Yanmar 4JH-DTE - Chapter 10: DISASSEMBLY AND REASSEMBLY

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Contents3
General: Contents4
Exterior Views: 4JHE5
Exterior Views: 4JH-TE6
Exterior Views: 4JH-HTE and 4JH-DTE7
Specifications8
Construction9
Performance Curves: 4JHE10
Performance Curves: 4JH-TE11
Performance Curves: 4JH-HTE12
Performance Curves: 4JH-DTE13
Engine Cross Section14
Dimensions: 4JHE15
Dimensions: 4JH-TE16
Dimensions: 4JH-HTE17
Dimensions: 4JH-DTE18
Piping Diagrams: 4JHE19
Piping Diagrams: 4JH-TE20
Piping Diagrams: 4JH-HTE and 4JH-DT(B)E21
Parts Interchangeability22
Inspection and Servicing of Basic Engine Parts: Contents23
Cylinder Block24
Cleaning of Oil Holes24
Color Check Procedure24
Replacement of Cup Plugs25
Cylinder Bore Measurement26
Cylinder Liners27
Measuring Cylinder Liners27
Measuring Cylinder Liner Projection28
Cylinder Head29
Inspecting the Cylinder Head30
Checking the Intake and Exhaust Valve Seats30
Checking for Cracks in the Combustion Surface30
Valve Seat Correction Procedure31
Intake/Exhaust Valves, Valve Guides31
Wearing and Corrosion of Valve Stem31
Inspection of Valve Seat Wear and Contact Surface32
Valve Sinking32
Valve Guide32
Assembling the Cylinder Head34
Intake and Exhaust Valve Arms34
Measuring Top Clearance34
Adjustment of Valve Head Clearance35
Pistons and Piston Pins36
Piston Pin37
Piston Head and Combustion Surface37
Measurement of Piston Outside Diameter/Inspection37
Replacing the Piston37
Piston Rings38
Measuring Piston Ring Gap38
Measuring the Rings38
Replacing the Piston Rings39
Connecting Rod40
Inspecting the Connection Rod40
Twist and Parallelism of the Large and Small Ends40
Checking Thrust Clearance40
Crank Pin Bushing41
Piston Pin Bushing41
Measuring Crank Pin Oil Clearance41
Precautions on Replacement of Crank Pin Bushing41
Crankshaft and Main Bearing43
Camshaft and Tappets46
Timing Gear49
Inspecting the Gears49
Gear Timing Marks50
Flywheel and Housing51
Specifications of Flywheel51
Dimensions of Flywheel and Mounting Flange52
Ring Gear53
Position of Top Dead Center and Fuel Injection Timing53
Fuel Injection Equipment: Contents55
Fuel Supply System56
Fuel Injection Pump Construction58
Fuel Injection Pump Specifications59
Functioning of Fuel Injection Pump59
Injection Volume Control59
Governor Construction60
Function of Governor62
Disassembly, Reassembly and Inspection of Governor64
Governor Disassembly65
Inspection of Governor69
Assembling Governor69
Disassembly, Reassembly and Inspection of Fuel Injection Pump73
Disassembly of Fuel Injection Pump74
Inspection of Fuel Injection Pump78
Reassembly of Fuel Injection Pump79
Adjustment of Fuel Injection Pump and Governor83
Adjustment of Top Clearance84
Adjusting of Injection Timing85
Plunger Pressure Test86
Delivery Valve Pressure Test86
Adjusting Injection Volume (Unifomity of each Cylinder)86
Adjustment of Governor87
Adjusting Fuel Limit Bolt87
Adjusting RPM Limit Bolt87
Adjusting Idling87
Check Injection Volume When Starting88
Automatic Timer (Automatic Advancing Timer)89
Timer Construction89
Functioning and Characteristics of Timer90
Timer Disassembly, Reassembly90
Timer Inspection90
Fuel Feed Pump91
Construction of Fuel Feed Pump91
Fuel Feed Pump Specifications91
Disassembly and Reassembly of Fuel Feed Pump92
Fuel Feed Pump Inspection92
Fuel Injection Nozzle93
Functioning of Fuel Injection Nozzle93
Fuel Injection Nozzle Disassembly/Inspection94
Fuel Injection Nozzle Reassembly95
Adjusting Fuel Injection Nozzle96
Adjusting Opening Pressure96
Injection Test96
Troubleshooting of Fuel Injection Pump97
Fuel Injection Pump Service Data99
Tools100
Fuel Filter Inspection102
Fuel Filter Specifications102
Fuel Tank103
Design Change of Fuel Piping Line104
Modification of Fuel Piping Line104
Applicable Engine Models and Serial Numbers104
Intake and Exhaust System: Contents105
Intake and Exhaust System: Overview106
4JH-TE Engine107
Air Cooler for Models 4JH-HTE and 4JH-DTE108
Intake Silencer Inspection109
Intake Manifold Inspection110
Turbocharger Specifications, Construction111
Turbocharger Function112
Interchangeability of Turbochargers113
Interchangeability of Turbocharger Components114
Turbocharger: Preparations for Disassembly115
Turbocharger: Inspection Prior to Disassembly116
Turbocharger Disassembly116
Turbocharger: Preparation for Reassembly116
Turbocharger Reassembly117
Turbocharger Disassembly/Reassembly Precautions118
Turbocharger Inspection and Maintenance118
Turbocharger Inspection Procedure120
Turbocharger Periodic Inspection121
Turbocharger: Troubleshooting124
Turbocharger: Excessive Smoke, White Exhaust Smoke124
Turbocharger: Excessive Oil Consumption124
Turbocharger: Decrease in Engine Output124
Turbocharger Blower Washing Procedure125
Turbocharger: Poor (Slow) Turbocharger Responsiveness125
Turbocharger: Abnormal Noise or Vibration125
Mixing Elbow Inspection126
Breather Inspection127
Lubrication System: Contents128
Lubrication System: Overview129
Lube Oil Pump Construction131
Lube Oil Pump Specifications132
Lube Oil Pump Disassembly, Inspection133
Lube Oil Filter Construction134
Lube Oil Filter Replacement135
Oil Pressure Control Valve Construction136
Oil Pressure Control Valve Replacement136
Vibration Preventing Damper136
Lube Oil Cooler Construction137
Inspecting the Lube Oil Cooler137
Piston Cooling Nozzle Construction139
Inspection of Piston Cooling Nozzle139
Rotary Waste Oil Pump Construction140
Inspecting the Waste Oil Pump140
Cooling Water System: Contents141
Cooling Water System: Overview142
Fresh Water Line/Sea Water Line143
Sea Water Pump Construction and Functioning145
Specifications of Sea Water Pump146
Sea Water Pump Disassembly, Inspection146
Sea Water Pump Reassembly147
Fresh Water Pump Construction148
Specifications of Fresh Water Pump149
Fresh Water Pump Disassembly149
Fresh Water Pump Inspection149
Heat Exchanger Construction151
Specifications of Heat Exchanger152
Disassembly and Reassembly of the Heat Exchanger152
Heat Exchanger Inspection152
Pressure Cap and Sub Tank153
Pressure Cap Construction, Pressure Control153
Pressure Cap Inspection153
Function of the Sub Tank153
Specifications of Sub Tank154
Mounting the Sub Tank154
Precautions on Usage of the Sub Tank154
Thermostat Construction, Characteristics155
Functioning of Thermostat155
Thermostat Inspection156
Testing the Thermostat156
Kingston Cock Construction, Inspection157
Kingston Cock Handling Precautions157
Sea Water Filter158
Bilge Pump and Bilge Strainer159
Bilge Pump Specifications, Performance of Pump159
Reduction and Reversing Gear: Contents160
Reduction and Reversing Gear: Construction, Specifications161
Power Transmission System162
Reduction and Reversing Gear Drawing163
Reduction and Reversing Gear: Cross Section164
Installation Angle166
Remote Control Unit166
Clutch Operation Force166
Reduction and Reversing Gear: Operation and Maintenance167
Lube Oil, Side Cover167
Inspection and Servicing168
Clutch Case, Bearing, Gear168
Steel Plate168
Friction Plate169
Pressure Plate169
Driving Plate170
Retainer170
Plate Spring170
Thrust Collar170
Shift Ring171
Shift Fork and Shift Lever171
Damper Disc171
Output Shaft171
Input Shaft172
Intermediate Shaft172
Disassembling the Clutch and Accessories173
Disassembling the Input/Output Shafts174
Disassembling the Intermediate Shaft175
Disassembling the Operating System176
Reduction and Reversing Gear: Reassembly Precautions177
Reassembling the Output Shaft177
Reassembling the Input Shaft180
Reassembling the Intermediate Shaft180
Installing the Input Shaft and Output Shaft180
Reassembling and Installing the Operating System181
Installing the Output Shaft Coupling182
Reduction and Reversing Gear: Special Tools183
Marine Gear Model KM4A: Construction184
Specifications of Angle Drive Marine Gear185
KM4A Sectional View186
Power Transmission System: Arrangement of Shafts and Gear, Reduction Ratio187
Shifting Device188
Construction of Shifting Mechanism188
Clutch Gear a and Clutch Gear B Operation189
Engagement and Disengagement of Clutch189
Clutch Shifting Force190
Adjustment of Shifting Device190
Measurement and Adjustment of Clearance191
Inspect for the Following Points191
Adjustment of the Remote Control Head Marine Gearbox Control Side192
Reduction and Reversing Gear: Inspection and Servicing193
Clutch Case and Cover193
Gears193
Drive Cone193
Lapping Procedure for Drive Cone195
Thrust Coller a and B for Clutch Shaft196
Input/Output Shaft197
Shifter Spring, Stopper Bolt, Damper Disc199
Side Cover and Oil Seal199
Shim Adjustment for Output and Input Shafts200
Reduction and Reversing Gear: Tools203
Reduction and Reversing Gear: Disassembly205
Disassembling the Clutch Shaft209
Disassembling the Input/Output Shaft211
Disassembling the Shifting Device212
Reduction and Reversing Gear: Reassembly213
Reassembly of Clutch Shaft213
Reassembly of Input Shaft216
Reassembly of the Clutch Case217
Reassembly of the Bearing Outer Races and Shims in the Clutch Case217
Reassembly of the Input Shaft218
Reassembly of the Mounting Flange218
Reassembly of the Oil Cooler219
Reassembly of the Shifting Device220
Reassembly of the Lube Oil Drain Plug and the Dipstick221
Remote Control: Contents222
Remote Control System: Construction223
Remote Control Device Components223
Remote Control Installation224
Speed Control224
Clutch Control225
Engine Stop226
Remote Control Inspection227
Remote Control Adjustment228
Electrical System: Contents229
Electrical System: System Diagrams of Electric Parts230
B-Type Instrument Panel230
C-Type and D-Type Instrument Panel231
Wiring Diagram: B-Type Instrument Panel232
Wiring Diagram: C-Type Instrument Panel233
Wiring Diagram: D-Type Instrument Panel234
Battery Construction235
Battery Capacity and Battery Cables235
Battery Inspection235
Checking the Electrolyte236
Voltage Test236
Washing the Battery236
Battery Storage Precautions237
Charging Methods237
Charging Procedure, Precautions237
Starter Motor Construction238
Starter Motor Specifications and Performance238
Starter Motor Overview239
Starter Motor: Adjustment and Performance Test240
Starter Motor Operation240
Starter Motor: Pinion Movement240
Starter Motor: Plunger Movement241
Pinion Lock Torque Measurement241
Mesh Clearance241
Starter Motor Disassembly241
Starter Motor: Brush Holder, Yoke, Armature, Pinion242
Starter Motor Inspection242
Field Coil243
Brush244
Magnetic Switch245
Starter Motor Reassembly Precautions245
Starter Motor Testing246
No Load Test246
Starter Motor: Maintenance Standard247
Starter Motor: Various Problems and Their Remedies248
Alternator Characteristics, Specifications249
Alternator Construction250
Alternator Functioning251
Alternator Handling Precautions251
Disassembling the Alternator252
Inspection and Adjustment of Alternator253
Reassembling the Alternator255
Alternator Performance Test256
Alternator Troubleshooting257
Alternator: Charging Failure257
Alternator: Overcharging258
Alternator: Charge Lamp Failure258
Instrument Panel and Wiring Codes259
B-Type Instrument Panel and Wire Harness259
Wire Harness for B-Type Instrument Panel260
Extension Cord for B-Type Instrument Panel260
C-Type, D-Type Instrument Panel and Wire Harness261
Wire Harness for C-Type and D-Type Instrument Panel263
Extension Cord for C-Type and D-Type Instrument Panel263
Warning Devices264
Oil Pressure Alarm264
Cooling Water Temperature Alarm265
Sender Unit for Lube Oil Pressure Gauge265
Sender Unit for the Cooling Water Temperature Gauge266
Air Heater267
Electric Type Engine Stopping Device268
Tachometer: Construction, Specifications and Dimensions270
Measurement of Sensor Unit Characteristics271
Alternator Features, Characteristics, Specifications273
Alternator Constructions274
Alternator Functioning, Handling Precautions275
Alternator: Inspection and Adjustment277
Performance Test: Alternator280
Alternator: Troubleshooting281
Disassembly and Reassembly: Contents283
Disassembly and Reassembly Precautions284
Disassembly and Reassembly Tools285
Disassembly: Drain Cooling Water292
Disassembly: Drain Lube Oil292
Disassembly: Removing Electrical Wiring292
Disassembly: Removing the Fuel Oil Filter and Fuel Oil Pipe293
Disassembly: Removing the Mixing Elbow293
Disassembly: Removing the Intake Silencer293
Disassembly: Removing the Turbine293
Disassembly: Removing the Mixing Elbow and the Turbocharger294
Disassembly: Removing the Air Cooler294
Disassembly: Removing the Starting Motor295
Disassembly: Removing the Alternator295
Disassembly: Removing the Cooling Water Pipe295
Disassembly: Removing the Cooling Water (Sea Water) Pipe296
Disassembly: Removing the High Pressure Fuel Pipe296
Disassembly: Removing the Lube Oil Filter296
Disassembly: Removing the Intake Manifold296
Disassembly: Removing the Fresh Water Pump297
Disassembly: Removing the Valve Elbow Shaft Assembly297
Disassembly: Removing the Fuel Injection Nozzles297
Disassembly: Removing the Cylinder Head297
Disassembly: Removing the Crankshaft V-Pulley298
Disassembly: Removing the Lube Oil Cooler298
Disassembly: Removing the Marine Gearbox298
Disassembly: Removing the Flywheel298
Disassembly: Turning the Engine over299
Disassembly: Removing the Oil Pan299
Disassembly: Removing the Gear Case299
Disassembly: Removing the Lube Oil Pump299
Disassembly: Remove the Fuel Injection Pump300
Disassembly: Removing the Pistons and Connecting Rods300
Disassembly: Removing the Idling Gear300
Disassembly: Removing the Cylinder Liner300
Disassembly: Removing the Crankshaft, Camshaft301
Disassembly: Removing the Flywheel Housing301
Disassembly: Removing the Main Bearing301
Disassembly: Removing the Gear Case Flange301
Disassembly: Removing the Piston Cooling Nozzle302
Reassembly: Mounting the Piston Cooling Nozzle302
Reassembly: Mounting the Gear Case Flange302
Reassembly: Inserting the Tappets302
Reassembly: Mounting the Camshaft303
Reassembly: Mounting the Crankshaft303
Reassembly: Mounting the Main Bearing Metal with Engine Oil, and Mounting the Main Bearing Cap303
Reassembly: Mounting the Flywheel Housing304
Reassembly: Stand Ip the Cylinder Block304
Reassembly: Inserting the Cylinder Liners304
Reassembly: Mounting the Piston and Connecting Rod304
Reassembly: Mounting the Idling Gear305
Reassembly: Mounting the Fuel Injection Pump305
Reassembly: Mounting the Fuel Feed Pump Drive Gear and Automatic Advancing Timer305
Reassembly: Mounting the Lube Oil Pump305
Reassembly: Mounting the Gear Case306
Reassembly: Mounting the Oil Pan306
Reassembly: Mounting the Lube Oil Intake Pipe306
Reassembly: Mounting the Marine Gearbox307
Reassembly: Mounting the Cylinder Head307
Reassembly: Mounting the Crank V-Pulley307
Reassembly: Mounting the Valve Rocker Arm Shaft Assembly Pushrod308
Reassembly: Mounting the Fuel Injection Nozzle308
Reassembly: Mounting the Fresh Water Pump308
Reassembly: Mounting the Intake Manifold309
Reassembly: Mounting the Lube Oil Cooler309
Reassembly: Mounting the High Pressure Fuel Pipe and Fuel Oil Return Pipe309
Reassembly: Mounting the Lube Oil Filter309
Reassembly: Mounting the Lube Oil Pipe310
Reassembly: Mounting the Dipstic Guide310
Reassembly: Mounting the Sea Water Pump310
Reassembly: Mounting the Cooling Water Pipe310
Reassembly: Mounting the Alternator311
Reassembly: Mounting the Turbine311
Reassembly: Mounting the Starting Motor311
Reassembly: Mounting the Mixing Elbow312
Reassembly: Mounting the Mixing Elbow and the Turbocharger312
Reassembly: Mounting the Air Cooler312
Reassembly: Mounting the Intake Silencer313
Reassembly: Electrical Wiring313
Reassembly: Mounting the Fuel Filter and Fuel Oil Pipe313
Reassembly: Filling with Lube Oil313
Reassembly: Filling with Cooling Water314
Reassembly: Checking Fuel Injection Timing314
Bolt/Nut Tightening Torque315
Test Running316
Preliminary Precautions316
Check Points and Precautions During Running316

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Yanmar 4JH-DTE - Chapter 10: DISASSEMBLY AND REASSEMBLY

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