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182 CHAPTER EIGHT Table 1 TIGHTENING TORQUES Fastener N*m ft.-lb. in.-lb. Seawater pump lGM, lGMlO 9 - 80 All other models 25 18 - Freshwater pump 20-25 - 177-221 Table 2 RECOMMENDED THERMOSTAT Model Opening temperature Full open temperature I All engines Seawater system Freshwater system
Chapter Nine Electrical System All engines covered in this manual are equipped with a 12-volt, negative-ground electrical system. Many electrical problems can be traced to a simple cause such as a blown fuse, a loose or corroded connection, a loose alternator drive belt or a frayed wire. While these are easily corrected problems that may not appear to be important, they can quickly lead to serious difficulty if allowed to go uncorrected. Complete overhaul of electrical components, such as the alternator or starter motor, may not be practical or economical. In some cases, the necessary bushings, bearings or other worn parts are not available for individual replacement. If tests indicate a unit with problems other than those discussed in this chapter, replace it with a new or rebuilt marine unit. Make certain, however, that the new or rebuilt part is an exact replacement for the defective one removed. Also be sure to isolate and correct the cause of the failure before installing a replacement. For example, an uncorrected short in an alternator circuit will most likely burn out a new alternator as quickly as it damaged the old one. If in doubt, always consult an expert. This chapter provides service procedures for the battery, charging system, starting system and switches. Wiring diagrams are included at the end of this book. Table 1 and Table 2 are located at the end of this chapter. NOTE Except where speczjied, F and D series engines are included when a basic model number is speczjied. For example, ifmodel 3GM is called out in a procedure, the procedure also applies to 3GMD and 3GMF BATTERY Because batteries used in marine applications endure far more rigorous treatment and are often used differently than those used in an automotive charging system, they are constructed differently. However, battery advancements developed for automotive batteries have been applied to marine batteries. This has resulted in new battery designs that provide the boater with more choices. A battery may be selected that better accommodates the electrical requirements for the engine and the boat's accessories than the typical older, wet-cell battery designs. If buying a new battery, consult with a marine dealership that sells a full line of marine batteries. To obtain the best advice, provide the engine model and a list of electri-
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YANMAR DIESEL INBOARD SHOP MANUAL O
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Contents QUICKREFERENCEDATA .......
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CHAPTER EIGHT COOLINGSYIZM ........
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GENERAL INFORMATION 7 Common nut Se
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GENERAL INFORMATION 21 Bearing Bloc
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GENERAL INFORMATION 23 b. Remove th
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Chapter Two Troubleshooting Every i
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2 8 CHAPTER TWO Ohmmeter Ohmmeter (
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30 CHAPTER TWO CHARGING SYSTEM (TYP
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32 CHAPTER TWO VOLTAGE OUTPUT TEST
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TROUBLESHOOTING 35 1. Loose pump dr
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TROUBLESHOOTING 37 LUBRICATION SYST
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TROUBLESHOOTING 39 LUBRICATION SYST
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Chapter Three Operation, Lubricatio
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OPERATION, LUBRICATION, MAINTENANCE
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50 CHAPTER THREE I Intake port Alte
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54 CHAPTER THREE Freshwater (Closed
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56 CHAPTER THREE flush it down a dr
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OPERATION, LUBRICATION, MAINTENANCE
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CHAPTER THREE Table 4 FRESHWATER (C
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66 CHAPTER FOUR able containers and
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Chapter Five Single-Cylinder Engine
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70 CHAPTER FIVE Fuel injector Open
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78 CHAPTER FIVE 5. Remove the valve
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80 CHAPTER FIVE 3. Remove the cylin
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82 CHAPTER FIVE Cylinder block 7 su
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98 CHAPTER FIVE Camshaft Valve lobe
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100 CHAPTER SIX Have the engine mod
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102 CHAPTER SIX VALVE COVER 3HM AND
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104 CHAPTER SIX EXHAUST MANIFOLD WI
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106 CHAPTER SIX
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MULTICYLINDER ENGINES 109 CYLINDER
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MULTICYLINDER ENGINES 111 Valve Rem
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MULTICYLINDER ENGINES 113 OIL PICKU
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MULTICYLINDER ENGINES 115 Cyllnder
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MULTICYLINDER ENGINES 121 3. Thorou
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126 CHAPTER SIX d. Install a dial i
Page 138 and 139: 132 CHAPTER SIX Bore 2GM 2GM20 Stro
Page 140 and 141: 134 CHAPTER SIX Cylinder block warp
Page 142 and 143: 136 CHAPTER SIX Piston ring side cl
Page 144 and 145: Chapter Seven Fuel Injection and Go
Page 146 and 147: 140 CHAPTER SEVEN Individual pumpin
Page 159 and 160: FUEL INJECTION AND GOVERNOR SYSTEMS
Page 166 and 167: 160 CHAPTER EIGHT SEAWATER COOLING
Page 168 and 169: 162 CHAPTER EIGHT SEAWATER COOLING
Page 170 and 171: 164 CHAPTER EIGHT CLOSED COOLING SY
Page 173: COOLING SYSTEM 167 1 Testing (Out o
Page 179 and 180: COOLING SYSTEM 173 SEAWATER PUMP (1
Page 181 and 182: COOLING SYSTEM 175 SEAWATER PUMP (2
Page 183: COOLING SYSTEM 177 ant or water may
Page 186 and 187: 180 CHAPTER EIGHT FRESHWATER EXHAUS
Page 191 and 192: ELECTRICAL SYSTEM 185 making or bre
Page 193 and 194: ELECTRICAL SYSTEM 187 NEEDS FULLY D
Page 195: ELECTRICAL SYSTEM 189 CHARGING SYST
Page 199 and 200: ELECTRICAL SYSTEM 193 STARTER MOTOR
Page 203: ELECTRICAL SYSTEM 197 3. To determi
Page 207: TRANSMISSION-KM SERIES 201 0 SHIFTE
Page 211 and 212: TRANSMISSION-KM SERIES 205 OUTPUT S
Page 213 and 214: TRANSMISSION-KM SERIES 207 Neutral
Page 215 and 216: TRANSMISSION-KM SERIES 209 SHIFTER
Page 217 and 218: TRANSMISSION-KM SERIES 211 Output s
Page 220 and 221: 214 CHAPTER TEN 1 Model Transmissio
Page 222 and 223: Chapter Eleven Transmission-KBW Ser
Page 224 and 225: 218 CHAPTER ELEVEN
Page 226 and 227: 220 CHAPTER ELEVEN Input shaft 1. C
Page 228 and 229: 222 CHAPTER ELEVEN 16. Measure the
Page 230: 224 CHAPTER ELEVEN 3. Push in the d
Page 233 and 234: Index A ................. Alarm buz
Page 236 and 237: 230 INDEX Tune-up cover battery ...
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232 WIRING DIAGRAMS EARLY MODELS WI
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234 WIRING DIAGRAMS LATE MODELS WIT
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