This site documents the Yanmar 2GM rebuild effort done during the winter of 2006 - 2007. Additional links are provided
for various Yanmar 2GM engine resources.
This rebuild can be done by anyone with moderate mechanical skills, access to a good Yanmar parts supplier, the Yanmar
Service Manual, and time to be patient (this can't be rushed). It helps to have a warm place to work out of the
elements, and to have access to mechanics tools. This rebuild was performed during nights and weekends starting in October
2006 and completed near the end of January 2007. The engine is ready to be installed back in Rhapsody as soon as the
weather is warm!
May 2007 Update - Rhapsody went in the water on 28 April. Over the winter the system had biocide fuel conditioner
added, recirculated with an electric fuel pump and filtered with 30 & 10 micron Racor spin on filters to get rid of "Diesel
Bug" in the fuel tank. Prior to launching the fuel system was reconnected, and bleed of air. The good news - the
Yanmar started on the first try and ran noticeably smoother! The bad news - the fuel filters plugged up within 3 days
and the engine was starved for fuel. I was not successful in removing the "bug" from the fuel tank. After replacing
the filters (and plugging up a second set), I decided it was easier to pump the tank dry and replace the fuel. On 8
May I filled a few 5 gallon fuel cans with the same 12V electric pump I used over the winter for recirc. New 10 micron
primay and 2 micron secondary filters were installed and 5 gallons of fresh fuel with biocide conditioner was added.
The Yanmar started right away and appears to work fine. Before completely filling the tank, I want to make sure the
"bug" is eliminated. Hopefully, this is the end... time will tell.
15 May 2007 - all is well. Added 5 more gallons of fuel. The Yanmar is running well. No more signs
of "bug" in the fuel.
Click the link below to download the presentation
PDF File with Pictures & Rebuild Chronology
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