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Old 28-05-2023, 10:38   #1
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Massive oil leak Yanmar 4jh2-te

Hi everyone!

Iíve finally managed to finish the rebuild of my Yanmar but when starting it to test it, it fires up nicely but leaks a LOT from behind the governor.

Itís not the following:
1) oil filter as it comes from above
2) itís also not the pipe and banjos going from block to FI pump
3) 4 caps on the engine block on that side
4) it doesnít come from above the caps on that side either because what I can see from above and behind the Injection pump is all dry.
5) also doesn't come from pressure sending unit as it comes from above

To me, it looks like itís coming from the bottom of the governor but the oil stream is a thumb size so it has to be a bolt thatís entirely loose or something.

I canít access that side of the motor as itís inside the engine compartment and canít see from below but the governor and injection pump werenít taken apart so there shouldnít be anything looseÖ

Any help would be very appreciated!!

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Old 28-05-2023, 15:14   #2
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Massive oil leak Yanmar 4jh2-te

Glad to hear that you got your engine running again, well done. On the oil leak problem, I know you discounted the oil feed pipe to the injector pump but in your photoís , if thatís it at the top of the pic it seems to be corroded quite badly under the paint and thereís a good chance itís either snapped off or has a rust hole. Yanmar uses a similar thinwall tube on its 3GM engines and they fail fairly often purely because of that type of corrosion. Even a pinhole in that tube on your engine would leak a lot of oil.
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Old 28-05-2023, 21:04   #3
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Re: Massive oil leak Yanmar 4jh2-te

That oil pipe that goes from the block to the injector pump is the work of the devil. I had the first one fail the night before making landfall in the Galapagos. The replacement one just failed. The third one (just received) uses a copper tube rather than a steel one. Here’s hoping …..
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Old 28-05-2023, 21:28   #4
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Re: Massive oil leak Yanmar 4jh2-te

Donít be fooled by the appearance, the GM series ones look like copper too but are still steel.... run a magnet past your new one
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Old 28-05-2023, 22:03   #5
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Re: Massive oil leak Yanmar 4jh2-te

There's also the oil pressure alarm sender. On the block at about the right height, but quite a bit aft of the area you're seeing the problem.
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Old 29-05-2023, 12:43   #6
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Re: Massive oil leak Yanmar 4jh2-te

Hii everyone!

Thanks for your inputs!!

Iíve narrowed down that it isnít from the metal pipe surprisingly.

Iíve managed to have quite a good look while running the engine and it seems to be coming from the bottom of the governor-FI pump joint.

Now, on this engine, as I only have a few inches in that side of the engine room, itís going to be hard to take the governor off without pulling the engine out againÖ


Also, maybe more worrying, the oil is now draining with a creamy color as if it had water in it but it smells slightly sweet so Iíd say that itís oil and fuel? (But that shouldnít turn creamy I suppose)

Any ideas?
Iíve checked the oil in the sump through the dipstick and itís crystal clear, not as dark as it was where itís pouring out and also not creamy like itís pouring nowÖ
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Old 29-05-2023, 13:53   #7
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Re: Massive oil leak Yanmar 4jh2-te

Ok, new update!

It’s a tiny pinhole at the bend of that pipe after all.

I seriously don’t get why that pipe is run that way…

I’m going to attempt to jbweld it until the new one comes in which should be ina few days. Let’s see if it holds….

Any ideas on the milky oil? The only part of the engine I didn’t rebuilt that has a mix of water and oil is the lube oil cooler but it surprises me that water and oil could be mixing…

Engine starts up first crank and doesn’t smoke excessively, maybe a little white but not too much.

Dipstick comes out clean, no water what so ever…

Might have to drain a little from the sump to see if it’s really mixed with water or not…
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Old 29-05-2023, 14:43   #8
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Re: Massive oil leak Yanmar 4jh2-te

You had me worried for a while when you proposed removing the governor housing, not an easy feat with the pump still in place. If it proves to be impossible to buy a new pipe you could get a motorcycle flexible brake hose with the right size banjo fittings, I recently did this on a 2GM Yanmar, it works quite well but I spent a bit of time finding one with 8mm banjo x10mm banjo.
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Old 29-05-2023, 15:09   #9
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Re: Massive oil leak Yanmar 4jh2-te

Sounds like an optionÖ

I probably can order a genuine Yanmar pipe but it will probably be 50-100$ for a piece of metal with 2 banjos so Iíll try to jbweld it until I can find a good solution.

As for the milky oil, Iím completely confused because the head gasket is new, head gasket is new and the oil pan doesnít show any sign of water but it did at the beginning of the leak come out clean, then dark brown (like old oil) and now milky and I was hoping that maybe the pressurised oil coming out was aerated and therefore milky but I think Iím dreaming 😅

Any ideas where to start with checks?

I'm going to wait till tomorrow and I fit the pipe back in as I currently can't really do much troubleshooting I think.

Coolant level has gone down but I just refilled it and had the engine running 1-2minutes each time for about 5 different starts as I was looking for oil leak. Suppose the coolant has to be topped up first as it's likely it's gone down because of filling the system.

Oil level hasn't risen, rather gone down but that's also normal because of all the oil that was pouring out so can't figure it out that way either...

Anyways, any suggestions would the appreciated as always! 🙂
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Old 29-05-2023, 15:44   #10
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Re: Massive oil leak Yanmar 4jh2-te

Hereís the flex hose
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Old 30-05-2023, 10:08   #11
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Re: Massive oil leak Yanmar 4jh2-te

So, just an update:

The patch in the pipe proved that the leak came from there so now Iím going to try and get a permanent replacement if that part.

As for the water in oil, Iím going to start a new thread as I think itís easier for other Yanmar owners to make use of the thread titles ! 😅

Basically yesterday when running the engine with the broken pipe for the last time the oil started to flow creamy but the oil pan didnít appear to have any oil in it when checking the dipstick but Iíve just ran the engine for 2-3 minutes and now the dipstick as traces of water although nothing foamy yet.

Thank you all!
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Old 03-06-2023, 08:41   #12
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Re: Massive oil leak Yanmar 4jh2-te

SkipperPete — You’re right. The silly pipe is still steel, but this time, instead of painting it grey, they’ve plated it with copper. You caught me being credulous and believing my lyin' eyes.
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Old 03-06-2023, 09:22   #13
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Re: Massive oil leak Yanmar 4jh2-te

I've had a couple custom hose assemblies made by West Michigan Rubber, a local industrial hose shop here in Muskegon. There are similar shops most anyplace. They can put whatever fittings you need on a piece of hot oil rated hose.
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Old 03-06-2023, 11:14   #14
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Re: Massive oil leak Yanmar 4jh2-te

I've had good luck at Hydraulic shops getting this type of hose made up . Usually very inexpensive compared to OEM. And of the hose is oil resistant.
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