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Yanmar 4JH2-TE User Manual

Yanmar 4JH2-TE
406 pages
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SERVICE MANUAL
MARINE DIESEL ENGINE
2001.4
A0A1029-0104
4JH2E,4JH2-TE,
4JH2-HTE,4JH2-DTE

Table of Contents

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Yanmar 4JH2-TE Specifications

General IconGeneral
Engine Model4JH2-TE
Number of Cylinders4
Fuel SystemDirect injection
Cooling SystemFreshwater cooling
Starting SystemElectric
RotationCounterclockwise, viewed from flywheel

Summary

CHAPTER 1 GENERAL

1. Exterior Views

Overview of engine exterior components and their layout.

2. Specifications

Technical specifications for engine models.

3. Construction

Details on the engine's internal structure and components.

4. Performance Curves

Graphs showing engine performance characteristics.

5. Engine Cross Section

Diagram illustrating the engine's internal cross-section.

6. Dimensions

Dimensional drawings and measurements of the engine.

7. Piping Diagrams

Schematics of fuel, oil, and cooling systems.

CHAPTER 2 BASIC ENGINE PARTS

1. Cylinder Block

Details on the engine's cylinder block construction and inspection.

2. Cylinder Liners

Information on cylinder liner specifications and maintenance.

3. Cylinder Head

Details on cylinder head construction, inspection, and valve adjustments.

4. Piston and Piston Pins

Information on pistons, piston pins, and their related measurements.

5. Connecting Rod

Details on connecting rod inspection, measurement, and assembly.

6. Crankshaft and Main Bearing

Information on crankshaft and main bearing inspection and measurement.

7. Camshaft and Tappets

Details on camshaft and tappet inspection and adjustment.

8. Timing Gear

Information on timing gear specifications and inspection.

9. Flywheel and Housing

Details on flywheel and housing specifications and assembly.

CHAPTER 3 FUEL INJECTION EQUIPMENT

1. Fuel Injection Pump Service Data

Service data and specifications for the fuel injection pump.

2. Governor

Explanation of governor function, construction, and adjustment.

3. Disassembly, Reassembly and Inspection of Fuel Injection Pump

Step-by-step guide for fuel injection pump maintenance.

4. Adjustment of Fuel Injection Pump and Governor

Procedures for adjusting fuel injection pump and governor settings.

5. Fuel Feed Pump

Details on the fuel feed pump's construction, specifications, and replacement.

6. Fuel Injection Nozzle

Information on fuel injection nozzle construction, inspection, and testing.

7. Troubleshooting

Common problems and solutions related to the fuel injection system.

8. Tools

List and illustration of specialized tools for fuel injection system maintenance.

CHAPTER 4 INTAKE AND EXHAUST SYSTEM

1. Intake and Exhaust System

Overview of the intake and exhaust system components.

2. Turbocharger

Details on turbocharger construction, specifications, and maintenance.

3. Mixing Elbow

Information on mixing elbow construction and inspection.

CHAPTER 5 LUBRICATION SYSTEM

1. Lubrication System

Diagram and explanation of the engine's lubrication system.

2. Lube Oil Pump

Details on the lube oil pump's construction, specifications, and disassembly.

3. Lube Oil Filter

Information on the lube oil filter's construction and replacement.

4. Oil Pressure Control Valve

Details on the oil pressure control valve construction and adjustment.

5. Lube Oil Cooler

Information on the lube oil cooler's construction and inspection.

6. Piston Cooling Nozzle

Details on the piston cooling nozzle and its inspection.

7. Rotary Waste Oil Pump (Optional)

Information on the optional rotary waste oil pump.

CHAPTER 6 COOLING WATER SYSTEM

1. Cooling Water System

Schematic and explanation of the cooling water system.

2. Sea Water Pump

Details on the sea water pump's construction, specifications, and disassembly.

3. Fresh Water Pump

Information on the fresh water pump's construction and inspection.

4. Heat Exchanger

Details on the heat exchanger's construction and inspection.

5. Pressure Cap and Sub Tank

Information on pressure caps and sub tanks.

6. Thermostat

Details on the thermostat's function, construction, and testing.

7. Kingston Cock (Optional)

Information on the optional Kingston cock.

8. Sea Water Filter (Optional)

Details on the optional sea water filter.

9. Bilge Pump and Bilge Strainer (Optional)

Information on optional bilge pump and strainer.

CHAPTER 7 REDUCTION AND REVERSING GEAR

1. Construction

Overview of marine gear construction and specifications.

2. Shifting Device

Details on the shifting mechanism, its construction, and adjustment.

3. Inspection and Servicing

Procedures for inspecting and servicing gear components.

4. Special Tools

List of specialized tools for gear maintenance.

CHAPTER 8 REMOTE CONTROL (OPTIONAL)

1. Remote Control System

Explanation of the remote control system and its components.

2. Remote Control Installation

Procedures for installing the remote control system.

3. Remote Control Inspection

Steps for inspecting the remote control system for proper function.

4. Remote Control Adjustment

Instructions for adjusting the remote control system.

CHAPTER 9 ELECTRICAL SYSTEM

1. Electrical System

System diagram of electric parts and wiring.

2. Battery

Details on battery capacity, inspection, and charging.

3. Starter Motor

Information on starter motor construction, troubleshooting, and reassembly.

4. Alternator

Details on alternator construction, specifications, and troubleshooting.

5. Instrument Panel

Overview of different instrument panel types and their wiring.

6. Warning Devices

Explanation of oil pressure and cooling water temperature alarms.

7. Air Heater (Optional)

Details on the optional air heater.

8. Electric Type Engine Stop Device (Optional)

Information on the optional electric engine stop device.

9. Tachometer

Details on tachometer construction, specifications, and troubleshooting.

10. Alternator 12V/80A (Optional)

Specifications for an optional 12V/80A alternator.

CHAPTER 10 DISASSEMBLY AND REASSEMBLY

1. Disassembly and Reassembly Precautions

General precautions for engine disassembly and reassembly.

2. Disassembly and Reassembly Tools

List of tools required for disassembly and reassembly.

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