Yanmar 3JH5E, 4JH5E, 4JH4-TE, 4JH4-HTE Service Workshop Manual

Workshop Service and Repair Manual for the Yanmar 3JH5E, 4JH5E 4JH4-TE & 4JH4-HTE 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 engine 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.

Below Is An Exhaustive List Of The Items Covered Within This Workshop Manual:

Safety Precautions
Engine Outline Drawings
3JH5E Models
4JH5E Models
4JH4-TE Models
4JH4-HTE Models
Piping Diagrams
3JH5E Models
4JH5E Models
4JH4-TE Models
4JH4-HTE Models
Exhaust Gas Emission Regulations
Engine Identification (Epa/ Garb)
Emission Control Label (Epa/ Garb)
Location Of Nameplates
Engine Nameplates (Typical)
Diesel Fuel
Diesel Fuel Specifications
Bleeding The Fuel System
Engine Oil
Engine Oil Specifications
Engine Coolant
Engine Coolant Specifications
Principal Engine Specifications
3Jh5E Engine Specifications
4Jh5E Engine Specifications
4Jh4-te Engine Specifications

General Service Information
4JH4-HTE Engine Specifications
Tightening Torques
Hexagon Bolts And Nuts
Hose Clamps
Prepare Engine For Long-term Storage
Abbreviations And Symbols

Periodic Maintenance
Introduction
The Importance Of Periodic Maintenance
Performing Periodic Maintenance
Yanmar Replacement Parts
Required Epa Maintenance
Epa Requirements
Conditions To Ensure Compliance With Epa
Emission Standards
Inspection And Maintenance
Periodic Maintenance Schedule
Inspection And Maintenance Of Epa Emission-related Parts
Inspection And Maintenance Of Epa Emission-related Parts For Cl Marine Engines
Periodic Maintenance Procedures
After Initial 50 Hours Of Operation
Every 50 Hours Of Operation
Every 250 Hours Of Operation
Every 500 Hours Of Operation
Every 1000 Hours Of Operation

Engine:
Safety Precautions
Introduction
Specifications
General Information
Test And Adjustment Specifications
Repair Specifications
Special Torque Chart
Standard Torque Chart (W/O Lubricating Oil)
Special Service Tools
Measuring Instruments
Sealants And Compounds
Tests And Adjustments
Test Compression
Disassembly
Inspection
Cylinder Block
Cylinder Head
Piston And Piston Rings
Connecting Rod
Crankshaft And Main Bearings
Camshaft And Tappets
Timing Gear
Flywheel And Housing
Assembly
Checking And Adjusting Remote Control Operation

Fuel System
Safety Precautions
Introduction
Specifications
Test And Adjustment Specifications
Special Torque Chart
Special Service Tools
Fuel System Components
Fuel System Diagram
Fuel System Tests
Measuring Fuel Feed Pump Pressure
Testing Return Fuel Pressure
Servicing The Fuel System
Removing The Fuel Injection Nozzle
Cleaning Fuel Injection Nozzle Cavities
Installing Fuel Injection Nozzles
Removing Fuel Injection Lines
Installing Fuel Injection Lines
Replacing The Fuel Injection Pump
Adjusting Fuel Injection Timing
Mp2 Fuel Injection Pump System (3 / 4JH5E)
Introduction
Fuel Injection Pump
Stop Solenoid
Trochoid Fuel Pump
Fuel System Specifications
Special Torque Chart
Test And Adjustment Specifications
Special Service Tools
Measuring Instruments
Fuel System Components
Fuel Injection Pump
Removing The Fuel Injection Pump
Installing The Fuel Injection Pump
Checking And Adjusting Fuel Injection Timing
Determining The Fuel Injection Timing Specification
Checking Fuel Injection Timing
Adjusting Fuel Injection Timing
Fuel Injection Pump Service Data
Fuel Line Replacement Filter
Replacing Injection Nozzle Return
Bleeding The Fuel System
Fuel Injectors
Removing Fuel Injectors Testing Fuel Injectors
Disassembling And Inspecting Fuel Injectors
Adjusting Fuel Injector Pressure
Reassembling Fuel Injectors

Cooling System:
Safety Precautions
Introduction
Specifications
Test And Adjustment Specifications
Repair Specifications
Special Service Tools
Measuring Instruments
Cooling Flow Diagram
Tests And Adjustments
Pressure Testing Cooling System And Filler Cap
Testing Thermostat.
Draining/ Refilling Seawater Cooling System
Draining And Filling Closed Cooling System
Removing/ Installing Intercooler (4JH4-HTE)
Disassembling And Assembling Intercooler
Removing And Installing Heat Exchanger
Disassembling/ Assembling Heat Exchanger
Removing And Installing Coolant Pump
Removing And Installing Thermostat
Seawater Pump
Coolant Recovery Tank
Bilge Pump And Bilge Strainer (Optional)

Lubrication:
Safety Precautions
Introduction
Specifications
Test And Adjustment Specifications
Special Torque Chart
Special Service Tools
Measuring Instruments
Tests And Adjustments
Engine Oil Flow
Checking Engine Oil Pressure
Repair
Engine Lubrication System Components
Changing Engine Oil, Replacing Engine Oil Filter Element
And Cleaning Engine Oil Cooler
Removing And Installing Engine Oil Sump
Engine Oil Pump
Checking Piston Cooling Oil Nozzle

Turbocharger:
Safety Precautions
Introduction
Specifications
Turbocharger Components
Special Service Tools
Washing The Turbocharger Blower
Cleaning The Air Cleaner
Turbocharger Service

Starter Motor:
Safety Precautions
Introduction
Starter Motor Specifications
General Specifications
Special Torque Chart
Characteristics
Starter Motor Troubleshooting
Starter Motor Service

Alternator:
Safety Precautions
Introduction
Specifications
General Specifications (Standard)
General Specifications
(Optional For 4JH4-TE And 4JH4-HTE)
Special Torque Chart
Wiring Diagram
Output Characteristics
Alternator Service
Replace V-belt
Removing And Installing The Alternator

Electrical:
Safety Precautions
Introduction
Component Locations
Sensor And Switch Locations
Wiring Diagram
3JH5E / 4JH5E – C-type
Instrument Panel (Optional)
3JH5E / 4JH5E 12V B- And Bx B-type
Instrument Panel (Optional)
3JH5E / 4JH5E 12V C X B-type
Instrument Panel (Optional)
3JH5E / 4JH5E With Keyless B- And BX B-type
Instrument Panel (Optional)
3JH5E / 4JH5E With Keyless C X B-type
Instrument Panel (Optional)
4JH4-te / 4JH4-HTE With Panel BX B-type
Instrument Panel
4JH4-te / 4JH4-HTE With Panel C X B-type
Instrument Panel
Instrument Panel
B-type Instrument Panel (Selectable Optional)
B-type (Keyless) Instrument Panel (Selectable Optional)
C-type Instrument Panel (Selectable Optional)
C-type (Keyless) Instrument Panel (Selectable Optional)
Function Description – Warning Devices
Oil Pressure Alarm
Sending Unit For Lubricating Oil Pressure Gauge
Coolant Temperature Alarm
Sending Unit For The Coolant Temperature Gauge
Air Heater (Standard)
Electric Engine Stop Solenoid

Troubleshooting:
Safety Precautions
Introduction
Troubleshooting Chart
Starting Trouble
Exhaust Gas Colour
Vibration – Drive Disengaged
Vibration – Drive Engaged
Engine Knocks
Low Power Output
Engine Overheat
Engine Runs Cold
Coolant Loss
Lubricating Oil Pressure Low
Panel Display
Measuring Compression Pressure
After Troubleshooting Or Repair

Service Standards:
Engine Tuning
Engine Body
Cylinder Head
Camshaft And Gear Train
Cylinder Block
Lubricating Oil System (Trochoid Pump)
Outside Clearance Of Outer Rotor
Tip Clearance Between Outer Rotor And Inner Rotor
Side Clearance Of Outer Rotor
Inside Clearance Of Inner Rotor
Main Bolt And Nut
Standard Bolts And Nuts (W/O Lubricating Oil)