Part of the Yanmar Repair Manuals.
With a Yanmar 2S apart on the stand, the questions come fast: what is the wear limit on that liner bore, which undersize metal do you order, and how tight do the rod bolts go before the pan goes back on. This is Yanmar's own factory service book for the 2S diesel engine, 95 pages of the maker's maintenance standards instead of forum guesswork, which matters when you are the only mechanic in the room and there is no one left to ask.
Inside are the maintenance standards and wear limits for the main parts, full disassembly and reassembly procedures, and dedicated coverage of the fuel injection pump, governor, injection timing, injection valves, cylinder head, liners, and the cooling water and lubricating oil pumps. A countermeasures chapter matches symptoms to causes when the engine runs rough.
It arrives as a 6.31 MB PDF you can print for the bench, so the clearances and torque figures are in front of you before anything goes back together, and the undersize and oversize metal lists mean you order the right bearing set the first time.
What's Inside This Manual
| System | Pages | Key Topics |
|---|---|---|
| Preface | 5 | |
| Outline of Major Structures | 6 | Cyl. Block, Cyl. Head, Crankshaft, Piston, Lub. Oil Pump, Fuel Injection Pump |
| Fuel and Lubricating Oil | 7-19 | Fuel (Light Oil, Heavy Oil, Quality Fuel Oil, Properties of Fuel & Engine Performances, Cautions on Fuel) |
| Periodical Checking & Servicing | 20-26 | 3-1.Periodical List of Items to Be Checked and Frequency of Checks, 3-2.Checking Locations, 3-3.Checking Locations by Systems |
| Maintenance Standards of Main Parts | 27-32 | 4-1.Maintenance Standards, 4-2.List of Measuring Positions, 4-3.List of Wear Limit, 4-4.List of Undersize Metals, 4-5.List of Oversize Metals |
| Engine Disassembly | 33-51 | 5-1.Precautions Prior to the Disassembly of the Engine, 5-2.General Cautions for Maintenance and Cleaning, 5-3.Cautions for Disassembling the Engine, 5-4.Procedure on Disassembling |
| Engine Reassembly | 52-69 | 6-1.Cautions for Reassembling the Engine, 6-2.Procedure on Reassembling |
| Disassembly & Reassembly of Other Parts | 70-91 | Fuel Injection Pump, Governor, Fuel Injection Time, Fuel Injection Valve, Air Venting of Fuel Injection System, Cylinder Head, Piston Pin and Connecting Rod, Cylinder Liner |
| Countermeasures to Engine Troubles | 92-93 | Lubricating Oil Issues, Fuel System Malfunctions, Mechanical Wear, Compression Problems, Cooling System Failures, Governor Control Issues |
| Storing Engine | 94 |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Cylinder head bolt locking torque | 15 kg/m | p. 60 |
| Fuel injection pressure | 160 kg/cm² | p. 76 |
| Normal oil pressure | 2 ~ 2.5 kg/cm² | p. 88 |
| Diesel Light Oil Cetane Number | over 45 | p. 7 |
| Engine Oil Exchange Interval (after second) | 100 hours | p. 18 |
| Cylinder Liner Inner Diameter Wear Limit | +0.030 mm | p. 27 |
| Connecting Rod Bolt Locking Torque | 6 kg/m | p. 59 |
| Cylinder Head Locking Torque | 15 kg/m | p. 60 |
| Valve Head Clearance (Suction & Exhaust) | 0.2mm | p. 82 |
| Cooling Water Pump Standard Delivery | 544 ℓ/1800 rpm-1 hr | p. 87 |
| Lubricating Oil Pressure (Normal) | 2~2.5 kg/cm² | p. 89 |
| Lubricating Oil Pump Backlash | 0.08~0.16mm | p. 91 |
