Replacing injectors

Oct 26, 2008
6,296
Catalina 320 Barnegat, NJ
I have a Yanmar 3GM30F with completely unknown engine hours. The hour meter supposedly stopped working long ago so for 20 years I couldn't even estimate the hours. For the past 6 years, engine usage has been light. On my recent trip in the Atlantic, my engine lost RPM very suddenly and quit while bashing through waves on an upwind slog. Limping into Atlantic CIty under sail, I found that at low RPM I could maneuver in the anchorage to set anchor. After a lot of trials in the harbor I found that the middle injector leaks fuel profusely at the base of the injector. I had removed the fuel return pipe to inspect at the top of the injectors and detected no leaking or blockage in the fuel return system. Mixing elbow was clear. Racor and secondary filters where replaced in June so filters were new. However, I changed the Racor as it was dirty (but not necessarily dirty enough to need replacement - but I did it anyway). I found secondary filter (spin on next to the butterfly pump) clean as a whistle.

So I called a mechanic and his almost immediate diagnosis was that the middle injector is irreparably damaged. I'm replacing all 3.

So my question is ... what causes an injector to leak fuel? Could it simply be the hours? Could it be the extremely rough ride I was putting the boat thru? Could it be other engine performance issues? In neutral, the engine feels and sounds normal and powerful. During my trials, the engine ran smoothly and powerfully up to about 2400 rpm and start to fail with higher rpm while running in gear. However, the leaking seemed to worsen as I was making adjustments and trials around the harbor and the leaking persisted even in neutral at all rpm levels. I lived four nights on anchor before finally moving into a marina and getting a mechanic involved. The mechanic explained that the leaking is reduced when the engine is cold and heating up. But when the engine gets heated at running temp and put under load, the heat will allow increased leaking and start to cause the loss in rpm.
 
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Likes: Ward H
Jun 21, 2004
2,935
Beneteau 343 Slidell, LA
Can you send them to a rebuild service. Years ago I sent the injectors for a Yamaha outboard to a service center for rebuild & recalibration. Good results & very reasonable cost at approximately $30 per injector. Provided a print out with before & after specs.
 
Nov 22, 2011
1,259
Ericson 26-2 San Pedro, CA
Normally a bronze washer between the Injector and Engine.
Jim...
I believe on the Yanmar it's a copper washer. I think this is the part he would need for the GM-series--but definitely do confirm. It may be that there was a change made from earlier (1980s vintage) models.

Screenshot 2025-08-12 083106.jpg
 
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Likes: JamesG161

jssailem

SBO Weather and Forecasting Forum Jim & John
Oct 22, 2014
23,322
CAL 35 Cruiser #21 moored EVERETT WA
Certainly the copper washer may have been ignored when the injector was last removed. Some times these washers stay in the injector hole and a second washer is added in error.

Hard to identify remotely.
I took my injectors to a specialty shop that services injectors for the trucking fleets. They rebuilt them and returned them. They now run like new. If there is a unrepairable issue the shop will tell you. Is it best to get new ones or service the ones you got? In part it depends on the availability and cost of new injectors. Even new out of the box can have defects. In my case the new ones are believed to be made with gold parts by the sellers.:yikes:

Your experience may be better.
 
Jul 5, 2011
754
Oday 28 Madison, CT
I also pulled my injectors out many years ago and sent them to a diesel outfit that specialized in cleaning these up. I guess they de-carboned them and put new seals in them or something like that but they have been beautiful ever since. Engine you would not properly idle as it had been overheated apparently, and the injectors had been coked or so I was told by the yard that the sold me the boat.