Part of the Yanmar Repair Manuals.
The head is off, the shim pack from the injection pump is laid out on the bench, and the question is no longer what failed but what the numbers should be. This Yanmar service manual settles that for the whole 3JH2 marine family: 3JH2-E, 3JH2-BE, 3JH2-TE, 3JH2-TBE, 3JH25A and 3JH30A, under factory publication 0BJH2-G00101.
Across 153 pages it works through the basic engine parts, the fuel injection pump and governor, the turbocharger and mixing elbow, the lubrication system, and both circuits of the cooling water system, sea water and fresh. Separate chapters take the reduction and reversing gears, KM3A included, through inspection, disassembly and reassembly. Each system ends in the clearances, wear limits and torque figures that decide whether a part goes back in.
An engine on the stand is time lost every day it stays apart. Download the PDF, print the pages you need at the bench, and reassemble to the figures Yanmar built these engines to.
Other edition of this manual
What's Inside This Manual
| System | Pages | Key Topics |
|---|---|---|
| History of Revision | 3 | Exterior Views, Specifications, Engine Outline, Performance Curves, Piping Diagrams, Fuel Injection Pump Service Data |
| General | 5-30 | Exterior Views, Specifications, Engine Outline, Performance Curves, Piping Diagrams |
| Basic Engine Parts | 31-60 | Cylinder Block, Cylinder Head, Pistons and Piston Pins, Connecting Rod, Crankshaft and Main Bearing, Camshaft and Tappets, Timing Gear, Flywheel and Housing |
| Fuel Injection Equipment | 61-100 | Fuel Injection Pump Service Data, Governor, Disassembly, Reassembly and Inspection of Fuel Injection Pump, Fuel Injection Pump and Governor, Fuel Feed Pump, Fuel Injection Nozzle |
| Intake and Exhaust System | 101-119 | Turbocharger, Mixing Elbow |
| Lubrication System | 120-133 | Lube Oil Pump, Lube Oil Filter, Oil Pressure Control Valve, Lube Oil Cooler, Piston Cooling Nozzle, Rotary Waste Oil Pump (Optional) |
| Cooling Water System | 134-153 | Sea Water Pump, Fresh Water Pump, Heat Exchanger, Pressure Cap and Sub Tank, Thermostat, Kingston Cock (Optional) |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Cylinder head bolts tightening torque (First) | 3.5 ~ 4.5 kg-m (25.33 ~ 32.56 ft-lb) | p. 39 |
| Cylinder head bolts tightening torque (Second) | 7.5 ~ 8.5 kg-m (54.29 ~ 61.48 ft-lb) | p. 39 |
| Outer rotor and inner rotor clearance (Standard) | 0.050 ~ 0.105 mm (0.0019 ~ 0.0041 in.) | p. 125 |
| Outer rotor and pump body clearance (Standard) | 0.100 ~ 0.170 mm (0.0039 ~ 0.0066 in.) | p. 125 |
| Nozzle opening pressure (Injection starting pressure) | 195 ~ 205 kg/cm² (2,773 ~ 2,915 lb/in.²) | p. 93 |
| Nozzle nut tightening torque | 4 ~ 4.5 kg-m (28.9 ~ 32.5 ft-lb) | p. 92 |
| Thermostat opening temperature | 75 ~ 78 °C (167 ~ 174 °F) | p. 149 |
| Thermostat full open temperature | 90 °C (194 °F) | p. 149 |
| Connecting rod tightening torque | 5.0 ~ 5.5 kg-m (36.15 ~ 39.77 ft-lb) | p. 47 |
| Main bearing cap bolt tightening torque | 10.5 ~ 11.5 kg-m (76.27 ~ 83.15 ft-lb) | p. 51 |
| Cylinder Bore Diameter (Standard) | 82.00 ~ 82.03 mm | p. 34 |
| Governor Weight Nut Tightening Torque | 4.5 ~ 5.0 kg-m (32.54 ~ 36.16 ft-lb) | p. 72 |
