Join Date: Nov 2010
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Warning! New filter system on new Yanmar engines is Bad!
I got into a very serious problem the other day.
I have a new Yanmar 4JH57 the new common rail engine. 300 hours on the clock. It has a new pre-filter replacing the Racor 500. The inlet on the new Yanmar pre-filter has a Banjo bolt where the fuel must turn at 90 degrees and go through a hole in the bolt about 1mm wide.
This turn gunked up and the engine stopped.... in a remarkably difficult and dangerous location with a contrary current of 5 knots and me being only able to sail at 1.3 knots - directly towards the rocks!!! With another 6 hours of current sucking me into the infamous Alderney race with currents up to 9 knots.
If it had stopped 15 minutes later there is no way I could have turned around and been able to sail into the current.
So I had a fun few hours trying to sail and locate the fuel fault.
Also the filter needs a spanner/wrench far larger than I have so I couldn't change the filter at sea!
On a brand new engine its not expected to stop!
Anyway I finally traced it back to the Banjo Bolt and its tiny hole. A tiny piece of orange plastic has gummed it up then crap built up around it.
I though a pre-filter was meant to suck anything out of the tank and filter it before the primary fuel filter mounted on the engine.
I do not want / and will not have this possible situation again. Cruising boats can often pick up dirty fuel (I've fuelled in Venezuela, Egypt, Oman, Indonesia, Malaysia etc) or some goop can get in or grow, no matter the additives etc.
My solution is to buy a new Racor 500 as a pre-pre-filter and to mount it in the aft cabin on the external riser for the bunk, adjacent but on the outside wall to the Yanmar filter. Thus I will be able to ensure gunk the size that blocked the Banjo Bolt will not cause a problem, and that I can visually see the Racor from the Saloon, and change that Racor filter in less than 1 minute.
I found the problem and cleaned the Banjo Bolt and was able to get back to harbour no problems... but by then another bit of gunk was in the bolt.
I pumped out the whole tank and filtered the fuel and its clean as a whistle.
I will upload a pic of the problem off my phone in a few moments... but heres a location snap of exactly where you do NOT wanna have the engine clag up.
Your comments appreciated.
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