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F250 LF250 2005: STARTING SERIAL No. F250: 6P2 1000001–1002894 LF250: 6P3 1000001–1000956 2006: STARTING SERIAL No. F250: 6P2 1002895– LF250: 6P3 1000957–

SERVICE MANUAL REVISED EDITION *LIT186160297* LIT-18616-02-97

6P2-28197-1H-11

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.

Important information

Particularly important information is distinguished in this manual by the following notations: 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 machine operator, a bystander, or a person inspecting or repairing the outboard motor.

CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to the outboard motor. NOTE: A NOTE provides key information to make procedures easier or clearer.

F250, LF250 SERVICE MANUAL REVISED EDITION ÂŠ2006 by Yamaha Motor Corporation, USA 1st Edition, May 2006 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, USA is expressly prohibited. Printed in USA LIT-18616-02-97

Contents General information Specification Periodic check and adjustment Fuel system Power unit Lower unit Bracket unit

GEN INFO

SPEC

CHK ADJ

FUEL

POWR

LOWR

BRKT â&#x20AC;&#x201C;

Electrical system Troubleshooting Index

ELEC

TRBL SHTG

1 2 3 4 5 6 7 8 9

GEN INFO

General information How to use this manual ................................................................................. 1-1 Manual format............................................................................................ 1-1 Symbol....................................................................................................... 1-2 Abbreviation............................................................................................... 1-3 Safety while working......................................................................................1-4 Fire prevention........................................................................................... 1-4 Ventilation..................................................................................................1-4 Self-protection ........................................................................................... 1-4 Part, lubricant, and sealant........................................................................ 1-4 Good working practice............................................................................... 1-5 Disassembly and assembly ....................................................................... 1-5 Identification...................................................................................................1-6 Model......................................................................................................... 1-6 Serial number ............................................................................................ 1-6 Special service tool .......................................................................................1-7 Feature and benefit ......................................................................................1-13 ECM system ............................................................................................ 1-13 Electronic fuel injection control system....................................................1-25 Ignition timing control system .................................................................. 1-29 Knock control system .............................................................................. 1-32 Variable camshaft timing control system ................................................. 1-35 Electronic throttle valve control system ...................................................1-40 Engine speed control system .................................................................. 1-43 Lower unit ................................................................................................1-47 Propeller selection ....................................................................................... 1-48 Propeller size........................................................................................... 1-48 Selection.................................................................................................. 1-48

6P21H11

Predelivery check ........................................................................................ 1-49 Checking the fuel system ........................................................................1-49 Checking the engine oil level................................................................... 1-49 Checking the gear oil level ...................................................................... 1-49 Checking the battery................................................................................ 1-49 Checking the outboard motor mounting height........................................ 1-50 Checking the remote control cable .......................................................... 1-50 Checking the steering system .................................................................1-51 Checking the gear shift and throttle operation.........................................1-51 Checking the PTT system ....................................................................... 1-51 Checking the engine start switch and engine stop lanyard switch ..........1-51 Checking the cooling water pilot hole ......................................................1-52 Test run ................................................................................................... 1-52 Break-in ................................................................................................... 1-52 After test run ............................................................................................ 1-52

6P21H11

1 2 3 4 5 6 7 8 9

GEN INFO

General information

How to use this manual

Manual format The format of this manual has been designed to make service procedures clear and easy to understand. Use the information below as a guide for effective and quality service. • Parts are shown and detailed in an exploded diagram and are listed in the component list (see 1 in the figure below for an example page). • The component list consists of part names and quantities, as well as bolt and screw dimensions (see 2 in the figure below). • Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant and lubrication point (see 3 in the figure below). • Tightening torque specifications are provided in the exploded diagrams (see 4 in the figure below for an example), and in the related detailed instructions. Some torque specifications are listed in stages as torque figures or angles in degrees. • Separate procedures and illustrations are used to explain the details of removal, checking, and installation where necessary (see 5 in the figure below for an example page). NOTE: For troubleshooting procedures, see Chapter 9, “Troubleshooting.”

LOWR

Lower unit

LOWR

Lower unit

Removing the drive shaft 1. Remove the drive shaft assembly and pinion, and then pull out the forward gear.

S62Y6740K

2 S68S6360J

No.

Part name

Q’ty

Lower unit

Plastic tie

Hose

Check screw

Gasket

Dowel pin

2 4

Bolt

Drain screw

Grommet

Not reusable

Disassembling the drive shaft

M10

Bolt

M10

Bolt

Thrust washer

Propeller

Washer

Cotter pin

Propeller nut

Trim tab

1. Install the pinion nut 1, tighten it finger tight, and then remove the drive shaft bearing 2 using a press.

Not reusable

Drive shaft holder 4 1: 90890-06518 Pinion nut holder 2: New: 90890-06715 Current: 90890-06505

Remarks

Do not reuse the bearing, always replace it with a new one.

Bearing separator 1: 90890-06534 2. Remove the needle bearing from the forward gear.

40 mm

45 mm 60 mm

CAUTION: CAUTION:

6-5

CAUTION:

• Do not press the drive shaft threads a directly. • Do not reuse the bearing, always replace it with a new one.

Not reusable

Bearing inner race attachment 3: 90890-06639

62Y5A11

Do not reuse the bearing, always replace it with a new one. Stopper guide plate 2: 90890-06501 Stopper guide stand 3: 90890-06538 Bearing puller 4: 90890-06535 Bearing puller claw 1 5: 90890-06536

Disassembling the forward gear 1. Remove the taper roller bearing from the forward gear using a press.

6-19

62Y5A11

1-1

6P21H11

How to use this manual

Symbol The symbols below are designed to indicate the content of a chapter. General information

Fuel system

GEN INFO

Bracket unit

FUEL

Specification

BRKT

Power unit

SPEC

Electrical system

POWR

Periodic check and adjustment

CHK ADJ

â&#x20AC;&#x201C;

ELEC

Lower unit

Troubleshooting

TRBL SHTG

LOWR

Symbols 1 to 6 indicate specific data. 1

1 2 3 4

5 Specified measurement 6 Specified electrical value (resistance, voltage, electric current)

Special service tool Specified oil or fluid Specified engine speed Specified tightening torque

Symbols 7 to C in an exploded diagram indicate the grade of lubricant and the lubrication point. 7

0 A

E 7 8 9 0

A M

B D

C C

Apply Yamaha 4-stroke motor oil Apply gear oil Apply water resistant grease (Yamaha grease A) Apply molybdenum disulfide grease

A Apply corrosion resistant grease (Yamaha grease D) B Apply low temperature resistant grease (Yamaha grease C) C Apply injector grease

Symbols D to I in an exploded diagram indicate the type of sealant or locking agent and the application point. D

E GM

F 1104J

D Apply Gasket Maker E Apply ThreeBond 1104J F Apply LOCTITE 271 (red) 6P21H11

271

242

572

G Apply LOCTITE 242 (blue) H Apply LOCTITE 572 I Apply silicon sealant

1-2

1 2 3 4 5 6 7 8 9

GEN INFO

General information

Abbreviation The following abbreviations are used in this service manual. Abbreviation

Description

ABYC

American Boat and Yacht Council

AFT

Aft end

API

American Petroleum Institute

BOW

Bow end

CCA

Cold Cranking Ampere

DES

Dual Engine System

ECM

Electronic Control Module

Exhaust

Intake

MCA

Marine Cranking Ampere

PCV

Pressure Control Valve

PON

Pump Octane Number = (RON + Motor Octane Number)/2

PORT

Port side

PTT

Power Trim and Tilt

Reserve Capacity

RON

Research Octane Number

SAE

Society of Automotive Engineers

STBD

Starboard side

TDC

Top Dead Center

TPS

Throttle Position Sensor

Upside

YDIS

Yamaha Diagnostic System

1-3

6P21H11

How to use this manual / Safety while working

Safety while working

To prevent an accident or injury and to ensure quality service, follow the safety procedures provided below.

Fire prevention Gasoline is highly flammable. Keep gasoline and all flammable products away from heat, sparks, and open flames.

Part, lubricant, and sealant Use only genuine Yamaha parts, lubricants, and sealants or those recommended by Yamaha, when servicing or repairing the outboard motor.

Ventilation Gasoline vapor and exhaust gas are heavier than air and extremely poisonous. If inhaled in large quantities they may cause loss of consciousness and death within a short time. When test running an engine indoors (e.g., in a water tank) be sure to do so where adequate ventilation can be maintained.

Under normal conditions, the lubricants mentioned in this manual should not harm or be hazardous to your skin. However, you should follow these precautions to minimize any risk when working with lubricants. 1. Maintain good standards of personal and industrial hygiene. 2. Change and wash clothing as soon as possible if soiled with lubricants.

Self-protection Protect your eyes by wearing safety glasses or safety goggles during all operations involving drilling and grinding, or when using an air compressor. Protect your hands and feet by wearing protective gloves and safety shoes when necessary.

6P21H11

3. Avoid contact with skin. Do not, for example, place a soiled rag in your pocket. 4. Wash hands and any other part of the body thoroughly with soap and hot water after contact with a lubricant or lubricant soiled clothing has been made. 5. To protect your skin, apply a protective cream to your hands before working on the outboard motor.

1-4

1 2 3 4 5 6 7 8 9

GEN INFO

General information

6. Keep a supply of clean, lint-free cloths for wiping up spills, etc.

Disassembly and assembly 1. Use compressed air to remove dust and dirt during disassembly.

Good working practice Special service tool Use the recommended special service tools to protect parts from damage. Use the right tool in the right mannerâ&#x20AC;&#x201D;do not improvise.

Tightening torque Follow the tightening torque specifications provided throughout the manual. When tightening nuts, bolts, and screws, tighten the large sizes first, and tighten fasteners starting in the center and moving outward. Non-reusable part Always use new gaskets, seals, O-rings, cotter pins, circlips, etc., when installing or assembling parts.

1-5

2. Apply engine oil to the contact surfaces of moving parts before assembly.

3. Install bearings with the manufacture identification mark in the direction indicated in the installation procedure. In addition, be sure to lubricate the bearings liberally. 4. Apply a thin coat of water-resistant grease to the lip and periphery of an oil seal before installation. 5. Check that moving parts operate normally after assembly.

6P21H11

Safety while working / Identification

Identification

2006

Model Model name

Approved model code

Serial No.

Applicable model

F250TR

6P2

1002895–

F250TR, LF250TR

LF250TR

6P3

1000957–

This manual covers the following model.

Serial number The outboard motor serial number is stamped on a label attached to the port clamp bracket.

1 2 3 4

Model name Approved model code Transom height Serial number

2005 Model name

Approved model code

Serial No.

F250TR

6P2

1000001– 1002894

LF250TR

6P3

1000001– 1000956

6P21H11

1-6

1 2 3 4 5 6 7 8 9

GEN INFO

General information

Special service tool

Pressure/vacuum tester YB-35956-A

Test harness (3 pins) YB-06869

Fuel pressure gauge adapter B YB-06942

Flywheel holder YB-06139

Fuel pressure gauge YB-06766

Universal puller YB-06117

Compression gauge YU-33223

Primary sheave holder YS-01880-A

Compression gauge extension YB-06563

Valve spring compressor YM-01253

1-7

6P21H11

Special service tool

Valve attachment YB-06320

Needle bearing installer YB-06434

Valve guide remover YB-06801

Driver handle (large) YB-06071

Valve guide installer YB-06810

Roller bearing installer/remover YB-06432

Valve guide reamer YB-06804

Needle bearing installer YB-06111

Neway valve seat kit YB-91044

Piston ring compressor YM-08037

6P21H11

1 2 3 4 5 6 7 8 9 1-8

GEN INFO

General information

Slide hammer YB-06096

Oil seal installer YB-06195-A

Propeller shaft and bearing housing remover YB-06335

Forward bearing installer YB-06430

Bearing puller legs YB-06523

Drive shaft bearing installer YB-06155

Drive shaft needle bearing installer and remover YB-06196

1-9

Bearing outer race attachment YB-06109

Drive shaft holder YB-06201

Taper roller bearing installer YB-06431

6P21H11

Special service tool

Needle bearing installer YB-06435

Shift rod push arm YB-06052

Pinion gear bushing installer YB-06029-4

Pinion gear shim gauge YB-06441

Needle bearing guide plate YB-06213

Shim gauge YB-06439

Forward gear bearing cup installer YB-06276-B

Digital vernier calipers YU-A5400

Forward gear outer race installer YB-06085

Backlash adjustment plate YB-07003

6P21H11

1 2 3 4 5 6 7 8 9 1-10

GEN INFO

General information

Dial indicator gauge YU-03097

Reverse gear bearing remover YB-41707

Magnetic base stand YU-A8438

Shim gauge YB-06440-A

Bearing housing puller YB-06207

PTT pressure gauge YB-06580

Backlash indicator rod YB-06265

PTT cylinder wrench YB-06175-2B

Gland nut wrench YB-06578

PTT piston vice tool YB-06572

1-11

6P21H11

Special service tool

Tilt rod wrench YB-06569

Test harness (1 pin) YB-06888

Digital multimeter YU-34899-A

Yamaha diagnostic system 60V-85300-02-00

Peak volt meter adapter YU-39991

Yamaha diagnostic system 60V-WS853-03

Spark checker YM-34487

Diagnostic test lead YB-06795

1 2 3 4 5 6 7 8 9

Test harness (2 pins) YB-06867

6P21H11

1-12

GEN INFO

General information

Feature and benefit

ECM system In the engine of the F250/LF250, the ECM controls the fuel injection volume, ignition timing, intake valve opening and closing timing, and the electronic throttle valve opening angle as well as the engine speed when the engine overheats and when the engine oil pressure is low. Reliable starting, stabilized trolling, excellent acceleration, maximum output, low fuel consumption, and low emissions are achieved by maintaining the optimum air-fuel ration and ignition timing under various engine conditions. Electronic control module system diagram

Canister

Filter Lowpressure fuel pump High-pressure fuel pump

Check valve

Fuel flow

Vapor separator tank

Oil control valve (PORT) Cam position sensor (PORT IN)

Fuel injector

Fuel filter with water separator

Vapor gas flow

Cam position sensor (PORT EX)

Vapor shut-off valve

Air flow

Control signal

Electronic throttle valve assembly TPS and Electronic throttle valve motor

Cam position sensor (STBD IN) Oil control valve (STBD)

Accelerator position sensor Electronic throttle valve control Crank position sensor Intake air pressure sensor

Variable camshaft timing control

Oil pressure sensor

Fuel injection control

ECM

Ignition timing control

: Air : Fuel : Vapor gas

1-13

Engine temperature sensor Intake air temperature sensor Knock sensor Shift cut switch

Battery

Neutral switch

S6P21110

6P21H11

Feature and benefit ECM component

4 2

E D

C 6

0 9

8 S6P21111

1 2 3 4 5 6 7 8 9 0 A B C D E F

Crank position sensor Oil control valve (PORT) Cam position sensor (PORT IN) Oil control valve (STBD) Cam position sensor (PORT EX) ECM Cam position sensor (STBD IN) Knock sensor Fuel injector Vapor separator tank High-pressure fuel pump Check valve Low-pressure fuel pump Filter Intake air temperature sensor Engine temperature sensor

6P21H11

1-14

1 2 3 4 5 6 7 8 9

GEN INFO

General information

2 3

4 5

6 A B 7

0 9

S6P21112

1 2 3 4 5 6 7 8 9 0 A B

Vapor shut-off valve TPS 1 TPS 2 Electronic throttle valve assembly Intake air pressure sensor Canister Fuel filter with water separator Neutral switch Shift cut switch Oil pressure sensor Accelerator position sensor 1 Accelerator position sensor 2

1-15

6P21H11

Feature and benefit Sensor function Sensor

Function

Crank position sensor

• Detects the engine speed. • Controls the ignition timing, fuel injection volume, engine speed, engine knock, variable camshaft timing, and electronic throttle valve opening angle. • Detects the angle of the crankshaft and the position of the pistons. (Cannot detect the position of the exhaust and compression strokes.) • Identifies cylinder groups #1 and #4, #2 and #5, and #3 and #6.

Cam position sensor (PORT EX)

• Detects the stroke position. (Example: TDC of the compression stroke or TDC of the exhaust stroke.) • Detects the strokes of the different cylinders using signals of both the crank position sensor and cam position sensor (PORT EX). • Control the variable camshaft timing.

Cam position sensor (STBD IN)

Detects the starboard advance angle using variable camshaft timing control.

Cam position sensor (PORT IN)

Detects the port advance angle using variable camshaft timing control.

TPS 1

Detects the electronic throttle valve opening angle.

TPS 2

Detects the electronic throttle valve opening angle.

Accelerator position sensor 1

Detects the throttle lever opening angle.

Accelerator position sensor 2

Detects the throttle lever opening angle.

Intake air pressure sensor

Detects the intake air pressure and controls the ignition timing and fuel injection volume.

Intake air temperature sensor

Detects the intake air temperature and controls the correction of the ignition timing.

Engine temperature sensor

Controls the correction of the ignition timing and fuel injection volume.

Neutral switch

Detects the neutral position.

Oil pressure sensor

Detects the engine oil pressure and controls the warning and engine speed when the engine oil pressure is low.

Thermoswitch

Sends signals to warn that the engine is overheating and controls the engine speed when the overheat warning is activated.

Shift cut switch

Outputs signals to decrease the engine speed to facilitate shifting.

Knock sensor

Detects abnormal combustion knock and controls the ignition timing.

6P21H11

1-16

1 2 3 4 5 6 7 8 9

GEN INFO

General information

2005 F250 6P2 1000001â&#x20AC;&#x201C;1002894 LF250 6P3 1000001â&#x20AC;&#x201C;1000956 Circuit diagram NOTE: The circled numbers in the illustration indicate the ECM terminal numbers.

Crank position sensor

Fuel injector #1 59

Fuel injector #2 60 15

Fuel injector #3 58 Fuel injector #4

Cam position sensor (PORT EX)

Fuel injector #5 56 Cam position sensor (PORT IN)

Fuel injector #6 55

Cam position sensor (STBD IN)

1 Ignition coil #1 5V

TPS 1

TPS 2

51 Ground

Accelerator position sensor 1

71 Ignition coil #2

70 47

Ignition coil #3

ECM

32 Ground

Ignition coil #4

41 62

Accelerator position sensor 2

Ignition coil #5

44 38

Ground

54 Ignition coil #6

5V Intake air pressure sensor

53 31 36 85

Electronic throttle valve relay

86 Oil pressure sensor

81 37 77 84

Electronic throttle valve motor

68 76

cd e S6P21117

1-17

6P21H11

Feature and benefit 2005 F250 6P2 LF250 6P3

1000001–1002894 1000001–1000956

c de

Intake air temperature sensor 5V Engine temperature sensor 5V

Oil control valve (STBD) 82 23 Oil control valve (PORT) 83 High-pressure fuel pump relay High-pressure fuel pump

Thermoswitch

Low-pressure fuel pump 61 Shift cut switch

Vapor shut-off valve

6 69

Neutral switch

Low oil pressure warning indicator

ECM Ground

18 Overheat warning indicator 75

Knock sensor

Diagnosis indicator

8 67

Buzzer (DES switch)

Engine stop lanyard switch

74 79

DES switch

Tachometer 72 Main relay

27 34

YDIS

7 46

Rectifier Regulator

65 Engine start switch 13

– + Battery

6P21H11

S6P21127U

1-18

1 2 3 4 5 6 7 8 9

GEN INFO

General information

2006 F250 6P2 1002895â&#x20AC;&#x201C; LF250 6P3 1000957â&#x20AC;&#x201C; Circuit diagram NOTE: The circled numbers in the illustration indicate the ECM terminal numbers.

Crank position sensor

Fuel injector #1

Fuel injector #2

60 15

Fuel injector #3

58 Fuel injector #4

Cam position sensor (PORT EX)

Fuel injector #5

Cam position sensor (PORT IN)

Fuel injector #6

55 Cam position sensor (STBD IN)

1 Ignition coil #1

TPS 1

TPS 2

50 Ground

Accelerator position sensor 1

71 Ignition coil #2

70 47

Ignition coil #3

ECM

31 Ground

Accelerator position sensor 2

Ignition coil #4

41 62

Ignition coil #5

44 38

Ground

54 Ignition coil #6

Intake air pressure sensor

Oil pressure sensor

Electronic throttle valve relay

80 Cooling water pressure sensor

66 42 83 81

Speed sensor

Electronic throttle valve motor

75 84

cd e S6P21130C

1-19

6P21H11

Feature and benefit 2006 F250 6P2 LF250 6P3

1002895– 1000957–

c de

ab Intake air temperature sensor

Oil control valve (STBD)

86 23 Oil control valve (PORT)

Engine temperature sensor

77 5V

High-pressure fuel pump relay

High-pressure fuel pump P

Trim sensor

Low-pressure fuel pump

Thermoswitch

Vapor shut-off valve

85 Shift cut switch

Low oil pressure warning indicator

72 Neutral switch

ECM Overheat warning indicator

73 Ground

Diagnosis indicator

74 Knock sensor

Buzzer (DES switch)

DES switch

Tachometer

Engine stop lanyard switch

20 21 Main relay

LAN communication

27 34

YDIS

7 46

Rectifier Regulator

69 Engine start switch

– + Battery

6P21H11

S6P21140C

1-20

1 2 3 4 5 6 7 8 9

GEN INFO

General information

2005 F250 6P2 1000001â&#x20AC;&#x201C;1002894 LF250 6P3 1000001â&#x20AC;&#x201C;1000956 ECM coupler layout

1234567 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52

53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 S6P21120

No.

Connecting part

Color code

Cam position sensor (STBD IN)

White/black

Cam position sensor (PORT IN)

White/green

Cam position sensor (PORT EX)

White/blue

No.

Connecting part

Color code

Battery power source

Red/yellow

Personal computer

White/black

Sensor power source

Orange

Accelerator position sensor 1 (main)

Pink/white

Battery power source

Red/yellow

Intake air pressure sensor

Pink/green

Oil pressure sensor

Pink/white

Accelerator position sensor 2 (sub)

Pink

Accelerator position sensor 2 ground (sub)

Black

Accelerator position sensor 1 ground (main)

Black

Cooling water pressure sensor (optional)

Blue/black

Speed sensor (optional)

Blue

Accelerator position sensor 2 power source (sub)

Orange

TPS 1 (main)

Pink

Unit ground

Black

TPS ground

Black

4 5 6

Shift cut switch

Blue/yellow

Main relay

Yellow/green

Knock sensor

Green

9 10 11 12

Neutral switch

Blue/green

Engine start switch

Yellow

14 15

Crank position sensor ground

Black

Crank position sensor

White/black

Engine temperature sensor

Black/yellow

Sensor ground

Black

Trim sensor

Pink

29 30

33 34 35

20 21 22 23

1-21

Intake air temperature sensor

Black/yellow

6P21H11

Feature and benefit 2005 F250 6P2 LF250 6P3

1000001â&#x20AC;&#x201C;1002894 1000001â&#x20AC;&#x201C;1000956

1234567 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52

53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 S6P21120

No.

Connecting part

Color code

49 50

No.

Connecting part

Color code

Overheat warning indicator

Pink/black

Electronic throttle valve ground

Black

Electronic throttle valve motor

Green/red

Accelerator position sensor 1 power source (main)

Orange

TPS 2 (sub)

Pink/white

TPS power source

Orange

Ignition coil #6

Black/brown

Thermoswitch

Pink

Ignition coil #5

Black/blue

White

Fuel injector #6

Purple/white

Engine stop lanyard switch

Fuel injector #5

Purple/blue

High-pressure fuel pump relay

Blue/red

Fuel injector #4

Purple/green

Fuel injector #3

Purple/yellow

Electronic throttle valve relay

Yellow

58 59

Fuel injector #1

Purple/red

Purple

Fuel injector #2

Purple/black

Oil control valve (STBD)

Low-pressure fuel pump

Blue/white

Oil control valve (PORT)

Purple

Ignition coil #4

Black/green

Green/black

Ignition coil #3

Black/yellow

Electronic throttle valve motor

ECM ground

Black

Electronic throttle valve power source

Red/green

ECM ground

Black

Low oil pressure warning indicator

Pink/white

Electronic throttle valve power source

Red/green

66 67

Diagnostic test lead

Blue/white

Electronic throttle valve ground

Black

Vapor shut-off valve

Green/black

Ignition coil #2

Black/white

Ignition coil #1

Black/orange

Tachometer

Green

ECM ground

Black

Buzzer

Pink

6P21H11

1-22

1 2 3 4 5 6 7 8 9

GEN INFO

General information

2006 F250 6P2 1002895â&#x20AC;&#x201C; LF250 6P3 1000957â&#x20AC;&#x201C; ECM coupler layout

1234567 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52

53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 S6P21150

No.

Connecting part

Color code

Cam position sensor (STBD IN)

White/black

Cam position sensor (PORT IN)

White/green

Cam position sensor (PORT EX)

White/blue

No.

Connecting part

Color code

25 26 27

Battery power source

Red/yellow

Personal computer

White/black

Accelerator position sensor 1 (main)

Pink/white

Battery power source

Red/yellow

Intake air pressure sensor

Pink/green

Shift cut switch

Blue/yellow

Main relay

Yellow/green

Knock sensor

Green

32 33 34 35

10 11 12

Neutral switch

Blue/green

Oil pressure sensor

Pink/white

Engine start switch

Yellow

Accelerator position sensor 2 (sub)

Pink

Crank position sensor ground

Black

39 40

Crank position sensor

White/black

Accelerator position sensor 2 ground (sub)

Black

16 17

Engine temperature sensor

Black/yellow

Black

Sensor ground

Black

Accelerator position sensor 1 ground (main)

Trim sensor (LAN)

Pink

Blue/black

LAN communication (H)

White

Cooling water pressure sensor (optional)

LAN communication (L)

Blue

Speed sensor (optional)

Blue

Orange

Intake air temperature sensor

Black/yellow

Accelerator position sensor 2 power source (sub)

TPS 1 (main)

Pink

Unit ground

Black

22 23 24

1-23

6P21H11

Feature and benefit 2006 F250 6P2 LF250 6P3

1002895â&#x20AC;&#x201C; 1000957â&#x20AC;&#x201C;

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27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52

53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 S6P21150

No.

Connecting part

Color code

TPS ground

Black

Sensor power source

Orange

Accelerator position sensor 1 power source (main)

Orange

TPS 2 (sub)

No.

Connecting part

Color code

Overheat warning indicator

Pink/black

Diagnostic test lead

Blue/white

Electronic throttle valve ground

Black

Pink/white

ECM ground

Black

TPS power source

Orange

Purple

Thermoswitch

Pink

Oil control valve (PORT)

Ignition coil #6

Black/brown

White

Ignition coil #5

Black/blue

Engine stop lanyard switch

Fuel injector #6

Purple/white

Electronic throttle valve power source

Red/green

Fuel injector #5

Purple/blue

Fuel injector #4

Purple/green

Electronic throttle valve power source

Red/green

57 58

Fuel injector #3

Purple/yellow

Green/black

Fuel injector #1

Purple/red

Electronic throttle valve motor

Fuel injector #2

Purple/black

Low-pressure fuel pump

Blue/white

Electronic throttle valve motor

Green/red

Ignition coil #4

Black/green

Black

Ignition coil #3

Black/yellow

Electronic throttle valve ground

Tachometer

Green

Vapor shut-off valve

Green/black

High-pressure fuel pump relay

Blue/red

Oil control valve (STBD)

Purple

Electronic throttle valve relay

Yellow

Buzzer

Pink

ECM ground

Black

ECM ground

Black

Ignition coil #2

Black/white

Ignition coil #1

Black/orange

Low oil pressure warning indicator

Pink/white

6P21H11

1-24

1 2 3 4 5 6 7 8 9

GEN INFO

General information

Electronic fuel injection control system In the F250/LF250 engine, the electronic fuel injection control system controls the fuel injection timing and volume. Maximum output, low fuel consumption, and low emissions are achieved by maintaining the optimum air-fuel ratio under various engine operating conditions. Fuel injection control Description Injection timing

Injection volume

Asynchronous injection

1-25

Control

Engine condition

Simultaneously injects into cylinder groups #1 and #4, #2 and #5, and #3 and #6.

Starting

Sequential injection in order of cylinders #1, #2, #3, #4, #5, and #6.

Normal operation

Controls the operation time of the injectors according to the atmospheric pressure and intake air temperature.

From cranking to starting

Controls the operation time of the injectors according to the atmospheric pressure, intake air temperature, and engine temperature.

Normal operation

Stops injection.

Turned off

Simultaneously injects into all cylinders to prevent a lean air-fuel ratio.

Accelerated operating speeds

6P21H11

Feature and benefit Electronic fuel injection system diagram Fuel flows through the fuel filter in the water separator and the low-pressure fuel pump sends the fuel through the fuel filter and is sent to the vapor separator tank. When the fuel in the vapor separator tank exceeds the specified volume, it returns to the low-pressure fuel pump via the fuel hose. Fuel in the vapor separator tank that is pressurized by the high-pressure fuel pump is sent to the port and starboard fuel rails and is injected from the fuel injectors into the combustion chambers. When the fuel pressure exceeds the specified value, the fuel is sent back to the vapor separator tank from the pressure regulator via the fuel cooler to maintain the specified fuel pressure. When the engine is turned off and when the engine is cranked, the vapor shut-off valve closes to prevent the fuel vapor gas from entering the surge tank. After the engine is started, the vapor shutoff valve opens and closes repeatedly to control the fuel vapor gas volume that enters the surge tank. When the vapor shut-off valve is closed, the fuel vapor gas is adsorbed by the activated carbon in the canister and some is released into the atmosphere. Primer pump

Inboard fuel filter (optional)

Boat fuel tank

Check valve Fuel filter with water separator

Intake silencer

Check valve

Check valve Atmosphere

Low-pressure fuel pump Vapor shut-off valve

Canister Filter Fuel cooler

Surge tank

Vapor Separator tank High-pressure fuel pump

Fuel rail (STBD)

Pressure regulator

Fuel rail (PORT)

Injector #1

Injector #3

Injector #5

Injector #6

Injector #4

Injector #2

Combustion chamber #1

Combustion chamber #3

Combustion chamber #5

Combustion chamber #6

Combustion chamber #4

Combustion chamber #2

Intake manifold (STBD)

: Air : Fuel : Vapor gas

6P21H11

Intake manifold (PORT)

S6P21116

1-26

1 2 3 4 5 6 7 8 9

GEN INFO

General information

2005 F250 6P2 1000001–1002894 LF250 6P3 1000001–1000956 Circuit diagram

Crank position sensor

Fuel injector #1 16

Fuel injector #2 60

Cam position sensor (PORT EX)

Cam position sensor (PORT IN)

Fuel injector #3 58 Fuel injector #4

Cam position sensor (STBD IN)

Fuel injector #5 5V

56 52 Fuel injector #6 55

TPS 1

TPS 2

51 Ground

Accelerator position sensor 1

47 50 32

Ground Accelerator position sensor 2

41 44 38

Ground

5V 31 Intake air pressure sensor

ECM

Intake air temperature sensor 5V Engine temperature sensor Neutral switch

5V 5V

Ground

Vapor shut-off valve 69

12 18

Engine stop lanyard switch 79

Main relay

27 34 7

Engine start switch 13

– + Battery

1-27

S6P21118

6P21H11

Feature and benefit 2006 F250 6P2 1002895– LF250 6P3 1000957– Circuit diagram

Crank position sensor

1 2 3 4 5 6 7 8 9

Fuel injector #1

Fuel injector #2

Cam position sensor (PORT EX)

Fuel injector #3

Cam position sensor (PORT IN)

2 Fuel injector #4

Cam position sensor (STBD IN)

Fuel injector #5

56 51 Fuel injector #6

TPS 1

TPS 2

50 Ground

Accelerator position sensor 1

47 49 31

Ground Accelerator position sensor 2

41 44 38

Ground

5V 48 Intake air pressure sensor

Intake air temperature sensor Engine temperature sensor Neutral switch

ECM

5V 5V

Ground

Vapor shut-off valve

12 18

Engine stop lanyard switch

Main relay

27 34 7

Engine start switch

–

Battery

6P21H11

S6P21160

1-28

GEN INFO

General information

Ignition timing control system In the F250/LF250 engine, the ignition timing control system controls the ignition timing and the power supply timing to the ignition coils. Maximum output, low fuel consumption, and low emissions are achieved by securing the optimum ignition timing under various engine operating conditions. Ignition timing control Description Ignition timing

Power supply timing

Control

Engine condition

Stops ignition.

Turned off

Simultaneous ignition for cylinder groups #1 and #4, #2 and #5, and #3 and #6.

Cranking and starting

Sequential ignition in order of cylinders #1, #2, #3, #4, #5, and #6.

Normal operation

Controls the power supply timing to the ignition coils.

Normal operation

Ignition timing when cranking and starting the engine When the engine is cranked and started, the spark plug ignites at BTDC 10Â°. Ignition at normal operation During normal operation, map control is performed according to the engine speed, the intake air pressure, and the octane value of the fuel. The power supply timing to the ignition coils is controlled by the battery voltage.

1-29

6P21H11

Feature and benefit 2005 F250 6P2 1000001–1002894 LF250 6P3 1000001–1000956 Circuit diagram

1 2 3 4 5 6 7 8 9

Crank position sensor 16 15 Cam position sensor (PORT EX)

Cam position sensor (PORT IN)

Cam position sensor (STBD IN)

Ignition coil #1

Ignition coil #2

70 5V

Ignition coil #3

TPS 1

TPS 2

63 Ignition coil #4

Ground Accelerator position sensor 1

47 50

32 Ground Accelerator position sensor 2

Ignition coil #5

41 54 44

Ignition coil #6

38 Ground 5V Intake air pressure sensor

40 31 36

ECM ECM

Intake air temperature sensor 5V 23 Engine temperature sensor Shift cut switch

5V 5V

Ground

17 6 18

Knock sensor 8 Engine stop lanyard switch 79 Main relay

27 34 7

Engine start switch 13

– + Battery

6P21H11

S6P21119

1-30

GEN INFO

General information

2006 F250 6P2 1002895– LF250 6P3 1000957– Circuit diagram

Crank position sensor

16 Ignition coil #1

15 Cam position sensor (PORT EX)

Cam position sensor (PORT IN)

Cam position sensor (STBD IN)

Ignition coil #2

70 5V

Ignition coil #3

TPS 1

TPS 2

63 Ignition coil #4

Ground Accelerator position sensor 1

47 49

Ignition coil #5

31 Ground Accelerator position sensor 2

41 54 44

Ignition coil #6

38 Ground

5V Intake air pressure sensor

Engine temperature sensor Shift cut switch

48 36

Intake air temperature sensor

ECM ECM

5V 23 5V 5V

Ground

17 6 18

Knock sensor

8 Engine stop lanyard switch

78 Main relay

27 34 7

Engine start switch

–

Battery

1-31

S6P21170

6P21H11

Feature and benefit

Knock control system In the F250/LF250 engine, the knock sensor detects the engine knock that occurs due to abnormal combustion during operation and determines whether there is engine knock and its size. When engine knock is determined, the knock control system retards the ignition timing to prevent the occurrence of engine knock. Knock control Description Knock

6P21H11

Control

Engine condition

Detects whether engine knock occurs at ignition. When engine knock is detected, the ignition timing is retarded by a fixed amount.

When the engine speed is higher than the engine idle speed after warming the engine up.

1-32

1 2 3 4 5 6 7 8 9

GEN INFO

General information

2005 F250 6P2 1000001–1002894 LF250 6P3 1000001–1000956 Circuit diagram

Crank position sensor 16 15

Ignition coil #1

Ignition coil #2

70 5V

TPS 1

TPS 2

51 Ground

5V Intake air pressure sensor

Ignition coil #3

52 63 Ignition coil #4

54 31

Ignition coil #5

Ignition coil #6

36 53

ECM

Ground

Knock sensor 8

Main relay

27 34 7

S6P21122

1-33

6P21H11

Feature and benefit 2006 F250 6P2 1002895â&#x20AC;&#x201C; LF250 6P3 1000957â&#x20AC;&#x201C; Circuit diagram

1 2 3 4 5 6 7 8 9

Crank position sensor

16 15

Ignition coil #1

Ignition coil #2

70 5V TPS 1

TPS 2

50 Ground

5V Intake air pressure sensor

Ignition coil #3

51 63 Ignition coil #4

54 48

Ignition coil #5

Ignition coil #6

36 53

ECM

Ground

Knock sensor

Main relay

27 34 7

S6P21180

6P21H11

1-34

GEN INFO

General information

Variable camshaft timing control system In the F250/LF250 engine, the opening and closing timing of the intake valves is controlled. The ECM operates the oil control valve according to the engine speed and the electronic throttle valve opening angle and controls the optimum opening and closing timing of the intake valves. Maximum output is achieved by increasing the volumetric efficiency of the combustion chambers under various engine operating conditions. Variable camshaft timing control Description Variable camshaft timing

Control

Engine condition

â&#x20AC;˘ Sets the advance target angle according to the engine speed and electronic throttle valve opening. â&#x20AC;˘ Detects the exhaust and intake camshaft positions, operates the oil control valve to reach the advance target angle, and controls the optimum opening and closing timing of the intake valves.

At mid-speed range, operates to the advance angle, and at engine idle speed and the fully open range, operates to the retard angle.

Variable camshaft timing control diagram The ECM determines the intake valve opening and closing timing suitable for the operating conditions according to the engine speed, electronic throttle valve opening angle, and engine temperature. In addition, the exhaust and intake cam position sensors detect the actual advance position and perform feedback control of the oil control valve to reach the target advance position. The ECM sends a signal to the oil control valve to switch the oil passage to send engine oil to the advance chamber or retard chamber in the rotor vane housing. According to the engine oil pressure in the respective chamber, the rotor vane operates to advance or retard the camshaft that is connected to the rotor vane. (PORT EX)

(PORT IN) (STBD IN) Rotor vane housing Rotor vane housing Advance/Retard Advance/Retard Cam Cam direction Cam direction Cam position sensor

Cam position sensor

Sensor signal

Engine temperature sensor

Crank position sensor TPS

Advance

Retard

Cam position sensor Advance

Oil flow Oil control valve Return

Oil control valve

Oil filter

Oil pump

Return

Oil pan ECM

Drive signal

S6P21113

1-35

6P21H11

Feature and benefit Oil control valve operation When the camshaft advances, the spool valve moves toward the coil spring according to the magnetic force of the magnetic coil, the spring is compressed, and the engine oil is sent to the advance chamber passage. The engine oil in the retard chamber returns to the oil pan via the spool valve passage. When the camshaft retards, the spool valve moves toward the magnetic coil according to the magnetic force of the magnetic coil and the force of the coil spring, and the engine oil is sent to the retard chamber passage. The engine oil in the advance chamber returns to the oil pan via the spool valve passage.

Í Ê

Î Ë

Í Î

Ë S6P21190

1 Coil spring 2 Magnetic coil È É Ê Ë Ì Í Î

Advance Retard Advance oil flow Retard oil flow Operation direction of spool valve Oil return Oil supply

6P21H11

1-36

1 2 3 4 5 6 7 8 9

GEN INFO

General information

Rotor vane operation The variable camshaft timing unit consists of a rotor vane and rotor vane housing. The rotor vane is fastened to the intake camshaft with a bolt, which allows them to rotate together. The rotor vane housing is fastened to the driven sprocket of the intake camshaft with a bolt, which allows them to rotate together. The rotor vane in the rotor vane housing is operated by the engine oil pressure to advance or retard the camshaft. When the engine is started, the engine oil pressure is low and the rotor vane is fixed to the housing by a lock pin. After the engine is started, the engine oil pressure increases as the engine speed increases and the engine oil enters the advance chamber in the housing and the lock pin is released. When the camshaft advances, the engine oil that entered the advance chamber in the housing moves the rotor vane to the advance direction, and the engine oil in the retard chamber passes through the spool valve and returns to the oil pan. When the camshaft retards, the engine oil enters the retard chamber in the housing and moves the rotor vane to the retard direction, and the engine oil in the advance chamber passes through the spool valve and returns to the oil pan.

Ă&#x2C6; B 2 A 0 1 7 9

D 0

2 3 4

C 1 2 3 4 5 6 7 8

Rotor vane Rotor vane housing Bolt Retard passage Drive sprocket (IN) Camshaft Advance port Retard port

1-37

6 9 0 A B C D

S6P21115

Advance chamber Lock pin Seal Retard chamber Advance passage Spring

Ă&#x2C6; Rotation direction of variable camshaft timing

6P21H11

Feature and benefit 2005 F250 6P2 1000001–1002894 LF250 6P3 1000001–1000956 Circuit diagram

1 2 3 4 5 6 7 8 9

Crank position sensor 16 15 Cam position sensor (PORT EX)

Cam position sensor (PORT IN)

Cam position sensor (STBD IN)

1 5V

TPS 1

TPS 2

51 Ground

Oil control valve (STBD) 82 Oil control valve (PORT) 83

Engine temperature sensor 5V

Ground

Main relay

ECM 17

27 34 7

S6P21123

6P21H11

1-38

GEN INFO

General information

2006 F250 6P2 1002895– LF250 6P3 1000957– Circuit diagram

Crank position sensor

16 15 Cam position sensor (PORT EX)

Cam position sensor (PORT IN)

Cam position sensor (STBD IN)

1 5V

TPS 1

TPS 2

50 Ground

Oil control valve (STBD)

86 Oil control valve (PORT)

Engine temperature sensor

ECM 5V

Ground

Main relay

27 34 7

S6P21200

1-39

6P21H11

Feature and benefit

Electronic throttle valve control system In the F250/LF250 engine, the electronic throttle valve control system converts the opening and closing of the remote control lever accelerator to an electronic signal and the ECM controls the throttle valves according to the operating condition of the accelerator opening. Electronic throttle valve control Description

Control

Engine condition

Setting of the target throttle valve opening

Detects the accelerator sensor signal and the ECM sets the target throttle valve opening.

Starting and normal operation.

Throttle valve opening feedback

Checks the difference between the signal from the TPS and the target throttle valve opening and performs feedback control on the throttle valve opening.

Starting and normal operation.

Engine idle speed

Controls the throttle valve opening to stabilize the engine speed at idle while controlling the intake air volume.

Operation at engine idle speed.

Limp home processing (electronic throttle valve fail-safe)

Fixes the throttle valve opening to the specified opening angle and controls the ignition timing control according to the accelerator position sensor opening angle.

• The engine idle speed is increased and stabilized. • The engine speed is fixed even if the accelerator lever is opened.

Electronic throttle valve operation A cable transmits the operation of the remote control lever to the accelerator position sensor, which converts the accelerator lever opening angle to an electronic signal. The ECM uses this signal to set the target opening angle of the throttle valve. At the same time, the TPS detects the throttle valve opening angle and checks the difference to that of the target opening angle. Then, the ECM sends an electronic signal to the electronic throttle valve motor and performs feedback control of the difference of the target opening angle and throttle valve opening angle.

6 È

3 1 1 2 3 4 5 6 È É

S6P21121

Remote control box Accelerator position sensor Accelerator lever ECM Electronic throttle valve assembly (TPS) Electronic throttle valve motor Throttle cable Sensor signal

6P21H11

1-40

1 2 3 4 5 6 7 8 9

GEN INFO

General information

2005 F250 6P2 1000001–1002894 LF250 6P3 1000001–1000956 Circuit diagram

Fuel injector #1 59 5V

Fuel injector #2 60

TPS 1

TPS 2

51 Ground

Accelerator position sensor 1

Fuel injector #3 58 Fuel injector #4 57

Fuel injector #5 56

50 32

Ground Accelerator position sensor 2

Fuel injector #6 55

41 44 38

Ground

Electronic throttle valve relay

86 81 Engine temperature sensor 5V

ECM

77 84

Electronic throttle valve motor

68 76 Shift cut switch Neutral switch

5V 5V

Ground

Main relay

6 12

27 34 7

Engine start switch 13

– + Battery

1-41

S6P21124

6P21H11

Feature and benefit 2006 F250 6P2 1002895– LF250 6P3 1000957– Circuit diagram

1 2 3 4 5 6 7 8 9

Fuel injector #1

59 5V

Fuel injector #2

60 TPS 1

TPS 2

Fuel injector #3

58 Fuel injector #4

Ground Accelerator position sensor 1

Fuel injector #5

49 31

Ground Accelerator position sensor 2

Fuel injector #6

41 44 38

Ground

Electronic throttle valve relay

80 66 Engine temperature sensor

ECM

83 81

Electronic throttle valve motor

75 84 Shift cut switch Neutral switch

5V 5V

Ground

Main relay

6 12

27 34 7

Engine start switch

–

Battery

6P21H11

S6P21210

1-42

GEN INFO

General information

Engine speed control system In the F250/LF250 engine, the engine speed control system decreases the engine speed to protect the engine from damage when the engine overheats or when the engine oil pressure is low. Engine speed control Description

Control

Engine condition

Overheat

Detects when the engine overheats and controls the engine speed.

• Detects that the engine is overheating when the thermoswitch is turned on or the engine temperature exceeds 120 °C (248 °F). • The ECM causes the cylinders to misfire, cuts off injection, decreases the engine speed to less than 2,000 r/min, activates the warning buzzer, and turns the overheat warning indicator on.

Low oil pressure

Detects when the engine oil pressure is low and controls the engine speed.

• Detects that the engine oil pressure is low when the oil pressure is less than 250 kPa (2.5 kg/cm2, 36.3 psi) when operating at engine idle speed, and when all engine speeds, except the engine idle speed, are below the standard value. • The ECM causes the cylinders to misfire, cuts off injection, decreases the engine speed to less than 2,000 r/min, activates the warning buzzer, and turns the low oil pressure warning indicator on.

1-43

6P21H11

Feature and benefit Description

Control

Engine condition

Detects the status of the DES control and controls the engine speed.

• When the overheat warning or low oil pressure warning is activated, the DES switch is turned on and the warning buzzer is activated. • When this occurs, the ECM causes the cylinders to misfire, injection is cut off, and the engine speed decreases to less than 2,000 r/min.

Shift cut

Detects the status of the shift cut control and controls the engine speed.

Two cylinders misfire and the engine speed decreases so that the shift can be shifted.

Over-revolution

Detects the status of the over-revolution control and controls the engine speed.

• When the engine over revs and the engine speed exceeds 6,449 r/min, all cylinders misfire. • When the engine over revs and the engine speed exceeds 6,199 r/min and is 6,449 r/min or less, cylinders #2 to #5, #3, and #6 misfire for a short time. • Normal operation when the engine speed is 6,199 r/min or less.

DES

6P21H11

1-44

1 2 3 4 5 6 7 8 9

GEN INFO

General information

2005 F250 6P2 1000001–1002894 LF250 6P3 1000001–1000956 Circuit diagram

Crank position sensor

Fuel injector #1 16

Fuel injector #2 60

Fuel injector #3

TPS 1

TPS 2

58 Fuel injector #4 57 Fuel injector #5

Ground

Fuel injector #6 5V

55 31 Ignition coil #1

Oil pressure sensor

Ignition coil #2

70 Ignition coil #3 Engine temperature sensor

63 17

ECM

Ignition coil #4

Thermoswitch 78 62 Shift cut switch

Ignition coil #5 5V

6 54 Ignition coil #6

Ground

Low oil pressure warning indicator 66 Overheat warning indicator Main relay

75 27 34 7

Engine start switch

Buzzer (DES switch) 74

DES switch

– + Battery

1-45

S6P21125U

6P21H11

Feature and benefit 2006 F250 6P2 1002895– LF250 6P3 1000957– Circuit diagram

Crank position sensor

1 2 3 4 5 6 7 8 9

Fuel injector #1

Fuel injector #2

60 5V

Fuel injector #3

TPS 1

TPS 2

58 Fuel injector #4

57 Fuel injector #5

Ground

Fuel injector #6

55 48 Ignition coil #1

Oil pressure sensor

Ignition coil #2

70 Ignition coil #3 Engine temperature sensor

Thermoswitch

63 17

ECM

Ignition coil #4

52 62

Shift cut switch

Ignition coil #5

6 54 Ignition coil #6

Ground

Low oil pressure warning indicator

72 Overheat warning indicator Main relay

73 27 34 7

Buzzer (DES switch)

DES switch

Engine start switch

–

Battery

6P21H11

S6P21220

1-46

GEN INFO

General information

Lower unit A spring has been added to the lower unit for the F250/LF250 The spring is used to push the drive shaft toward the water pump and stabilize the thrust free play of the shaft. This spring facilitates the backlash measurement procedure since the lower unit does not need to be turned upsidedown to carry out the measurement.

S6P21126C

1 2 3 4 5

Shim Thrust bearing Drive shaft Spring Washer

Ă&#x2C6; Water pump side

1-47

6P21H11

Feature and benefit / Propeller selection

Propeller selection

The performance of a boat and outboard motor will be critically affected by the size and type of propeller you choose. Propellers greatly affect boat speed, acceleration, engine life, fuel economy, and even boating and steering capabilities. An incorrect choice could adversely affect performance and could also seriously damage the engine. Use the following information as a guide for selecting a propeller that meets the operating conditions of the boat and the outboard motor.

Selection When the engine speed is at the full throttle operating range (5,000–6,000 r/min), the ideal propeller for the boat is one that provides maximum performance in relation to boat speed and fuel consumption. Regular rotation model Propeller size (in)

Material

13 3/4 × 17 - M2 13 3/4 × 19 - M2 13 3/4 × 21 - M 14 1/2 × 15 - M 14 1/2 × 19 - T

Propeller size The size of the propeller is indicated on the propeller boss end, on the side of the propeller boss.

14 1/2 × 21 - T 14 1/2 × 23 - M 14 7/8 × 21 - M

Stainless

15 × 17 - T 15 × 21 - T ×

15 1/4 × 15 - M 15 1/4 × 17 - M 15 1/4 × 19 - M 15 1/4 × 19 - T 15 1/2 × 17 - T

S69J1100

Counter rotation model Propeller size (in)

Material

13 3/4 × 17 - ML1 13 3/4 × 19 - ML1

b c

13 3/4 × 21 - ML

14 1/2 × 19 - TL

14 1/2 × 21 - TL S6P21100

a Propeller diameter (in inches) b Propeller pitch (in inches) c Propeller type (propeller mark)

14 1/2 × 23 - ML 14 7/8 × 21 - ML 15 × 17 - TL

Stainless

15 × 21 - TL 15 1/4 × 15 - ML 15 1/4 × 17 - ML 15 1/4 × 19 - ML 15 1/4 × 19 - TL 15 1/2 × 17 - TL

6P21H11

1-48

1 2 3 4 5 6 7 8 9

GEN INFO

General information

Predelivery check

To make the delivery process smooth and efficient, the predelivery checks should be completed as explained below.

NOTE: If the engine oil is below the minimum level mark (L), add sufficient oil until the level is between (H) and (L).

Checking the fuel system 1. Check that the fuel hoses are securely connected and that the fuel tank is full with fuel.

Recommended engine oil: 4-stroke motor oil API: SE, SF, SG, SH, SJ, or SL SAE: 10W-30, or 10W-40 Engine oil quantity: Without oil filter replacement: 5.6 L (5.92 US qt, 4.93 Imp qt)

Checking the gear oil level 1. Check the gear oil level.

S60C1140

CAUTION: This is a 4-stroke engine. Never use premixed fuel or 2-stroke outboard motor oil.

Checking the engine oil level 1. Check the engine oil level.

Checking the battery 1. Check the capacity, electrolyte level, and specified gravity of the battery. Recommended battery capacity: CCA/SAE: 512 A MCA/ABYC: 675 A RC/SAE: 182 Minute Electrolyte specified gravity: 1.280 at 20 Â°C (68 Â°F) 2. Check that the positive and negative battery cables are securely connected.

1-49

6P21H11

Predelivery check

Checking the outboard motor mounting height 1. Check that the anti-cavitation plate is aligned with the bottom of the boat. If the mounting height is too high, cavitation will occur and propulsion will be reduced. Also, the engine speed will increase abnormally and cause the engine to overheat. If the mounting height is too low, water resistance will increase and reduce engine efficiency.

S6P21030

NOTE: To adjust the throttle cable, see Chapter 3, â&#x20AC;&#x153;Adjusting the throttle cable.â&#x20AC;?

NOTE: The optimum mounting height is affected by the combination of the boat and the outboard motor. To determine the optimum mounting height, test run the outboard motor at different heights.

3. Check that the center of the set pin a is aligned with the alignment mark b on the bracket.

2. Check that the clamp brackets are secured with the clamp bolts.

Checking the remote control cable 1. Set the remote control lever to the neutral position and fully close the throttle lever. 2. Check that the accelerator lever 1 contacts the fully closed stopper 2. S69J3370

WARNING The shift/throttle cable joint must be screwed in a minimum of 8.0 mm (0.31 in) c.

6P21H11

1-50

1 2 3 4 5 6 7 8 9

GEN INFO

General information

Checking the steering system 1. Check that smoothly.

the

steering

operates

3. Check that there is no interference with wires or hoses when the tilted-up outboard motor is steered. 4. Check that the trim meter points down when the outboard motor is tilted all the way down.

Checking the engine start switch and engine stop lanyard switch 1. Check that the engine starts when the engine start switch is turned to START.

2. Check that there is no interference with wires or hoses when the outboard motor is steered.

2. Check that the engine turns off when the engine start switch is turned to OFF. OFF

START OFF

START

Checking the gear shift and throttle operation 1. Check that the gear shift operates smoothly when the remote control lever is shifted from the neutral position to forward or reverse. S6P21080

2. Check that the throttle operates smoothly when the remote control lever is shifted from forward or reverse to the fully open position a.

3. Check that the engine turns off when the engine stop lanyard is pulled from the engine stop lanyard switch.

N F

a a S6P21070

S6P21090E

Checking the PTT system 1. Check that the outboard motor tilts up and down smoothly when operating the PTT unit. 2. Check that there is no abnormal noise produced when the outboard motor is tilted up or down.

1-51

6P21H11

Predelivery check

Checking the cooling water pilot hole 1. Start the engine, check that cooling water is discharged from the cooling water pilot hole.

a Ă&#x2C6; 0

S69J1240

Ă&#x2C6; Hour

After test run 1. Check for water in the gear oil. S6P21050

Test run 1. Start the engine, and then check that the gear shift operates smoothly. 2. Check the engine idle speed after the engine has been warmed up. 3. Operate at trolling speed. 4. Run the outboard motor for 1 hour at 2,000 r/min or at half throttle, then for another hour at 3,000 r/min or at 3/4 throttle.

2. Check for fuel leakage in the cowling. 3. Flush the cooling water passage with fresh water using the flushing kit and with the engine running at idle.

CAUTION: Be sure to supply sufficient water and water pressure when flushing the cooling water passage. If sufficient water and sufficient water pressure are not supplied, the engine can overheat.

5. Check that the outboard motor does not tilt up when shifting into reverse and that water does not flow in over the transom. NOTE: The test run is part of the break-in operation.

Break-in During the test run, perform the break-in operation in the following three stages. 1. 1 hour a at 2,000 r/min or at approximately half throttle 2. 1 hour b at 3,000 r/min or 3/4 throttle and 1 minute out of every 10 at full throttle 3. 8 hours c at any speed, however, avoid running at full speed for more than 5 minutes 6P21H11

1-52

1 2 3 4 5 6 7 8 9

GEN INFO

General information

— MEMO —

1-53

6P21H11

SPEC

Specification General specification.....................................................................................2-1 Maintenance specification ............................................................................2-3 Power unit..................................................................................................2-3 Lower unit ..................................................................................................2-6 Electrical .................................................................................................... 2-7 Dimension................................................................................................2-10 Tightening torque......................................................................................... 2-12 Specified torque....................................................................................... 2-12 General torque......................................................................................... 2-15

6P21H11

1 2 3 4 5 6 7 8 9

SPEC

Specification

General specification Item Dimension Overall length Overall width Overall height (X) (U) Boat transom height (X) (U) Weight (without propeller) (X) (U) Performance Maximum output Full throttle operating range Maximum fuel consumption Engine idle speed Power unit Type Cylinder quantity Total displacement Bore × stroke Compression ratio Control system Starting system Fuel system Ignition control system Advance type Maximum generator output Spark plug Firing order Cooling system Exhaust system Lubrication system

2-1

Unit

Model F250TR

LF250TR

mm (in) mm (in)

892 (35.1) 634 (25.0)

mm (in) mm (in)

1,829 (72.0) 1,956 (77.0)

mm (in) mm (in)

635 (25.0) 762 (30.0)

kg (lb) kg (lb)

274.0 (604) 280.0 (617)

kW (hp) r/min L (US gal, Imp gal)/hr r/min

183.9 (250) at 5,500 r/min 5,000–6,000 81.0 (21.4, 17.8) at 6,000 r/min

cm3 (cu. in) mm (in)

V, A

600–700 4-stroke, DOHC V6 3,352 (204.5) 94.0 × 80.5 (3.70 × 3.17) 9.9 Remote control Electric Fuel injection TCI Micro computer 12, 46 LFR6A-11 (NGK) 1–2–3–4–5–6 (Normal operation) Water Propeller boss Wet sump

6P21H11

General specification Item

Unit

Fuel and oil Fuel type Fuel minimum rating

RON PON

Engine oil Engine oil grade Engine oil quantity (without oil filter replacement) (with oil filter replacement) Gear oil type Gear oil grade(*1) Gear oil quantity Bracket unit Trim angle (at 12° boat transom) Tilt-up angle Steering angle Drive unit Gear shift positions Gear ratio Reduction gear type Clutch type Propeller shaft type Propeller direction (rear view) Propeller mark Electrical Battery minimum capacity CCA/SAE MCA/ABYC RC/SAE (*1)

API SAE L (US qt, Imp qt) L (US qt, Imp qt) API SAE cm3 (US oz, Imp oz)

Model F250TR

LF250TR

Premium unleaded gasoline 94 89 4-stroke motor oil SE, SF, SG, SH, or SJ 10W-30 or 10W-40 5.6 (5.92, 4.93) 5.8 (6.13, 5.10) Hypoid gear oil GL-4 90 1,150 (38.9, 40.6) 1,000 (33.8, 35.3)

Degree

–3 to 16

Degree Degree

70 32 + 32 F-N-R 2.00 (30/15) Spiral bevel gear Dog clutch Spline Clockwise Counterclockwise T, M TL, ML

A A Minute

512 675 182

Meeting both API and SAE requirements

6P21H11

2-2

1 2 3 4 5 6 7 8 9

SPEC

Specification

Maintenance specification

Power unit Item Power unit Minimum compression pressure(*1) Oil pressure(*2) Cylinder head Warpage limit

(lines indicate straightedge position) Camshaft cap inside diameter Cylinder Bore size

Piston Piston diameter (D) Measuring point (H) Piston clearance(*3) Piston pin boss bore Piston pin Outside diameter Piston ring Top ring Dimension B Dimension T End gap(*3) Side clearance 2nd piston ring Dimension B Dimension T End gap(*3) Side clearance

Unit kPa (kgf/cm2, psi) kPa (kgf/cm2, psi)

Model F250TR

LF250TR 740 (7.4, 107.3)

600 (6.0, 87.0) at 600–900 r/min

mm (in)

0.1 (0.0039)

mm (in)

25.000–25.021 (0.9843–0.9851)

mm (in)

94.000–94.017 (3.7008–3.7014)

mm (in) mm (in) mm (in) mm (in)

93.921–93.941 (3.6977–3.6985) 5.0 (0.20) 0.075–0.080 (0.0030–0.0031) 21.017–21.031 (0.8274–0.8280)

mm (in)

20.995–21.000 (0.8266–0.8268)

mm (in) mm (in) mm (in) mm (in)

1.17–1.19 (0.046–0.047) 2.80–3.00 (0.110–0.118) 0.15–0.30 (0.006–0.012) 0.04–0.08 (0.002–0.003)

mm (in) mm (in) mm (in) mm (in)

1.17–1.19 (0.046–0.047) 3.70–3.90 (0.146–0.154) 0.30–0.45 (0.012–0.018) 0.03–0.07 (0.001–0.003)

(*1)

Measuring conditions: Ambient temperature 20 °C (68 °F), wide open throttle, with spark plugs removed from all cylinders. The figures are for reference only. (*2) For details of the checking method, see Chapter 5, “Checking the oil pressure.” The figures are for reference only. (*3) The figures are for reference only.

2-3

6P21H11

Maintenance specification Item Oil ring Dimension B Dimension T End gap(*1) Side clearance Camshaft Intake (A) Exhaust (A) Intake and exhaust (B) Camshaft journal diameter Camshaft runout limit Valve Valve clearance (cold) Intake Exhaust Head diameter (A) Intake Exhaust Face width (B) Intake Exhaust Seat contact width (C) Intake Exhaust Margin thickness (D) Intake Exhaust Stem diameter Intake Exhaust Guide inside diameter Intake and exhaust Stem-to-guide clearance Intake Exhaust Stem runout limit Valve spring Free length Tilt limit (*1)

Unit

Model F250TR

LF250TR

mm (in) mm (in) mm (in) mm (in)

2.40–2.47 (0.094–0.097) 2.30–2.70 (0.091–0.106) 0.15–0.60 (0.006–0.024) 0.04–0.13 (0.002–0.005)

mm (in) mm (in) mm (in)

46.30–46.40 (1.823–1.827) 45.35–45.45 (1.785–1.789) 35.95–36.05 (1.415–1.419)

mm (in) mm (in)

24.96–24.98 (0.9826–0.9834) 0.015 (0.0006)

mm (in) mm (in)

0.20 ± 0.03 (0.008 ± 0.001) 0.34 ± 0.03 (0.013 ± 0.001)

mm (in) mm (in)

36.4–36.6 (1.43–1.44) 31.4–31.6 (1.24–1.24)

mm (in) mm (in)

2.35–2.78 (0.092–0.110) 2.13–3.30 (0.084–0.130)

mm (in) mm (in)

1.10–1.40 (0.043–0.055) 1.40–1.70 (0.055–0.067)

mm (in) mm (in)

0.50–0.90 (0.020–0.035) 0.90–1.30 (0.035–0.051)

mm (in) mm (in)

5.477–5.492 (0.2156–0.2162) 5.464–5.479 (0.2151–0.2157)

mm (in)

5.504–5.522 (0.2167–0.2174)

mm (in) mm (in) mm (in)

0.012–0.045 (0.0005–0.0018) 0.025–0.058 (0.0010–0.0023) 0.01 (0.0004)

mm (in) mm (in)

44.2 (1.74) 1.2 (0.05)

1 2 3 4 5 6 7 8 9

The figures are for reference only.

6P21H11

2-4

SPEC

Specification Item

Valve lifter Valve lifter outside diameter Valve lifter-to-cylinder head clearance Valve shim Valve shim thickness (in 0.020 mm increments) Connecting rod Small end inside diameter Big end inside diameter Big end side clearance(*1) Crankpin oil clearance Big end bearing thickness Yellow Green Blue Crankshaft Crankshaft journal diameter Crankpin diameter Crankpin width Runout limit Crankcase Crankshaft journal oil clearance Upper crankcase main bearing thickness 1 2 3 Lower crankcase main bearing thickness 1 2 3 Lower crankcase main bearing thickness (J3) 1 2 3 Thrust bearing thickness (J3) (*1)

Unit

Model F250TR

LF250TR

mm (in) mm (in)

32.982–32.997 (1.2985–1.2991) 0.020–0.055 (0.0008–0.0022)

mm (in)

2.320–2.960 (0.0913–0.1165)

mm (in) mm (in) mm (in) mm (in)

21.017–21.031 (0.8274–0.8280) 53.015–53.035 (2.8720–2.0880) 0.15–0.30 (0.006–0.012) 0.028–0.066 (0.0011–0.0026)

mm (in) mm (in) mm (in)

1.492–1.496 (0.0587–0.0589) 1.496–1.500 (0.0589–0.0591) 1.500–1.504 (0.0591–0.0592)

mm (in) mm (in) mm (in) mm (in)

62.968–62.992 (2.4791–2.4800) 49.976–50.000 (1.9676–1.9685) 21.50–21.55 (0.8465–0.8484) 0.03 (0.0012)

mm (in)

0.025–0.050 (0.0010–0.0020)

mm (in) mm (in) mm (in)

2.494–2.500 (0.0982–0.0984) 2.498–2.504 (0.0983–0.0986) 2.502–2.508 (0.0985–0.0987)

mm (in) mm (in) mm (in)

2.494–2.500 (0.0982–0.0984) 2.498–2.504 (0.0983–0.0986) 2.502–2.508 (0.0985–0.0987)

mm (in) mm (in) mm (in) mm (in)

2.492–2.500 (0.0981–0.0984) 2.496–2.504 (0.0983–0.0986) 2.500–2.508 (0.0984–0.0987) 1.907–1.957 (0.0751–0.0770)

The figures are for reference only.

2-5

6P21H11

Maintenance specification Item Thermostat Opening temperature Fully open temperature Valve open lower limit

Unit °C (°F) °C (°F) mm (in)

Model F250TR

LF250TR

58–62 (136–144) 70 (158) 4.3 (0.17)

Lower unit Item

Unit

Gear backlash Pinion-to-forward gear

mm (in)

Pinion-to-reverse gear

mm (in)

Propeller shaft free play

mm (in)

Pinion shims Forward gear shims Reverse gear shims Propeller shaft shims

6P21H11

mm mm mm mm

Model F250TR

LF250TR

0.32–0.55 0.46–0.82 (0.0126–0.0217) (0.0181–0.0323) 0.32–0.65 0.45–0.78 (0.0126–0.0256) (0.0177–0.0307) 0.20–0.50 0.25–0.35 (0.0079–0.0197) (0.0098–0.0138) 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 1.80, 1.90, 2.00, 2.10, 0.10, 0.12, 0.15, 0.18, 2.20 0.30, 0.40, 0.50

2-6

1 2 3 4 5 6 7 8 9

SPEC

Specification

Electrical Item Ignition and ignition control system Spark plug gap Crank position sensor output peak voltage (W/B – B) at cranking (unloaded) at cranking (loaded) at 1,500 r/min (loaded) at 3,500 r/min (loaded) Crank position sensor resistance(*1) (W/R – B) Crank position sensor air gap Knock sensor resistance Intake air temperature sensor resistance at 20 °C (68 °F) Engine temperature sensor resistance (B/Y – B/Y) at 20 °C (68 °F) at 100 °C (212 °F) Electronic throttle valve control system TPS output voltage(*1) at 20 °C (68 °F) with remote control lever fully closed Sensor 1 with remote control lever fully open Sensor 2 Electronic throttle valve motor resistance(*1) at 20–30 °C (68–86 °F) Accelerator position sensor output voltage(*1) (P – B) with remote control lever fully closed Sensor 1 Sensor 2 with remote control lever fully open Sensor 1 and 2 (*1)

Unit

Model F250TR

LF250TR

mm (in)

1.0–1.1 (0.039–0.043)

V V V V Ω

3.0 2.7 14.5 17.8 396–594

mm (in) kΩ

1.4–1.6 (0.055–0.063) 504–616

kΩ

2.21–2.69

kΩ kΩ

54.2–69.0 3.12–3.48

0.750

4.550

Ω

1.23–1.67

V V

0.550–0.850 0.400–1.000

Above 3.250

The figures are for reference only.

2-7

6P21H11

Maintenance specification Item Accelerator position sensor resistance(*1) at 20 °C (68 °F) with accelerator lever fully closed with accelerator lever fully open Variable camshaft timing control system Oil control valve resistance at 20 °C (68 °F) Fuel control system Fuel injector resistance(*1) at 21 °C (70 °F) Starter motor Type Output Cranking time limit Brushes Standard length Wear limit Commutator Standard diameter Wear limit Standard undercut Wear limit Charging system Fuse Stator coil output peak voltage (G – G) at cranking (unloaded) at 1,500 r/min (unloaded) at 3,500 r/min (unloaded) Stator coil resistance(*1) (G – G) at 20 °C (68 °F) Rectifier Regulator output peak voltage (R – Ground) at 1,500 r/min (unloaded) at 3,500 r/min (unloaded) (*1)

Unit

Model F250TR

LF250TR

kΩ

0.800

kΩ

5.300

Ω

6.7–7.7

Ω

12.0

kW Second

Sliding gear 1.40 30

mm (in) mm (in)

15.5 (0.61) 9.5 (0.37)

mm (in) mm (in) mm (in) mm (in)

29.0 (1.14) 28.0 (1.10) 0.8 (0.03) 0.2 (0.01)

V V V

8.3 44.7 97.7

Ω

0.1144–0.1716

V V

13.0 13.0

1 2 3 4 5 6 7 8 9

The figures are for reference only.

6P21H11

2-8

SPEC

Specification Item

PTT system Trim sensor Setting resistance Resistance Fluid type Motor brushes Standard length Wear limit Motor commutator Standard diameter Wear limit Standard undercut Wear limit

2-9

Unit

Model F250TR

LF250TR

Ω Ω

10 ± 1 9–387.6 ATF Dexron II

mm (in) mm (in)

11.5 (0.45) 4.5 (0.18)

mm (in) mm (in) mm (in) mm (in)

23.0 (0.91) 22.0 (0.87) 1.40 (0.055) 0.90 (0.035)

6P21H11

Maintenance specification

Dimension Exterior

723.9 (28.5)

453 (17.8)

mm (in)

317 (12.5)

32˚

X: 1,155 (45.5) U: 1,272 (50.1)

619 (24.4)

651 (25.6)

219 (8.6)

59 (2

.3) ˚ 67

X: 847 (33.3) U: 924 (36.4)

45 (1.8)

387 (15.2) 39 (1.5)

752 (29.6) X: 643 (25.3) U: 770 (30.3)

230 (9.1)

216 (8.5)

X: 1,078 (42.4) U: 1,205 (47.4)

902 (35.5)

75 (3.0)

25 (1.0)

12˚ 3˚

X: 52 (2.0) U: 59 (2.3)

673 (26.5) S6P22020

6P21H11

2-10

1 2 3 4 5 6 7 8 9

SPEC

Specification

Clamp bracket mm (in)

180 (7.1)

163.5 (6.4) 50.8 (2.0)

163.5 (6.4)

101.5 (4.0)

125.4 (4.9)

55.5 (2.2)

13 (0.5)

254 (10.0)

411 (16.2)

13 (0.5)

18.5 (0.7)

79 (3.1)

S6P22010

2-11

6P21H11

Maintenance specification / Tightening torque

Tightening torque

Specified torque Part to be tightened Fuel system Filter cup Intake manifold bolt Intake silencer bolt Electronic throttle valve assembly nut Throttle damper plate bolt Canister mounting bolt Canister bracket bolt Vapor shut-off valve mounting nut Intake air pressure sensor bolt Low-pressure fuel pump cover bolt Check valve holder screw Fuel cooler bolt Pressure regulator screw Float chamber cover screw Float chamber cover inner plate screw Float pin screw Vapor separator drain screw Power unit Power unit mounting bolt Apron bolt Upper case cover bolt PTT motor lead bolt Ignition coil bolt Spark plug Cooling water pressure sensor adapter plug Flywheel magnet nut Crank position sensor screw Timing belt tensioner bolt Timing belt pulley bolt Variable camshaft timing cap Variable camshaft timing bolt Driven sprocket bolt Cylinder head cover plate screw 1st Camshaft cap bolt 2nd 1st Cylinder head cover bolt 2nd Positive battery cable bolt Negative battery cable nut Negative terminal bolt

6P21H11

Thread size

Tightening torques N·m kgf·m ft·lb

— M6 M6 — M8 M6 M6 — M6 M6 M5 M6 M6 M4 M4 M4 —

3.5 10 7 13 13 5 5 5 5 9 4 5 5 2 2 2 2

0.35 1.0 0.7 1.3 1.3 0.5 0.5 0.5 0.5 0.9 0.4 0.5 0.5 0.2 0.2 0.2 0.2

2.6 7.4 5.2 9.6 9.6 3.7 3.7 3.7 3.7 6.6 3.0 3.7 3.7 1.5 1.5 1.5 1.5

M10 M6 M6 M6 M6 — M14 — M5 — M10 — M12 M10 M4

42 8 8 4 7 25 23 240 4 39 39 32 60 60 2 8 17 8 8 18 13 26

4.2 0.8 0.8 0.4 0.7 2.5 2.3 24.0 0.4 3.9 3.9 3.2 6.0 6.0 0.2 0.8 1.7 0.8 0.8 1.8 1.3 2.6

31.0 5.9 5.9 3.0 5.2 18.4 17.0 177.0 3.0 28.8 28.8 23.6 44.3 44.3 1.5 5.9 12.5 5.9 5.9 13.3 9.6 19.2

M7 M6 M8 — —

2-12

1 2 3 4 5 6 7 8 9

SPEC

Specification Part to be tightened

Thread size

ECM bolt PTT relay lead nut Rectifier Regulator bolt Exhaust cover bolt Exhaust cover plug

M6 — 1st 2nd 1st 2nd 1st 2nd

1st 2nd 1st 2nd 3rd 4th 5th 6th

Knock sensor Cooling water passage cover bolt Oil filter Oil pressure sensor Oil filter joint Crankcase cover bolt Connecting rod cap bolt

Oil pump cover screw Thermostat cover plug Lower unit (regular rotation model) Gear oil check screw Gear oil drain screw Lower case mounting bolt (nut) Trim tab bolt Propeller nut

2-13

M10

— M6 — — — 1st 2nd 1st 2nd 3rd

Engine temperature sensor

Crankcase bolt

M18 M4 M6

Anode screw Engine hanger bolt

Cylinder head bolt

M8 M9 —

1st 2nd 1st 2nd 1st 2nd

M8 M8 M10 M6 M14 — — M10 M10 —

Tightening torques N·m kgf·m ft·lb 7 0.7 5.2 4 0.4 3.0 6 0.6 4.4 12 1.2 8.9 6 0.6 4.4 12 1.2 8.9 14 1.4 10.3 28 2.8 20.7 55 5.5 40.6 3 0.3 2.2 12 1.2 8.9 14 1.4 10.3 28 2.8 20.7 23 2.3 17.0 45 4.5 33.2 Loosen completely 23 2.3 17.0 45 4.5 33.2 90° 32 3.2 23.6 12 1.2 8.9 18 1.8 13.3 18 1.8 13.3 34 3.4 25.1 14 1.4 10.3 28 2.8 20.7 23 2.3 17.0 43 4.3 31.7 90° 15 1.5 11.1 14 1.4 10.3 28 2.8 20.7 25 2.5 18.4 90° 40 4.0 29.5 90° 4 0.4 3.0 23 2.3 17.0 9 9 47 42 54

0.9 0.9 4.7 4.2 5.4

6.6 6.6 34.7 31.0 39.8 6P21H11

Tightening torque Part to be tightened Grease nipple Propeller shaft housing bolt Cooling water inlet cover screw Pinion nut Lower unit (counter rotation model) Gear oil check screw Gear oil drain screw Lower case mounting bolt (nut) Trim tab bolt Propeller nut Ring nut Grease nipple Propeller shaft housing bolt Cooling water inlet cover screw Pinion nut Bracket unit Shift cut switch screw Shift cut switch bracket bolt Neutral switch screw Shift rod detent bolt Grease nipple Flushing hose adapter screw Upper mount bracket bolt Apron stay Engine oil drain bolt Upper mount nut Lower mount nut Oil pan assembly bolt PCV Baffle plate screw Oil strainer bolt Oil pan bolt Exhaust manifold bolt Muffler bolt Friction plate screw Grease nipple Self-locking nut Thrust receiver nut PTT unit Reservoir mounting bolt PTT motor mounting bolt Reservoir cap Manual valve 6P21H11

— M8 M5 —

Tightening torques N·m kgf·m ft·lb 6 0.6 4.4 30 3.0 22.1 4 0.4 3.0 142 14.2 104.7

— — M10 M10 — — — M8 M5 —

9 9 47 42 54 108 6 30 4 142

0.9 0.9 4.7 4.2 5.4 10.8 0.6 3.0 0.4 14.2

6.6 6.6 34.7 31.0 39.8 79.7 4.4 22.1 3.0 104.7

M4 — M4 — — M6 M10 — M14 — — M8 M10 — M6 M6 M8 M8 M8 M6 — — —

2 19 2 18 1 5 54 8 27 72 72 20 42 8 4 10 20 20 20 4 1 22 36

0.2 1.9 0.2 1.8 0.1 0.5 5.4 0.8 2.7 7.2 7.2 2.0 4.2 0.8 0.4 1.0 2.0 2.0 2.0 0.4 0.1 2.2 3.6

1.5 14.0 1.5 13.3 0.7 3.7 39.8 5.9 19.9 53.1 53.1 14.8 31.0 5.9 3.0 7.4 14.8 14.8 14.8 3.0 0.7 16.2 26.6

M8 M8 M12 —

19 19 7 2

1.9 1.9 0.7 0.2

14.0 14.0 5.2 1.5

Thread size

2-14

1 2 3 4 5 6 7 8 9

SPEC

Specification Part to be tightened

Pipe joint Pipe joint adapter Gear pump bolt Gear pump bracket bolt Trim cylinder end screw Tilt ram Tilt cylinder end screw Tilt piston bolt

Thread size — — M5 M5 — — — M6

Tightening torques N·m kgf·m ft·lb 15 1.5 11.1 20 2.0 14.8 7 0.7 5.2 7 0.7 5.2 160 16 118.0 55 5.5 40.6 90 9.0 66.4 7 0.7 5.2

General torque This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided in applicable sections of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion and progressive stages until the specified torque is reached. Unless otherwise specified, torque specifications require clean, dry threads. Components should be at room temperature. Nut (A)

Bolt (B)

8 mm 10 mm 12 mm 14 mm 17 mm

M5 M6 M8 M10 M12

2-15

General torque specifications N·m kgf·m ft·lb 5 0.5 3.7 8 0.8 5.9 18 1.8 13.3 36 3.6 26.6 43 4.3 31.7

6P21H11

CHK ADJ

Periodic check and adjustment Maintenance interval chart............................................................................3-1 Top cowling .................................................................................................... 3-3 Checking the top cowling...........................................................................3-3 Fuel system .................................................................................................... 3-3 Checking the fuel joint and fuel hose (fuel joint-to-fuel injector) ................ 3-3 Checking the fuel filter ............................................................................... 3-4 Power unit....................................................................................................... 3-4 Checking the engine oil .............................................................................3-4 Changing the engine oil using an oil changer............................................3-4 Changing the engine oil by draining it .......................................................3-5 Replacing the oil filter ................................................................................ 3-6 Checking the timing belt ............................................................................3-6 Checking the spark plug ............................................................................3-7 Checking the thermostat............................................................................3-7 Checking the cooling water passage.........................................................3-9 Control system ............................................................................................... 3-9 Checking the engine idle speed ................................................................3-9 Adjusting the throttle cable ...................................................................... 3-10 Checking the gear shift operation............................................................ 3-11 Bracket unit .................................................................................................. 3-12 Checking the PTT operation.................................................................... 3-12 Checking the PTT fluid level.................................................................... 3-12 Lower unit ..................................................................................................... 3-13 Checking the gear oil level ...................................................................... 3-13 Changing the gear oil .............................................................................. 3-13 Checking the lower unit for air leakage ...................................................3-14 Checking the propeller............................................................................. 3-14 General..........................................................................................................3-14 Checking the anode................................................................................. 3-14 Checking the battery................................................................................ 3-15 Lubricating the outboard motor................................................................3-16

6P21H11

1 2 3 4 5 6 7 8 9

CHK ADJ

Periodic check and adjustment

Maintenance interval chart

Use the following chart as a guideline for general maintenance. Adjust the maintenance intervals according to the operating conditions of the outboard motor. Initial Item Anodes (external) Anodes (cylinder head, thermostat cover) Battery Cooling water passages Top cowling Fuel filter (can be disassembled) Fuel system Gear oil Lubrication points Engine idle speed PCV PTT unit Propeller and cotter pin Shift link/shift cable Thermostat Throttle link/throttle cable/ throttle pick-up timing Water pump Engine oil Oil filter (cartridge) Spark plugs Timing belt

Remarks

Every

10 hours 50 hours 100 hours 200 hours (1 month) (3 months) (6 months) (1 year)

Refer to page

Check/replace Check/replace

3-14 3-14

Check/charge Clean Check Check/replace

3-15 3-9 3-3 3-4

Check Change Lubricate Check Check Check Check/replace Check/adjust Check/replace Check/adjust

3-3 3-13 3-16 3-9 7-7 3-12 3-14 3-11 3-7 3-10

Check/replace Check/change Change Clean/adjust/ replace Check/replace

6-5, 6-33 3-4 3-6 3-7 3-6

NOTE: When operating in salt water, turbid or muddy water, the engine should be flushed with clean water after each use.

3-1

6P21H11

Maintenance interval chart Every Item Timing belt Valve clearance (DOHC) Fuel filter (vapor separator tank) Oil control valve filter Anodes (exhaust cover, cooling water passage cover, Rectifier Regulator cover) Exhaust guide, exhaust manifold

6P21H11

Remarks

500 hours (2.5 years)

1,000 hours (5 years)

Refer to page

Replace Check/adjust Replace

5-15 5-10 4-23

Check/replace Replace

5-41 3-14

Check/replace

7-8

3-2

1 2 3 4 5 6 7 8 9

CHK ADJ

Periodic check and adjustment

Top cowling

Checking the top cowling 1. Check the fitting by pushing the cowling with both hands. Adjust if necessary.

Fuel system

Checking the fuel joint and fuel hose (fuel joint-to-fuel injector) 2. Loosen the bolts 1.

1. Remove the flywheel magnet cover, port intake manifold, and fuel rail covers.

3. Move the hook 2 up or down slightly to adjust its position.

NOTE: See the exploded diagram (4-12, 4-26). 2. Check the low-pressure fuel hose connections. Also, check the fuel filter 1, low-pressure fuel pump 2, filter 3, check valve 4, and fuel cooler 5. Replace if there is leakage or deterioration.

NOTE: • To loosen the fitting, move the hook in direction a. • To tighten the fitting, move the hook in direction b.

3. Check the high-pressure fuel hose connections. Also, check the vapor separator 6, pressure regulator 7, fuel rails 8, and fuel injectors 9. Replace if there is leakage or deterioration.

4. Tighten the bolts.

3 5. Check the fitting again and, if necessary, repeat steps 2–4. 6. Check the top cowling hoses. Replace if cracked or damaged.

4 1

5 6 S6P23020

4. Install the port intake manifold, fuel rail covers, and flywheel magnet cover.

3-3

6P21H11

Top cowling / Fuel system / Power unit NOTE: To install the intake manifold, see Chapter 4, “Installing the intake manifold.”

Checking the fuel filter 1. Check the fuel filter element 1. Replace if there is dirt or residue. 2. Check the cup 2. Clean with straight gasoline if there are foreign substance or replace if cracked.

NOTE: • Change the oil if it appears milky or dirty. • If the engine oil is below the minimum level mark (L), add sufficient oil until the level is between (H) and (L).

Changing the engine oil using an oil changer 1. Start the engine, warm it up, and then turn it off. 2. Remove the oil dipstick and oil filler cap 1.

NOTE: Be sure not to spill any fuel when removing the fuel filter cup.

Power unit

3. Insert the tube of the oil changer 2 into the dipstick guide 3.

Checking the engine oil 1. Place the outboard motor in an upright position. 2. Remove the oil dipstick, wipe it clean, and then insert it back into the dipstick guide. 3. Remove the oil dipstick again to check the oil level, and to check the oil for discoloration and its viscosity.

4. Operate the oil changer to extract the oil. NOTE: Be sure to clean up any oil spills.

6P21H11

3-4

1 2 3 4 5 6 7 8 9

CHK ADJ

Periodic check and adjustment

5. Pour the specified amount of the recommended engine oil into the oil filler hole.

4. Place a drain pan under the drain hole, and then remove the engine oil drain bolt 3 and let the oil drain completely.

Recommended engine oil: 4-stroke motor oil API: SE, SF, SG, SH, SJ, or SL SAE: 10W-30, or 10W-40 Engine oil quantity: Without oil filter replacement: 5.6 L (5.92 US qt, 4.93 Imp qt) 6. Install the oil filler cap and oil dipstick, and then start the engine and warm it up for 5 minutes. 7. Turn the engine off, and then check the oil level and that there is no oil leakage. If the oil level is low, add engine oil to the correct level.

Changing the engine oil by draining it 1. Start the engine, and warm it up, and then turn it off.

5. Install the engine oil drain bolt, and then tighten it to the specified torque.

T. R.

2. Remove the oil dipstick and oil filler cap 1.

NOTE: Be sure to clean up any oil spills.

Engine oil drain bolt 3: 27 N·m (2.7 kgf·m, 19.9 ft·lb)

6. Pour the specified amount of the recommended engine oil into the oil filler hole. Recommended engine oil: 4-stroke motor oil API: SE, SF, SG, SH, SJ or SL SAE: 10W-30, or 10W-40 Engine oil quantity: Without oil filter replacement: 5.6 L (5.92 US qt, 4.93 Imp qt) 3. Remove the starboard apron 2.

7. Install the oil filler cap and oil dipstick, and then start the engine and warm it up for 5 minutes. 8. Turn the engine off, and then check the oil level and that there is no oil leakage. If the oil level is low, add engine oil to the correct level. 9. Install the starboard apron 2, and then tighten the bolts to the specified torque.

3-5

6P21H11

Power unit 4. Install the oil filter, and then tighten it to the specified torque using a 72.5 mm (2.9 in) oil filter wrench.

2 LT

572

572 S6S13220

T. R.

Apron bolt: 8 N·m (0.8 kgf·m, 5.9 ft·lb)

Replacing the oil filter CAUTION:

S6P23090

Do not damage the oil pressure sensor and its lead when replacing the oil filter. T. R.

1. Extract the engine oil with an oil changer or drain it. 2. Place a rag under the oil filter, and then remove the oil filter using a 72.5 mm (2.9 in) oil filter wrench 1.

S6P23080

NOTE: • Wait more than 5 minutes after turning the engine off to replace the oil filter. • Be sure to clean up any oil spills.

Oil filter: 18 N·m (1.8 kgf·m, 13.3 ft·lb)

5. Pour the specified amount of the recommended engine oil into the oil filler hole. Recommended engine oil: 4-stroke motor oil API: SE, SF, SG, SH, SJ, or SL SAE: 10W-30, or 10W-40 Engine oil quantity: With oil filter replacement: 5.8 L (6.13 US qt, 5.10 Imp qt) 6. Install the oil filler cap and oil dipstick, and then start the engine and warm it up for 5 minutes. 7. Turn the engine off, and then check the oil level and that there is no oil leakage. If the oil level is low, add engine oil to the correct level.

Checking the timing belt Oil filter wrench 1: (commercially available) 3. Apply a thin coat of engine oil to the Oring of the new oil filter.

CAUTION: Do not turn the flywheel magnet counterclockwise, otherwise the water pump impeller may be damaged. 1. Remove the flywheel magnet cover.

6P21H11

3-6

1 2 3 4 5 6 7 8 9

CHK ADJ

Periodic check and adjustment

2. While turning the flywheel magnet clockwise, check the interior a and the exterior b of the timing belt. Replace if cracked, damaged, or worn.

b S6P23100

NOTE: To replace the timing belt, see Chapter 5, “Replacing the timing belt.”

4. Check the electrodes for erosion and excessive carbon or other deposits, and the gasket for damage. Replace the spark plug if necessary. 5. Check the spark plug gap a. Adjust if out of specification.

Checking the spark plug 1. Remove the ECM cover. 2. Remove the ignition coils, and then remove the spark plugs.

Specified spark plug: LFR6A-11 (NGK) Spark plug gap a: 1.0–1.1 mm (0.039–0.043 in) 6. Install the spark plugs, tighten them temporary, then to the specified torque using a spark plug wrench.

T. R.

Spark plug: 25 N·m (2.5 kgf·m, 18.4 ft·lb)

7. Install the ignition coils.

T. R.

3. Clean the electrodes 1 with a spark plug cleaner or wire brush. Replace the spark plug if necessary.

Ignition coil bolt: 7 N·m (0.7 kgf·m, 5.2 ft·lb)

8. Install the ECM cover.

Checking the thermostat 1. Reduce the fuel pressure.

3-7

6P21H11

Power unit NOTE: To reduce the fuel pressure, see Chapter 4, “Reducing the fuel pressure.”

2005 F250 6P2 LF250 6P3

1000001–1002894 1000001–1000956

2. Remove the flywheel magnet cover.

3. Disconnect the oil control valve couplers 1. 4. Disconnect the thermoswitch connectors 2. 5. Disconnect the quick connectors 3.

4 2006 F250 6P2 LF250 6P3

PORT

S6P23140

1002895– 1000957–

5 6 2

S6P23120

STBD

S6P23320E

CAUTION: Do not reuse the gaskets 6, always replace them with new ones.

1 S6P23130

WARNING It is dangerous if the quick connector is removed suddenly since pressurized fuel will spray out. Be sure to reduce the fuel pressure before removing the quick connector. NOTE: To disconnect the quick connector, see Chapter 4, “Disconnecting the quick connector.”

7. Suspend the thermostat in a container of water. 8. Place a thermometer in the water and slowly heat the water.

S69J5E40

6. Remove the covers 4 and thermostats 5 (port and starboard). 6P21H11

3-8

1 2 3 4 5 6 7 8 9

CHK ADJ

Periodic check and adjustment

9. Check the thermostat valve opening at the specified water temperatures. Replace if out of specification.

1 1 Water temperature

Valve lift a

58–62 °C (136–144 °F)

0.05 mm (0.0020 in) (valve begins to lift)

above 70 °C (158 °F)

more than 4.3 mm (0.17 in)

10. Install the thermostats and covers. NOTE: It is recommended to check the thermostat cover anodes before installing the thermostat covers.

S6P23150

2. Place the lower unit in water, and then start the engine. 3. Check for water flow at the cooling water pilot hole. If there is no water flow, check the cooling water passage inside the outboard motor.

11. Connect the thermoswitch connectors, quick connectors, and oil control valve couplers. 12. Route and fasten the wiring harness in its original position. 13. Install the flywheel magnet cover.

Checking the cooling water passage 1. Check the cooling water inlet covers 1 and cooling water inlet. Clean if clogged.

S6P21050

Control system

Checking the engine idle speed 1. Start the engine and warm it up for 5 minutes. 2. Check the engine idle speed using the Yamaha genuine tachometer (on-board meter) or using the YDIS. NOTE: To connect and operate the YDIS, see Chapter 9, “YDIS” and the YDIS (version 1.23a or later) Instruction Manual.

3-9

6P21H11

Power unit / Control system

Engine idle speed: 600â&#x20AC;&#x201C;700 r/min

Adjusting the throttle cable 1. Set the remote control lever to the neutral position and fully close the throttle lever. 2. Loosen the locknut 1, remove the clip 2, and then disconnect the throttle cable joint 3.

a S6D53190

WARNING The throttle cable joint must be screwed in a minimum of 8.0 mm (0.31 in) a.

2 3 1 NOTE: Pull the throttle cable towards the engine to remove any free play in the cable before adjusting the position of the throttle cable joint. 5. Connect the throttle cable joint 3, install the clip 2, and then tighten the locknut 1. S6P23330

3. Check that the accelerator lever 4 contacts the fully closed stopper 5.

3 1

S6P23350

4 S6P23340

4. Adjust the position of the throttle cable joint until its hole is aligned with the set pin on the lever.

6P21H11

3-10

1 2 3 4 5 6 7 8 9

CHK ADJ

Periodic check and adjustment

6. Operate the remote control lever several times, and then check that the mark b on the lever 4 has passed the mark c on the stopper 5 when the remote control lever is in the fully open position of the throttle.

4. Loosen the locknut 1, remove the clip 2, and then disconnect the shift cable joint 3.

4 5

b S6P23360

5. Align the alignment mark a on the bushing and alignment mark b on the bracket.

7. Check that the lever 4 contacts the fully closed stopper 5 when the remote control lever is in the fully closed position. 8. Check the throttle cable for smooth operation and, if necessary, repeat steps 2–7.

Checking the gear shift operation 1. Check that the gear shift operates smoothly when shifting it from the neutral position to forward or reverse. Adjust the shift cable length if necessary.

6. Adjust the position of the shift cable joint until its hole is aligned with the set pin.

2. Check the neutral switch for continuity. Adjust the shift cable length or check the neutral switch if necessary. NOTE: To check the neutral switch, see Chapter 8, “Checking the neutral switch.”

Gear shift position

Lead color Blue/green (L/G)

Black (B)

Forward or reverse

S69J3370

WARNING The shift cable joint must be screwed in a minimum of 8.0 mm (0.31 in) c.

Neutral 3. Set the gear shift to the neutral position.

3-11

7. Connect the cable joint, install the clip, and then tighten the locknut.

6P21H11

Control system / Bracket unit 8. Check the gear shift for smooth operation, check the operation of the neutral switch and, if necessary, repeat steps 3â&#x20AC;&#x201C;7.

Bracket unit

Checking the PTT fluid level 1. Fully tilt the outboard motor up, and then support it with the tilt stop lever 1.

Checking the PTT operation 1. Fully tilt the outboard motor up and down a few times and check the entire trim and tilt range for smooth operation. Check the PTT fluid level if necessary.

WARNING After tilting up the outboard motor, be sure to support it with the tilt stop lever. Otherwise, the outboard motor could suddenly lower if the PTT unit should lose fluid pressure. 2. Remove the reservoir cap 2, and then check the fluid level in the reservoir.

S6P23190

NOTE: Be sure to listen to the winding sound of the PTT motor for smooth operation. 2. Fully tilt the outboard motor up, and then support it with the tilt stop lever 1 to check the lock mechanism of the lever.

WARNING Make sure that the trim and tilt rams are fully extended when removing the reservoir cap, otherwise fluid can spurt out from the unit due to internal pressure. NOTE: If the fluid is at the correct level, a small amount of fluid should overflow out of the filler hole when the cap is removed.

6P21H11

3-12

1 2 3 4 5 6 7 8 9

CHK ADJ

Periodic check and adjustment

Recommended PTT fluid: ATF Dexron II

3. If necessary, add sufficient fluid of the recommended type until it overflows out of the filler hole.

Gear oil check screw: 9 N·m (0.9 kgf·m, 6.6 ft·lb)

Changing the gear oil 1. Tilt the outboard motor up slightly.

4. Install the new O-ring and reservoir cap, and then tighten the cap to the specified torque.

2. Place a drain pan under the drain screw 1, remove the drain screw, then the check screw 2 and let the oil drain completely.

T. R.

Reservoir cap: 7 N·m (0.7 kgf·m, 5.2 ft·lb)

Lower unit

Checking the gear oil level 1. Fully tilt the outboard motor down. 2. Remove the check screw 1, and then check the gear oil level in the lower case.

3. Check the oil for metal and discoloration, and check its viscosity. Check the internal parts of the lower case if necessary.

1 S60V3320

NOTE: If the oil is at the correct level, a small amount of oil should overflow out of the check hole when the check screw is removed.

4. Insert a gear oil tube or gear oil pump into the drain hole and slowly fill the gear oil until oil flows out of the check hole and no air bubbles are visible.

3. If necessary, add sufficient gear oil of the recommended type until it overflows out of the check hole. Recommended gear oil: Hypoid gear oil API: GL-4 SAE: 90 4. Install the new gasket and check screw, and then tighten the screw to the specified torque.

3-13

6P21H11

Bracket unit / Lower unit / General Recommended gear oil: Hypoid gear oil API: GL-4 SAE: 90 Gear oil quantity: Regular rotation model: 1,150 cm3 (38.9 US oz, 40.6 Imp oz) Counter rotation model: 1,000 cm3 (33.8 US oz, 35.3 Imp oz) 5. Install the new gaskets, check screw, and quickly install the drain screw, and then tighten them to the specified torque.

T. R.

Gear oil check screw and drain screw: 9 N·m (0.9 kgf·m, 6.6 ft·lb)

Checking the lower unit for air leakage

NOTE: Cover the check hole with a rag when removing the tester from the lower unit. Lower unit holding pressure: 70 kPa (0.7 kgf/cm2, 10 psi) 3. If the specified pressure cannot be maintained, check the drive shaft, propeller shaft and shift rod oil seals for damage. If necessary, check the each shaft for bends and damage.

Checking the propeller 1. Check the propeller blades and splines. Replace if cracked, damaged, or worn.

General

Checking the anode 1. Check the anodes and trim tab. Clean if there are scales, grease, or oil.

1. Remove the check screw 1, and then install the special service tool.

Pressure/vacuum tester: YB-35956-A 2. Apply the specified pressure to check that the pressure is maintained in the lower unit for at least 10 seconds.

S6P23310E

CAUTION: Do not over pressurize the lower unit, otherwise the oil seals may be damaged.

6P21H11

3-14

1 2 3 4 5 6 7 8 9

CHK ADJ

Periodic check and adjustment

S6P23270E

CAUTION: S6P23210

Do not oil, grease, or paint the anodes or the trim tab, otherwise they will be ineffective. NOTE: If it is necessary to disassemble the outboard motor to check an anode, refer to the applicable disassembly procedure in this manual. 2. Replace the anodes or trim tab if excessively eroded. In addition, check the ground lead.

Checking the battery

S6P23400

3-15

1. Check the battery electrolyte level. If the level is at or below the minimum level mark a, add distilled water until the level is between the maximum and minimum level marks.

6P21H11

General NOTE: • Batteries vary per manufacturer. The procedures mentioned in this manual may not always apply, therefore, consult the instruction manual of the battery. • Disconnect the negative battery cable first, then the positive battery cable. S69J3620

2. Check the specific gravity of the electrolyte. Fully charge the battery if below specification.

WARNING Battery electrolyte is dangerous; it contains sulfuric acid which is poisonous and highly caustic. Always follow these preventive measures: • Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury. • Wear protective eye gear when handling or working near batteries. Antidote (EXTERNAL): • SKIN – Wash 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 generate explosive, hydrogen gas. Always follow these preventive measures: • Charge batteries in a well-ventilated area. • Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes). • DO NOT SMOKE when charging or handling batteries. KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN.

6P21H11

Electrolyte specific gravity: 1.280 at 20 °C (68 °F)

Lubricating the outboard motor 1. Apply water resistant grease to the areas shown.

S6P23240

3-16

1 2 3 4 5 6 7 8 9

CHK ADJ

Periodic check and adjustment

S6D03010

NOTE: Apply grease to the grease nipple until it flows from the bushings a. 2. Apply low temperature resistant grease to the area shown.

S6P23410

3. Apply corrosion resistant grease to the area shown.

3-17

6P21H11

FUEL

Fuel system Hose routing ...................................................................................................4-1 Fuel hose and blowby hose....................................................................... 4-1 Vapor gas hose ......................................................................................... 4-2 Cooling water hose.................................................................................... 4-3 Checking the throttle valve operation ........................................................4-5 Checking the TPS......................................................................................4-5 Measuring the fuel pressure ...................................................................... 4-7 Checking the pressure regulator ............................................................... 4-7 Reducing the fuel pressure........................................................................ 4-8 Disconnecting the quick connector............................................................ 4-9 Draining the fuel ........................................................................................4-9 Fuel filter ....................................................................................................... 4-11 Intake manifold............................................................................................. 4-12 Installing the intake manifold ................................................................... 4-13 Installing the intake silencer .................................................................... 4-13 Throttle body ................................................................................................4-15 Checking the canister .............................................................................. 4-18 Checking the canister check valve .......................................................... 4-18 Installing the throttle body........................................................................4-18 Low-pressure fuel pump ............................................................................. 4-20 Checking the check valve........................................................................4-21 Vapor separator............................................................................................ 4-22 Removing the fuel hose clamp ................................................................4-25 Installing the fuel hose clamp .................................................................. 4-25 Checking the vapor separator .................................................................4-25 Fuel injector.................................................................................................. 4-26 Installing the fuel injector .........................................................................4-27

6P21H11

1 2 3 4 5 6 7 8 9

FUEL

Fuel system

Hose routing

Fuel hose and blowby hose

4 6 1 3 B

7 2

S6P24010

1 2 3 4 5 6 7 8 9 0 A B C

Fuel hose (fuel joint-to-fuel filter) Fuel hose (fuel filter-to-joint) Fuel hose (joint-to-low-pressure fuel pump) Fuel hose (low-pressure fuel pump-to-filter) Fuel hose (filter-to-joint) Fuel hose (joint-to-check valve) Fuel hose (check valve-to-joint) Fuel hose (vapor separator-to-quick connector) Fuel hose (quick connector-to-joint) Fuel hose (joint-to-quick connector) Fuel hose (pressure regulator-to-fuel cooler) Fuel hose (fuel cooler-to-vapor separator) Blowby hose (starboard cylinder head cover-to-intake silencer)

4-1

6P21H11

Hose routing

Vapor gas hose

STBD

E Ê

È É

E 1

9 0 F

G 8 Ë

E G 8

7 6

6 5

S6P24020E

1 2 3 4 5 6 7 8

Vapor gas hose (vapor separator-to-joint) Vapor gas hose (vapor separator-to-joint) Vapor gas hose (joint-to-joint) Vapor gas hose (joint-to-joint) Vapor gas hose (joint-to-canister tank port) Vapor gas hose (canister purge port-to-joint) Vapor gas hose (joint-to-vapor shut-off valve) Vapor gas hose (vapor shut-off valve-to-surge tank) 9 Vapor gas hose (intake silencer-to-check valve) 0 Vapor gas hose (check valve-to-joint) A Vapor gas hose (canister atmospheric port-tojoint) 6P21H11

B Vapor gas hose (joint-to-joint) C Vapor gas hose (joint-to-check valve) D Vapor gas hose (check valve-to-top cowling lock) E Vacuum hose (pressure regulator-to-joint) F Vacuum hose (intake air pressure sensor-tojoint) G Vacuum hose (joint-to-surge tank)

4-2

1 2 3 4 5 6 7 8 9

FUEL

Fuel system

Cooling water hose 2

PORT

STBD

2 b 4 5 a 3

6 1 c d e

1 2 3 4 5 6 7

Cooling water hose (cylinder block-to-fuel cooler) Cooling water hose (fuel cooler-to-Rectifier Regulator) Cooling water hose (Rectifier Regulator-to-cooling water pilot hole) Cooling water hose (port thermostat cover-to-cylinder block) Cooling water hose (starboard thermostat cover-to-cylinder block) Cooling water hose (starboard cylinder head-to-cooling water pressure sensor adapter) Flushing hose (joint-to-cooling water passage cover)

a b c d e

Fuel cooler Rectifier Regulator Cooling water pilot hole (on the bottom cowling) Cooling water pressure sensor adapter Cooling water passage cover (on the cylinder block)

4-3

S6P24450E

6P21H11

Hose routing

1 3 5

S6P24490C

1 2 3 4 5

Cooling water hose (cylinder block-to-fuel cooler) Cooling water hose (Rectifier Regulator-to-cooling water pilot hole) Flushing hose (joint-to-cooling water passage cover) Flushing hose (flushing hose adapter-to-joint) Speedometer hose

6P21H11

4-4

1 2 3 4 5 6 7 8 9

FUEL

Fuel system

Checking the throttle valve operation 1. Remove the flywheel magnet cover and intake silencer. NOTE: See the exploded diagram (4-12). 2. Push the throttle valve, and check that the valve moves smoothly when the engine start switch is turned to OFF. 3. Turn the engine start switch to ON. 4. Check that the throttle valves operate smoothly when the remote control lever is shifted from the fully closed position to the fully open position.

S6P24140

NOTE: • Be sure to check the accelerator position sensor before checking the TPS. • To connect and operate the YDIS, see Chapter 9, “YDIS” and the YDIS (version 1.23a or later) Instruction Manual. 2. Check that the accelerator lever 1 contacts the fully closed stopper 2 when the remote control lever is at the fully closed position.

2 S6P24130

5. Install the intake silencer and flywheel magnet cover. NOTE: • To install the intake silencer, see “Installing the intake silencer.” • To check the accelerator position sensor, see Chapter 8, “Checking the accelerator position sensor circuit” and “Checking the accelerator position sensor.”

Checking the TPS 1. Connect a computer to the outboard motor and use the YDIS to display “Throttle position sensor 1,” “Throttle valve opening,” and “Throttle position sensor 2.”

4-5

S6P21030

NOTE: To adjust the throttle cable, see Chapter 3, “Adjusting the throttle cable.” 3. Start the engine, warm it up, and then turn it off.

6P21H11

Hose routing 4. Check that the remote control lever is in the fully closed position of the throttle, and then check the output voltage of TPS 1 and the throttle valve opening angle.

S6P24150

S6P24440

CAUTION: Do not loosen the throttle stop screw nut, and do not turn the throttle stop screw. NOTE: • Check the TPS after the engine has been warmed up. • When checking the TPS, do not start the engine. • The actual TPS output voltage and throttle valve opening angle may vary according to environmental conditions and engine temperature.

6P21H11

Output voltage of TPS 1 with the remote control lever at the fully closed position: at 20 °C (68 °F): 0.750 V (reference data) Throttle valve opening angle with the remote control lever at the fully closed position: at 20 °C (68 °F): 0.5–7.0° (reference data) 5. Shift the remote control lever to the fully open position and hold it.

S6P24160

6. Check the output voltage of TPS 2 and the throttle valve opening angle. TPS 2 output voltage with the remote control lever at the fully open position: at 20 °C (68 °F): 4.550 V Throttle valve opening angle with the remote control lever at the fully open position: Above 80° (reference data) 7. Operate the remote control lever, and check that the output voltages of TPS 1 and TPS 2 change continuously.

4-6

1 2 3 4 5 6 7 8 9

FUEL

Fuel system

Measuring the fuel pressure 1. Disconnect the quick connector from the vapor separator. NOTE: Before disconnecting the quick connector, reduce the fuel pressure. 2. Connect fuel pressure gauge adapter B 1 between the quick connector and vapor separator. 3. Connect the fuel pressure gauge 2 to fuel pressure gauge adapter B.

PORT

NOTE: â&#x20AC;˘ The fuel pressure will decreases after 5 seconds later when the engine start switch is turned to ON. â&#x20AC;˘ The high-pressure fuel pump does not operate when the engine start switch is turned to ON again within 10 seconds after turning the switch to OFF. Fuel pressure (reference data): 300 kPa (3.0 kgf/cm2, 43.5 psi) 5. Measure the fuel pressure 5 seconds after turning the engine start switch to ON. Fuel pressure (reference data): 280 kPa (2.8 kgf/cm2, 40.6 psi) 6. Start the engine, warm it up for 5 minutes, and then measure the fuel pressure at engine idle speed. If below specification, check the high-pressure fuel line and the vapor separator.

S6P24290C

WARNING Gently screw in the gauge until it is firmly connected to prevent fuel from leaking out.

Fuel pressure (reference data): 260 kPa (2.6 kgf/cm2, 37.7 psi) 7. Reduce the fuel pressure. 8. Remove the special service tools. 9. Connect the quick connector.

Fuel pressure gauge adapter B 1: YB-06942 Fuel pressure gauge 2: YB-06766 4. Turn the engine start switch to ON, and then measure the fuel pressure within 5 seconds.

Checking the pressure regulator 1. Disconnect the quick connector from the vapor separator. NOTE: Before disconnecting the quick connector, reduce the fuel pressure. 2. Connect fuel pressure gauge adapter B between the quick connector and vapor separator. 3. Connect the fuel pressure gauge to fuel pressure gauge adapter B.

4-7

6P21H11

Hose routing 4. Disconnect the pressure regulator hose, and then connect the special service tool to the pressure regulator.

Reducing the fuel pressure WARNING Always reduce the fuel pressure in the high-pressure fuel line before servicing the line or the vapor separator. If the fuel pressure is not released, pressurized fuel may spray out. 1. Remove the fuse holder cover 1, and then remove the high-pressure fuel pump fuse (15 A) 2.

S6P24300C

WARNING Gently screw in the gauge until it is firmly connected to prevent fuel from leaking out. Fuel pressure gauge: YB-06766 Fuel pressure gauge adapter B: YB-06942 Pressure/vacuum tester: YB-35956-A 5. Start the engine and let it idle. 2. Start the engine. 6. Check that the fuel pressure reduces when vacuum pressure is applied to the pressure regulator. If the fuel pressure does not reduce, replace the pressure regulator. NOTE: When the specified vacuum pressure is reached, the pressure regulator is operated and the fuel pressure is reduced.

NOTE: â&#x20AC;˘ If the engine starts, it will stall after a few seconds. â&#x20AC;˘ If the engine does not start, crank the engine 2 or 3 times. 3. After the engine stalls, crank the engine 2 or 3 times. 4. Turn the engine start switch to OFF.

7. Reduce the fuel pressure. 8. Remove the special service tools. 9. Connect the pressure regulator hose and quick connector.

6P21H11

4-8

1 2 3 4 5 6 7 8 9

FUEL

Fuel system

Disconnecting the quick connector WARNING If the quick connector is removed suddenly, pressurized fuel could spray out. Be sure to reduce the fuel pressure before removing the quick connector.

1. Reduce the fuel pressure. S6P24280

2. Wrap the quick connector with a rag, and then rotate the quick connector tab 1 to the stopper position a.

Draining the fuel 1. Reduce the fuel pressure. 2. Remove the cap 1.

PORT

3. Cover the pressure check valve of the vapor separator with a rag, and then press in the pressure check valve using a thin screwdriver to release the fuel pressure.

4. Place a drain pan under the vapor separator drain hose, and then loosen the drain screw 2.

5. Drain the fuel from the vapor separator drain hose by pressing the pressure check valve using a thin screwdriver.

STBD

S6P24270

CAUTION: â&#x20AC;˘ Do not rotate the quick connector tab 1 past the stopper position a, otherwise it could be damaged. â&#x20AC;˘ When the fuel hose is disconnected, quickly remove the retainer 2 from the quick connector, otherwise the retainer could be lost.

2 1

3. Disconnect the quick connector 3 from the fuel rail or vapor separator directly.

S6P24310

4-9

6P21H11

Hose routing

WARNING Reduce the fuel pressure before loosening the vapor separator drain screw, or pressurized fuel will spray out and may result in serious injury.

1 2 3 4 5 6 7 8 9

6. Tighten the drain screw.

T. R.

Vapor separator drain screw: 2 N·m (0.2 kgf·m, 1.5 ft·lb)

6P21H11

4-10

FUEL

Fuel system

Fuel filter

6 1 13

3 10

4 5

11 T.

3.5 N · m (0.35 kgf · m, 2.6 ft · lb)

S6P24040E

No. 1 2 3 4 5 6 7 8 9 10 11 12 13

4-11

Part name O-ring O-ring Fuel filter element Float Cup Fuel filter assembly Bracket Bolt Bolt Fuel hose Holder Joint Plastic tie

Q’ty 1 1 1 1 1 1 1 2 2 2 1 1 3

Remarks Not reusable Not reusable

M6 × 16 mm M6 × 20 mm

Not reusable

6P21H11

Fuel filter / Intake manifold

Intake manifold

7 N · m (0.7 kgf · m, 5.2 ft · Ib)

16 1

3 A

13 15

13 9

10 N · m (1.0 kgf · m, 7.4 ft · Ib)

14 T.

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Part name Flywheel magnet cover Damper Grommet Blowby hose Plastic tie Intake air temperature sensor Grommet Bolt Bolt Bolt Intake manifold (STBD) Gasket Gasket Gasket Intake manifold (PORT) Intake silencer

6P21H11

Q’ty 1 1 4 1 1 1 1 4 8 7 1 1 6 1 1 1

10 N · m (1.0 kgf · m, 7.4 ft · Ib)

S6P24050E

Remarks

M6 × 25 mm M8 × 40 mm M6 × 40 mm Not reusable Not reusable Not reusable

4-12

1 2 3 4 5 6 7 8 9

FUEL

Fuel system

Installing the intake manifold STBD

1. Install new gaskets onto the intake manifolds.

PORT $ !

T. R.

S6P24060

NOTE: Be sure to install the projection on each gasket into its corresponding slit in the intake manifolds.

S6P24090

Intake manifold bolt: 10 N·m (1.0 kgf·m, 7.4 ft·lb)

4. Tighten the M8 bolts in the sequence shown.

PORT

STBD

2. Install the intake manifolds and bolts temporarily.

3 1

2 4

S6P24100E

Installing the intake silencer 1. Install the intake silencer.

S6P24080E

NOTE: When installing the intake manifolds, make sure that the gaskets do not come off when the projection of the gasket comes into contact with the fuel rail cover.

Intake silencer bolt: 7 N·m (0.7 kgf·m, 5.2 ft·lb)

2. Fasten the intake air temperature sensor lead 1 to the holder on the oil filler neck as shown. 3. Connect the blowby hose 2, and then fasten the plastic tie 3 as shown.

3. Tighten the M6 bolts to the specified torque in the sequence shown.

4-13

6P21H11

Intake manifold

1 2 3 4 5 6 7 8 9

1 3

2 2 S6P24380

6P21H11

4-14

FUEL

Fuel system

Throttle body

13 N · m (1.3 kgf · m, 9.6 ft · Ib)

13 N · m (1.3 kgf · m, 9.6 ft · Ib) T.

5 N · m (0.5 kgf · m, 3.7 ft · Ib)

22 23

3 LT

242

15 6 26 16

11 17

18 T.

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

4-15

29 T.

20 19

5 N · m (0.5 kgf · m, 3.7 ft · Ib)

Part name Joint Plastic tie Nut Washer Electronic throttle valve assembly Gasket Bolt Plate Gasket Surge tank Collar Bolt Holder Bolt Canister Bolt Bracket

S6P24530

Q’ty 1 1 4 2 1 1 4 1 1 1 2 4 2 2 1 1 1

Remarks

Not reusable

M8 × 18 mm Not reusable

M8 × 40 mm M6 × 14 mm M6 × 10 mm

6P21H11

Throttle body 4

13 N · m (1.3 kgf · m, 9.6 ft · Ib)

13 N · m (1.3 kgf · m, 9.6 ft · Ib) T.

5 N · m (0.5 kgf · m, 3.7 ft · Ib)

22 23

3 LT

242

15 6 26 16

11 17

18 T.

No. 18 19 20 21 22 23 24 25 26 27 28 29

29 T.

20 19

5 N · m (0.5 kgf · m, 3.7 ft · Ib)

Part name Bolt Collar Grommet Bracket Nut Holder Bracket Vapor shut-off valve Sub wiring harness Bolt Washer Intake air pressure sensor

6P21H11

S6P24530

Q’ty 2 2 2 1 1 1 1 1 1 1 1 1

Remarks M6 × 28 mm

M6 × 20 mm

4-16

1 2 3 4 5 6 7 8 9

FUEL

Fuel system 4

1 3 4

5 2

2 6

7 9 mm 7 mm (0.35 in) (0.27 in) 3 7

7 8 8 9 9

9 mm 7 mm 9 mm (0.35 in) (0.27 in) (0.35 in) 9

9 mm (0.35 in)

12 mm 9 mm (0.47 in) (0.35 in) S6P24500E

No. 1 2 3 4 5 6 7 8 9 10

4-17

Part name Check valve Holder Holder Joint Joint Joint Holder Joint Holder Holder

Qâ&#x20AC;&#x2122;ty 1 3 2 1 2 1 2 2 2 1

Remarks

6P21H11

Throttle body

Checking the canister 1. Check the canister. Replace if cracked.

2. Apply positive pressure to the check valve port.

2. Connect the special service tool to the atmospheric port 1 and cover the other ports, each with a finger.

3. Check that air comes out of the opposite end of the check valve. Replace if no air comes out. 4. Connect the special service tool to the opposite check valve port as shown.

S6P24180

3. Apply the specified positive pressure and check that there is no air leakage. Replace if there is air leakage. Pressure/vacuum tester: YB-35956-A Specified pressure: 19.6 kPa (0.196 kgf/cm2, 2.8 psi)

5. Apply positive pressure to the check valve port. 6. Check that no air comes out of the opposite end of the check valve. Replace if air comes out.

Installing the throttle body 1. Connect the check valve to the hose 1 and 2.

Ă&#x2C6;

Checking the canister check valve

1. Connect the special service tool to the check valve port as shown.

S6P24390

Ă&#x2C6; To the intake silencer

Pressure/vacuum tester: YB-35956-A

6P21H11

4-18

1 2 3 4 5 6 7 8 9

FUEL

Fuel system

2. Connect the hoses and fasten them.

3 É Ê

21 4

Ë 3

6 3 S6P24410

NOTE: Fasten the pressure regulator hose 3 and vapor separator hose 6 to the holder. S6P24400E

É To the pressure regulator Ê To the atmosphere (top cowling lock) Ë To the vapor separator

6. Fasten the wiring harness to the holders.

NOTE: Fasten the pressure regulator hose 3 and canister vent hose 4 to the holder.

7. Fasten the vapor gas hose 7 and fuel hose 8 to the holder.

3. Fasten hoses 2 and 5 to the holder.

2 5

8 7

S6P24420E

S6P24470

4. Install the throttle body. 5. Connect the hoses and fasten them.

4-19

6P21H11

Throttle body / Low-pressure fuel pump

Low-pressure fuel pump

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Part name Low-pressure fuel pump Cover Bolt Screw Holder Check valve Clamp Clamp Joint Holder Cover Filter Fuel hose Plastic tie Plastic tie

6P21H11

Q’ty 1 1 2 1 1 1 6 4 1 1 1 1 5 1 1

1 2 3 4 5 6 7 8 9

Remarks

M6 × 15 mm ø5 × 8 mm

Not reusable Not reusable

4-20

FUEL

Fuel system

Checking the check valve 1. Connect the special service tool to the check valve port as shown.

Pressure/vacuum tester: YB-35956-A 2. Apply positive pressure to the check valve port. 3. Check that air comes out of the opposite end of the check valve. Replace if no air comes out. 4. Connect the special service tool to the opposite check valve port as shown.

5. Apply positive pressure to the check valve port. 6. Check that no air comes out of the opposite end of the check valve. Replace if air comes out.

4-21

6P21H11

Low-pressure fuel pump / Vapor separator

Vapor separator

12 T.

13 1

2 3

5 N · m (0.5 kgf · m, 3.7 ft · Ib)

12 11

2 3

11 4

15 10

10 3 12 mm (0.47 in)

9 4

7 3

11 8

11 10

10 mm (0.39 in)

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Part name Bracket Bolt Collar Grommet Nut Bolt Collar Fuel cooler Bolt Clamp Clamp Quick connector Clamp Joint Clamp Clamp

6P21H11

3 6 Q’ty 1 2 8 4 2 2 2 1 2 3 4 3 3 1 1 1

5 S6P24520

Remarks M6 × 16 mm

M6 × 35 mm

M6 × 25 mm

Not reusable

4-22

1 2 3 4 5 6 7 8 9

FUEL

Fuel system 4

5 N · m (0.5 kgf · m, 3.7 ft · Ib)

2 N · m (0.2 kgf · m, 1.5 ft · Ib)

24 3

23 4 24

19 2 25

12 1

11 14

7 T.

2 N · m (0.2 kgf · m, 1.5 ft · Ib)

21 22

Part name Cover assembly O-ring Pressure regulator Screw Screw Wiring harness High-pressure fuel pump Grommet Filter Filter holder Plate Plate Screw O-ring Needle valve Float Pin

Q’ty 1 1 1 2 7 1 1 1 1 1 1 1 3 1 1 1 1

2 N · m (0.2 kgf · m, 1.5 ft · Ib)

4-23

9 10

16 18 No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

2 N · m (0.2 kgf · m, 1.5 ft · Ib)

S6P24250E

Remarks Not reusable

ø6 × 12 mm ø4 × 16 mm

ø4 × 8 mm Not reusable

6P21H11

Vapor separator 4

5 N · m (0.5 kgf · m, 3.7 ft · Ib)

2 N · m (0.2 kgf · m, 1.5 ft · Ib)

24 3

23 4 24

19 2 25

12 1

11 14

7 T.

2 N · m (0.2 kgf · m, 1.5 ft · Ib)

22 R.

Q’ty 1 1 1 1 1 1 2 1

6P21H11

2 N · m (0.2 kgf · m, 1.5 ft · Ib)

Part name Screw Gasket Float chamber Drain screw Drain hose Joint Hose Cap

9 10

16 18 No. 18 19 20 21 22 23 24 25

2 N · m (0.2 kgf · m, 1.5 ft · Ib)

S6P24250E

Remarks ø4 × 8 mm Not reusable

4-24

1 2 3 4 5 6 7 8 9

FUEL

Fuel system

Removing the fuel hose clamp 1. Remove the fuel hose clamps by cutting the crimped section of the clamp.

S6D54200

2. Check the float. Replace if there is deterioration.

CAUTION: If the fuel hose clamps are removed without cutting the crimp first, the fuel hose could be damaged.

Installing the fuel hose clamp 1. Crimp the fuel hose clamps properly to securely fasten them.

3. Check the filter. Clean if there is dirt or residue. 4. Install the needle valve and float to the vapor separator cover. 5. Place the vapor separator cover assembly in the position shown in the illustration, and then check the float height a.

S6P24480

WARNING Do not reuse the fuel hose clamps, always replace them with new ones, otherwise the fuel leakage may occur.

Checking the vapor separator

NOTE: To measure the height of the float, it should be resting on the needle valve. Do not press the float. Float height a: 60.5 Âą 3.0 mm (2.38 Âą 0.12 in)

1. Check the needle valve. Replace if bent or worn.

4-25

6P21H11

Vapor separator / Fuel injector

Fuel injector

10 8 1

3 12

5 3

10 E

3 6

3 7 10 11

2 5

No. 1 2 3 4 5 6 7 8 9 10 11 12

Part name Fuel injector O-ring set Holder Fuel rail (PORT) Bolt Cover Bolt Fuel rail (STBD) Cover Plastic tie Fuel rail assembly (PORT) Fuel rail assembly (STBD)

6P21H11

Q’ty 6 2 6 1 4 1 4 1 1 3 1 1

S6P24320

Remarks Not reusable

M6 × 35 mm M6 × 20 mm

4-26

1 2 3 4 5 6 7 8 9

FUEL

Fuel system

Installing the fuel injector 1. Apply engine oil to new O-rings, and then install them onto the fuel injectors.

4. Install the fuel rails onto the cylinder heads. 5. Tighten the bolts 7 equally and gradually.

7 7 S6P24330

2. Install the fuel injectors 1 onto the port fuel rail 2, and then install the holders 3 as shown.

6. Connect the fuel injector couplers. 7. Fasten the wiring harness to the holders, and then fasten the plastic ties 8 as shown.

3 1

S6P24360E

3 PORT 2

STBD

S6P24340

3. Install the fuel injectors 4 onto the starboard fuel rail 5, and then install the holders 6 as shown.

S6P24370

6 4 5

S6P24350

4-27

6P21H11

Fuel injector

— MEMO —

1 2 3 4 5 6 7 8 9 6P21H11

4-28

POWR

Power unit Power unit....................................................................................................... 5-1 Checking the compression pressure .........................................................5-1 Checking the oil pressure ..........................................................................5-1 Checking the oil pressure sensor .............................................................. 5-2 Checking the valve clearance.................................................................. 5-10 Adjusting the valve clearance.................................................................. 5-12 Replacing the timing belt .........................................................................5-15 Removing the wiring harness guide ........................................................ 5-20 Removing the power unit.........................................................................5-22 Removing the timing belt, driven sprocket, and camshaft .......................5-24 Checking the timing belt and sprocket.....................................................5-27 Checking the valve lifter ..........................................................................5-27 Checking the camshaft ............................................................................5-27 Installing the camshaft, driven sprocket, and timing belt ......................... 5-28 Starter motor and accelerator position sensor .........................................5-35 ECM ............................................................................................................... 5-36 Fuse box ....................................................................................................... 5-37 Junction box.................................................................................................5-38 Exhaust cover ..............................................................................................5-39 Removing the exhaust cover ................................................................... 5-40 Checking the exhaust cover anode ......................................................... 5-40 Installing the exhaust cover ..................................................................... 5-40 Cylinder head ...............................................................................................5-41 Removing the cylinder head .................................................................... 5-43 Checking the valve spring ....................................................................... 5-43 Checking the valve .................................................................................. 5-43 Checking the valve guide ........................................................................5-44 Replacing the valve guide ....................................................................... 5-45 Checking the valve seat ..........................................................................5-45 Refacing the valve seat ...........................................................................5-46 Checking the cylinder head ..................................................................... 5-48 Installing the valve ...................................................................................5-48 Removing the cooling water passage cover............................................5-49 Checking the cooling water passage cover anode ..................................5-49 Installing the cooling water passage cover.............................................. 5-50 Installing the cylinder head ...................................................................... 5-51

6P21H11

Crankcase ..................................................................................................... 5-52 Cylinder block ..............................................................................................5-54 Cylinder block ..............................................................................................5-56 Disassembling the cylinder block ............................................................ 5-58 Checking the piston diameter .................................................................. 5-59 Checking the cylinder bore ...................................................................... 5-59 Checking the piston clearance (reference).............................................. 5-59 Checking the piston ring ..........................................................................5-59 Checking the piston ring end gap (reference) .........................................5-60 Checking the piston ring groove ..............................................................5-60 Checking the piston ring side clearance.................................................. 5-60 Checking the piston pin boss bore .......................................................... 5-61 Checking the piston pin ...........................................................................5-61 Checking the connecting rod small end inside diameter ......................... 5-61 Checking the connecting rod big end side clearance ..............................5-61 Checking the crankshaft ..........................................................................5-61 Checking the crankpin oil clearance........................................................ 5-62 Selecting the connecting rod bearing ......................................................5-63 Checking the crankshaft journal oil clearance .........................................5-64 Selecting the main bearing ...................................................................... 5-65 Disassembling the oil pump..................................................................... 5-66 Checking the oil pump ............................................................................. 5-66 Assembling the oil pump .........................................................................5-66 Assembling the power unit ...................................................................... 5-67 Installing the wiring harness .................................................................... 5-72 Installing the power unit...........................................................................5-74

6P21H11

1 2 3 4 5 6 7 8 9

POWR

Power unit

Checking the compression pressure 1. Start the engine, warm it up for 5 minutes, and then turn it off. 2. Remove the engine stop lanyard from the engine stop lanyard switch. 3. Disconnect all fuel injector couplers. 4. Remove the ECM cover, all ignition coils and spark plugs, and then install the special service tools into a spark plug hole.

2 S6P25010

6. Crank the engine until the reading on the compression gauge stabilizes, and then check the compression pressure. Minimum compression pressure (reference data): 740 kPa (7.4 kgf/cm2, 107.3 psi) 7. If the compression pressure is below specification and the compression pressure for each cylinder is unbalanced, add a small amount of engine oil to the cylinder, and then check the compression pressure again. NOTE: â&#x20AC;˘ If the compression pressure increases, check the pistons and piston rings. Replace if worn. â&#x20AC;˘ If the compression pressure does not increase, check the valve clearances, valves, valve seats, cylinder head gaskets, and cylinder heads. Adjust or replace if necessary.

CAUTION: Before removing the spark plugs, blow compressed air in the spark plug well to clear out any dirt or dust that may fall into the cylinder. Compression gauge 1: YU-33223 Compression gauge extension 2: YB-06563

Checking the oil pressure 1. Place a rag under the oil pressure sensor. 2. Remove the oil pressure sensor, and then install an oil pressure gauge 1 into the oil pressure sensor installation hole.

1 5. Disconnect the throttle cable joint from the accelerator lever, and then place and hold the lever in the fully open position of the throttle.

S6P25020

NOTE: Use a general pressure gauge.

S6P25015

5-1

3. Start the engine and warm it up for 5 minutes.

6P21H11

Power unit 4. Check the oil pressure. Check for oil leakage and check the oil pump and oil strainer if out of specification. NOTE: • If the engine is started with the coupler disconnected from the oil pressure sensor, the ECM will determine that an oil pressure sensor malfunction (trouble code 39) has occurred and increase the engine idle speed (approximately 900 r/min). Delete the diagnosis record using the YDIS after checking the oil pressure. • The actual oil pressure may vary depending on the temperature and viscosity of the engine oil being used. Oil pressure (reference data): 600 kPa (6.0 kgf/cm2, 87.0 psi) at 600–900 r/min

Checking the oil pressure sensor 1. Connect the test harness to the oil pressure sensor.

3.4 V

É 600 kpa

(6.0 kgf/cm2, 87.0 psi)

S6P25040

È Output voltage É Oil pressure

Test harness (3 pins): YB-06869

Oil pressure sensor input voltage (reference data): Orange (O) – Black (B) 4.75–5.25 V Oil pressure sensor output voltage (reference data): Pink/white (P/W) – Black (B) 3.4 V at engine idle speed

2. Start the engine and warm it up for 5 minutes. 3. Measure the oil pressure sensor input voltage. Check the wiring harness connection or replace the ECM if out of specification. 4. Measure the oil pressure sensor output voltage. Replace if out of specification.

S6P25030

6P21H11

5-2

1 2 3 4 5 6 7 8 9

POWR

Power unit 5

4 N · m (0.4 kgf · m, 3.0 ft · Ib)

8 N · m (0.8 kgf · m, 5.9 ft · Ib)

1 20 17

4 7

11 10

572

2 3

572

11 11 13

572

8 N · m (0.8 kgf · m, 5.9 ft · Ib)

4 LT

Part name Power unit Gasket Dowel Bolt Bolt Oil dipstick Dipstick guide O-ring Bolt Upper case cover Bolt Apron (STBD) Grommet Apron (PORT) Bolt Nut Bolt

572 T.

5-3

572

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

572

42 N · m (4.2 kgf · m, 31.0 ft · Ib)

Q’ty 1 1 2 6 7 1 1 1 1 1 7 1 6 1 1 2 2

S6P25050E

Remarks Not reusable

M10 × 140 mm M10 × 35 mm

Not reusable

M6 × 20 mm M6 × 14 mm

M6 × 30 mm M6 × 10 mm

6P21H11

Power unit 5

4 N · m (0.4 kgf · m, 3.0 ft · Ib)

8 N · m (0.8 kgf · m, 5.9 ft · Ib)

1 20 17

4 7

11 10

572

2 3

572

11 11 13

572

8 N · m (0.8 kgf · m, 5.9 ft · Ib)

5 4

572 T.

Part name Cap PTT motor lead Clamp

6P21H11

572

No. 18 19 20

572

42 N · m (4.2 kgf · m, 31.0 ft · Ib)

Q’ty 2 1 3

S6P25050E

Remarks

5-4

1 2 3 4 5 6 7 8 9

POWR

Power unit 5

2 3

1 T.

4 T.

25 N · m (2.5 kgf · m, 18.4 ft · Ib)

6 8

14 15 12 14

11 10

7 N · m (0.7 kgf · m, 5.2 ft · Ib)

25 26

18 17

9 E

13 12 T.

25 N · m (2.5 kgf · m, 18.4 ft · Ib)

7 N · m (0.7 kgf · m, 5.2 ft · Ib)

27 19

23 T.

14 15 16 17

5-5

Part name Wiring harness guide Plastic tie Bolt Holder Damper Bolt Timing belt guide (PORT) Timing belt guide (STBD) Bolt ECM cover Bolt Bolt Cam position sensor (STBD IN, PORT EX) O-ring Cam position sensor (PORT IN) Bolt Ignition coil

14 13

21 22

No. 1 2 3 4 5 6 7 8 9 10 11 12 13

Q’ty 1 2 6 3 2 4 1 1 4 1 4 3 2 3 1 12 6

12 E

23 N · m (2.3 kgf · m, 17.0 ft · Ib)

S6P25060E

Remarks

M6 × 35 mm

M6 × 14 mm

M6 × 20 mm M6 × 28 mm M6 × 20 mm

Not reusable

M6 × 20 mm

6P21H11

Power unit 5

2 3

1 T.

4 T.

25 N · m (2.5 kgf · m, 18.4 ft · Ib)

6 8

14 15 12 14

11 10

7 N · m (0.7 kgf · m, 5.2 ft · Ib)

25 26

18 17

9 E

13 12 T.

25 N · m (2.5 kgf · m, 18.4 ft · Ib)

7 N · m (0.7 kgf · m, 5.2 ft · Ib)

27 19

23 T.

Part name Spark plug Clamp Cooling water pressure sensor adapter Gasket Plug Bolt ECM base assembly Bolt Holder Hose

6P21H11

14 13

21 22

No. 18 19 20 21 22 23 24 25 26 27

Q’ty 6 1 1 1 1 2 1 1 1 1

12 E

23 N · m (2.3 kgf · m, 17.0 ft · Ib)

S6P25060E

Remarks

Not reusable

M14 × 12 mm M6 × 30 mm M6 × 12 mm

5-6

1 2 3 4 5 6 7 8 9

POWR

Power unit 5

240 N · m (24.0 kgf · m, 177.0 ft · lb)

1 2

11 E

5 T.

39 N · m (3.9 kgf · m, 28.8 ft · Ib)

5 7

12 4

17 10

5 8

13 14

15 16

4 N · m (0.4 kgf · m, 3.0 ft · Ib)

S6P25070

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

5-7

Part name Nut Washer Flywheel magnet Stator assembly Bolt Collar Holder Bracket Crank position sensor Screw Timing belt Timing belt tensioner Bolt Washer Pulley Collar Woodruff key

Q’ty 1 1 1 1 4 2 2 1 1 2 1 1 2 2 2 2 1

Remarks Width across flats: 36 mm

M6 × 35 mm

ø5 × 12 mm

M10 × 55 mm

6P21H11

Power unit 5

2 N · m (0.2 kgf · m, 1.5 ft · Ib)

7 8

7 26

1280B

24 33

8 7 9

8 7 10

12 11

14 14

1 2

18 R.

6P21H11

E T.

Part name Cap Gasket Bolt Variable camshaft timing assembly Bolt Driven sprocket Dowel Oil seal Camshaft (STBD IN) Camshaft (STBD EX) Valve lifter Valve shim Camshaft cap Gasket Bolt Bolt Camshaft cap

8 N · m (0.8 kgf · m, 5.9 ft · lb) 17 N · m (1.7 kgf · m, 12.5 ft · lb)

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

16 15

8 N · m (0.8 kgf · m, 5.9 ft · lb) 8 N · m (0.8 kgf · m, 5.9 ft · lb)

32 N · m (3.2 kgf · m, 23.6 ft · Ib)

5 E

8 N · m (0.8 kgf · m, 5.9 ft · lb) 8 N · m (0.8 kgf · m, 5.9 ft · lb)

60 N · m (6.0 kgf · m, 44.3 ft · Ib)

1 2

12 11 E

1 2

27 30

29 31

21 6

1 2

23 24

271

1386B

1280B

1 2 3

8 N · m (0.8 kgf · m, 5.9 ft · lb) 17 N · m (1.7 kgf · m, 12.5 ft · lb)

1 2

17 Q’ty 2 2 2 2 2 2 4 4 1 1 24 24 1 4 4 1 7

1 2

8 N · m (0.8 kgf · m, 5.9 ft · lb) 17 N · m (1.7 kgf · m, 12.5 ft · lb) S6P25080E

Remarks Not reusable

M12 × 35 mm M10 × 35 mm

Not reusable

M7 × 48 mm M6 × 30 mm

5-8

1 2 3 4 5 6 7 8 9

POWR

Power unit 5

2 N · m (0.2 kgf · m, 1.5 ft · Ib)

7 8

7 26

1280B

24 33

8 7 9

8 7 10

12 11

14 14

1 2

18 T.

5-9

Part name Bolt Gasket Screw Plate Cylinder head cover (STBD) Grommet Bolt Bolt Camshaft (PORT EX) Camshaft (PORT IN) Camshaft cap Bolt Camshaft cap Camshaft cap Bolt Gasket Cylinder head cover (PORT)

8 N · m (0.8 kgf · m, 5.9 ft · lb) 17 N · m (1.7 kgf · m, 12.5 ft · lb)

No. 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

16 15

8 N · m (0.8 kgf · m, 5.9 ft · lb) 8 N · m (0.8 kgf · m, 5.9 ft · lb)

32 N · m (3.2 kgf · m, 23.6 ft · Ib)

5 E

8 N · m (0.8 kgf · m, 5.9 ft · lb) 8 N · m (0.8 kgf · m, 5.9 ft · lb)

60 N · m (6.0 kgf · m, 44.3 ft · Ib)

1 2

12 11 E

1 2

27 30

29 31

21 6

1 2

23 24

271

1386B

1280B

1 2 3

8 N · m (0.8 kgf · m, 5.9 ft · lb) 17 N · m (1.7 kgf · m, 12.5 ft · lb)

1 2

17 Q’ty 14 1 8 1 1 2 2 28 1 1 1 6 1 6 12 1 1

1 2

8 N · m (0.8 kgf · m, 5.9 ft · lb) 17 N · m (1.7 kgf · m, 12.5 ft · lb) S6P25080E

Remarks M7 × 37 mm Not reusable

ø4 × 8 mm

M6 × 19 mm M6 × 30 mm

M7 × 48 mm

M7 × 37 mm Not reusable

6P21H11

Power unit

Checking the valve clearance CAUTION:

2005 F250 6P2 LF250 6P3

Do not turn the flywheel magnet counterclockwise, otherwise the water pump impeller may be damaged. NOTE: • Check the valve clearances when the engine is cold. • When adjusting the valve clearances, the fuel pressure must be reduced before removing any parts. To reduce the fuel pressure, see Chapter 4, “Reducing the fuel pressure.”

1000001–1002894 1000001–1000956

7 2

2 3 4

1. Remove the flywheel magnet cover and ECM cover. 2. Remove the blowby hose 1. 3. Disconnect the ignition coil couplers 2, cam position sensor couplers 3, knock sensor coupler 4, and cooling water pressure sensor adapter hose 5.

S6P25090

2006 F250 6P2 LF250 6P3

1002895– 1000957–

4. Remove the speed sensor coupler 6 from the bracket.

5. Remove all ignition coils and spark plugs. 6. Remove the ECM bracket bolts 7.

7 2

2 3 4

6 5 S6P25090C

7. Remove the cylinder head covers. NOTE: See the exploded diagram (5-8).

6P21H11

5-10

1 2 3 4 5 6 7 8 9

POWR

Power unit

8. Turn the flywheel magnet clockwise and align the “1TDC” mark a on the flywheel magnet with the pointer b. 9. Check that the “II” marks c on the port driven sprockets are aligned, and check that the “I” marks d on the starboard driven sprockets are aligned.

STBD

PORT S6P25120

NOTE: Note the measurement data.

11. Check the intake and exhaust valve clearance for cylinder #4.

a b S6P25100

10. Check the valve clearances to the following steps.

Valve clearance (cold): Intake e: 0.20 ± 0.03 mm (0.008 ± 0.001 in) Exhaust f: 0.34 ± 0.03 mm (0.013 ± 0.001 in)

12. Turn the flywheel magnet an additional 120° clockwise and align the “2TDC” mark g on the flywheel magnet with the pointer b. 13. Check the intake and exhaust valve clearances for cylinder #5.

IN 14. Turn the flywheel magnet an additional 120° clockwise and align the “3TDC” mark h on the flywheel magnet with the pointer b.

#1 #2 #3

15. Check the intake and exhaust valve clearances for cylinder #6.

#4 #5 #6 PORT

STBD S6P25110

5-11

6P21H11

Power unit 16. Similarly, check the valve clearances for cylinders #1, #2, and #3 in order, and be sure to turn the flywheel magnet 120° clockwise each time. Adjust the valve clearances if out of specification.

Adjusting the valve clearance CAUTION: Do not turn the flywheel magnet or the driven sprockets when the timing belt is not installed. Otherwise the pistons and valves or intake and exhaust valves will collide with each other and be damaged. 1. Turn the flywheel magnet clockwise and align the “1TDC” mark a on the flywheel magnet with the pointer b.

S6P25125E

NOTE: To remove the wiring harness guide, see “Removing the wiring harness guide.” 4. Loosen the flywheel magnet nut.

2. Check that the “II” marks c on the port driven sprockets are aligned, and check that the “I” marks d on the starboard driven sprockets are aligned.

CAUTION: Apply force in the direction of the arrows shown to prevent the flywheel holder from slipping off easily.

Flywheel holder: YB-06139

a b S6P25100

3. Remove the wiring harness guide 1.

6P21H11

5-12

1 2 3 4 5 6 7 8 9

POWR

Power unit

5. Remove the flywheel magnet and Woodruff key, and then remove the stator assembly.

NOTE: Do not mix the valve train parts. Keep them organized in their proper groups. 8. Measure the valve shim thickness using a micrometer, and then note the measurement data. 9. Select the necessary valve shim by calculating its thickness using the following formula. S6P25E00C

CAUTION: To prevent damage to the engine or tools, screw in the puller set bolts evenly and completely so that the universal puller is parallel to the flywheel magnet. NOTE: Apply force to the crankshaft end until the flywheel magnet comes off the tapered portion of the crankshaft.

Necessary valve shim thickness = Removed valve shim thickness + Measured valve clearance – Specified valve clearance Example: If the “Removed valve shim thickness” is 2.10 mm, the “Measured valve clearance” is 0.30 mm and the “Specified valve clearance” is 0.20 mm, then the “Necessary valve shim thickness” = 2.10 + 0.30 – 0.20 = 2.20 mm. 10. Install the necessary valve shim into the valve lifter.

Universal puller: YB-06117 6. Remove the timing belt, driven sprockets, and camshafts. NOTE: To remove the timing belt, driven sprockets, and camshafts, see “Removing the timing belt, driven sprocket, and camshaft.”

11. Install the camshafts, driven sprockets, and timing belt. NOTE: To install the camshafts, driven sprockets, and timing belt, see “Installing the camshaft, driven sprocket, and timing belt.” 12. Install the stator assembly.

7. Remove the valve shim 2 from the valve lifter 3 using compressed air.

5-13

13. Install the Woodruff key and then flywheel magnet. 6P21H11

Power unit

e NOTE: • Apply engine oil to the thread of the flywheel magnet nut and washer before installation. • Be sure to remove any grease from the tapered portion of the crankshaft and the flywheel magnet.

S6P25145

Timing belt-to-timing belt guide clearance e: 1.0 ± 0.5 mm (0.04 ± 0.02 in)

Flywheel holder: YB-06139

T. R.

Flywheel magnet nut: 240 N·m (24.0 kgf·m, 177.0 ft·lb)

17. Check the crank position sensor air gap f.

14. Check each valve clearance and adjust again if out of specification. Valve clearance (cold): Intake: 0.20 ± 0.03 mm (0.008 ± 0.001 in) Exhaust: 0.34 ± 0.03 mm (0.013 ± 0.001 in)

S6P25160

15. Install the cylinder head covers. NOTE: • Apply sealant to the edge of the cylinder head cover gasket before installation. • See the exploded diagram (5-8).

NOTE: It is recommended to check the crank position sensor air gap before installing the wiring harness guide to improve working efficiency. Crank position sensor air gap f: 1.4–1.6 mm (0.055–0.063 in)

T. R.

Cylinder head cover bolt: 1st: 8 N·m (0.8 kgf·m, 5.9 ft·lb) 2nd: 8 N·m (0.8 kgf·m, 5.9 ft·lb) T. R.

16. Install the timing belt guides, and then adjust the timing belt-to-timing belt guide clearance e. 6P21H11

Crank position sensor screw: 4 N·m (0.4 kgf·m, 3.0 ft·lb)

5-14

1 2 3 4 5 6 7 8 9

POWR

Power unit

18. Install the wiring harness guide. NOTE: To install the wiring harness guide, see “Installing the wiring harness.” 19. Install the spark plugs and ignition coils.

T. R.

Spark plug: 25 N·m (2.5 kgf·m, 18.4 ft·lb) Ignition coil bolt: 7 N·m (0.7 kgf·m, 5.2 ft·lb)

20. Install all parts removed during disassembly.

4. Disconnect the ignition coil couplers 2, cam position sensor couplers 3, and knock sensor coupler 4. 5. Remove all ignition coils and spark plugs. 6. Remove the speed sensor coupler 5 from the bracket. 7. Remove the ECM bracket bolts 6 and timing belt guides 7. 2005 F250 6P2 LF250 6P3

1000001–1002894 1000001–1000956

6 7

21. Check that the wiring harness, hoses, and other parts do not interfere with any moving parts.

Replacing the timing belt 6

CAUTION: • Do not turn the flywheel magnet counterclockwise, otherwise the water pump impeller may be damaged. • Do not turn the flywheel magnet or the driven sprockets when the timing belt is not installed. Otherwise the pistons and valves or intake and exhaust valves will collide with each other and be damaged.

2 3 4

S6P25170

NOTE: To remove and install the timing belt without replacing it, see “Removing the timing belt, driven sprocket, and camshaft” and “Installing the camshaft, driven sprocket, and timing belt.” 1. Reduce the fuel pressure. NOTE: To reduce the fuel pressure, see Chapter 4, “Reducing the fuel pressure.” 2. Remove the flywheel magnet cover and ECM cover. 3. Remove the blowby hose 1.

5-15

6P21H11

Power unit 2006 F250 6P2 LF250 6P3

1002895– 1000957–

6 7

S6P25130E

6 2

2 3

NOTE: To remove the wiring harness guide, see “Removing the wiring harness guide.” 11. Loosen the flywheel magnet nut.

4 5

S6P25170C

CAUTION: Apply force in the direction of the arrows shown to prevent the flywheel holder from slipping off easily.

Flywheel holder: YB-06139

a b S6P25100

10. Remove the wiring harness guide 8. 6P21H11

5-16

1 2 3 4 5 6 7 8 9

POWR

Power unit

12. Remove the flywheel magnet and Woodruff key.

d c f e

S6P25180

S6P25E00C

Universal puller: YB-06117 13. Remove the stator assembly bolt, and then move the stator assembly to remove the timing belt.

16. Turn the timing belt tensioner gradually clockwise using a hexagon wrench, and then insert a ø5.0 mm (0.2 in) pin 9 into the hole g.

9 g

S6P25190E

NOTE: Leave the pin inserted into the timing belt tensioner until the timing belt is installed again. 17. Remove the timing belt from the driven sprockets, then from the drive sprocket.

14. Check that the “ ” mark e on the drive sprocket and the “ ” mark f on the cylinder block are aligned. 15. Check that the “II” marks c on the port driven sprockets are aligned, and check that the “I” marks d on the starboard driven sprockets are aligned.

5-17

6P21H11

Power unit

S6P25200

18. Check that the “ ” mark e on the drive sprocket and the “ ” mark f on the cylinder block are aligned. 19. Check that the “II” marks c on the port driven sprockets are aligned, and check that the “I” marks d on the starboard driven sprockets are aligned.

h S6P25220

0123

60 88

133 160

È S6P25230

È Number of belt teeth

CAUTION:

f e

S6P25210

• Do not twist, turn inside out, or bend the timing belt beyond the maximum limit of 25 mm (1.0 in) otherwise it can be damaged. • Do not get oil or grease on the timing belt.

20. Install a new timing belt onto the drive sprocket with its part number in the upright position and align the belt position mark h with the “ ” mark on the drive sprocket.

6P21H11

5-18

1 2 3 4 5 6 7 8 9

POWR

Power unit

21. Install the timing belt onto the driven sprockets by aligning belt position marks k through p with the “ ” marks on the driven sprockets.

23. Turn the crankshaft clockwise two full turns, and then check that alignment marks c through f are aligned.

d c f e

k S6P25180 S6P25240E

24. Install the stator assembly. 25. Install the Woodruff key.

26. Install the flywheel magnet.

S6P25250

Timing belt installation height r: 2.0 mm (0.08 in) 22. Check that belt position marks h through p are aligned with each alignment mark on the sprockets, and then remove the pin 9.

NOTE: • Apply engine oil to the thread of the flywheel magnet nut and washer before installation. • Be sure to remove any grease from the tapered portion of the crankshaft and flywheel magnet.

Flywheel holder: YB-06139 S6P25260E

5-19

6P21H11

Power unit

T. R.

Flywheel magnet nut: 240 N·m (24.0 kgf·m, 177.0 ft·lb)

27. Check the crank position sensor air gap s.

Timing belt-to-timing belt guide clearance t: 1.0 ± 0.5 mm (0.04 ± 0.02 in) 29. Install the wiring harness guide. NOTE: To install the wiring harness guide, see “Installing the wiring harness.”

s 30. Install all parts removed during disassembly. S6P25270

NOTE: It is recommended to check the crank position sensor air gap before installing the wiring harness guide to improve working efficiency. Crank position sensor air gap s: 1.4–1.6 mm (0.055–0.063 in)

31. Check that the wiring harness, hoses, and other parts do not interfere with any moving parts.

Removing the wiring harness guide NOTE: This procedure is for adjusting the valve clearance and replacing the timing belt. 1. Remove the joint connector 1 from the wiring harness guide.

T. R.

Crank position sensor screw: 4 N·m (0.4 kgf·m, 3.0 ft·lb)

28. Install the timing belt guide, and then adjust the timing belt-to-timing belt guide clearance t.

S6P25380

t t

S6P25280

6P21H11

5-20

1 2 3 4 5 6 7 8 9

POWR

Power unit

2. Disconnect the oil control valve couplers 2, engine temperature sensor coupler 3, and thermoswitch connectors 4.

3. Remove the engine temperature sensor coupler 3 and low-pressure fuel pump coupler 5 from the wiring harness guide. 4. Remove the 3-pin communication coupler 6 and diagnosis connector 7 from the bracket.

PORT

2 7

S6P25390

STBD

S6P25410

NOTE: • Be sure to reduce the fuel pressure before removing the quick connector. To reduce the fuel pressure, see Chapter 4, “Reducing the fuel pressure.” • To disconnect the quick connector, see Chapter 4, “Disconnecting the quick connector.” 8. Remove the plastic ties 9 and clips 0, and then pull up the wiring harness.

0 9

0 S6P25400

0 5. Remove the port and starboard fuel rail covers and plastic ties. NOTE: See the exploded diagram (4-26). 6. Disconnect all fuel injector couplers.

9 S6P25420

9. Remove the bolts and wiring harness guide A.

7. Disconnect the quick connectors 8 and remove the high-pressure fuel hose assembly (vapor separator-to-starboard fuel rail). S6P25135E

5-21

6P21H11

Power unit

Removing the power unit 7

NOTE: It is recommended to loosen the flywheel magnet nut before removing the power unit to improve working efficiency. 1. Remove the flywheel magnet cover. 2. Remove the retaining plate 1, grommet 2, and cable holder 3, and then disconnect the remote control cables.

S6P25310

6. Disconnect the cooling water pilot hose 8. 7. Remove the neutral switch coupler 9 from the bracket, and disconnect the neutral switch coupler and shift cut switch coupler 0. 8. Remove the oil dipstick A and dipstick guide B.

3. Remove the starboard intake manifold.

NOTE: See the exploded diagram (4-12).

4. Remove the clamps 4 and caps 5, and then disconnect the PTT motor lead 6.

S6P25320

4 5

6 S6P25300

5. Disconnect the vapor gas hose 7 from the starboard top cowling lock.

6P21H11

9. Disconnect the battery cables. NOTE: See the exploded diagram (5-35). 10. Disconnect the fuel hose from the fuel filter.

5-22

1 2 3 4 5 6 7 8 9

POWR

Power unit

11. Removing the PTT switch coupler C, isolator coupler D, warning indicator coupler E, coupler F, 10-pin main harness coupler G, and trim sensor coupler H from the brackets, and then disconnect them.

H G C

S6P25330

12. Remove the speed sensor coupler I from the bracket, and then disconnect it.

15. Retract the port and starboard top cowling lock levers.

PORT

STBD

13. Disconnect the flushing hose J. 2005 F250 6P2 LF250 6P3

1000001–1002894 1000001–1000956 S6P25360

STBD

PORT

I S6P25340

2006 F250 6P2 LF250 6P3

1002895– 1000957–

S6P25365

CAUTION: Make sure that the top cowling lock levers are retracted and the engine stoppers are installed before removing the power unit, otherwise the fuel rails could be damaged.

S6P25340C

14. Remove the aprons and upper case cover.

5-23

16. Suspend the power unit from the engine hangers K. 17. Remove the power unit by removing the bolts L and M. 6P21H11

Power unit

K K

M M L

d c b a

S6P25430

S6P25370C

Removing the timing belt, driven sprocket, and camshaft

3. Remove the timing belt guides 1 and cylinder head covers 2.

CAUTION: • Do not turn the crankshaft counterclockwise, otherwise the water pump impeller may be damaged. • Do not turn the crankshaft or the driven sprockets when the timing belt is not installed. Otherwise the piston and valves or intake and exhaust valves will collide with each other and be damaged. • Do not turn the crankshaft and camshafts unless instructions have been given.

S6P25440E

NOTE: See the exploded diagram (5-8).

1. Check that the “ ” mark a on the drive sprocket and the “ ” mark b on the cylinder block are aligned. 2. Check that the “II” marks c on the port driven sprockets are aligned, and check that the “I” marks d on the starboard driven sprockets are aligned.

6P21H11

5-24

1 2 3 4 5 6 7 8 9

POWR

Power unit

4. Make marks e through m on the timing belt as shown.

NOTE: Leave the pin inserted into the timing belt tensioner until the timing belt is installed again.

h 6. Remove the timing belt from the driven sprockets, then from the drive sprocket.

m e

S6P25200

f S6P25450E

7. Align the “ ” mark a on the drive sprocket with the mating surface of the crankcase and cylinder block by turning the crankshaft counterclockwise 60° gradually.

STBD e 0123

60 88

133 160

PORT

È S6P25460

È Number of belt teeth

NOTE: It is not necessary to mark the timing belt when replacing it.

S6P25480

CAUTION: 5. Turn the timing belt tensioner gradually clockwise using a hexagon wrench, and then insert a ø5.0 mm (0.2 in) pin 3 into the hole n.

Do not turn the crankshaft counterclockwise more than 60°. Otherwise the piston and valves will collide with each other and be damaged. 8. Align the “I” marks p on the port driven sprockets by turning them clockwise 60° gradually.

3 n

S6P25470E

5-25

6P21H11

Power unit 10. Hold the intake camshaft using a wrench, and then remove the variable camshaft timing bolt 6.

PORT

11. Remove the variable camshaft timing assembly with the driven sprocket.

S6P25490

CAUTION: Do not turn the driven sprockets clockwise more than 60°, and do not turn the starboard driven sprockets. Otherwise the intake and exhaust valves will collide with each other and be damaged. 9. Hold the intake driven sprocket using the special service tool, and then remove the variable camshaft timing cap 4.

4 5

S6P25510

CAUTION: • Do not hold the driven sprocket when removing the variable camshaft timing bolt. Otherwise the variable camshaft timing assembly can be damaged. • Do not turn the intake camshaft when removing the variable camshaft timing bolt. Otherwise the intake and exhaust valves will collide with each other and be damaged. 12. Hold the exhaust camshaft using a wrench, and then remove the bolt 7.

S6P25500

13. Remove the exhaust driven sprocket.

CAUTION: • Do not hold the camshaft when removing the variable camshaft timing cap. Otherwise the variable camshaft timing assembly can be damaged. • Do not turn the driven sprocket when removing the variable camshaft timing cap. Otherwise the intake and exhaust valves will collide with each other and be damaged. • Do not reuse the gasket 5, always replace it with a new one.

Primary sheave holder: YS-01880-A

6P21H11

S6P25520

CAUTION: Do not turn the exhaust camshaft when removing the bolt. Otherwise the intake and exhaust valves will collide with each other and be damaged.

5-26

1 2 3 4 5 6 7 8 9

POWR

Power unit

14. Remove the camshaft caps in the sequence shown.

Checking the timing belt and sprocket

15. Remove the camshafts 8 and oil seals 9.

1. Check the interior and exterior of the timing belt. Replace if cracked, damaged, or worn.

PORT

STBD

2. Check the drive sprocket. Replace the crankshaft assembly if cracked, damaged, or worn.

! !

% ±

3. Check the driven sprockets. Replace the variable camshaft timing assembly or driven sprocket if cracked, damaged, or worn.

Checking the valve lifter 1. Check the valve lifters. Replace if damaged, scratched, or worn.

S6P25530

Checking the camshaft

9 8 0

1. Check the edge and face of the brim on the port camshafts and starboard intake camshaft that is used for the cam position sensor. Replace if rough, damaged, or scratched.

0 S6P25540E

CAUTION: Do not reuse the gaskets 0, always replace them with new ones.

S6P25550C

16. Remove the valve lifters from the cylinder heads.

NOTE: • Do not scratch or damage the face of the brim. • If there is a scratch more than 0.2 mm (0.008 in) deep or more than 0.5 mm (0.020 in) wide on the surface of the brim, a malfunction may occur in the cam position sensor signal.

NOTE: Do not mix the valve train parts. Keep them organized in their proper groups.

2. Measure the cam lobe. Replace if out of specification.

NOTE: See the exploded diagram (5-8).

5-27

6P21H11

Power unit

d S69J5970C

Cam lobe a: Intake: 46.30–46.40 mm (1.823–1.827 in) Exhaust: 45.35–45.45 mm (1.785–1.789 in) Cam lobe b: Intake and exhaust: 35.95–36.05 mm (1.415–1.419 in)

Camshaft journal diameter c: 24.96–24.98 mm (0.9826–0.9834 in) Camshaft cap inside diameter d: 25.000–25.021 mm (0.9843–0.9851 in)

Installing the camshaft, driven sprocket, and timing belt CAUTION:

3. Measure the camshaft runout. Replace if above specification.

S6P25560

Camshaft runout limit: 0.015 mm (0.0006 in)

• Do not turn the crankshaft counterclockwise, otherwise the water pump impeller may be damaged. • Do not turn the crankshaft or the driven sprockets when the timing belt is not installed. Otherwise the pistons and valves or intake and exhaust valves will collide with each other and be damaged. • Do not turn the crankshaft and camshafts unless instructions have been given. 1. Check that the “ ” mark a on the drive sprocket is aligned with the mating surface of the crankcase and cylinder block.

STBD

PORT

4. Measure the camshaft journal diameter c and cylinder head journal inside diameter d. Replace the camshaft or cylinder head assembly, or both if out of specifications.

a S6P25480 S6P25570

6P21H11

5-28

1 2 3 4 5 6 7 8 9

POWR

Power unit

2. Install the valve lifters onto the cylinder heads. NOTE: • Apply engine oil to the valve shims and valve lifters before installation. • Install the valve shims and valve lifters in their original positions.

PORT

STBD

3. Apply a thin, even coat of sealant to the mating surface of the cylinder heads as shown.

6P2 P-IN

6P2 S-IN

E M

6P2 P-EX

6P2 S-EX S6P25590

STBD NOTE: • Apply molybdenum disulfide grease to the cam lobes. • Be sure to install the camshafts in the proper positions. • See the exploded diagram (5-8).

1386B

5. Check that the camshaft dowel holes are in the position shown in the illustration.

AFT

S6P25580

STBD UP

PORT

PORT 1386B 1386B

BOW

S6P25600

6. Install the camshaft caps in their proper positions as shown and with the stamped numbers upside down. S6P25D40

NOTE: When applying the sealant, be sure not to block the oil passages or oil holes. 4. Install the camshafts with the oil seals.

5-29

6P21H11

Power unit

STBD 6S

PORT 5P

8S 7P

PORT

9S 4P

8P 5S S6P25E20

7. Tighten the camshaft cap bolts to the specified torques in 2 stages and in the sequence shown.

PORT

È STBD

S6P25F10E

STBD 5

1 4 S6P25610E

NOTE: Apply engine oil to the camshaft caps and camshaft cap bolts before installation.

T. R.

Camshaft cap bolts: 1st: 8 N·m (0.8 kgf·m, 5.9 ft·lb) 2nd: 17 N·m (1.7 kgf·m, 12.5 ft·lb)

6P21H11

CAUTION: Do not turn the exhaust camshaft when tightening the bolt. Otherwise the intake and exhaust valves will collide with each other and be damaged. NOTE: Slight turn the driven sprockets in direction È to remove any free play É before tightening the driven sprocket bolt 1.

9. Hold the exhaust camshaft using a wrench, and then tighten the driven sprocket bolt 1 to the specified torque.

S6P25620

8. Install the dowel and exhaust driven sprocket on the exhaust camshaft.

Driven sprocket bolt 1: 60 N·m (6.0 kgf·m, 44.3 ft·lb)

10. Install the dowel and variable camshaft timing assembly on the intake camshaft.

5-30

1 2 3 4 5 6 7 8 9

POWR

Power unit

11. Check that the lower edge of the intake and exhaust driven sprockets are aligned.

CAUTION: • Do not hold the driven sprocket when tightening the variable camshaft timing bolt. Otherwise the variable camshaft timing assembly could be damaged. • Do not turn the intake camshaft when tightening the variable camshaft timing bolt. Otherwise the intake and exhaust valves will collide with each other and be damaged.

S6P25630

12. Hold the intake camshaft using a wrench, and then tighten the variable camshaft timing bolt 2 to the specified torque.

NOTE: Slight turn the driven sprockets in direction Ê to remove any free play Ë before tightening the driven sprocket bolt 2.

Variable camshaft timing bolt 2: 60 N·m (6.0 kgf·m, 44.3 ft·lb)

Ê 13. Hold the driven sprocket using the special service tool, and then tighten the variable camshaft timing cap 3 to the specified torque.

PORT Ê

STBD

S6P25F20E S6P25650

CAUTION: E

• Do not hold the camshaft when tightening the variable camshaft timing cap. Otherwise the variable camshaft timing assembly could be damaged. • Do not turn the driven sprocket when tightening the variable camshaft timing cap. Otherwise the intake and exhaust valves will collide with each other and be damaged.

S6P25640E

5-31

6P21H11

Power unit

Primary sheave holder: YS-01880-A

T. R.

Variable camshaft timing cap 3: 32 N·m (3.2 kgf·m, 23.6 ft·lb)

14. Align the “II” marks b on the port driven sprockets by turning them counterclockwise 60° gradually.

CAUTION: Do not turn the crankshaft clockwise more than 60°. Otherwise the piston and valves will collide with each other and be damaged. 16. Check that the “I” marks d on the starboard driven sprockets are aligned.

STBD

PORT

d b

S6P25680 S6P25660

CAUTION: Do not turn the port driven sprockets counterclockwise more than 60°, and do not turn the starboard driven sprockets. Otherwise the intake and exhaust valves will collide with each other and be damaged. 15. Align the “ ” mark a on the drive sprocket with the “ ” mark c on the cylinder block by turning the crankshaft clockwise 60° gradually.

c STBD

a PORT

S6P25480 S6P25670

6P21H11

5-32

1 2 3 4 5 6 7 8 9

POWR

Power unit

17. Install the timing belt onto the drive sprocket with the arrow mark e facing upward and align the timing belt mark f with the “ ” mark on the drive sprocket.

m e

g S6P25700E

f S6P25690

S6P25710

e 0123

60 88

133 160

Timing belt installation height n: 2.0 mm (0.08 in)

S6P25460E

Ì Number of belt teeth

CAUTION: • Do not twist, turn inside out, or bend the timing belt beyond the maximum limit of 25 mm (1.0 in) otherwise it can be damaged. • Do not get oil or grease on the timing belt. 18. Install the timing belt onto the driven sprockets by aligning belt position marks g through m with the “ ” marks on the driven sprockets.

5-33

19. Check that belt position marks g through m are aligned with each alignment mark on the drive sprocket and driven sprockets, and then remove the pin 4.

S6P25720E

6P21H11

Power unit 20. Turn the crankshaft clockwise two full turns, and then check that alignment marks a through d are aligned.

22. Install the timing belt guide, and then adjust the timing belt-to-timing belt guide clearance p.

d b c

p a

S6P25725

21. Install the cylinder head covers, and then tighten the bolts to the specified torque in 2 stages.

S6P25150

Timing belt-to-timing belt guide clearance p: 1.0 ± 0.5 mm (0.04 ± 0.02 in)

1280B 1280B

S6P25730E

NOTE: See the exploded diagram (5-8).

T. R.

Cylinder head cover bolt: 1st: 8 N·m (0.8 kgf·m, 5.9 ft·lb) 2nd: 8 N·m (0.8 kgf·m, 5.9 ft·lb)

6P21H11

5-34

1 2 3 4 5 6 7 8 9

POWR

Power unit

Starter motor and accelerator position sensor

4 8 7

11 15

18 N · m (1.8 kgf · m, 13.3 ft · Ib)

26 N · m (2.6 kgf · m, 19.2 ft · Ib)

13 N · m (1.3 kgf · m, 9.6 ft · Ib) S6P25740E

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

5-35

Part name Starter motor Bolt Nut Bolt Positive battery cable Terminal Bolt Terminal bolt Negative battery cable Washer Nut Accelerator position sensor assembly Grommet Collar Bolt Bolt Cap

Q’ty 1 3 1 2 1 1 1 1 1 1 1 1 3 3 3 1 1

Remarks M8 × 45 mm M8 × 16 mm

M8 × 20 mm

M6 × 35 mm M6 × 20 mm

6P21H11

Starter motor and accelerator position sensor / ECM

ECM

4 14 13 T.

7 N · m (0.7 kgf · m, 5.2 ft · Ib)

5 5 14

7 6

10 8

11 S6P25750

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Part name Bolt ECM Holder Plastic tie Holder Bolt Plate Holder Holder Plate Holder ECM bracket Grommet Collar

6P21H11

Q’ty 4 1 1 2 5 2 1 1 1 1 2 1 4 4

Remarks M6 × 20 mm

M6 × 16 mm

5-36

1 2 3 4 5 6 7 8 9

POWR

Power unit

Fuse box

2 1

5 6 7 6 8 9 13

2 6

4 3

8 9

11 12

10 14

S6P25760

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14

5-37

Part name Fuse box assembly Screw Cover Fuse puller Fuse Fuse Fuse Fuse Fuse Screw Cover Screw Fuse Grommet

Q’ty 1 4 1 1 2 3 2 2 2 4 1 4 3 1

Remarks ø5 × 20 mm

10 A, Spare is included. 30 A, Spare is included. 20 A, Spare is included. 5 A, Spare is included. 15 A, Spare is included. ø3 × 10 mm ø5 × 10 mm 80 A, Spare is included.

6P21H11

Fuse box / Junction box

Junction box

4 N · m (0.4 kgf · m, 3.0 ft · Ib)

14 6

5 4

2 12

11 3

8 7 T.

6P21H11

Part name Cap Nut Bolt Sub wiring harness Bolt PTT relay Bolt Rectifier Regulator Gasket Anode Cover Bolt Bolt Junction box Grommet Collar Wiring harness

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

6 N · m (0.6 kgf · m, 4.4 ft · lb) 12 N · m (1.2 kgf · m, 8.9 ft · lb)

1 2

6 N · m (0.6 kgf · m, 4.4 ft · lb) 12 N · m (1.2 kgf · m, 8.9 ft · lb)

3 N · m (0.3 kgf · m, 2.2 ft · Ib) S6P25770E

Q’ty 2 2 3 1 2 1 2 1 1 1 1 4 5 1 5 5 1

Remarks

M6 × 20 mm M6 × 25 mm M6 × 35 mm Not reusable

M6 × 25 mm M6 × 28 mm

5-38

1 2 3 4 5 6 7 8 9

POWR

Power unit

Exhaust cover

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

5-39

Part name Bolt Plug Gasket Plug Gasket Exhaust outer cover (PORT) Gasket Exhaust inner cover (PORT) Anode Screw Anode Screw Gasket Exhaust outer cover (STBD) Exhaust inner cover (STBD) Gasket

Q’ty 28 4 4 2 2 1 2 1 2 2 2 2 1 1 1 1

Remarks M6 × 50 mm M8 × 14 mm Not reusable

M18 × 17 mm Not reusable Not reusable

ø6 × 16 mm ø4 × 12 mm Not reusable

Not reusable

6P21H11

Exhaust cover

Removing the exhaust cover 1. Remove the exhaust cover bolts in the sequences shown.

Checking the exhaust cover anode 1. Check the anodes. Clean if there are scales, grease, or oil.

CAUTION: Do not oil, grease, or paint the anodes, otherwise they will be ineffective. 2. Replace eroded.

the

anodes

excessively

Installing the exhaust cover 1. Install the anodes to the exhaust covers. 2. Install new gaskets and the exhaust covers, and then tighten the bolts to the specified torques in 2 stages and in the sequence shown.

NOTE: Apply engine oil to the exhaust cover bolts before installation.

T. R.

6P21H11

Anode screws 1: 3 N·m (0.3 kgf·m, 2.2 ft·lb) Exhaust cover bolt: 1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb) 2nd: 12 N·m (1.2 kgf·m, 8.9 ft·lb)

5-40

1 2 3 4 5 6 7 8 9

POWR

Power unit

Cylinder head

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Part name Bolt Oil control valve assembly Filter Engine hanger (PORT) Bolt Bolt Bolt Cover Anode Grommet Bolt Bolt Bolt Cylinder head (PORT) Gasket Collar Knock sensor

Q’ty 6 2 2 1 6 16 4 4 4 4 4 4 2 1 1 4 1

Remarks M6 × 40 mm Not reusable

M6 × 20 mm M10 × 120 mm/T55 M6 × 20 mm

M8 × 40 mm M8 × 55 mm M8 × 90 mm Not reusable

*: Loosen completely

5-41

6P21H11

Cylinder head 5

No. 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

Part name Flushing hose Bolt Cooling water passage cover Gasket Anode Screw Valve cotter Valve spring retainer Valve spring Valve seal Valve guide Intake valve Exhaust valve Engine hanger (STBD) Gasket Cylinder head (STBD) Cooling water pressure sensor adapter hose

Q’ty 1 13 1 1 4 4 48 24 24 24 24 12 12 1 1 1 1

1 2 3 4 5 6 7 8 9

Remarks M6 × 30 mm Not reusable

ø4 × 12 mm

Not reusable Not reusable

Not reusable

*: Loosen completely 6P21H11

5-42

POWR

Power unit

Removing the cylinder head 1. Remove the cylinder head bolts in the sequence shown.

PORT

Valve spring compressor 1: YM-01253 Valve attachment 2: YB-06320

STBD

Checking the valve spring 1. Measure the valve spring free length a. Replace if below specification.

(T55)

S6P25810E

CAUTION: Do not scratch or damage the mating surfaces of the cylinder head and cylinder block.

Valve spring free length a: 44.2 mm (1.74 in) 2. Measure the valve spring tilt b. Replace if above specification.

2. Remove the intake and exhaust valves.

Valve spring tilt limit b: 1.2 mm (0.05 in)

Checking the valve 1. Check the valve face. Replace if pitted or worn.

NOTE: Be sure to keep the valves, springs, and other parts in the order as they were removed.

5-43

2. Measure the valve margin thickness a. Replace if out of specification.

6P21H11

Cylinder head Valve stem runout limit: 0.01 mm (0.0004 in)

Checking the valve guide NOTE: Before checking the valve guides, make sure that the valve stem diameter is within specification. Valve margin thickness a: Intake: 0.50–0.90 mm (0.020–0.035 in) Exhaust: 0.90–1.30 mm (0.035–0.051 in) 3. Measure the valve stem diameter b. Replace if out of specification.

1. Measure the valve guide inside diameter a.

S69J5770

Valve guide inside diameter a: Intake and exhaust: 5.504–5.522 mm (0.2167–0.2174 in)

Valve stem diameter b: Intake: 5.477–5.492 mm (0.2156–0.2162 in) Exhaust: 5.464–5.479 mm (0.2151–0.2157 in) 4. Measure the valve stem runout. Replace if above specification.

6P21H11

2. Calculate the valve stem-to-valve guide clearance as follows. Replace the valve guide if out of specification. Valve stem-to-valve guide clearance = valve guide inside diameter – valve stem diameter: Intake: 0.012–0.045 mm (0.0005–0.0018 in) Exhaust: 0.025–0.058 mm (0.0010–0.0023 in)

5-44

1 2 3 4 5 6 7 8 9

POWR

Power unit

Replacing the valve guide 1. Remove the valve guide 1 using the special service tool from the combustion chamber side.

1 S69J5790

NOTE: • Turn the valve guide reamer clockwise to ream the valve guide. • Do not turn the reamer counterclockwise when removing the reamer.

Valve guide remover: YB-06801 2. Install the new valve guide 2 using the special service tools from the camshaft side until the valve guide installer 3 contacts the cylinder head.

Valve guide reamer: YB-06804 4. Measure the valve guide inside diameter. Valve guide inside diameter: Intake and exhaust 5.504–5.522 mm (0.2167–0.2174 in)

3 a

Checking the valve seat 1. Eliminate carbon or deposits from the valves.

E S6P25E30

NOTE: Apply engine oil to the surface of the new valve guide.

2. Apply a thin, even layer of Mechanic’s blueing dye (Dykem) onto the valve seat. 3. Lap the valve slowly on the valve seat with a valve lapper (commercially available) as shown.

Valve guide remover: YB-06801 Valve guide installer: YB-06810 Valve guide position a: 13.8 ± 0.2 mm (0.5 ± 0.01 in) 3. Insert the special service tool into the valve guide 2, and then ream the valve guide.

5-45

6P21H11

Cylinder head 4. Measure the valve seat contact width a where the blueing dye is adhered to the valve face. Reface the valve seat if the valve is not seated properly or if the valve seat contact width is out of specification. Replace the valve guide if the valve seat contact is uneven.

45˚

30˚

60˚

30˚ 45˚ S69J5845

Neway valve seal kit: YB-91044 2. Cut the surface of the valve seat with a 45° cutter by turning the cutter clockwise until the valve seat face has become smooth. È

S69J5855

Valve seat contact width a: Intake: 1.10–1.40 mm (0.043–0.055 in) Exhaust: 1.40–1.70 mm (0.055–0.067 in)

Refacing the valve seat 1. Reface the valve seat with the valve seat cutter.

6P21H11

a Slag or rough surface

CAUTION: Do not over cut the valve seat. Be sure to turn the cutter evenly downward at a pressure of 40–50 N (4–5 kgf, 8.8–11 lbf) to prevent chatter marks.

5-46

1 2 3 4 5 6 7 8 9

POWR

Power unit

3. Use a 30° cutter to adjust the contact width of the top edge of the valve seat.

30˚

b Previous contact width S69J5880

b Previous contact width

4. Use a 60° cutter to adjust the contact width of the bottom edge of the valve seat.

7. If the valve seat contact area is too narrow and situated near the top edge of the valve face, use a 30° cutter to cut the top edge of the valve seat. If necessary, use a 45° cutter to center the area and set its width.

60˚ S69J5890

b Previous contact width b Previous contact width

5. Use a 45° cutter to adjust the contact width of the valve seat to specification.

b c

8. If the valve seat contact area is too narrow and situated near the bottom edge of the valve face, use a 60° cutter to cut the bottom edge of the valve seat. If necessary, use a 45° cutter to center the area and set its width.

45˚ S69J5900

b Previous contact width c Specified contact width

6. If the valve seat contact area is too wide and situated in the center of the valve face, use a 30° cutter to cut the top edge of the valve seat, a 60° cutter to cut the bottom edge to center the area and set its width.

5-47

b Previous contact width

6P21H11

Cylinder head 9. Apply a thin, even layer of lapping compound onto the valve seat, and then lap the valve using a valve lapper (commercially available).

Cylinder head warpage limit: 0.1 mm (0.0039 in)

CAUTION: Do not get the lapping compound on the valve stem and valve guide.

Installing the valve 1. Install a new valve seal 1 onto the valve guide.

10. After every lapping procedure, be sure to clean off any remaining lapping compound from the cylinder heads and the valves. 11. Check the valve seat contact area of the valve again.

Checking the cylinder head 1. Eliminate carbon deposits from the combustion chambers and check for deterioration. 2. Check the cylinder head warpage using a straightedge 1 and thickness gauge 2 in the directions shown. Replace the cylinder head assembly if above specification.

6P21H11

5-48

1 2 3 4 5 6 7 8 9

POWR

Power unit

2. Install the valve 2, valve spring 3, and valve spring retainer 4 in the sequence shown, and then attach the special service tools.

NOTE: Be sure to install the camshafts after completing the procedure in â&#x20AC;&#x153;Installing the cylinder head.â&#x20AC;?

Removing the cooling water passage cover NOTE: The valve spring can be installed in any direction. Valve spring compressor 5: YM-01253 Valve attachment 6: YB-06320

1. Remove the knock sensor. 2. Disconnect the flushing hose. 3. Remove the cooling water passage cover bolts in the sequence shown.

4 5

3. Compress the valve spring, and then install the valve cotters 7.

9 C 0 6 1

3 8 B A 7 2 S6P25860

4. Lightly tap the valve spring retainer with a plastic hammer to set the valve cotters securely.

NOTE: See the exploded diagram (5-41).

Checking the cooling water passage cover anode 1. Check the anodes. Clean if there are scales, grease, or oil.

5-49

6P21H11

Cylinder head

CAUTION: T. R.

Do not oil, grease, or paint the anodes, otherwise they will be ineffective.

Cooling water passage cover bolt: 12 N·m (1.2 kgf·m, 8.9 ft·lb)

4. Connect the flushing hose and fasten it. 2. Replace eroded.

the

anodes

excessively

Installing the cooling water passage cover 1. Install the anodes to the cooling water passage cover.

T. R.

Anode screw: 3 N·m (0.3 kgf·m, 2.2 ft·lb)

2. Install the new gasket and cooling water passage cover.

5. Tighten the knock sensor to the specified torque, and then fasten the knock sensor lead 1 and flushing hose 2 as shown.

1 2

S6P25900

NOTE: Fasten the knock sensor lead so that it is taut.

NOTE: See the exploded diagram (5-41).

T. R.

3. Tighten the cooling water passage cover bolts to the specified torque in the sequence shown.

Knock sensor: 32 N·m (3.2 kgf·m, 23.6 ft·lb)

0 9 5 D1 G4 8 C

A 6 2E 3F 7 B S6P25880 S6P25860

6P21H11

5-50

1 2 3 4 5 6 7 8 9

POWR

Power unit

Installing the cylinder head

2. Install the new gaskets and cylinder heads, and then tighten the bolts to the specified torques in the sequence shown.

PORT

Cylinder head bolt (M10): 1st: 23 N·m (2.3 kgf·m, 17.0 ft·lb) 2nd: 45 N·m (4.5 kgf·m, 33.2 ft·lb) 3rd: Loosen completely 4th: 23 N·m (2.3 kgf·m, 17.0 ft·lb) 5th: 45 N·m (4.5 kgf·m, 33.2 ft·lb) 6th: 90° Cylinder head bolt (M8): 1st: 14 N·m (1.4 kgf·m, 10.3 ft·lb) 2nd: 28 N·m (2.8 kgf·m, 20.7 ft·lb)

3. Install the new filters and oil control valve assemblies.

STBD

NOTE: See the exploded diagram (5-41).

1. Install the grommets and collars into the cylinder block.

CAUTION: Do not reuse the oil control valve filters, always replace them with new ones. NOTE: Make sure that the oil control valve filter does not come off when installing the oil control valve.

0 A a

90˚ (T55) S6P25910E

CAUTION: Do not reuse the cylinder head gaskets, always replace them with new ones.

4. Install the camshafts, driven sprockets, and timing belt. NOTE: To install the camshafts, driven sprockets, and timing belt, see “Installing the camshaft, driven sprocket, and timing belt.”

NOTE: • Apply engine oil to the cylinder head bolts before installation. • Tighten the M10 bolts to the specified torques in 6 stages first, and then tighten the M8 bolts to the specified torques in 2 stages. • Make a mark a on the M10 bolts and the cylinder heads, and then tighten the bolts 90° from the mark.

5-51

6P21H11

Cylinder head / Crankcase

Crankcase

30 33

32 23 N · m (2.3 kgf · m, 17.0 ft · lb) 43 N · m (4.3 kgf · m, 31.7 ft · Ib) 90˚

1 2 3

34 E

25 E

27 28 28

29 T.

7 5

34 N · m (3.4 kgf · m, 25.1 ft · Ib) T.

Part name Oil filter Oil pressure sensor O-ring Bolt Joint Oil filter bracket Gasket Bolt Engine hanger Crankcase cover Bolt Oil filler cap O-ring Holder Gasket Dowel Cap

6P21H11

15 N · m (1.5 kgf · m, 11.1 ft · Ib)

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

17 19 T.

12 13 14

18 N · m (1.8 kgf · m, 13.3 ft · Ib)

24 26

12 N · m (1.2 kgf · m, 8.9 ft · Ib)

11 Q’ty 1 1 1 5 1 1 1 2 1 1 17 1 1 1 1 2 2

1 2

15 14 N · m (1.4 kgf · m, 10.3 ft · lb) 28 N · m (2.8 kgf · m, 20.7 ft · lb)

S6P25840E

Remarks

Not reusable

M6 × 45 mm

Not reusable

M6 × 20 mm

M8 × 45 mm

Not reusable

5-52

1 2 3 4 5 6 7 8 9

POWR

Power unit 5

30 33

32 23 N · m (2.3 kgf · m, 17.0 ft · lb) 43 N · m (4.3 kgf · m, 31.7 ft · Ib) 90˚

1 2 3

34 E

25 E

27 28 28

29 T.

7 5

34 N · m (3.4 kgf · m, 25.1 ft · Ib) T.

30 31 32 33 34

5-53

Part name Engine stopper (STBD) Bolt Engine stopper (PORT) Washer Engine temperature sensor Piston ring set Clip Piston pin Piston Connecting rod Connecting rod bearing Bolt Bolt Holder Cooling water hose Vapor gas hose Check valve

15 N · m (1.5 kgf · m, 11.1 ft · Ib)

No. 18 19 20 21 22 23 24 25 26 27 28 29

17 19 T.

12 13 14

18 N · m (1.8 kgf · m, 13.3 ft · Ib)

24 26

12 N · m (1.2 kgf · m, 8.9 ft · Ib)

11 Q’ty 1 4 1 1 1 6 12 6 6 6 12 12 1 1 1 2 1

1 2

15 14 N · m (1.4 kgf · m, 10.3 ft · lb) 28 N · m (2.8 kgf · m, 20.7 ft · lb)

S6P25840E

Remarks M6 × 25 mm

Not reusable

M9 × 42 mm M6 × 12 mm

6P21H11

Crankcase / Cylinder block 2005 F250 6P2 LF250 6P3

1000001–1002894 1000001–1000956

Cylinder block

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Part name Bolt Bolt Bolt Crankcase assembly Main bearing Main bearing Oil seal Crankshaft Main bearing Thrust bearing O-ring O-ring Oil seal Oil seal O-ring Gasket Oil seal

6P21H11

Q’ty 8 8 13 1 3 1 1 1 4 2 2 1 1 1 2 1 1

Remarks M10 × 105 mm M8 × 95 mm M8 × 55 mm

Not reusable

Not reusable Not reusable Not reusable Not reusable Not reusable Not reusable Not reusable

5-54

1 2 3 4 5 6 7 8 9

POWR 2005 F250 6P2 LF250 6P3

Power unit 1000001–1002894 1000001–1000956 5

No. 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

5-55

Part name Oil seal Oil pump assembly Bolt Bolt Plug O-ring Hose Thermostat cover Anode Thermoswitch Bolt Bolt Thermostat Plug Gasket Thermostat cover Bolt

Q’ty 2 1 4 2 1 1 2 1 2 2 4 4 2 1 1 1 2

Remarks Not reusable

M6 × 40 mm M6 × 20 mm Not reusable

M6 × 16 mm M6 × 25 mm M14 × 12 mm Not reusable

M5 × 20 mm 6P21H11

Cylinder block 2006 F250 6P2 LF250 6P3

1002895– 1000957–

Cylinder block

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Part name Bolt Bolt Bolt Crankcase assembly Main bearing Main bearing Oil seal Crankshaft Main bearing Thrust bearing O-ring O-ring Oil seal Oil seal O-ring Gasket Oil seal

6P21H11

Q’ty 8 8 13 1 3 1 1 1 4 2 2 1 1 1 2 1 1

Remarks M10 × 105 mm M8 × 95 mm M8 × 55 mm

Not reusable

Not reusable Not reusable Not reusable Not reusable Not reusable Not reusable Not reusable

5-56

1 2 3 4 5 6 7 8 9

POWR 2006 F250 6P2 LF250 6P3

No. 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

5-57

Power unit 1002895– 1000957–

Part name Oil seal Oil pump assembly Bolt Bolt Plug O-ring Gasket Thermostat cover Anode Thermoswitch Bolt Bolt Thermostat Plug Gasket Thermostat cover Bolt

Q’ty 2 1 4 2 1 1 2 1 2 2 4 4 2 1 1 1 2

Remarks Not reusable

M6 × 40 mm M6 × 20 mm Not reusable Not reusable

M6 × 16 mm M6 × 25 mm M14 × 12 mm Not reusable

M5 × 20 mm 6P21H11

Cylinder block

Disassembling the cylinder block 1. Remove the oil filter using a 72.5 mm (2.9 in) oil filter wrench. Oil filter wrench: (commercially available) 2. Remove the oil filter bracket bolts in the sequence shown.

STBD

PORT

% ! ±

$ # S6P25930

3. Remove the crankcase cover bolts in the sequence shown.

UP 3

2 1

NOTE: • See the exploded diagram (5-53). • Be sure to keep the bearings in the order as they were removed. • Mark each piston with an identification number a of the corresponding cylinder. • Mark each connecting rod and connecting rod cap on the side facing up (flywheel magnet side) with an identification mark b. • Do not mix the connecting rods and caps. Keep them organized in their proper groups. • Remove the piston rings and arrange them in order.

8 9

6. Remove the oil pump.

C STBD

PORT

NOTE: See the exploded diagram (5-54).

7. Remove the crankcase bolts in the sequence shown.

A 0 4

5 6

S6P25940

4. Remove the connecting rod cap bolts and the connecting rod caps, and then remove the connecting rod and piston assemblies.

8 9

B PORT

STBD NOTE: See the exploded diagram (5-52).

C 0

5. Remove the clips 1 and piston pin, and then remove the piston.

6P21H11

A 3 S6P25960J

5-58

1 2 3 4 5 6 7 8 9

POWR

Power unit

8. Remove the crankshaft and bearings. NOTE: Be sure to keep the bearings in the order as they were removed.

Cylinder bore (D1–D6): 94.000–94.017 mm (3.7008–3.7014 in)

Checking the piston clearance (reference)

Checking the piston diameter 1. Measure the piston outside diameter at the specified measuring point. Replace the piston if out of specification.

1. Check the clearances by referring to the specified values if replacing the piston, the piston rings as a set, the cylinder block, or all parts. Piston clearance (reference data): 0.075–0.080 mm (0.0030–0.0031 in)

Checking the piston ring 1. Check the piston ring dimensions of B and T. Replace the piston ring set if out of specification. Piston diameter a: 93.921–93.941 mm (3.6977–3.6985 in) Measuring point b: 5.0 mm (0.2 in) up from the bottom of the piston skirt

Checking the cylinder bore 1. Measure the cylinder bore (D1–D6) at measuring points a, b, and c, and in direction d (D1, D3, D5), which is parallel to the crankshaft, and direction e (D2, D4, D6), which is at a right angle to the crankshaft.

D5 S69J5B70

a 20 mm (0.8 in) b 50 mm (2.0 in) c 80 mm (3.1 in)

5-59

Piston ring dimensions: Top ring a: B: 1.17–1.19 mm (0.046–0.047 in) T: 2.80–3.00 mm (0.110–0.118 in) Second ring b: B: 1.17–1.19 mm (0.046–0.047 in) T: 3.70–3.90 mm (0.146–0.154 in) Oil ring c: B: 2.40–2.47 mm (0.094–0.097 in) T: 2.30–2.70 mm (0.091–0.106 in)

6P21H11

Cylinder block

Checking the piston ring end gap (reference) 1. Level the piston ring 1 in the cylinder with a piston crown. 2. Check the piston ring end gap a at the specified measuring point b.

Piston ring groove: Top ring a: 1.23–1.25 mm (0.048–0.049 in) Second ring b: 1.22–1.24 mm (0.048–0.049 in) Oil ring c: 2.51–2.53 mm (0.099–0.100 in)

Checking the piston ring side clearance 1. Measure the piston ring side clearance. Replace the piston and piston rings as a set if out of specification.

Piston ring end gap a (reference data): Top ring: 0.15–0.30 mm (0.006–0.012 in) Second ring: 0.30–0.45 mm (0.012–0.018 in) Oil ring: 0.15–0.60 mm (0.006–0.024 in) Measuring point b (reference data): 20 mm (0.8 in)

Piston ring side clearance: Top ring a: 0.04–0.08 mm (0.002–0.003 in) Second ring b: 0.03–0.07 mm (0.001–0.003 in) Oil ring c: 0.04–0.13 mm (0.002–0.005 in)

Checking the piston ring groove 1. Measure the piston ring grooves. Replace the piston if out of specification.

6P21H11

5-60

1 2 3 4 5 6 7 8 9

POWR

Power unit

Checking the piston pin boss bore 1. Measure the piston pin boss bore. Replace the piston if out of specification.

Piston pin boss bore: 21.017–21.031 mm (0.8274–0.8280 in)

Checking the piston pin 1. Measure the piston pin outside diameter. Replace the piston pin if out of specification.

Piston pin outside diameter: 20.995–21.000 mm (0.8266–0.8268 in)

Checking the connecting rod small end inside diameter 1. Measure the connecting rod small end inside diameter a. Replace the connecting rod assembly if out of specification.

5-61

Connecting rod small end inside diameter a: 21.017–21.031 mm (0.8274–0.8280 in)

Checking the connecting rod big end side clearance 1. Measure the connecting rod big end side clearance a.

Connecting rod big end side clearance a (reference data): 0.15–0.30 mm (0.006–0.012 in)

Checking the crankshaft 1. Measure the crankshaft journal diameter a, crankpin diameter b, and crankpin width c. Replace the crankshaft if out of specification.

6P21H11

Cylinder block

Checking the crankpin oil clearance 1. Clean the bearings and the connecting rod. 2. Install the upper bearing into the connecting rod 1 and the lower bearing into the connecting rod cap 2.

Crankshaft journal diameter a: 62.968–62.992 mm (2.4791–2.4800 in) Crankpin diameter b: 49.976–50.000 mm (1.9676–1.9685 in) Crankpin width c: 21.50–21.55 mm (0.8465–0.8484 in)

NOTE: • Install the connecting rod bearings in their original positions. • Insert the projection a of each bearing into the slots in the connecting rod cap and connecting rod. 3. Put a piece of Plastigauge (PG-1) onto the crankpin, parallel to the crankshaft.

2. Measure the crankshaft runout. Replace the crankshaft if above specification.

NOTE: Be sure not to put the Plastigauge (PG-1) over the oil hole in the crankpin of the crankshaft.

S6P25970

Crankshaft runout limit: 0.03 mm (0.0012 in) 6P21H11

5-62

1 2 3 4 5 6 7 8 9

POWR

Power unit

4. Install the connecting rod onto the crankpin 3. T. R.

Connecting rod cap bolt: 1st: 23 N·m (2.3 kgf·m, 17.0 ft·lb) 2nd: 43 N·m (4.3 kgf·m, 31.7 ft·lb) 3rd: 90°

6. Remove the connecting rod cap and measure the width of the compressed Plastigauge (PG-1) on each crankpin. Replace the connecting rod bearing if out of specification.

NOTE: Make sure that the marks b of the connecting rod face toward the flywheel magnet end of the crankshaft. 5. Tighten the connecting rod cap bolts to the specified torques in 3 stages.

Crankpin oil clearance: 0.028–0.066 mm (0.0011–0.0026 in)

Selecting the connecting rod bearing 1. When replacing the connecting rod bearing, select the suitable bearing as follows. 2. Check the crankpin mark a on the crankshaft.

NOTE: • Reuse the removed connecting rod cap bolts when checking the oil clearance. • Do not turn the connecting rod until the crankpin oil clearance measurement has been completed. • Make a mark c on the connecting rod cap bolts, connecting rod caps, and then tighten the bolts 90° from the mark.

5-63

6P21H11

Cylinder block

NOTE: • Install the bearings in their original positions. • Insert the projection a of each bearing into the slots in the cylinder block.

3. Select the suitable color b for the connecting rod bearing from the table.

Crankpin mark a

Bearing color b

92–00

Yellow

84–91

Green

76–83

Blue

Checking the crankshaft journal oil clearance 1. Clean the bearings, crankshaft journals, and bearing portions of the crankcase and cylinder block. 2. Place the cylinder block upside down on a bench. 3. Install half of the main bearings 1 and the crankshaft 2 into the cylinder block 3.

6P21H11

4. Put a piece of Plastigauge (PG-1) on each crankshaft journal parallel to the crankshaft.

NOTE: Do not put the Plastigauge (PG-1) over the oil hole in the main journals of the crankshaft. 5. Install the remaining half of the main bearings into the crankcase. NOTE: • Install the bearings in their original positions. • Insert the projection a of each bearing into the slots in the crankcase. 6. Install the crankcase onto the cylinder block and apply engine oil to the threads of the crankcase bolts.

5-64

1 2 3 4 5 6 7 8 9

POWR

Power unit

7. Tighten the crankcase bolts to the specified torques in 2 stages and in the sequence shown.

90˚

8. Gently remove the crankcase, and then measure the width of the compressed Plastigauge (PG-1) on each crankshaft journal. Replace the main bearing if out of specification.

UP E

P 5C

O L K

H PORT

STBD G J R

I Q S6P25990J

NOTE: • Crankcase bolts 1–F can be reused 5 times. • Do not turn the crankshaft until the crankshaft journal oil clearance measurement has been completed. • Tighten crankcase bolts 1–F to the specified torques in 2 stages first, and then tighten crankcase bolts G–S to the specified torques in 2 stages. • Make a mark b on the crankcase and crankcase bolts, and then tighten crankcase bolts 1–F 90° from the mark.

T. R.

5-65

Crankshaft journal oil clearance: 0.025–0.050 mm (0.0010–0.0020 in)

Selecting the main bearing 1. When replacing the main bearing, select the suitable bearing as follows. 2. Check the crankshaft journal mark a on the crankshaft and the cylinder block mark b on the cylinder block.

1–8 Crankcase bolt (M8): 1st: 25 N·m (2.5 kgf·m, 18.4 ft·lb) 2nd: 90° 9–F Crankcase bolt (M10): 1st: 40 N·m (4.0 kgf·m, 29.5 ft·lb) 2nd: 90° G–S Crankcase bolt (M8): 1st: 14 N·m (1.4 kgf·m, 10.3 ft·lb) 2nd: 28 N·m (2.8 kgf·m, 20.7 ft·lb)

6P21H11

Cylinder block

Disassembling the oil pump 1. Remove the screws 1 and disassemble the oil pump.

3. Select the suitable main bearing number c from the table.

NOTE: See the exploded diagram (5-54).

Checking the oil pump Cylinder block mark b

Crankshaft journal mark a

98 99 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 92 1

91 1

90 1

89 1

88 1

87 1

86 1

85 1

84 1

83 1

82 1

81 1

80 1

79 1

78 1

77 1

76 1

75 1

74 2

73 2

72 2

71 2

70 2

69 2

68 2

NOTE: • Example: If the crankshaft journal mark a is “81” and the cylinder block mark b is “04,” then the main bearing number c is “1.” • Lower main bearing for J3 is a thrust bearing 1.

6P21H11

1. Check the gear teeth and inner surface of the oil pump case. Replace the oil pump assembly if the gear teeth are cracked or worn, or if inner surface of the oil pump case is scratched.

Assembling the oil pump 1. Install a new oil seal into the oil pump cover.

Needle bearing installer 1: YB-06434 Driver handle (large) 2: YB-06071

5-66

1 2 3 4 5 6 7 8 9

POWR

Power unit

2. Install new oil seals into the oil pump housing.

Driver handle (large) 2: YB-06071 Roller bearing installer/remover 3: YB-06432 3. Install a new oil seal into the oil pump housing. T. R.

Oil pump cover screw 7: 4 N·m (0.4 kgf·m, 3.0 ft·lb)

Assembling the power unit NOTE: See the exploded diagram (5-54).

Needle bearing installer 4: YB-06111

1. Assemble the piston 1, connecting rod 2, piston pin 3, and new piston pin clips 4.

4. Install a new gasket 5, and then tighten the screws 7 to the specified torque. 5. Install a new oil seal 6 into the oil pump, making sure to install it in the proper direction.

5-67

6P21H11

Cylinder block NOTE: • Face the mark a on the connecting rod in the same direction as the “UP” mark b on the piston. • Always use new piston pin clips, and do not allow the piston pin clip end to align with the piston pin slot c. 2. Install the oil rings 5, second ring 6, and top ring 7 to the piston with the “2R” mark d of the second ring and the “R” mark d of the top ring facing upward. 3. Offset the piston ring end gaps as shown.

d #3

45˚

NOTE: • Install the connecting rod bearings in their original positions. • Insert the projection e of the bearing into the slots on the connecting rod cap and connecting rod. 5. Install half of the main bearings 9 into the cylinder block 0.

5 #1,#4

#3 #2

d S6P25A70

CAUTION: Do not scratch the pistons or break the piston rings.

S69J5F10

NOTE: • Install the bearings in their original positions. • Insert the projection f of each bearing into the slots in the cylinder block.

NOTE: After installing the piston rings, check that they move smoothly. 4. Install the upper bearing into the connecting rod 2 and the lower bearing into the connecting rod cap 8.

6P21H11

5-68

1 2 3 4 5 6 7 8 9

POWR

Power unit

6. Set the crankshaft A, new oil seal B, and thrust bearings C into the cylinder block as shown.

NOTE: • Install the main bearings in their original positions. • Insert the projection h of each bearing into the slots in the crankcase. • Do not get any sealant on the main bearings. 9. Install the crankcase onto the cylinder block, and then tighten the crankcase bolts to the specified torques in 2 stages and in the sequence shown.

90˚

UP E

CAUTION:

Do not damage the oil seal when installing it by contacting the edge g of the drive sprocket. NOTE: • Apply engine oil to the inner oil seal and the thrust bearings before installation. • Do not get any engine oil to the drive sprocket.

8. Apply sealant to the mating surface of the crankcase.

5-69

O L STBD

H G J

R 7. Install half of the main bearings D and the thrust bearing E into the crankcase.

P 5C

PORT

I Q S6P25B00J

NOTE: • Crankcase bolts 1–F can be reused 5 times. • The oil seal must be installed before tightening the crankcase bolts. • Apply engine oil to the crankcase bolts before installation. • Tighten crankcase bolts 1–F to the specified torques in 2 stages first, and then tighten crankcase bolts G–S to the specified torques in 2 stages. • Make a mark k on the crankcase and crankcase bolts, and then tighten crankcase bolts 1–F 90° from the mark. • After tightening the crankcase bolts, check that the crankshaft rotates smoothly.

6P21H11

Cylinder block

T. R.

10. Install the piston with the “UP” mark on the piston crown facing towards the flywheel magnet.

CAUTION: Do not reuse the connecting rod cap bolts, always replace them with new ones.

NOTE: Apply engine oil to the side of the pistons and piston rings before installation.

Piston ring compressor: YM-08037

6P21H11

11. Install the connecting rod cap 8 to the connecting rod, and then tighten the connecting rod cap bolts to the specified torques in 3 stages.

NOTE: • Align the marks m on the connecting rod cap and connecting rod. • Apply engine oil to the connecting rod caps and connecting rod cap bolts before installation. • Make a mark n on the connecting rod cap bolts and connecting rod caps, and then tighten the bolts 90° from the mark. • After tightening the connecting rod cap bolts, check that the crankshaft rotates smoothly. Connecting rod cap bolt: 1st: 23 N·m (2.3 kgf·m, 17.0 ft·lb) 2nd: 43 N·m (4.3 kgf·m, 31.7 ft·lb) 3rd: 90°

5-70

1 2 3 4 5 6 7 8 9

POWR

Power unit

12. Install the oil pump F by aligning the oil pump gear with the crankshaft.

UP E

F G 0

9 6

5 STBD

PORT

7 8 D

C B

S6P25B40

NOTE: Apply engine oil to the crankcase bolts before installation.

T. R.

F E S6P25B30E

Crankcase cover bolt: 1st: 14 N·m (1.4 kgf·m, 10.8 ft·lb) 2nd: 28 N·m (2.8 kgf·m, 20.7 ft·lb)

14. Install the new gasket and oil filter bracket, and then tighten the bolts in the sequence shown.

CAUTION: Before installing the oil pump, be sure to fill it with engine oil through the oil passage p.

STBD

PORT

! %

NOTE: When installing the oil pump, install it so that the oil seal does not get damaged.

± # S6P25B50

13. Install the new gasket and crankcase cover, and then tighten the bolts to the specified torques in 2 stages and in the sequence shown.

NOTE: Apply engine oil to the oil filter bracket bolts before installation. 15. Supply engine oil to the oil passage r of the oil filter bracket.

5-71

6P21H11

Cylinder block

H 16. Install the oil filter, and then tighten it to the specified torque using a 72.5 mm (2.9 in) oil filter wrench. 8

S6P25B80

18. Install the cooling water passage cover and cylinder heads. NOTE: To install the cooling water passage cover and cylinder heads, see “Installing the cooling water passage cover” and “Installing the cylinder head.”

NOTE: Apply a thin coat of engine oil to the O-ring of the new oil filter before installation. Oil filter wrench: (commercially available)

T. R.

Oil filter: 18 N·m (1.8 kgf·m, 13.3 ft·lb)

Installing the wiring harness NOTE: • To install all of the wiring harnesses, see Chapter 8, “Wiring harness routing.” • Perform this procedure after assembling the power unit. 1. Install the wiring harness and sub wiring harness to the junction box.

17. Fasten the cooling water hose G, vapor gas hoses, and check valve H using the holder as shown.

6P21H11

5-72

1 2 3 4 5 6 7 8 9

POWR

Power unit

2. Fasten the wiring harnesses at the white tape a using a plastic tie 1. 3. Fasten the oil pressure sensor lead 2, isolator lead 3, positive terminal lead 4 and its cap, with white tape b of the oil pressure sensor lead is in the position as shown.

6. Install the engine temperature sensor lead 7 into the slit in the wiring harness guide, and then install the wiring harness guide.

5 6

7 S6P25C10

NOTE: It is recommended to check the crank position sensor air gap before installing the wiring harness guide to improve working efficiency.

4 3 b 2

S6P25B90

NOTE: Do not fasten the PTT relay lead 5 with the plastic tie 6.

7. Install the wiring harness onto the wiring harness guide with the mark c facing upward, and then install the clips 8 in the sequence shown. 8. Fasten the wiring harness using the plastic ties.

8 8

4. Install the junction box onto the power unit.

Âą

CAUTION: Do not bend the terminal of the starter motor leads when connecting them.

5-73

d #

5. Connect the starter motor leads.

S6P25C00E

! c

S6P25C20

NOTE: â&#x20AC;˘ Be sure to install the wiring harness onto the wiring harness guide so that the wiring harness does not come out from the top edge of the wiring harness guide. â&#x20AC;˘ Be sure to install the wiring harness between swells d. 9. Install the wiring harness onto the ECM bracket, and fasten it at the white tape e.

6P21H11

Cylinder block

CAUTION: Make sure that the top cowling lock levers are retracted and the engine stoppers are installed before installing the power unit, otherwise the fuel rails could be damaged. 2. Clean the power unit mating surface, and install the dowels 1 and a new gasket 2.

3. Install the power unit by installing the bolts 3 and 4, then tightening them to the specified torque. S6P25C30

3 4

10. Check that the wiring harness, hoses, and the other parts do not interfere with any moving parts.

4 3

Installing the power unit 1. Retract the port and starboard top cowling lock levers.

PORT

STBD

LT LT

572

3 S6P25360 T. R.

STBD

S6P25C40E

Power unit mounting bolt 3 and 4: 42 NÂˇm (4.2 kgfÂˇm, 31.0 ftÂˇlb)

PORT

S6P25365

6P21H11

5-74

1 2 3 4 5 6 7 8 9

POWR

Power unit

4. Install the upper case cover 5 and aprons 6.

2006 F250 6P2 LF250 6P3

1002895– 1000957–

S6P25C60C

T. R.

Apron bolt and upper case cover bolt: 8 N·m (0.8 kgf·m, 5.9 ft·lb)

7. Connect the warning indicator coupler 9, trim sensor coupler 0, isolator coupler A, coupler B, PTT switch coupler C, 10-pin main harness coupler D, and then install them onto the brackets.

5. Install the speed sensor coupler 7 to the bracket.

6. Connect the flushing hose 8. 2005 F250 6P2 LF250 6P3

D 1000001–1002894 1000001–1000956

S6P25C70

8. Connect the cooling water pilot hose E.

9. Connect the neutral switch coupler F and shift cut switch coupler G, and then install them onto the bracket. 10. Install the dipstick guide H and oil dipstick I.

7 S6P25C60

5-75

6P21H11

Cylinder block

K F E M L a S6P25C80

S6P25D00

NOTE: To wire the battery cables, see Chapter 8, “Wiring harness routing.”

11. Connect the vapor gas hose J to the starboard top cowling lock.

PTT motor lead bolt: 4 N·m (0.4 kgf·m, 3.0 ft·lb) Positive battery cable bolt: 18 N·m (1.8 kgf·m, 13.3 ft·lb) Negative battery cable nut: 13 N·m (1.3 kgf·m, 9.6 ft·lb)

NOTE: Apply engine oil to the O-ring before installing the dipstick guide.

14. Connect the fuel hose.

S6P25C90

12. Connect the PTT motor leads K, and then fasten them. 13. Connect the positive battery cable L and negative battery cable M along the bottom of the bottom cowling a.

6P21H11

15. Install the grommet with the speedometer hose N, fuel hose O, positive battery cable L, negative battery cable M, shift cable P, gauge harness Q, throttle cable R, and 10-pin main harness S. 16. Install the cable holder T and retaining plate U.

5-76

1 2 3 4 5 6 7 8 9

POWR

Power unit

17. Connect the shift cable and throttle cable, and then adjust their lengths. To adjust the shift cable and throttle cable, see Chapter 3, “Adjusting the throttle cable” and “Checking the gear shift operation.” 18. Install the starboard intake manifold. NOTE: To install the intake manifold, see Chapter 4, “Installing the intake manifold.” 19. Install all the parts that were removed.

5-77

6P21H11

— MEMO —

1 2 3 4 5 6 7 8 9 6P21H11

5-78

LOWR

Lower unit Lower unit (regular rotation model) ............................................................. 6-1 Removing the lower unit ............................................................................6-4 Removing the water pump and shift rod.................................................... 6-4 Checking the water pump and shift rod .....................................................6-5 Propeller shaft housing (regular rotation model) ....................................... 6-6 Removing the propeller shaft housing assembly....................................... 6-8 Disassembling the propeller shaft assembly .............................................6-8 Disassembling the propeller shaft housing................................................ 6-8 Checking the propeller shaft housing ........................................................6-9 Checking the propeller shaft...................................................................... 6-9 Assembling the propeller shaft assembly .................................................. 6-9 Assembling the propeller shaft housing.....................................................6-9 Drive shaft and lower case (regular rotation model) ................................6-12 Removing the drive shaft.........................................................................6-14 Disassembling the drive shaft housing ....................................................6-14 Disassembling the forward gear ..............................................................6-14 Disassembling the lower case .................................................................6-14 Checking the pinion and forward gear.....................................................6-15 Checking the bearing............................................................................... 6-15 Checking the drive shaft ..........................................................................6-15 Checking the lower case .........................................................................6-15 Assembling the lower case...................................................................... 6-15 Assembling the forward gear................................................................... 6-16 Assembling the drive shaft housing......................................................... 6-16 Installing the drive shaft...........................................................................6-16 Installing the propeller shaft housing .......................................................6-17 Installing the water pump and shift rod....................................................6-18 Installing the lower unit ............................................................................6-19 Shimming (regular rotation model) ............................................................ 6-21 Shimming.................................................................................................6-22 Selecting the pinion shim.........................................................................6-22 Selecting the forward gear shim ..............................................................6-23 Selecting the reverse gear shim ..............................................................6-24 Selecting the propeller shaft shim ........................................................... 6-25 Backlash (regular rotation model)..............................................................6-26 Measuring the forward and reverse gear backlash .................................6-26

6P21H11

Lower unit (counter rotation model) .......................................................... 6-29 Removing the lower unit ..........................................................................6-32 Removing the water pump and shift rod.................................................. 6-33 Checking the water pump and shift rod ...................................................6-33 Propeller shaft housing (counter rotation model) .................................... 6-34 Removing the propeller shaft housing assembly..................................... 6-36 Disassembling the propeller shaft housing.............................................. 6-36 Checking the propeller shaft housing ......................................................6-37 Checking the propeller shaft.................................................................... 6-37 Assembling the propeller shaft housing...................................................6-38 Drive shaft and lower case (counter rotation model) ...............................6-41 Removing the drive shaft.........................................................................6-43 Disassembling the drive shaft housing ....................................................6-43 Disassembling the reverse gear ..............................................................6-43 Disassembling the lower case .................................................................6-43 Checking the pinion and reverse gear.....................................................6-44 Checking the bearing............................................................................... 6-44 Checking the drive shaft ..........................................................................6-44 Checking the lower case .........................................................................6-44 Assembling the lower case...................................................................... 6-44 Assembling the reverse gear................................................................... 6-45 Assembling the drive shaft housing......................................................... 6-46 Installing the drive shaft...........................................................................6-46 Installing the propeller shaft housing .......................................................6-47 Installing the water pump and shift rod....................................................6-48 Installing the lower unit ............................................................................6-49 Shimming (counter rotation model) ........................................................... 6-51 Shimming.................................................................................................6-52 Selecting the pinion shim.........................................................................6-52 Selecting the reverse gear shim ..............................................................6-53 Selecting the forward gear shim ..............................................................6-54 Selecting the propeller shaft shim ........................................................... 6-55 Backlash (counter rotation model)............................................................. 6-56 Measuring the forward and reverse gear backlash .................................6-56

6P21H11

1 2 3 4 5 6 7 8 9

LOWR

Lower unit

Lower unit (regular rotation model)

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

6-1

Part name Lower unit Plate Rubber seal Check screw Gasket Bolt Drain screw Grommet Bolt Bolt Spacer Propeller Washer Washer Cotter pin Propeller nut Trim tab

Q’ty 1 1 1 1 2 7 1 1 1 1 1 1 1 1 1 1 1

Remarks

Not reusable

M10 × 45 mm/X-transom model

M10 × 45 mm M10 × 70 mm/X-transom model

Not reusable

6P21H11

Lower unit (regular rotation model) 6

No. 18 19 20 21 22 23 24 25 26 27

Part name Extension Rubber seal Dowel Rubber seal Stud bolt Bolt Bolt Nut Spring washer Washer

6P21H11

Q’ty 1 1 2 1 6 1 1 6 6 6

1 2 3 4 5 6 7 8 9

Remarks

M10 × 190 mm M10 × 200 mm M10 × 174 mm

6-2

LOWR

Lower unit 6

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

6-3

Part name Shift rod Oil seal Oil seal housing O-ring Bolt Seal Woodruff key Bolt Water pump housing O-ring Insert cartridge O-ring Impeller Outer plate cartridge Gasket Dowel Dowel

Q’ty 1 1 1 1 3 1 1 4 1 1 1 1 1 1 1 2 2

Remarks Not reusable Not reusable

M6 × 20 mm

M8 × 45 mm Not reusable Not reusable

Not reusable

6P21H11

Lower unit (regular rotation model)

Removing the lower unit 1. Drain the gear oil.

3. Mark the trim tab 1 at the area shown, and then remove it. 4. Loosen the bolts (nuts), and then remove the lower unit from the upper case.

2. Set the gear shift to the neutral position, and place a block of wood between the anti-cavitation plate and propeller to keep the propeller from turning, and then remove the propeller nut and propeller. È U-transom model

Removing the water pump and shift rod 1. Remove the water pump housing 1 and impeller 2. 2. Remove the Woodruff key 3. 3. Remove the outer plate cartridge 4.

WARNING • Do not hold the propeller with your hands when loosening or tightening it. • Be sure to disconnect the battery cables from the battery and the clip from the engine stop lanyard switch. • Put a block of wood between the anticavitation plate and propeller to keep the propeller from turning. • When removing the lower unit with the power unit installed, be sure to suspend the outboard motor. If the outboard motor is not suspended it can fall suddenly and result in severe injury.

6P21H11

6-4

1 2 3 4 5 6 7 8 9

LOWR

Lower unit

4. Set the gear shift to the neutral position, and then remove the shift rod assembly 5.

Shift rod push arm: YB-06052

Checking the water pump and shift rod 1. Check the water pump housing. Replace if there is deformation. 2. Check the impeller and insert cartridge. Replace if cracked or worn. 3. Check the Woodruff key 1 and the groove a on the drive shaft. Replace if worn.

a 1

S6P26660

4. Check the shift rod. Replace if cracked or worn.

6-5

6P21H11

Lower unit (regular rotation model) / Propeller shaft housing (regular rotation model)

Propeller shaft housing (regular rotation model)

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Part name Water pipe Rubber seal Rubber seal Shift rod joint Ball Slider Shift plunger Dog clutch Cross pin Spring Propeller shaft Shim Reverse gear Reverse gear shim Ball bearing O-ring Propeller shaft housing

6P21H11

Qâ&#x20AC;&#x2122;ty 1 1 1 1 2 1 1 1 1 1 1 1 1 â&#x20AC;&#x201D; 1 1 1

1 2 3 4 5 6 7 8 9

Remarks

Not reusable Not reusable

6-6

LOWR

Lower unit 6

No. 18 19 20 21 22 23 24 25 26 27 28 29 30

6-7

Part name Dowel Grease nipple Rubber seal O-ring Needle bearing Oil seal Ring Bolt Bolt Washer Cooling water inlet cover Nut Screw

Q’ty 1 1 1 1 1 2 1 2 2 2 2 1 1

Remarks Not reusable

Not reusable Not reusable

M8 × 20 mm M8 × 33 mm

ø5 × 53 mm

6P21H11

Propeller shaft housing (regular rotation model)

Removing the propeller shaft housing assembly

Disassembling the propeller shaft assembly

1. Remove the water pipe 1 and shift rod 2.

1. Remove the spring 1, and then remove the cross pin 2, dog clutch 3, shift plunger 4, slider 5, and shift rod joint 6.

2. Remove the bolts 3, ring 4, and bolts 5.

Disassembling the propeller shaft housing 1. Remove the reverse gear and reverse gear shim(s).

3. Pull out the propeller shaft housing with the propeller shaft.

7 Slide hammer 1: YB-06096

S6P26730

NOTE: Before removing the propeller shaft from the lower case, remove the shift rod. Slide hammer 6: YB-06096 Propeller shaft and bearing housing remover 7: YB-06335

6P21H11

6-8

1 2 3 4 5 6 7 8 9

LOWR

Lower unit

Checking the propeller shaft

2. Remove the ball bearing.

1. Check the propeller shaft. Replace if bent or worn.

2. Measure the propeller shaft runout.

S6P26740

CAUTION: Do not reuse the bearing, always replace it with a new one. Slide hammer 1: YB-06096 Bearing puller legs 2: YB-06523 3. Remove the oil seals and needle bearing.

S6P26200C

Runout limit: 0.02 mm (0.0008 in) 3. Check the dog clutch, shift rod joint, and slider. Replace if cracked or worn.

Assembling the propeller shaft assembly 1. Install the dog clutch 1 as shown.

Drive shaft bearing installer 3: YB-06155 Driver handle (large) 4: YB-06071

Checking the propeller shaft housing 1. Clean the propeller shaft housing using a soft brush and cleaning solvent, and then check it. Replace if cracked or damaged. 2. Check the teeth and dogs of the reverse gear. Replace if cracked or worn.

NOTE: Install the dog clutch 1 with the â&#x20AC;&#x153;Fâ&#x20AC;? mark a facing toward the shift plunger.

Assembling the propeller shaft housing 1. Install the needle bearing into the propeller shaft housing to the specified depth.

3. Check the bearings. Replace if pitted or if there is rumbling.

6-9

6P21H11

Propeller shaft housing (regular rotation model) 3. Install the new ball bearing into the propeller shaft housing.

NOTE: Install the needle bearing with the manufacture identification mark a facing toward the oil seal (propeller side). Driver handle (large) 1: YB-06071 Drive shaft needle bearing installer and remover 2: YB-06196

NOTE: Install the ball bearing with the manufacture identification mark facing toward the propeller shaft housing (propeller side). Driver handle (large) 1: YB-06071 Forward bearing installer 4: YB-06430

Depth b: 25.3 ± 0.25 mm (1.00 ± 0.01 in) 2. Apply grease to the new oil seals, and then install them into the propeller shaft housing to the specified depth.

NOTE: Install an oil seal halfway into the propeller shaft housing, then the other oil seal. Driver handle (large) 1: YB-06071 Oil seal installer 3: YB-06195-A Depth c: 5.0 ± 0.25 mm (0.20 ± 0.01 in)

6P21H11

6-10

1 2 3 4 5 6 7 8 9

LOWR

Lower unit

4. Install the reverse gear 5 and original shim(s) 6 into the propeller shaft housing using a press.

NOTE: • Be sure to select the reverse gear shim(s) if replacing the propeller shaft housing, lower case, or ball bearing. Select the propeller shaft shim if replacing the reverse gear. • To select the shims, see “Shimming (regular rotation model).” • After installing the reverse gear and shim(s), check that the reverse gear rotates smoothly. Bearing outer race attachment 7: YB-06109

6-11

6P21H11

Propeller shaft housing (regular rotation model) / Drive shaft and lower case (regular rotation model)

Drive shaft and lower case (regular rotation model)

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Part name Drive shaft Thrust bearing Spring Washer Cover Oil seal Bolt Drive shaft housing Needle bearing O-ring Pinion shim Thrust bearing Lower case Needle bearing assembly Pinion Washer Nut

6P21H11

Q’ty 1 1 1 1 1 2 4 1 1 1 — 1 1 1 1 1 1

1 2 3 4 5 6 7 8 9

Remarks

Not reusable

M8 × 25 mm

Not reusable

6-12

LOWR

Lower unit 6

No. 18 19 20

6-13

Part name Forward gear shim Taper roller bearing assembly Forward gear

Q’ty — 1 1

Remarks Not reusable

6P21H11

Drive shaft and lower case (regular rotation model)

Removing the drive shaft 1. Loosen the pinion nut.

1 1

S69J6186

S68S6150

Drive shaft holder 1: YB-06201 2. Remove the drive shaft, drive shaft housing, pinion, thrust bearing, spring and washer. 3. Pull out the forward gear.

CAUTION: Do not reuse the bearing, always replace it with a new one. Bearing splitter plate 1: (commercially available)

Disassembling the lower case 1. Remove the taper roller bearing outer race and shim(s).

Disassembling the drive shaft housing 1. Remove the cover, oil seals, and needle bearing.

NOTE: Install the claws as shown. Slide hammer 1: YB-06096 Bearing puller legs 2: YB-06523 Drive shaft needle bearing installer and remover 1: YB-06196 Driver handle (large) 2: YB-06071

Disassembling the forward gear 1. Remove the taper roller bearing from the forward gear using a press.

6P21H11

6-14

1 2 3 4 5 6 7 8 9

LOWR

Lower unit

2. Remove the needle bearing from the lower case.

Roller bearing installer/remover 3: YB-06432 Driver handle (large) 4: YB-06071

Checking the pinion and forward gear 1. Check the teeth of the pinion, and the teeth and dogs of the forward gear. Replace if cracked or worn.

Checking the bearing 1. Check the bearings. Replace if pitted or if there is rumbling.

Checking the drive shaft 1. Check the drive shaft. Replace if bent or worn.

Assembling the lower case 1. Install the original shim(s) and taper roller bearing outer race.

NOTE: • Be sure to select the forward gear shim(s) if replacing the lower case or taper roller bearing assembly. Select the propeller shaft shim if replacing the forward gear. • To select the shims, see “Shimming (regular rotation model).” Taper roller bearing installer 1: YB-06431 Driver handle (large) 2: YB-06071 2. Install the needle bearing into the lower case.

2. Measure the drive shaft runout.

S6P26210

NOTE: • Apply gear oil to the needle bearing outer case before installation. • The needle bearing contains 24 rollers.

Runout limit: 0.2 mm (0.008 in)

Checking the lower case 1. Check the skeg and torpedo. Replace the lower case if cracked or damaged.

6-15

6P21H11

Drive shaft and lower case (regular rotation model) Roller bearing installer/remover 3: YB-06432 Pinion gear bushing installer 4: YB-06029-4 Needle bearing guide plate 5: YB-06213

2. Apply grease to the new oil seals, and then install them into the drive shaft housing to the specified depth.

2 3

Assembling the forward gear 1. Install a new taper roller bearing into the forward gear using a press. S6P26120C

NOTE: Install an oil seal halfway into the drive shaft housing, then the other oil seal. Driver handle (large) 2: YB-06071 Forward gear outer race installer 3: YB-06085 Forward gear bearing cup installer 1: YB-06276-B

Depth b: 0.5 ± 0.25 mm (0.02 ± 0.01 in)

Assembling the drive shaft housing

Installing the drive shaft

1. Install the needle bearing into the drive shaft housing to the specified depth.

1. Install the forward gear into the lower case. 2. Install the washer, spring and thrust bearing into the lower case.

Drive shaft needle bearing installer and remover 1: YB-06196 Driver handle (large) 2: YB-06071 Depth a: 4.5 ± 0.25 mm (0.18 ± 0.01 in)

6P21H11

6-16

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LOWR

Lower unit

3. Install the drive shaft housing 1, thrust bearing 2, and original shim(s) 3 onto the drive shaft 4.

NOTE: Apply LOCTITE 572 to the drive shaft housing bolts before installation.

Installing the propeller shaft housing 1. Set the shift rod joint and dog clutch to the neutral position 1 as shown. 2. Install the propeller shaft shim 2 and propeller shaft assembly 3 into the propeller shaft housing. NOTE: • Be sure to select the pinion shim(s) if replacing the thrust bearing, drive shaft housing, drive shaft or lower case. • To select the shims, see “Shimming (regular rotation model).”

3. Apply grease to the new O-rings and propeller shaft housing.

4. Install the drive shaft and drive shaft housing into the lower case, then the pinion, washer and pinion nut, and then tighten the nut to the specified torque.

S63P6300

NOTE: To install the pinion nut, push down on the drive shaft.

Drive shaft holder 5: YB-06201

NOTE: • Be sure to select the propeller shaft shim if replacing propeller shaft, forward gear or reverse gear. • To select the shims, see “Shimming (regular rotation model).” 4. Install the propeller shaft housing assembly into the lower case, and then tighten the bolts 4 to the specified torque. 5. Install the ring 5 and bolts 6.

T. R.

Pinion nut: 142 N·m (14.2 kgf·m, 104.7 ft·lb)

5. Tighten the drive shaft housing bolts.

6-17

6P21H11

Drive shaft and lower case (regular rotation model)

T. R.

Propeller shaft housing bolt 4: 30 N·m (3.0 kgf·m, 22.1 ft·lb)

6. Install the water pipe and rubber seals.

Installing the water pump and shift rod 1. Install the shift rod assembly 1. 3. Install the Woodruff key into the drive shaft. 4. Align the groove on the impeller 5 with the Woodruff key 6, and then install the impeller onto the drive shaft.

NOTE: • Check the gear shift to the neutral position, when installing the shift rod. • After assembling the lower unit, check that the shift rod operates smoothly, and check that the drive shaft and propeller shaft rotate smoothly. 2. Install a new gasket 2, the outer plate cartridge 3, and dowels 4.

6P21H11

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Lower unit

5. Install the new O-ring 7 and insert cartridge 8 into the pump housing 9.

7 A

NOTE: â&#x20AC;˘ When installing the pump housing, apply grease to the inside of the housing, and then turn the drive shaft clockwise while pushing down the pump housing. â&#x20AC;˘ Align the cover projection c with the hole d in the pump housing.

Installing the lower unit

b 1104J

S6P26110

NOTE: Align the insert cartridge projections a with the holes b in the pump housing. 6. Install the new O-ring 0 and pump housing assembly A into the lower case, tighten the bolts B, and then install the seal C and cover D.

WARNING When installing the lower unit with the power unit installed, be sure to suspend the outboard motor. If the outboard motor is not suspended it can fall suddenly and result in severe injury. 1. Align the center of the set pin a with the alignment mark b on the bottom cowling.

2. Set the gear shift to the neutral position at the lower unit.

CAUTION: Do not turn the drive shaft counterclockwise, otherwise the water pump impeller may be damaged. Shift rod push arm: YB-06052 3. Install the dowels 1 into the lower unit.

6-19

6P21H11

Drive shaft and lower case (regular rotation model) 4. Install the lower unit into the upper case, and then tighten the lower case mounting bolts (nuts) 2 to the specified torque. 5. Install the trim tab 3 to its original position, and then tighten the bolt 4 to the specified torque.

WARNING

È U-transom model

T. R.

Lower case mounting bolt (nut) 2: 47 N·m (4.7 kgf·m, 34.7 ft·lb) Trim tab bolt 4: 42 N·m (4.2 kgf·m, 31.0 ft·lb)

6. Install the propeller and propeller nut, and then tighten the nut temporary. Place a block of wood between the anti-cavitation plate and propeller to keep the propeller from turning, and then tighten the nut to the specified torque.

• Do not hold the propeller with your hands when loosening or tightening it. • Be sure to disconnect the battery cables from the battery and the clip from the engine stop lanyard switch. • Put a block of wood between the anticavitation plate and propeller to keep the propeller from turning. NOTE: If the grooves in the propeller nut 5 do not align with the cotter pin hole, tighten the nut until they are aligned.

T. R.

Propeller nut 5: 54 N·m (5.4 kgf·m, 39.8 ft·lb)

7. Fill the gear oil to the correct level.

6P21H11

6-20

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LOWR

Lower unit

Shimming (regular rotation model)

F P

65.0

C2 T4 B5

B1 39.4 41.0 A1

S6P26270

6-21

6P21H11

Shimming (regular rotation model)

Shimming

1. Calculate the specified value M0 as shown in the examples below.

NOTE: “P” is the deviation of the lower case dimension from standard. The “P” mark a is stamped on the trim tab mounting surface of the lower case in 0.01 mm units. If the “P” mark is unreadable, assume that “P” is zero and check the backlash when the unit is assembled.

Selecting the pinion shim

Pinion gear shim gauge 4: YB-06441

NOTE: • Shimming is not required when assembling the original lower case and inner parts. • Shimming is required when assembling the original inner parts and a new lower case. • Shimming is required when replacing the inner part(s).

3. Install the pinion and pinion nut, and then tighten the nut to the specified torque.

Pinion nut: 142 N·m (14.2 kgf·m, 104.7 ft·lb)

4. Measure the clearance M between the special service tool and the pinion as shown.

NOTE: Measure the pinion at 3 points to find the clearance average.

Calculation formula: Specified value M0 = 1.00 + P/100 mm Example: If “P” is (+2), then M0 = 1.00 + (+2)/100 mm = 1.00 + 0.02 mm = 1.02 mm If “P” is (–3), then M0 = 1.00 + (–3)/100 mm = 1.00 – 0.03 mm = 0.97 mm 2. Install the drive shaft 1, thrust bearing 2, and drive shaft housing 3 onto the special service tool.

6P21H11

6-22

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LOWR

Lower unit

5. Select the pinion shim(s) T3.

Example: If “F” is (+5), then M0 = 0.60 – (+5)/100 mm = 0.60 – 0.05 mm = 0.55 mm If “F” is (–3), then M0 = 0.60 – (–3)/100 mm = 0.60 + 0.03 mm = 0.63 mm 2. Set the special service tool on the taper roller bearing.

NOTE: The sum of T3 and M should not be more than M0.

3. Measure the clearance M between the special service tool and the bearing outer race 2 as shown.

Calculation formula: Pinion shim thickness T3 = M0 – M Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm

Selecting the forward gear shim 1. Calculate the specified value M0 as shown in the examples below.

NOTE: Measure the taper roller bearing at 3 points to find the clearance average.

Shim gauge 1: YB-06439 4. Select the forward gear shim(s) T1.

NOTE: “F” is the deviation of the lower case dimension from standard. The “F” mark a is stamped on the trim tab mounting surface of the lower case in 0.01 mm units. If the “F” mark is unreadable, assume that “F” is zero and check the backlash when the unit is assembled.

NOTE: The sum of T1 and M0 should not be more than M.

Calculation formula: Specified value M0 = 0.60 – F/100 mm

6-23

6P21H11

Shimming (regular rotation model) Calculation formula: Forward gear shim thickness T1 = M – M0

4. Measure the clearance M between the special service tool and the ball bearing 2 as shown.

Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm

Selecting the reverse gear shim 1. Calculate the specified value M0 as shown in the examples below. NOTE: Measure the ball bearing at 3 points to find the clearance average.

Shim gauge 1: YB-06439 5. Select the reverse gear shim(s) T2. NOTE: “R” is the deviation of the lower case dimension from standard. The “R” mark a is stamped on the trim tab mounting surface of the lower case in 0.01 mm units. If the “R” mark is unreadable, assume that “R” is zero and check the backlash when the unit is assembled. Calculation formula: Specified value M0 = 0.50 – R/100 mm Example: If “R” is (+5), then M0 = 0.50 – (+5)/100 mm = 0.50 – 0.05 mm = 0.45 mm If “R” is (–3), then M0 = 0.50 – (–3)/100 mm = 0.50 + 0.03 mm = 0.53 mm 2. Install the ball bearing into the propeller shaft housing.

NOTE: The sum of T2 and M0 should not be more than M. Calculation formula: Reverse gear shim thickness T2 = M – M0 Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm

3. Set the special service tool on the ball bearing.

6P21H11

6-24

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LOWR

Lower unit

Selecting the propeller shaft shim NOTE: Be sure to make this measurement in metrics. 1. Measure the forward gear height M1, M2 as shown and then calculate the value C1.

C2 M3 M4

S6P26340

C1 M1 M2

S6P26330

S6P26360

Calculation formula: Reverse gear height C2 = M3 â&#x20AC;&#x201C; M4 3. Measure the propeller shaft spline width C3. S6P26360

Digital vernier calipers: YU-A5400

Calculation formula: Forward gear height C1 = M1 â&#x20AC;&#x201C; M2 2. Measure the reverse gear height M3, M4 as shown and then calculate the value C2. S6P26370

4. Select the propeller shaft shim T4.

6-25

6P21H11

Shimming (regular rotation model) / Backlash (regular rotation model) Backlash adjustment plate 1: YB-07003 Dial indicator gauge 2: YU-03097 Magnetic base stand 3: YU-A8438

Backlash (regular rotation model)

Measuring the forward and reverse gear backlash NOTE: Select the shim with the closest thickness. Calculation formula: Propeller shaft shim thickness T4 = 79.8 – C1 – C2 – C3 Calculated numeral

Shim thickness (mm)

1.81–1.84

1.80

1.85–1.94

1.90

1.95–2.04

2.00

2.05–2.14

2.10

2.15–2.20

2.20

1. Remove the water pump assembly. 2. Set the gear shift to the neutral position at the lower unit.

Shift rod push arm: YB-06052 5. Assembling the lower unit. 6. Measure the propeller shaft axial free play. Reselect the propeller shaft shim if out of specification.

3. Install the special service tools so that it pushes against the propeller shaft.

3 2 1

S6P26530

Propeller shaft free play: 0.20–0.50 mm (0.0079–0.0197 in)

NOTE: Tighten the universal puller while turning the drive shaft until the drive shaft can no longer be turned. Bearing housing puller 1: YB-06207 Universal puller 2: YB-06117

6P21H11

6-26

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LOWR

Lower unit

4. Install the backlash indicator onto the drive shaft (22.4 mm [0.88 in] in diameter), and then install the dial gauge.

Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm 7. Remove the special service tools from the propeller shaft. 8. Apply a load to the reverse gear by installing the propeller 7, the spacer 8 (without the washer 9), then the washer 0 as shown.

NOTE: Install the dial gauge so that the plunger a contacts the mark b on the backlash indicator. Backlash indicator rod 3: YB-06265 Backlash adjustment plate 4: YB-07003 Dial indicator gauge 5: YU-03097 Magnetic base stand 6: YU-A8438 5. Slowly turn the drive shaft clockwise and counterclockwise and measure the backlash when the drive shaft stops in each direction.

NOTE: Tighten the propeller nut A while turning the drive shaft until the drive shaft can no longer be turned. 9. Slowly turn the drive shaft clockwise and counterclockwise and measure the backlash when the drive shaft stops in each direction.

Forward gear backlash: 0.32–0.55 mm (0.0126–0.0216 in) 6. Add or remove shim(s) if out of specification. Forward gear backlash

Shim thickness

Less than 0.32 mm (0.0126 in)

To be decreased by (0.44 – M) × 0.71

More than 0.55 mm (0.0216 in)

To be increased by (M – 0.44) × 0.71

M: Measurement

6-27

Reverse gear backlash: 0.32–0.65 mm (0.0126–0.0256 in)

6P21H11

Backlash (regular rotation model) 10. Add or remove shim(s) if out of specification. Reverse gear backlash

Shim thickness

Less than 0.32 mm (0.0126 in)

To be decreased by (0.49 – M) × 0.71

More than 0.65 mm (0.0256 in)

To be increased by (M – 0.49) × 0.71

1 2 3 4 5 6 7 8 9

M: Measurement Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm 11. Remove the special service tools, and then install the water pump assembly.

6P21H11

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Lower unit

Lower unit (counter rotation model)

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

6-29

Part name Lower unit Plate Rubber seal Check screw Gasket Bolt Drain screw Grommet Bolt Bolt Spacer Propeller Washer Washer Cotter pin Propeller nut Trim tab

Q’ty 1 1 1 1 2 7 1 1 1 1 1 1 1 1 1 1 1

Remarks

Not reusable

M10 × 45 mm/X-transom model

M10 × 45 mm M10 × 70 mm/X-transom model

Not reusable

6P21H11

Lower unit (counter rotation model) 6

No. 18 19 20 21 22 23 24 25 26 27

Part name Extension Rubber seal Dowel Rubber seal Stud bolt Bolt Bolt Nut Spring washer Washer

6P21H11

Q’ty 1 1 2 1 6 1 1 6 6 6

1 2 3 4 5 6 7 8 9

Remarks

M10 × 190 mm M10 × 200 mm M10 × 174 mm

6-30

LOWR

Lower unit 6

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

6-31

Part name Shift rod Oil seal Oil seal housing O-ring Bolt Seal Woodruff key Bolt Water pump housing O-ring Insert cartridge O-ring Impeller Outer plate cartridge Gasket Dowel Dowel

Q’ty 1 1 1 1 3 1 1 4 1 1 1 1 1 1 1 2 2

Remarks Not reusable Not reusable

M6 × 20 mm

M8 × 45 mm Not reusable Not reusable

Not reusable

6P21H11

Lower unit (counter rotation model)

Removing the lower unit 1. Drain the gear oil.

3. Mark the trim tab 1 at the area shown, and then remove it. 4. Loosen the bolts (nuts), and then remove the lower unit from the upper case.

6P21H11

6-32

1 2 3 4 5 6 7 8 9

LOWR

Lower unit

Removing the water pump and shift rod 1. Remove the water pump housing 1 and impeller 2.

a 1

2. Remove the Woodruff key 3. 3. Remove the outer plate cartridge 4. 4. Set the gear shift to the neutral position, and then remove the shift rod assembly 5.

S6P26660

4. Check the shift rod. Replace if cracked or worn.

Shift rod push arm: YB-06052

6-33

6P21H11

Lower unit (counter rotation model) / Propeller shaft housing (counter rotation model)

Propeller shaft housing (counter rotation model)

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Part name Water pipe Rubber seal Rubber seal Shift rod joint Ball Slider Shift plunger Dog clutch Cross pin Spring Forward gear Forward gear shim Ring nut Claw washer Taper roller bearing assembly Propeller shaft Thrust bearing

6P21H11

Qâ&#x20AC;&#x2122;ty 1 1 1 1 2 1 1 1 1 1 1 â&#x20AC;&#x201D; 1 1 1 1 1

1 2 3 4 5 6 7 8 9

Remarks

Not reusable

6-34

LOWR

Lower unit 6

No. 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

6-35

Part name Propeller shaft shim O-ring Propeller shaft housing Dowel Grease nipple Rubber seal O-ring Needle bearing Oil seal Ring Bolt Bolt Washer Cooling water inlet cover Nut Screw

Q’ty — 1 1 1 1 1 1 1 2 1 2 2 2 2 1 1

Remarks Not reusable Not reusable

Not reusable Not reusable

M8 × 20 mm M8 × 33 mm

ø5 × 53 mm

6P21H11

Propeller shaft housing (counter rotation model)

Removing the propeller shaft housing assembly

Disassembling the propeller shaft housing

1. Remove the water pipe 1 and shift rod 2.

1. Remove the spring 1, and then remove the cross pin 2, dog clutch 3, slider, shift plunger, and shift rod joint.

3 2. Remove the bolts 3, ring 4, and bolts 5.

1 S69J6375

2. Remove the forward gear and forward gear shim(s) from the propeller shaft housing using a press.

3. Pull out the propeller shaft housing with the propeller shaft. Bearing splitter plate 4: (commercially available)

7 6

3. Remove the dowel from the lower case. 4. Install the propeller shaft housing assembly in the reverse direction into the lower case. S6P26730

NOTE: Before removing the propeller shaft from the lower case, remove the shift rod. Slide hammer 6: YB-06096 Propeller shaft and bearing housing remover 7: YB-06335

6P21H11

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Lower unit

5. Remove the ring nut 5 and claw washer 6.

Ring nut wrench 7: YB-06578 6. Remove the bearing outer race 8, taper roller bearing 9, thrust bearing 0, and propeller shaft shim(s) A using a press.

Drive shaft bearing installer B: YB-06155 Driver handle (large) C: YB-06071

Checking the propeller shaft 1. Check the propeller shaft. Replace if bent or worn. 2. Measure the propeller shaft runout.

CAUTION: â&#x20AC;˘ Do not press the propeller shaft threads a directly. â&#x20AC;˘ Do not reuse the taper roller bearing, always replace it with a new one. 7. Remove the oil seals and needle bearing.

6-37

S6P26220C

Runout limit: 0.02 mm (0.0008 in) 3. Check the dog clutch, shift rod joint, and slider. Replace if cracked or worn.

6P21H11

Propeller shaft housing (counter rotation model)

Assembling the propeller shaft housing 1. Install the needle bearing into the propeller shaft housing to the specified depth.

Depth c: 5.0 ± 0.25 mm (0.20 ± 0.01 in) 3. Install the original shim(s) 4 and thrust bearing 5 with the propeller shaft into the propeller shaft housing.

NOTE: • Be sure to select the propeller shaft shim(s) if replacing the propeller shaft, propeller shaft housing, thrust bearing or taper roller bearing. • To select the shims, see “Shimming (counter rotation model).”

Depth b: 25.3 ± 0.25 mm (1.00 ± 0.01 in) 2. Apply grease to the new oil seals, and then install them into the propeller shaft housing to the specified depth.

NOTE: Install an oil seal halfway into the propeller shaft housing, then the other oil seal. Driver handle (large) 1: YB-06071 Oil seal installer 3: YB-06195-A 6P21H11

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LOWR

Lower unit

4. Install the new taper roller bearing 6 and bearing outer race 7 into the propeller shaft housing using a press.

Gland nut wrench 8: YB-06578

T. R.

NOTE: After installing the taper roller bearing and bearing outer race, check that the propeller shaft rotates smoothly.

Ring nut 0: 108 N·m (10.8 kgf·m, 79.7 ft·lb)

7. Install the original shim(s) A, forward gear B, and dog clutch C using a press.

Gland nut wrench 8: YB-06578 5. Install the propeller shaft housing assembly in the reverse direction into the lower case.

6. Install the claw washer 9 and ring nut 0, and then tighten the ring nut to the specified torque.

NOTE: • Be sure to select the forward gear shim(s) if replacing the propeller shaft housing, taper roller bearing, or lower case. • To select shims, see “Shimming (counter rotation model).” • Install the dog clutch C with the “F” mark d facing toward the forward gear. • After installing the forward gear, check that the propeller shaft and forward gear rotate smoothly.

Gland nut wrench 8: YB-06578

6-39

6P21H11

Propeller shaft housing (counter rotation model) 8. Install the shift plunger D and slider E into the propeller shaft, and then install the cross pin F and spring G.

1 2 3 4 5 6 7 8 9

E F

S6P26770

6P21H11

6-40

LOWR

Lower unit

Drive shaft and lower case (counter rotation model)

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

6-41

Part name Drive shaft Thrust bearing Spring Washer Cover Oil seal Bolt Drive shaft housing Needle bearing O-ring Pinion shim Thrust bearing Lower case Needle bearing Pinion Washer Nut

Q’ty 1 1 1 1 1 2 4 1 1 1 — 1 1 1 1 1 1

Remarks

Not reusable

M8 × 25 mm

Not reusable

6P21H11

Drive shaft and lower case (counter rotation model) 6

No. 18 19 20 21 22 23 24

Part name Reverse gear shim Retainer Needle bearing Thrust bearing Circlip Needle bearing Reverse gear

6P21H11

Q’ty — 1 1 1 1 1 1

1 2 3 4 5 6 7 8 9

Remarks

Not reusable Not reusable

6-42

LOWR

Lower unit

Removing the drive shaft 1. Loosen the pinion nut.

S6P26190

S68S6150

2. Remove the needle bearing from the reverse gear as shown.

Drive shaft holder 1: YB-06201 2. Remove the drive shaft, drive shaft housing, pinion, thrust bearing, spring and washer. 3. Pull out the reverse gear.

Disassembling the drive shaft housing 1. Remove the cover, oil seals, and needle bearing.

S68S6160

CAUTION: Do not reuse the bearing, always replace it with a new one.

Disassembling the lower case 1. Remove the retainer and shim(s).

Drive shaft needle bearing installer and remover 1: YB-06196 Driver handle (large) 2: YB-06071

Disassembling the reverse gear 1. Remove the circlip 1 from the reverse gear 2.

Universal puller 1: YB-06117 Reverse gear bearing remover 2: YB-41707 2. Remove the needle bearing from the retainer.

6-43

6P21H11

Drive shaft and lower case (counter rotation model)

S6P26210

Needle bearing installer 3: YB-06434 Driver handle (large) 4: YB-06071

Runout limit: 0.2 mm (0.008 in)

Checking the lower case 3. Remove the needle bearing from the lower case.

1. Check the skeg and torpedo. Replace the lower case if cracked or damaged.

Assembling the lower case 1. Install the needle bearing into the retainer to the specified depth.

Roller bearing installer/remover 4: YB-06432 Driver handle (large) 5: YB-06071

Checking the pinion and reverse gear 1. Check the teeth of the pinion, and the teeth and dogs of the reverse gear. Replace if cracked or worn.

Checking the bearing

Needle bearing installer 1: YB-06434 Driver handle (large) 2: YB-06071 Depth a: 0 Âą 0.25 mm (0 Âą 0.01 in)

1. Check the bearings. Replace if pitted or if there is rumbling.

Checking the drive shaft 1. Check the drive shaft. Replace if bent or worn. 2. Measure the drive shaft runout.

6P21H11

6-44

1 2 3 4 5 6 7 8 9

LOWR

Lower unit

2. Install the original shim(s) and retainer halfway into the lower case using the special service tools assembled as shown A, and then install them completely into the lower case using the special service tools assembled as shown B.

NOTE: • Apply gear oil to the needle bearing outer case before installation. • The needle bearing contains 24 rollers. S6P26170C

Roller bearing installer/remover 4: YB-06432 Pinion gear bushing installer 5: YB-06029-4 Needle bearing guide plate 6: YB-06213

Assembling the reverse gear

B S6P26700

1. Install the new needle bearing into the reverse gear to the specified depth.

CAUTION: If the shim(s) and retainer are installed completely into the lower case using the special service tools assembled as shown A, the lower case may be damaged or deformed. NOTE: • Be sure to select the reverse gear shim(s) if replacing the thrust bearing, retainer or lower case. • To select the shims, see “Shimming (counter rotation model).” Driver handle (large) 2: YB-06071 Forward bearing installer 3: YB-06430

Needle bearing installer 1: YB-06435 Driver handle (large) 2: YB-06071 Depth a: 7 ± 0.25 mm (0.28 ± 0.01 in) 2. Install the new circlip 3 into the reverse gear 4.

3. Install the needle bearing into the lower case.

6-45

6P21H11

Drive shaft and lower case (counter rotation model)

NOTE: Install an oil seal halfway into the drive shaft housing, then the other oil seal. Driver handle (large) 2: YB-06071 Forward gear outer race installer 3: YB-06085

S6P26230

Assembling the drive shaft housing 1. Install the needle bearing into the drive shaft housing to the specified depth.

Depth b: 0.5 ± 0.25 mm (0.02 ± 0.01 in)

Installing the drive shaft 1. Install the thrust bearing and reverse gear into the lower case.

Drive shaft needle bearing installer and remover 1: YB-06196 Driver handle (large) 2: YB-06071

2. Install the washer, spring and thrust bearing into the lower case.

Depth a: 4.5 ± 0.25 mm (0.18 ± 0.01 in) 2. Apply grease to the new oil seals, and then install them into the drive shaft housing to the specified depth.

2 3

S6P26120C

6P21H11

6-46

1 2 3 4 5 6 7 8 9

LOWR

Lower unit

3. Install the drive shaft housing 1, thrust bearing 2, and original shim(s) 3 onto the drive shaft 4.

NOTE: Apply LOCTITE 572 to the drive shaft housing bolts before installation.

Installing the propeller shaft housing 1. Set the shift rod joint and dog clutch to the neutral position as shown. 2. Apply grease to the new O-rings and propeller shaft housing.

NOTE: • Be sure to select the pinion shim(s) if replacing the thrust bearing, drive shaft housing, drive shaft or lower case. • To select the shims, see “Shimming (counter rotation model).”

3. Install the dowel and propeller shaft housing assembly into the lower case.

4. Install the drive shaft and drive shaft housing into the lower case, then the pinion, washer and pinion nut, and then tighten the nut to the specified torque.

5 S6P26190E

4. Install the washer and propeller shaft housing bolts 1, and then tighten the bolts to the specified torque. 5. Install the ring 2 and bolts 3. S63P6300

NOTE: To install the pinion nut, push down on the drive shaft.

Drive shaft holder 5: YB-06201

T. R.

Pinion nut: 142 N·m (14.2 kgf·m, 104.7 ft·lb)

5. Tighten the drive shaft housing bolts.

6-47

Propeller shaft housing bolt 1: 30 N·m (3.0 kgf·m, 22.1 ft·lb)

6. Install the water pipe and rubber seals.

6P21H11

Drive shaft and lower case (counter rotation model)

Installing the water pump and shift rod 1. Install the shift rod assembly 1.

3. Install the Woodruff key into the drive shaft. NOTE: â&#x20AC;˘ Check the gear shift to the neutral position, when installing the shift rod. â&#x20AC;˘ After assembling the lower unit, check that the shift rod operates smoothly, and check that the drive shaft and propeller shaft rotate smoothly.

4. Align the groove on the impeller 5 with the Woodruff key 6, and then install the impeller onto the drive shaft.

2. Install a new gasket 2, the outer plate cartridge 3, and dowels 4.

6P21H11

6-48

1 2 3 4 5 6 7 8 9

LOWR

Lower unit

5. Install the new O-ring 7 and insert cartridge 8 into the pump housing 9.

7 A

Installing the lower unit

b 1104J

S6P26110

2. Set the gear shift to the neutral position at the lower unit.

CAUTION: Do not turn the drive shaft counterclockwise, otherwise the water pump impeller may be damaged. Shift rod push arm: YB-06052 3. Install the dowels 1 into the lower unit.

6-49

6P21H11

Drive shaft and lower case (counter rotation model) 4. Install the lower unit into the upper case, and then tighten the lower case mounting bolts (nuts) 2 to the specified torque. 5. Install the trim tab 3 to its original position, and then tighten the bolt 4 to the specified torque.

WARNING

È U-transom model

T. R.

Lower case mounting bolt (nut) 2: 47 N·m (4.7 kgf·m, 34.7 ft·lb) Trim tab bolt 4: 42 N·m (4.2 kgf·m, 31.0 ft·lb)

T. R.

Propeller nut 5: 54 N·m (5.4 kgf·m, 39.8 ft·lb)

7. Fill the gear oil to the correct level.

6P21H11

6-50

1 2 3 4 5 6 7 8 9

LOWR

Lower unit

Shimming (counter rotation model)

F P

65.0

B8 B5 A5 T2

B1 38.4 47.5 A1 B7 B6

A4 A2 TÂ´4

S6P26300

6-51

6P21H11

Shimming (counter rotation model)

Shimming

1. Calculate the specified value M0 as shown in the examples below.

Selecting the pinion shim

Pinion gear shim gauge 4: YB-06441

3. Install the pinion and pinion nut, and then tighten the nut to the specified torque.

Pinion nut: 142 N·m (14.2 kgf·m, 104.7 ft·lb)

4. Measure the clearance M between the special service tool and the pinion as shown.

NOTE: Measure the pinion at 3 points to find the clearance average.

6P21H11

6-52

1 2 3 4 5 6 7 8 9

LOWR

Lower unit

5. Select the pinion shim(s) T3.

Example: If “F” is (+5), then M0 = 30.60 + (+5)/100 mm = 30.60 + 0.05 mm = 30.65 mm If “F” is (–3), then M0 = 30.60 + (–3)/100 mm = 30.60 – 0.03 mm = 30.57 mm 2. Set the thrust bearing 1 to the bearing retainer 2 as shown.

NOTE: The sum of T3 and M should not be more than M0.

3. Turn the thrust bearing 2 or 3 times to seat the bearing retainer, and then measure the bearing height M.

Calculation formula: Pinion shim thickness T3 = M0 – M Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm

Selecting the reverse gear shim 1. Calculate the specified value M0 as shown in the examples below.

NOTE: Measure the bearing retainer at 3 points to find the clearance average. 4. Select the reverse gear shim(s) T1.

6-53

NOTE: The sum of T1 and M should not be more than M0. Calculation formula: Reverse gear shim thickness T1 = M0 – M

6P21H11

Shimming (counter rotation model) Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm

1 2 3 4 5 6 7 8 9

Selecting the forward gear shim 1. Calculate the specified value M0 as shown in the examples below.

Gland nut wrench: YB-06578

T. R.

Ring nut 6: 108 N·m (10.8 kgf·m, 79.7 ft·lb)

NOTE: “R” is the deviation of the lower case dimension from standard. The “R” mark a is stamped on the trim tab mounting surface of the lower case in 0.01 mm units. If the “R” mark is unreadable, assume that “R” is zero and check the backlash when the unit is assembled. Calculation formula: Specified value M0 = 2.50 + R/100 mm Example: If “R” is (+5), then M0 = 2.50 + (+5)/100 mm = 2.50 + 0.05 mm = 2.55 mm If “R” is (–1), then M0 = 2.50 + (–1)/100 mm = 2.50 – 0.01 mm = 2.49 mm 2. Install the shim(s) 1, thrust bearing 2, propeller shaft 3, taper roller bearing 4, and claw washer 5, and then tighten the ring nut 6 to the specified torque.

6P21H11

6-54

LOWR

Lower unit

3. Set the special service tool 7 on the taper roller bearing inner race. 4. Measure the clearance M between the special service tool and the propeller shaft housing 8 as shown.

NOTE: The sum of T2 and M should not be more than M0. Calculation formula: Forward gear shim thickness T2 = M0 – M

7 Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm

S69J6684

Selecting the propeller shaft shim 1. Install the shim(s) 1, thrust bearing 2, propeller shaft 3, taper roller bearing 4, and claw washer 5, and then tighten the ring nut 6 to the specified torque.

NOTE: Measure the clearance at 4 points to find the clearance average.

Gland nut wrench: YB-06578

T. R.

Ring nut 6: 108 N·m (10.8 kgf·m, 79.7 ft·lb)

Shim gauge 7: YB-06440-A 5. Select the forward gear shim(s) T2.

6-55

2. Measure the propeller shaft axial free play as shown.

6P21H11

Shimming (counter rotation model) / Backlash (counter rotation model) 3. Install the special service tools so that it pushes against the propeller shaft.

Propeller shaft free play: 0.25–0.35 mm (0.0098–0.0138 in) Magnetic base stand 7: YU-A8438 Dial indicator gauge 8: YU-03097 3. Select the propeller shaft shim(s) T’4.

NOTE: Tighten the universal puller while turning the drive shaft until the drive shaft can no longer be turned. T´4

S69J6705

NOTE: Add or remove shim(s) if the free play is out of specification.

Bearing housing puller 1: YB-06207 Universal puller 2: YB-06117

Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm

Backlash (counter rotation model)

Measuring the forward and reverse gear backlash 1. Remove the water pump assembly. 2. Set the gear shift to the neutral position at the lower unit.

Shift rod push arm: YB-06052

6P21H11

6-56

1 2 3 4 5 6 7 8 9

LOWR

Lower unit

4. Install the backlash indicator onto the drive shaft (22.4 mm [0.88 in] in diameter), and then install the dial gauge.

Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm 7. Remove the special service tools from the propeller shaft. 8. Turn the shift rod in direction c to the reverse position using the shift rod push arm. 9. Turn the drive shaft clockwise until the dog clutch 7 is fully engaged.

10. Turn the shift rod in direction d to the neutral position using the shift rod push arm. 11. Turn the drive shaft counterclockwise approximately 30°.

Forward gear backlash: 0.46–0.82 mm (0.0181–0.0323 in) 6. Add or remove shim(s) if out of specification. Forward gear backlash

Shim thickness

Less than 0.46 mm (0.0181 in)

To be decreased by (0.64 – M) × 0.71

More than 0.82 mm (0.0323 in)

To be increased by (M – 0.64) × 0.71

M: Measurement

6-57

12. Turn the shift rod in direction c to the reverse position using the shift rod push arm. 13. Slowly turn the drive shaft clockwise and counterclockwise and measure the backlash when the drive shaft stops in each direction.

6P21H11

Backlash (counter rotation model)

1 2 3 4 5 6 7 8 9

NOTE: When measuring the reverse gear backlash, add force to the reverse direction c using the shift rod push arm. Reverse gear backlash: 0.45–0.78 mm (0.0177–0.0307 in) 14. Add or remove shim(s) if out of specification. Reverse gear backlash

Shim thickness

Less than 0.45 mm (0.0177 in)

To be decreased by (0.62 – M) × 0.71

More than 0.78 mm (0.0307 in)

To be increased by (M – 0.62) × 0.71

M: Measurement Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm 15. Remove the special service tools, and then install the water pump assembly.

6P21H11

6-58

BRKT

Bracket unit Shift rod and bottom cowling ....................................................................... 7-1 Upper case and steering arm........................................................................ 7-5 Removing the upper case........................................................................7-10 Disassembling the upper case ................................................................7-10 Checking the drive shaft bushing ............................................................ 7-10 Disassembling the oil pan........................................................................7-10 Checking the oil strainer ..........................................................................7-11 Assembling the oil pan ............................................................................7-11 Assembling the upper case ..................................................................... 7-12 Installing the upper case..........................................................................7-13 Removing the steering arm ..................................................................... 7-14 Installing the steering arm ....................................................................... 7-14 Clamp bracket and swivel bracket ............................................................. 7-16 Removing the PTT unit............................................................................7-18 Removing the clamp bracket ................................................................... 7-19 Installing the clamp bracket ..................................................................... 7-19 Installing the PTT unit.............................................................................. 7-19 Adjusting the trim sensor .........................................................................7-20 PTT unit.........................................................................................................7-22 Checking the hydraulic pressure ............................................................. 7-24 PTT motor ..................................................................................................... 7-27 Disassembling the PTT motor .................................................................7-28 Checking the PTT motor..........................................................................7-28 Assembling the PTT motor ...................................................................... 7-29 Gear pump .................................................................................................... 7-31 Disassembling the gear pump .................................................................7-34 Checking the gear pump .........................................................................7-35 Checking the gear pump housing............................................................ 7-35 Checking the reservoir............................................................................. 7-35 Checking the filter....................................................................................7-35 Assembling the gear pump...................................................................... 7-35

6P21H11

Tilt cylinder and trim cylinder ..................................................................... 7-37 Disassembling the tilt cylinder and trim cylinder...................................... 7-39 Checking the tilt cylinder and trim cylinder .............................................. 7-40 Checking the valve .................................................................................. 7-41 Assembling the tilt ram ............................................................................7-41 Assembling the trim ram..........................................................................7-42 Installing the tilt cylinder ..........................................................................7-42 Installing the trim ram .............................................................................. 7-42 Installing the PTT motor ..........................................................................7-43 Installing the reservoir ............................................................................. 7-44 Installing the tilt ram................................................................................. 7-44 Bleeding the PTT unit .............................................................................. 7-45 Bleeding the PTT unit (built-in) ................................................................7-46 PTT electrical system .................................................................................. 7-46 Checking the fuse....................................................................................7-46 Checking the PTT relay ...........................................................................7-47 Checking the PTT switch.........................................................................7-47 Checking the trim sensor.........................................................................7-48

6P21H11

1 2 3 4 5 6 7 8 9

BRKT

Bracket unit

Shift rod and bottom cowling

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

7-1

Part name Bracket Shift cut switch Bracket Neutral switch Screw Plate Spring Bushing Grease nipple Bolt Bolt Clamp Screw Plate Clip Bushing Washer

Q’ty 1 1 1 1 2 1 1 2 1 1 2 1 2 1 2 1 1

Remarks

ø4 × 16 mm

M6 × 35 mm ø4 × 16 mm

6P21H11

Shift rod and bottom cowling 7

No. 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

Part name Shift lever Cotter pin Bushing Bolt Bracket Ball Spring Bolt Shift rod O-ring Grommet Screw Adapter Hose joint gasket Hose joint Clamp Grommet

6P21H11

Q’ty 1 1 2 1 1 1 1 1 1 1 1 2 1 1 1 1 1

1 2 3 4 5 6 7 8 9

Remarks Not reusable

M6 × 30 mm

Not reusable

ø6 × 20 mm

7-2

BRKT

Bracket unit 7

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

7-3

Part name Bottom cowling Rubber seal Cowling lock lever Bushing Plate Bolt Bolt Wave washer Lever Bolt Spring Hook Bracket Bracket Rivet Bolt Plate

Q’ty 1 1 3 6 3 13 7 3 3 3 3 3 1 1 2 2 2

Remarks

M6 × 20 mm M6 × 30 mm

M6 × 20 mm

M6 × 25 mm

6P21H11

Shift rod and bottom cowling 7

No. 18 19 20 21 22 23 24 25 26 27 28 29 30

Part name Collar Grommet Bolt Cooling water pilot hole Wire lead extension Bracket Switch Bracket Bracket Cover Gasket Clamp Bracket

6P21H11

Qâ&#x20AC;&#x2122;ty 4 1 4 1 1 2 1 1 1 1 2 1 1

1 2 3 4 5 6 7 8 9

Remarks

M8 Ă&#x2014; 35 mm Counter rotation model

7-4

BRKT

Bracket unit

Upper case and steering arm

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

7-5

Part name Upper case assembly Bolt Washer Washer Washer Upper mount Bracket Bolt Bolt Mount housing Bolt Lower mount Engine oil drain bolt Gasket Bolt Damper Apron stay

Q’ty 1 2 2 2 2 2 1 3 4 2 2 2 1 1 2 1 6

Remarks M14 × 190 mm

M10 × 45 mm M10 × 45 mm M14 × 205 mm M14 × 12 mm Not reusable

M6 × 14 mm

6P21H11

Upper case and steering arm 7

No. 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

Part name Bolt Dowel Adapter Bolt Drive shaft bushing Circlip Nut Circlip Bushing O-ring Bushing Washer Steering yoke Washer Steering arm Washer Washer

6P21H11

Q’ty 1 1 1 1 1 1 4 1 2 1 1 2 1 2 1 2 2

1 2 3 4 5 6 7 8 9

Remarks M6 × 10 mm

M6 × 30 mm

Not reusable

7-6

BRKT

Bracket unit 7

20 N · m (2.0 kgf · m, 14.8 ft · Ib)

4 N · m (0.4 kgf · m, 3.0 ft · Ib) LT

8 N · m (0.8 kgf · m, 5.9 ft · Ib)

42 N · m (4.2 kgf · m, 31.0 ft · Ib)

2 3 4

5 6

572

13 A

572

16 14

11 LT

271

15 10

S6P27040E

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

7-7

Part name Bolt Plate Collar Bolt O-ring O-ring PCV Bolt Rubber seal Rubber seal Screw Baffle plate Rubber seal Dowel Upper case Rubber seal

Q’ty 1 1 1 7 1 1 1 2 1 1 2 1 1 2 1 1

Remarks M6 × 20 mm

M10 × 45 mm Not reusable Not reusable

M8 × 30 mm

ø6 × 16 mm

6P21H11

Upper case and steering arm 7

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Part name Upper exhaust guide Gasket Dowel Lower exhaust guide Gasket Oil strainer Collar Bolt Gasket Dowel Rubber seal Oil pan Gasket Exhaust manifold Bolt Bolt Bolt

6P21H11

Q’ty 1 1 2 1 1 1 3 3 1 2 1 1 1 1 10 2 4

1 2 3 4 5 6 7 8 9

Remarks Not reusable

Not reusable

M6 × 25 mm Not reusable

Not reusable

M8 × 60 mm M8 × 30 mm M8 × 90 mm

7-8

BRKT

Bracket unit 7

No. 18 19 20 21 22 23 24 25 26

7-9

Part name Rubber seal Gasket Plate Pipe Rubber seal Gasket Dowel Muffler Bolt

Q’ty 1 1 1 1 1 1 2 1 10

Remarks Not reusable

Not reusable

M8 × 35 mm

6P21H11

Upper case and steering arm

Removing the upper case

Disassembling the oil pan

1. Place a drain pan under the drain hole, and then remove the engine oil drain bolt 1 and let the oil drain completely.

1. Remove the muffler 1, plate 2, and exhaust manifold 3 from the oil pan 4.

1 2 3 4 5 6 7 8 9

2. Remove the cover 2 and damper 3.

3. Disconnect the ground lead and speedometer hose. 4. Remove the upper and lower mounting nuts, and then remove the upper case.

Disassembling the upper case 1. Remove the oil pan assembly from the upper case. 2. Remove the circlip as shown. 3. Remove the drive shaft bushing.

S6P27840C

Slide hammer 1: YB-06096

Checking the drive shaft bushing 1. Check the drive shaft bushing. Replace if cracked or worn.

6P21H11

7-10

BRKT

Bracket unit

2. Remove the oil pan 4 from the upper exhaust guide 5 and lower exhaust guide 6.

2. Install the new gasket, oil strainer 4 and bolts, and then tighten the bolts to the specified torque.

3. Remove the oil strainer 7 from the lower exhaust guide 6. NOTE: Clean dirt from the removed parts and check the parts for cracks or corrosion.

T. R.

Oil strainer bolt: 10 N·m (1.0 kgf·m, 7.4 ft·lb)

3. Install the new gasket, oil pan 5, and then tighten the bolts 6 temporary. 4. Install the new gasket, exhaust manifold 7, rubber seal, and then tighten the bolts 8 temporary.

Checking the oil strainer 1. Check the oil strainer. Clean if there is dirt and residue.

Assembling the oil pan 1. Install the dowels, new gasket 1 and lower exhaust guide 2 onto the upper exhaust guide 3.

5. Tighten the exhaust manifold bolts 8, then the oil pan bolts 6 to the specified torques.

7-11

6P21H11

Upper case and steering arm

T. R.

Oil pan bolt 6: 20 N·m (2.0 kgf·m, 14.8 ft·lb) Exhaust manifold bolt 8: 20 N·m (2.0 kgf·m, 14.8 ft·lb)

2 1

6. Install the new gasket and plate 9. 7. Install the rubber seal and cooling water pipe 0 into the muffler A. 8. Install the new gasket, muffler A and bolts onto the oil pan, and then tighten the bolts to the specified torque.

WR-No.2

S6P27850E

NOTE: After installing the drive shaft bushing, apply grease to the inside of the bushing. Drive shaft needle bearing installer and remover 1: YB-06196 Driver handle (large) 2: YB-06071

NOTE: Install the cooling water pipe positioned as shown.

T. R.

Muffler bolt: 20 N·m (2.0 kgf·m, 14.8 ft·lb)

Assembling the upper case 1. Install the drive shaft bushing into the upper case, and then install the circlip.

6P21H11

7-12

1 2 3 4 5 6 7 8 9

BRKT

Bracket unit

2. Install the rubber seal 3 into the joint hole a of the upper case.

6. Install the upper mounts B and bolts into the upper case.

3. Install the oil pan assembly 4 by inserting the tip of the cooling water pipe 5 into the joint hole a of the upper case.

7. Install the bracket C, and then tighten the bolts D to the specified torque.

4. Install muffler assembly bolts 6 and 7, and PCV 8, and then tighten them to the specified torques. A

7 LT

572

572 A

3 4

T. R.

5 A

Upper mount bracket bolt D: 54 N·m (5.4 kgf·m, 39.8 ft·lb)

8. Install the lower mounts E and mount housings F.

3 S6P27480E

T. R.

Oil pan assembly bolt (M8) 6: 20 N·m (2.0 kgf·m, 14.8 ft·lb) Oil pan assembly bolt (M10) 7: 42 N·m (4.2 kgf·m, 31.0 ft·lb) PCV 8: 8 N·m (0.8 kgf·m, 5.9 ft·lb)

5. Install the damper 9, cover 0, and engine oil drain bolt A.

Installing the upper case 1. Install the upper and lower mounting bolts into the swivel bracket 1 simultaneously.

T. R.

7-13

Engine oil drain bolt A: 27 N·m (2.7 kgf·m, 19.9 ft·lb)

2. Install the upper mounting nuts 2 and lower mounting nuts 3, and then tighten them to the specified torques.

6P21H11

Upper case and steering arm 3. Pass the speedometer hose through the steering arm, and then connect it to the adapter.

3. Remove the steering arm from the swivel bracket by pulling the arm off the bracket.

Installing the steering arm 4. Connect the ground lead.

1. Install the washer 1 and bushing 2 onto the steering arm 3. 2. Place the swivel bracket 4 in an upright position, and then install the steering arm onto the swivel bracket.

T. R.

Upper mounting nut 2: 72 N·m (7.2 kgf·m, 53.1 ft·lb) Lower mounting nut 3: 72 N·m (7.2 kgf·m, 53.1 ft·lb)

3. Install the bushing 5, new O-ring 6, bushing 7, and washer 8 onto the swivel bracket.

Removing the steering arm 1. Remove the circlip 1. 2. Remove the steering yoke 2 by striking it with a plastic hammer.

6P21H11

7-14

1 2 3 4 5 6 7 8 9

BRKT

Bracket unit

4. Install the steering yoke 9 onto the steering arm 3, making sure that they are both facing in the same direction (a and b are aligned). 5. Install the circlip 0.

6. Inject grease into the grease nipple until grease comes out from both the upper and lower bushings c.

7-15

6P21H11

Upper case and steering arm / Clamp bracket and swivel bracket

Clamp bracket and swivel bracket

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Part name Through tube Clamp bracket (PORT) Bolt Ground lead Bushing Washer Bushing Friction plate Screw Screw Trim sensor Grease nipple Clamp bracket (STBD) Self-locking nut Collar Pin Distance collar

6P21H11

Q’ty 1 1 8 1 2 2 4 2 4 2 1 6 1 1 1 2 2

1 2 3 4 5 6 7 8 9

Remarks

M10 × 45 mm

ø6 × 10 mm ø6 × 15 mm

a: 30.3–30.4 mm (1.19–1.20 in)

7-16

BRKT

Bracket unit 7

No. 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

7-17

Part name Pin Bolt Spring Spring holder Tilt stop lever (PORT) Shaft Trim stopper Tilt stop lever (STBD) Circlip Nut Swivel bracket PTT unit Ground lead Bushing Bushing Anode Ground lead

Q’ty 1 2 1 1 1 1 2 1 1 2 1 1 1 2 2 1 1

Remarks M6 × 10 mm

6P21H11

Clamp bracket and swivel bracket

Removing the PTT unit 1. Fully tilt the outboard motor up, and then support it with the tilt stop lever 1.

5. Remove the PTT motor lead from the holder 7, and then pull out the PTT motor lead 8. 6. Remove the circlip 9 and shaft 0, then the upper end of the tilt rod from the swivel bracket. 7. Remove the PTT unit A.

WARNING â&#x20AC;˘ After tilting up the outboard motor, be sure to support it with the tilt stop lever. Otherwise, the outboard motor could suddenly lower if the PTT unit should lose fluid pressure. â&#x20AC;˘ When removing the PTT unit with the power unit installed, be sure to suspend the outboard motor. If the outboard motor is not suspended it can fall suddenly and result in severe injury. NOTE: If the PTT does not operate, turn the manual valve counter clockwise and tilt the outboard motor up manually. 2. Remove the anode 2 and the PTT unit bolts 3 (8 bolts). 3. Loosen the self-locking nut 4 of the through tube, and then move the clamp brackets slightly in the direction of the arrows.

WARNING Do not remove the tilt stop lever 1 from the clamp brackets. 4. Remove the PTT motor lead and trim sensor lead holder 5 and the plastic ties 6.

6P21H11

7-18

1 2 3 4 5 6 7 8 9

BRKT

Bracket unit

Removing the clamp bracket 1. Remove the self-locking nut 1 of the through tube and ground lead 2, then clamp brackets 3 and 4. 2. Remove the trim sensor 5.

T. R.

Grease nipple 5: 3 N·m (0.3 kgf·m, 2.2 ft·lb)

Installing the PTT unit Installing the clamp bracket

1. Fully tilt the outboard motor up, and then support it with the tilt stop lever 1.

1. Install the trim sensor 1 onto the starboard clamp bracket.

WARNING NOTE: Adjust the trim sensor after installing the PTT unit. To adjust the trim sensor, see “Adjusting the trim sensor.” 2. Assemble the clamp brackets and the swivel bracket by connecting the ground lead 2, installing the through tube 3, then tightening the self-locking nut 4 temporary.

7-19

• When installing the PTT unit with the power unit installed, be sure to suspend the outboard motor. If the outboard motor is not suspended it can fall suddenly and result in severe injury. • After tilting the outboard motor up, be sure to support it with the tilt stop lever. 2. Install the PTT unit mounting bolts 2 onto both clamp brackets together with the PTT unit 3, and then tighten them.

6P21H11

Clamp bracket and swivel bracket 3. Install the upper end of the tilt ram into the swivel bracket with the shaft 4 and circlip 5. 4. Tighten the self-locking nut 6 of the through tube to the specified torque. 5. Install the anode 7. 6. Install the PTT motor lead to the holder 8. 7. Pass the PTT motor lead and trim sensor lead through the hole of the starboard clamp bracket. 8. Fasten the PTT motor lead and trim sensor lead with the plastic ties 9 and then install the holder 0.

Adjusting the trim sensor 1. Fully tilt the outboard motor up, and then support it with the tilt stop lever 1.

WARNING

T. R.

Self-locking nut 6: 22 N·m (2.2 kgf·m, 16.2 ft·lb)

After tilting up the outboard motor, be sure to support it with the tilt stop lever. Otherwise, the outboard motor could suddenly lower if the PTT unit should lose fluid pressure.

9. Inject grease into all grease nipples until grease comes out from the bushings a.

6P21H11

7-20

1 2 3 4 5 6 7 8 9

BRKT

Bracket unit

2. Loosen the trim sensor screws 2.

WARNING

3. Adjust the position of the trim sensor, and then tighten the trim sensor screws 2 temporary.

After tilting up the outboard motor, be sure to support it with the tilt stop lever. Otherwise, the outboard motor could suddenly lower if the PTT unit should lose fluid pressure. 7. Tighten the trim sensor screws 2. 8. Fully tilt the outboard motor down.

NOTE: • To decrease the resistance, turn the trim sensor in direction a. • To increase the resistance, turn the trim sensor in direction b.

NOTE: • Check the trim sensor resistance again after tighten the trim sensor screws 2 and fully tilt the outboard motor down. • To check the trim sensor, see “Checking the trim sensor.”

4. Fully tilt the outboard motor down. 5. Measure the trim sensor resistance. Repeat steps 1–4 if out of specification.

S6P27810E

Trim sensor resistance: Pink (P) – Black (B) 10 ± 1 Ω 6. Fully tilt the outboard motor up, and then support it with the tilt stop lever.

7-21

6P21H11

Clamp bracket and swivel bracket / PTT unit

PTT unit

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Part name PTT body Reservoir Bolt O-ring Reservoir cap O-ring Sheet Filter Spacer PTT motor assembly O-ring Joint O-ring Manual valve Circlip Shaft Circlip

6P21H11

Q’ty 1 1 6 1 1 1 1 1 1 1 1 1 1 1 1 1 1

1 2 3 4 5 6 7 8 9

Remarks

M8 × 20 mm Not reusable

M12 × 10 mm Not reusable

Not reusable Not reusable

7-22

BRKT

Bracket unit 7

No. 18 19 20 21 22 23

7-23

Part name Bushing Pipe Pipe Spacer O-ring Adapter

Qâ&#x20AC;&#x2122;ty 2 1 1 1 1 1

Remarks

Not reusable

6P21H11

PTT unit

Checking the hydraulic pressure 1. Check the hydraulic pressure. Check the internal parts if out of specification. 2. Fully extend the PTT rams.

Ram Down

3. Loosen the pipe joints 1, and then remove the pipe joint at end a.

PTT motor lead

Battery terminal

Light green (Lg)

Sky blue (Sb)

Hydraulic pressure (down): 6.7–8.7 MPa (68–89 kgf/cm2)

4. Install the special service tool. 6. Reverse the PTT motor leads between the battery terminals to fully extend the rams.

NOTE: Put the PTT unit in the drain pan.

PTT pressure gauge 2: YB-06580

Ram Up

5. Connect the PTT motor leads to the battery terminals to retract the trim rams, and then measure the hydraulic pressure.

PTT motor lead

Battery terminal

Sky blue (Sb)

Light green (Lg)

7. Remove the special service tool. 8. Install the pipe joints 1, and then tightening them to the specified torque.

T. R.

Pipe joint 1: 15 N·m (1.5 kgf·m, 11.1 ft·lb)

9. Connect the PTT motor leads to the battery terminals to fully retract the trim and tilt rams.

6P21H11

7-24

1 2 3 4 5 6 7 8 9

BRKT

Bracket unit

10. Loosen the pipe joints 3, and then remove the pipe joint at end b.

Hydraulic pressure (up): 13.0–15.0 MPa (130–150 kgf/cm2)

11. Install the special service tool. 13. Reverse the PTT motor leads between the battery terminals to fully retract the rams.

NOTE: Put the PTT unit in the drain pan. PTT pressure gauge 2: YB-06580

Ram Down

12. Connect the PTT motor leads to the battery terminals to extend the trim rams, and then measure the hydraulic pressure.

PTT motor lead

Battery terminal

Light green (Lg)

Sky blue (Sb)

14. Remove the special service tool. 15. Install the pipe joints 3, and then tightening them to the specified torque.

T. R.

Pipe joint 3: 15 N·m (1.5 kgf·m, 11.1 ft·lb)

16. After measuring the hydraulic pressure, connect the PTT motor leads to the battery terminals to fully extend the trim and tilt rams.

Ram Up

7-25

PTT motor lead

Battery terminal

Sky blue (Sb)

Light green (Lg)

6P21H11

PTT unit

1 2 3 4 5 6 7 8 9

17. Place the PTT unit in an upright position. 18. Remove the reservoir cap 4, and then check the fluid level in the reservoir.

20. Install the reservoir cap 4, and then tighten it to the specified torque.

T. R.

Reservoir cap 4: 7 N·m (0.7 kgf·m, 5.2 ft·lb)

6P21H11

7-26

BRKT

Bracket unit

PTT motor

No. 1 2 3 4 5 6 7 8 9 10 11

7-27

Part name Stator Bolt Wave washer Washer Bearing Armature Brush Spring PTT motor base assembly O-ring Oil seal

Q’ty 1 2 1 1 2 1 4 4 1 1 1

Remarks M5 × 12 mm

Not reusable Not reusable

6P21H11

PTT motor

Disassembling the PTT motor 1. Remove the PTT motor assembly, Oring, and joint from the PTT unit.

WARNING Do not push the trim and tilt rams down while the PTT motor is removed from the PTT unit, otherwise fluid can spurt out. 2. Remove the PTT motor screws 1, then the stator 2.

Checking the PTT motor

CAUTION:

1. Check the commutator. Clean with 600â&#x20AC;&#x201C; grit sandpaper and compressed air if dirty.

Do not allow grease or oil to contact the commutator. NOTE: Place a clean cloth over the end of the armature shaft, hold it with a pair of pliers, and then carefully slide the stator off of the armature. 3. Remove the screws 3, disconnect the PTT motor leads 4, and then remove the springs 5 and brushes 6 from the PTT motor base assembly.

6P21H11

7-28

1 2 3 4 5 6 7 8 9

BRKT

Bracket unit

2. Measure the commutator diameter. Replace the armature if below specification.

Armature continuity Commutator segments b

Continuity

Segment â&#x20AC;&#x201C; Armature core c No continuity Segment â&#x20AC;&#x201C; Armature shaft d No continuity 5. Check the circuit breaker of brush holder for continuity. Replace the PTT motor base assembly if there is no continuity.

Motor commutator standard diameter: 23.0 mm (0.91 in) Wear limit: 22.0 mm (0.87 in) 3. Measure the commutator undercut a. Replace the armature if below specification.

Motor commutator standard undercut a: 1.40 mm (0.055 in) Wear limit: 0.90 mm (0.035 in) 4. Check the armature for continuity. Replace if out of specifications.

6. Measure the brush length. Replace if below specification.

Motor brush standard length: 11.5 mm (0.45 in) Wear limit e: 4.5 mm (0.18 in) 7. Check the motor base. Replace if cracked or damaged. 8. Check the bearing and oil seal. Replace if damaged or worn.

Assembling the PTT motor 1. Install the new oil seal 1 and bearing 2 into the motor base 3 as shown.

7-29

6P21H11

PTT motor 6. Install the wave washer A and washer B into the stator C.

2. Connect the PTT motor leads 4 to the brush holder 5, and then install the brush holder 5 to the motor base 6. 3. Install the brushes 7 and springs 8 to the brush holder as shown.

7. Install the new O-ring and stator C to the motor base.

NOTE: Place a clean cloth over the end of the armature shaft, hold it with a pair of pliers, and then carefully slide the stator over the armature.

4. Install the bearing 9 to the armature 0. 5. Push the brushes 7 into the holders, and then install the armature 0.

6P21H11

7-30

1 2 3 4 5 6 7 8 9

BRKT

Bracket unit

Gear pump

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

7-31

Part name Gear housing 1 Bolt Plate Filter Plate Valve lock screw Down-relief spring Valve support pin Relief valve seal Up-relief spring Valve support pin O-ring Ball Circlip Main valve seal Shuttle piston O-ring

Qâ&#x20AC;&#x2122;ty 1 3 1 1 1 2 1 1 1 1 1 1 1 2 2 1 1

Remarks M5 Ă&#x2014; 40 mm

Not reusable

6P21H11

Gear pump 7

No. 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

Part name Return spring Shuttle piston Driven gear Drive gear Ball Gear housing 2 Manual release spring Pin Ball Valve pin Spring Spacer O-ring Pin Filter Bracket Washer

6P21H11

Qâ&#x20AC;&#x2122;ty 2 1 1 1 2 1 1 1 4 2 2 2 2 2 1 1 2

1 2 3 4 5 6 7 8 9

Remarks

Not reusable

7-32

BRKT

Bracket unit 7

No. 35 36 37 38 39 40 41 42 43 44 45 46 47

7-33

Part name Bolt O-ring Spacer Filter Gear pump assembly Relief valve seat O-ring Down-relief valve Up-relief valve Down-absorber valve Up-absorber valve Down-main valve Up-main valve

Qâ&#x20AC;&#x2122;ty 2 2 2 2 1 1 1 1 1 1 1 1 1

Remarks M5 Ă&#x2014; 25 mm Not reusable

Not reusable

6P21H11

Gear pump 3. Remove the bracket 5, then the balls 6.

Disassembling the gear pump 1. Remove the manual valve 1, then gear pump 2 and filters.

4. Remove the gear housing 2 7, then the shuttle pistons 8. 2. Remove the relief valve seal 3 and ball 4.

5. Remove the drive gear 9 and driven gear 0, balls A, and pins B.

S6AL7771

NOTE: Before removing the relief valves, measure and note the screw height a and screw depth b.

6P21H11

7-34

1 2 3 4 5 6 7 8 9

BRKT

Bracket unit

Checking the gear pump 1. Check the drive gear 1 and driven gear 2. Replace if damaged or excessive worn. 2. Check the up-relief valve 3 and downrelief valve 4. Clean if there is dirt or residue. 3. Check the main valves 5, 6. Clean if there is dirt or residue.

Assembling the gear pump 4. Check the absorber valves 7, 8. Clean if there is dirt or residue.

1. Install the drive gear 1 and driven gear 2, pins 3, balls 4, and shuttle pistons 5, 6 into the gear housing 1 7. 2. Install the gear housing 2 8.

Checking the gear pump housing 1. Check the gear pump housing. Replace if scratched.

Checking the reservoir 1. Check the reservoir. Replace if cracked or if there is corrosion.

3. Install the balls 9, manual release spring 0, and bracket A by installing the bolts B, then tightening them to the specified torque.

Checking the filter 1. Check gear pump filters 1 and 2, and shuttle piston filters 3. Clean if there is dirt or residue.

7-35

6P21H11

Gear pump

T. R.

Gear pump bracket bolt B: 7 N·m (0.7 kgf·m, 5.2 ft·lb)

Up-relief lock screw height a (reference data): From the top of the gear housing: 1.07–1.27 mm (0.042–0.050 in) Down-relief lock screw depth b (reference data): From the top of the gear housing: 1.95–2.45 mm (0.077–0.096 in)

4. Install the relief valve seal C and ball D into the gear housing 1 7, and then install the up-relief lock screw E and down-relief lock screw F as shown.

5. Install the filters G, H and gear pump I by installing the bolts J, then tightening them to the specified torque. 6. Install the manual valve K.

6P21H11

NOTE: • If reinstalling the removed parts, install them according to the screw height a and screw depth b measurements noted before they were removed. • If installing new parts, install them according to the following reference data for the screw height a and screw depth b.

S6P27590E

Gear pump bolt J: 7 N·m (0.7 kgf·m, 5.2 ft·lb)

7. Check the hydraulic pressure. NOTE: • To check the hydraulic pressure, see Chapter 7, “Checking the hydraulic pressure.” • If the hydraulic pressure is out of specification, adjust the relief lock screws to adjust the pressure to specification.

7-36

1 2 3 4 5 6 7 8 9

BRKT

Bracket unit

Tilt cylinder and trim cylinder

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

7-37

Part name Circlip Dust seal Trim cylinder end screw O-ring Trim ram assembly Trim piston Backup ring O-ring Spring Adapter Circlip Tilt piston assembly Tilt ram assembly Power tilt assembly Tilt ram Dust seal Tilt cylinder end screw

Qâ&#x20AC;&#x2122;ty 2 2 2 2 2 2 2 2 2 2 2 1 1 1 1 1 1

Remarks Not reusable Not reusable

Not reusable

6P21H11

Tilt cylinder and trim cylinder 7

No. 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

Part name O-ring Backup ring O-ring Spring Adapter Tilt piston O-ring Backup ring Ball Pin Spring Bolt Free piston O-ring Tilt cylinder

6P21H11

Qâ&#x20AC;&#x2122;ty 1 1 1 1 1 1 1 1 5 5 5 1 1 1 1

1 2 3 4 5 6 7 8 9

Remarks Not reusable Not reusable

Not reusable

M6 Ă&#x2014; 10 mm Not reusable

7-38

BRKT

Bracket unit

Disassembling the tilt cylinder and trim cylinder 1. Hold the tilt cylinder 1 in a vise using aluminum plates a on both sides. 2. Loosen the tilt cylinder end screw, and then remove the tilt ram assembly.

WARNING Never look into the tilt cylinder opening when removing the free piston. The free piston and PTT fluid can be forcefully expelled out. NOTE: Be sure to cover the opposite end of the tilt cylinder with a rag. 5. Hold the tilt ram end in a vise using aluminum plates on both sides. 6. Remove the piston absorber valves.

WARNING Make sure that the ram are fully extended before removing the end screw. S6P27740E

PTT cylinder wrench 2: YB-06175-2B 3. Drain the PTT fluid.

7. Hold the tilt piston in a vise using the special service tool 4 on both sides. 8. Remove the tilt piston from tilt ram assembly.

4. Blow compressed air through the hole b to remove the free piston 3.

PTT piston vice tool 4: YB-06572 Tilt rod wrench 5: YB-06569

7-39

6P21H11

Tilt cylinder and trim cylinder 9. Hold the PTT body 6 in a vise using aluminum plates a on both sides.

Checking the tilt cylinder and trim cylinder 1. Check the PTT body 1 and tilt cylinder 2. Replace if cracked or if there is corrosion. 2. Check the inner surface of the PTT body 1 and tilt cylinder 2. Replace if scratched.

10. Loosen the trim cylinder end screws 7, and then remove them.

3. Check the outer surface of the tilt piston 3, trim piston 4, adapter 5, free piston 6, and dust seal 7 of end screw. Replace if scratched. 4. Check the trim rams 8 and tilt ram 9. Polish with 400â&#x20AC;&#x201C;600â&#x20AC;&#x201C;grit sandpaper if there is light rust or replace if bent or if there is excessive corrosion. 5. Check the pipes 0. Replace if cracked or if there is corrosion.

PTT cylinder wrench: YB-06175-2B 11. Remove the trim ram assemblies. 12. Drain the PTT fluid. 13. Remove the circlip 8, adapter 9, and spring 0 from the trim pistons.

6P21H11

7-40

1 2 3 4 5 6 7 8 9

BRKT

Bracket unit

Checking the valve 1. Check the tilt piston absorber valves 1. Clean if there is dirt or residue.

3. Hold the tilt piston in a vise using the special service tool 0 on both sides. 4. Tighten the tilt ram 9 to the specified torque.

1 S6P27560E

Assembling the tilt ram CAUTION: Do not use a rag when assembling the PTT unit as dust and particles on the PTT unit components can lead to poor performance.

T. R.

1. Install the new dust seal 1, new O-rings 2 and 3, and backup ring 4 into the tilt cylinder end screw 5.

PTT piston vice tool 0: YB-06572 Tilt rod wrench A: YB-06569 Tilt ram 9: 55 N·m (5.5 kgf·m, 40.6 ft·lb)

5. Install the new O-ring B and backup ring C onto the tilt piston 8. 6. Install the balls D, absorber valve pins E, and springs F as shown. 7. Install the washers G, plate H, and bolt I to the tilt piston 8, and then tighten the bolt to the specified torque. 2. Install the tilt cylinder end screw 5, spring 6, adapter 7, and tilt piston 8 to the tilt ram 9.

I LT

271

H F E G C B 8

E D

G C B 8 D

S6P27210

T. R.

7-41

Tilt piston bolt I: 7 N·m (0.7 kgf·m, 5.2 ft·lb)

6P21H11

Tilt cylinder and trim cylinder

Assembling the trim ram 1. Install the new O-ring 1, backup ring 2, spring 3, adapter 4, and circlip 5 to the trim piston 6.

2. Install the new dust seal 7, circlip 8, and new O-ring 9 to the trim cylinder end screw 0.

T. R.

3. Install the trim cylinder end screw 0 onto the trim ram A.

Pipe joint: 15 N·m (1.5 kgf·m, 11.1 ft·lb)

Installing the trim ram CAUTION: Do not use a rag when installing the PTT unit as dust and particles on the PTT unit components can lead to poor performance.

Installing the tilt cylinder

1. Hold the PTT body 1 in a vise using aluminum plates a on both sides.

1. Install the new O-ring 1 to the free piston 2. 2. Push the free piston 2 into the tilt cylinder 3 until it bottoms out. 3. Install the tilt cylinder 3 to the PTT body 4. 4. Install pipes 5 and 6, and then tighten the pipe joints to the specified torque.

6P21H11

7-42

1 2 3 4 5 6 7 8 9

BRKT

Bracket unit

2. Fill the trim cylinders with the recommended fluid to the correct level b as shown.

2. Fill the pump housing with the recommended fluid to the correct level a as shown. 3. Install the trim ram assembly into the trim cylinder, and then tighten the trim cylinder end screws 2 to the specified torque.

3. Remove all of the air bubbles with a syringe or suitable tool.

WARNING Do not push the trim rams down while installing them into the trim cylinders. Otherwise, the PTT fluid may spurt out from the unit.

NOTE: Turn the joint 1 with a screwdriver, and then remove any air between the pump gear teeth. 4. Install the new O-ring 2 and PTT motor 3, and then tighten the bolts 4 to the specified torque.

PTT cylinder wrench: YB-06175-2B

T. R.

Trim cylinder end screw 2: 160 N·m (16.0 kgf·m, 118.0 ft·lb)

Installing the PTT motor 1. Install the joint 1 into the gear pump.

7-43

6P21H11

Tilt cylinder and trim cylinder NOTE: Align the armature shaft with the recess in the joint.

T. R.

PTT motor mounting bolt 4: 19 N·m (1.9 kgf·m, 14.0 ft·lb)

Installing the reservoir 1. Install the spacer 1, filter 2 and sheet 3 to the PTT body. 2. Install the new O-ring 4 and reservoir 5, and then tighten the bolts 6 to the specified torque. 3. Install the reservoir cap 7, and then tighten it to the specified torque.

3. Install the tilt piston assembly into the tilt cylinder, and then tighten the tilt cylinder end screw 1 to the specified torque.

T. R.

Reservoir mounting bolt 6: 19 N·m (1.9 kgf·m, 14.0 ft·lb) Reservoir cap 7: 7 N·m (0.7 kgf·m, 5.2 ft·lb)

NOTE: Place the tilt cylinder end screw at the bottom of the tilt ram a and install the tilt piston assembly into the tilt cylinder.

Installing the tilt ram PTT cylinder wrench: YB-06175-2B

2. Add a small amount of the recommended fluid through the PTT body hole b as shown.

Tilt cylinder end screw: 90 N·m (9.0 kgf·m, 66.4 ft·lb)

6P21H11

1. Fill the tilt cylinder with the recommended fluid to the correct level a as shown.

7-44

1 2 3 4 5 6 7 8 9

BRKT

Bracket unit

Bleeding the PTT unit 1. Close the manual valve 1 by turning it clockwise.

T. R.

Manual valve 1: 2 N·m (0.2 kgf·m, 1.5 ft·lb)

2. Place the PTT unit in an upright position. 3. Remove the reservoir cap, and then check the fluid level in the reservoir.

Ram

NOTE: If the fluid is at the correct level, a small amount of fluid should overflow out of the filler hole.

4. If fluid is below the correct level, add fluid of the recommended type. 5. Install the reservoir cap, and then tighten it to the specified torque.

T. R.

Reservoir cap: 7 N·m (0.7 kgf·m, 5.2 ft·lb)

6. Connect the PTT motor leads 2 to the battery terminals to fully retract the rams. 7. Reverse the PTT motor leads between the battery terminals to fully extend the rams.

7-45

Down

PTT motor lead

Battery terminal

Sky blue (Sb)

Light green (Lg)

Sky blue (Sb)

NOTE: • Repeat this procedure so that the rams go up and down 4 to 5 times (be sure to wait a few seconds before switching the leads). • If the rams do not move up and down easily, push and pull on the rams to assist operation. 8. Check the fluid level when the rams are fully extended. If the fluid level is low, add sufficient fluid, and then repeat steps 6– 7.

6P21H11

Tilt cylinder and trim cylinder / PTT electrical system

Bleeding the PTT unit (built-in) 1. Fully tilt the outboard motor up and down a few times.

NOTE: If the fluid is at the correct level, a small amount of fluid should overflow out of the filler hole when the cap is removed. 6. If the fluid is below the correct level, add fluid of the recommended type.

S6P23190

NOTE: Connect the PTT motor leads directly to the battery terminals when the power unit is not installed. To connect the PTT motor leads, see “Bleeding the PTT unit.”

7. Install the reservoir cap, and then tighten it to the specified torque. NOTE: Repeat steps 1–7 until the fluid remains at the correct level.

T. R.

Reservoir cap 1: 7 N·m (0.7 kgf·m, 5.2 ft·lb)

2. Let the fluid settle for 5 minutes. 3. Push the PTT switch to fully tilt the outboard motor up. 4. Support the outboard motor with the tilt stop lever, and then let the fluid settle for 5 minutes.

WARNING

PTT electrical system

Checking the fuse 1. Check the fuse for continuity. Replace if there is no continuity. NOTE: For the location of the fuse, see Chapter 8, “Fuse holder.”

After tilting up the outboard motor, be sure to support it with the tilt stop lever. Otherwise, the outboard motor could suddenly lower if the PTT unit should lose fluid pressure. 5. Remove the reservoir cap 1, and then check the fluid level in the reservoir.

6P21H11

7-46

1 2 3 4 5 6 7 8 9

BRKT

Bracket unit

Checking the PTT relay 1. Check the PTT relay for continuity. Replace if out of specification.

4. Connect the sky blue (Sb) lead to the positive battery terminal and the terminal 4 lead to the negative battery terminal as shown.

Sb 2

3 1

5. Check for continuity between terminals 2 and 3. Replace the PTT relay if there is no continuity.

Sb 3

S6P27260J

NOTE: Be sure to set the measurement range a when checking for continuity.

S6P27280J

Checking the PTT switch

PTT relay continuity

1. Check the PTT switch for continuity. Replace if out of specification.

Sky blue (Sb) – Terminal 4 Light green (Lg) – Terminal 4

Continuity

Terminal 1 – Terminal 4 Terminal 2 – Terminal 4

Continuity

Terminal 1 – Terminal 3 Terminal 2 – Terminal 3

No continuity

2. Connect the light green (Lg) lead to the positive battery terminal and the terminal 4 lead to the negative battery terminal as shown. 3. Check for continuity between terminals 1 and 3. Replace the PTT relay if there is no continuity.

Lead color Switch position

Sky blue (Sb)

Red (R)

Light green (Lg)

Up Free

Down

Sb 3

7-47

S6P27270J

6P21H11

PTT electrical system

Checking the trim sensor 1. Measure the trim sensor resistance. Replace if out of specification.

1 2 3 4 5 6 7 8 9

NOTE: Turn the lever 1 and measure the resistance as it gradually changes. Trim sensor resistance: Pink (P) – Black (B) 9–11 Ω at a 247.6–387.6 Ω at b

6P21H11

7-48

ELEC

â&#x20AC;&#x201C;

Electrical system Checking the electrical component.............................................................. 8-1 Checking using the YDIS...........................................................................8-1 Measuring the peak voltage ...................................................................... 8-1 Electrical component.....................................................................................8-3 Port view.................................................................................................... 8-3 Starboard view........................................................................................... 8-4 Fuse holder................................................................................................8-5 Aft view ...................................................................................................... 8-6 Aft view ...................................................................................................... 8-7 Top view .................................................................................................... 8-8 Wiring harness routing.................................................................................. 8-9 Port view.................................................................................................... 8-9 Starboard view......................................................................................... 8-11 Aft view .................................................................................................... 8-14 Aft view .................................................................................................... 8-15 Top view .................................................................................................. 8-16 Ignition and ignition control system .......................................................... 8-17 Checking the ignition spark ..................................................................... 8-17 Checking the ignition coil input voltage ...................................................8-17 Checking the crank position sensor......................................................... 8-17 Checking the crank position sensor air gap............................................. 8-18 Checking the intake air temperature sensor............................................8-18 Checking the intake air pressure sensor ................................................. 8-19 Checking the engine temperature sensor................................................ 8-20 Checking the thermoswitch ..................................................................... 8-20 Checking the shift cut switch ................................................................... 8-21 Checking the neutral switch..................................................................... 8-21 Checking the knock sensor ..................................................................... 8-22 Checking the engine start switch............................................................. 8-22 Checking the engine stop lanyard switch ................................................ 8-23 ECM and electronic throttle valve control system.................................... 8-23 Checking the main relay and electronic throttle valve relay ....................8-23 Checking the ECM circuit ........................................................................8-24 Checking the electronic throttle valve and TPS circuit ............................ 8-26 Checking the electronic throttle valve motor............................................8-28 Checking the accelerator position sensor circuit ..................................... 8-29 Checking the accelerator position sensor................................................ 8-30 Variable camshaft timing control system .................................................. 8-32 Checking the cam position sensor........................................................... 8-32 Checking the oil control valve.................................................................. 8-34

6P21H11

Fuel control system .....................................................................................8-34 Checking the fuel injector ........................................................................8-34 Checking the low-pressure fuel pump and high-pressure fuel pump ...... 8-35 Checking the high-pressure fuel pump relay ...........................................8-35 Checking the vapor shut-off valve ........................................................... 8-36 Starting system ............................................................................................ 8-36 Checking the fuse....................................................................................8-36 Checking the starter relay........................................................................8-36 Starter motor ................................................................................................8-38 Disassembling the starter motor..............................................................8-40 Checking the starter motor pinion............................................................ 8-40 Checking the armature ............................................................................8-40 Checking the brush.................................................................................. 8-41 Checking the magnet switch.................................................................... 8-41 Checking the starter motor operation ......................................................8-42 Charging system .......................................................................................... 8-42 Checking the stator coil ...........................................................................8-42 Checking the Rectifier Regulator............................................................. 8-42

6P21H11

1 2 3 4 5 6 7 8 9

ELEC

–

Electrical system

Checking the electrical component

Measuring the peak voltage 8

Checking using the YDIS When checking the electronic throttle valve, accelerator position sensor, oil control valve, or each sensor, use the YDIS. When deleting the diagnosis record using the YDIS, be sure to check the occurrence time of diagnosis codes. When deleting the diagnosis record in the YDIS, be sure to check the time that the trouble codes were detected. When checking the input voltage of a part, the coupler or connector must be disconnected. As a result, the ECM determines that the part is disconnected and a trouble code is detected. Therefore, be sure to delete the diagnosis record after checking the input voltage. Since the main relay comes on for approximately 10 seconds after the start switch is turned to OFF, the power of the ECM cannot be turned off. Therefore, if the start switch is turned to ON within 10 seconds after it was turned to OFF, the trouble codes cannot be deleted. NOTE: • Before checking the electrical components, make sure that the battery is fully charged. • The YDIS requires that you use an exclusive communication cable and CD-ROM to connect to a computer. For a description of the communication cable and CD-ROM to be used, see Chapter 9, “YDIS.” Also, be sure to check the CD-ROM version before using it. • To connect the YDIS, see Chapter 9, “YDIS” or the YDIS (version 1.23a or later) Instruction Manual.

To check the electrical components or measure the peak voltage, use the special service tools. A faulty electrical component can be easily checked by measuring the peak voltage. The specified engine speed when measuring the peak voltage is effected by many factors such as fouled spark plugs or a weak battery. If one of these factors is present, the peak voltage cannot be measured properly.

WARNING When checking the peak voltage, do not touch any of the connections of the digital tester leads.

CAUTION: When testing the voltage between the terminals of an electrical component with the digital tester, do not allow any of the leads to touch any metal parts. If touched, the electrical component can short and be damaged.

YDIS (connecting kit): 60V-85300-02-00 YDIS (CD-ROM, ver 1.23a) 60V-WS853-03

8-1

6P21H11

Checking the electrical component NOTE: • Before measuring the peak voltage, check all wiring for proper connection and corrosion, and check that the battery is fully charged. • Use the peak volt adapter with the recommended digital circuit tester. • Connect the positive pin of the peak volt adapter to the positive terminal of the digital tester, and the negative pin to the negative terminal. • When measuring the peak voltage, set the selector on the digital circuit tester to the DC voltage mode.

1 2 3 4 5 6 7 8 9

Digital multimeter: YU-34899-A Peak volt adapter: YU-39991

6P21H11

8-2

ELEC

â&#x20AC;&#x201C;

Electrical system

Electrical component

Port view

A 1

2 0

7 5

S6P28010E

1 2 3 4 5 6 7 8

Intake air temperature sensor Electronic throttle valve assembly High-pressure fuel pump Low-pressure fuel pump Intake air pressure sensor Oil control valve (PORT) Fuel injector Ignition coil

8-3

9 0 A B

Cam position sensor (PORT IN) Cam position sensor (PORT EX) 3-pin communication coupler Condenser assembly (connect to the intake air pressure sensor)

6P21H11

Electrical component

Starboard view

2 0

8 S6P28020E

1 2 3 4 5 6 7 8 9 0

Ignition coil Fuel injector Cam position sensor (STBD IN) Oil control valve (STBD) PTT relay Rectifier Regulator Accelerator position sensor Oil pressure sensor Starter motor Diode (connect to the PTT relay)

6P21H11

8-4

1 2 3 4 5 6 7 8 9

ELEC

â&#x20AC;&#x201C;

Electrical system

Fuse holder

S6P28025

1 Fuse (10 A) (electronic throttle valve, ECM) 2 Fuse (30 A) (ignition coil, fuel injector, variable camshaft timing, ECM) 3 Fuse (20 A) (engine start switch, PTT switch) 4 Fuse (30 A) (starter relay) 5 Fuse (5 A) (low-pressure fuel pump) 6 Fuse (15 A) (high-pressure fuel pump relay) 7 Fuse (80 A) (starting battery) 8 Fuse (80 A) (accessory battery)

8-5

9 0 A B

High-pressure fuel pump relay Electronic throttle valve relay Main relay Starter relay

6P21H11

Electrical component 2005 F250 6P2 LF250 6P3

1000001–1002894 1000001–1000956

Aft view 2

4 4

5 6

7 S6P28030U

1 2 3 4 5 6

ECM Cam position sensor (PORT EX) Cam position sensor (PORT IN) Ignition coil Cam position sensor (STBD IN) Knock sensor

6P21H11

7 Coupler (knock sensor) (white)

8-6

1 2 3 4 5 6 7 8 9

ELEC

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2006 F250 6P2 LF250 6P3

Electrical system 1002895– 1000957–

Aft view 2

4 4

5 6

8 S6P28860C

1 2 3 4 5 6

ECM Cam position sensor (PORT EX) Cam position sensor (PORT IN) Ignition coil Cam position sensor (STBD IN) Knock sensor

8-7

7 Condenser assembly (connect to the cam position sensor (PORT EX)) 8 Coupler (knock sensor) (white)

6P21H11

Electrical component

Top view

1 2 4 5

S6P28040E

1 2 3 4 5 6 7 8 9 0

Oil control valve (STBD) Oil control valve (PORT) Thermoswitch (STBD) Thermoswitch (PORT) Engine temperature sensor Crank position sensor Vapor shut-off valve Stator assembly Neutral switch Shift cut switch

6P21H11

A Neutral switch coupler (blue) B Shift cut switch coupler (black)

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Wiring harness routing

Port view

È Ô

A Ò

Ñ Ì

Í Ï Î

S6P28320

È Install the low-pressure fuel pump coupler onto the wiring harness guide. É Fasten the thermoswitch connectors and wiring harness (oil control valve and fuel injectors) to the holder. Ê Fasten the engine temperature sensor lead and thermoswitch lead on the hook of the wiring harness guide. Ë Install the engine temperature sensor coupler onto the wiring harness guide. Ì Fasten the wiring harness to the holder at the white tape. Í Fasten the fuel injector lead in the order of Î, Ï, and Ñ. Î Fasten the fuel injector lead (#6) using a plastic tie at the white tape.

8-9

6P21H11

Wiring harness routing

È Ô

A Ò

Ñ Ì

Í Ï Î

S6P28320

Ï Ñ Ò Ó Ô

Fasten the fuel injector lead (#4) to the clip. It is not necessary to fasten the lead if its length is short. Fasten the fuel injector lead (#2), and then fasten the fuel injector lead (#4 and #6) to the clip. Fasten the fuel injector harness using a plastic tie. Fasten the fuel injector harness to the fuel rail cover after installing the cover. Fasten the intake air temperature sensor lead to the holder on the oil filler neck.

6P21H11

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Electrical system

Starboard view 1

3 1 5

1 2

A 3

3 1

2 C

2 6 45 E

8 7

1 2

1 F

4 H

3 2 4 A B

652 G

É C D Ê G E Ê F Ë Ì

Ó Ó Ï

Í Ñ H

Î S6P28330E

1 2 3 4 5 6 7 8

Wiring harness Stator coil lead Sub wiring harness Rectifier Regulator lead Starter motor lead PTT motor lead Oil pressure sensor lead Isolator lead

8-11

6P21H11

Wiring harness routing

3 1 5

1 2

A 3

3 1

2 C

2 6 45 E

8 7

1 2

1 F

4 H

3 2 4 A B

652 G

É C D Ê G E Ê F Ë Ì

Ó Ó Ï

Í Ñ H

Î S6P28330E

È É Ê Ë Ì

Fasten the PTT motor lead and ground lead of the wiring harness to the holder. Install the starter motor lead and brown lead of the wiring harness with the bolt. Fasten the starter motor lead and sub wiring harness to the holders. Fasten the starter motor lead, oil pressure sensor lead, sub wiring harness, and isolator lead to the holder. Route the oil pressure sensor lead, isolator lead, and PTT motor leads through the guide. Align the white tape on the oil pressure sensor lead with the guide of the positive battery terminal. Í Fasten the oil pressure sensor lead, isolator lead, and PTT motor lead to the holder. Î Route the battery cables along the bottom of the bottom cowling.

6P21H11

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Electrical system

3 1 5

1 2

A 3

3 1

2 C

2 6 45 E

8 7

1 2

1 F

4 H

3 2 4 A B

652 G

É C D Ê G E Ê F Ë Ì

Ó Ó Ï

Í Ñ H

Î S6P28330E

Ï Ñ Ò Ó Ô Õ

Fasten the fuel injector lead in the order of Ñ, Ò, Ó, and Ô. Fasten the fuel injector lead (#5) to the clip at the white tape. Fasten the fuel injector lead (#3) to the clip. It is not necessary to fasten the lead if its length is short. Fasten the fuel injector lead (#1), and then fasten the fuel injector lead (#3 and #5) to the clip. Fasten the fuel injector harness using a plastic tie. Fasten the fuel injector lead and quick connector to the holder.

8-13

6P21H11

Wiring harness routing 2005 F250 6P2 LF250 6P3

1000001–1002894 1000001–1000956

Aft view È É

Ì S6P28340

1 Cooling water pressure sensor coupler 2 Joint connector È Fasten the wiring harness and cam position sensor lead (PORT IN) using a plastic tie. É Fasten the cam position sensor lead (PORT IN) to the holder. 6P21H11

Ê Install the clip of knock sensor coupler to the hole of the ECM bracket. Ë Fasten the cooling water pressure sensor lead to the holder at the white tape. Ì Fasten the ignition coil lead (#5) and cam position sensor lead (STBD IN) to the holder at the white tape.

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2006 F250 6P2 LF250 6P3

Electrical system 1002895– 1000957–

Aft view È

Ì S6P28870C

8-15

Ê Install the clip of knock sensor coupler to the hole of the ECM bracket. Ë Fasten the cooling water pressure sensor lead to the holder at the white tape.

Ì Fasten the ignition coil lead (#5) and cam position sensor lead (STBD IN) to the holder at the white tape. Í Fasten the wiring harness and condenser assembly using a plastic tie.

6P21H11

Wiring harness routing

Top view 7

D-D È

C 6

E D B

Ê A

E-E Ë

4 2

1 A-A 3

2 B-B

C-C S6P28350E

1 2 3 4 5 6 7

Stator coil lead Wiring harness Thermoswitch connector High-pressure fuel hose Vapor gas hose Engine temperature sensor lead Joint connector

6P21H11

È Fasten the fuel injector lead and quick connector to the holder. É Fasten the fuel injector lead and vapor gas hose to the holder. Ê Face the white mark on the wiring harness upward. Ë Install the crank position sensor coupler to the bracket.

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Ignition and ignition control system

Checking the ignition spark

NOTE: The ignition spark can also be checked using the “Stationary test” of the YDIS.

1. Remove the ECM cover. 2. Remove the ignition coils.

Checking the ignition coil input voltage

3. Connect a ignition coil assembly to the special service tool.

1. Disconnect the ignition coil coupler. 2. Turn the engine start switch to ON. 3. Measure the voltage at the ignition coil coupler. Check the wiring harness if below specification.

1 2 S6P28050

3 4

Spark checker: YM-34487

5 4. Crank the engine and check the spark. If the spark is weak, check the ignition system.

S6P28605E

Ignition coil input voltage: Red/yellow (R/Y) – Black (B) 12 V (battery voltage)

Checking the crank position sensor S6P28060

WARNING • Do not touch any of the connections of the spark checker leads. • Be sure to install the special service tool to the ignition coil so that sparks do not leak out. • Keep flammable gas or liquids away, since this test can produce sparks.

8-17

1. Remove the flywheel magnet cover. 2. Disconnect the crank position sensor coupler. 3. Connect the test harness (2 pins) to the crank position sensor and measure the crank position sensor out put peak voltage. 4. Check the crank position sensor air gap and projection of the flywheel magnet if below specification.

6P21H11

Ignition and ignition control system 3. Measure the crank position sensor air gap a. Adjust if out of specification. Crank position sensor air gap a: 1.4–1.6 mm (0.055–0.063 in) 4. Loosen the screws 1 and adjust the crank position sensor air gap.

S6P28110

CAUTION: Check that the wiring harness does not interfere with the flywheel magnet. Test harness (2 pins): YB-06867 Peak volt adapter: YU-39991

Loaded

Cranking

DC V

3.0

2.7

1,500

3,500

14.5

17.8

5. Measure the resistance of the crank position sensor.

r/min

Unloaded

S6P28260

5. Tighten the screws 1, and then check the crank position sensor air gap. Adjust again if out of specification.

Crank position sensor output peak voltage: White/black (W/B) – Black (B)

Crank position sensor screw 1: 4 N·m (0.4 kgf·m, 3.0 ft·lb)

Checking the intake air temperature sensor 1. Measure the ambient temperature. 2. Connect a computer to the outboard motor and use the YDIS to display the intake air temperature.

Crank position sensor resistance (reference data): White/red (W/R) – Black (B) 396–594 Ω

Checking the crank position sensor air gap 1. Remove the wiring harness guide bolts and uphold wiring harness guide.

S6P28270

2. Turn the flywheel magnet clockwise to align the projection of the flywheel magnet with the crank position sensor projection.

6P21H11

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3. Check that the difference between the ambient temperature and the displayed intake air temperature is within ± 5 °C (± 9 °F). NOTE: • Check the intake air temperature sensor when the engine is cold. • When checking the intake air temperature sensor, remove the top cowling and do not start the engine. 4. Disconnect the intake air temperature sensor coupler. 5. Turn the engine start switch to ON. 6. Measure the input voltage at the intake air temperature sensor coupler (wiring harness end). Check the wiring harness if out of specification.

8. Measure the intake air temperature sensor resistance. Replace if out of specification. Intake air temperature sensor resistance: at 20 °C (68 °F): 2.21–2.69 kΩ

Checking the intake air pressure sensor 1. Disconnect the intake air pressure sensor coupler. 2. Turn the engine start switch to ON. 3. Measure the input voltage at the intake air pressure sensor coupler (wiring harness end). Check the wiring harness if out of specification.

PORT

S6P28625E

S6P28615E

Intake air temperature sensor input voltage (reference data): Black/yellow (B/Y) – Black (B) 4.75–5.25 V 7. Place the intake air temperature sensor in a container of water and slowly heat the water.

Intake air pressure sensor input voltage (reference data): Orange (O) – Black (B) 4.75–5.25 V 4. Remove the intake air pressure sensor, and then connect the coupler. 5. Connect the special service tool.

S6P28280 S6P28730

8-19

6P21H11

Ignition and ignition control system 6. Check the intake air pressure using the YDIS. 7. Apply the negative pressure to the intake air pressure sensor slowly. Check that the displayed intake air pressure is varied. NOTE: When checking the intake air pressure sensor, do not start the engine.

S6P28740

5. Measure the engine temperature sensor resistance. Replace if out of specification.

Pressure/vacuum tester: YB-35956-A

Checking the engine temperature sensor 1. Disconnect the engine temperature sensor coupler.

Engine temperature sensor resistance: Black/yellow (B/Y) – Black/yellow (B/Y) at 20 °C (68 °F): 54.2–69.0 kΩ at 100 °C (212 °F): 3.12–3.48 kΩ

2. Turn the engine start switch to ON. 3. Measure the input voltage at the engine temperature sensor coupler (wiring harness end). Check the wiring harness if out of specification.

Checking the thermoswitch 1. Disconnect the thermoswitch connectors. 2. Turn the engine start switch to ON. 3. Measure the input voltage at the thermoswitch connector (wiring harness end). Check the wiring harness if below specification.

PORT

STBD

S6P28636E

Engine temperature sensor coupler input voltage (reference data): Black/yellow (B/Y) – Black (B) 4.75–5.25 V 4. Place the engine temperature sensor in a container of water and slowly heat the water.

6P21H11

S6P28645E

Thermoswitch input voltage: Pink (P) – Black (B) 12 V (battery voltage)

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4. Place the thermoswitches in a container of water and slowly heat the water.

S6P28655E

S6P28750

5. Check the switch for continuity at the specified temperatures. Replace if out of specification.

Shift cut switch input voltage (reference data): Blue/yellow (L/Y) – Black (B) 4.75–5.25 V 4. To check the shift cut switch, measure the resistance of the shift cut switch at position a. Replace if out of specification. 5. Check the shift cut switch for continuity at position b. Replace if there is no continuity.

a b c d

a b

Temperature Time No continuity Continuity

Thermoswitch continuity temperature: Pink (P) – Black (B) e: 84–90 °C (183–194 °F) f: 68–82 °C (154–180 °F)

Checking the shift cut switch

S6P28760E

Shift cut switch resistance: 4.465–4.935 kΩ

1. Disconnect the shift cut switch coupler. 2. Turn the engine start switch to ON. 3. Measure the input voltage at the shift cut switch coupler (wiring harness end). Check the wiring harness if out of specification.

Switch position

Lead color Blue/yellow (L/Y)

Black (B)

Free a Push b

Checking the neutral switch 1. Disconnect the neutral switch coupler. 2. Turn the engine start switch to ON.

8-21

6P21H11

Ignition and ignition control system 3. Measure the input voltage at the neutral switch coupler (wiring harness end). Check the wiring harness if out of specification.

1 S6P28200E

S6P28635E

2. Measure the knock sensor resistance. Check the installation (ground state) of the knock sensor if out of specification. NOTE: To check the installation of the knock sensor, the cylinder head must be removed.

Neutral switch input voltage (reference data): Blue/green (L/G) – Black (B) 4.75–5.25 V 4. To check the neutral switch, check the neutral switch for continuity. Replace if there is no continuity at position b.

Knock sensor resistance: 504–616 kΩ

Checking the engine start switch 1. Disconnect the 10-pin main harness coupler.

a b

S6P28760

Switch position

Lead color Blue/green (L/G)

Black (B)

Free a Push b

Checking the knock sensor 1. Disconnect the knock sensor coupler 1 and connect the tester leads to the sensor coupler and ground.

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2. Check the engine start switch for continuity at the 10-pin main harness coupler (engine start switch end). Check the wiring harness or replace the engine start switch if there is no continuity. OFF

START OFF

START

1 2

S6P28370E

3 4

Switch position

1 2

Lead color White (W) 1 Black (B) 2

Clip removed S6P28360

Lead color Switch White Black Red Yellow Brown position (W) (B) (R) (Y) (Br) 4 1 2 3 5 Off On Start

Clip installed

ECM and electronic throttle valve control system

Checking the main relay and electronic throttle valve relay 1. Remove the main relay 1 and electronic throttle valve relay 2.

Checking the engine stop lanyard switch 1. Disconnect the 10-pin main harness coupler. 2. Turn the engine start switch to ON. 3. Check the engine stop lanyard switch for continuity at the 10-pin main harness coupler (engine stop lanyard switch end). Check the wiring harness or replace the engine stop lanyard switch if out of specification.

S6P28150

2. Connect the digital circuit tester (checking continuity) leads to relay terminals 3 and 4. 3. Connect the positive battery lead to the relay terminal 5. 4. Connect the negative battery lead to the relay terminal 6.

8-23

6P21H11

Ignition and ignition control system / ECM and electronic throttle valve control system 5. Check for continuity between relay terminals 3 and 4. Replace if there is no continuity.

6. Check that there is no continuity between relay terminals 3 and 4 after disconnecting a battery terminal from relay terminal 5 or 6. Replace if there is continuity. S6P28390

Terminal 8–9: 12 V (battery voltage)

Checking the ECM circuit 1. Disconnect the ECM couplers a and b.

6 S6P28160J

CAUTION: Do not reverse the battery leads. 7. Measure the voltage between the terminal 7 and ground, and the terminal 8 and ground as shown.

DC V

2005 F250 6P2 LF250 6P3

1000001–1002894 1000001–1000956

2. Check for continuity between the ECM coupler terminals c (46, 64, 65, 68, 73, and 76, wiring harness end) and ground. Check the wiring harness and ground if there is no continuity.

a b 8 7

S6P28450 S6P28380J

Terminal 7 – Ground: Terminal 8 – Ground: 12 V (battery voltage) 8. Turn the engine start switch to ON. 9. Measure the voltage between terminals 8 and 9 as shown.

S6P28460

6P21H11

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2006 F250 6P2 LF250 6P3

Electrical system 1002895– 1000957–

d 2. Check for continuity between the ECM coupler terminals c (46, 68, 69, 75, 76, and 84, wiring harness end) and ground. Check the wiring harness and ground if there is no continuity.

a b S6P28470

d e

a b S6P28450

S6P28480U

Terminal e (yellow) C – Ground: 12 V (battery voltage) 6. Turn the engine start switch to OFF, and then connect the ECM coupler d. 7. Disconnect the ECM coupler a, and then turn the engine start switch to ON.

S6P28820

8. Check the voltage at ECM coupler terminals f (27 and 34, wiring harness end). Check the fuse, relay, and wiring harness if below specification.

3. Connect ECM couplers a and b. 4. Disconnect the ECM coupler d, and then turn the engine start switch to ON. 5. Check the voltage at ECM coupler terminal e (13, wiring harness end). Check the fuse, wiring harness, and engine start switch if below specification.

d a

S6P28490

8-25

6P21H11

ECM and electronic throttle valve control system 2005 F250 6P2 LF250 6P3

1000001–1002894 1000001–1000956

S6P28500

Terminal f (red/yellow) (R/Y): Q – Ground: X – Ground: 12 V (battery voltage)

Checking the electronic throttle valve and TPS circuit NOTE: To check the TPS output voltage, see Chapter 4, “Checking the TPS.” 1. Disconnect ECM couplers a and b.

S6P28520

Wiring harness continuity Terminal No.

Color

Coupler c

Coupler a, b

G/R

G/B

P/W

b S6P28450

2. Disconnect the electronic throttle valve coupler c.

S6P28510

3. Check the wiring harness for continuity.

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2006 F250 6P2 LF250 6P3

6. Check the wiring harness for continuity. 1002895– 1000957–

2005 F250 6P2 LF250 6P3

1000001–1002894 1000001–1000956

S6P28830 S6P28540

Wiring harness continuity Terminal No.

Color

Coupler c

Coupler a, b

G/R

G/B

P/W

4. Connect the electronic throttle valve coupler c.

NOTE: Depending on the outboard motor, the location of the red/green terminals (85 and 86) of the coupler b may be switched.

Wiring harness continuity Terminal No.

Color

Coupler d, e

Coupler b

R/G

5. Disconnect fuse holder couplers d and e.

d S6P28530

8-27

6P21H11

ECM and electronic throttle valve control system 2006 F250 6P2 LF250 6P3

1002895– 1000957–

S6P28555E

TPS input voltage (reference data): Terminal 5 (O) – terminal 3 (B): 5.0 V

S6P28840

NOTE: Depending on the outboard motor, the location of the red/green terminals (79 and 80) of the coupler b may be switched.

Wiring harness continuity Terminal No.

Color

Coupler d, e

Coupler b

R/G

9. Turn the engine start switch to OFF, and then connect the electronic throttle valve coupler.

Checking the electronic throttle valve motor 1. Disconnect the electronic throttle valve coupler. 2. Check the electronic throttle valve motor continuity between the terminal 1 and 2.

1 2

7. Connect the ECM couplers and fuse holder couplers, and then disconnect the electronic throttle valve coupler. S6P28130E

8. Turn the engine start switch to ON, and then measure the TPS input voltage at the electronic throttle valve coupler (wiring harness end).

6P21H11

Electronic throttle valve motor resistance 1–2 (reference data): 1.23–1.67 Ω at 20–30 °C (68–86 °F)

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Checking the accelerator position sensor circuit

Wiring harness continuity

1. Disconnect the ECM coupler a. Terminal No. Coupler a

P/W

S6P28560

2. Disconnect the accelerator position sensor coupler b.

Color

Coupler b

2006 F250 6P2 LF250 6P3

1002895– 1000957–

b S6P28570 S6P28850

3. Check the wiring harness for continuity. 2005 F250 6P2 LF250 6P3

Wiring harness continuity 1000001–1002894 1000001–1000956

Terminal No.

S6P28580

Color

Coupler b

Coupler a

P/W

4. Connect the ECM coupler a, and then turn the engine start switch to ON. 5. Measure the input voltage at each terminal of the accelerator position sensor coupler b (wiring harness end).

8-29

6P21H11

ECM and electronic throttle valve control system

STBD

1 S6P28595E

Accelerator position sensor input voltage: Terminal 2 (O) – terminal 1 (B): Terminal 8 (O) – terminal 7 (B): 5.0 V 6. Turn the engine start switch to OFF, and then connect the accelerator position sensor coupler b.

Checking the accelerator position sensor 1. Connect a computer to the outboard motor and use the YDIS to display “Accelerator position sensor 1” and “Accelerator position sensor 2.”

S6P21030

NOTE: To adjust the throttle cable, see Chapter 3, “Adjusting the throttle cable.” 3. Check that the remote control lever is in the fully closed position of the throttle, and then check the output voltages of accelerator sensor 1 and accelerator sensor 2.

S6P24150

S6P24140

NOTE: To connect and operate the YDIS, see Chapter 9, “YDIS” and the YDIS (version 1.23a or later) Instruction Manual. 2. Check that the accelerator lever 1 contacts the fully closed stopper 2 when the remote control lever is at the fully closed position.

6P21H11

Output voltage of accelerator position sensor 1 with the remote control lever at the fully closed position (reference data): 0.550–0.850 V Output voltage of accelerator position sensor 2 with the remote control lever at the fully closed position (reference data): 0.400–1.000 V

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4. Shift the remote control lever to the fully open position and hold it.

S6P24160

5. Check the output voltages of accelerator position sensor 1 and accelerator position sensor 2. Output voltage of accelerator position sensor 1 and 2 with the remote control lever at the fully open position (reference data): Above 3.250 V 6. Operate the remote control lever, and check that the output voltages of accelerator position sensor 1 and accelerator position sensor 2 change continuously.

S6P28300

Accelerator position sensor resistance between 3 – 4, and between 5 – 6 with the accelerator lever at the fully closed position (reference data): at 20 °C (68 °F): 0.800 kΩ 10. Measure the resistance at the fully open position.

7. Disconnect the throttle cable joint from the accelerator position sensor. 8. Disconnect the accelerator position sensor coupler.

7 9. Connect the tester leads to the accelerator position sensor terminals and measure the resistance at the fully closed position.

S6P28290J

NOTE: Be sure to contact the accelerator lever to the stopper 7. Accelerator position sensor resistance between 3 – 4, and between 5 – 6 with the accelerator lever at the fully open position (reference data): at 20 °C (68 °F): 5.300 kΩ

8-31

6P21H11

ECM and electronic throttle valve control system / Variable camshaft timing control system

Variable camshaft timing control system

Checking the cam position sensor 1. Disconnect the cam position sensor coupler. 2. Turn the engine start switch to ON. 3. Measure the input voltage at the cam position sensor coupler (wiring harness end). Check the wiring harness if below specification.

Cam position sensor input voltage: Red/yellow (R/Y) 1 – Black (B) 12 V (battery voltage) White/blue (W/L) 2 – Black (B) (PORT EX) White/black (W/B) 2 – Black (B) (STBD IN) White/green (W/G) 2 – Black (B) (PORT IN) 4.75–5.25 V (reference data) 4. Turn the engine start switch to OFF.

PORT EX STBD IN AFT

1 DC V

S6P28665EU

PORT IN AFT

2 DC V

S6P28885EU

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5. Remove the cam position sensor 3.

8. Turn the engine start switch to ON.

6. Connect the wire leads between cam position sensor and cam position sensor coupler (wiring harness end) as shown.

9. Measure the output voltage when moving the screwdriver close to the sensor. Replace the cam position sensor if out of specification.

7. Connect the tester leads to the wire leads.

È 12V

ECM

c È

S6P28000EU

PORT EX STBD IN

S6P28240F

3 DC V

S6P28002EU

PORT IN 3

NOTE: Be sure to move the screwdriver in front of the cam position sensor in direction È as shown, otherwise the correct output voltage measurement cannot be obtained. Cam position sensor output voltage: White/blue (W/L) – Black (B) (PORT EX) White/black (W/B) – Black (B) (STBD IN) Position

Voltage (V)

a, c

More than 4.8

Less than 1.0

White/green (W/G) – Black (B) (PORT IN)

DC V

Position

Voltage (V)

a, c

Less than 1.0

More than 4.8

10. Turn the engine start switch to OFF. S6P28003EU

11. Disconnect the wire leads.

NOTE: Be sure to connect the wire leads to the corresponding terminals.

8-33

6P21H11

Variable camshaft timing control system / Fuel control system

Checking the oil control valve 1. Operate the oil control valve using the “Stationary test” of the YDIS and listen for the operating sound. 2. Disconnect the oil control valve coupler. 3. Turn the engine start switch to ON.

Oil control valve resistance: 6.7–7.7 Ω at 20 °C (68 °F) 6. Connect the battery leads to the oil control valve terminals, and then check the operation of the spool valve. Replace the oil control valve if it does not operate.

4. Measure the input voltage between the oil control valve coupler and ground. Check the wiring harness if below specification.

PORT

STBD

S6P28210

Fuel control system

Checking the fuel injector 1. Check the operation of the fuel injectors using the “Stationary test” of the YDIS. 2. Disconnect the fuel injector coupler. 3. Turn the engine start switch to ON.

S6P28687C

Oil control valve input voltage: Red/yellow (R/Y) – Ground 12 V (battery voltage)

4. Measure the input voltage between the fuel injector coupler terminal and ground. Check the wiring harness if below specification.

STBD

5. Measure the oil control valve resistance. Replace the oil control valve if out of specification.

S6P28445E

Fuel injector input voltage: Red/yellow (R/Y) – Ground 12 V (battery voltage)

S6P28220

6P21H11

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5. Measure the resistance of the fuel injectors.

Low-pressure fuel pump resistance 1 (reference data): 1.3–4.0 Ω High-pressure fuel pump resistance 2 (reference data): 0.5–10 Ω

Checking the high-pressure fuel pump relay S6P28780

Fuel injector resistance (reference data): 12.0 Ω at 21 °C (70 °F)

1. Remove the high-pressure fuel pump relay 1 and check it. To check the relay, see “Checking the main relay and electronic throttle valve relay” in this chapter.

Checking the low-pressure fuel pump and high-pressure fuel pump 1. Check the low-pressure fuel pump and high-pressure fuel pump operating sound with “Stationary test” of the YDIS. Check the fuel pump motors if there is no sound. 2. Disconnect the low-pressure fuel pump coupler 1 and high-pressure fuel pump coupler 2.

S6P28180

2. Connect the tester leads to terminals 2 and 3 as shown.

3. Measure the resistance of the fuel pump motors.

2 2

3 S6P28400

3. Turn the engine start switch to ON, and then measure the voltage within 5 seconds.

1 2

S6P28250

Terminal 2–3: 12 V (battery voltage) 4. Measure the voltage between the terminal 2 and ground, and the terminal 4 and ground as shown.

8-35

6P21H11

Fuel control system / Starting system Vapor shut-off valve resistance (reference data): 30.0–34.0 Ω at 20 °C (68 °F)

Starting system Checking the fuse

4 2

S6P28410

1. Check the fuses for continuity. Replace if there is no continuity. NOTE: For the location of the fuse, see “Fuse holder.”

Terminal 2 – Ground: Terminal 4 – Ground: 12 V (battery voltage)

Checking the vapor shut-off valve 1. Connect the special service tool to the vapor shut-off valve. 2. Apply the specified negative pressure to the vapor shut-off valve.

Checking the starter relay 1. Remove the starter relay 1 and check it. To check the relay, see “Checking the main relay and electronic throttle valve relay” in this chapter.

Pressure/vacuum tester: YB-35956-A Specified negative pressure: 67 kPa (0.7 kgf/cm2, 9.7 psi) 3. Check that the vapor shut-off valve opens and the negative pressure is released when the battery voltage is applied to the vapor shut-off valve terminals 1.

S6P28190

2. Measure the voltage between the terminal 2 and ground as shown.

S6P28420 S6P28170

4. Measure resistance of vapor shut-off valve.

6P21H11

Terminal 2 – Ground: 12 V (battery voltage)

8-36

1 2 3 4 5 6 7 8 9

ELEC

â&#x20AC;&#x201C;

Electrical system

3. Connect the tester leads to terminals 3 and 4 as shown.

S6P28430

4. Turn the engine start switch to START position, and then measure the voltage. Terminal 3â&#x20AC;&#x201C;4: 12 V (battery voltage)

8-37

6P21H11

Starting system / Starter motor

Starter motor

1 2 30

4 6 16

7 8 9 10

34 31

26 11

18 19

21 22

14 15

23 24 No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Part name Clip Pinion stopper Starter motor pinion Spring Bolt Cover assembly Bearing Clutch assembly E-clip Washer Bracket Pinion shaft Planetary gear Outer gear Plate Armature Stator

6P21H11

S6P28070

Qâ&#x20AC;&#x2122;ty 1 1 1 1 2 1 1 1 1 1 1 1 3 1 1 1 1

Remarks

M6 Ă&#x2014; 35 mm

Not reusable

8-38

1 2 3 4 5 6 7 8 9

ELEC

–

Electrical system 8

1 2 30

4 6 16

7 8 9 10

34 31

26 11

18 19

21 22

14 15

23 24 No. 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

8-39

Part name Brush assembly Brush spring Plate Plate Bracket Screw Bolt Rubber seal Shift lever Spring Magnet switch assembly Nut Pinion stopper set Washer set Starting motor gear assembly Brush holder assembly Lever assembly

S6P28070

Q’ty 1 4 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1

Remarks

ø4 × 15 mm M6 × 120 mm

6P21H11

Starter motor

Disassembling the starter motor 1. Slide the pinion stopper 1 down as shown, and then remove the clip 2.

NOTE: Remove the clip with a screwdriver. 2. Remove the bolts, and then disassemble the starter motor. NOTE: See the exploded diagram (8-38).

2. Measure the commutator diameter. Replace the armature if below specification.

Commutator standard diameter: 29.0 mm (1.14 in) Wear limit: 28.0 mm (1.10 in) 3. Measure the commutator undercut a. Replace the armature if below specification.

Checking the starter motor pinion 1. Check the teeth of the pinion. Replace if cracked or worn. 2. Check for smooth operation. NOTE: Turn the pinion counterclockwise to check that it operates smoothly and turn it clockwise to check that it locks in place.

Commutator standard undercut a: 0.8 mm (0.03 in) Wear limit: 0.2 mm (0.01 in)

Checking the armature 1. Check the commutator. Clean with 600â&#x20AC;&#x201C; grit sandpaper and compressed air if dirty.

6P21H11

8-40

1 2 3 4 5 6 7 8 9

ELEC

–

Electrical system

4. Check the armature for continuity. Replace if out of specifications.

S69J8440

Brush continuity Brush 1 – Brush 2

Armature continuity

No continuity

Commutator segments b

Continuity

Checking the magnet switch

Segment – Armature core c

No continuity

1. Connect the tester leads between the magnet switch terminals as shown.

Segment – Armature shaft d

No continuity

Checking the brush 1. Measure the brush length. Replace the brush assembly if below specification.

2. Connect the positive battery lead to the brown (Br) lead. 3. Connect the negative battery lead to the starter motor body.

S6P28790C

Brush standard length: 15.5 mm (0.61 in) Wear limit a: 9.5 mm (0.37 in) 2. Check the brush holder assembly for continuity. Replace if out of specification.

CAUTION: Do not connect the battery for more than 1 second, otherwise the magnet switch can be damaged. 4. Check that there is continuity between the magnet switch terminals. Replace if there is no continuity. 5. Check that there is no continuity between the main switch terminals when the negative battery terminal is removed from the starter motor body. Replace if there is continuity.

8-41

6P21H11

Starter motor / Charging system NOTE: The starter motor pinion should be pushed out while the magnet switch is “ON”.

Stator coil output peak voltage: Green (G) – Green (G) r/min

Unloaded Cranking

1,500

3,500

8.3

44.7

97.7

Checking the starter motor operation

DC V

1. Check the operation of the starter motor after installing it onto the power unit.

6. Measure the resistance of the stator coil.

Charging system

Checking the stator coil 1. Remove the starboard intake manifold. 2. Disconnect the stator coil couplers.

NOTE: Select any two of the three couplers (leads) and measure the resistance between the selected couplers. Then, measure the resistance between the coupler that was not measured and any coupler.

3. Install the intake manifold. NOTE: To install the intake manifold, see Chapter 4, “Installing the intake manifold.” 4. Connect the test harness (1 pin) to any stator coil coupler. 5. Measure the stator coil output peak voltage. Replace the stator coil if below specification.

Stator coil resistance (reference data): Green (G) – Green (G) 0.1144–0.1716 Ω at 20 °C (68 °F)

Checking the Rectifier Regulator CAUTION: If the battery cables are connected in reverse, the Rectifier Regulator can be damaged. 1. Remove the starboard intake manifold. 2. Remove the fuse holder and disconnect the Rectifier Regulator coupler 1. 3. Install the intake manifold.

S6P28080

NOTE: Select any two of the three couplers (leads) and measure the peak voltage between the selected couplers. Then, measure the voltage between the coupler that was not measured and any coupler.

NOTE: To install the intake manifold, see Chapter 4, “Installing the intake manifold.”

Test harness (1 pin): YB-06888 Peak volt adapter: YU-39991

6P21H11

8-42

1 2 3 4 5 6 7 8 9

–

ELEC

Electrical system

4. Measure the Rectifier Regulator output peak voltage. If below specification, measure the stator coil output peak voltage. Check the Rectifier Regulator if the output peak voltage of the stator coil is above specification.

b a

S6P28720

R 1 S6P28090E

NOTE: Do not use the peak volt adapter when measuring the output peak voltage of the Rectifier Regulator. Rectifier Regulator output peak voltage: Red (R) – Ground Unloaded

r/min DC V

NOTE: Be sure to set the measurement range a, and display the mark b by pushing the “SHIFT” switch when checking the Rectifier Regulator continuity. Rectifier Regulator continuity (testing diode) Tester lead +

1,500

3,500

13.0

5. Check the Rectifier Regulator for continuity. Replace if out of specification.

R2 R3

Display value (V)

0.42–0.45 V (reference data)

OL (over load)

G4 G5 G6 B R2 R3 G4 G5 G6 B S6P28100

8-43

6P21H11

TRBL SHTG

Troubleshooting YDIS................................................................................................................. 9-1 Introduction................................................................................................9-1 Connecting the communication cable to the outboard motor .................... 9-4 Troubleshooting the power unit ...................................................................9-5 Troubleshooting the power unit using the YDIS ........................................ 9-5 Trouble code and checking step................................................................9-7 Troubleshooting the power unit using the diagnostic test lead................ 9-15 Troubleshooting the power unit (trouble code not detected) ................... 9-17 Troubleshooting the PTT unit .................................................................. 9-22 Troubleshooting the lower unit ................................................................9-23

6P21H11

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TRBL SHTG

Troubleshooting

YDIS

Introduction Feature The newly developed YDIS provides quicker detection and analysis of engine malfunctions. By connecting your computer to the ECM of an outboard motor using the communication cable, this software can be used to display sensor data and data stored in the ECM on a computer’s monitor. If this software is run on Microsoft Windows® 95, Windows 98, Windows Me, Windows 2000, or Windows XP, the information can be displayed in colorful graphics. Also, the software can be operated using either a mouse or a keyboard. In addition, the data for the main functions (Diagnosis, Diagnosis record, Engine monitor, and Data logger) can be saved on a disk or printed out. Function 1. Diagnosis: Displays each part name, and the ECM trouble codes and status when the engine start switch is turned to ON. This allows you to quickly specify malfunctioning parts. The trouble codes displayed are the same as those described in “Trouble code and checking step” in this chapter (9-7). 2. Diagnosis record: Displays each part name and the ECM trouble codes that have been registered. This allows you to check the outboard motor’s record of malfunctions. The trouble codes displayed are the same as those described in “Trouble code and checking step” in this chapter (9-7). 3. Engine monitor: Each sensor status and the ECM data are displayed while the engine is running. This enables you to find malfunctioning parts quickly. In addition, the data displayed using the Engine Monitor function can be displayed in a graph. Items: For F250/LF250 1

Engine speed

Fuel injection duration

Dual engine system switch

Intake pressure(*1)

Ignition timing

Shift cut-off switch(*4)

Throttle position sensor 1 12

Engine temperature

Overheat thermoswitch(*5)

Throttle valve opening (0–90)

Intake temperature(*2)

Main switch(*6)

Throttle position sensor 2 14

Oil pressure

Main relay

Accelerator position sensor 1

Intake cam timing (STBD)

Electronic throttle relay(*7)

Accelerator position sensor 2

Intake cam timing (PORT)

Fuel pump relay(*8)

Atmospheric pressure

Engine stop lanyard switch

Battery voltage (12–16)

Shift position switch(*3)

(*1):

(*5):

(*2):

(*6):

Intake air pressure Intake air temperature (*3): Neutral switch (*4): Shift cut switch

9-1

Thermoswitch Engine start switch (*7): Electronic throttle valve relay (*8): High-pressure fuel pump relay

6P21H11

YDIS 4. Stationary test: Operation tests can be performed with the engine off. Items: For F250/LF250 1

Ignite ignition coil (#1â&#x20AC;&#x201C;#6)

Oil ctrl. valve drive (STBD)(*1)

Operate electric fuel pump(*3)

Operate injector (#1â&#x20AC;&#x201C;#6)

Oil ctrl. valve drive (PORT)(*2)

Operate elect. fuel feed pump(*4)

(*1):

Oil control valve drive (starboard) Oil control valve drive (port) (*3): Operate high-pressure fuel pump (*4): Operate low-pressure fuel pump (*2):

5. Data logger: Displays 13 minutes of recorded data for 2 or more of the items stored in the ECM. In addition, the operating time as compared to the engine speed and the total operating time are displayed. This allows you to check the operating status of the engine. For the F250/LF250 models, you can also save the ECM record data on a file so that you can view and display the graph later. Items: For F250/LF250 1

Engine speed

Throttle position sensor

Intake pressure(*1)

Battery voltage

Engine temperature

Oil pressure

(*1):

Intake air pressure

6P21H11

9-2

1 2 3 4 5 6 7 8 9

TRBL SHTG

Troubleshooting

6. ECM record data graph: When a malfunction occurs in the electronic throttle valve system, 4 seconds (2 seconds before and after the malfunction) of recorded data are saved in the ECM. This data can be displayed on a graph using the â&#x20AC;&#x153;ECM record data graphâ&#x20AC;? of the Data logger function. When the communication cable is used to connect a computer to the ECM, the ECM record data can be saved and viewed on the computer. The saved ECM record data can also be viewed offline. Items: For F250/LF250 1

Engine speed

Target TPS voltage(*2)

Engine stop lanyard switch

Accelerator position sensor 1

Ref. TPS voltage(*3)

Main relay

Accelerator position sensor 2

Ref. acc. pos. sensor voltage(*4)

Electronic throttle relay(*7)

Throttle position sensor 1

Target TPS voltage for ISC(*5)

Overheat warning

Throttle position sensor 2 12

Engine stop mode

Low oil pressure

Intake pressure(*1)

Engine start mode

Battery voltage

Engine stop mode with SW(*6)

(*1):

Intake air pressure Target TPS voltage This item shows the target output voltage of the TPS. This value is the control voltage that the ECM requires to set the target opening angle of the throttle valve. (*3): Reference TPS voltage This item shows the criterion output voltage of the TPS. This value is used to detect the TPS output voltage during engine operation. (*4): Reference accelerator position sensor voltage This item shows the criterion output voltage of the accelerator position sensor. This value is used to detect the accelerator position sensor output voltage when the remote control throttle lever is opened. (*5): Target TPS voltage for Idle Speed Control ECM controls the engine idle speed by using the throttle valve attached to the TPS. This target voltage is used by the ECM to achieve the target opening angle of the throttle valve at the engine idle speed. (*6): Engine stop mode with switch (*7): Electronic throttle valve relay (*2):

NOTE: To display the displays and graphs, see the YDIS (version 1.23a or later) Instruction Manual.

9-3

6P21H11

YDIS

Contents 1. CD-ROM (software + instruction manual) (1) 2. Adapter (1) 3. Communication cable (1)

Connecting the communication cable to the outboard motor

3-pin communication coupler (gray) S6P29010

6P21H11

9-4

1 2 3 4 5 6 7 8 9

TRBL SHTG

Troubleshooting

Troubleshooting the power unit

NOTE: • Before troubleshooting the outboard motor, make sure that fresh fuel of the specified type has been used. • Check the trouble code using the YDIS (or diagnostic test lead) first, and then check the electronic control system follow the trouble code chart. • When a three-digit trouble code is detected, check the data logger of the ECM record data graph as well. • It is recommended to use the YDIS for troubleshooting, it is not enough to check the electronic throttle valve system (electronic throttle valve, TPS, and accelerator position sensor) when only using the diagnostic test lead. • If a trouble code is not detected, check the power unit according to “Troubleshooting the power unit (trouble code not detected).” • Before using the YDIS or diagnosis indicator B to check the power unit, check the ECM circuit. To check the ECM circuit, see Chapter 8, “Checking the ECM circuit.” • Be sure to check that the couplers and connectors are securely connected. • When deleting the diagnosis record on the YDIS, be sure to check the time that the trouble codes were detected. • When checking the input voltage of a part, the coupler or connector must be disconnected. As a result, the ECM determines that the part is disconnected and a trouble code is detected. Therefore, be sure to delete the diagnosis record after checking the input voltage. • Since the main relay comes on for approximately 10 seconds after the start switch is turned to OFF, the power of the ECM cannot be turned off. Therefore, if the start switch is turned to ON within 10 seconds after it was turned to OFF, the trouble codes cannot be deleted.

Troubleshooting the power unit using the YDIS NOTE: • Use the trouble codes displayed by the YDIS to check each part according to the “Trouble code and checking step” table. • Delete the trouble codes after checking, repairing, or replacing a part and check that the trouble codes are not detected again. If the same trouble codes are detected, the ECM may be faulty. • Check the items listed in the table, if all the items are in good condition delete the trouble code, and then check the trouble codes again. If the same trouble codes are detected again, the ECM is faulty. • A break down of the engine symptoms are described in the table below, however, multiple malfunctions that have been duplicated cannot be limited to these items. The symptoms may change according to the operating conditions and other conditions.

9-5

6P21H11

Troubleshooting the power unit Symptoms table Engine startability Starts

Engine idle speed Normal(*1) Increases (steady)

Maximum engine speed

Symptom

Normal(*2)

Normal(*4)

Decreases(*3)

Poor(*5)

Normal

Poor

Normal

Poor

Decreases

Does not starts

Acceleration

Increases (unsteady)

Normal

Down

Poor

Unsteady

Down

Poor

Increases(*6)

1,200–1,500 r/min

Impossible

Engine does not operate

1 2 3 4 5 6 7 8 9

(*1):

600–700 r/min at engine idle speed 5,000–6,000 r/min (*3): Less than the specified engine speed (*4): Engine speed increases according to throttle opening angle (*5): Engine speed does not increase according to throttle opening angle (*6): Limp home processing (*2):

6P21H11

9-6

TRBL SHTG

Troubleshooting

Trouble code and checking step Trouble code

Symptom Item

Crank position sensor (pulser coil in YDIS)

Engine temperature sensor malfunction Knock sensor malfunction

Battery voltage malfunction

Intake air temperature sensor malfunction

Remarks

Trolling speed is unstable

—

Maximum power decreases

—

Checking steps

Refer to page

1. Measure the crank position sensor resistance.

8-17

2. Check the white/black (W/B) lead and black (B) lead (ECM-tocrank position sensor) for continuity.

3. Measure the crank position sensor output peak voltage.

8-17

4. Measure the crank position sensor air gap.

8-18

5. Check the projections of the flywheel magnet for damage.

5-7

1. Check the engine temperature using the YDIS.

9-1

2. Measure the input voltage.

8-20

3. Measure the resistance.

8-20

1. Measure the resistance.

8-22

2. Check the green (G) lead (ECMto-knock sensor) for continuity.

1. Check the battery voltage using the YDIS.

9-1

2. Measure the Rectifier Regulator output peak voltage.

8-42

3. Measure the stator coil output peak voltage.

8-42

4. Check the fuse.

8-5

5. Check the battery cables and terminals for proper connection.

3-15

1. Check the intake air temperature using the YDIS.

9-1

2. Measure the input voltage.

8-18

3. Measure the resistance.

8-18

*1: See the wiring diagram.

9-7

6P21H11

Troubleshooting the power unit Trouble code

Symptom Item

Cam position sensor (PORT EX) malfunction

Neutral switch malfunction

Intake air pressure sensor malfunction

Intake air passage malfunction

Remarks

â&#x20AC;&#x201D;

Maximum power decreases

Trolling speed is unstable

Refer to page

Checking steps 1. Check the cam timing using the YDIS.

9-1

2. Measure the input voltage.

8-32

3. Check the white/blue (W/L) lead (cam position sensor-to-ECM) for continuity.

4. Measure the output voltage.

8-32

5. Check the brim of the camshaft.

5-27

1. Check the switch using the YDIS.

9-1

operation

2. Check the switch continuity.

8-21

3. Measure the input voltage.

8-21

4. Check the shift bushing and shift mechanism.

7-1

1. Check the intake air pressure using the YDIS.

9-1

2. Check the vacuum hoses.

4-2

3. Measure the input voltage.

8-19

4. Check the operation of the intake air pressure sensor.

8-19

5. Check the pink/green (P/G) lead (ECM-to-sub wiring harness-tointake air pressure sensor) for continuity.

1. Check the O-rings and gaskets of the intake manifold, surge tank, and throttle body.

4-12 4-15

2. Check the hose between the vapor shut-off valve and surge tank.

4-2

3. Check the throttle valve condition.

4-5

4. Check the intake air pressure sensor hose.

4-2

5. Check the pressure regulator hose.

4-2

*1: See the wiring diagram.

6P21H11

9-8

1 2 3 4 5 6 7 8 9

TRBL SHTG Trouble code

Troubleshooting Symptom Item

Oil pressure sensor malfunction

Engine stop lanyard switch malfunction

Shift cut switch malfunction

Thermoswitch malfunction

Remarks

â&#x20AC;&#x201D;

Engine stalls (when running engine) Buzzer comes on

Shifting to neutral is difficult

â&#x20AC;&#x201D;

Refer to page

Checking steps 1. Check the engine oil pressure using the YDIS.

9-1

2. Measure the input voltage.

5-2

3. Measure the output voltage.

5-2

4. Check the pink/white (P/W) lead (ECM-to-oil pressure sensor) for continuity.

5. Check the oil pressure using an oil pressure gauge.

5-1

1. Check the switch using the YDIS.

9-1

operation

2. Check the clip.

8-23

3. Check the switch continuity.

8-23

4. Check the white (W) lead (ECMto-10-pin main harness coupler) for continuity.

5. Check the black (B) lead (10-pin main harness coupler-to-joint connector-to-ground) for continuity.

1. Check the switch using the YDIS.

operation

9-1

2. Check the switch continuity and resistance.

8-21

3. Measure the input voltage.

8-21

4. Check the shift bracket and shift mechanism.

7-1

1. Check the switch condition using the YDIS.

9-1

2. Measure the input voltage.

8-20

3. Check the switch continuity.

8-20

4. Check the engine temperature sensor.

8-20

*1: See the wiring diagram.

9-9

6P21H11

Troubleshooting the power unit Trouble code

Symptom Item

Cam position sensor (STBD IN) malfunction

Cam position sensor (PORT IN) malfunction

Remarks

112 114

—

Oil control valve (STBD) D

—

Oil control valve (PORT)

Electronic throttle valve malfunction

—

Checking steps

Refer to page

1. Check the cam timing using the YDIS.

9-1

2. Measure the input voltage.

8-32

3. Check the white/black (W/B) lead (cam position sensor-toECM) for continuity.

4. Measure the output voltage.

8-32

5. Check the brim of the camshaft.

5-27

6. Check the battery cables and terminals for proper connection.

3-15

1. Check the cam timing using the YDIS.

9-1

2. Measure the input voltage.

8-32

3. Check the white/green (W/G) lead (cam position sensor-toECM) for continuity.

4. Measure the output voltage.

8-32

5. Check the brim of the camshaft.

5-27

6. Check the battery cables and terminals for proper connection.

3-15

1. Check the valve operation using the YDIS.

9-1

2. Measure the resistance.

8-34

3. Measure the input voltage.

8-34

4. Check the purple (Pu) lead (oil control valve-to-ECM) for continuity.

5. Check the filter and plunger.

8-34

1. Check the ECM circuit.

8-24

2. Check the electronic throttle valve circuit.

8-26

3. Check the electronic throttle valve relay and fuse.

8-23

*1: See the wiring diagram.

6P21H11

9-10

1 2 3 4 5 6 7 8 9

TRBL SHTG Trouble code

113

115 116

117 118

Troubleshooting Symptom Item

Electronic throttle valve malfunction

Remarks

—

119

Electronic throttle valve malfunction

121

Electronic throttle valve malfunction

—

122

Electronic throttle valve malfunction

—

123

9-11

Electronic throttle valve malfunction

—

Checking steps

Refer to page

1. Check the electronic throttle valve operation.

4-5

2. Check the TPS output voltage using the YDIS.

9-1

3. Check the throttle opening angle using the YDIS.

9-1

4. Check the ECM circuit.

8-24

5. Check the electronic throttle valve circuit.

8-26

6. Check the electronic throttle valve relay and fuse.

8-23

7. Check the electronic throttle valve motor continuity.

8-28

1. Check the electronic throttle valve circuit.

8-26

2. Check the electronic throttle valve relay and fuse.

8-23

3. Check the electronic throttle valve motor continuity.

8-28

1. Check the electronic throttle valve circuit.

8-26

2. Check the electronic throttle valve relay and fuse.

8-23

3. Check the electronic throttle valve motor continuity.

8-28

1. Check the electronic throttle valve circuit.

8-26

1. Replace the ECM.

5-36

1. Replace the electronic throttle valve assembly (electronic throttle valve motor malfunction).

4-15

1. Check the electronic throttle valve relay and fuse.

8-23

2. Check the electronic throttle valve circuit.

8-26

3. Check the electronic throttle valve motor continuity.

8-28

6P21H11

Troubleshooting the power unit Trouble code

124 125

124 125 126 127 128

127 128

129

131 132

6P21H11

Symptom Item

TPS malfunction

Accelerator position sensor malfunction

Remarks

—

Checking steps

Refer to page

1. Check the TPS output voltage using the YDIS.

9-1

2. Check the throttle opening angle using the YDIS.

9-1

3. Check the electronic throttle valve circuit.

8-26

1. Check the TPS output voltage using the YDIS.

9-1

2. Check the throttle opening angle using the YDIS.

9-1

3. Check the electronic throttle valve circuit.

8-26

1. Check the TPS output voltage using the YDIS.

9-1

2. Check the throttle opening angle using the YDIS.

9-1

3. Check the electronic throttle valve circuit.

8-26

1. Check the TPS output voltage using the YDIS.

9-1

2. Check the throttle opening angle using the YDIS.

9-1

3. Check the electronic throttle valve circuit.

8-26

1. Check the TPS output voltage using the YDIS.

9-1

2. Check the throttle opening angle using the YDIS.

9-1

3. Check the electronic throttle valve circuit.

8-26

1. Check the accelerator position sensor output voltage using the YDIS.

9-1

2. Check the accelerator position sensor circuit.

8-29

3. Check the accelerator position sensor resistance.

8-30

9-12

1 2 3 4 5 6 7 8 9

TRBL SHTG Trouble code

131 132 133 134

133 134

135

136 137

138 139

141

9-13

Troubleshooting Symptom Item

Accelerator position sensor malfunction

Electronic throttle valve malfunction

TPS malfunction

Remarks

—

Checking steps

Refer to page

1. Check the accelerator position sensor output voltage using the YDIS.

9-1

2. Check the accelerator position sensor circuit.

8-29

3. Check the accelerator position sensor resistance.

8-30

1. Check the accelerator position sensor output voltage using the YDIS.

9-1

2. Check the accelerator position sensor circuit.

8-29

3. Check the accelerator position sensor resistance.

8-30

1. Check the accelerator position sensor output voltage using the YDIS.

9-1

2. Check the accelerator position sensor circuit.

8-29

3. Check the accelerator position sensor resistance.

8-30

1. Check the ECM circuit.

8-24

2. Check the electronic throttle valve relay and fuse.

8-23

3. Check the electronic throttle valve circuit.

8-26

1. Check the battery cables and terminals for proper connection.

3-15

2. Check the ECM circuit.

8-24

3. Check the electronic throttle valve circuit.

8-26

4. Check the electronic throttle valve relay and fuse.

8-23

1. Check the battery cables and terminals for proper connection.

3-15

2. Check the ECM circuit.

8-24

3. Check the electronic throttle valve circuit.

8-26

4. Check the electronic throttle valve relay and fuse.

8-23

6P21H11

Troubleshooting the power unit Trouble code

142

143 144

145

6P21H11

Symptom Item Electronic throttle valve malfunction

Electronic throttle valve malfunction

Remarks J

—

Checking steps

Refer to page

1. Check the electronic throttle valve operation.

4-5

1. Check the battery cables and terminals for proper connection.

3-15

2. Check the ECM circuit.

8-24

3. Check the electronic throttle valve circuit.

8-26

4. Check the electronic throttle valve relay and fuse.

8-23

1. Check the electronic throttle valve operation.

4-5

9-14

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TRBL SHTG

Troubleshooting

Troubleshooting the power unit using the diagnostic test lead 1. Connect the special service tool to the outboard motor as shown.

• Trouble code indication Example: The illustration code numbers 23 and 113. a: Light on, 0.33 second b: Light off, 4.95 seconds c: Light off, 0.33 second d: Light off, 1.65 seconds

indicates

L/W S6P29030

NOTE: When performing this diagnosis, all of the electrical wires must be properly connected.

Diagnostic test lead: YB-06795

1 2. Start the engine and let it idle. 3. Check the flash pattern of the special service tool to determine if there are any malfunctions.

1 c d

d a

b a a a S6P29040

• Normal condition (no defective part or irregular processing is found)

4. If a flash pattern listed in the trouble code chart is displayed, check the malfunctioning part according to the flash pattern.

• Single flash is given every 4.95 seconds. a: Light on, 0.33 second b: Light off, 4.95 seconds

9-15

6P21H11

Troubleshooting the power unit NOTE: • When more than one problem is detected, the light of the special service tool flashes in the pattern of the lowest numbered problem. After that problem is corrected, the light flashes in the pattern of the next lowest numbered problem. This continues until all of the problems are detected and corrected. • See “Trouble code and checking step” in this chapter for the trouble code.

6P21H11

1 2 3 4 5 6 7 8 9 9-16

TRBL SHTG

Troubleshooting

Troubleshooting the power unit (trouble code not detected) Troubleshooting when a trouble code is not available consists of the following 4 items. Symptom 1: Specific trouble conditions Symptom 2: Trouble conditions of an area or individual part Cause 1: The content considered as the trouble factors of symptom 2. Cause 2: The content considered as the trouble causes of cause 1 (described if necessary). Symptom 1: Engine does not crank

Symptom 2 Starter motor does not operate

Cause 1

Cause 2

Discharged battery Loose connection battery terminal

Refer to page

—

Check the battery.

3-15

—

Check the battery terminal.

3-15

Check the wiring harness continuity.

Check the starter relay.

8-36

Short, open, or loose connection in starter motor circuit

—

Starter relay malfunction

—

Blown fuse

—

Check the fuse.

8-5

Starter motor malfunction

—

Disassemble and check the starter motor.

8-38

Engine start malfunction

—

Check the engine start switch.

8-22

Shift the remote control lever to the neutral position.

1-51

—

Disassemble and check the power unit.

5-1

switch

Gear shift not in the neutral position Starter motor operates, but the engine does not crank

Checking step

Stuck piston Piston lock due to water or oil in the combustion chamber

—

Salt buildup on the drive shaft and bushing

—

Disassemble and check the upper case.

7-5

Starter motor malfunction

—

Disassemble and check the starter motor.

8-38

*1: See the wiring diagram.

9-17

6P21H11

Troubleshooting the power unit Symptom 1: Engine will not start (engine cranks)

Symptom 2 ECM does not operate

Spark plug does not spark (all cylinders)

Cause 1

Cause 2 —

Check the relay.

8-23

Blown fuse

—

Check the fuse.

8-5

Short, open, or loose connection in ECM circuit

8-24

—

Check the ECM circuit.

Engine start switch malfunction

—

Check the engine start switch.

8-22

Check the crank position sensor and cam position sensor.

8-17 8-32

Check the wiring harness continuity.

Short, open, or loose connection in high-pressure fuel pump circuit

Check the wiring harness continuity.

Blown fuse

Check the fuse.

8-5

Relay malfunction

Check the relay.

8-35

High-pressure fuel pump malfunction

Check the highpressure fuel pump continuity.

8-35

Short, open, or loose connection in low-pressure fuel pump circuit

Check the wiring harness continuity.

Blown fuse

Check the fuse.

8-5

Low-pressure fuel pump malfunction

Check the low-pressure fuel pump continuity.

8-35

Crank position sensor malfunction and cam position sensor (PORT EX) malfunction

High-pressure pump does operate

Low-pressure pump does operate

Vapor shut-off valve does not close

Refer to page

Relay malfunction

Short, open, or loose connection in ignition coil ground circuit Fuel not supplied (all cylinders)

Checking step

fuel not

—

Fuel not supplied to the fuel rails

—

Check the fuel pressure.

4-7

Fixed vapor shut-off valve

—

Check the vapor shut-off valve.

8-36

*1: See the wiring diagram.

6P21H11

9-18

1 2 3 4 5 6 7 8 9

TRBL SHTG

Troubleshooting

Symptom 1: Unstable engine idle speed, poor acceleration, poor performance, or limited engine speed

Symptom 2

Cause 1

Spark plug does not spark (some cylinders)

Spark plug malfunction

Short, open, or loose connection in ignition coil circuit Ignition coil function

Cause 2

Checking step

—

Check the ignition spark. Check the spark plugs.

3-7 8-17

Check the wiring harness continuity.

8-17

—

Change the ignition coil and check the ignition spark. Change the ignition coil and check the ignition spark.

8-17

—

Check the pressure regulator.

4-7

Check the highpressure fuel pump continuity.

8-35

—

8-34

—

Check the fuel injector operation. Check the fuel injector resistance. Check the wiring harness continuity.

—

Change the fuel injector and check the fuel injector operation.

4-26 8-34

—

Replace injector.

fuel

4-26 5-1

—

Check the compression pressure. Disassemble and check the power unit.

—

mal-

ECM malfunction

High-pressure fuel line malfunction (fuel pressure is low)

Pressure regulator malfunction

Fuel not supplied (some cylinders)

Fuel injector malfunction

High-pressure fuel pump malfunction

Short, open, or loose connection in fuel injector circuit

—

ECM malfunction

Clogged fuel injector filter Low compression pressure

Scratched piston Damaged valve Valve stuck to valve guide

Refer to page

the

*1: See the wiring diagram.

9-19

6P21H11

Troubleshooting the power unit Symptom 1: High engine idle speed (below 1,200 r/min)

Symptom 2

Cause 1

â&#x20AC;&#x201D;

Air leakage (throttle valve-cylinder head)

Cause 2

Checking step

â&#x20AC;&#x201D;

Check the O-rings and gaskets of the intake manifold, surge tank, and throttle body.

Refer to page 4-12 4-15

Symptom 1: Engine stalls, unstable engine idle speed, or poor acceleration

Symptom 2 Incorrect intake cam timing (check using the YDIS)

6P21H11

Cause 1

Cause 2

Checking step

Refer to page

Variable camshaft Stuck oil control timing operation mal- valve plunger function

Check the oil control valve operation using the YDIS. Check the oil control valve plunger.

8-34 9-1

Clogged oil control valve filter

Replace the oil control valve filter.

5-41

Clogged sage

pas-

Check the oil passage.

1-35

Stuck variable camshaft timing

Replace the variable camshaft timing.

5-8

oil

9-20

1 2 3 4 5 6 7 8 9

TRBL SHTG

Troubleshooting

Symptom 1: Limited engine speed (below 2,000 r/min) Refer to page

Symptom 2

Cause 1

Cause 2

Checking step

• Buzzer comes on • Overheat warning indicator comes on • Cooling water does not discharge from the cooling water pilot hole

Clogged cooling water inlet

—

Check the cooling water inlet.

3-9

Water pump malfunction

Water pump impeller malfunction

Check the impeller.

6-5 6-33

Check the druff key.

Woo-

6-5 6-33

Check the water pump housing.

6-5 6-33

Check the cartridge.

insert

6-5 6-33

Check the outer plate cartridge.

6-5 6-33 3-9

—

Check the cooling water passage (power unit, exhaust guide, and upper case).

Thermostat malfunction

—

Check the thermostat.

3-7

Insufficient engine oil

—

Add sufficient oil.

3-4

de- Oil pump malfunction

Check the oil pump.

5-66

Clogged oil strainer

Check the oil strainer.

7-11

Clogged sage

Check the oil passage (power unit and oil pump).

5-2

Replace the oil filter.

3-6

Water leakage from water pump housing

Clogged cooling water passage

• Buzzer comes on • Oil pressure warning indicator comes on

Oil pressure crease

oil

pas-

Clogged oil filter

9-21

6P21H11

Troubleshooting the power unit

Troubleshooting the PTT unit Symptom 1: PTT unit does not operate

Symptom 2 PTT relay does not operate

PTT motor does not operate

Oil pressure does not increase

Cause 1 PTT switch function

Cause 2 mal-

—

Short, open, or loose connection of the wiring harness

—

PTT relay malfunction

—

Short, open, or loose connection of the PTT motor lead

—

Checking step Check switch.

the

PTT

Refer to page 7-47

Check the wiring harness continuity.

Check the PTT relay.

7-47

Check the PTT motor lead.

7-28

PTT motor malfunction

Disassemble and check the PTT motor.

7-27

—

Blown fuse

—

Check the fuse.

8-5

Loose connection of the battery terminal

—

Check the terminal

3-15

Discharged battery

—

Check the battery.

3-15

Check the manual valve.

7-22

Add sufficient fluid.

3-12

Check the PTT unit for leakage.

7-22

Disassemble and check the PTT unit.

7-22

Manual opened

valve

Insufficient PTT fluid PTT fluid leakage

Manual valve malfunction — —

Clogged filter Clogged fluid passage

—

battery

*1: See the wiring diagram.

6P21H11

9-22

1 2 3 4 5 6 7 8 9

TRBL SHTG

Troubleshooting

Symptom 1: PTT unit does not hold the outboard motor up

Symptom 2

Cause 1 Manual opened

—

valve

Insufficient PTT fluid PTT fluid leakage Clogged fluid passage

Refer to page

Cause 2

Checking step

Manual valve malfunction

Check the manual valve.

7-22

Add sufficient fluid.

3-12

—

Check the PTT unit for leakage.

7-22

—

Disassemble and check the PTT unit.

7-22

—

Troubleshooting the lower unit Symptom 1: Shift mechanism of the forward gear and reverse gear does not operate properly

Symptom 2

Cause 1

Cause 2

Checking step

Remote control box malfunction

—

Check the remote control box.

1-51

Check the shift cable and shift cable end.

3-11

Adjust the shift cable.

3-11

Detent malfunction

Check the detent.

7-1

Shift rod connection malfunction

Check the shift rod connection.

6-5 6-33

—

Check the internal parts of the lower unit.

6-1 6-29

Shift cable and shift cable end malfunction

—

— Shift rod operation malfunction Shift mechanism malfunction (in lower unit)

9-23

Refer to page

6P21H11

Index

A. Abbreviation ................................................1-3 Adjusting the throttle cable........................3-10 Adjusting the trim sensor ..........................7-20 Adjusting the valve clearance ...................5-12 Aft view ............................ 8-6, 8-7, 8-14, 8-15 After test run .............................................1-52 Assembling the drive shaft housing ......................................... 6-16, 6-46 Assembling the forward gear ....................6-16 Assembling the gear pump .......................7-35 Assembling the lower case ............. 6-15, 6-44 Assembling the oil pan..............................7-11 Assembling the oil pump...........................5-66 Assembling the power unit........................5-67 Assembling the propeller shaft assembly ...6-9 Assembling the propeller shaft housing................................... 6-9, 6-38 Assembling the PTT motor .......................7-29 Assembling the reverse gear ....................6-45 Assembling the tilt ram..............................7-41 Assembling the trim ram ...........................7-42 Assembling the upper case.......................7-12

B. Backlash (counter rotation model) ............6-56 Backlash (regular rotation model) .............6-26 Bleeding the PTT unit ...............................7-45 Bleeding the PTT unit (built-in) .................7-46 Bracket unit ...............................................3-12 Break-in.....................................................1-52

C. Changing the engine oil by draining it.........3-5 Changing the engine oil using an oil changer ...........................................3-4 Changing the gear oil................................3-13 Charging system .......................................8-42 Checking the accelerator position sensor .....................................................8-30 Checking the accelerator position sensor circuit...........................................8-29 Checking the anode ..................................3-14 Checking the armature..............................8-40 Checking the battery ....................... 1-49, 3-15 Checking the bearing ...................... 6-15, 6-44 Checking the brush ...................................8-41 Checking the cam position sensor ............8-32 Checking the camshaft .............................5-27 Checking the canister ...............................4-18 Checking the canister check valve............4-18 Checking the check valve .........................4-21 6P21H11

Checking the compression pressure .......... 5-1 Checking the connecting rod big end side clearance ........................................ 5-61 Checking the connecting rod small end inside diameter ................................ 5-61 Checking the cooling water passage.......... 3-9 Checking the cooling water passage cover anode............................................ 5-49 Checking the cooling water pilot hole ....... 1-52 Checking the crank position sensor.......... 8-17 Checking the crank position sensor air gap..................................................... 8-18 Checking the crankpin oil clearance......... 5-62 Checking the crankshaft ........................... 5-61 Checking the crankshaft journal oil clearance ........................................... 5-64 Checking the cylinder bore ....................... 5-59 Checking the cylinder head ...................... 5-48 Checking the drive shaft ..................6-15, 6-44 Checking the drive shaft bushing ............. 7-10 Checking the ECM circuit ......................... 8-24 Checking the electrical component............. 8-1 Checking the electronic throttle valve and TPS circuit ....................................... 8-26 Checking the electronic throttle valve motor ............................................. 8-28 Checking the engine idle speed ................. 3-9 Checking the engine oil .............................. 3-4 Checking the engine oil level.................... 1-49 Checking the engine start switch.............. 8-22 Checking the engine start switch and engine stop lanyard switch .............. 1-51 Checking the engine stop lanyard switch...................................................... 8-23 Checking the engine temperature sensor..................................................... 8-20 Checking the exhaust cover anode .......... 5-40 Checking the filter..................................... 7-35 Checking the fuel filter ................................ 3-4 Checking the fuel injector ......................... 8-34 Checking the fuel joint and fuel hose (fuel joint-to-fuel injector) .......................... 3-3 Checking the fuel system ......................... 1-49 Checking the fuse............................7-46, 8-36 Checking the gear oil level ..............1-49, 3-13 Checking the gear pump .......................... 7-35 Checking the gear pump housing............. 7-35 Checking the gear shift and throttle operation................................................. 1-51 Checking the gear shift operation............. 3-11 Checking the high-pressure fuel pump relay.............................................. 8-35 Checking the hydraulic pressure .............. 7-24

i-1

1 2 3 4 5 6 7 8 9

Index Checking the ignition coil input voltage.....8-17 Checking the ignition spark.......................8-17 Checking the intake air pressure sensor...8-19 Checking the intake air temperature sensor.................................8-18 Checking the knock sensor.......................8-22 Checking the lower case................. 6-15, 6-44 Checking the lower unit for air leakage.....3-14 Checking the low-pressure fuel pump and high-pressure fuel pump ..................8-35 Checking the magnet switch .....................8-41 Checking the main relay and electronic throttle valve relay...................................8-23 Checking the neutral switch ......................8-21 Checking the oil control valve ...................8-34 Checking the oil pressure ...........................5-1 Checking the oil pressure sensor................5-2 Checking the oil pump ..............................5-66 Checking the oil strainer ...........................7-11 Checking the outboard motor mounting height ......................................1-50 Checking the pinion and forward gear ......6-15 Checking the pinion and reverse gear ......6-44 Checking the piston clearance (reference) ..............................................5-59 Checking the piston diameter ...................5-59 Checking the piston pin.............................5-61 Checking the piston pin boss bore............5-61 Checking the piston ring ...........................5-59 Checking the piston ring end gap (reference) ..............................................5-60 Checking the piston ring groove ...............5-60 Checking the piston ring side clearance ...5-60 Checking the pressure regulator.................4-7 Checking the propeller ..............................3-14 Checking the propeller shaft ............. 6-9, 6-37 Checking the propeller shaft housing ........................................... 6-9, 6-37 Checking the PTT fluid level .....................3-12 Checking the PTT motor ...........................7-28 Checking the PTT operation .....................3-12 Checking the PTT relay ............................7-47 Checking the PTT switch ..........................7-47 Checking the PTT system.........................1-51 Checking the Rectifier Regulator ..............8-42 Checking the remote control cable ...........1-50 Checking the reservoir ..............................7-35 Checking the shift cut switch.....................8-21 Checking the spark plug .............................3-7 Checking the starter motor operation........8-42 Checking the starter motor pinion .............8-40 Checking the starter relay .........................8-36 Checking the stator coil.............................8-42

i-2

Checking the steering system .................. 1-51 Checking the thermostat............................. 3-7 Checking the thermoswitch ...................... 8-20 Checking the throttle valve operation ......... 4-5 Checking the tilt cylinder and trim cylinder ............................................ 7-40 Checking the timing belt ............................. 3-6 Checking the timing belt and sprocket...... 5-27 Checking the top cowling............................ 3-3 Checking the TPS....................................... 4-5 Checking the trim sensor.......................... 7-48 Checking the valve ..........................5-43, 7-41 Checking the valve clearance................... 5-10 Checking the valve guide ......................... 5-44 Checking the valve lifter ........................... 5-27 Checking the valve seat ........................... 5-45 Checking the valve spring ........................ 5-43 Checking the vapor separator .................. 4-25 Checking the vapor shut-off valve ............ 8-36 Checking the water pump and shift rod............................................6-5, 6-33 Checking using the YDIS............................ 8-1 Clamp bracket and swivel bracket............ 7-16 Connecting the communication cable to the outboard motor ............................... 9-4 Control system............................................ 3-9 Cooling water hose..................................... 4-3 Crankcase ................................................ 5-52 Cylinder block .................................. 5-54, 5-56 Cylinder head ........................................... 5-41

D. Dimension................................................. 2-10 Disassembling the cylinder block ............. 5-58 Disassembling the drive shaft housing ..........................................6-14, 6-43 Disassembling the forward gear ............... 6-14 Disassembling the gear pump .................. 7-34 Disassembling the lower case .........6-14, 6-43 Disassembling the oil pan......................... 7-10 Disassembling the oil pump...................... 5-66 Disassembling the propeller shaft assembly.......................................... 6-8 Disassembling the propeller shaft housing ...................................6-8, 6-36 Disassembling the PTT motor .................. 7-28 Disassembling the reverse gear ............... 6-43 Disassembling the starter motor............... 8-40 Disassembling the tilt cylinder and trim cylinder ............................................ 7-39 Disassembling the upper case ................. 7-10 Disassembly and assembly ........................ 1-5 Disconnecting the quick connector............. 4-9 6P21H11

Index Installing the exhaust cover ...................... 5-40 Installing the fuel hose clamp ................... 4-25 Installing the fuel injector .......................... 4-27 Installing the intake manifold .................... 4-13 Installing the intake silencer ..................... 4-13 Installing the lower unit ....................6-19, 6-49 Installing the power unit............................ 5-74 Installing the propeller shaft housing ..........................................6-17, 6-47 Installing the PTT motor ........................... 7-43 Installing the PTT unit............................... 7-19 Installing the reservoir .............................. 7-44 Installing the steering arm ........................ 7-14 Installing the throttle body......................... 4-18 Installing the tilt cylinder ........................... 7-42 Installing the tilt ram.................................. 7-44 Installing the trim ram ............................... 7-42 Installing the upper case........................... 7-13 Installing the valve .................................... 5-48 Installing the water pump and shift rod..........................................6-18, 6-48 Installing the wiring harness ..................... 5-72 Intake manifold ......................................... 4-12 Introduction................................................. 9-1

Draining the fuel..........................................4-9 Drive shaft and lower case (counter rotation model)..........................6-41 Drive shaft and lower case (regular rotation model)...........................6-12

E. ECM ..........................................................5-36 ECM and electronic throttle valve control system.........................................8-23 ECM system..............................................1-13 Electrical .....................................................2-7 Electrical component...................................8-3 Electronic fuel injection control system .....1-25 Electronic throttle valve control system.....1-40 Engine speed control system....................1-43 Exhaust cover ...........................................5-39

F. Feature and benefit...................................1-13 Fire prevention ............................................1-4 Fuel control system...................................8-34 Fuel filter ...................................................4-11 Fuel hose and blowby hose ........................4-1 Fuel injector ..............................................4-26 Fuel system.................................................3-3 Fuse box ...................................................5-37 Fuse holder .................................................8-5

J. Junction box ............................................. 5-38

G. Gear pump ................................................7-31 General .....................................................3-14 General specification ..................................2-1 General torque ..........................................2-15 Good working practice ................................1-5

H. Hose routing................................................4-1 How to use this manual...............................1-1

I. Identification................................................1-6 Ignition and ignition control system...........8-17 Ignition timing control system....................1-29 Installing the camshaft, driven sprocket, and timing belt.........................................5-28 Installing the clamp bracket ......................7-19 Installing the cooling water passage cover.........................................5-50 Installing the cylinder head .......................5-51 Installing the drive shaft .................. 6-16, 6-46

6P21H11

Knock control system ............................... 1-32

L. Lower unit ................................ 1-47, 2-6, 3-13 Lower unit (counter rotation model).......... 6-29 Lower unit (regular rotation model)............. 6-1 Low-pressure fuel pump ........................... 4-20 Lubricating the outboard motor................. 3-16

M. Maintenance interval chart ......................... 3-1 Maintenance specification .......................... 2-3 Manual format............................................. 1-1 Measuring the forward and reverse gear backlash ...................6-26, 6-56 Measuring the fuel pressure ....................... 4-7 Measuring the peak voltage ....................... 8-1 Model.......................................................... 1-6

P. Part, lubricant, and sealant......................... 1-4 Port view..............................................8-3, 8-9

i-3

1 2 3 4 5 6 7 8 9

Index Power unit ....................................2-3, 3-4, 5-1 Predelivery check......................................1-49 Propeller selection ....................................1-48 Propeller shaft housing (counter rotation model)..........................6-34 Propeller shaft housing (regular rotation model).............................6-6 Propeller size ............................................1-48 PTT electrical system................................7-46 PTT motor .................................................7-27 PTT unit ....................................................7-22

R. Reducing the fuel pressure .........................4-8 Refacing the valve seat.............................5-46 Removing the clamp bracket ....................7-19 Removing the cooling water passage cover.........................................5-49 Removing the cylinder head .....................5-43 Removing the drive shaft ................ 6-14, 6-43 Removing the exhaust cover ....................5-40 Removing the fuel hose clamp..................4-25 Removing the lower unit ................... 6-4, 6-32 Removing the power unit ..........................5-22 Removing the propeller shaft housing assembly ........................... 6-8, 6-36 Removing the PTT unit .............................7-18 Removing the steering arm.......................7-14 Removing the timing belt, driven sprocket, and camshaft ................5-24 Removing the upper case .........................7-10 Removing the water pump and shift rod .................................... 6-4, 6-33 Removing the wiring harness guide..........5-20 Replacing the oil filter..................................3-6 Replacing the timing belt...........................5-15 Replacing the valve guide.........................5-45

S. Safety while working ...................................1-4 Selecting the connecting rod bearing........5-63 Selecting the forward gear shim ..... 6-23, 6-54 Selecting the main bearing .......................5-65 Selecting the pinion shim ................ 6-22, 6-52 Selecting the propeller shaft shim... 6-25, 6-55 Selecting the reverse gear shim ..... 6-24, 6-53 Selection ...................................................1-48 Self-protection.............................................1-4 Serial number..............................................1-6 Shift rod and bottom cowling.......................7-1 Shimming ........................................ 6-22, 6-52 Shimming (counter rotation model)...........6-51

i-4

Shimming (regular rotation model) ........... 6-21 Special service tool..................................... 1-7 Specified torque........................................ 2-12 Starboard view...................................8-4, 8-11 Starter motor............................................. 8-38 Starter motor and accelerator position sensor ....................................... 5-35 Starting system......................................... 8-36 Symbol........................................................ 1-2

T. Test run .................................................... 1-52 Throttle body............................................. 4-15 Tightening torque...................................... 2-12 Tilt cylinder and trim cylinder .................... 7-37 Top cowling ................................................ 3-3 Top view ............................................8-8, 8-16 Trouble code and checking step................. 9-7 Troubleshooting the lower unit ................. 9-23 Troubleshooting the power unit .................. 9-5 Troubleshooting the power unit (trouble code not detected)..................... 9-17 Troubleshooting the power unit using the diagnostic test lead ................. 9-15 Troubleshooting the power unit using the YDIS.......................................... 9-5 Troubleshooting the PTT unit ................... 9-22

U. Upper case and steering arm ..................... 7-5

V. Vapor gas hose .......................................... 4-2 Vapor separator........................................ 4-22 Variable camshaft timing control system ...........................................1-35, 8-32 Ventilation................................................... 1-4

W. Wiring harness routing................................ 8-9

Y. YDIS ........................................................... 9-1

6P21H11

Index

— MEMO —

1 2 3 4 5 6 7 8 9 6P21H11

i-5

2005 F250 6P2 LF250 6P3

1000001–1002894 1000001–1000956

Wiring diagram F250TR, LF250TR 1 Condenser (connect to the intake air pressure sensor) 2 PTT switch 3 Trim sensor 4 Crank position sensor 5 Stator coil 6 Starter motor 7 Battery 8 Accessory battery 9 PTT motor 0 Rectifier Regulator A PTT relay B Fuse box C Diode (connect to the PTT relay) D Oil pressure sensor E Shift cut switch F Neutral switch G Accelerator position sensor H Fuel injector I Thermoswitch (STBD) J Oil control valve (STBD) K Knock sensor L Cam position sensor (STBD IN) M Ignition coil N Spark plug O ECM P Cam position sensor (PORT IN) Q Cam position sensor (PORT EX) R Engine temperature sensor S Oil control valve (PORT) T Thermoswitch (PORT) U High-pressure fuel pump V Low-pressure fuel pump W Intake air temperature sensor X Electronic throttle valve assembly Y Vapor shut-off valve Z Intake air pressure sensor È É Ê Ë Ì Í

To remote control/switch panel To warning indicator/trim meter To cooling water pressure sensor (optional) To speed sensor (optional) To diagnostic test lead (special service tool) To personal computer for diagnosis

(*1) Isolator cable (optional) (*2) Negative battery cable (commercially available)

Color code B Br G L Lg O P R Sb W Y B/R B/W B/Y Br/W G/B G/R G/Y L/G L/W L/Y O/W P/B P/G P/W Pu/B Pu/R R/B R/Y W/B W/L W/R

: Black : Brown : Green : Blue : Light green : Orange : Pink : Red : Sky blue : White : Yellow : Black/red : Black/white : Black/yellow : Brown/white : Green/black : Green/red : Green/yellow : Blue/green : Blue/white : Blue/yellow : Orange/white : Pink/black : Pink/green : Pink/white : Purple/black : Purple/red : Red/black : Red/yellow : White/black : White/blue : White/red

NOTE: Depending on the outboard motor, the location of the coupler terminal may be changed as indicated in the table below. Coupler

Terminal No.

Color

F (on the wiring harness guide)

2 through 18 (except 13)

F (on the ECM bracket)

1 through 12

13 through 17

R/Y

20 through 24

12, 13, 16, 21, and 24

1 through 22 (except 11 through 15)

R/Y

3 and 4

11 and 12

R/G

2006 F250 6P2 LF250 6P3

1002895– 1000957–

To remote control/switch panel To warning indicator/trim meter To diagnostic test lead (special service tool) To personal computer for diagnosis To cooling water pressure sensor (optional) To speed sensor (optional) To trim meter (LAN) To LAN meter

(*1) Isolator cable (optional) (*2) Negative battery cable (commercially available)

Color code B Br G L Lg O P R Sb W Y B/R B/W B/Y Br/W G/B G/R G/Y L/G L/W L/Y O/W P/B P/G P/W Pu/B Pu/R R/B R/Y W/B W/L W/R

NOTE: Depending on the outboard motor, the location of the coupler terminal may be changed as indicated in the table below. Coupler

Terminal No.

Color

F (on the wiring harness guide)

2 through 18 (except 13)

F (on the ECM bracket)

1 through 12

14 through 17

R/Y

20 through 24

1 and 8

R/Y

16, 17, 23, 24, and 32

27 and 28

R/Y

1 through 22 (except 11 through 15)

R/Y

3 and 4

11 and 12

R/G

YAMAHA MOTOR CORPORATION, USA

Printed in USA May 2006 – 0.0 × 1 CR (E_1)

1000001–1002894 1000001–1000956

F250TR, LF250TR

(*1)

B B B

B B

(*2)

B B B

R R

1 2 3 4 5 6 7 8 9 101112 R R

Br B Y/G L/R R R/G R/G

1 2 3 4 5 6 7 8 9 10111213 14151617181920212223

Br R/Y R R

R R

R/Y R/Y R/Y R/Y R/Y R/Y R/Y

G/R G/B B P O P/W

R/Y R/Y R/Y R/Y R/Y R/Y R/Y R/Y R/Y R/Y Y

1 2 3 4 5 6

20A

R/Y G/B

P/G B O R/Y G/B

30A

1 2 3 4 5 6

P/G B O

15A

O B P/G

123

1 2

Lg Sb

B/Y B

1 2

1 2 3

R/Y L/W

O B P/W

1 2 3

B L/Y

1 2

B L/Y

L/G B

1 2

L/G B

B O P P/W B O

1 2 3 4 5 6 7 8

R/Y Pu/L

1 2

R/Y Pu/Y

1 2

R/Y Pu/R

1 2

R B

R/Y W/B B

1 2 3 4 5 6 7 8 9 10111213 14151617181920212223242526

1 2 3 4 5 6 7 8 9 10111213 14151617181920212223 24252627 28 29 30 3132 33 34

123

1 R

123

L/W B

123

R/Y W/B B

R/Y W/B

123

O P/W O

B/Br B/L Pu/W Pu/L Pu/G Pu/Y Pu/R Pu/B L/W B/G B/Y B B P/W L/W B G/B B/W B/O G B P P/B B G/R P W L/R Y Pu Pu G/B R/G R/G

123

B B L/B L O P B B

B W/G R/Y

123

R/Y

R/Y W/L B

1 2 3 4 5 6 7 8 9 10111213 1415161718192021222324

P/G P/W P

B/W B R/Y

123

O P/W

B/G B R/Y

B/Y B

B/Br B R/Y

1 2

O O O O O

Pu R/Y

B B B B B B B B B B B B R/Y R/Y R/Y R/Y R/Y

1 2

O B L/B

B/L B R/Y

B/Y B R/Y

B/O B R/Y

R/Y Pu/B

B/Y

1 2

B W/B B/Y B P W L

R/Y Pu/G

L/G Y

1 2

L/Y Y/G G

R/Y Pu/W

O B L

B/Y B/Y

1 2

W/B W/G W/L L/W

L/W L/W

Pu R/Y

1 2

B B B B B B B B B B B B B B B B B B

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

W/R G

1 2

1 G

10A

P B

1 2

30A

Lg Sb R

G B W/B

80A

P/B P P/B P/W

1234 80A

W L

123

G R Y Lg P Sb W Br B

1234

R R

Sb Br

P B

Lg Sb R

Lg Sb

2005 F250 6P2 LF250 6P3

1002895– 1000957–

F250TR, LF250TR

(*1)

B B B

B B

(*2)

B B B

B G

Br R/Y R R

R R

1 2 3 4 5 6 7 8 9 101112

R/Y R/Y R/Y R/Y R/Y R/Y R/Y

1 2 3 4 5 6 7 8 9 10111213 14151617181920212223

R R B

1 2

Lg Sb

B/Y B

1 2

1 2 3

B B

R/Y L/W

O B P/W

1 2 3

B L/Y

1 2

B L/Y

L/G B

1 2

L/G B

B O P P/W B O

1 2 3 4 5 6 7 8

R/Y Pu/L

1 2

R/Y Pu/Y

1 2

R/Y Pu/R

1 2

R B

R/Y W/B B

123

1 R

L/W B

1 2 3 4 5 6 7 8 9 10111213 14151617181920212223242526

O B L/B

1 2 3 4 5 6 7 8 9 10111213 14151617181920212223242526

R/Y W/B B

1 2 3 4 5 6 7 8 9 10111213 14151617181920212223 24252627 28 29 30 3132 33 34

B/L B R/Y

123

B/Y B R/Y

123

B/Y

123

B R/Y B/O B R/Y

1 2 3 4 5 6 7 8 9 10111213 1415161718192021222324

123

O O O O O

123

B R

B W/B B/Y B P W L

B/Y B

L/G Y

1 2

L/Y Y/G G

Pu R/Y

B B B B B B B B B B B B R R/Y R/Y R/Y R/Y

1 2

W/B W/G W/L L/W

B B L/B L O P B B O O P/W O P

R/Y

O B L

B/Y B/Y

P/G P/W P

R/Y Pu/B

P/W

1 2

R/Y W/B

G/R B G/B Pu

R/Y Pu/G

B/Br B/L Pu/W Pu/L Pu/G Pu/Y Pu/R Pu/B L/W B/G B/Y G L/R Y P B B B/W B/O P/W P/B L/W B B Pu W R/G R/G G/B

1 2

B W/G R/Y

R/Y W/L B

R/Y Pu/W

B/W B R/Y

1 2

B/G B R/Y

B/Br B R/Y

L/W L/W

Pu R/Y

1 2

B B B B B B B B B B B B B B B B B B

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

G/R G/B B P O P/W

R/Y R/Y R/Y R/Y R/Y R/Y R/Y R/Y R/Y R/Y Y

1 2 3 4 5 6

20A

30A

R/Y G/B

P/G B O R/Y G/B

Br B Y/G L/R R R/G R/G

1 2 3 4 5 6

P/G B O

15A

O B P/G

123

W/R R

1 2

10A

P B

G B W/B

30A

Lg Sb R

1 2

1234 80A

P/B P P/B P/W

B 80A

W L

123

G R Y Lg P Sb W Br B

1234

R R

Sb Br

P B

Lg Sb R

R R

Lg Sb

2006 F250 6P2 LF250 6P3