Part of the Yanmar Repair Manuals.
Torque a cylinder head on a 4JH5E from memory and you are betting a head gasket, and a second teardown, on a number you half remember. This Yanmar service manual covers the 3JH5E, 4JH5E, 4JH4-TE, and 4JH4-HTE marine diesels: 380 pages in English, Yanmar publication 0BJHM-G00200.
It carries the figures a rebuild stands on. The Engine section holds the special and standard torque charts, sealants, and specifications. Fuel System covers tests, servicing, and injector pressures with shim correction. Cooling System walks the seawater circuit, Lubrication covers the trochoid pump, and the turbo models get their own Turbocharger section. Wiring diagrams, a troubleshooting chart, and full service standards close it out.
As a PDF download with 409 bookmarks, the same pages sit on the laptop at the bench and the phone down in the engine compartment.
What's Inside This Yanmar 3JH5E, 4JH5E, 4JH4-TE, 4JH4-HTE Manual
| System | Pages | Key Topics |
|---|---|---|
| Introduction | 5-6 | Revision History |
| Safety | 7-16 | Safety Statements, Location of Safety Labels |
| General Service Information | 17-92 | Engine Outline Drawings, Piping Diagrams, Exhaust Gas Emission Regulations, Location of Nameplates, Diesel Fuel, Engine Oil, Engine Coolant |
| Periodic Maintenance | 93-100 | EPA Requirements, Periodic Maintenance Schedule, Periodic Maintenance Procedures |
| Engine | 101-202 | Special Torque Chart, Standard Torque Chart (W/O Lubricating Oil), Sealants and Compounds, Measuring Instruments, Special Service Tools, Specifications |
| Fuel System | 203-258 | Fuel System Components, Fuel System Diagram, Fuel System Tests, Servicing the Fuel System, Special Service Tools, Specifications |
| Cooling System | 259-284 | Cooling Flow Diagram, Draining / Refilling Seawater Cooling System, Measuring Instruments, Tests and Adjustments, Special Service Tools, Specifications |
| Lubrication | 285-296 | Repair, Tests and Adjustments, Special Service Tools, Specifications |
| Turbocharger | 297-308 | Turbocharger Components, Washing the Turbocharger Blower, Cleaning the Air Cleaner, Special Service Tools, Specifications |
| Starter Motor | 309-314 | Starter Motor Specifications, Starter Motor Troubleshooting, Starter Motor Service |
| Alternator | 315-324 | Alternator Service, Specifications |
| Electrical | 325-350 | Component Locations, Wiring Diagram, Instrument Panel, Function Description - Warning Devices |
| Troubleshooting | 351-362 | Troubleshooting Chart, Measuring Compression Pressure, After Troubleshooting or Repair |
| Service Standards | 363-380 | Engine Tuning, Engine Body, Lubricating Oil System (Trochoid Pump), Main Bolt and Nut, Standard Bolts and Nuts (W/O Lubricating Oil) |
Every system also includes safety precautions.
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| 3JH5E, 4JH5E | ||
| Fuel Supply Restriction (3JH5E, 4JH5E) | 400 mmAq (16 in.Aq) | p. 206 |
| Fuel Injector Pressure | 20.5-21.6 MPa (2986-3132 psi) | p. 223 |
| Connecting Rod Bolt Torque | 44.1 ± 5.0 N-m | p. 106 |
| Oil Pressure (Idle) | 0.05 MPa or more | p. 290 |
| 4JH4-TE | ||
| Fuel Supply Restriction, 4JH4-TE | 1000 mmAq (40 in.Aq) | p. 206 |
| 4JH4-HTE | ||
| Fuel Supply Restriction Excluding Fuel Filter Loss Pressure | 1000 mmAq (40 in.Aq) | p. 206 |
| All Models | ||
| Injection Pressure Change per Shim Thickness | 1.9 MPa (275 psi) per 0.1 mm (0.004 in.) shim thickness | p. 255 |
| Cylinder Head Bolt Torque | 88.2 ± 3.0 N-m | p. 106 |
| 4JH4-TE, 4JH4-HTE | ||
| Turbine Shaft End Nut Torque | 20±2 N·cm (196±19 lb-in) | p. 300 |
Yanmar 3JH5E, 4JH5E, 4JH4-TE, 4JH4-HTE Common Problems This Manual Covers
Cranks well but will not fire
Air ingress, clogged filters, or contaminated diesel starves these engines of fuel, and the symptom looks identical from the outside. The Fuel System section gives the system diagram, fuel system tests, and servicing procedures to isolate the restriction instead of swapping parts.
Manual Section: Fuel System p. 203Oil level rising with diesel smell
Prolonged light-load running lets unburned fuel wash past the rings and dilute the crankcase oil, which owners report as a rising dipstick and, in the worst case, overspeed risk. The Lubrication section covers repair plus tests and adjustments, including oil pressure checks.
Manual Section: Lubrication p. 285Overheating under sustained load
A restricted seawater side or a lazy thermostat shows up only when the engine is worked hard. The Cooling System section includes the cooling flow diagram, draining and refilling the seawater circuit, and tests and adjustments to find the blockage.
Manual Section: Cooling System p. 259Turbo models down on power, smoking
On the 4JH4-TE and 4JH4-HTE, a fouled blower wheel or dirty air cleaner robs boost long before the turbo actually fails. The Turbocharger section covers component breakdown, washing the turbocharger blower, and cleaning the air cleaner.
Manual Section: Turbocharger p. 297Warning alarms and panel faults
Owners of the JH series ask constantly how to trace alarms and warning circuits. The Electrical section provides component locations, the wiring diagram, instrument panel coverage, and function descriptions for the warning devices so you can test the sender instead of silencing the buzzer.
Manual Section: Electrical p. 325Slow cranking or no crank
A tired starter drags cranking speed below what a cold diesel needs to light off. The Starter Motor section carries specifications, troubleshooting, and service procedures so you can bench-test before buying a replacement.
Manual Section: Starter Motor p. 309Tired engine, weak compression
Hard starting with white smoke on an engine with hours on it points at compression, not fuel. The Troubleshooting section pairs its troubleshooting chart with the procedure for measuring compression pressure, plus checks to run after the repair.
Manual Section: Troubleshooting p. 351Frequently Asked Questions
Which Yanmar engines does this manual cover?
The 3JH5E, 4JH5E, 4JH4-TE, and 4JH4-HTE marine diesel engines. It is the Yanmar service manual, publication 0BJHM-G00200, 380 pages in English, covering the naturally aspirated and turbocharged JH models in one book.
What is the cylinder head bolt torque for the Yanmar 3JH5E, 4JH5E, 4JH4-TE, 4JH4-HTE marine engines?
The Engine section's special torque chart gives cylinder head bolts as a TWO-STAGE tightening, not a single figure: first 44-54 N-m (32-40 lb-ft), then 85.2-91.2 N-m (62.9-67.3 lb-ft), which is the 88.2 ± 3.0 N-m the chart also states. Bolts are M10x1.25 and are coated with lubricating oil before tightening. Values for the 4JH4-TE and 4JH4-HTE are in the same chart. p. 106
Does it include wiring diagrams?
Yes. The Electrical section covers component locations, the wiring diagram, the instrument panel, and function descriptions for the warning devices, which is where to start when chasing an alarm or a dead gauge. p. 325
What injector pressures does it give?
The Fuel System section specifies 3JH5E and 4JH5E injector pressure at 20.5 to 21.6 MPa (2986 to 3132 psi), and the servicing procedures explain adjusting pop pressure by shim thickness. p. 223
How will I receive this Service Manual?
Instant PDF download. You get the full 380-page searchable Service Manual immediately after payment. Open it on your laptop, tablet, or phone right in the shop.
Can I print this manual?
No restrictions at all. Print individual pages, full chapters, or the entire manual. The PDF is completely unlocked.
Are wiring diagrams part of this Yanmar 3JH5E Service Manual?
Yes. Wiring diagrams for the Yanmar 3JH5E, 4JH5E, 4JH4-TE and 4JH4-HTE are included, together with component locations, the instrument panel, and function descriptions for the warning devices.
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