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Old 15-12-2021, 01:21   #31
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Re: Yanmar 4JH3-HTE down on power - revs slowly drop off

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Anyone got any wise ideas on how to confirm a turbo is dead before I order another one?
i think cheapest order this Chinese replacement turbo


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Old 15-12-2021, 08:59   #32
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Re: Yanmar 4JH3-HTE down on power - revs slowly drop off

Sam,

The part of the story that I haven't been able to sort is when you first changed the pitch and were able to get the revs up to 3200 for a while but have never been able to achieve that again. It appears like you have more turbo experience than me so I'll let you have at it but to me, it sounds like high backpressure and fouled injectors. Measuring exhaust backpressure isn't time-consuming and won't set you back the cost of a turbo.
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Old 15-12-2021, 16:25   #33
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Re: Yanmar 4JH3-HTE down on power - revs slowly drop off

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Sam,

The part of the story that I haven't been able to sort is when you first changed the pitch and were able to get the revs up to 3200 for a while but have never been able to achieve that again. It appears like you have more turbo experience than me so I'll let you have at it but to me, it sounds like high backpressure and fouled injectors. Measuring exhaust backpressure isn't time-consuming and won't set you back the cost of a turbo.
Yeah I tend you agree with you on that one. The higher revs seems to sound more like a blockage of some sort that has driven itself further down when the load was reduced and blocked up even more??

I will see if I can tap into the exhaust somewhere and measure the back pressure next. I also have a diesel specialist coming to take a look tomorrow so fingers crossed he’s smarter then I am
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Old 17-12-2021, 06:34   #34
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Re: Yanmar 4JH3-HTE down on power - revs slowly drop off

I have been on this road with my Yanmar not achieving max revs under load. Also had fuel injectors serviced and turbo serviced etc etc

Long story short. There is/was a coarse strainer in the fuel tank that had clogged up with gunk over time. Once it was removed the engine went to 3500 easily. Only problem was that by removing the coarse strainer (as advised by an expert) we had a problem of gunk causing a block of the fuel pick up. So engine died mid-channel in strong winds!!!

Tank now clean and diesel treated with Marine 16, plus course filter replaced. Worked fine for the 2 weeks we were on board last October

Next question is whether the bio-fuel induced gunk re-accumulates over the winter in Greece

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Old 17-12-2021, 06:34   #35
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Re: Yanmar 4JH3-HTE down on power - revs slowly drop off

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Thanks Mike - will rule that one out as well. Easy check will be to remove the fuel fill cap and see if that makes a difference.
I had this problem, with similar symptoms. Removed the sender so that the tank could breath and operated fine until I could get to the slip and clean out the breather tube. Replaced the fitting with one that has screens.
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Old 17-12-2021, 07:31   #36
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Re: Yanmar 4JH3-HTE down on power - revs slowly drop off

We had that problem with a Volvo MD2040D. Both fuel filters were replaced and remained clean. We could pull fuel through the filter with a small Jabsco hand pump that we use for oil changes. We ran wire into the fuel tank from the pickup. No joy.
We finally used a separate fuel line and the engine ran fine. It turned out to be a dam of gunk in the fuel tank that built up around the pickup. The mechanical fuel pump wouldn't pick up fuel through the dam and didn't have enough suction to pull the gunk into the filter. We temporarily added an electric fuel pump to the fuel line.

I've since heard of others with the same problem. Cleaning the fuel tank solved the problem and we were able to remove the electric fuel pump.
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Old 17-12-2021, 08:14   #37
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Re: Yanmar 4JH3-HTE down on power - revs slowly drop off

We had a similar problem with our Beneteau Sense 50 returning from Puerto Rico. After motoring for hours the engine would lose revs then stabilize at 1800-2000. Over days, the engine shut down 3-4 times, but readily restart

We did all of the same diagnostics without finding a cure. Ultimately the problem resolved by replacing the wire harnesses. To be accurate, no harnesses were available through Yanmar or Beneteau. We were instructed by my contact at Beneteau to simple hard wire from point to point. This solved the problem. Engine has been flawless

Hope this helps
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Old 17-12-2021, 13:30   #38
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Re: Yanmar 4JH3-HTE down on power - revs slowly drop off

I’ve the same engine. Question: Was the 1000 hr. Service done? It’s critical.
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Old 17-12-2021, 16:04   #39
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Re: Yanmar 4JH3-HTE down on power - revs slowly drop off

Looks like all the usual suspects were arrested. Having the Volvo Penta version of this class (TMD31-100HP), that had the same issue, my first thought was the turbo and elbow. But as we progress here and Sam’s comment of no black smoke at a quick full throttle as well as the other comments was leading me to the other end of the food chain, which I (and three different mechanics) had the pleasure to experience.

Even after bypassing the fuel tank, replacement of both primary and secondary filters, the last mechanic found a tiny piece of old sticky gunk at the (Separ) primary filter ball check valve that limited the fuel flow under higher vacuum, the filter has been cleaned before but that small piece of gunk could hardly be seen. Once cleaned the problem was over.

Worth a second and third look…
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Old 17-12-2021, 19:51   #40
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Re: Yanmar 4JH3-HTE down on power - revs slowly drop off

Check your turbo wastegate, you should be making20 pounds of boost pressure, put your pressure gauge between the inner cooler and the turbo, have the inner cooler sonic cleaned to ensure a good airflow, inspect your intake manifold and gaskets and the flex line from the manifold to the governor on the injection pump to ensure you are not losing boost pressure.
Check that your throttle linkage isn’t moving while underway.
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Old 19-12-2021, 16:29   #41
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Re: Yanmar 4JH3-HTE down on power - revs slowly drop off

Right guys, time for an update....and not a good one!

I had my diesel mechanic friend come take a look and we ruled out exhaust blockage with a fairly simple test. I have one of those very fancy, expensive silicon high heat exhaust hoses off the elbow and before the muffler. The beauty of this is its really flexible and you can squeeze it with the motor running. Under load, you can squeeze this really easily telling us there is no pressure building up in the exhaust. So thats all ok.

He also took a really good look at the turbo and said while its worn, its not buggered by any means and should still make well over 2PSI the way it is.

So that pointed me back to the original suspect - Fuel. The only parts left in the fuel system were injector pump and injectors.

So off they came on Saturday night and dropped them off to the Diesel and Turbo specialists here. 3 hours later a phone call came to say the pump was full or rust and metal filings. The injector nozzles are damaged from the filings and both the injector pump and all 4 injectors need rebuilding. They said the fuel that came out of the pump didnt have any water in it now, but there has obviously been water in there at some stage that was not cleaned out properly.

They said I was really lucky the metal shavings didn't jam an injector open and flood a cylinder, in turn hydraulic'ing the engine and snapping rods, so I guess that has to be the silver lining.

They are currently stripping the pump to find a list of parts needed to fix it, but it sounds like the cam wheel and injector nozzles are likely ex Japan, so there goes our Xmas holiday =(.

Will update you all later this arvo when I have the verdict.

Thanks for all the help so far, and at least we have found the cause of the power issue!
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Old 19-12-2021, 16:46   #42
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Re: Yanmar 4JH3-HTE down on power - revs slowly drop off

I'm grateful you found the culprit, Sam, before more catastrophic things might have happened, demanding a complete repower.

Have a look at this thread for comparison's sake.

Advice Sought. Engine Seized After Installing Injection Pump
https://www.cruisersforum.com/forums...mp-254051.html

As far as Jack C is concerned, I still don't think he's figured it out...

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Old 22-12-2021, 12:06   #43
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Re: Yanmar 4JH3-HTE down on power - revs slowly drop off

So I got the official report from the Diesel specialist today. This is what they said:
"Severe rust to internal components. Advance piston seized in housing, supply pump seized and severe wear to operating components. Some parts available ex Japan, pump housing available mid March 22 - needs to be fabricated"

They said the Advance piston needed to be removed with a hammer and the supply pump had scored the housing rendering it useless. The quote to repair was ~$3500NZD and Mid March at the earliest.

I went down and had a look at it, and sure enough, it was pretty bad. I've left the injectors with them to recondition with parts 8-10 working days away, and luckily enough have found a second hand reconditioned pump in Florida that I have just purchased. Fingers crossed it arrives around the same time so we can salvage a bit of the New Zealand summer cruising season!
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Old 22-12-2021, 12:54   #44
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Re: Yanmar 4JH3-HTE down on power - revs slowly drop off

Sorry to hear your woes.

It bothers me that Yanmar keeps so little spare stock. I have been quoted lead times of 4 weeks for a head gasket. I now carry one spare on the boat.
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Old 22-12-2021, 13:48   #45
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Re: Yanmar 4JH3-HTE down on power - revs slowly drop off

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Sorry to hear your woes.

It bothers me that Yanmar keeps so little spare stock. I have been quoted lead times of 4 weeks for a head gasket. I now carry one spare on the boat.
Yeah that was more of a shock then the price. Yanmar did have a complete pump on the shelf in Japan, but that was ~$7500 plus freight, plus 15% tax here in NZ. Half the price a whole engine!!!
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