Description

Model List:
- 6SY-STP2, 6SY655, 8SY-STP

1. Revision History
1.1. Revision Control Table
2. Safety Precautions
3. Safety Precautions
4. Engine Outline Drawings
4.1. Y-STP2 X ZF325-1
4.2. Y-STP X MG5114 IV
5. Engine Piping Diagrams
6. Location of Nameplates
6.1. Engine Nameplate (Typical)
7. Diesel Fuel
7.1. Diesel Fuel Specifications
7.2. Filling the Fuel Tank
7.3. Bleeding the Fuel System
8. Engine Oil
8.1. Engine Oil Specifications
8.2. Engine Oil Viscosity
8.3. Selection of Marine Gear Oil
9. Engine Coolant
9.1. Engine Coolant Specifications
9.2. Coolant (Closed Cooling System)
10. Principal Engine Specifications
11. Engine Service Standards
12. Tightening Torques for Standard Bolts and Nuts
12.1. Tightening Fasteners
13. Introduction
13.1. The Importance of Periodic Maintenance
13.2. Performing Periodic Maintenance
13.3. Yanmar Replacement Parts
13.4. Required EPA Maintenance – USA Only
13.5. EPA Installation Requirements – USA Only
14. Periodic Maintenance Schedule
14.1. Inspection and Maintenance of EPA Emission-Related Parts
15. Periodic Maintenance Procedures

15.1.

15.2.

15.3.

15.4.

15.5.

15.6.

16. EPA Requirements

16.1. Conditions to Ensure Compliance with EPA Emission Standards

16.2. Inspection and Maintenance

17. Safety Precautions

18. Introduction

18.1. Principal Engine Specifications

18.2. Adjustment Specifications

18.3. Cylinder Head Specifications

18.4. Camshaft and Timing Gear Train Specifications

18.5. Crankshaft and Pistons Specifications

19. Special Torque Chart

20. Special Service Tools

21. Measuring Instruments

22. Tests and Adjustments

22.1. Adjust Valve and Unit Injector Clearances

23. Cylinder Head

23.1. Cylinder Head Components

23.2. General Guidelines

23.3. Remove and Install Rocker Covers

23.4. Remove the Cylinder Head

23.5. Disassemble the Cylinder Head

23.6. Clean the Cylinder Head Components

23.7. Inspect the Cylinder Head Components

23.8. Replace the Valve Stem Seals

23.9. Replace the Valve Seat

23.10. Machine the Valves

23.11. Machine the Valve Seat Inserts

23.12. Replace the Valve Guides

23.13. Replace the Unit Injector Sleeves

23.14. Reassemble the Cylinder Head

23.15. Install the Cylinder Head

24. Pistons and Cylinder Liners

24.1. Remove and Disassemble Piston and Connecting Rod

24.2. Inspect the Connecting Rods

24.3. Replace the Wrist Pin Bushing

24.4. Inspect the Pistons and Piston Rings

24.5. Assemble the Piston and Connecting Rod

24.6. Remove the Cylinder Liners

24.7. Measure the Cylinder Liner Height

24.8. Install the Cylinder Liners

24.9. Install the Piston and Connecting Rod

25. Flywheel and Flywheel Housing

25.1. Flywheel Housing Components – 6SY Engines

25.2. Flywheel Housing Components – 8SY Engines

25.3. Remove the Flywheel

25.4. Flywheel Inspection and Repair

25.5. Replace the Rear Crankshaft Seal

25.6. Remove the Flywheel Housing

25.7. Install the Flywheel Housing

25.8. Install the Flywheel

26. Timing Gear Train

26.1. Y Components

26.2. Y Components

26.3. Check the Camshaft Timing

26.4. Remove the Front Gear Housing – 8SY

26.5. Install the Front Gear Housing – 8SY

26.6. Intermediate Gear

26.7. Camshaft Gear

26.8. Crankshaft Gear

26.9. Remove the Camshaft

26.10. Replace the Camshaft Bearings – 6SY

26.11. Replace the Camshaft Bearings – 8SY

26.12. Install the Camshaft

27. Cylinder Block and Crankshaft

27.1. Remove the Crankshaft

27.2. Measure the Oil Clearance

27.3. Inspect the Crankshaft

27.4. Recondition the Crankshaft

27.5. Inspect the Cylinder Block

27.6. Install Crankshaft

27.7. Replace the Front Crankshaft Seal

28. Exhaust Manifold

28.1. Replacing Gaskets

29. Lifting the Engine

29.1. Y Engines

29.2. Y Engines

30. Attaching Engine to Repair Stand

31. Safety Precautions

32. Introduction

33. Specifications

34. Special Service Tools

35. Fuel System Components

35.1. Fuel Delivery Components

35.2. Fuel Injector Components

36. Tests and Adjustments

36.1. Adjust the Unit Injectors

36.2. Measure the Fuel Feed Pump Pressure

36.3. Test the Fuel Pressure Relief Valve

36.4. Remove the Unit Injector

36.5. Install the Unit Injector

36.6. Replace the Fuel Feed Pump

36.7. Replace the Fuel Filter and Fuel Filter / Water Separator

36.8. Replace Return Fuel Line

36.9. Bleed the Fuel System

37. Introduction

38. Specifications

39. Special Service Tools

40. Measuring instruments

41. Tests and Adjustments

41.1. Pressure Testing Cooling System and Filler Cap

41.2. Testing the Thermostat

41.3. Drain, Flush and Fill the Engine with Engine Coolant

41.4. Venting the Cooling System – 8SY Engines Only

41.5. Coolant Pump Removal

41.6. Install Coolant Pump

41.7. Remove and Install Pulley

41.8. Change the Coolant Pump Seal

41.9. Remove and Install Thermostat

41.10. Remove and Install Fresh Water Charge Air Cooler

41.11. Remove and Install Seawater Charge Air Cooler – 6SY Engines Only

41.12. Remove and Install the Heat Exchanger

41.13. Seawater Pump

41.14. Check or Replace the Zinc Anodes

42. Introduction

43. Specifications

44. Special Service Tools

45. Tests and Adjustments

45.1. Check the Engine Oil Pressure

45.2. Remove and Install the Oil Cooler

45.3. Remove and Install Oil Cleaning Components

45.4. Replace the Engine Oil Filter – 8SY

45.5. Clean the Centrifugal Engine Oil Cleaner

45.6. Oil Pump

46. Introduction

47. General Information

47.1. Oil Leaks

47.2. Foreign Bodies

47.3. Air and Exhaust Leaks

47.4. Oil Filter

47.5. Cleaning the Compressor Wheel

48. Specifications

49. Special Service Tools

50. Component Location

50.1. Y Engines

50.2. Y Engines

51. Tests and Adjustments

51.1. Measuring Charge Pressure

51.2. If the Turbocharger Does Not Operate

51.3. Remove Turbocharger

51.4. Inspect the Turbocharger

51.5. Measure the Radial and Axial Clearance

51.6. Install the Turbocharger

52. Before You Begin Servicing

53. Introduction

54. Starter Motor Specifications

55. Starter Motor Troubleshooting

56. Remove and Install Starter Motor

57. Repair Starter Motor – Bosch JE

57.1. Components

57.2. Brush Replacement

57.3. Replace Solenoid

58. Before You Begin Servicing

59. Introduction

60. Specifications

61. Calculating Alternator Capacity

62. Alternator and Charging System Troubleshooting

63. Test and Inspection

63.1. Output Test

63.2. Brush Length

63.3. Replace Alternator Belt

64. Introduction

65. Specifications

65.1. Specifications

66. Special Service Tools

67. Function Description – Engine Management System (EMS S6)

67.1. General

67.2. Component Location

67.3. Engine Speed Sensors – T28 and T29

67.4. Charge Air Pressure and Temperature Sensor – T26

67.5. Coolant Temperature Sensor – T27

67.6. Oil Pressure Sensor – T25

67.7. EMS S6 Control Unit E44

67.8. EMS S6 Control Unit Connections

67.9. Replace the EMS S6 Control Unit

67.10. Remove the EMS S6 Wiring

67.11. Installing EMS S6 Wiring

68. Introduction

69. Troubleshooting Chart

70. Fault Codes

70.1. Working Procedure

71. After Troubleshooting or Repair

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Yanmar 6SY-STP2, 6SY655, 8SY-STP Service Manual

Description

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