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.
What's Inside This Yanmar 3JH2 Series 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 |
Yanmar 3JH2 Series Common Problems This Manual Covers
Overheating and high temperature alarm
A fouled heat exchanger, a stuck thermostat or a failing sea water pump will all push the temperature up. The Cooling Water System chapter covers both the sea water and fresh water circuits, with test values for the thermostat and service procedures for the pumps and heat exchanger.
Manual Section: Chapter 6 Cooling Water System p. 134Low oil pressure alarm underway
Worn oil pump rotors or a sticking oil pressure control valve can drop pressure long before the bearings complain. The Lubrication System chapter gives rotor clearance limits for the lube oil pump and covers the filter, pressure control valve and lube oil cooler.
Manual Section: Chapter 5 Lubrication System p. 120Hard starting or stalling under load
Air in the fuel line, worn nozzles or a tired injection pump show up as hard starts and stalling when the throttle comes up. The Fuel Injection Equipment chapter covers pump disassembly and adjustment, governor setup, nozzle testing and a dedicated fuel system troubleshooting table.
Manual Section: Chapter 3 Fuel Injection Equipment p. 61Knocking and heavy vibration
Knock that survives a check of the mounting bolts usually means bearing or piston clearances have opened up. The Basic Engine Parts chapter gives measurement procedures and wear limits for the crankshaft, main and rod bearings, pistons, rings and cylinder bores.
Manual Section: Chapter 2 Basic Engine Parts p. 31Black smoke and weak turbo boost
On the turbocharged versions of these engines, a carboned mixing elbow or fouled turbocharger chokes the exhaust and shows up as smoke and lost power. The Intake and Exhaust System chapter covers turbocharger inspection and mixing elbow service.
Manual Section: Chapter 4 Intake and Exhaust System p. 101Marine gear slips or shifts hard
Harsh engagement or clutch slip in the gear ends a season fast. The Reduction and Reversing Gear chapter covers construction, the shifting device, inspection, disassembly and reassembly for the KM3A, KM3P1, KM3P3 and KM35P1 marine gears.
Manual Section: Reduction and Reversing GearFrequently Asked Questions
Which engine models does this manual cover?
It covers the Yanmar 3JH2 series marine diesels: 3JH2-E, 3JH2-BE, 3JH2-TE and 3JH2-TBE, plus the 3JH25A and 3JH30A, under Yanmar publication 0BJH2-G00101. Reduction and reversing gear chapters cover the KM3A, KM3P1, KM3P3 and KM35P1 marine gears.
Does it give the cylinder head bolt torque and sequence?
Yes. The Cylinder Head section in Basic Engine Parts gives a two-stage tightening procedure, 3.5 to 4.5 kg-m on the first pass and 7.5 to 8.5 kg-m on the final, along with the bolt sequence. p. 39
Are injector pop pressures listed?
Yes. The Fuel Injection Nozzle section lists nozzle opening pressure, 195 to 205 kg/cm² for the 3JH2-E and 3JH2-TE, plus the nozzle nut tightening torque and the testing and adjustment procedure. p. 93
At what temperature should the thermostat open?
The Thermostat section of the Cooling Water System chapter lists opening at 75 to 78 °C, full open at 90 °C with 8 mm valve lift, and calls for replacement every year or 2000 hours, whichever comes first. p. 149
How will I receive this Service Manual?
This is a 153-page searchable PDF ready for immediate download. Works on any device, so pull it up on your phone while you're under the hood. No shipping, no waiting.
Can I print this manual?
Yes. The PDF has no DRM restrictions, so print any page or section you need for your shop. Works with any standard printer.
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