Yanmar 3JH4 | 4JH4 Service Workshop Manual

Workshop Service and Repair Manual for the Yanmar 3JH4 & 4JH4 engines, an absolute must-have for any Yanmar owner. This full workshop manual covers every component, service and repair procedure in full Yanmar factory specification with clear step by step photographs and technical drawings for the Yanmar 3 and 4 cylinder engines with torque setting values throughout each chapter, this is the most comprehensive service manual available as used by boatyards and independent marine engineers the world over.

General
Exterior views
Specifications
Fuel oil, lubricating oil and cooling water
Exhaust gas emission regulation
Engine identification (3JH4E)
Emission Standard
Guarantee conditions for emission standard
Inspection and Adjustment
Periodic maintenance schedule
Periodic inspection and maintenance procedure
Checks before starting
Inspection every 50, 250 & 1000 hours
Adjusting the no-load maximum or minimum speed
Sensor inspection
Oil pressure switch
Thermo switch
Thermostat inspection
Adjusting operation
Preliminary precautions
Adjusting operation procedure
Checkpoints and precautions during running
Long term storage

Troubleshooting:
Preparation before troubleshooting
Quick reference chart for troubleshooting
Troubleshooting (Concerning engine and fuel injection equipment)
Troubleshooting by measuring compression pressure
Disassembly and reassembly precautions
Disassembly and reassembly tools
General handtools
Special handtools
Measuring instruments
Disassembly and reassembly

Inspection and Servicing of Basic Engine Parts:
Cylinder block
Inspection of parts
Cleaning of oil holes
Color check procedure
Replacement of cup plugs.
Cylinder bore measurement
Cylinder head
Inspecting the cylinder head
Valve seat correction procedure
Intake/exhaust valves, valve guides
Valve springs
Assembling the cylinder head
Measuring top clearance
Intake and exhaust rocker arms
Adjustment of valve clearance
Piston and piston pins
Piston
Piston pin
Piston rings
Connecting rod
Inspecting the connection rod
Crank pin metal
Piston pin bushing
Assembling piston and connecting rod
Crankshaft and main bearing
Crankshaft
Main bearing
Camshaft and tappets
Camshaft
Tappets

Timing gear:
Inspecting the gears
Gear timing marks
Flywheel and housing
Position of top dead centre and fuel injection timing
Damper disc and cooling fan

Fuel Injection:
Equipment
Fuel Injection Pump/governor
Fuel system diagram
Fuel injection pump service data
Fuel injection pump structure
Removing a fuel injection pump
Installing a fuel injection pump
Adjusting fuel injection timing
Troubleshooting of the fuel injection pump
Major faults and troubleshooting
Tools

Fuel feed pump:
Construction of fuel feed pump
Fuel feed pump specifications
Disassembly and reassembly of the fuel feed pump
Fuel feed pump inspection6.3 Fuel filter
Fuel filter specifications
Fuel filter inspection
Fuel tank

Intake and Exhaust System:
Intake system
Breather system (A reductor to intake air system of blowby gas)
Diaphragm assy inspection
Exhaust system
Construction
Mixing elbow inspection

Lubrication System:
Lube oil pump
Lube oil pump construction
Specifications of lube oil pump
Lube oil pump disassembly and reassembly
Lube oil pump inspection
Oil pressure control valve construction
Lube oil filter
Lube oil filter construction
Lube oil filter replacement
Lube oil cooler
Lube oil cooler construction
Inspecting the lube oil cooler
Rotary waste oil pump (Optional)

Cooling Water System:
Seawater pump
Specifications of seawater pump
Seawater pump disassembly
Seawater pump Inspection
Seawater pump reassembly
Fresh water pump
Fresh water pump construction
Specifications of fresh water pump
Fresh water pump disassembly
Fresh water pump inspection

Heat exchanger:
Heat exchanger construction
Specifications of heat exchanger
Disassembly and reassembly of the heat exchanger
Heat exchanger inspection

Pressure cap and coolant recovery tank:
Pressure cap construction
Pressure cap pressure control
Pressure cap inspection
Replacing filler neck
Function of the coolant recovery tank
Specifications of the coolant recovery tank
Mounting the coolant recovery tank
Precautions on usage of the coolant recovery tank

Thermostat:
Functioning of thermostat
Thermostat construction
Characteristics of thermostat
Thermostat inspection
Testing the thermostat

Bilge pump and bilge strainer (Optional):
Introduction
Description
Cautions
Assembly procedure
Cautions for assembling
Troubleshooting

Reduction and Reversing Gear:
Specifications
Specifications of 4JH4E marine gears

Remote Control System (Optional):
Construction of remote control system
Remote control device components
Remote control installation
Remote control inspection
Remote control adjustment

Electrical System:
Wiring diagram
Battery

Starting motor:
Specifications
Characteristics
Structure
Wiring diameter of a starting motor

Alternator standard, 12V/60A:
Alternator 12V/80A (Optional)
Specifications
Structure
Wiring diagram
Standard output characteristics

Instrument panel:
B-type instrument panel (Optional)
C-type instrument panel
Specifications
Structure
Wiring diagram
Standard output characteristics
Instrument panel
B-type instrument panel (Optional)
C-type instrument panel

Warning devices:
Oil pressure alarm
Sender unit for lube oil pressure gauge
Cooling water temperature alarm
Sender unit for the cooling water temperature gauge
Air heater (Optional)
Electric engine stopping device (Optional)

Service Standards:
Engine tuning
Engine body
Cylinder head
Camshaft and gear train
Cylinder block
Lubricating oil system (Trochoid pump)

Tightening torque for bolts and nuts:
Main bolt and nut
Standard bolts and nuts (without lube oil)