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Old 18-09-2018, 21:54   #1
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Removing Intercooler on Yanmar 4JH3-DTE

I need some help understanding the process in removing the Intercooler on our Yanmar engine. The impeller dis integrated because when we had the initial service of our new purchased 2nd hand yacht, the mechanic did not replace the impeller! Why??? Anyway we need to find all the broken off blades from the impeller and when attempting to take off the Intercooler end 3 bolts sheared the thread off the Intercooler housing. So now we need to remove the Intercooler to not only find the missing impeller blades but now to machine the Intercooler housing to accept new bolts.

Anyway I would like to know the best way to remove the Intercooler. Do I need to remove the turbo and alternator as well? And where are the fixing points for the Intercooler?
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Old 19-09-2018, 04:46   #2
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Re: Removing Intercooler on Yanmar 4JH3-DTE



From the above drawing you remove the three bolts/studs/nuts #23/26, loosen clamps #20 holding the air inlet and outlet hoses #13 and 28, the cooling water inlet and outlet hoses (not listed), and remove the intercooler #1 and airhorn #15-1 as a unit. Actually looks relatively simple...
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Old 19-09-2018, 04:51   #3
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Re: Removing Intercooler on Yanmar 4JH3-DTE

Thanks
You were right it was relatively easy. Unfortunately I have found some oil in the air intake and return in the intercooler so I will have to remove the turbo now and service this as well with new seals and bearings. Any suggestions where to start there?
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Old 19-09-2018, 05:07   #4
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Re: Removing Intercooler on Yanmar 4JH3-DTE

Depending on the engine hours, you may not need to service the turbo just yet. Seems I remember that a lot of these model series engines have an issue with oil burning via the crankcase vent line that feeds into the intake.

There are a lot of people here that have this engine, or one of its' permutations, a search under Yanmar oil consumption or some such thing might yield results, or maybe someone will chime in here.


Here's a link to a thread on a non-intercooled version, where the OP removed his turbo, perhaps it will be useful, or you might try messaging him...


Heat Exchanger Replace - Yanmar 4JH3-TE
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Old 19-09-2018, 08:58   #5
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Re: Removing Intercooler on Yanmar 4JH3-DTE

I have a 2000 4JH3TE, tubro only, and do indeed have a bit of oil blow by exiting the crankcase breather and fed directly to the air intake of the turbo. Perhaps every 300 hours I remove the intake filter (actually just a perforated cage) and wipe up the oil. Examination of the turbo intake blades does not show any build up on the blades, so I just live with it. BTW, I have NOT washed my turbo since buying the boat 1200 engine hours ago. I did buy an AirSep for this issue 2 years ago but never got around to installing it.

Can anyone with the 4JH3TE confirm that there is only a perforated metal cage around the turbo air intake, or is there an actual filter element that I am missing? One is not shown on my shop docs.
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Old 19-09-2018, 09:19   #6
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Re: Removing Intercooler on Yanmar 4JH3-DTE

Quote:
Originally Posted by Jeanneau 45.2 View Post
I......
Can anyone with the 4JH3TE confirm that there is only a perforated metal cage around the turbo air intake, or is there an actual filter element that I am missing? One is not shown on my shop docs.
That's all I have on mine. Seems surprising along with no zinc.
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Old 19-09-2018, 09:28   #7
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Re: Removing Intercooler on Yanmar 4JH3-DTE

4JH4-TE
I have just the wire cage with a screen in it. I also have the oil issue. I was thinking maaaaybe It’s because I was using too light an oil (15w40), this season I’ll switch to 10w30 weight oil. I’m now in Carribean.
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Old 20-09-2018, 15:21   #8
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Re: Removing Intercooler on Yanmar 4JH3-DTE

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Thanks guys I have removed the turbo an found a fair bit oil in the compressor air discharge and hoses/pipes to the intercooler. The engine has over 4000 hours on it so I was thinking that the turbo will need servicing with new seals put in. I have put up a pic to show you the oil coming out of the turbo compressor.
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Old 20-09-2018, 17:21   #9
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Removing Intercooler on Yanmar 4JH3-DTE

10W-30 oil is a lighter or thinner oil than 15W-40 I believe.
Be careful cause most 10W-30 is for gas motors and not Diesels, although there is apparently a Diesel version.
If it were mine, I believe Iíd stick with the 15W-40, being a turbo motor itís my belief that a multi vis oil is called for.

I would also be very tempted to re-route my crankcase vent to a catch can myself, I think plumbing one into the suck side of the turbo to be foolish, but understand itís likely done to pass emissions.
It does funk things up, and add even a tiny amount fo dust, say belt dust and itís a mess, you really ought to do the wash like Yanmar says.
Or donít feed the turbo oil mist
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Old 20-09-2018, 17:28   #10
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Removing Intercooler on Yanmar 4JH3-DTE

Of course a turbo center section seal can be leaking, especially on an older one, usually when one goes, it scares you cause the motor starts smoking bad and you think you have a blown motor.

At 4,000 hours I would send the turbo in for an overhaul and have the center section bearing replaced, once it wears enough so that the compressor can touch the housing, the turbo is done, no overhaul.
But overhauled now ought to give you many more years of trouble free operation.
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Old 20-09-2018, 17:41   #11
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Re: Removing Intercooler on Yanmar 4JH3-DTE

All diesel rated.

In Newfoundland I can ONLY getn10w30
Grenada ONLY 5w40
In States both are available.
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