter:

33.000 – 33.012 mm
(1.2992 – 1.2997 in.)
2) Measure the connecting rod bushing in-

side diameter B.
Bushing inside diameter:

33.008 – 33.020 mm
(1.2992 – 1.3000 in.)
3) Calculate the piston to bushing clearance

using the following formula.
Piston pin to bushing clearance =

Bushing inside diameter B –
Piston pin diameter A
4) If out of specification, replace the con-

necting rod bushing.
Piston pin to bushing clearance:

0.004 – 0.0012 mm
(0.0002 – 0.0005 in.)
<Limit> 0.03 mm (0.0012 in.)
5-84
OVER
Connecting rod bushing replacement steps
1) Press out the bushing 1, using the re-
mover/replacer 2 and the base 3.
Connecting rod bush remover and

replacer:
09222-17011
 09222-05021 
 
 09222-05041 
or (90890-07602)
2) Lightly file off any roughness from the

small end of the connecting rod.
3) Attach the bushing 1 to the guide 4 with

the ball A of the guide inside the oil hole
B of the bushing.
Connecting rod bush remover and

replacer:
09222-17011
 09222-05031 
 
4) Press in the bushing 1 into the small end

of the connecting rod, using the remover
and replacer 2, guide 4 and base 3.
NOTE:
Align the oil holes B of the bushing and con-
necting rod.
5-85
OVER
5) Using a pin hole grinder, hone the bush-
ing to obtain the standard specified pis-
ton pin to bushing clearance.
Piston pin to bushing clearance:

0.004 – 0.012 mm
(0.0002 – 0.0005 in.)
6) Lubricate the piston pin 5 with engine

oil, and push it into the connecting rod.
Check for free movement.
Crankshaft and Bearings

1. Measure:
¡ Crankshaft runout
(at the center journal A)
Crankshaft runout:
2. Check:
¡ Main journal surfaces
¡ Crank pin surfaces
¡ Bearing surfaces
Scratches/Pitting Damage → Replace
bearings.
If necessary, grind or replace the
crankshaft.
3. Measure:
¡ Main journal diameter A
¡ Crank pin diameter B
Use micrometer.
Out of specification → Check oil clear-
ance.
5-86
OVER
Main journal diameter

STD: 66.982 – 67.000 mm
(2.6371 – 2.6378 in.)
Crank pin diameter
STD: 58.982 – 59.000 mm
(2.3221 – 2.3228 in.)
4. Measure:
¡ Taper and out-of-round (of main jour-
nals and crank pins)
Out of specification → Replace the
crankshaft.
Taper and out-of-round:

5. Measure:
¡ Main journal oil clearance
Out of specification → Replace bear-
ings.
If necessary, replace the crankshaft.
Main journal oil clearance:

0.036 – 0.054 mm
(0.0014 – 0.0021 in.)
<Limit> 0.10 mm (0.0039 in.)
Measurement steps
CAUTION:
Do not intercharge the bearings and cylin-
der block and bearing caps. They must be
reinstalled in their original positions, or the
correct oil clearance may not be obtained,
causing engine damage.
1) Clean each main journal, bearing and

bearing portion of the cylinder block and
the bearing cap.
2) Install the lower half of the bearings 1
and crankshaft 2 on the cylinder block.
NOTE:
Align the projection A of the bearing with
the notch B in the cylinder block.
5-87
OVER
3) Put a piece of Plastigage® 3 on each
main journal.
NOTE:
Do not put the Plastigage® 3 over the oil hole
in the main journal of the crankshaft.
4) Install the upper half of the bearings 2

into the bearing cap 4 and assemble the
bearing cap.
5) Tighten the bolts to specification in the

sequence illustrated.
Bolt (main bearing cap)

1st:
T.R
105 N·m (10.7 kgf·m, 75 lbf·ft)

2nd:
turn 90°
NOTE:
Do not turn the crankshaft while measuring
the clearance.
6) Remove the bearing caps and measure

the width of the Plastigage®.
If oil clearance is out of specification,
select a replacement bearing from the
following table.
Refer to next page.
5-88
OVER
Crankshaft number marked
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
number marked 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:
Main bearing cap (E) + Crankshaft (7)
= (4) → 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 that case, 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.
¡ If the applicable bearing number cannot
be determined, refer to the table to select
the correct bearing based on the numbers
marked on the main bearing cap and the
crankshaft.
¡ There are four sizes of standard bearing,
marked 3, 4, 5, and 6.
5-89
OVER
6. Measure:
¡ Crank pin oil clearance
Out of specification → Replace bear-
ings.
If necessary, replace the crankshaft.
Crank pin oil clearance:

0.036 – 0.054 mm
(0.0014 – 0.0021 in.)
<Limit> 0.10 mm (0.0039 in.)
Measurement steps
CAUTION:
Do not intercharge the bearings and connect-
ing rods. They must be installed in their origi-
nal positions, or the correct oil clearance may
not be obtained, causing engine damage.
1) Clean the bearings, crank pins and bear-

ing portions of the connecting rods.
2) Install the upper half of the bearing 1
into the connecting rod 2 and lower half
of the bearing 3 into the connecting rod
cap 4.
NOTE:
Align the projection A of the bearing with
the notch B of the cap and connecting rod.
3) Put a piece of Plastigage® 5 on the crank

pin.
4) Install the connecting rod assembly onto

the crankshaft.
NOTE:
¡ Match the numbered connecting rod cap
with the appropriate connecting rod.
¡ Install the connecting rod cap with the
front mark C facing forward.
5-90
OVER
5) Tighten the bolts to specification.
Bolt (connecting rod cap)

1st:
37 N·m (3.8 kgf·m, 27 lbf·ft)
2nd:
turn 90°
NOTE:
Do not turn the crankshaft while measuring
the clearance.
6) Remove the connecting rod caps and

measure the width of the Plastigage®.
If the oil clearance is out of specification,
select a replacement bearing from the
following table.
Number marked
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) + Crankshaft (1) =
Total (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
adding together the numbers punched on
the crankshaft and connecting rod, then
selecting a bearing with the same num-
ber as the total.
¡ There are five sizes of standard bearings,
marked 2, 3, 4, 5, and 6.
5-91
OVER
Main Bearing Cap and Connecting Rod Cap
Bolts
1. Check:
¡ Main bearing cap bolts
¡ Connecting rod cap bolts
Cracks/Scratches/Damage →
Replace.
2. Measure:
¡ Main bearing cap bolt diameter A
¡ Connecting rod cap bolt diameter B
(at point where thread is compressed
C)
Out of specification → Replace the
bolts as a set.
Main bearing cap bolt diameter:

11.800 – 12.000 mm
(0.4646 – 0.4724 in.)
<Limit> 11.50 mm (0.4528 in.)
Connecting rod cap bolt diameter:
8.300 – 8.400 mm
(0.3268 – 0.33007 in.)
<Limit> 7.95 mm (0.3130 in.)
Crankshaft Oil Seal Retainer and Oil Seal

1. Check:
¡ Crankshaft oil seal retainer 1
¡ Oil seal 2 (crankshaft)

If the crankshaft oil seal retainer has been
removed from the cylinder block.
1) Using a screwdriver and hammer, tap out
the oil seal 1.
5-92
OVER
and a hammer, tap in a new oil seal until
its surface is flush with the oil seal re-
tainer edge.
If the crankshaft oil seal retainer is installed

on the cylinder block.
1) Using a knife, cut off the oil seal lip A.
2) Using a screwdriver, pry out the oil seal
1.
CAUTION:
¡ Wind tape around the screw driver tip.
¡ Take care not to scratch the crankshaft.
3) Apply marine grease to the new oil seal

lip.
and a hammer, tap in the oil seal until its
surface is flush with the oil seal retainer
edge.
Oil Passage orifice and Oil Nozzle

1. Check:
¡ Oil passage orifice 1
¡ Oil nozzle 2
Damage → Replace.
Clog → Blow out with compressed air.
5-93
OVER
Assembly
CAUTION:
sembled.
¡ Before installing the parts, apply clean en-
gine oil to all sliding and rotating sur-
faces.
¡ Replace all gaskets and oil seals with new
ones.
Piston and Connecting Rod Assembly

1. Install:
¡ Snap ring 1 (new)
(on one side of the piston pin hole)
NOTE:
Position the snap ring so that end A of the
snap ring is aligned with the notch, then push
the snap ring into the piston groove starting
from end B.
2. Gradually heat the piston to approxi-

mately 80 °C (176 °F).
3. Lubricate:
¡ Piston pin 1
(with a light coat of engine oil)
4. Connect:
¡ Piston 2 (to connecting rod 3 with
piston pin 1)
NOTE:
¡ Align the front mark A (arrow) of the pis-
ton with the front mark B (protrusion) of
the connecting rod.
¡ Each piston, connecting rod and piston
pin must be reinstalled in its original po-
sition.
5. Install:
¡ Snap ring (new)
(onto other side of piston pin hole)
5-94
OVER
6. Install:
¡ Spring (oil ring)
¡ Oil ring
NOTE:
Make sure the end gap A of the oil ring 2
faces in the opposite direction to the spring
joint B.
7. Install:
Compression ring 1 (2nd)
Compression ring 2 (top)
NOTE:
¡ Install the rings with the code mark fac-
ing A upward.
¡ Offset the piston ring end gaps as shown
in the illustration.
3 Oil ring
4 Spring joint (oil ring)
Crankshaft and Main Bearing Cap

1. Install:
Oil passage orifice 1
(onto top of cylinder block)
Gasket 2 (oil passage, bottom of cylin-
der block)
5-95
OVER
2. Install:
¡ Oil nozzles 1
¡ Check valves 2
Check valve:
27 N·m (2.8 kgf·m, 19 lbf·ft)
T.R
NOTE:
Align the projection A of the oil nozzle with
the hole B in the cylinder block.
3. Install:
¡ Main bearings 1 (lower)
(onto main bearing cap)
¡ Main bearings 2 (upper)
(onto cylinder block)
NOTE:
¡ Align the projection A of each bearing
with the groove B of the cap and cylin-
der block.
¡ Align the oil holes C of the bearing and
cylinder block.
¡ Each bearing must be reinstalled in its
original position.
4. Lubricate:
¡ Main bearings
(with light coat of engine oil)
5. Install:
¡ Crankshaft 1
6. Install:
¡ Thrust washers 1
NOTE:
Install the thrust washers at the #4 main jour-
nal position of the cylinder block with the oil
grooves facing outward.
5-96
OVER
NOTE:
Position the tab of the thrust washers 1 as
shown in the illustration.
7. Check:
¡ Crankshaft thrust clearance
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
(0.0016 – 0.094 in.)
<Limit> 0.30 mm (0.018 in.)
Thrust washer thickness:
2.930 – 2.980 mm
(0.1154 – 0.1173 in.)
8. Lubricate:
¡ Thrust washer
(with clean engine oil)
9. Remove any old packing material from
the main bearing cap and cylinder block.
10. Clean the contacting surfaces of the bear-
ing cap and cylinder block with non-resi-
due solvent.
11. Apply:
(to cylinder block)
NOTE:
The main bearing cap must be installed
within 5 minutes of application. Otherwise
the material must be removed and reapplied.
5-97
OVER
12. Install:
¡ Main bearing cap
¡ Bolts (main bearing cap)
NOTE:
¡ If any of the bolts are broken or deformed,
replace them.
¡ Apply a light coat of engine oil on the
threads and under the head of the bolts.
13. Tighten:
Bolts (main bearing cap)
Tightening steps
1) First, tighten the bearing cap bolts in sev-
eral passes in the sequence illustrated.
NOTE:
2) Mark the front of the bolt head with paint

A.
3) Retighten the cylinder head bolts 90° in

numerical order as shown above.
4) Check that the painted mark is now at a
90° angle to the front.
Bolt (main bearing cap)

1st:
T.R
105 N·m (10.7 kgf·m, 75 lbf·ft)

2nd:
turn 90°
5) Check that the crankshaft turns smoothly.

6) Check the crankshaft thrust clearance.
Refer to “Check:” on page 5-97.
5-98
OVER
7) Install and torque the bearing cap hold-
ing bolts.
Holding bolt (main bearing cap):

18 N·m (1.8 kgf·m, 13 lbf·ft)
T.R
NOTE:
Tighten the bolt in a crisscross pattern start-
ing in the middle.
Piston and Connecting Rod

1. Install:
¡ Connecting rod bearing 1 (upper)
(onto connecting rod 2)
¡ Connecting rod bearing 3 (lower)
(onto connecting rod cap 4)
NOTE:
¡ Align the projection of the bearing with
the groove of the rod and cap.
¡ Each bearing must be reinstalled in its
original position.
2. Install:
¡ Piston/Connecting rod assembly
Use the piston ring compressor.
NOTE:
¡ Before installing the piston, apply clean
engine oil to the piston and cylinder wall.
¡ Push the correctly numbered piston and
connecting rod assemblies into the re-
spective cylinder with the front mark A
(arrow) of the piston facing forward.
5-99
OVER
3. Install:
¡ Connecting rod caps 1
¡ Bolts (connecting rod cap)
NOTE:
¡ Apply engine oil to the bearings, bolt
threads and bolt heads.
¡ Match numbered A connecting rod caps
with the appropriate connecting rods.
¡ Install the connecting rod cap with the
front mark B (protrusion) facing forward.
4. Tighten:
¡ Bolts (connecting rod cap)
Tightening steps
1) Tighten the bolts in several passes.
NOTE:
2) Mark the front of the connecting rod cap

holding bolts with paint A.
5-100
OVER
3) Tighten the holding bolts by an addi-
tional 90°.
4) Check that the painted mark A in now at
a 90° angle to the front.
Bolt (connecting rod cap)

1st:
T.R
37 N·m (3.8 kgf·m, 27 lbf·ft)
2nd:
turn 90°
5) Check that the crankshaft turns smoothly.
6) Check the connecting rod thrust clear-
ance.
(Refer to “Check:” on page 5-97.)
Crankshaft oil seal retainer

1. Remove any old gasket from the oil seal
retainer and cylinder block.
2. Clean the sealing and contacting sur-
faces of the retainer and cylinder block
with non-residue solvent.
3. Apply:
(to groove of crankshaft oil seal re-
tainer)
NOTE:
The retainer must be reassembled within 5
minutes of application. Otherwise the mate-
rial must be removed and reapplied.
4. Install:
¡ Crankshaft oil seal retainer 1
Bolt (oil seal retainer):

6.5 N·m (0.65 kgf·m, 4.7 lbf·ft)
T.R
NOTE:
5-101
OVER
Installation
1. Install:
¡ Bracket (heat exchanger)
¡ Bracket (control unit)
Bolt (bracket - heat exchanger):

117 N·m (11.9 kgf·m, 85 lbf·ft)
T.R
Bolt (bracket - control unit):
58.5 N·m (5.97 kgf·m, 43 lbf·ft)
2. Install:
¡ Oil pressure switch joint 1
¡ Oil pressure switch 2
¡ Oil pressure sender 3
NOTE:
Apply LOCTITE® 243 on the threads when
installing the oil pressure switch joint 1.
Oil pressure switch joint:

9.0 N·m (0.9 kgf·m, 6.5 lbf·ft)
T.R
A 3. Install:
¡ Engine brackets 1
(left and right )
Bolt (engine bracket):

117 N·m (11.9 kgf·m, 85 lbf·ft)
T.R
5-102
OVER
4. Remove the engine assembly from the
engine stand 1, and install the follow-
ing parts:
¡ Oil strainer
¡ Oil pan
¡ Tension rod
Refer to the installation steps below.
¡ Oil cooler
¡ Timing gear case
Refer to “LUBRICATION SYSTEM” on
page CHAPTER 9.
¡ Timing gears
Refer to “TIMING GEARS” on page
5-17.
¡ Injection pump
¡ Fuel pump
Refer to “FUEL SYSTEM” on page
CHAPTER 6.
¡ Water pump
¡ Seawater pump
¡ Heat exchanger
Refer to “COOLING SYSTEM” on
page CHAPTER 8.
¡ Engine wire harness
¡ Starter motor
¡ Alternator
Refer to “ELECTRICAL SYSTEM” on
page CHAPTER 12.
¡ Rear end plate
¡ Flywheel
¡ 2-stage rate coupling assembly
¡ Flywheel housing
Refer to “2- STAGE RATE COUPLING
AND FLYWHEEL” on page 5-1.
5-103
OVER
5. Install:
¡ Tension rod
Installation steps
1) Install the tension rod bracket 1 at the
bottom of engine bracket provided on
both sides of the engine unit.
Tightening torque:
63 N·m (6.4 kgf·m, 46.4 lbf·ft)
T.R
2) Tighten the nut at one end of the tension
bracket (either on the right or on the left)
so that the tip of the tension rod pro-
trudes from tne nut face by approxi-
mately 14 mm.
Tightening torque:
T.R 206 N·m (21 kgf·m, 151.9 lbf·ft)
3) 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:
8 N·m (0.8 kgf·m, 6 lbf·ft)
T.R
4) 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.
5) Tighten the outer nut 2 on the tension
rod to the specified ttorque.
Tightening torque:
206 N·m (21 kgf·m, 151.9 lbf·ft)
T.R
6. Fill:
¡ Cooling system
page 3-36.
5-104
OVER
7. Fill:
¡ Crankcase
page 3-7.

Engine oil capacity

8.4 L (1.85 lmp qt, 2.22 US qt)
9.2 L (2.02 lmp qt, 2.43 US qt)
5-105
FUEL E
CHAPTER 6
FUEL SYSTEM
INJECTION NOZZLES............................................................................................................. 6-1

Removal .............................................................................................................................. 6-2
Injection Nozzle Test .......................................................................................................... 6-3
Disassembly ....................................................................................................................... 6-4
Check .................................................................................................................................. 6-5
Assembling the Injection Nozzle ...................................................................................... 6-7
Installation ........................................................................................................................ 6-16
INJECTION PUMP................................................................................................................. 6-17

Removal ............................................................................................................................ 6-19
Check ................................................................................................................................ 6-21
Installation ........................................................................................................................ 6-22
6
FUEL INJECTION NOZZLES E
INJECTION NOZZLES
Connect to:
1 Nozzle holder body A Maximum lift adjusting shim
2 #1 Opening pressure adjusting shim B Nozzle assembly
3 #1 spring C Nozzle retaining nut
4 Pressure pin D Clamp holder
5 Spring seat E Leakage pipe
6 #2 opening pressure adjusting shim F Injection nozzle
7 #2 spring G O-ring
8 Pre-lift adjusting spring seat (shim) H Gasket
9 Straight pins I Fuel return hose #1
0 Tip packing
6-1
¡ WARNING
When servicing the fuel system, pay particu-
lar attention to the following points:
¡ Be sure 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 do
accidentally spill some, wipe it up imme-
diately with dry rags. When the engine
is still hot from operation, spilled diesel
fuel could catch fire. Always allow the
engine to cool off completely before start-
ing to work.
Removal
1. Loosen:
¡ Fitting nuts (injection pipe)
2. Remove:
¡ Holders 1 (injection pipe)
¡ Injection pipe
NOTE:
Put a mark on each pipe to facilitate reassem-
bly.
3. Disconnect:
¡ Fuel return hose #1 1
(from leakage pipe 2)
4. Remove:
¡ Hollow bolts 3
¡ Gaskets
¡ Leakage pipe 2
6-2
5. Remove:
¡ Clamp holders 1
(injection nozzle)
¡ Gaskets
¡ O-ring
(from injection nozzle)
NOTE:
Identify the position of each injection nozzle
carefully, so that they can be reinstalled in
their original place.
Injection Nozzle Test

1. Check:
¡ Injection nozzle
Fuel leakage → Replace.
Improper spray pattern → Wash/Re-
place.
Injection pressure checking steps (#1 open-
ing pressure)
¡ WARNING
Do not hold your hand under the tip of the
nozzle.
1) Install the injection nozzle on the nozzle

tester.
2) Blow away the carbon at the injection
orifice by pumping the tester handle as
quickly as possible for a few times.
3) Raise the pressure by pressing the tester
handle slowly. Read out the pressure at
the moment when the pointer on the
gauge drops quickly.
Standard value:
25 – 26 Mpa
(250 – 260 kgf/cm2, 3625 – 3770 psi)
6-3
NOTE:
¡ If the reading is out of specification, dis-
assemble ad re-assemble (inspect and ad-
just) the injection nozzle.
¡ #2 opening pressure (injection pressure)
cannnot be checked as assembled. For
this purpose, disassemble and re-as-
semble (inspect and adjust) the injection
nozzle.
Fuel reakage checking steps
¡ WARNING
nozzle.
1) Raise the pressure to approximately 17

MPa (170 kgf/cm2, 2465 psi) by pushing
down the tester handle slowly. Hold the
pressure for about 10 seconds. Then, no
fuel leakage shall be detected at the in-
jection orifice or at the retaining nut.
Spray pattern checking steps
NOTE:
The nozzle tester handle shall be pumped at
the rate of 1 press per 1 – 2 seconds.
1) Check the spray pattern of the nozzle

while giving the continuous injection.
2) Make sure that there is no dipping after
injection. If any abnormality is observed,
disassemble and wash the nozzle for re-
check, or replace it.
Disassembly
1. Remove:
¡ Nozzle retaining nut 1
NOTE:
When removing the nozzle retaining nut, be
careful not to drop the inner parts.
6-4
2. Remove:
¡ Nozzle assembly 2
¡ Maximum lift adjusting shim 3
¡ Tip packing 4
¡ Straight pins 5
¡ Pre-lift adjusting spring seat (shim) 6
¡ #2 spring 7
¡ #2 opening pressure adjusting shim
8
¡ Spring seat 9
¡ Pressure pin 0
¡ #1 spring A
¡ #1 Opening pressure adjusting shim
B
Check
Nozzle Cleaning
NOTE:
Do not touch mating surfaces of the nozzle
with your fingers.
1. Remove:
¡ Carbon deposit
(from nozzle needle tip)
Use a wooden stick with clean diesel
fuel.
2. Remove:
¡ Carbon deposit
(from nozzle body exterior, except
lapped surfaces)
6-5
3. Check:
¡ Nozzle body seat
¡ Nozzle needle tip
Burns/Corrosion/Damage → Replace
nozzle assembly.
Nozzle Assembly Check

1. Check:
¡ Nozzle needle movement
(in nozzle body)
Sticking → Replace nozzle assembly.
Check steps
1) Thoroughly wash the nozzle sub-assem-
bly in clean diesel fuel.
NOTE:
Do not touch mating surfaces of the nozzle
with your fingers.
2) Install the nozzle needle 1 into the nozzle

body 2. Tilt the nozzle body to 60 de-
grees A and pull the needle out about
one third of its length.
3) When released, the needle 1 should

slide smoothly back under its own
weight.
4) Repeat this test, rotating the needle
slightly each time.
6-6
Assembling the Injection Nozzle

Assemble:
¡ Injection nozzle
Assembling steps
CAUTION:
The injection nozzle adjustment requires
great precision. Therefore, make sure all
parts and tools are clean and no foreign sub-
stances is trapped between two parts.
1 Maximum lift adjusting shim

2 Pre-lift adjusting spring seat (shim)
3 #2 opening pressure adjusting shim
1) Checking and adjusting the maximum lift

(1) Attach the special tool 1 to the dial
gauge so that the distance between
the measuring tip and the special tool
1 end is 2 mm (0.079 in.) or more.
Attachment measure:
95093-10300
(2) Set the nozzle assembly 3 on the spe-

cial tool 2, and then put the pre-lift
adjusting spring seat 4 on it as
shown in the illustration .
2-spring base:
95093-10230
(3) Align the special tool 1 with the pre-

lift adjusting spring seat 4, and set
the dial gauge scale to “0”.
Attachment measure:
95093-10300
6-7
(4) Invert the orientation of the pre-lift ad-

justing spring seat as shown in the
illustration .
Align the special tool 1 with the pre-
lift adjusting spring seat, and measure
the distance L1.
(5) Set the dial gauge scale to “0” on the

special tool 2.
2-spring base:
95093-10230
(6) Set the nozzle body on the special tool

2, and put the tip packing 1 with its
groove A facing upward.
NOTE:
¡ Put the tip packing 1 upside down in con-
trast to its proper assembly.
¡ Remove the nozzle needle from the nozzle
assembly. Only the nozzle body must be
set on the special tool.
(7) Measure the distance L2 by pressing

the dial gauge measuring tip against
the groove on the tip packing 1.
NOTE:
Set the dial gauge aligning the straight pins
3 and the holes on the measure attachment
2. Measure the distance L2.
(8) Measure the maximum lift adjusting

shim thickness L3 with the microme-
ter.
L3
6-8
(9) Calculate the maximum lift based on

the measurements L1, L2, and L3.
Formula
Maximum Maximum lift = (L1 + L2) – L3
lift
Maximum lift:
0.33 mm – 0.38 mm
(0.013 in. – 0.015 in.)
(10)If out of specification, select the ap-

Maximum lift adjusting shim propriate maximum lift adjusting
YAMAHA Part No. DENSO Part No. L3 mm(in.) shim and replace.
N51-13485-00-35 093175-6350 2.400(0.0945)
NOTE:
N51-13485-00-36 093175-6360 2.425(0.0955)
Decrease (increase) the thickness of the shim
N51-13485-00-37 093175-6370 2.450(0.0965)
L3 when the maximum lift falls short of (ex-
N51-13485-00-38 093175-6380 2.475(0.0974) ceeds) the specification.
N51-13485-00-39 093175-6390 2.500(0.0984)
2) Checking and adjusting the pre-lift

(1) Measure the tip packing thickness L4
with the micrometer.
L4
(2) Measure the leg length L5 of the pre-

lift adjusting spring seat with the mi-
crometer.
A – B = L5
6-9
(3) Calculate the pre-lift based on the

measurements L1, L3, L4, and L5.
Formula
Pre-lift = L4 – L5 – (L3 – L1)
Pre-lift
Pre-lift:
0.07 mm – 0.09 mm
(0.0028 in. – 0.0035 in.)
(4) If out of specification, select the ap-

Pre-lift adjusting spring seat (shim)
propriate pre-lift adjusting spring seat
YAMAHA Part No. DENSO Part No. L5 mm(in.)
(shim) and replace.
N51-12219-00-55 093128-0550 2.67(0.1051)
N51-12219-00-57 093128-1570 2.68(0.1055) NOTE:
N51-12219-00-59 093128-0590 2.69(0.1059) Decrease (increase) the thickness of the
N51-12219-00-61 093128-0610 2.70(0.1063) spring seat L5 when the pre-lift falls short of
N51-12219-00-63 093128-0630 2.71(0.1067) (exceeds) the specification.
N51-12219-00-65 093128-0650 2.72(0.1071)
N51-12219-00-67 093128-0670 2.73(0.1075)
N51-12219-00-69 093128-0690 2.74(0.1079)
N51-12219-00-71 093128-0710 2.75(0.1083)
N51-12219-00-73 093128-0730 2.76(0.1087)
N51-12219-00-75 093128-0750 2.77(0.1091)
N51-12219-00-77 093128-0770 2.78(0.1094)
N51-12219-00-79 093128-0790 2.79(0.1098)
N51-12219-00-81 093128-0810 2.80(0.1102)
N51-12219-00-83 093128-0830 2.81(0.1106)
N51-12219-00-85 093128-0850 2.82(0.1110)
N51-12219-00-87 093128-0870 2.83(0.1114)
N51-12219-00-89 093128-0890 2.84(0.1118)
N51-12219-00-91 093128-0910 2.85(0.1122)
N51-12219-00-93 093128-0930 2.86(0.1125)
N51-12219-00-95 093128-0950 2.87(0.1129)
6-10
3) Adjusting the #2 opening pressure

(1) Assemble the following parts and the
master spring seat 5 to the nozzle
holder body, and tighten the retain-
ing nut.
1 Nozzle holder body

2 Spring seat
4 #2 spring
5 Master spring seat (SST)
6 Straight pin
7 Tip packing
8 Maximum lift adjusting shim
9 Nozzle assembly
0 Retaining nut
NOTE:
¡ Do not assemble the #1 opening pressure
pin, #1 spring, and #1 opening pressure
adjusting shim.
¡ Assemble the master spring seat 5 in
place of the pre-lift adjusting spring seat
(shim).
¡ At the assembly, align the holes A on the
nozzle body, the tip packing, and the
nozzle holder body.
Tightening torque:
29.4 N·m (3.0 kgf·m, 21 lbf·ft)
T.R
Master spring seat 5:

95093-10330
(2) Install the nozzle holder and nozzle set

assembled in (1) above on the nozzle
tester.
6-11
(3) Pump the nozzle tester lever slowly

to raise the pressure, and take note
of the pressure gauge reading just
where the injection pressure begins
to drop.
¡ WARNING
nozzle.
Standard value:
29.91 ± 0.49 MPa
(305 ± 5 kgf/cm2, 4422 ± 72 psi)
Spring
seal #2 opening
pressure
adjusting shim
#2 spring
Master spring
seat (SST)

#2 opening pressure adjusting shim propriate #2 opening pressure adjust-
ing shim and replace.
NOTE:
t Injection pressure rises (drops) when the #2
YAMAHA Part No. DENSO Part No. t mm(in.)
opening pressure adjusting shim thickness
is increased (decreased).
6TA-12859-00-06 093175-2230 1.250(0.0492)
6TA-12859-00-07 093175-2240 1.300(0.0511)
6TA-12859-00-08 093175-2250 1.350(0.0531)
6TA-12859-00-09 093175-2260 1.400(0.0551)
6TA-12859-00-10 093175-2270 1.450(0.0571)
6TA-12859-00-11 093175-2280 1.500(0.0591)
6TA-12859-00-12 093175-2290 1.550(0.0610)
6TA-12859-00-13 093175-2300 1.600(0.0640)
6TA-12859-00-A1 093175-2420 1.275(0.0502)
6TA-12859-00-A2 093175-2430 1.325(0.0522)
6TA-12859-00-A3 093175-2440 1.375(0.0541)
6TA-12859-00-A4 093175-2450 1.425(0.0561)
6TA-12859-00-A5 093175-2460 1.475(0.0581)
6TA-12859-00-A6 093175-2470 1.525(0.0600)
6TA-12859-00-A7 093175-2480 1.575(0.0620)
6TA-12859-00-A8 093175-2490 1.625(0.0640)
6-12
(5) Make sure that there is no dripping

after injection.
4) Adjusting the #1 opening pressure

(1) Assemble the following parts to the
nozzle holder body, and tighten the
retaining nut.
1 Nozzle holder body

3 #1 spring
4 Pressure pin
5 Spring seat
7 #2 spring
8 Pre-lift adjusting spring seat (shim)
9 Straight pin
0 Tip packing
A Maximum lift adjusting shim
B Nozzle assembly
C Retaining nut
NOTE:
At the assembly, align the holes A on the
nozzle body, the tip packing, and the nozzle
holder body.
Tightening torque:
29.4 N·m (3.0 kgf·m, 21 lbf·ft)
T.R
(2) Install the nozzle holder and nozzle set

assembled in 1 above on the nozzle
tester.
6-13
(3) Pump the nozzle tester lever slowly

to raise the pressure, and take note
of the pressure gauge reading just
where the injection pressure begins
to drop.
¡ WARNING
nozzle.
Standard value:
24.99 ± 0.49 MPa
#1 opening (255 ± 5 kgf/cm2, 3697 ± 72 psi)
#1 spring pressure
adjusting
shim
Pressure
pin
Pre-lift
6-14

#1 opening pressure adjusting shim propriate #1 opening pressure adjust-
ing shim and replace.
NOTE:
t Injection pressure rises (drops) when the #2
YAMAHA Part No. DENSO Part No. t mm(in.) opening pressure adjusting shim thickness
N51-13147-00-25 093175-4250 1.250(0.0492) is increased (decreased).
N51-13417-00-26 093175-4260 1.275(0.0502)
N51-13147-00-27 093175-4270 1.300(0.0511)
N51-13147-00-28 093175-4280 1.325(0.0522)
N51-13147-00-29 093175-4290 1.350(0.0531)
N51-13147-00-30 093175-4300 1.375(0.0541)
N51-13147-00-31 093175-4310 1.400(0.0551)
N51-13147-00-32 093175-4320 1.425(0.0561)
N51-13147-00-33 093175-4330 1.450(0.0571)
N51-13147-00-34 093175-4340 1.475(0.0581)
N51-13147-00-35 093175-4350 1.500(0.0591)
N51-13147-00-36 093175-4360 1.525(0.0600)
N51-13147-00-37 093175-4370 1.550(0.0610)
N51-13147-00-38 093175-4380 1.575(0.0620)
N51-13147-00-39 093175-4390 1.600(0.0630)
N51-13147-00-40 093175-4400 1.625(0.0640)
N51-13147-00-41 093175-4410 1.650(0.0650)
N51-13147-00-42 093175-4420 1.675(0.0659)
N51-13147-00-43 093175-4430 1.700(0.0669)
N51-13147-00-44 093175-4440 1.725(0.0679)
N51-13147-00-45 093175-4450 1.750(0.0689)
(5) Make sure that there is no dripping

after injection.
6-15
Installation
1. Install:
¡ O-ring 1 (new)
(onto injection nozzle)
¡ Gaskets (new)
¡ Injection nozzles 2
¡ Clamp holders 3 (injection nozzle)
NOTE:
Be sure to install each injection nozzle in its
original place.
Bolt (clamp holder):

39 N·m (4.0 kgf·m, 28 lbf·ft)
T.R
2. Install:
¡ Gaskets (new)
¡ Leakage pipe 1
¡ Hollow bolts 2
Hollow bolt (leakage pipe):

12.5 N·m (1.25 kgf·m, 9.0 lbf·ft)
T.R
3. Connect:
(to leakage pipe)
4. Install:
¡ Injection pipes
¡ Holders 1 (injection pipe)

25 N·m (2.5 kgf·m, 18 lbf·ft)
T.R
NOTE:
Fix the injection pipes following the sequence
below.
Injection order: 1-4-2-6-3-5
5. Start the engine and check for fuel leaks.

6-16
FUEL INJECTION PUMP E
INJECTION PUMP
NOTE:
1. Breaking of the lead seals or crimp caps
by anyone other than YAMAHA or *pump
manufacturer authorized service stations
to make these adjustments will void the
warranty.
2. If fuel pump or governor difficulties are
suspected, consult only YAMAHA or
*pump manufacturer authorized service
stations, where the problem can be cor-
rected and the injection pump lead seals
and crimp caps can be reinstalled as re-
quired.
*Pump manufacture: DENSO CORPORATION
6-17
Connect to:
1 Injection pipe 8 Valve
2 Injection pipe holder 9 Fuel strainer
3 Pickup (tacho) sensor 0 Washer
4 Gasket A Injection pump
5 Fuel cut solenoid B Set key
6 O-ring C O-ring
7 Spring
6-18
Removal
Injection Pump Assembly
NOTE:
Before removing the injection pump, listen
for abnormal noises from the pump while the
engine is running.
1. Drain:
¡ Engine coolant
2. Remove:
¡ Timing belt
¡ #2 camshaft pulley
3. Remove:
¡ Injection pipes
5 1 2 page 6-1.
4
4. Disconnect:
3 ¡ Throttle connecting rod 4
5. Remove:
(with gaskets)
6. Disconnect:
¡ Injection pump coupler 1
7. Loosen:
NOTE:
Lock the crankshaft when removing the nut.
8. Remove:
¡ O-ring
6-19
9. Remove:
¡ Nuts/Bolt (injection pump)
NOTE:
Put alignment marks A on the injection
pump and timing gear case before remov-
ing so that the injection pump can be rein-
stalled in exactly the same position.
10. Remove:
¡ Injection pump
Use the puller C set 1.
Puller C set:
09950-50013
 09951-05010 
 09952-05010 
 
 09953-05020 
 09954-05020 
or (90890-0740A, 90890-07512)
NOTE:
than 8 mm (0.31 in.).
the drive gear.
CAUTION:
¡ When tightening the puller bolt 4, hold
the injection pump 1 so that it does not
drop downwards.
¡ Do not hold or carry the injection pump
by the adjusting lever 5.
11. Remove:
¡ O-ring 1
¡ Set key 2
6-20
Fuel Cut Solenoid and Pickup (tacho) Sen-

sor
1. Pull back the dust cover 1 of the fuel cut
solenoid.
2. Disconnect:
¡ Fuel cut solenoid lead 2
3. Remove:
¡ Fuel cut solenoid 1
¡ O-ring 2
¡ Spring 3
¡ Valve 4
¡ Fuel strainer 5
¡ Washer 6
4. Disconnect:
¡ Pickup (tacho) sensor lead 1
(from lead clamps 2)
5. Remove:
¡ Pickup (tacho) sensor 3
Check
Injection Pump Body
1. Check:
¡ Injection pump operation
Abnormal noise/Malfunction → Re-
place injection pump assembly.
Fuel Cut Solenoid and Pickup (tacho) Sen-

sor
1. Check:
¡ Fuel cut solenoid
Refer to “Fuel Cut Solenoid Valve” on
page 12-41.
6-21
2. Check:
¡ Spring 1
¡ Fuel strainer 2
Damage → Replace.
3. Clean:
¡ Fuel strainer
Use cleaning solvent and blow dry
with compressed air.
4. Check:
¡ Rubber seal A (valve 1)
Wear/Damage → Replace valve.
5. Check:
¡ Pick sensor
Refer to “Pickup (tacho) Sensor” on
page 12-40.
Installation
Fuel Cut Solenoid and Pickup Sensor
1. Install:
¡ O-ring (new)
(onto pickup sensor)
¡ Pickup (tacho) sensor 1
Pickup (tacho) sensor

21 N·m (2.1 kgf·m, 15 lbf·ft)
T.R
NOTE:
Apply grease to the O-ring of the pickup
(tacho) sensor.
2. Connect:
¡ Pickup (tacho) sensor lead 2
(to lead clamps 3)
6-22
3. Install:
¡ Washer 1
¡ Fuel strainer 2
¡ Valve 3
¡ Spring 4
¡ O-ring (new) 5
¡ Fuel cut solenoid 6
Fuel cut solenoid:

22 N·m (2.2 kgf·m, 16 lbf·ft)
T.R
4. Connect:
¡ Fuel cut solenoid lead 1
Bolt (fuel cut solenoid lead):

1.7 N·m (0.17 kgf·m, 1.2 lbf·ft)
T.R
5. Install:
¡ Dust cover 2
(onto fuel cut solenoid)
Injection Pump Assembly

1. Install:
¡ O-ring 1 (new)
2. Install:
¡ Injection pump 1
NOTE:
¡ Align the set key 2 on the drive shaft and
the groove A of the injection pump drive
gear.
¡ Align the match marks B of the injection
pump and timing gear case.
3. Install:
¡ Nuts 3 (injection pump to gear case)
Nut (injection pump – gear case):

18 N·m (1.8 kgf·m, 13 lbf·ft)
T.R
6-23
4. Install:
¡ Bolt 1 (injection pump to pump stay)
Bolt (injection pump to pump stay):

70 N·m (7.1 kgf·m, 50 lbf·ft)
T.R
CAUTION:
Before tightening the bolt to standard
torque, check whether the pump bracket 2
touches the pump stay 3.
If there is a gap, loosen the nuts and set the
pump bracket against the pump stay.
5. Install:
¡ O-ring 1 (new)
(onto injection pump drive gear)
6. Install:
Nut (pump drive gear):

100 N·m (10.2 kgf·m, 72 lbf·ft)
T.R
NOTE:
Lock the crankshaft when tightening the nut.
7. Adjust:
¡ Injection timing
Refer to “Injection Timing Adjust-
6-24
8. Connect:
¡ Injection pump coupler 1
1 9. Install:
¡ Gaskets (new)
Hollow bolt (fuel delivery hose):

30 N·m (3.1 kgf·m, 22 lbf·ft)
T.R
4 3 10. Connect:
1
A
(with new gaskets)
2
NOTE:
Connect the fuel return hose #2 2 at right
angle to the pump body’s vertical line.
11. Install:
¡ Injection pips
page 6-1.

25 N·m (2.5 kgf·m, 18 lbf·ft)
T.R
6-25
12. Install:
¡ #2 Camshaft pulley
¡ Timing belt
5-17.
13. Fill:
¡ Cooling system
page 3-36.
14. Check:
¡ Injection timing
Refer to “Injection Timing Adjust-
¡ Engine idle speed and maximum
speed
Refer to “Engine Idle Speed and Maxi-
mum Speed Adjustment” on page 3-
16.
6-26
EXHT E
CHAPTER 7
EXHAUST SYSTEM
MIXING ELBOW AND EXHAUST MANIFOLD ...................................................................... 7-1

Removal .............................................................................................................................. 7-2
Check and Repair ............................................................................................................... 7-3
Installation .......................................................................................................................... 7-6
EXHAUST COLLECTOR .......................................................................................................... 7-9

Removal ............................................................................................................................ 7-10
Check And Repair ............................................................................................................ 7-10
Installation ........................................................................................................................ 7-11
7
EXHT MIXING ELBOW AND EXHAUST MANIFOLD E
MIXING ELBOW AND EXHAUST MANIFOLD
Connect to:
1 Coolant filler cap
2 Filler neck
3 O-ring
4 Mixing elbow
5 Gasket
6 Exhaust manifold
7-1
Removal
1. Drain:
¡ Engine coolant
2. Remove:
¡ Mixing elbow
¡ Turbocharger
CHAPTER 10.
3. Remove:
¡ Bracket 1
(with seawater strainer assembly)
¡ Gasket 3
4. Remove:
5. Remove:
1 6. Disconnect:
¡ Shift cable 2 (drive unit side)
7. Remove:
4
3 ¡ Shift assist assembly 4
¡ Hose holder
8. Remove:
2
¡ Turbocharger
10-1.
1
7-2
9. Remove:
¡ Bolts 1 (thermostat housing 2)
¡ Gasket 3
¡ Bolt 4
¡ Clamp 5
10. Remove:
¡ Heat exchanger
Refer to “HEAR EXCHANGER” on
page 8-18.
11. Remove:
12. Remove:
¡ Bolt 2
¡ Joint 3
13. Remove:
¡ Gaskets 1 (exhaust manifold)
Check and Repair

Exhaust Manifold
1. Remove:
¡ Gasket material
(from gasket contact surface)
NOTE:
surface.
2. Using a soft brush and solvent, clean the

exhaust manifold.
3. Check:
Use dye penetrant.
7-3
4. Measure:
¡ Exhaust manifold warpage
(contacting surface to the cylinder
head)
gauge.
Manifold warpage:
1
5. Check:
¡ Filler neck 1
Refer to “CLOSED COOLING SYS-
TEM” on page 8-2.
Replacement steps
1) Remove the filler neck 1.
2) Remove the O-ring 2 from the filler neck.
3) Install the new filler neck 1 with a new
O-ring 2.
NOTE:
Position the breather pipe A so that it points
away from the engine.
7-4
Mixing Elbow
1. Remove:
¡ Gasket material
(from gasket contact surface)
NOTE:
surface.
2. Use a soft brush and solvent to clean the

mixing elbow.
3. Check:
Mixing elbow 1
Use dye penetrant.
NOTE:
¡ Once the plug 1 is removed, LOCTITE®
243 shall be applied before mounting it
again.
¡ Once the joint plug 2 is removed, replace
the O-ring with the new one, and apply
LOCTITE® 243 before mounting it again.
Mounting angle shall be 90? relative to
the mixing elbow mounting face.
Screw plug 1:
10 N·m (1.0 kgf·m, 7.2 lbf·ft)
T.R
7-5
Installation
1. Install:
¡ Gasket 1 (new)
(exhaust manifold)
NOTE:
Install the exhaust manifold gasket with the
gasket links A on the upper side.
2. Install:
Bolt:
40 N·m (4.1 kgf·m, 29 lbf·ft)
T.R
Nut:
33 N·m (3.4 kgf·m, 24 lbf·ft)
NOTE:
Tighten the bolts and nuts in a crisscross
pattern starting in the middle.
¡ Joint 2
3. Install:
4. Install:
¡ Heat exchanger
page 8-18.
5. Install:
¡ Gasket 1 (new)
¡ Hose holders
¡ Clamp 3
¡ Bolt 4
6. Install:
¡ Turbocharger
10-1.
7-6
3 7. Install:
4
8. Connect:
2 ¡ Shift cable 2 (drive unit side)
9. Install:
10. Install:
11. Install:
¡ Gasket 1 (new)
¡ Bracket 3
(with seawater strainer assembly)
7-7
12. Install:
¡ Mixing elbow
¡ Turbocharger
CHAPTER 10.
13. Fill:
¡ Cooling system
¡ Refer to “Coolant Level Check” on
page 3-36.
14. Check:
¡ Cooling system
Pressure drop (leaks) → Repair as re-
quired.
Refer to “COOLING SYSTEM” on
page CHAPTER 8.
7-8
EXHT EXHAUST COLLECTOR E
EXHAUST COLLECTOR
Connect to:
1 Hose clamp
2 Exhaust joint
3 Grommet
4 Seawater shutter
5 Pin
6 Exhaust collector
7-9
Removal
1. Remove:
¡ Engine assembly
Refer to “REMOVAL” on page 4-1.
2. Loosen:
¡ Hose clamps 1
3. Remove:
¡ Exhaust joint 2
¡ Exhaust collector 3
Check And Repair

1. Check:
¡ Use dye penetrant.
2. Check:
¡ Exhaust joint 1
Wear/Tear/ Damage → Replace.
3. Check:
¡ Seawater shutter 1
¡ Sealing rubber A
¡ Seawater shutter movement
Unsmooth → Replace.
7-10
Replacement steps
1) Remove the pin 1 and the seawater
shutter 2.
2) Check the grommets 3 for wear or dam-
age, and replace if necessary.
3) Strike out the grommets, using a suitable
punch 4 and a hammer.
4) With the punch, install the new grom-
mets into the exhaust collector flush with
the inner wall.
5) Install the seawater shutter 2 with the
flanges A upwards, and secure it with
the pin 1.
4. Check:
¡ Gasket 1 (exhaust collector)
NOTE:
¡ If replacing the gasket:
Apply weather strip type adhesive onto
the gimbal housing gasket groove, then
install the new gasket into the groove.
¡Thoroughly wipe off excess adhesive.
Installation
1. Install:
Bolt (exhaust collector):

17.7 N·m (1.8 kgf·m, 13 lbf·ft)
T.R
CAUTION:
To avoid warping of the mating surfaces,
tighten the bolts in even steps following a
crisscross pattern.
2. Install:
¡ Engine assembly
Refer to “Engine Installation” on page
4-5.
7-11
COOL E
CHAPTER 8
COOLING SYSTEM
COMPONENTS ....................................................................................................................... 8-1
PRE CHECK.............................................................................................................................. 8-2

Hose Check ......................................................................................................................... 8-2
CLOSED COOLING SYSTEM ................................................................................................. 8-2

Check .................................................................................................................................. 8-2
CIRCULATION PUMP .............................................................................................................. 8-5

Removal .............................................................................................................................. 8-5
Check and Repair ............................................................................................................... 8-5
Installation .......................................................................................................................... 8-6
THERMOSTAT ......................................................................................................................... 8-8

Removal .............................................................................................................................. 8-8
Check and Repair ............................................................................................................... 8-9
Installation ........................................................................................................................ 8-10
SEAWATER PUMP ................................................................................................................ 8-12

Removal ............................................................................................................................ 8-12
Disassembly ..................................................................................................................... 8-12
Check and Repair ............................................................................................................. 8-12
Assembly .......................................................................................................................... 8-17
Installation ........................................................................................................................ 8-17
HEAT EXCHANGER .............................................................................................................. 8-18

Heat Exchanger Check (for Internal Leak) ...................................................................... 8-18
Anodes Check .................................................................................................................. 8-18
Removal ............................................................................................................................ 8-19
Disassembly ..................................................................................................................... 8-19
Check and Repair ............................................................................................................. 8-19
8
Assembly .......................................................................................................................... 8-21
Installation ........................................................................................................................ 8-21
COOL COMPONENTS E
COMPONENTS
Connect to:
1 Joint 8 Thermostat housing E Key L Mechanical seal
2 Gasket 9 Thermo switch F Pump shaft M Impeller
3 Heat exchanger 0 Water temperature sensor G Circlip N Wear plate
4 Clamp A Bypass pipe H Bearing O Cover
5 Bracket B Circulation pump assembly I Spacer P O-ring
6 Thermostat cover C Driven gear J Pump housing Q V-ring
7 Thermostat D Oil seal K Washer
8-1
COOL PRE CHECK / CLOSED COOLING SYSTEM E
PRE CHECK
Hose Check
1. Check if there is any looseness, damage,
etc., in the hoses and hose joint clamps.
Tighten loose clamps and replace any
damaged part.
CLOSED COOLING SYSTEM

Check
Coolant Filler Cap
1. Check:
¡ Gasket 1
¡ Sealing rubber 2
Wear/Damage → Replace coolant
filler cap.
¡ Locking tabs A
Bent/Cracks/Damage → Replace cool-
ant filler cap.
2. Check:
¡ Coolant filler cap opening pressure
Opens at a pressure below the speci-
fication → Replace.
Coolant filler cap opening pressure:

73 – 103 kPa
(0.74 – 1.03 kgf/cm2, 10.7 – 14.9 psi)
<Limit>
More than 60 kPa (0.6 kgf/cm2, 8.5 psi)
8-2
COOL CLOSED COOLING SYSTEM E
Measurement steps
1) Apply a small amount of coolant to the
coolant filler cap gasket.
2) Attach the coolant filler cap 2 onto the
cooling system tester 1.
3) Apply the specified pressure for 10 sec-
onds, and check that it stays constant.
If the cap fails to hold the pressure, re-
place it.
Closed Cooling System - Check for Leaks

1. Check:
All hose connections
Refer to “Hose Check” on page 8-2.
2. Check:
a ¡ Sealing surfaces A
(on filler neck)
Dents/Damage → Replace filler neck.
Rust or dirt → Clean with cloth.
¡ Locking tabs B
b
Bent/Damage → Replace filler neck.
Refer to “EXHAUST COLLECTOR” on
page 7-9.
3. Check:
¡ Closed cooling circuit
Leaks → Repair or replace damaged
parts.
Checking steps
1) Fill the closed cooling circuit with cool-
ant and attach the cooling system tester
1.
8-3
COOL CLOSED COOLING SYSTEM E
2) Start the engine and let it warm up to

normal operating temperature, than stop
it.
3) Apply 100 kPa (1.0 kgf/cm2, 14 psi) pres-
sure with the cooling system tester.
NOTE:
If the pressure drops, check for leaks in the
following locations.
¡ Hoses
¡ Heat exchanger
¡ Circulation pump
¡ Joint
¡ Bypass pipe
(thermostat housing – turbocharger)
¡ Heater cocks
NOTE:
If no external leaks are found, check the fol-
lowing parts.
¡ Exhaust manifold
¡ Turbocharger
¡ Cylinder block
8-4
COOL CIRCULATION PUMP E
CIRCULATION PUMP
Removal
1. Drain:
¡ Engine coolant
2. Remove:
¡ Drive belts
3-21.
3. Remove:
¡ Timing belt
¡ Idler pulley
¡ #1 camshaft timing pulley
4. Remove:
5-30.
5. Remove:
¡ Circulation pump pulleys 1
6. Remove:
¡ Alternator stay 1
¡ Circulation pump 2
¡ Gasket
Check and Repair

1. Check:
¡ Bearing (circulation pump)
Turn the pulley with the finger.
Roughness → Replace circulation
pump assembly.
8-5
2. Check:
¡ Impeller 1 (circulation pump)
¡ Circulation pump housing 2
Cracks/Damage → Replace circulation
pump assembly.
Installation
1. Install:
¡ Gasket (new)
¡ Circulation pump 1
¡ Stay 2 (alternator)
Nut/Bolt (circulation pump):

T.R 20 N·m (2.0 kgf·m, 14 lbf·ft)
2. Install:
¡ Circulation pump pulleys
NOTE:
Install the #1 pulley 1 as shown in the illus-
tration.
Nut (pump pulley):

20 N·m (2.0 kgf·m, 14 lbf·ft)
T.R
3. Install:
4. Install:
¡ #1 camshaft timing pulley
¡ Idler pulley
¡ Timing belt
5. Install:
¡ Drive belts
3-21.
8-6
6. Fill:
¡ Cooling system
page 3-36.
7. Check:
Drop in pressure (leak) → Repair as
required.
TEM” on page 8-2.
8-7
COOL THERMOSTAT E
THERMOSTAT
Removal
1. Drain:
¡ Engine coolant
2. Remove:
¡ Thermostat cover 1
3. Remove:
¡ Thermostat 1
4. Remove:
¡ Hollow bolt 1
¡ Gaskets 2
¡ Bypass pipe 3
5. Disconnect:
¡ Thermo switch lead 1
¡ Water temperature sensor lead 2
6. Remove:
¡ Gasket (thermostat housing)
8-8
COOL THERMOSTAT E
Check and Repair

1. Check:
¡ Rubber gasket 1
Wear/Damage → Replace the thermo-
stat.
2. Check:
¡ Thermostat operation
If the valve opening temperature or
the valve lift is not as specified, re-
place the thermostat.
NOTE:
The valve opening temperature is marked on
the thermostat.
Checking steps
1) Hold the thermostat in water and heat it
up slowly.
Keep checking the thermometer and stir-
ring water.
2) Check the valve opening temperature
and the valve lift.
Thermostat
Valve opening temperature:
74.5 – 78.5 °C (166 – 173 °F)
Valve lift A :
10 mm (0.39 in.) or more
at 90 °C (194 °F)
3) Check that the valve spring is tight when

the thermostat is fully closed.
3. Check:
8-9
COOL THERMOSTAT E
NOTE:
When replacing the thermo switch 3 or wa-
ter TEMP. sensor 4, apply a layer of
LOCTITE® No. 243 or equivalent to two or
three threads before installation. Thoroughly
wipe off the excess adhesive after tighten-
ing.
Thermo switch:
35 N·m (3.6 kgf·m, 26 lbf·ft)
T.R
Water temperature sensor:
11 N·m (1.1 kgf·m, 8 lbf·ft)
Installation
1. Install:
¡ Gasket (new) 1
2. Connect:
¡ Thermo switch lead 2
¡ Water temperature sensor lead 3
3. Install:
¡ Gaskets 1
¡ Bypass pipe 2
¡ Hollow bolt 3
Hollow bolt:
20 N·m (2.0 kgf·m, 14 lbf·ft)
T.R
4. Install:
¡ Thermostat 1
NOTE:
Install the thermostat with the jigger valve
upwards.
8-10
COOL THERMOSTAT E
5. Install:
6. Fill:
¡ Cooling system
page 3-36.
7. Check:
Drop of pressure (leak) → Repair as
required.
TEM” on page 8-2.
CAUTION:
If the engine is running with the thermostat
removed, will overheat the engine.
8-11
COOL SEAWATER PUMP E
SEAWATER PUMP
Removal
¡ WARNING
As soon as the seawater pump hose is dis-
connected, plug the seawater inlet side to
prevent seawater from entering.
1. Remove:
¡ Inlet hose 1
2
¡ Outlet hose 2
¡ Seawater pump assembly 3
3
1
Disassembly
2 1. Remove:
1
¡ Cover 1
¡ O-ring 2
2. Remove:
¡ Impeller 1
1
CAUTION:
Take care not to damage the impeller.
Check and Repair

1. Check:
1
¡ Driven gear
Replace driven gear.
8-12
¡ Cover
Wear/Crack → Replace cover.
¡ Wear plate
Wear/Crack → Replace wear plate.
¡ Housing A
Wear/Cracks/Damage → Replace
housing.
¡ Impeller 1
Wear/Cracks/Damage → Replace im-
peller.
8-13
Replacement steps
1
3
1) Clamp the driven gear 1 in a vise with
soft-jaws 2 to loosen the nut 3.
2) Remove the nut 3.
3) Remove the driven gear 1 and then re-

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

Replace it if necessary.
A 2. Check:
¡ Oil seal 1
B Wear/Damage → Replace oil seal.
¡ Seawater pump housing 2
Checks/Damage → Replace pump as-
sembly.
Component replacement steps

1) Remove the oil seal 1 using a screw-
driver or similar tool
NOTE:
Be careful not to damage the shaft.
2) Remove the circlip 2.

2
8-14
3) Remove the circlip 3 and the place

3 washer 4.
4
4) Press out the pump shaft 5 in the illus-

trated direction.
NOTE:
Put out the pump shaft 5 and the bearing 6
as a set.
5) Remove the bearing 7.

6) After removing the circlip 8 and the
spacer 9, remove bearing 0.
7) Remove the mechanical seal A and V-

seal B using a screw driver or similar
tool.
8) After inset a new bearing 0 onto pump

shaft C, install spacer 9, circlip 8, and
then install the bearing 7 until it con-
tacts circlip 8.
8-15
9) Install a new V-ring B on the housing.

10) Install the mechanical seal A so that the
sealing surface faces the V-ring.
NOTE:
¡ Position V-ring B so that the direction of
the cone is facing toward the mechanical
seal.
¡ Press in the mechanical seal uniformly by
hand.
b 11) Install the pump shaft with bearings into

a the housing using a hydraulic press.
NOTE:
¡ Plate the pump shaft in the housing from
the gear side while bearing careful not to
tear the V-ring.
¡ Press outer race A of the bearing and
push it in until it aligns with circlip groove
B.
12) Install circlip 2.

13) Face the marking on the oil seal 1 to-
ward the circlip and push in until it con-
tacts the circlip using an appropritate
tool.
14) After installing mechanical seal B on the
shaft from the impeller side, place
washer 4 on the shaft and then install
circlip 3.
NOTE:
¡ Install the mechanical seal with the spring
facing toward the impeller side.
¡ Do not apply oil to seal parts.
¡ Do not spread open the snap ring more
than necessary.
15) Attach the wear plate D and then install

the impeller E.
16) Install the O-ring F and cover G.
Bolt (cover):
2 N·m (0.2 kgf·m, 1.4 lbf·ft)
T.R
17) Install the driven gear.
Driven gear nut:

110 N·m (11.2 kgf·m, 80 lbf·ft)
T.R
8-16
Assembly
1. Lubricate:
1
¡ Impeller 1
(with YAMAHA Marine grease)
2. Install:
¡ Impeller 1
NOTE:
When inserting the impeller into the pump
body, turn it counterclockwise while push-
ing.
CAUTION:
Make sure that the impeller blades are
turned as shown in the illustration.
3. Install:
2 New ¡ O-ring 2 (new)
1 ¡ Cover 1
Bolt (cover):
2 N·m (0.2 kgf·m, 1.4 lbf·ft)
T.R
Installation
1. Install:
¡ O-ring 1 (new)
¡ Seawater pump assembly 2
NOTE:
Turn the seawater pump completely in the
clockwise direction and then tighten the nut.
8-17
COOL HEAT EXCHANGER E
HEAT EXCHANGER
Heat Exchanger Check
(for Internal Leak)
1. Check:
¡ Heat exchanger
Drop of pressure (leak) → Repair or
replace heat exchanger.
Checking steps
1
1) Remove the coolant filler cap 1.
¡ WARNING
Do not remove the filler cap when the en-
gine is hot. Scalding hot fluid and steam may
be blown out under pressure, causing severe
injury.
2) Apply a small amount of coolant to the

tester cap gasket.
3) Attach the cooling system tester 2 to the
filler neck.
NOTE:
Before attaching the cooling system tester,
check the filler neck.
Refer to “CLOSED COOLING SYSTEM” on
page 8-2.
4) With the cooling system tester, apply 100

kPa (1.0 kgf/cm2, 14 psi) pressure to the
closed cooling circuit.
If seawater begins to drip from the cock,
repair or replace the heat exchanger.
Anodes Check
1. Check:
¡ Anode 1
Anodes:
19 N·m (1.9 kgf·m, 14 lbf·ft)
T.R
NOTE:
Apply LOCTITE® 243 on the threads when in-
stalling the anodes.
8-18
1 Removal
2
1. Drain:
¡ Engine coolant
2. Disconnect:
3
3. Remove:
NOTE:
DO NOT disconnect the shift cables 3.
4. Remove:
¡ Nuts 1 (clamp)
¡ Clamps 2
¡ Joint 3
¡ Gasket
5. Disconnect:
¡ Hose #5 4
¡ Hose #1 5
¡ Hose #4 6
6. Remove:
¡ Heat exchanger 7
1 Disassembly
1. Remove:
2
¡ Bolts 1
2 ¡ Side plates 2
3
¡ Gaskets 3
Check and Repair

2
1. Check:
¡ Side plates 1
¡ Heat exchanger unit 2
Cracks/Rust/Corrosion/Damage → Re-
place.
8-19
2. Clean:
¡ Heat exchanger assembly.
Cleaning steps
1) Soak the heat exchanger assembly for
from 90 to 120 minutes in clean water to
loosen deposits.
2) Wash thoroughly with tap water and use
a stiff rod 1 to remove any deposits in-
side coolant passages A.
3) Blow off any debris or deposits from
coolant passages, then dry with com-
pressed air.
NOTE:
When removing the drain cock unit 1, apply
LOCTITE® No. 572 or equivalent to two or
three threads. Install the drain cock unit and
thoroughly wipe off the excess adhesive.
Drain cock unit:

20 N·m (2.0 kgf·m, 14 lbf·ft)
T.R
3. Check:
¡ Joint
NOTE:
¡ When removing the drain cock 2 (op), ap-
ply LOCTITE® No. 572 or equivalent to two
or three threads. Install the drain cock unit
and thoroughly wipe off the excess ad-
hesive.
¡ Position the drain cock 2 (op) with hose
joint 3 toward the downward.
Drain cock:
44 N·m (4.5 kgf·m, 32 lbf·ft)
T.R
8-20
Assembly
TB
1207B 1. Remove old adhesive and clean the gas-
ket matching surfaces of the side plate
2 and heat exchanger.
2. Apply Three Bond® TB-1207B to the gas-
3
ket 1 matching surfaces of the side
plate 2 and heat exchanger 3. Let it dry
1 NEW for at least 5 minutes.
3. Install:
¡ Gasket 1 (new)
¡ Side plates 2
a
¡ Bolts
(onto heat exchanger 3)
Bolt (side plate):

12 N·m (1.2 kgf·m, 8.7 lbf·ft)
T.R
NOTE:
¡ Install the left side plate, inlet pipe A up-
wards.
¡ Apply LOCTITE® No. 572 or equivalent to
the bolt threads before installation.
Installation
Reverse the “REMOVAL” procedure.
1. Install:
¡ Heat exchanger 1
NOTE:
Align the projection A of the heat exchanger
with hole B in the heat exchanger bracket
2.
2. Install:
¡ Gasket (new)
¡ Joint 1
8-21
3. Fill:
¡ Cooling system
page 3-36.
4. Check:
Drop in pressure (leak) → Repair as
required.
TEM” on page 8-2.
8-22
LUB E
CHAPTER 9
LUBRICATION SYSTEM
OIL PUMP ................................................................................................................................ 9-1

Removal .............................................................................................................................. 9-2
Oil Pump Disassembly ...................................................................................................... 9-4
Check and Repair ............................................................................................................... 9-4
Installation .......................................................................................................................... 9-6
OIL COOLER, RELIEF VALVE AND CHECK VALVE ............................................................. 9-11

Removal ............................................................................................................................ 9-12
Check ................................................................................................................................ 9-13
Installation ........................................................................................................................ 9-14
OIL NOZZLES AND CHECK VALVES ................................................................................... 9-17

Removal ............................................................................................................................ 9-18
Check ................................................................................................................................ 9-18
Installation ........................................................................................................................ 9-19
9
LUB OIL PUMP E
OIL PUMP
12 3
1
2
42 N.m(4.3 kgf.m,30 lbf.ft)

11
6 7 10
8
9
6.5 N.m(0.65 kgf.m,4.6 lbf.ft)
Connect to:
1 Timing belt cover 7 Gasket
2 Oil seal 8 Spring
3 Camshaft oil seal retainer 9 Relief valve
4 Oil seal 0 Timing gear case (oil pump assembly)
5 Timing gear case cover A Gasket
6 Plug B Gasket
9-1
LUB OIL PUMP E
Removal
1. Drain:
¡ Engine coolant
2. Drain:
¡ Engine oil
Refer to ”Engine Oil and Oil Filter
Replacement” on page 3-9.
3. Remove:
¡ Timing gears
5-17.
4. Remove:
¡ Dipstick tube 1
5. Remove:
¡ Tension rod 1
A B 6. Remove:
¡ Brackets 1 (flywheel housing)
Left side
Right side
9-2
LUB OIL PUMP E
7. Remove:
¡ Oil pan 1
Use oil pan seal cutter 2.
Oil pan seal cutter:

09032-00100
NOTE:
Insert the oil pan seal cutter 2 between the
cylinder block and the oil pan, cut through
the old gasket and remove the oil pan.
CAUTION:
¡ Do not use the oil pan seal cutter on the
timing gear case side or for the rear oil
seal retainer.
¡ Be careful not to damage the oil pan
flange.
8. Remove:
¡ Oil strainer 1
¡ Gasket 2
9. Remove:
on page 11-7.
10. Loosen:
¡ Nuts 1 (injection pump)
NOTE:
Put marks A on the injection pump and tim-
ing gear case before removal, so that the in-
jection pump can be reinstalled in the origi-
nal position.
9-3
LUB OIL PUMP E
11. Remove:
¡ Timing gear case
(oil pump assembly) 1
¡ Gasket (timing gear)
NOTE:
Using a plastic-faced hammer, lightly tap out
the timing gear case.
Oil Pump Disassembly

1. Remove:
¡ Outer rotor 1
1
2. Remove:
2 ¡ Plug 1
3
4 ¡ Gasket 2
¡ Spring 3
¡ Relief valve 4
Check and Repair

1. Check:
¡ Relief valve 1
Scratches/Wear/Damage → Replace.
9-4
LUB OIL PUMP E
2. Check:
¡ Relief valve movement
Sticking → Replace relief valve.
If necessary, replace oil pump assem-
bly.
NOTE:
Lubricate the valve with engine oil and en-
sure that it drops smoothly into the valve hole
under its own weight.
3. Check:
¡ Spring 1
4. Measure:
A ¡ Rotor body clearance
(between outer rotor 1 and pump
body 2)
¡ Rotor side clearance
(between rotors 1, 3 and precision
straight edge)
¡ Rotor tip clearance
(between outer rotor 1 and inner ro-
tor 3)
B gauge.
Out of specification → Replace oil
pump assembly.
Rotor body clearance:

0.10 – 0.17 mm
(0.0039 – 0.0067 in.)
<Limit>
0.20 mm (0.0079 in.)
Rotor side clearance:
0.03 – 0.09 mm
C
(0.0012 – 0.0035 in.)
<Limit>
0.15 mm (0.0059 in.)
Rotor tip clearance:
0.08 – 0.16 mm
(0.0031 – 0.0063 in.)
<Limit>
0.21 mm (0.0083 in.)
9-5
LUB OIL PUMP E
5. Check:
¡ Oil pump gear 1
Replace oil pump assembly.
6. Check:
¡ Oil pump rotation
Unsmooth rotation → Replace oil
pump assembly.
7. Check:
¡ Oil strainer 1
¡ Strainer net A
¡ Oil passage
Contamination → Wash and blow out.
Installation
NOTE:
sembled.
¡ Before installation, apply clean engine oil
to the oil pump rotor.
Oil Pump Assembly

1. Install:
¡ Outer rotor 1
9-6
LUB OIL PUMP E
2. Install:
4 3
¡ Relief valve 1
2
1 ¡ Spring 2
¡ Gasket 3 (new)
¡ Plug 4
NOTE:
Install the relief valve head first into the valve
body bore.
Plug:
42 N·m (4.3 kgf·m, 30 lbf·ft)
T.R
Installation
1. Remove old gasket from the cylinder
block and timing gear case.
2. Clean the sealing and contacting sur-
faces of the cylinder block and timing
gear case with non-residue solvent.
3. Apply:
(onto the groove in the timing gear
case sealing surface)
NOTE:
The gasket must be installed within 5 min-
utes of application. Otherwise the material
must be removed and reapplied.
4. Install:
¡ Gasket 1 (new)
(as shown in illustration)
5. Install:
¡ Timing gear case 1
Bolt (timing gear case):

20 N·m (2.0 kgf·m, 14 lbf·ft)
T.R
NOTE:
9-7
LUB OIL PUMP E
6. Tighten:
¡ Nuts (injection pump)
NOTE:
Align the match marks A of the timing gear
case and injection pump.
Nuts (injection pump – gear case):

18 N·m (1.8 kgf·m, 13 lbf·ft)
T.R
7. Install:
on page 11-7.
8. Fill:
¡ Engine oil
(into the oil pump housing)
Filling steps
1) Remove the screw plug 1.
2) Pour approx. 10 cc (0.061 cu. in.) of en-

gine oil into the oil pump housing.
3) Apply a layer of LOCTITE® No. 572 or

equivalent to the screw plug 1.
4) Install the screw plug.
9-8
LUB OIL PUMP E
8. Install:
¡ Gasket (new)
¡ Oil strainer 1
Bolt (oil strainer):

9 N·m (0.9 kgf·m, 6.5 lbf·ft)
T.R
9. Remove old gasket from the cylinder
block and oil pan.
10. Clean the sealing surfaces of the cylin-
der block and oil pan with non-residue
solvent.
NOTE:
Do not use a solvent which will attack the
painted surface.
11. Apply:
(to the oil pan as shown in the illus-
tration)
12. Install:
¡ Oil pan 1
Bolt (oil pan):

10 N·m (1.0 kgf·m, 7.2 lbf·ft)
T.R
NOTE:
Tighten the bolt in a crisscross pattern from
inside to outside.
A B 13. Install:
¡ Brackets 1 (flywheel housing)
Left side
Right side
9-9
LUB OIL PUMP E
14. Install:
¡ Tension rod 1
15. Install:
¡ Dipstick tube 1
Nut/Bolt (dipstick tube):

20 N·m (2.0 kgf·m, 14 lbf·ft)
T.R
Union bolt (dipstick tube):
13 N·m (1.3 kgf·m, 9.4 lbf·ft)
16. Install:
¡ Timing gears
5-17.
17. Fill:
¡ Crack case
page 3-7.

Engine oil capacity:

without oil filter change
8.4 L (7.4 imp qt, 8.9 US qt)
with oil filter change
9.2 L (8.1 lmp, 9.7 US qt)
18. Fill:
¡ Cooling system
page 3-36.
9-10
LUB OIL COOLER, RELIEF VALVE AND CHECK VALVE E
OIL COOLER, RELIEF VALVE AND CHECK VALVE
Connect to:
1 Oil cooler 7 Check valve
2 Gasket 8 Relief valve body
3 Gasket 9 Relief valve
4 Oil cooler cover 0 Spring
5 Gasket A Plug
6 Plug Tightening position
9-11
Removal
1. Drain:
¡ Engine coolant
2. Drain:
¡ Engine oil
Refer to “Engine Oil and Oil Filter
3. Remove:
¡ Oil filter
Refer to "Engine Oil and Oil Filter Re-
placement" on page 3-9.
4. Remove:
¡ Injection pump
6-17.
5. Remove:
¡ Dipstick tube 1
6. Remove:
¡ Oil cooler cover 1
(with oil cooler)
¡ Gasket
7. Remove:
¡ Oil cooler 1
¡ Gaskets
(from oil cooler cover 2)
9-12
8. Remove:
¡ Relief valve 1
¡ Gasket
9. Remove:
¡ Check valve 1
¡ Gasket
Check
1. Check:
¡ Relief valve
Push the valve with a wooden stick
to check its movement.
Sticking → Replace.
2. Check:
¡ Check valve
Push the valve ball with a wooden
stick to check its movement.
9-13
3. Check:
¡ Oil cooler 1
Clog → Wash and clean.
4. Check:
Installation
NOTE:
Thoroughly clean all parts to be assembled.
1. Install:
¡ Check valve
(with new gasket)
Check valve:
27 N·m (2.8 kgf·m, 19 lbf·ft)
T.R
2. Install:
¡ Relief valve
(with new gasket)
Relief valve:
40 N·m (4.1 kgf·m, 29 lbf·ft)
T.R
9-14
3. Install:
¡ Gaskets (new)
¡ Oil cooler 1
(to oil cooler cover 2)
Nut (oil cooler):

20 N·m (2.0 kgf·m, 14 lbf·ft)
T.R
4. Install:
¡ Gasket (new)
Nut (oil cooler):

20 N·m (2.0 kgf·m, 14 lbf·ft)
T.R
5. Install:
¡ Dipstick tube 1
Nut/bolt (dipstick tube):

20 N·m (2.0 kgf·m, 14 lbf·ft)
T.R
6. Install:
¡ Injection pump
6-17.
7. Fill:
¡ Crankcase
page 3-7.

Engine oil capacity:

Without oil filter change
8.4 L (1.85 lmp qt, 2.22 US qt)
With oil filter change
9.2 L (2.02 lmp qt, 2.43 US qt)
9-15
8. Fill
¡ Cooling system
page 3-36.
9-16
LUB OIL NOZZLES AND CHECK VALVES E
OIL NOZZLES AND CHECK VALVES
Connect to:
1 Oil nozzle
2 Check valve
3 Oil pan
9-17
Removal
1. Drain:
¡ Engine oil
Refer to “Engine Oil and Oil Filter
2. Remove:
¡ Oil pan
Refer to “OIL PUMP” on page 9-1.
3. Remove:
¡ Check valves 1
¡ Oil nozzles 2
Check
1. Check:
¡ Oil nozzle 1
Damage → Replace.
Clog → Blow out with compressed air.
2. Check:
¡ Check valve
Push the valve ball with a wooden
stick to check the movement.
9-18
Installation
1. Install:
¡ Oil nozzle 1
¡ Check valves 2
Check valves:
27 N·m (2.8 kgf·m, 19 lbf·ft)
T.R
NOTE:
Align the projection A of the oil nozzle with
the hole B in the cylinder block.
2. Install:
¡ Oil pan
Refer to “OIL PUMP” on page 9-1.
3. Fill:
¡ Crack case
page 3-7.

Engine oil capacity

8.4 L (1.85 lmp qt, 2.22 US qt)
9.2 L (2.02 lmp qt, 2.43 US qt)
9-19
TURB E
CHAPTER 10
TURBOCHARGER
TURBOCHARGER ................................................................................................................. 10-1

Precautions ....................................................................................................................... 10-3
Removal ............................................................................................................................ 10-4
Check and Repair ............................................................................................................. 10-6
Disassembly ..................................................................................................................... 10-8
Check and Repair ........................................................................................................... 10-10
Assembly ........................................................................................................................ 10-11
Installation ...................................................................................................................... 10-15
Turbocharger Pressure Measurement ......................................................................... 10-17
INTER COOLER ................................................................................................................... 10-19

Removal .......................................................................................................................... 10-20
Disassembly ................................................................................................................... 10-21
Check and Repair ........................................................................................................... 10-21
Assembly ........................................................................................................................ 10-23
Installation ...................................................................................................................... 10-24
10
TURB TURBOCHARGER E
TURBOCHARGER
Connect to:
1 Oil pipe #3 6 Air filter frame
2 Gasket 7 Air filter
3 Turbocharger 8 Joint hose
4 Oil drain pipe #1 9 Boost pipe
5 Air filter cover 0 Spacer
10-1
TURB TURBOCHARGER E
No. Part name Qty Remarks No. Part name Qty Remarks
1 Center housing 1 *2, *4 C Corer thrust 1 *2, *3, *4
2 Compressor housing 1 *2 D Plate clamp 3
3 Exhaust turbine housing 1 *1 E Snap ring 1 *2, *3, *4
4 Stud bolt 4 *1 F Ring seal 1 *2, *3, *4
5 Plug 2 *1 G O-ring 1 *2, *3, *4
6 Impeller 1 *2, *4 H Snap ring 1 *2
7 Sleeve 1 *2, *4 I O-ring 1 *2
8 Shelled wheel 1 *2, *4 J Impeller lock nut 1 *2, *4
9 Turbine wheel and shaft 1 *2, *4 K Floating bearing 2 *2, *3, *4
0 Retainer 1 *2, *4 L Thrust bearing 1 *2, *3, *4
A Seal 1 *2, *4 M Screw 5 *2, *4
B Spacer 1 *2, *3, *4 N Bolt 6
*1: Housing sub assembly
*2: Housing sub assembly
*3: Turbocharger repair kit
*4: Rotor assembly
10-2
TURB TURBOCHARGER E
Precautions
CAUTION:
1. Do not stop the engine immediately af-
ter high speed running. Let the engine
idle for about two minutes to cool it.
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 accumulation of sludge particles in the
oil pipes and, if necessary, replace the oil
pipes.
7. Completely remove old gasket adhered
to the lubrication oil pipe flange and tur-
bocharger oil flange.
8. Replace bolts or nuts only with new ones
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 overhauling or engine replacement,
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.
10-3
TURB TURBOCHARGER E
11. If the engine is running with the air filter,

case cover and hose removed, entering
foreign particles will damage the turbines
which run at very high speed.
Removal
1. Drain:
¡ Engine coolant
2. Remove:
¡ Air filter assembly 1
3. Disconnect:
3 1
(from mixing elbow 2)
4. Loosen:
¡ Clamps 3
5. Remove:
¡ Mixing elbow 2
¡ Gasket
10-4
TURB TURBOCHARGER E
6. Disconnect:
¡ Bypass pipe 1 (cooling water)
¡ Gaskets 2
¡ Oil pipe #1 3
¡ Gasket 4
NOTE:
Place a rag under the pipe ends to avoid spill-
ing fluid.
7. Disconnect:
¡ Oil drain pipe #1 1
¡ Gasket 2
8. Loosen:
¡ Hose clamp 1
(joint hose 2)
9. Remove:
¡ Bolts 3
10. Remove:
¡ Nuts 1
¡ Turbocharger 2
¡ Gasket 3
11. Remove:
¡ Boost pipe 1
¡ Gaskets
¡ Spacer 2
10-5
TURB TURBOCHARGER E
Check and Repair

1. Check:
¡ Turbine wheels 1
¡ Turbo housing 2
Cracks/Damage → Replace turbo-
charger assembly.
2. Check:
¡ Turbine wheel rotation
Rotate turbine wheel with finger.
Roughness → Replace turbocharger
assembly.
3. Check:
¡ Axial play (turbine wheel)
Insert a dial indicator into the exhaust
side, hold the turbine wheel edge by
hand and check the axial play.
Out of specification → Replace turbo-
charger assembly.
Axial play (turbine wheel)

STD:
0.050 – 0.125 mm
(0.0020 – 0.0049 in.)
<Limit>
0.155 mm (0.022 in.)
10-6
TURB TURBOCHARGER E
4. Check:
¡ Radial play (turbine shaft)
Set the dial indicator as shown in the
illustration and moving the turbine
shaft in radial direction, measure the
radial play of the shaft.
Out of specification → Replace turbo
charger assembly.
Radial play (turbine shaft)

STD:
0.075 – 0.125 mm
(0.0030 – 0.0049 in.)
<Limit>
0.165 mm (0.0065 in.)
5. Check:
¡ Oil pipe #1 1
10-7
TURB TURBOCHARGER E
Disassembly
1. Remove:
¡ Bolts 1
¡ Plate clamps 2
¡ Turbin hausing assembly 3
CAUTION:
Pay attention that the turbine wheel does
not come in touch with the exhaust turbo-
charger housing.
NOTE:
Provide match marks on the turbocharger
housing and the rotor assembly.
2. Remove:
¡ Snap ring 1
¡ Compressor housing 2
¡ O-ring
CAUTION:
¡ Put your hands on the snap ring to stop
it from jumping out.
¡ Pay attention that the impeller does not
come in touch with the compressor hous-
ing.
¡ Install the rotor assembly on the exhaust
turbocharger housing fixed to the vise.
NOTE:
Check in which way the tapered surface of
the snap ring faces.
10-8
TURB TURBOCHARGER E
3. Remove:
¡ Impeller rock nut
NOTE:
¡ Impeller rock nut is a left-handed screw.
¡ Do not knock the shaft end with a ham-
mer or the like.
4. Remove:
¡ Impeller
¡ Spacer
¡ Turbine wheel and shaft
¡ Shelled wheel
¡ Floating bearings
¡ Sleeve
5. Remove:
¡ Snap ring 1
NOTE:
Check in which way the tapered surface of
the snap ring faces.
(The flat surface should face the retainer sub
assembly.)
6. Remove:
¡ Retainer subassembly
10-9
TURB TURBOCHARGER E
7. Remove:
¡ O-ring
¡ Thrust bearing
¡ Corer thrust
¡ Ring seal
8. Cleaning and visual inspection of each

part
¡ Visually inspect the parts before
cleaning, to check any trace of seizure,
abrasion, foreign matters, and carbon
deposition.
¡ 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.
Check and Repair

1. Measure:
¡ Turbine shaft
Turbine shaft diameter limit:
C: More than 11.986 mm (0.472 in.)
Turbine shaft runout limit:
D: Less than 0.005 mm (0.0001 in.)
2. Measure:
¡ Center housing
Bearing case inside diameter limit:

A: Less than 18.012 mm (0.713 in.)
B: Less than 20.02 mm (0.778 in.)
10-10
TURB TURBOCHARGER E
3. Measure:
¡ Corer thrust
Corer thrust height limit:

H: More than 5.075 mm (0.2 in.)
4. Measure:
¡ Floating bearing
Floating bearing
Inside diameter limit:
Outside diameter limit:
More than 17.92 mm (0.705 in.)
5. Measure:
¡ Thrust bearing
Thrust bearing thickness limit:

More than 4.94 mm (0.194 in.)
Assembly
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.
1. Install:
¡ Exhaust turbine housing
Clamp the exhaust turbocharger
housing in a vise with soft-jaws.
10-11
TURB TURBOCHARGER E
2. Install:
¡ Turbine wheel and shaft 1
¡ Ring seal 2
¡ Ring guide 3
NOTE:
¡ DO NOT use any deformed ring seal.
¡ Apply engine oil to ring seal.
3. Install:
¡ Center housing
¡ Shelled wheel
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. Install:
¡ Center housing
5. Install:
¡ Floating bearings
¡ Sleeve
NOTE:
Apply engine oil to floating bearings.
10-12
TURB TURBOCHARGER E
6. Install:
¡ Thrust bearing 1
¡ Corer thrust 2
NOTE:
¡ Make sure that the notch on the thrust
bearing is aligned with the oil drain line
on the center housing.
¡ The chamfer on the corer thrust must face
the center housing.
Screw:
1.5 – 2.0 N·m
T.R
(0.15 – 0.2 kgf·m, 1.0 – 1.4 lbf·ft)
7. Install:
¡ O-ring 1
¡ Retainer 2
¡ Snap ring 3
NOTE:
The flat face of the snap ring must face the
retainer sub assembly.
8. Install:
¡ Spacer 1
¡ Impeller 2
¡ Impeller rock nut 3
NOTE:
Impeller rock nut is a left-handed screw.
Impeller rock nut:

8.5 – 10.0 N·m
T.R
(0.85 – 1.0kgf·m, 6.2 – 7.2 lbf·ft)
10-13
TURB TURBOCHARGER E
9. Check:
¡ Rotor assembly
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.
10. Install:
¡ Compressor housing
¡ Rotor assembly
¡ O-ring
¡ Snap ring
CAUTION:
¡ Pay attention that impeller does not
come in touch with the compressor hous-
ing.
¡ Align the match marks on the compres-
sor housing and the center housing.
NOTE:
The flat face of the snap ring must face the
retainer sub assembly.
11. Install:
¡ Plate clamps
¡ Plate lock
¡ Bolts
Bolt:
20 – 25 N·m
T.R
(2.0 – 2.5 kgf·m, 14 – 18 lbf·ft)
NOTE:
¡ Check to prevent free turning.
¡ Align the match marks on the exhaust tur-
bocharger housing and the center hous-
ing.
¡ Pay attention that impeller does not come
in touch with the exhaust turbocharger
housing.
10-14
TURB TURBOCHARGER E
Installation
NOTE:
After replacing the turbocharger assembly,
pour approx. 20 cc (1.2 cu. in.) of new oil into
the oil inlet and turn the turbine wheel by
hand to splash oil on the bearing.
1. Install:
¡ Gaskets (new)
¡ Spacer 2
¡ Boost pipe 1
2. Install:
¡ Gasket 1 (new)
¡ Turbocharger 2
¡ Nuts 3
NOTE:
While installing the turbocharger, connect the
joint hose 4 to the turbocharger housing.
3. Tighten:
¡ Bolts 5
¡ Hose clamp 6
(joint hose 4)
4. Install:
¡ Gasket 1 (new)
5. Connect:
¡ Oil drain pipe #1 2
10-15
TURB TURBOCHARGER E
A B 6. Install:
¡ Oil pipe #1 1
(with new gaskets 2)
Hollow bolt (oil pipe #1):

11 N·m (1.1 kgf·m, 8.0 lbf·ft)
T.R
Turbocharger housing side
Cylinder block side
7. Connect:
¡ Bypass pipe 1 (cooling water)
(with new gaskets 2)
Hollow bolt (bypass pipe):

20 N·m (2.0 kgf·m, 14 lbf·ft)
T.R
a 8. Install:
4 3
¡ Gasket 1 (new)
¡ Mixing elbow 2
NOTE:
1
2 Install the gasket 1 with the small holes A
to the side.
9. Connect:
(to mixing elbow)
10. Tighten:
¡ Hose clamps 4
11. Install:
¡ Air filter assembly 1
10-16
TURB TURBOCHARGER E
12. Fill:
¡ Cooling system
page 3-36.
13. Check:
¡ Engine oil level
Oil level low → Add engine oil to
proper level.
page 3-7.
¡ Engine oil
Leaks → Repair.
¡ Turbocharger operation
Abnormal noise/Malfunction →
Repar or replace turbocharger.
Turbocharger Pressure Measurement
NOTE:
¡ After disassembling or replacing turbo-
charger components, check the turbo-
charger pressure.
¡ Following systems should be properly
maintained before measuring the turbo-
charger pressure.
1) Air intake system
Check for leakage or clogging between
the air filter and turbocharger inlet and
between the turbocharger outlet and cyl-
inder head.
Clogged air filter → Clean or replace the
element.
Leakage from components → Repair or
replace.
Deformed or damaged componentes →
Repair or replace.
2) Exhaust system
Check for leakage or clogging between
the cylinder head and turbocharger inlet
and between the turbocharger outlet and
exhaust pipe.
Foreign material in passages → Remove.
Leakage from components → Repair or
replace.
Deformed or damaged components →
Repair or replace.
10-17
TURB TURBOCHARGER E
1. Measure:
¡ Turbocharge pressure
Out of specification → Check.
NOTE:
When the boost pressure is lower than speci-
fication, check the air induction system in-
cluding engine room air intake, air filter, and
inter cooler.
If no malfunction is detected in those areas,
check the turbo-charger and the engine body.
Measurement steps
1) Start the engine and let it warm up to
normal operating temperature.
2) Remove the screw plug 1.
3) Install the adapter 2 and connect the
turbocharge pressure gauge 3 to it.
4) Measure the turbocharge pressure at
specified engine speed.
Standard pressure (at 3,800 r/min)

ME422STI P1:
211 ± 10 kPa
(2.15 ± 0.1 kgf/cm2, 30.6 ± 1.5 psi)
ME422STI P2:
185 ± 10 kPa
(1.89 ± 0.1 kgf/cm2, 26.5 ± 1.5 psi)
5. Remove the turbocharger pressure

gauge and adapter.
6. Apply LOCTITE® No. 572 or equivalent
to the screw plug thread.
7. Install the screw plug 1.
Screw plug 1:
10 N·m (1.0 kgf·m, 7.2 lbf·ft)
T.R
10-18
TURB INTER COOLER E
INTER COOLER
Connect to:
1 Gasket 7 Inter cooler element
2 Intake pipe 8 Side cover (right)
3 Side cover (left) 9 Seawater flow sensor
4 Rubber gasket 0 Drain hose
5 Inter cooler housing A Inter cooler bracket
6 Gasket B Anode
10-19
TURB INTER COOLER E
Removal
1. Drain:
¡ Seawater (from engine unit)
2. Check:
¡ Anode 1
NOTE:
Apply LOCTITE® 243 on the threads when
installing the anodes.
Anodes:
T.R
19 N·m (1.9 kgf·m, 14 lbf·ft)
3. Remove:
3
¡ Bolt 1 (oil separator – clamp 2)
4
2 4. Disconnect:
1 ¡ Breather hose 3
(from air filter 4)
¡ Seawater flow sensor leads 5
5
¡ Cooling hose
(from inter cooler)
5. Remove:
¡ Boost pipe 1
¡ Gaskets
¡ Spacer 2
6. Loosen:
¡ Hose clamps 1
7. Remove:
¡ Intake pipe 2
¡ Gasket 3
¡ Hose 4
10-20
TURB INTER COOLER E
8. Remove:
Disassembly
1. Remove:
¡ Side cover 1 (left)
¡ Rubber gasket 2
(with collars)
2. Remove:
¡ Side cover 1 (right)
1 ¡ Gasket
3. Remove:
¡ Rubber seal 1
¡ Inter cooler element 2
¡ Gasket
Check and Repair

1. Check:
¡ Element core
Obstruction → Blow out with com-
pressed air.
Flattened fins A → Repair or replace
element.
10-21
TURB INTER COOLER E
2. Clean:
Cleaning steps
1) Soak inter cooler element 1 for 90 to 120
minutes in clean water to loosen depos-
its.
2) Wash thoroughly with tap water and use

a stiff rod 2 to remove any deposits in-
side seawater passages.
3) Blow off any debris or deposits from sea-
water passages and dry with com-
pressed air.
3. Check:
2
1 ¡ Side covers 1
¡ Inter cooler housing 2
¡ Drain hose 3
3
1
NOTE:
Before reinstalling the seawater flow sensor
2 1 and elbow joint 2 on the right side cover
1 3, apply a layer of Three Bond® TB-1207B
or equivalent to the threads. Thoroughly
wipe off excess adhesive.
4
3
Seawater flow sensor:
65 N·m (6.6 kgf·m, 47 lbf·ft)
T.R
CAUTION:
Always use a new gasket 4 for the seawa-
ter flow sensor.
10-22
TURB INTER COOLER E
Assembly
1. Install:
¡ Gasket 1 (new)
¡ Rubber seal 3 (new)
2. Install a new gasket 1 on the housing

(rear side), and apply Three Bond® TB-
1207B over the range indicated in the il-
lustration.
NOTE:
¡ Be careful that Three Bond® TB-1207B
does not enter the sealing surface of the
gasket.
¡ Place a wave washers on the four corners.
3. Install:
¡ Gasket (new)
¡ Side cover 1 (right)
1 Nut/Bolt (side cover-right):
10 N·m (1.0 kgf·m, 7.2 lbf·ft)
T.R
NOTE:
Tighten the nuts and bolts in two stages and
in a crisscross pattern.
4. Install:
¡ Rubber gasket (new)
(with collars)
¡ Side cover (left)
Bolt (side cover-left):

10 N·m (1.0 kgf·m, 7.2 lbf·ft)
T.R
NOTE:
Tighten the bolts in two stages and in a criss-
cross pattern.
10-23
TURB INTER COOLER E
Installation
Reverse the “Removal” procedure.
CAUTION:
Always use a new gasket.
1. Install:
NOTE:
Pass the drain hose 2 through the hole in
the inter cooler bracket 3.
2. Install:
¡ Gasket 1 (new)
¡ Intake pipe 2
3. Install:
¡ Gasket (new)
¡ Spacer 2
¡ Boost pipe 1
10-24
STEER E
CHAPTER 11
POWER STEERING SYSTEM
POWER STEERING FLUID LEVEL CHECK ........................................................................... 11-1
POWER STEERING SYSTEM AIR BLEEDING ..................................................................... 11-3

11
POWER STEERING FLUID PRESSURE CHECK ................................................................... 11-4
POWER STEERING PUMP.................................................................................................... 11-7

Remorval .......................................................................................................................... 11-7
Check ................................................................................................................................ 11-7
Installation ........................................................................................................................ 11-7
POWER STEERING OIL COOLER ......................................................................................... 11-8

Remorval .......................................................................................................................... 11-8
Check ................................................................................................................................ 11-8
Installation ........................................................................................................................ 11-8
POWER STEERING CYLINDER ............................................................................................ 11-8

STEER POWER STEERING FLUID LEVEL CHECK E
POWER STEERING FLUID LEVEL

CHECK
1. Inspect:
¡ Power steering fluid level
Fluid level below the specified level
→ Add recommended fluid.
Inspection steps:
CAUTION:
DO NOT operate the engine without cool-
ing water supplied to the lower unit. Dam-
age can occur from the engine overheating.
¡ Run the engine until it reaches normal

operating temperature.
¡ While operating the engine, turn the
steering lever all the way to right and left
several time.
Turn the steering lever until the drive unit
is pointing straight back and is centered.
Stop the engine.
1 2
¡ Remove the filler cap 1 from the reser-
voir tank 2 of the power steering pump
and wipe the dipstick with a clean cloth.
¡ Reinstall the filler cap in the reservoir
tank, and remove the cap once again.
Check the level of fluid on the level gauge
of the filler cap.
A B When the engine is hot
A B The fluid level should be between the

“HOT” mark A on the level gauge.
When the engine is cold
The fluid level should be between the
“COLD” mark B and the end of the level
gauge.
11-1
STEER POWER STEERING FLUID LEVEL CHECK E
¡ 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 recommended power steering fluid.
Failure to use the proper fluid will cause
hose and seal damage and the system
will develop leaks.
¡ DO NOT add fluid above the indicated
level, as this will cause fluid to overflow.
If you fill the reservoir above the appro-
priate “FULL” mark, draw off the excess
with a mechanic’s syringe or a plastic
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-DHD STERN DRIVE SERVICE
MANUAL”
¡ Install the filler cap and start the engine.
After rotating the steering lever several
times all the way to right and left, set the
stern drive straight and stop the engine.
Re-inspect the fluid level.
¡ Perform air bleeding of the power steer-
ing hydraulic system if necessary.
11-2
STEER POWER STEERING SYSTEM AIR BLEEDING E
POWER STEERING SYSTEM AIR

BLEEDING
1. Air bleed
¡ 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” on page 11-1.)
2) Run the engine until it reaches normal
operating temperature.
While operating the engine, turn the
steering lever all the way to right and left
several times.
3) Turn the steering lever until the drive unit
is pointing straight back and is centered.
Stop the engine.
1 2 4) Remove the filler cap 1. Allow any foam
in the reservoir tank 2 to dissipate be-
fore checking fluid level. Add fluid to
bring the level up to the “HOT” mark A.
DO NOT over fill.
5) If the power steering fluid is foamy in
step 4), repeat steps 2) – 4) until the fluid
stops forming an the level remains con-
stant.
11-3
STEER POWER STEERING FLUID PRESSURE CHECK E
POWER STEERING FLUID PRES-

SURE CHECK
1. Install:
¡ Pressure gauge
Power steering fluid pressure

gauge set (From BANZAI):
PSG-6TB
 PSG-FJL...1
1
 
 2
PSG-2ST...2
CAUTION:
Fully open the pressure gauge valve.
2. Air bleed
Refer to “POWER STEERING SYSTEM
AIR BLEEDING” on page 11-3.
3. Check:
¡ Power steering fluid leaks
Start the engine and check for leaks.
Repair if necessary.
4. Warming-up
¡ Power steering fluid
Run the engine until it reaches nor-
mal specified temperature.
While operating the engine, turn the
steering lever all the way to right and
left several times.
Specified temperature:
100 – 110 °C (212 – 230 °F)
11-4
STEER POWER STEERING FLUID PRESSURE CHECK E
5. Inspection:
Power steering
cylinder
Reservoir tank ¡ Hydraulic pressure generated by the
power steering pump
While the engine is at idle, fully close
the pressure gauge valve and mea-
sure the hydraulic pressure.
Power steering CAUTION:

pump
¡ Do not keep the presser gauge valve
closed by more than10 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 – 109.2 kgf/cm2,
1422 – 1522 psi)
6. Inspection:
Power steering
cylinder
Reservoir tank ¡ Hydraulic pressure with no load
Measure the hydraulic pressure at en-
gine speeds of 1000 r/min and 3000
r/min. Identify the difference in pres-
sure.
If the difference exceeds the criteria,
Power steering
pump replace the flow control valve on the
power steering pump.
CAUTION:
¡ Fully open the presser gauge valve.
¡ Do not operate the steering lever.
Hydraulic pressure difference:

Less than 0.49 MPa (5 kgf/cm2,
70.0 psi)
11-5
STEER INSTALLATION E
7. Inspection:
Power steering
cylinder
Reservoir tank ¡ Hydraulic pressure generated by the
power steering cylinder
While the engine is at idle, turn the
steering lever all the way to right and
left, and measure the hydraulic pres-
sure.
Power steering
pump
If the measurement exceeds the cri-
teria, recheck the steering cable stroke
and the steering cylinder attachment.
Correct any abnormality by making
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,
70.0 psi)
8. Remove:
¡ Pressure gauge
9. Air bleed:
(Refer to “POWER STEERING SYS-
TEM AIR BLEEDING” on page 11-3.)
10. Inspect:
¡ Power steering fluid level.
(Refer to “POWER STEERING FLUID
LEVEL CHECK” on page 11-1.)
11-6
STEER POWER STEERING PUMP E
POWER STEERING PUMP

Remorval
1. Drain:
2. Disconnect:
¡ Power steering feed hose (from res-
ervoir tank
¡ Power steering high pressure hose (to
power steering cylinder)
3. Remove:
¡ Power steering pump 1
Check
1. Check:
Installation
1. Install:
¡ Power steering pump 1
(with new gasket)
2. Connect:
¡ Power steering feed hose
¡ Power steering return hose
3. Fill:
4. Check:
1 Leaks → Repair.
¡ Power steering operation
Abnormal noise/Malfunction →
Replace power steering pump.
11-7
POWER STEERING OIL COOLER /
STEER POWER STEERING CYLINDER E
POWER STEERING OIL COOLER

Remorval
1. Drain:
2. Remove:
¡ Boost pipe
3. Disconnect:
4 2
¡ Power steering hose 1 (from power
3
steering cylinder)
¡ Power steering hose 2 (to reservoir
tank)
¡ Water hoses 3
4. Remove:
1
3
Check
1. Check:
Installation
1. Install:
2. Connect:
¡ Power steering hose 1 (from power
steering cylinder)
¡ Power steering hose 2 (to reservoir
tank)
¡ Water hoses 3
3. Fill:
4. Check:
Leaks → Repair.
POWER STEERING CYLINDER

Refer to “DE-DHD STERN DRIVE SERVICE
MANUAL”.
11-8
– +
ELEC E
CHAPTER 12
ELECTRICAL SYSTEM
AUTO QUICK GLOW SYSTEM ............................................................................................ 12-1

Circuit Diagram ................................................................................................................ 12-1
Check and Repair ............................................................................................................. 12-2
Glow Relay ....................................................................................................................... 12-3
STARTING SYSTEM ............................................................................................................. 12-6

Circuit Diagram ................................................................................................................ 12-6
12
Check and Repair ............................................................................................................. 12-7
STARTER MOTOR ................................................................................................................. 12-9

Removal .......................................................................................................................... 12-10
Disassembly ................................................................................................................... 12-10
Check and Repair ........................................................................................................... 12-12
Assembly ........................................................................................................................ 12-18
Starter Motor Operation Test ........................................................................................ 12-20
Installation ...................................................................................................................... 12-21
CHARGING SYSTEM .......................................................................................................... 12-22

Circuit Diagram .............................................................................................................. 12-22
ON-Boat Check ............................................................................................................... 12-23
Charging Circuit Check .................................................................................................. 12-24
ALTERNATOR ...................................................................................................................... 12-26

Removal .......................................................................................................................... 12-27
Disassembly ................................................................................................................... 12-27
Check and Repair ........................................................................................................... 12-30
Assembly ........................................................................................................................ 12-34
Installaton ....................................................................................................................... 12-38
FUEL SYSTEM .................................................................................................................... 12-39

Circuit Diagram .............................................................................................................. 12-39
Check and Repair ........................................................................................................... 12-40
OTHER COMPONENTS ...................................................................................................... 12-42

Oil Pressure Sender ....................................................................................................... 12-42
Oil Pressure Switch ....................................................................................................... 12-42
Seawater Flow Sender .................................................................................................. 12-43
Water Temperature Sensor ........................................................................................... 12-43
Thermo Switch ............................................................................................................... 12-44
– +
ELEC AUTO QUICK GLOW SYSTEM E
AUTO QUICK GLOW SYSTEM

Circuit Diagram
Connect to:
1 Battery 7 Glow lamp
2 Main switch 8 Fuse (100 A)
3 Fuse (20 A) 9 Glow relay
4 Neutral switch 0 Glow plug
5 Pickup (tacho) sensor A Alternator
6 Glow control box B Starter motor
12-1
– +
NOTE:
Glow relay control:
The glow relay is switched ON for 19 ± 2 sec-
onds when the main switch is turned to ON.
When the engine speed reaches 400 ± 50
r/min, the relay is switched OFF.
The relay is also switched ON while the main
switch is held in the START position, and
stays ON for 1 ± 0.5 seconds after the main
switch returns to the ON position.
Glow lamp control:
The glow lamp is lit for 4 ± 0.4 seconds after
the main switch is switched ON.
When the engine speed reaches 400 ± 50
r/min, the lamp goes OFF.
Check and Repair

Terminal
R/Pu Pu Y/R
Main Switch
Switch
position 1. Check the continuity between terminals
OFF marked “ — ” in each position of the
main switch.
ON
If there is no continuity, replace the main
switch.
START
1 Neutral Switch
1. Check:
¡ Neutral switch
Checking steps
1) Disconnect the neutral switch coupler 1
from the wire harness.
2) Put the remote control lever in “NEU-
TRAL”.
Terminal A1 A2
Switch
position Y/R Y/R G/L B
FREE
PUSH
12-2
– +
3) Check the switch component for conti-

nuity between “Yellow/Red 2 and Yel-
low/Red 3“.
If there is no continuity, replace the neu-
tral switch.
Pickup (tacho) Sensor

1. Check:
¡ Pickup (tacho) sensor
Checking steps
1) Disconnect the pickup (tacho) sensor
1
coupler 1 from the wire harness.
2) Check the pickup (tacho) sensor for con-

tinuity between 2 and 3.
If there is no continuity, replace the
pickup (tacho) sensor.
Glow Relay
1. Check:
¡ Glow relay
NOTE:
Verify each wire color of the starter relay.
Checking steps
1) Disconnect the glow relay coupler 1
from the glow relay.
2) Connect the battery (12 V) to 2 and 3
terminals of the glow relay coupler.
3) Check the glow relay for continuity be-
tween 4 and 5 terminals.
If there is no continuity, replace the glow
relay.
12-3
– +
Glow Plug
NOTE:
¡ Be careful not to damage the glow plug
pipes as this could cause an open circuit
or shorten the life of the plug.
¡ Avoid contaminating the glow plug with
oil or gasoline when cleaning.
¡ During check, be sure to wipe any oil off
the glow plug terminal and bakelite
washer with a dry cloth.
¡ Be careful not to apply more than 11 volts
to the glow plug as this could cause an
open circuit.
1. Check:
¡ Glow plug
Checking step
1) Remove the glow plug holder 1.
2) Check the glow plug for continuity be-

tween the glow plug terminal 2 and
ground 3.
If there is no continuity, replace the glow
plug.
Glow Control Box

1. Check:
¡ Glow control box 1
Connect pocket tester leads to each
terminal of control box on indicated
table.
12-4
– +
NOTE:
(*) marks indicate that because of the con-
denser the pocket tester needle might keep
oscillating for a few moments after the tester
probes are connected to the terminals. Wait
until the needle stabilizes in order to get on
accurate reading.
Pocket tester positive (+) probe

Pocket tester negative (–) probe
12-5
– +
ELEC STARTING SYSTEM E
STARTING SYSTEM
Circuit Diagram
Connect to:
1 Battery 6 Diode
2 Starter motor 7 Fuse (20 A)
3 Starter relay 8 Alternator
4 Main switch 9 Fuse (100 A)
5 Neutral switch
12-6
– +
Check and Repair

Main Switch
1. Check:
¡ Main switch
Refer to “Main Switch” on page 12-2.
Neutral Switch
2. Check:
¡ Neutral switch
Refer to “Neutral Switch” on page 12-
2.
Diode
1
1. Check:
¡ Diode
Checking steps
1) Disconnect the diode from the lead cou-
pler 1.
2) Check the diode for continuity between
2 and 3 terminals.
Tester (+) lead → 2 terminal.

Tester (–) lead → 3 terminal.
If there is continuity, replace the diode.

3) Check the diode for continuity between
and terminals.
Tester (+) lead → 3 terminal.

Tester (–) lead → 2 terminal.
If there is no continuity, replace the di-

ode.
12-7
– +
Starter Relay
1. Check:
¡ Starter relay
NOTE:
Verify each wire color of the starter relay.
Checking steps
1. Disconnect the starter relay coupler 1
from the starter relay.
2. Connect the battery (12 V) to 2 and 3
terminals of the starter relay.
3. Check the starter relay for continuity be-
tween 4 and 5 terminals.
starter relay.
12-8
– +
ELEC STARTER MOTOR E
STARTER MOTOR
Connect to:
1 End cover 8 Magnetic switch
2 Brush holder 9 Compression spring
3 Brush 0 Steel ball
4 Field frame A Armature
5 Bearing B Starter housing
6 Armature C Idler gear
7 Plate washer D Bearing
12-9
– +
Removal
1. Disconnect:
¡ Negative (–) lead 1
(from battery terminal)
2. Disconnect:
¡ Starter motor leads 2
¡ Magnetic switch lead 3
3. Remove:
¡ Starter motor 4
Disassembly
1. Disconnect:
¡ Field coil lead 1
2. Remove:
¡ Bolts 2
¡ Field frame 3
(with armature)
3. Remove:
¡ Felt washer 1
(from starter housing)
4. Remove:
¡ Screws 1
¡ Starter housing 2
(from magnetic switch)
12-10
– +
5. Remove:
¡ Return spring 1
¡ Idler gear 2
¡ Bearing 3
¡ Plate washer 4
(from starter housing 5)
6. Remove:
¡ Steel ball 1
(from clutch shaft hole A)
Using a magnetic rod 2.
7. Remove:
¡ End cover 1
(from field frame)
8. Remove:
¡ Brushes 1
¡ Brush holder 2
NOTE:
Using a screwdriver, hold the spring back and
disconnect the brushes 1 from the brush
holders 2.
9. Remove:
¡ Armature 1
(from field frame 2)
12-11
– +
Check and Repair

Armature Coil
1. Check:
¡ Armature coil
(open circuit and ground)
A Checking steps
For open circuit : (continuity)
1) Using an ohmmeter (Ω x 1), check that
there is continuity between the segments
of the commutator.
If there is no continuity, replace the ar-
mature.
B For ground : (No continuity)

1) Using an ohmmeter, check that there is
no continuity between the commutator
and armature coil core.
If there is continuity, replace the arma-
ture.
Commutator
1. Check:
¡ Commutator 1
Dirty/Burnt → Clean it with #600 grit
sandpaper or on a lathe.
2. Check:
¡ Runout (commutator)
Using a dial indicator and V-blocks.
Out of specification → Correct it on a
lathe or replace armature.
Runout limit:
12-12
– +
3. Check:
¡ Commutator diameter A
Out of specification → Replace arma-
ture.
Commutator diameter:
36.0 mm (1.417 in.)
<Limit>
35.0 mm (1.378 in.)
4. Check:
¡ Undercut depth A
Out of specification → Scrape the
mica 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 (Field Frame)

1. Check:
¡ Field coil
Checking steps
For open circuit.
1) Using an ohmmeter (Ω x 1), check that
there is continuity between the lead wire
and field coil brush lead.
If there is no continuity, replace the field
frame.
12-13
– +
For ground.
1) Using an ohmmeter, check that there is
continuity between the field coil end and
field frame.
If there is no continuity, replace the field
frame.
Brush and Brush Spring

1. Measure:
¡ Brush length A
Out of specification → Replace brush
holder and field frame.
Brush length:
20.5 – 21.0 mm
(0.807 – 0.827 in.)
<Limit>
13.0 mm (0.512 in.)
2. Check:
¡ Brush spring load
Out of specification → Replace
springs as a set.
Brush spring load:

32 – 40 N
T.R
(3.2 – 4.0 kgf, 7.1 – 8.8 lbf)
Brush holder
1. Check:
¡ Brush holder insulation
Continuity → Repair or replace.
NOTE:
Check that there is no continuity between the
positive 1 (+) and negative 2 (–) brush hold-
ers.
12-14
– +
Clutch and Gears

1. Check:
¡ Gear teeth (pinion gear)
¡ Gear teeth (idler gear)
¡ Gear teeth (clutch gear)
Burrs/Chips/Wear/Damage →
Replace gear(s) and/or clutch assem-
bly and check flywheel ring gear for
wear or damage.
2. Check:
¡ Clutch operation
Damage → Replace clutch assembly.
NOTE:
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 starter
housing 2.
2) Using a plastic-faced hammer, tap in the
stopper collar 3.
3) Using a screwdriver, pry out the snap

ring 4.
4) Remove the following parts.

¡ Stopper collar 3
¡ Pinion gear 1
¡ Retainer 5
¡ Compression spring 6
¡ Starter clutch 8
¡ Clutch shaft 0
12-15
– +
5) Replace damaged parts with new ones.

6) Assemble the following parts:
(onto clutch shaft 0)
¡ Starter clutch 8
(onto clutch shaft)
7) Assemble the following parts.

¡ Clutch shaft 0
(with starter clutch 8 into starter
housing 7)
¡ Retainer 5
¡ Pinion gear 1
¡ Stopper collar 3
8) Push down the pinion gear 1 and starter

housing 7.
9) Using snap ring pliers, install the new
snap ring 4.
CAUTION:
Always use a new snap ring.
10) Using pliers, compress the snap ring.

Check that the snap ring fits correctly.
11) Using a plastic-faced hammer, tap the

clutch shaft and install the stop collar
onto the snap ring.
12-16
– +
Bearing
1. Check:
¡ Bearings
Turn each bearing while applying in-
ward force.
Replacement steps
1) Using the bearing puller 1, remove the
bearings.
Alternator bearing puller:

09286-46011
2) Install a new bearing 2 (front) tightly

against the shoulder of the shaft.
3) Using a suitable tool 3 press in a new

bearing 4 (rear) tightly against the
shoulder of the shaft.
CAUTION:
Do not press the outer race or balls of the
bearing. Contact should be made only with
the inner rare.
Magnetic Switch
1. Check:
¡ 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.
12-17
– +
2. Check:
¡ Hold-in coil (open circuit)
Check that there is continuity between
positive (+) lead terminal 1 and
switch body 2.
No continuity → Replace magnetic
switch.
Assembly
NOTE:
Apply grease to the armature bearings, and
insert the armature into the field frame.
1. Install:
¡ Armature 1
(into field frame 2)
2. Install:
¡ Brush holder 1
¡ Brushes 2
NOTE:
¡ Using a screwdriver, hold the brush
spring back, and insert the brush into the
brush holder.
¡ Make sure that the positive (+) leads are
not grounded.
3. Install:
¡ End cover 1
12-18
– +
4. Install:
¡ Steel ball 1
(into clutch shaft hole A)
5. Install:
¡ Return spring 1
(into magnetic switch hole)
¡ Plate washer 2
6. Install:
¡ Bearing 1
¡ Idler gear 2
7. Install:
(to magnetic switch 2)
8. Install:
¡ Felt washer 1 (new)
(to the armature)
12-19
– +
9. Install:
¡ Magnetic switch 1
(onto field frame 2)
NOTE:
Align the setting point A and B.
10. Tighten:
¡ Bolts 1
11. Connect:
¡ Field coil lead 2
NOTE:
Securely fit the rubber cover 3 onto the seat
4.
Starter Motor Operation Test
CAUTION:
This test must be performed within 3 to 5
seconds to avoid damaging the coil.
1. Check:
¡ Starter motor operation
Does not move/out of specification →
Replace starter motor.
Checking steps
Pull-in test.
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.
3) Check that the clutch pinion gear moves
outward.
If the clutch pinion gear does not move,
replace the magnetic switch assembly.
12-20
– +
Hold-in test.
1) While connected as above with the clutch
pinion gear out, disconnect the negative
(–) lead 4 from the field coil terminal 2.
2) Check that the pinion gear remains out.
If the clutch pinion gear returns inward,
Clutch pinion gear return test.

1) Disconnect the negative (–) lead 5 from
the switch body.
2) Check that the clutch pinion gear returns
inward.
If the clutch pinion gear does not return,
No-load performance test.
1) Connect the battery 3 and the ammeter
6 to the starter as shown.
2) Check that the starter rotates smoothly
and steadily with the pinion gear mov-
ing out.
Check that the ammeter shows the speci-
fied current.
Specified current:
180 A or less at 11 V
Installation
1. Install:
¡ Starter motor 1
2. Connect:
¡ Starter motor lead 2
¡ Magnetic switch lead 4
Nut (terminal):
21 N·m (2.1 kgf·m, 15.5 lbf·ft)
T.R
3. Connect:
(to battery terminal)
12-21
– +
ELEC CHARGING SYSTEM E
CHARGING SYSTEM
Circuit Diagram
2
3
100A
R R
3
20A 4
R R/Pu
R/Pu
5
Br Br
1 R/Pu
12V
Br
12V
6
7
R/Pu Pu Y/R
OFF
B
ON
START
8
Y/R Y/R Br
Pu
Connect to:
1 Battery 5 Charging system warning light
2 Stater motor 6 Main switch
3 Fuse 7 Stater relay
4 Alternator 8 Diode
12-22
– +
ON-Boat Check
Battery and Electrical Connection
1. Check:
¡ Battery
Refer to “Battery Check” on page 3-
43.
2. Check:
¡ Fuses
Refer to “Fuse Check” on page 3-46.
3. Check:
¡ Electrical connections
Refer to “ELECTRICAL SYSTEM WIR-
ING DIAGRAM” on page 2-22.
Drive Belt check

1. Check:
¡ Drive belt condition
3-21.
2. Check:
¡ Drive belt deflection

100 N·m (10 kgf·m, 22.0 lbf·ft)
pressure
Alternator drive belt 1:
10 – 12 mm (0.39 – 0.47 in.)
Refer to “Drive Belt Deflection Check

and Adjustment” on page 3-22.
12-23
– +
Charging Circuit Check

1. Check:
¡ Charging system warning light circuit
Checking 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” on page
CHAPTER 13.
2. Check:
¡ 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 terminal “B”

2 of the alternator and connect it to the
negative (–) lead 3 of the ammeter 4.
2) Connect the positive (+) lead 5 of the
ammeter to terminal “B” 2 of the alter-
nator 6.
3) Connect the positive (+) lead 7 of the
voltmeter to terminal “B” 2 of the alter-
nator 6.
4) Ground the negative (–) lead 9 of the
voltmeter 8.
12-24
– +
Without load
1) At engine speeds between idling and
2000 r/min, check the reading on the am-
meter and voltmeter.
Output amperage:
10 A or less
Out put 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

standard voltage, replace the IC regula-
tor.
If the voltmeter reading is more than
standard voltage, check the IC regulator
and alternator as follows;
¡ With terminal “F” grounded, start the
engine and check the voltmeter read-
ing of terminal “B”.
If the voltmeter reading is greater than
standard voltage, replace the IC regu-
lator.
If the voltmeter reading is less than
standard voltage, check the alterna-
tor.
With load
1) At an engine speed of 2000 r/min, turn
on all accessories.
2) Check the reading on the ammeter.
Output amperage:
30 A or more
If the ammeter reading is less than stan-
dard amperage, repair the alternator.
Refer to “ALTERNATOR” on page 12-26.
NOTE:
With the battery fully charged, the indication
will sometimes be less than standard amper-
age.
12-25
– +
ELEC ALTERNATOR E
ALTERNATOR
Connect to:
1 Pulley 9 Rectfier end frame
2 Drive end frame (stator) 0 Seal plate
3 Bearing A Rectifier holder
4 Bearing retainer B IC regulator
5 Rotor C Brush holder
6 Bearing D Holder cover
7 Bearing retainer E End cover
8 Bearing cover
12-26
– +
ELEC ALTERNATOR E
Removal
1. Disconnect:
(from battery terminal)
2. Disconnect:
¡ Alternator leads 1
3. Remove:
¡ Drive belt 1
¡ Alternator 2
3-21.
Disassembly
1. Remove:
¡ Nut 1
¡ Terminal insulator 2
2. Remove:
¡ End cover 1
12-27
– +
ELEC ALTERNATOR E
3. Remove:
¡ Brush holder cover 1
4. Remove:
¡ Brush holder 1
¡ IC regulator 2
5. Remove:
¡ Rectifier holder 1
6. Remove:
¡ Rubber insulators 1
7. Remove:
¡ Seal plate 1
12-28
– +
ELEC ALTERNATOR E
8. Remove:
¡ Pulley
Removal steps
1) Hold the alternator wrench “A” 1 with
a torque wrench, and tighten the alter-
nator wrench “B” 2 clockwise to the
specified torque.
Alternator wrench:
09820-63010 or (90890-07431)
T.R
Alternator wrench “B”:
40 N·m (4.1 kgf·m, 29 lbf·ft)
NOTE:
Check that the alternator wrench “A” is fit-
ted securely to the rotor shaft.
2) Clamp the alternator wrench “C” 3 in a

vise, and install the alternator to the al-
ternator wrench “C” as shown in the il-
lustration.
3) To loosen the pulley nut, turn alternator
wrench “A” clockwise .
NOTE:
To prevent damage to the rotor shaft, do not
loosen the pulley nut more that one-half of a
turn.
4) Remove the alternator from the alterna-

tor wrench “C”.
5) Remove the alternator wrench “A” and
“B”.
6) Remove the pulley nut 4 and pulley 5.
9. Remove:
¡ Nuts 1 (rectifier end frame 2)
12-29
– +
ELEC ALTERNATOR E
10. Remove:
¡ Rectifier end fram 1
Use bearing puller 2.

09286-46011
11. Remove:
¡ Washer 1
12. Remove:
¡ Rotor 1
(from drive end frame 2)
Check and Repair

Roter
1. Check:
¡ Rotor
Checking steps
A For open circuit .
1) Using an ohmmeter 1 (Ω x 1), check that
there is continuity between the slip rings
2.
If there is no continuity, replace the ro-
tor.
Rotor coil resistance:

2.7 – 3.1 Ω at 20 °C (68 °F)
12-30
– +
ELEC ALTERNATOR E
B For Ground .
there is continuity between the slip ring
2 and the rotor 3.
If there is continuity, replace the rotor.
Slip rings
1. Check:
¡ Slip rings
Rough/Scored → Replace rotor and
brushes as a set.
2. Measure:
¡ Slip ring diameters A
Out of specification → Replace rotor.
Slip ring diameter:

14.2 – 14.4 mm
(0.559 – 0.567 in.)
<Limit>
12.8 mm (0.504 in.)
Stator
1. Check:
¡ Stator
A Checking steps
For open circuit .
there is continuity between the coil leads
2.
If there is no continuity, replace the drive
end frame assembly.
12-31
– +
ELEC ALTERNATOR E
B For Ground .
there is continuity between the coil leads
2 and drive end frame 3.
If there is no continuity, replace the drive
end frame assembly.
Brushes
1. Measure:
¡ 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.)
Rectifiers
1. Check:
¡ Rectifiers
Checking steps
Positive side rectifier.
1) Connect one tester probe of the ohmme-
ter 1 (Ω x 1) to the positive (+) terminal
2 and the other to one of the rectifier
terminals 3. Read the ohmmeter.
2) Reverse the tester probes and read the
ohmmeter again.
3) One reading must show continuity, one
no continuity.
If both show continuity or no continuity,
replace the rectifier holder.
5) Repeat steps 1 and 2 with each terminal.
For negative side rectifier.

1) Connect one tester probe to one of the
rectifier terminals 3 and the other to the
rectifier negative (–) terminal 4.
Read the ohmmeter.
2) Reverse the tester probes and read the
ohmmeter again.
12-32
– +
ELEC ALTERNATOR E
3) One reading must show continuity, one

no continuity.
If both show continuity or no continuity,
replace the rectifier holder.
4) Repeat steps 1 to 3 for each terminal.
Bearings
1. Check:
¡ Bearing 1 (front)
Replacement steps
1) Remove the bearing retainer 1.
2) Using a suitable socket wrench 2, press

out the front bearing 3.
3) Using the suitable tool 4 and a press,

install a new bearing.
12-33
– +
ELEC ALTERNATOR E
4) Install the bearing retainer 1.
2. Check:
¡ Bearing 1 (rear)
Replacement steps
1) Using the bearing puller 1, remove the
bearing cover 2 and bearing 3.

09820-00021
CAUTION:
Be careful not to damage the fan.
2) Using a suitable pipe 4 and a press, in-

stall a new bearing and bearing cover.
Assembly
1. Install:
¡ Rotor 1
(into drive end frame 2 on the pulley
3)
NOTE:
Place the drive end frame 2 on the pulley
3.
12-34
– +
ELEC ALTERNATOR E
2. Install:
¡ Washer 1
3. Install:
¡ Rectifier end frame 1
NOTE:
Using a plastic-faced hammer, lightly tap in
the end frame.
4. Tighten:
¡ Nuts 1 (rectifier end frame 2)
NOTE:
Tighten the nuts in a criss-cross pattern.
5. Install:
¡ Pulley 1
Installation steps
1) Install the pulley 1 to the rotor shaft and
tighten the pulley nut 2 by hand.
2) Hold the alternator wrench “A” 1 with

a torque wrench, and tighten the alter-
nator wrench “B” 2 clockwise to the
specified torque.
Alternator wrench:
09820-63010 or (90890-07431)
Alternator wrench “B”:

40 N·m (4.1 kgf·m, 29 lbf·ft)
T.R
12-35
– +
ELEC ALTERNATOR E
NOTE:
Check that the alternator wrench “A” is se-
cured to the rotor shaft.
3) Clamp the alternator wrench “C” 3 with

a vise, and install the alternator to the
alternator wrench “C” as shown in the
illustration.
4) To tighten the pulley nut, turn the alter-
nator wrench “A” counterclockwise .
Alternator wrench “A”:

110 N·m (11.2 kgf·m, 80 lbf·ft)
T.R
5) Remove the alternator from the alterna-
tor wrench “C”.
6) Remove the alternator wrench “A” and
“B”.
6. Install:
¡ Seal plate 1
7. Install:
¡ Rubber insulators 1
8. Install:
¡ Rectifier holder 1
12-36
– +
ELEC ALTERNATOR E
9. Install:
¡ IC regulator 1
¡ Brush holder 2
(onto rectifier end frame)
NOTE:
¡ Be careful to install the holder in the right
way.
¡ Install the five screws so that there is a
clearance A of approx. 1.1 mm (0.043 in.)
between the brush holder and connec-
tor.
Upward
10. Install:
¡ Brush holder cover 1
11. Install:
¡ End cover 1
12. Install:
¡ Terminal insulator 1
¡ Nut 2
12-37
– +
ELEC ALTERNATOR E
13. Check:
¡ Rotor rotation
Unsmooth rotation → Repair or re-
place alternator.
Installaton
1. Install:
¡ Alternator 1
¡ Drive belts 2
3-21.

100 N·m (10 kgf·m, 22.0 lbf·ft)
pressure
Alternator drive belt:
10 – 12 mm (0.39 – 0.47 in.)
2. Connect:
¡ Alternator leads 1
Nut (terminal):
8.0 N·m (0.8 kgf·m, 5.8 lbf·ft)
T.R
3. Connect:
(to battery terminal)
12-38
– +
ELEC FUEL SYSTEM E
FUEL SYSTEM
Circuit Diagram
Connect to:
1 Battery 8 Water separator warning light
2 Fuse (100 A) 9 Control box
3 Fuse (20 A) 0 Water separator switch
4 Neutral switch A Fuel cut solenoid valve
5 Glow control box B Starter moter
6 Pickup (tacho) sensor C Alternator
7 Main switch
12-39
– +
ELEC ALTERNATOR E
Check and Repair

Main Switch
1. Check:
¡ Main switch
Refer to “Main Switch” on page 12-2.
Neutral Switch
1. Check:
¡ Neutral switch
Refer to “Neutral Switch” on page 12-
2.
Pickup (tacho) Sensor

1. Check:
¡ Pickup (tacho) sensor
Refer to “Pickup (tacho) Sensor” on
page 12-3.
Water Separator Switch

1. Check:
¡ Water separator switch
Checking steps
1) Remove fuel filter cover bolt 1 and fuel
filter cover 2.
1
2
2) Disconnect the water separator switch

coupler 1.
3) Remove the water separator switch 2
from the fuel filter.
4) Connect the pocket tester to the water
separator coupler.
12-40
– +
ELEC ALTERNATOR E
A 5) Hold the switch upright and check that

there is no continuity.
If there is continuity, replace the switch.
B 6) Hold the switch upside down and

check that there is continuity.
switch.
Fuel Cut Solenoid Valve

1. Check:
¡ Fuel cut solenoid valve
Checking steps
1) Remove the solenoid valve from the in-
jection pump.
Refer to “INJECTION PUMP” on page 6-
21.
2) Connect the battery to the solenoid valve
body and terminal.
Battery (+) terminal → solenoid valve ter-

minal.
Battery (–) terminal → solenoid valve body.
3) You should feel the operation of the so-

lenoid valve as the battery is connected
and disconnected.
If the solenoid valve is not operating
properly, replace it.
12-41
– +
ELEC OTHER COMPONENTS E
OTHER COMPONENTS
Oil Pressure Sender
1. Check:
¡ Oil pressure sender
Checking steps
1) Disconnect the oil pressure sender leads
1.
2) Connect the pocket tester to the oil pres-

sure sender terminals.
3) Start the engine, and measure the resis-
tance at the specified oil pressure.
If the resistance is not as specified be-
low, 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

1. Check:
¡ Oil pressure switch
Checking step
1) Disconnect the oil pressure switch 1
from the switch lead.
2) Check the oil pressure switch for conti-

nuity between the switch terminal 2 and
cylinder body 3.
switch.
12-42
– +
3) Warm up the engine and let it run at

idling speed.
4) Check that there is no continuity in the
oil pressure switch between the switch
terminal 2 and cylinder body 3.
If there is continuity, replace the switch.
2 Seawater Flow Sender

1. Check:
¡ Seawater flow sender
1
Checking steps
1) Remove the seawater flow sender 1
from the inter cooler 2.
A 2) Connect the pocket tester to the seawa-

ter flow sender leads.
3) Hold the seawater flow sender upright
and check that there is no continuity.
If there is continuity, replace the sender.
B 4) Hold the seawater flow sender upside

down and check that there is continu-
ity.
sender.
Water Temperature Sensor

1. Check:
¡ Water temperature sensor
Checking steps
1) Remove the water temperature sensor
1 from the thermostat housing 2.
12-43
– +
2) Immerse the water temperature sensor

in water.
3) Check the resistance at the specified tem-

peratures.
If the resistance is not as specified be-
low, replace the water temperature sen-
sor.
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
Thermo Switch
1. Check:
¡ Thermo switch
Checking steps
1) Remove the thermo switch 1 from the
thermostat housing 2.
2) Immerse the thermo switch in water.
While heating the water, check the con-
ductivity at the specified temperatures.
Water temperature Conductivity
0 – 98 °C (0 – 208.4 °F) No continuity
More than 98 – 102 °C Continuity
(208.4 – 215.6 °F)
3) While cooling the water, check the con-

ductivity at the specified temperatures.
If the conductivity is not as specified, re-
place the thermo switch.
Water temperature Conductivity
More than Continuity
102 °C (215.6 °F)
102 – 93 °C No continuity
(215.6 – 199.4 °F)
Less than 93 °C No continuity
(199.4 °F)
12-44
TRBL E
CHAPTER 13
TROUBLESHOOTING
TROUBLESHOOTING DIAGRAM ......................................................................................... 13-1

How to Trouble-shoot ...................................................................................................... 13-1
ENGINE AND RELATED PARTS ........................................................................................... 13-2

Engine is Head to Start .................................................................................................... 13-2
Engine Output is Insufficient .......................................................................................... 13-8
Engine Knocks ................................................................................................................ 13-14
Excessive Amount of Fuel is Consumed...................................................................... 13-16
Excessive Amount of Engine Oil is Consumed ........................................................... 13-16
Engine Runs But Not Properly ...................................................................................... 13-17
13
Engine Stalls During Operation .................................................................................... 13-18
Abnormal Vibration Occurs .......................................................................................... 13-18
Engine Gets Overheated ............................................................................................... 13-19
Starter Motor .................................................................................................................. 13-20
Alternator ....................................................................................................................... 13-21
Lubrication System ........................................................................................................ 13-22
TURBOCHARGER ............................................................................................................... 13-24

Excessive Amount of Exhaust Smoke Comes Out...................................................... 13-24
Exhaust Smoke is White ............................................................................................... 13-25
Oil Decreases Quickly .................................................................................................... 13-25
Output Reduces ............................................................................................................. 13-25
Follow-up of Turbocharger is Poor (Slow) ................................................................... 13-25
Abnormal Noise, Abnormal Viveration ........................................................................ 13-26
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 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.
13-1
TRBL ENGINE AND RELATED PARTS E
ENGINE AND RELATED PARTS

Engine is Head to Start
Engine turns Exhaust smoke No fuel is supplied

No fuel in fuel tank Fill fuel.
over but does hardly comes to injection pump.
not start. out.
Remove and
Clogged fuel pipe clean.
page 3-26
Air drawn into fuel Repair and bleed

pipe through con- air.
nections page 3-34
Clogged strainer at Remove and

intake port of injec- clean.
tion pump page 6-21
Disassemble and
Defective fuel pump check.
Replace.
Clogged fuel filter
page 3-31
Air trapped in fuel Bleed air.

system page 3-34
Fuel is supplied to Check and repair

Pump not driven
injection pump. or replace.
Loose connection of Retighten.

injection pipe page 6-25
Malfunctioning fuel Check and repair

cut solenoid of or replace.
pickup (tacho) sensor page 6-22
Stuck injection
pump of leakage
Check and repair.
from delivery valve
due to cut spring
NOTE:
When fuel is not injected, to find out whether fuel is sup-
plied or not, loosen the air bleed screw and operate the
Priming pump.
13-2
A small amount
Air drawn into fuel Bleed air.
of exhaust smoke
system page 3-34
comes out.
Injection pipe Retighten or

cracked or loose at replace.
its connection page 3-26
Stuck delivery valve,

Check and then
defective seat or
repair or replace.
broken spring
Worn or seized
Check and then
plunger of injection
repair or replace.
pump
Clogged strainer at Remove and

intake port of injec- clean.
tion pump page 6-21
Remove and
Clogged fuel pipe clean.
page 3-26
Replace.
Clogged fuel filter
page 3-31
Insufficient amount Disassemble and

of oil fed by oil check.
pump page 9-1
Injection pump con-

Check and cor-
trol lever not fully
rect.
opened
Injection pump not

Check and cor-
returning properly
rect.
due to stuck tappet
Excessively worm
roller ring or cam- Check and repair
plate of injection or replace.
pump
Loose set screw of

Check and
injection pump con-
retighten.
trol pinion
Poor fuel flow

because of high vis- Change fuel.
cosity.
Fuel leaking from

Check and cor-
nozzle in excessive
rect.
amount and injected
page 6-3
in small amount
NOTE:
In case the amount of injected fuel is insufficient, inves-
tigate the cause carefully.
13-3
Large amount of Loose set screw of

Injection timing is Check and
exhaust smoke injection pump cou-
incorrect. retighten.
comes out. pling.
Engine assembled
Check and cor-
incorrectly, resulting
rect.
in incorrect timing.
Incorrect timing to
push down plunger
due to excessive
Replace.
wear of injection
pump roller ring or
camplate.
Incorrect injection
timing due to defec- Replace or cor-
tive injection nozzle rect.
or incorrect injection page 3-28
pressure.
Pre-heating by glow
Defective glow relay Replace.
plug relay is not
or control unit page 12-3
done properly.
Replace.
Defective glow plug
page 12-4
Poor wiring connec-

Check and cor-
tion of disconnec-
rect or replace.
tion
Water is mixed in
Fuel is incorrect. Change fuel.
fuel.
Unsuitable fuel Change fuel.
Nozzle remaining
Check and cor-
Nozzle injection con- open caused by noz-
rect.
dition is poor. zle body-to-needle
page 6-3
valve seizure
Fuel leakage due to Check and cor-

poor wear-in of noz- rect.
zle valve seat page 6-3
Low injection pres-

Check and then
sure due to incorrect
retighten.
injection pressure
page 6-3
adjustment
Damaged nozzle Replace.

hole page 6-4
Check and clean.

Clogged nozzle hole
page 6-5
13-4
Check and cor-

Temperature fails to Excessive valve
rect.
rise to ignition level clearance
page 3-13
because of insuffi-
cient compression
Replace.
pressure of engine. Broken valve spring
page 5-49
Valve kept open by Check and cor-

valve lifter rect.
Insufficient engine
Change engine
speed due to solidi-
oil.
fied 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 page 5-39
Cylinder and cylin-

Check and cor-
der head not tight-
rect.
ened enough
Recharge or
Insufficient engine
replace the bat-
cracking due to dis-
tery.
charged battery
page 3-43
NOTE:
In this case, the fuel injection quantity is enough but it is
not ignited in the combustion chamber. Investigate a
possible cause carefully.
13-5
Engine can be Correct or

Engine fails to Starter fails to turn Poor contact of
turned over replace.
turn over. over. engine switch
manually. page 12-12
Blown fuse Replace.
Disconnection in
Correct or
wiring or loose ter-
replace.
minal
Recharge or
Insufficient battery
replace.
capacity, discharge
page 3-43
Poor contact of
Correct or
commutator due to
replace.
stuck, worn or bro-
page 12-14
ken starter crush
Disconnection in
engine magnet coil Correct or
or armature coil of replace.
starter
Defective diode in
Replace.
the electrical equip-
page 12-7
ment box
Defective IC regula- Replace.

tor page 12-28
Defective starter Replace.

relay page 12-8
Starter turns over

but dose not engage
Worn ring gear teeth Replace.
with flywheel prop-
erly.
Starter's magnetic
Correct or
switch is malad-
replace.
justed
Starter's magnetic
switch engagement
is maladjusted
Starter pinion and Recharge or

Insufficient battery
ring gear do not replace.
capacity, discharge
engage properly. page 3-43
Incorrect open/close
Check and cor-
timing of magnetic
rect.
switch contact point
Worn ring gear teeth Replace.
Starter pinion not Correct.

jumping out. page 12-15
13-6
Outdrive and related Disassemble and

Seized rotating parts
parts are in poor correct or
in outdrive
condition. replace.
Foreign matter Disassemble and

caught between remove foreign
gears matter.
Solidified outdrive Change reverse

oil due to cold and reduction
weather gear oil.
Starter pinion gets

Engine cannot Recharge or
engaged with ring Insufficient battery
be turned over replace.
gear but fails to capacity, discharge
manually. page 3-43
rotate.
Insufficient starter
Check and cor-
brush to commuta-
rect.
tor contact force
Stuck starter arma- Correct or

ture replace.
Valve contacts pis-

ton because valve
operation timing Disassemble and
has been set incor- correct.
rectly during engine
assembly.
Disassemble and
Engine rotating or
correct or
sliding parts seized.
replace.
Warm up or
Solidified engine oil. change engine
oil.
NOTE:
In case the engine fails to turn over, check the starter and rotating parts for
seizure.
13-7
Engine Output is Insufficient
Small amount of Amount of fuel Repair and bleed

exhaust gas supply is insuffi- Air drawn through fuel pipe air.
comes out. cient. page 3-26
Disassemble and
Clogged fuel pipe clean or replace.
page 3-26
Disassemble and
Clogged fuel filter clean or replace.
page 3-31
Disassemble and
Clogged strainer at intake port of injection
clean or replace.
pump
page 13-2
Check and then

Cause lies in
Loose pipe connection retighten.
injection pump.
page 3-27
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 weak- Correct or

ened spring replace.
Correct or
Excessive leakage from nozzle replace.
page 6-1
Adjust.
Maladjusted injection quality
page 6-6
Faulty connection of control cable (not fully

Check and adjust.
opened)
Fuel flow is poor due to high viscosity Change fuel.
13-8
Rotating part is Rotating part other than exhaust valve apt to Correct or
seized. get seized and hard to rotate replace.
Timing out of adjustment due to error in Correct and read-

engine assembly just timing.
Incorrect timing to push up plunger due to

Replace and read-
excessive wear of injection pump roller ring
just.
or cam plate
NOTE:
In this case, fuel injection quantity is insufficient. Check the fuel system
carefully and check rotating parts for seizure.
Combustion is Check and cor-

Valve kept open by valve lifter
poor because rect.
engine compres-
sion pressure is Correct or
not sufficient. Valve kept open because valve stem stuck
replace.
with guide
page 5-42
Correct or
Improper air-tightness due to poor wear-in of
replace.
valve seat
page 5-39
Replace.
Broken valve spring
page 5-49
Excessive leakage of compression pressure Correct to

due to worn cylinder or stuck piston ring replace.
Check and cor-

Lack of cylinder to cylinder head tightness
rect.
Combustion is
Water mixed in fuel Change fuel.
faulty.
Timing is
Advanced timing due to error in engine Correct and
advanced exces-
assembly adjust.
sively.
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 is black.
13-9
Spray condition Check and cor-

Nozzle kept open due to nozzle body-to-nee-
from nozzle is rect.
dle valve sticking
not good. page 6-3
Correct or
Leakage due to poor wear-in of nozzle needle replace.
page 6-5
Low injection pressure due to incorrect injec- Check and cor-

tion pressure adjustment rect.
Replace.
Broken nozzle pressure spring
page 6-4
Clean or replace.
Clogged nozzle injection hole
page 6-5
Combustion is Check and cor-

Valve kept open by valve lifter
not done prop- rect.
erly because of
insufficient Correct or
Valve kept open due to valve stem to guide
amount of com- replace.
sticking.
pressed air. page 5-41
Correct or
Improper air tighteness due to poor wear-in
replace.
of valve seat
page 5-39
Replace.
Broken valve spring
page 5-49
Excessive compressed air leakage due to Correct or

worn cylinder or stuck piston ring replace.
Cylinder and cylinder head not tightened Check and cor-

properly rect.
Amount of air reduced because engine is

overheated and intake air is expanded.
NOTE:
If fuel is injected unevenly among cylinders, combustion condition deteri-
orates, 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.
13-10
Exhaust gas con- Improper setting of injection pump timing Adjust.

Timing is
tains much white
retarded.
smoke. Loose timing adjusting bolt of coupling Retighten.
Worn injection pump cam plate and roller Correct or

ring replace.
Adjust and then

Loose adjusting bolt
tighten.
Correct or
Compression is
Excessively worn piston ring and liner replace.
low.
page 5-82
Correct of
Stuck piston ring
replace.
Make wear-in.
Poor contact of valve seat
page 5-39
Incorrect valve timing, broken valve spring or

Adjust or replace.
incorrect valve clearance
Exhaust gas con- Timing is

tains much black advanced (with Improper timing setting of injection pump Adjust.
smoke. knocking 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 Adjust.

Decreased injection pressure
inject properly. page 6-3
Replace.
Broken nozzle spring
page 6-4
Correct or
Nozzle needle valve apt to get seized replace.
page 6-5
Correct or
Improper spray condition replace.
page 6-4
13-11
Excessive Faulty condition Piping arranged improperly (Air apt to get Correct or
amount of exists in piping trapped) replace.
exhaust smoke and related
comes out. parts. Clogged pipe or fuel filter Clean or replace.
Check and cor-

Oil leakage from piping system
rect.
Check and cor-

Fuel oscillating in pipe
rect.
Injection pump is Bleed air.

Air mixed in pump
faulty. page 3-34
NOTE: Broken plunger spring Replace.

The color of the exhaust smoke
can be black or white depend- Worn plunger Replace.
ing on the engine and other cir-
Delivery valve spring damaged, broken or Replace or
cumstantial conditions (e.g., dust caught in it remove dust.
engine temperature, loads,
etc.). Cracked or distorted delivery valve packing Replace.
Check and adjust.

Inconsistent injection quantity
page 6-3
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.
Broken or weakened governor spring Replace.
NOTE:
The governor, being a precision part, should never be
serviced by yourself.
Replace.
Worn oil ring
page 5-82
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.
13-12
Clogged intake air port Check and clean.
Clogged exhaust air port Check and clean.
Interference to fuel flow due to engine vibra- Check and cor-

tion rect.
NOTE:
Check for any other causes for excessive exhaust smoke.
13-13
Engine Knocks
Engine is over- Immediately after engine start or while the

Engine knocks.
cooled. water temperature is low, this occurs
because compressed air at a low tempera-
ture retards the ignition timing. Normally
knocking lessens as the water temperature
rises.
Replace.
Defective thermostat
page 8-9
Injection timing
If excessively advanced, exhaust smoke
is not correct. Adjust.
becomes blackish and knocking noise
page 3-28
increases when accelerating quickly.
If excessively retarded, knocking noise is Adjust.

weak and the exhaust smoke is white. page 3-28
Fuel is not
Fuel injection pressure too low for atomiza- Adjust.
injected from
tion page 6-3
nozzle properly.
Incorrect timing due to improper fuel injec- Check and adjust.

tion pressure page 3-28
Replace.
Seized nozzle or broken nozzle spring
page 6-4
Correct or
After-dripping from nozzle replace.
page 6-3
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 and
Loose set screw
retighten.
Damaged delivery valve seat or broken

Replace.
spring
Throttle operation not available because of Replace.

worn tip of nozzle needle valve page 6-5
NOTE:
As speed increases, the injection timing becomes shorter in inverse pro-
portion to the speed, but ignition delay does not reduce as much. Thus
combustion is not controlled and both the maximum pressure and rate of
explosion increase.
13-14
Amount of intake
Maladjusted valve clearance Adjust.
air is not sufficient.
Low cetane value fuel causes large ignition

Cetane value of
delay, resulting in knocking with normal igni- Change fuel.
fuel in use is low.
tion timing
Seizure between piston or piston ring to cyl-

Engine oil comes Replace.
inder
excessively high
up to upper part
Insufficient oil scraping due to worn or stuck Replace.
of piston.
piston ring or oil ring page 5-82
Excessive clearance between cylinder and Replace.

piston page 5-80
Replace engine
Low engine oil viscosity
oil.
Engine is defec- Excessive clearance of connecting rod bear-

Replace.
tive. ing or peeled
Loose tightening bolt of connecting rod bear-

Retighten.
ing
Excessive clearance between cylinder and

Replace.
piston (the lower the engine temperature, the
page 5-82
louder the knock noise of the piston)
Remove foreign
Foreign matter in cylinder hit by piston.
matter.
13-15
Excessive Amount of Fuel is Consumed
Excessive
Nozzle is defec- Incorrect injection Adjust.
amount of fuel
tive. pressure page 6-3
is consumed.
Correct or
Faulty spray condi-
replace.
tion
page 6-3
Broken nozzle Replace.

spring page 6-4
Replace.
Stuck nozzle
page 6-5
Injection timing Refer to “Injection Timing Adjustment”

is incorrect. on page 3-28.
Amount of injec- Exhaust gas con-

Refer to “Exhaust gas contains much black
tion is not uni- tains much black
smoke.” on page 13-11.
form. smoke.
Low compres- Correct or

sion replace.
Over-cooled
Adjust or repair.
engine.
Slippery clutch
Repair or replace.
of outdrive
Excessive Amount of Engine Oil is Consumed
Excessive Oil leakage from oil seal or packing Check and correct
amount of
engine oil is Lessen oil to
Excessive amount of oil
consumed. specified amount.
Change with
Incorrect engine oil
specified oil.
Overheated or over-cooled engine Check and repair.
Replace.
Worn, stuck or broken ring
page 5-82
Replace.
Worn valve guide
page 5-42
Replace.
Worn or broken valve stem seal
page 5-57
Check and cor-

Low compression
rect.
13-16
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 defec- Adjust.

Incorrect injection pressure
tive. page 6-3
Correct or
Faulty spray condition replace.
page 6-3
Replace.
Broken nozzle spring.
page 6-4
Replace.
Stuck nozzle.
page 6-5
Compression pressure varies among cylin-

Repair.
ders excessively.
Leakage exists due to cracked or improp- Replace or

erly tightened high pressure pipe. retighten.
Air has entered fuel filter or injection Bleed air.

pump. page 3-34
Engine is over-cooled. Refer to “Engine Knocks” on page 13-14.
Poor return of control cable Repair.

Idling speed is
too high.
Defect in governor Repair.
Engine fails to Improper movement of governor spring. Repair.

operate prop-
erly at high Refer to above "Idling is rough" forcountermeasures for other symp-
speed. toms.
13-17
Engine Stalls During Operation
Engine stalls No fuel in fuel tank Fill tank.

Fuel is not fed to
during opera-
injection nozzle.
tion. Clogged ventilation device of fuel tank. Check and clean.
Clogged fuel system Check and clean.
Injection pump not operating Check and repair.
Fuel is fed to
Seized engine operation part Replace.
injection nozzle.
Check and cor-

Insufficient compression
rect.
Defective remote control box Replace.
Drain water or
Water or air mixed in fuel system
bleed air.
NOTE:
Possible cause for engine stop during operation are failure in feeding fuel and malfunction-
ing or seized propeller shaft. Check related parts to determine the cause.
Abnormal Vibration Occurs
Abnormal vibra-
Engine vibrates. Engine base is not strong enough Replace or correct.
tion occurs.
Loose engine mounting bolts Check and correct.
Loose flywheel nuts Check and correct.
Improper engine alignment Check and correct.
Loose 2-stage late coupling mounting nuts Check and correct.
Defective 2-stage late coupling Check and replace.
Unbalanced compression Check and correct.
Vibration occurs
Propeller shaft core not projecting Check and correct.
at outdrive side.
Noise occurs at
Damaged propeller Replace.
outdrive side.
Resonance Check and correct.

occurs due to
torsional vibra-
tion.
NOTE:
Possible causes for vibration are loose engine mounting bolts, resonance, defective shaft
core, etc. Check related parts to determine the cause.
13-18
Engine Gets Overheated
Engine gets Replenish.

Insufficient coolant
overheated. page 3-36
Replace.
Malfunctioning thermostat.
page 8-9
Blow by of cylinder head gasket Replace.
Loose or broken drive belt Adjust or replace.
Seized circulation pump bearing Replace.
Damaged or corroded circulation pump or

Replace.
vane
Clogged or grimed coolant passage. Clean.

• Seawater strainer
• Oil cooler element
• Water cooler element
Leakage from sea water pump sealed sec-

Replace seal.
tion
Worn or damaged sea water pump impel-

Replace.
ler
NOTE:
Possible cause for overheating are clogging in sea water system and a fault in each compo-
nent. Check entire cooling system the cause.
Sea water is Check and

Loose cap end hose
mixed in coolant. retighten.
Clean or replace.
Clogged element of heat exchanger
page 8-18
Broken pipe of water cooler element Replace.
NOTE:
Mainly check the part where sea water and fresh water are adjacent to each other.
Leakage from water pipe. Replenish.

No cooling
water comes
Check, clean and
out. Dust caught in impeller
remove dust.
Broken housing cover gasket Replace.
Damaged spline in impeller Replace.
13-19
Starter Motor
Disconnected or
Starter fails to operate even when Wiring Repair or replace.
short-circuited
starter main switch is turned to
"START" position.
Loose terminal Retighten.
Remove dust and

Poor continuity of
tighten or
terminal
replace.
Recharge.
Battery Undercharged
page 3-43
Disconnected, short-
Even when starter switch is turned Starter magnetic
circuited or broken Replace.
back, starter magnetic switch fails to switch
pull-in coil
operate and pinion doesn't get
engaged.
Poor sliding condi-
Correct.
tion or moving core
Starter magnetic switch operates and Correct or

Tooth surface not
pinion moves forward but fails to get Pinion replace. page 12-
finished properly
engaged with ring gear. 15
Tooth surface not Correct or

Ring gear
finished properly replace.
Starter magnetic switch operates and Contact point of

Starter magnetic
pinion gets engaged properly but main switch defec- Repair.
switch
starter fails to rotate. tive
Maladjusted main
Readjust timing.
switch interval
Recharge.
Battery Undercharged
page 3-43
Decrease in rotation
Wiring force due to poor Correct.
contact
Failure in motor sec-

Starter Repair or replace.
tion
Maximum speed revolution starts Starter magnetic Main contact point

Readjust timing.
before gets fully engaged. switch interval maladjusted
Starter remains engaged even after Starter magnetic Seized main contact
Replace.
engine has started. switch point
Return spring Broken of weakened Replace.
Pinion/clutch Poor sliding Correct.
13-20
Alternator
Undercharged alternator Drive belt Looseness Adjust.
Disconnected or Repair or replace.

Stator coil
short-circuited page 12-31
Disconnected or Repair or replace.

Rotor coil
short-circuited page 12-30
Alternator capacitor Defective Replace.
Transistor type reg-

Defective Replace.
ulator
Add distilled
Improper electro-
Battery water.
lytic solution
page 3-43
Short-circuited elec-
Repair or replace.
trode
Diode Defective Replace.
Transistor type reg-

Alternator is over charged. Defective Replace.
ulator
Replace.
Abnormal noise from alternator. Bearing Defective
page 12-33
Grounded or short- Replace.

Stator coil
circuited page 12-31
NOTE:
When there is trouble in the electric system, it is necessary to check parts in detail including
contact condition.
13-21
Lubrication System
A large amount of lubricant is con-

Lubricant viscosity Low Change lubricant.
sumed.
Lubricant pressure High Check and adjust.
Quantity of oil in oil

Excessive quantity Check and adjust.
pan
Correct or
Piston ring/oil ring Worn or stuck replace.
page 5-82
Correct or
Piston and liner Excessive clearance replace.
page 5-80
Correct or
Liner Deformed
replace.
Lubricant leakage
Each joint and due to loose con- Correct or
packing nection or defective replace.
packing
Piston ring and oil

Mating Correct.
ring
NOTE:
Possible cause for excessive consumption are a large gap at sliding part, leakage and exces-
sive amount of oil. Check each part of the lubrication system carefully.
Correct or
Oil pressure is slow to rise. Metal clearance Excessive
replace.
Oil filter Clogged Repair or replace.
Oil pan suction

Clogged Clean or replace.
strainer
Adjusting screw
Cylinder head Readjust.
maladjusted
Sliding part of Correct or

Worn
engine. replace.
Oil Insufficient amount Replenish.
Improper viscosity
(too high or too Change oil.
low).
13-22
Defective switch or Check and

Oil pressure fails to rise. Oil pressure sender failure in electric cir- replace.
cuit page 12-42
Oil pressure gauge Defective Repair or replace.
Defective pump or Repair or replace.

Oil pump
damaged gear page 9-4
Relief valve Defective Replace.
Improper installa- Check and

Oil pump/oil filter
tion retighten.
Pipe Clogged or cracked Clean or 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.
13-23
TRBL TURBOCHARGER E
TURBOCHARGER
Trouble in the turbocharger prevents the engine from performing its functions fully and pro-
viding 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 fol-
lowing flow chart to make proper judgement for correcting measures.
Excessive Amount of Exhaust Smoke Comes Out
Amount of Clogged air filter element Clean or replace.

intake air is not
sufficient. Close air intake port Correct.
Leakage from connection of intake air sys-

Check and repair.
tem
Impurities in oil collected at turbine seal

Turbo-charger Clean or change
causing frictional rotation of turbine spin-
fails to rotate. engine oil.
dle
Insufficient oil sup-

Seized bearing ply, clogged oil sup- Repair or replace.
ply pipe
Check and repair

High oil temperature or change engine
oil.
Unbalanced rotor Clean or replace.
Carefully observe
precautions for
Not fully warmed up
operation
or sudden stop from
described in
loaded operation
instruction man-
ual.
Contacting or broken turbine shaft or

Over-revolution Check and repair.
blower impeller
Excessive rise of Check and cor-

exhaust gas temper- rect injection
ature pump.
Remove foreign
matter and check
Entry of foreign
and repair air
matter
filter and
engine.
Damaged or worn Check and repair

bearing or replace.
Incorrect assembly Reassemble.
13-24
TRBL TURBOCHARGER E
Exhaust Smoke is White
Influence from Revolution speed fails to rise because of

Exhaust smoke
exhaust gas exhaust gas leakage before entering turbo- Clean or replace.
is white
resistance charger
Revolution speed of turbo-charger fails to

rise because of deformed or closed pipe of Correct.
exhaust system
Oil Decreases Quickly
Excessive Oil flowing out into blower and turbine

Repair or replace.
amount of due to clogged oil return pipe
engine oil is
consumed. Excessively worn or broken seal ring
Repair or replace.
caused by excessive wear of bearing
Output Reduces
Excessively worn or broken seal ring

Output reduces. Repair or replace.
caused by excessive wear of bearing
Follow-up of Turbocharger is Poor (Slow)
Follow-up of tur- Check each part

Gas leakage from exhaust system
bocharger is and repair.
poor (slow).
Air leakage from discharge side of blower Check and repair.
Clogged air filter element Clean or replace.
Grimed or damaged turbo-charger Repair or replace.
Carbon collected at sealed section of tur-

Clean or change
bine causing frictional rotation of turbine
engine oil.
spindle
Check fuel injec-

Faulty combustion tion system and
adjust.
13-25
TRBL TURBOCHARGER E
Abnormal Noise, Abnormal Viveration
Abnormal noise When nozzle of turbine casing is closed

Clean.
is heard. and gas passage is made excessively nar-
row when accelerating, blower discharge
air gets stuck and flows back (surging).
Rotating parts contact. Repair or replace.
Vibration Loose connections of turbo-charger to Check and cor-

occurs. intake/exhaust pipe and oil pipe rect.
Failure in bearing itself and contact

Repair or replace.
between its rotating parts and other parts.
Damaged blower impeller due to entry of Check and

foreign matter. remove.
Unbalanced rotor Repair or replace.
13-26
ME422STI
ME422STI
E ENGINE
SERVICE MANUAL
YAMAHA MOTOR CO., LTD.
Printed in Japan
Nov. 2005-0.5 × 1
070026
（ME422STI）
（E）
Printed on recycled paper N60-28197-ZH-11
300902-

Manul de Peças H - Onda

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ME422STI

ENGINE SERVICE MANUAL

K Apply Yamaha gear-case lubricant

indicate grade of sealing or locking agent,

ENGINE IDENTIFICATION ...................................................................................................... 1-1

PROPELLER AND ENGINE ROTATION .................................................................................. 1-1

PRE-DELIVERY CHECK ........................................................................................................... 1-4

OFF-SEASON STORAGE ........................................................................................................ 1-5

CHECKS BEFORE LAUNCHING AND STARTING THE ENGINE .......................................... 1-9

INTERNATIONAL SYSTEM OF UNITS [SI] ......................................................................... 1-11

SPECIAL TOOLS ................................................................................................................... 1-12

OTHER EQUIPMENT TOOLS ............................................................................................... 1-16

The model and serial number plate is located

MODEL PREFIX VARIATION* SERIAL NO.

PROPELLER AND ENGINE ROTA-

Handle Fuel Safety

Prevent Battery Explosion

Wear Protective Clothing

Operate Stern Drive Safely

Check Engine Alignment

When carrying out the following storage

1) Warm up the engine to normal operat-

11) Remove the battery and clean it. Add dis-

12) Lubricate the shift and throttle cables and

1) Remove the drain cocks, plugs and hoses

Preparation After Storage

1) Tighten the drain plugs of the water cool-

5) Check all the items listed under “CHECKS

CHECKS BEFORE LAUNCHING

1) Check that no fuel is leaking from a fuel

Description of “SI” Units in This Service Manual

Examples for major units

ILLUSTRATION TOOL No. TOOL NAME REMARKS

*TDG-7 Compression gauge To measure compression

09275-54001 Plunger stroke measur- To check injection timing

09950-40011 Puller B set (Page 5-11, 5-20, 5-22, 5-23)

09951-04010 Hanger 150 To remove camshaft timing pulley, oil

09955-04011 Craw No.1 To remove injection pump drive gear

09957-04010 Attachment To remove injection pump drive gear

09330-00021 Flange holder To secure crankshaft pulley

09950-50013 Puller C set (Page 5-19, 5-21, 6-20)

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

09954-05020 Claw No.2 To remove crankshaft pulley and injec-

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

09223-78010 Oil seal replacer To install crankshaft front oil seal

09316-20011 Oil seal replacer To install injection pump oil seal

09201-10000 Valve guide bush re- (Page 5-43, 5-44)

09950-70010 Handle set (Page 5-43, 5-44)

09951-07200 Handle 200 To install camshaft oil seal

09032-00100 Oil pan seal cutter To remove oil pan

09222-17011 Connecting rod bush (Page 5-85)

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

09222-05031 Guide To install connecting rod bush

09222-05041 Base To remove and install connecting rod

• 95093-10230 2-spring base To measure injection nozzle

• 95093-10300 Attachment measure To measure injection nozzle

• 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