2006 Yanmar 6LY3-ETP, 6LY3-STP & 6LY3-UTP Marine Diesel Engine Service & Repair Manual (0BLY3-G00100)

Yanmar publication 0BLY3-G00100, dated October 2006, covers the 2006 Yanmar 6LY3-ETP, 6LY3-STP, and 6LY3-UTP marine diesel engines. The emissions identification section lists EPA engine family 6YDXM5.81D6H.

• Engine repair: Engine removal, disassembly and reassembly, cylinder-head servicing, piston and connecting-rod inspection, crankshaft and main-bearing checks, and timing-gear alignment.

• Fuel injection equipment: Injection-pump removal and installation, governor and electro-hydraulic timer descriptions, DENSO nozzle checks, fuel feed pump overhaul, and fuel-system bleeding.

• Cooling and lubrication: Seawater pump overhaul, heat exchanger inspection and leak testing, thermostat checks, lube oil pump measurements, filter service, and cooler cleaning.

• Turbocharger, intake, and exhaust: RHC7W teardown and reassembly, rotor-play measurements, wastegate checks, intercooler flushing, intake-silencer cleaning, and mixing-elbow inspection.

• Electronic Control System: DTC diagnostics, temperature/pressure sensor fault isolation, ECU pin assignments, Teleflex i5501E alarm information, and control-head functions.

• Electrical references: Wiring diagrams, sensor characteristic charts, fuse and relay troubleshooting, harness-location drawings, and starter/alternator construction and specifications.

Written for engineers involved in service, inspection, and maintenance, this manual assumes basic engine knowledge.

Engine Repair and Periodic Maintenance

The internal-engine chapters cover cylinder-block inspection, cylinder-head service, camshaft and tappet checks, and piston-to-cylinder size matching. Service standards distinguish standard dimensions from wear limits, while torque tables distinguish new and reused cylinder-head and main-bearing bolts.

Periodic inspection ranges from initial 50-hour/one-month checks to 2,000-hour/eight-year fuel feed pump overhaul and cooling-system cleaning, with service due at the earlier time or hour limit.

Installation and marine gear: Propeller-shaft alignment checks are included, but the centering procedure is referred to a separate installation manual. Reduction and reversing gear removal/refitting is covered; gearbox inspection and internal disassembly/reassembly require the separate marine gear service manual.

Fuel Injection Variants and Service Limits

The YPES-AL II injection-pump section explains the electronic governor, electro-hydraulic timer, and FIC-lock requirements during pump removal. Incorrect pump-bracket installation can warp the pump body and interfere with rack movement.

The nozzle specifications distinguish DLLA155P913 for the ETP from DLLA155P954 for the STP/UTP, helping identify the correct replacement nozzle for each engine version.

Internal overhaul and adjustment of the injection pump, governor, and timer are covered in a separate service volume. Precision servicing of the DENSO double-spring nozzles is assigned to authorized fuel injection equipment service shops.

Cooling, Lubrication, and Turbocharger Service

The cooling-system diagram traces the seawater and fresh-water circuits through the engine and its coolers. Fresh water pump service calls for assembly replacement rather than internal rebuilding. The seawater-pump instructions explain how incorrect rotation can twist and damage the impeller.

Lubrication diagrams show oil routing through full-flow and bypass filters, pressure regulation, and the lube oil cooler. Optional rotary waste oil pump and bilge pump/strainer sections cover inspection and service requirements.

The turbocharger chapter provides sectional views, bearing inspection limits, and component-specific tightening torques. Engine outline drawings for the YT-15 mount and fluid piping diagrams provide installation reference dimensions and circuit routing.

ECS Diagnostics and Electrical Fault Tracing

DTC entries document detection conditions, fail modes, power reduction, and fault-release conditions. Temperature and pressure sensor flowcharts combine electrical test values with harness checks and ECU pin references to help distinguish sensor faults from wiring problems.

The ECU Connector Pin Configuration and Starter Interlock Relay, Starter, and Alternator circuit support electrical tracing. Exploded starter and alternator illustrations accompany their specifications.

Remote-control coverage includes first- and second-station panels, backup throttle operation, and the optional trolling interface.

After injection-pump replacement, the ECU requires pump adjustment data. The manual explains this data-management process; rewriting is restricted to Yanmar-authorized personnel using the Yanmar service tool.

Follow the manual's precautions for engine lifting, electrical isolation, hot coolant, and rotating machinery.

Examples of Idle and Cooling Specifications

These are a few of the setup and cooling-system specifications included in the manual.

The no-load low-idle standard is 700 ± 25 RPM after warm-up. Thermostat inspection specifies an opening temperature of 69–73°C.

The coolant recovery tank has a 3.4-liter overall capacity, with 1.5 liters at the FULL mark.

Search, Bookmarks, and PDF Contents

Navigation and wiring detail: Text sections are searchable, with embedded chapter and subsection bookmarks. Some drawing labels are not searchable; small labels in the overall wiring diagram require zooming.

The single printable, English-language download is a 366-page PDF. That total includes 16 pages of revision history, foreword, contents, and safety information, and 11 blank pages.