Part of the Yanmar Repair Manuals.
Chapter 3 of this manual strips the fuel injection pump and governor all the way down, and that is where a 4JH that cranks hard and smokes gets sorted: pump and governor disassembly, calibration and adjustment, the automatic advancing timer, and injector service at the correct 195 to 205 kg/cm² opening pressure.
The rest of the 1985 factory book, publication 0000A0A1647, works through the whole engine across 317 pages: cylinder liners, piston ring end gap, crankshaft and main bearing clearance, the two stage cylinder head torque sequence, turbocharger service, lubrication, sea and fresh water cooling, the KBW 20/21 and KM4A marine gears, and the electrical system, covering the 4JHE, 4JH-TE, 4JH-HTE and 4JH-DTE and their (B) variants.
Every weekend the engine sits in pieces is a weekend off the water. The PDF goes wherever the work is, laptop at the bench or tablet in the engine bay, and prints page by page so the clearance tables sit beside the vise.
Complete the set for your 4JH Series
What's Inside This Manual
| System | Pages | Key Topics |
|---|---|---|
| General | 4-22 | Exterior Views, Specifications, Performance Curves, Engine Cross Section, Dimensions, Piping Diagrams, Parts Interchangeability |
| Inspection and Servicing of Basic Engine Parts | 23-54 | Cylinder Block, Cylinder Liners, Cylinder Head, Piston and Piston Pins, Connecting Rod, Crankshaft and Main Bearing, Camshaft and Tappets, Timing Gear |
| Fuel Injection Equipment | 55-104 | Fuel Supply System, Disassembly, Reassembly and Inspection of Governor, Reassembly and Inspection of Fuel Injection Pump, Fuel Injection Pump and Governor |
| Intake and Exhaust System | 105-127 | Intake Silencer, Intake Manifold, Turbocharger, Mixing Elbow, Breather |
| Lubrication System | 128-140 | Lube Oil Pump, Lube Oil Filter, Oil Pressure Control Valve, Lube Oil Cooler, Piston Cooling Nozzle, Rotary Waste Oil Pump (Optional) |
| Cooling Water System | 141-159 | Sea Water Pump, Fresh Water Pump, Heat Exchanger, Pressure Cap and Sub Tank, Thermostat, Kingston Cock (Optional), Sea Water Filter (Optional) |
| Reduction and Reversing Gear | 160-221 | Marine Gear Model Kbw 20 and 21 (Construction, Installation, Servicing, Operation and Maintenance, Disassembly, Reassembly, Special Tools), Marine Gear Model KM4A |
| Remote Control (Optional) | 222-228 | Remote Control System, Remote Control Installation, Remote Control Inspection, Remote Control Adjustment |
| Electrical System | 229-282 | Battery, Starter Motor, Alternator, Instrument Panel and Wiring Codes, Warning Devices, Air Heater (Optional) |
| Disassembly and Reassembly | 283-316 | Disassembly and Reassembly Precautions, Disassembly and Reassembly Tools, Bolt/Nut Tightening Torque, Test Running |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Fuel pump automatic timer box nuts tightening torque | 6.0 ~ 7.0 kg-m (43.39 ~ 50.63 ft-lb) | p. 315 |
| Rotor play in shaft radial direction (Wear limit) | 0.08 (0.0031) mm (in.) | p. 116 |
| Blower blade nut tightening torque | 18 ~ 22 kg-m (1.30 ~ 1.59 ft-lb) | p. 118 |
| Nozzle nut tightening torque | 4 ~ 4.5 kg-m (28.9 ~ 32.5 ft-lb) | p. 94 |
| Injection starting pressure | 195 ~ 205 kg/cm² (2773 ~ 2915 lb/in.²) | p. 95 |
| Back lash (Standard) | 0.04 ~ 0.12 (0.0015 ~ 0.0047) mm (in.) | p. 49 |
| Idle shaft and bushing oil clearance (Standard) | 0.025 ~ 0.075 (0.0009 ~ 0.0029) mm (in.) | p. 50 |
| Fuel feed pump closed off pressure | 0.3 kg/cm² (4.26 lb/in.²) | p. 91 |
| Fuel feed pump tightening torque | 15 ~ 25 kg-cm (1.08 ~ 1.80 ft-lb) | p. 92 |
| Number of cylinders | 4 | p. 8 |
| Fuel injection pressure | 200 ±5 kg/cm² | p. 8 |
| Cylinder head bolt tightening torque (second stage) | 7.5 ~ 8.5 kg-m (54.25 ~ 61.48 ft-lb) | p. 35 |
