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Diesel This is a new forum dedicated to diesel engines and their applicable accessories.


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Old 02-21-2013
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Injector Removal- Yanmar Engines

I have a Yanmar 3gmd and have question on fuel injector removal. Looks like all Yanmars have similar injector arrangement.

How do you remove and reinstall an injector?

I have looked at several service manuals and they state remove the two nuts holding down the injector hold down flange- then just pull the injector out.

But there looks to be (from parts drawing) a lot of gasket, and o-ring, and insulators that are between injector and the head. Do you just leave these in if you plan to either replace or service the injector. Or do all or some of these parts need to be replaced when you reinstall the injector?

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Re: Injector Removal- Yanmar Engines

Not real up on Yanmars, Casey, but in my experience any and all seals/washers/ etc involved in injector installs are one time use only except perhaps in an emergency.
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Re: Injector Removal- Yanmar Engines

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Not real up on Yanmars, Casey, but in my experience any and all seals/washers/ etc involved in injector installs are one time use only except perhaps in an emergency.
Yes that is what I normally do. All these parts (o rings, insulators, washers) are deep in the head after pulling the injector. They look to be difficult to remove and to be sure you have all the items out. They can (or parts of them) fall into the injector hole then foul the cylinder (once in the cylinder, nearly impossible to remove). Normally the manuals I have specify to replace a gasket or o-ring, but with the injector removal, the manuals mention nothing.
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Re: Injector Removal- Yanmar Engines

A crochet-hook type tool can be helpful to try to remove those kinds of things and NOT drop them down.. but will they actually fit down and clear into the cylinder? Our Bosch seal rings wouldn't...
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Old 02-22-2013
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Re: Injector Removal- Yanmar Engines

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Originally Posted by Faster View Post
A crochet-hook type tool can be helpful to try to remove those kinds of things and NOT drop them down.. but will they actually fit down and clear into the cylinder? Our Bosch seal rings wouldn't...
Hook is a good idea. One of the parts is called an "insulator". Imagine it keeps the heet of combustion away from the fuel injector. Normally engine type "insulators" are made out of an asbestos or similar material. This material is normally somewhat brittle and breaks up into parts when you attempt to dis-assemble.
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Re: Injector Removal- Yanmar Engines

the parts below the injector are the insulator which is a fiber disc and needs to be replaced the pre combustion chamber does not. I found that I could buy a new injector for less then having the shop rebuild them. $100 each and $125 to rebuild, but then I only have one.
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Re: Injector Removal- Yanmar Engines

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Originally Posted by overbored View Post
the parts below the injector are the insulator which is a fiber disc and needs to be replaced the pre combustion chamber does not. I found that I could buy a new injector for less then having the shop rebuild them. $100 each and $125 to rebuild, but then I only have one.
So after you pull the injector out can the insulator be removed easily? Did you also replace the O-ring?
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Re: Injector Removal- Yanmar Engines

the insulation washer fits down in to a recess on the top of the pre-combustion chamber and can be dug out with an awl or the like. it is a aluminizsed fiber washer, like head gasket material. the o ring is up around the top of the body of the injector and helps keep moisture from getting down the side of the injector so it does not rust and make removal at a latter date difficult. On mine the pre combustion chamber was changed and required the head be removed and a 10 ton press to get it out. the PO's so called mechanic did not put in an o ring and the parts were rusted in. he told me it was not needed so he left it out. he also told me that the injector was still good and when i remove it the nozzle hole was about twice the size of the new one. he doesn't work on this engine anymore.
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Re: Injector Removal- Yanmar Engines

Thanks for the advice. How did the engine run with the large injector nozzel hole?
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Re: Injector Removal- Yanmar Engines

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Thanks for the advice. How did the engine run with the large injector nozzel hole?
it ran but very rich and a lot of black smoke with any rpm above idle. the engine was rebuilt about 5 years before I bought it. but they put on all the old stuff. the PO was tired of fixing the engine problems. which helped lead to him sell the boat. the compression checked out good. I replaced the entire fuel system. injectors, fuel pump, injection pump, lines, hoses, added a Racor and cleaned the tank out. set up the timing and adjusted the valves correctly. spent about $800 and $180 for new water pump, now it should be good for quite a while.
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