3TN and 4TN Series Yanmar Diesel Engines

John Deere Horicon Works CTM3 (03JAN90)
LITHO IN U.S.A.

ENGLISH

3TN and 4TN Series Yanmar Engines

CTM3 (03JAN90)

Introduction
This Component Technical Manual contains necessary instructions to repair the engine, engine fuel, and engine electrical systems. Use this Component Technical Manual in conjunction with the Machine Technical Manual. An engine application listing in the introduction identifies product-model/engine type-model relationship. See the Machine Technical Manual for information on engine removal and installation, theory of operation, diagnostic, and testing procedures.

N

CAUTION: THIS IS THE SAFETY-ALERT symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury.

M21,TM300,1

-19-27AUG87

CTM3 (03JAN90)

3TN/4TN Series Yanmar Engines
010897

PN=3

Contents
Page Page

05
Group 05— . . . . . . . . . . . About This Manual . . . . . . . Engine Serial Number Plate . Engine Application Chart . . . Engine Torque Specifications Metric Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 05-2 05-3 05-4 05-5 05-6 Exhaust Manifold Remove, Repair, and Intake Manifold Remove, Repair, and Cylinder Head Remove . . . . . . . . Disassemble . . . . . Assemble . . . . . . . Install . . . . . . . . . . Install . . . . . . . . . . . 15-2 Install . . . . . . . . . . . 15-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5 . 15-6 15-14 15-17

06 10 15 20 25 30 35 40 45 50

Group 06—Repair Specifications Engine 3TN66 . . . . . . . . . . . . . . . . . . 3TNA72 . . . . . . . . . . . . . . . . . 3TN75 . . . . . . . . . . . . . . . . . . 3TN78/4TN78 . . . . . . . . . . . . . 3TN82/3TN84/4TN82/4TN84 . . . 4TN100 . . . . . . . . . . . . . . . . .

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. 06-1 . 06-6 06-13 06-18 06-23 06-33

Group 10—Valve Train and Camshaft Service Equipment and Tools . . . . . . . Other Materials . . . . . . . . . . . . . . . . Service Part Kits . . . . . . . . . . . . . . . Rocker Arm Remove and Disassemble Cover . . . Measure and Adjust Valve Clearance Measure and Adjust Valve Clearance (4TN100) . . . . . . . . . . . . . . . . . Remove and Disassemble Assembly Remove and Inspect Pushrods and Cam Followers . . . . . . . . . . . . . Install Pushrods and Cam Followers . Assemble and Install Assembly . . . . Assemble and Install Cover . . . . . . Camshaft Remove . . . . . . . . . . . . . . . . . . . Disassemble and Inspect . . . . . . . . Assemble . . . . . . . . . . . . . . . . . . Install . . . . . . . . . . . . . . . . . . . . . . .

. . . . . 10-1 . . . . . 10-1 . . . . . 10-2 . . . . . 10-2 . . . . . 10-3 . . . . . 10-6 . . . . . 10-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11 10-14 10-15 10-18 10-19 10-21 10-25 10-25

Group 20—Flywheel Service Equipment and Tools . . Flywheel Housing and Flywheel Remove . . . . . . . . . . . . . . Inspect . . . . . . . . . . . . . . . Install . . . . . . . . . . . . . . . .

. . . . . . . . . . 20-1 . . . . . . . . . . 20-1 . . . . . . . . . . 20-3 . . . . . . . . . . 20-4 Pistons ...... ...... ...... ...... ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Group 25—Connecting Rods and Service Equipment and Tools . . . . Other Materials . . . . . . . . . . . . . Service Part Kits . . . . . . . . . . . . Measure Side Play . . . . . . . . . . . Measure Bearing Clearance . . . . . Pistons and Connecting Rods Remove . . . . . . . . . . . . . . . . Inspect . . . . . . . . . . . . . . . . . Deglaze . . . . . . . . . . . . . . . . . Rebore Cylinder Block . . . . . . . Assemble . . . . . . . . . . . . . . . Install . . . . . . . . . . . . . . . . . .

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25-1 25-1 25-1 25-2 25-3

. 25-4 . 25-6 25-14 25-16 25-17 25-19

Group 15—Cylinder Head, Valves, and Manifolds Essential Tools . . . . . . . . . . . . . . . . . . . . . 15-1 Service Equipment and Tools . . . . . . . . . . . . 15-2 Service Part Kits . . . . . . . . . . . . . . . . . . . . 15-2

Group 30—Crankshaft and Main Bearings Service Equipment and Tools . . . . . . . . . . Service Part Kits . . . . . . . . . . . . . . . . . . Other Materials . . . . . . . . . . . . . . . . . . . Measure Crankshaft End Play . . . . . . . . .

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30-1 30-1 30-1 30-2

55 60 65

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All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice.
CTM3-19-03JAN90 COPYRIGHT© 1989 DEERE & COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION™ Manual

CTM3 (03JAN90)

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Contents

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Page

05 06 10 15 20 25 30 35 40 45 50 55 60 65
Group 35—Gear Housing Service Equipment and Tools . . . . . . . . Other Material . . . . . . . . . . . . . . . . . . Timing Gear Cover Remove . . . . . . . . . . . . . . . . . . . . Install . . . . . . . . . . . . . . . . . . . . . . Timing Gears (Early 3TNA72UJ) Remove and Inspect . . . . . . . . . . . . Install . . . . . . . . . . . . . . . . . . . . . . Timing Gears (3TN66, Later 3TNA72) Remove and Inspect . . . . . . . . . . . . Install . . . . . . . . . . . . . . . . . . . . . . Timing Gears (All Except 3TN66/3TNA72 Remove and Inspect . . . . . . . . . . . . Install . . . . . . . . . . . . . . . . . . . . . . Gear Housing Remove . . . . . . . . . . . . . . . . . . . . Install . . . . . . . . . . . . . . . . . . . . . . Group 40—Lubrication System Service Equipment and Tools . . . . . Other Materials . . . . . . . . . . . . . . Remove and Install Oil Pump . . . . . Oil Pump (Early 3TNA72UJ) Remove . . . . . . . . . . . . . . . . . Inspect . . . . . . . . . . . . . . . . . . Install . . . . . . . . . . . . . . . . . . . Oil Pressure Regulating Valve (Early 3TNA72UJ) Remove . . . . . . . . . . . . . . . . . Install . . . . . . . . . . . . . . . . . . . CTM3 (03JAN90) . . . . 35-1 . . . . 35-1 . . . . 35-2 . . . . 35-4 . . . . 35-6 . . . . 35-7 . . . . 35-9 . . . 35-11 . . . 35-13 . . . 35-14 . . . 35-16 . . . 35-18 Balancer Assembly—4TN82/84 Remove . . . . . . . . . . . . . . . . . . . . . . Disassemble and Inspect . . . . . . . . . . . Assemble and Install . . . . . . . . . . . . . . Remove and Install Crankcase Extension Housing . . . . . . . . . . . . . . . . . . . . . Measure Crankshaft Bearing Clearance . . . Crankshaft Oil Seal Remove . . . . . . . . . . . . . . . . . . . . . . Install . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Remove . . . . . . . . . . . . . . . . . . . . . . Disassemble and Inspect . . . . . . . . . . . Assemble . . . . . . . . . . . . . . . . . . . . . Install . . . . . . . . . . . . . . . . . . . . . . . . . . 30-2 . . 30-3 . . 30-4 . . 30-5 . . 30-6 . . 30-9 . 30-10 . . . . 30-12 30-14 30-17 30-17 Oil Pump (All Engines Except Early 3TNA72UJ) Remove and Inspect . . . . . . . . . . . Assemble and Install . . . . . . . . . . . Oil Pressure Regulating Valve . . . . . . Remove, Inspect and Install Oil Cooler (3TN84UJ) . . . . . . . . . . . . . . . . . . Engine Oil Cooler Leak Test . . . . . . . Remove/Inspect/Install Oil Pressure Control Valve . . . . . . . . . . . . . . . . 4TN100RJF Lubrication System Remove and Inspect Oil Pump . . . . Assemble and Install Oil Pump . . . . Remove and Inspect Oil Cooler . . . . Assemble and Install Oil Cooler . . . . Inspect Oil Cooler By-Pass Valve . . Inspect Oil Pressure Control Valve . . Inspect Piston Cooling Nozzles . . . . Group 45—Cooling System Essential Tools . . . . . . . . . Service Equipment and Tools Thermostat and Housing Remove . . . . . . . . . . . . Install . . . . . . . . . . . . . . Water Pump Remove . . . . . . . . . . . . Disassemble . . . . . . . . . Assemble . . . . . . . . . . . Install . . . . . . . . . . . . . . . .

. . . . 40-22 . . . . 40-24 . . . . 40-25 . . . . 40-28 . . . . 40-29 . . . . 40-29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30 40-31 40-32 40-32 40-33 40-33 40-34

. . . . . . . . . . . . 45-1 . . . . . . . . . . . . 45-1 . . . . . . . . . . . . 45-2 . . . . . . . . . . . . 45-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-7 . 45-9 45-13 45-21

. . . . . . . 40-1 . . . . . . . 40-1 . . . . . . . 40-2 . . . . . . . 40-3 . . . . . . . 40-8 . . . . . . 40-11

Group 50—Fuel Injection Pump, Camshaft, and Nozzles Essential Tools . . . . . . . . . . . . . . . . . . . . . 50-1 Service Equipment and Tools . . . . . . . . . . . . 50-1 Other Materials . . . . . . . . . . . . . . . . . . . . . 50-2 Service Part Kits . . . . . . . . . . . . . . . . . . . . 50-2 Fuel Injection Pump (3TN66, 3TNA72) Remove . . . . . . . . . . . . . . . . . . . . . . . . 50-3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . 50-5 Fuel Injection Pump (3TN75/3TN78/3TN82/3TN84/4TN78/4TN82/4 . . . Remove . . . . . . . . . . . . . . . . . . . . . . . . 50-8 Install . . . . . . . . . . . . . . . . . . . . . . . . . 50-10 Fuel Injection Pump (4TN100RJF) Remove . . . . . . . . . . . . . . . . . . . . . . . 50-12 Install . . . . . . . . . . . . . . . . . . . . . . . . . 50-13
Continued on next page

. . . . . . 40-18 . . . . . . 40-20

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Contents

Page

Page

Fuel Injection Pump Camshaft Remove (Early 3TNA72UJ) . . . . . . Remove (3TN66 and Later 3TNA72) Disassemble and Inspect . . . . . . . Assemble and Install . . . . . . . . . . Pintle Type Fuel Injection Nozzle Operation and Application . . . . . . . Remove . . . . . . . . . . . . . . . . . . Test . . . . . . . . . . . . . . . . . . . . . Disassemble . . . . . . . . . . . . . . . Cross Section . . . . . . . . . . . . . . . Clean and Inspect . . . . . . . . . . . . Assemble . . . . . . . . . . . . . . . . . Install . . . . . . . . . . . . . . . . . . . . Hole Type Fuel Injection Nozzle Operation and Application . . . . . . . Remove . . . . . . . . . . . . . . . . . . Test . . . . . . . . . . . . . . . . . . . . . Disassemble . . . . . . . . . . . . . . . Clean and Inspect . . . . . . . . . . . . Cross Section View . . . . . . . . . . . Assemble and Install . . . . . . . . . .

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50-14 50-17 50-18 50-20 50-24 50-25 50-27 50-29 50-30 50-31 50-31 50-33 50-35 50-36 50-38 50-40 50-41 50-42 50-43

Nippon Denso 1.0 kW Starter Disassemble and Service . Assemble . . . . . . . . . . . Hitachi 0.8 kW Disassemble and Service . Assemble . . . . . . . . . . . Nippon Denso 1.4 kW Starter Disassemble and Service . Service Gear Train . . . . . Assemble . . . . . . . . . . .

. . . . . . . . . . . . 60-3 . . . . . . . . . . . . 60-9 . . . . . . . . . . . 60-15 . . . . . . . . . . . 60-19 . . . . . . . . . . . 60-20 . . . . . . . . . . . 60-24 . . . . . . . . . . . 60-26

Group 55—Fuel Control and Governor Linkage Service Equipment and Tools . . . . . . . . . . . . 55-1 Other Materials . . . . . . . . . . . . . . . . . . . . . 55-1 Service Part Kits . . . . . . . . . . . . . . . . . . . . 55-1 Fuel Control and Governor Linkage (Early 3TNA72UJ) Remove . . . . . . . . . . . . . . . . . . . . . . . . 55-2 Install . . . . . . . . . . . . . . . . . . . . . . . . . . 55-8 Fuel Control & Governor Linkage (3TN66 & Later 3TNA72) Remove . . . . . . . . . . . . . . . . . . . . . . . 55-13 Disassemble . . . . . . . . . . . . . . . . . . . . 55-15 Assemble . . . . . . . . . . . . . . . . . . . . . . 55-19 Install . . . . . . . . . . . . . . . . . . . . . . . . . 55-21 Fuel Control and Governor Linkage Service . . . . . . . . . . . . . . . . . . . . . . . . 55-22 Fuel Supply Pump (4TN100RJF) Remove and Inspect . . . . . . . . . . . . . . . 55-22 Assemble and Install . . . . . . . . . . . . . . . 55-24 Group 60—Starter Service Equipment and Tools . . Starter Specifications . . . . . . . Starter Application Chart . . . . . Bench Test Starter (All Engines) CTM3 (03JAN90)

Group 65—Alternator Service Equipment and Tools . . Specifications . . . . . . . . . . . . Nippon Denso Alternator Replace Voltage Regulator . . Disassemble . . . . . . . . . . . Test Rotor . . . . . . . . . . . . . Test Stator and Rectifier . . . Assemble . . . . . . . . . . . . . Service 20A Kokosan Alternator Hitachi 24V/25A Alternator Replace Voltage Regulator . . Disassemble . . . . . . . . . . . Test Rotor . . . . . . . . . . . . . Test Stator and Rectifier . . . Assemble . . . . . . . . . . . . .

. . . . . . . . . . 65-1 . . . . . . . . . . 65-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65-2 . 65-3 . 65-4 . 65-6 65-10 65-13 65-16 65-18 65-19 65-21 65-24

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60-1 60-1 60-1 60-2

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3TN/4TN Series Yanmar Engines
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Contents

CTM3 (03JAN90)

iv

3TN/4TN Series Yanmar Engines
010897

PN=353

FOS Manuals are for training new personnel and for reference by experienced technicians. and basic types of failures and their causes. general maintenance. Component Technical Manuals are concise service guides for specific components. FOS MANUALS—REFERENCE TECHNICAL MANUALS—MACHINE SERVICE COMPONENT MANUALS—COMPONENT SERVICE Fundamentals of Service (FOS) Manuals cover basic theory of operation.Group 05 Introduction INTRODUCTION This manual is part of a total service support program. 05 1 O53. Component Technical Manuals are written as stand alone manuals covering multiple machine applications. Technical manuals are on-the-job guides containing only the vital information needed by an experienced service technician.INTRO2 -19-03JUL85 CTM3 (03JAN90) 05-1 3TN/4TN Series Yanmar Engines 010897 PN=4 RW5559 -UN-23AUG88 . fundamentals of troubleshooting. Technical Manuals are concise service guides for specific machines.

and materials needed to do the job. Read each module completely before performing service to check for differences in procedure or specifications.Introduction/About This Manual FEATURES OF THIS TECHNICAL MANUAL 05 2 John Deere ILLUSTRUCTION format emphasizing illustrations and concise instructions in easy-to-use modules. The repair procedure for the Yanmar diesel engines in this manual are similar. M21. You may want to determine the repair procedure before you remove the engine. O53. that step applies to all Yanmar diesel engines in this manual. The 3TNA72UJ engine is shown except where differences are noted by engine model number. wear tolerances. torque values. and testing so you can understand the problem and correct it.INTRO3 -19-07OCT85 ABOUT THIS MANUAL This Component Technical Manual (CTM-3) covers the recommended repair procedures for all Yanmar Diesel Engines removed from the machine. Follow only the steps that apply to the engine model number you are working on. Summary listing at the beginning of each group of all applicable specifications.TM305. This technical manual was planned and written for you—an experienced service technician. Emphasis on diagnosis. An emphasis throughout on safety—so you do the job right without getting hurt. If only one step is given. Some components may be serviced without removing the engine from the machine. Refer to it when you need to know correct service procedures or specifications. Refer to Engine Application Chart in this group to identify product-model/engine type-model relationship. Step-by-step instructions for teardown and assembly. essential tools.1 -19-21APR86 CTM3 (03JAN90) 05-2 3TN/4TN Series Yanmar Engines 010897 PN=5 RW5560 -UN-23AUG88 . Keep it in a permanent binder in the shop where it is handy. Diagnostic information presented with the most logical and easiest to isolate problems first to help you identify the majority of routine failures quickly. analysis.

TM305.Introduction/Engine Serial Number Plate ENGINE SERIAL NUMBER PLATE The engine serial number plate is located on the rocker arm cover. Refer to the engine model designation on your engine’s serial number plate to identify repair information covered in the Component Technical Manual. -UN-29AUG88 M21.2 -19-21APR86 05 3 CTM3 (03JAN90) 05-3 3TN/4TN Series Yanmar Engines 010897 PN=6 M37502 .

. . . . 3TN66E-SP 575 . . . 870 . . . . . . . . . . . . . . . . 3TN78RJB . . . . . . . . . . . . . . . . . In this manual. . . . . 3TN66UJ 3TNA72UJX . . . . . . . . 3TN75RJ 3325 . . . . . . . . . . . . . . . . . . . . . . 3TNA72UJ engines. . . . . . . . . CONSUMER PRODUCTS INDUSTRIAL Loaders Machine No. . . 3TNA72UJB . . . . M21. . . . . . . . 755 . . . . . . . . . . . . . . . . 4TN82RJX . . . . . . . . . . . . . . . . . . . . 3TN75RJ . . . . . 670 . . . . . . . . . . . . . . . . are referred to as “Early 3TNA72”. . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Model 375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4TN82E-SP *430 Lawn and Garden Tractors were built with two slightly different versions of 3TNA72UJ engines. . . . . . . . . . . . . . . . . . . . . .TM305. . . . . . . . . . . . . . . . . . . . . . . . . 655 . . . . . . . . . . . . . . . . . . . . . . . . . 955 . . . . . . . . . . . . . . . . . . . . . . . 3TN82E-SP 675 . . . . 970 . . . . . . . . . . . 770 . . . . . . . . 3TN84RJX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TNA72UJ 3TNA82RJX . . .Introduction/Engine Application Chart ENGINE APPLICATION CHART 05 4 Refer to the engine application chart to identify product-model/engine type-model relationship. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TNA72UJ* Compact Utility Tractors Machine No. . . . . . . . . . . . . . . . . . . . . . 1070 . . . . 3TN82RJB 4TN78TRJB Golf and Turf Machine No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TNA72UJ 856 . Engines with serial numbers (5001— ) are referred to as “Later 3TNA72”. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TN84RJ . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TN66UJ F935 . . . . Engine Model Lawn and Garden Tractors 84 . . Engine Model . . 4TN1004JF Machine No. . . . . 15 25 30 50 . . . . . . . . . . . . Engine Model Excavators 330 .4 -19-27AUG87 CTM3 (03JAN90) 05-4 3TN/4TN Series Yanmar Engines 010897 PN=7 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4TN84RJX Machine No. 3TN66UJ 430 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 855 . . . . . . . . . . Engine Model . . . . . . . 3TN66UJ 332 . . 4TN82RJ Front Mowers Machine No. . . . . . . . . . . . . . . . . . Engine Model 756 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . serial numbers ( —5000). . . . . . . . . . . Engine Model F915 . . . . . . . . . . . . . . . . . . . . 3TNA72UJ Skid Steer Loaders Machine No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DD -19-11JUL85 CTM3 (03JAN90) 05-5 3TN/4TN Series Yanmar Engines 010897 PN=8 .2000. S11. 1/2 in. do not grease or oil bolts or cap screws unless otherwise specified in this manual. * Torque value for bolts and cap screws are identified by their head markings. Therefore. 3/4 in. Bolt Diameter lb-ft Plain Head* N·m lb-ft Three Radial Dashes* N·m Six Radial Dashes* lb-ft N·m 05 5 1/4 in. 5/16 in. 6 10 20 30 45 70 95 165 170 255 8 14 27 41 61 95 128 225 230 345 9 18 30 50 75 110 155 270 435 660 12 24 41 68 101 150 210 365 590 895 12 25 45 70 110 155 215 385 620 930 16 34 61 95 149 210 290 520 840 1260 Torque figures indicated above and in the Specification Sections of this manual are valid for non-greased or non-oiled threads and heads unless otherwise specified. 1 in. 5/8 in.Introduction/Engine Torque Specifications ENGLISH TORQUE SPECIFICATIONS NOTE: Wrench torque tolerance is ± 20%. 7/8 in. 7/16 in. 9/16 in. 3/8 in.

do not grease or oil bolts or cap screws unless otherwise specified in this manual.DE -19-11JUL85 CTM3 (03JAN90) 05-6 3TN/4TN Series Yanmar Engines 010897 PN=9 . Bolt Diameter Property Class 8.Introduction/Metric Torque Specifications METRIC TORQUE SPECIFICATIONS 05 6 NOTE: Wrench torque tolerance is ± 20%.8* lb-ft N·m Property Class 10. Therefore.9* lb-ft N·m M5 M6 M8 M10 M12 M16 M20 M24 5 8 18 37 66 166 321 554 6 10 25 50 90 225 435 750 7 11 26 52 92 229 450 775 9 15 35 70 125 310 610 1050 Torque figure indicated above and in the Specification Sections of this manual are valid for non-greased or non-oiled threads and heads unless otherwise specified. S11. * Torque value for bolts and cap screws are identified by their head markings.2000.

. . . . .97—30. . . . . . .0026—0. End Journal Clearance . . . .0020) . . ..169) 36. . . . . . . . . . . Intermediate Journal Clearance . . .0—10. . . . Rocker Arm Assembly Cap Screw and Nut Torque . .1 0. . . End Journals O. . . . . . . . . . .. . . . . . . . 5M4. .81 29. . . .D. . . . . . . .0013—0.398) (0. .007) 11 N·m (96 lb-in. . . . . . . . . . . . . . . . . . . . . .068 (0. . . . . . . .. . . . . .02 (0. . . . . . . . . . . . . 18 N·m (160 lb-in. . 18. . .410) (1. . 11 N·m (96 lb-in.007) 0. . . . .0027) Camshaft End Play . 9. . . . . . .003) Length . 5 (0. . . . . . . . . . . . .398) (0. . .115 (0. . . . . . . . . .065 (1.2 35. . . . . . Intake Manifold Cap Screw Torque . 35. .95—17... . . . . Attaching Cap Screw Torque . . .D. . 0.197) Cam Follower O. . .008) 06 1 . . . . . . . . . . . . . . . . . . . . . . 11 N·m (96 lb-in. .3925—0. . . .1 -19-28AUG87 CTM3 (03JAN90) 06-1 3TN/4TN Series Yanmar Engines 010897 PN=10 . . . . . . 26 N·m (226 lb-in. . . . . . . . . . Arm I.00—18. .. . Shaft Support I.411) (1. . . . .) . . . .. . . . . . . . . .95 10. Maximum Gear Backlash Between Each Gear . .180—1.392) (0. . . . . . . . . . . . . . . .D. . .0049) . .. .075 (0. . . . . . . .0016—0.. . . . . . . .182) . . . . . .421) 36. .0045) . . . .3933) . .. (Gearcase Side) . .3945) 0. . . . . 0. . . . . . . . . . . . . .032—0.18 (0. . . . ..R. . . . . . .) 9 N·m (78 lb-in. . . . .D. . .4 (0. . . . .) Push Rod Maximum T. . . . . . .) . . . . . . . . . . . . 114—115 (4. . . .528) . .415—1. . Intermediate Journals O. . . . . . . . . . . . . . . .7074) Bore I. . . . . . . . . . . 0. . . . . .03 (1. . . . Valves. . . . . . .94—35.. . 9.414—1.417—1. . . . . . . . . .D. .Group 06 Repair Specifications ENGINE: 3TN66 GROUP 10—Valve Train and Camshaft Item Standard mm (inches) Wear Limit mm (in.7067—0. . . . . . .418) . .008) (1.18 (0. . .. .16) . .01—0. . . . . . . and Manifolds Item Standard mm (in. . Bushing I. . . . Lobe Height . . . . . . . . . . . . . . . . .05—0.7094) Bore Clearance . . . . . . .1 (1. . . . . .0004—0. . . . . . . . .002—0. . . . . . .00—36. . . . . . .018 (0.00—36. . . . . .94 (1.0—10. . .D. . . . . .TM306.93 (0. . 0. . . .) Wear Limit mm (in. . . . . . . . . . .13 (0.49) Diameter .. . . .) . . . . . . . . .416) 35. 36. . .. . . 0. . . . . . .) 115 N·m (85 lb-ft) GROUP 15—Cylinder Head. . . . . . . . . . . . . . . . . . .417—1. . . . . . 18. . 0. . . . . .99 (0.420) . . . 0. .85 35.I. Intermediate and Flywheel End Bores I.D.3937—0. . . . . 17.) Manifold Exhaust Manifold Cap Screw Torque . . .415) 29. . .968 (0. .D. . . .711) 0. . . . . . . . . . . . .. 114 (4. . . . . . . .2 (0. . . . . . . . . . .3945) 10.040—0. . . .125 (0. . . .15 (0. . . . . . .91—35. . .. .025 (1. . . . 10. . . . . . Rocker Arm Cover Nut Torque . . . . . . . . . . . . . . . . . .706) . . . . . . . . . Shaft Clearance . . . . . . . . . . . . . . . 17. . . . .421) 0. . . . . . . . . . . . . . . . . . . . . . . . . . .3937—0. . . . . . .05 (0. Gear Housing Cover Cap Screw Torque Crankshaft Pulley Cap Screw Torque . . . . .006) . . . . . . . . . .) Valve Clearance . . . . . .7 (0. . . . . . . . . . .02 (0. .065—0.1 10.05 (0. . . . .97—9. .7087—0. . . . . . . . . . . .. . . . . .1 (1. . . .005) Rocker Arm Shaft O. . . .. . . . . . . . . . . . . . . . .D. . . . . .488—4.96 (1. . . . 36. .

. . ..460 (0. . . Exhaust . . . . . .4 (0. . . 83 N·m (61 lb-ft) . . . 49 N·m (36 lb-ft) . . . .2165—0. . 0. .008) . . . . . . . . . . . . . . . . . . . . . . . .91 (0. . . .. . . . (Exhaust) . . . . . . . (Intake) . . . . . . . 0. . . . . . . . .020) 0. .002) Attaching Cap Screw Torque . . Cylinder Head Flatness (Maximum Distortion) . . . .58 (0. . . . . .445—5. .. . . . . .008) .065) . . .D. . . . . .) Stub Shaft Maximum T. 88 N·m (65 lb-ft) 5M4. . . . . . . .. . 5. . . . .. . . . . .006—0. . . . . . . . . 5. .215—0. . . . . .65 (0. . @ Test Force . . . . . . . .. . . . . . 120˚ . .20 (0. . 5. . . . . . . . . . . . . .214—0. 1. .59) 125 N (28 lb) . . . . . . . 5. . . .40 (0. . . . . . 0.216) . . Valve Guide-to-Valve Stem Clearance: (Replace) . . . . . . . Exhaust . . . Flywheel Housing or Shield Cap Screw or Nut Torque M10 .) Wear Limit mm (in. . . . . . . . . . . . . . . . . . . . . . . . .034) .05 (0. . . . Cylinder Head Cap Screw Torque In Sequence (Lubricated) .20 (0. . .016) 0. . . 5. . . . . .15 (0. . . . . Valve Guide Height . . . . . . . .) . . . . . . . Mill Cylinder Head No More Than . . . . . .) Wear Limit mm (in. . . .217) . . . .85 (0. .213) . . . . . . . . ..D. .. . . . . . . . 26 N·m (226 lb-in... .006) . . . . .. . . . .2 -19-28AUG87 CTM3 (03JAN90) 06-2 3TN/4TN Series Yanmar Engines 010897 PN=11 . . . . . . . . .. . . .50 (0. . . . . . . . . . . . 49 N·m (36 lb-ft) . . . . . . 1.15—0. . . 1. M8 . . . . . .) . . . . . . 0. . . . . . . . . . . .. . . . . . . . . Attaching Cap Screw Torque Flywheel Housing Mounting Plate or Housing Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . .5 (0. . . . .R. . . . . . . .045) . . . . . . . . . Starter-to-Mounting Plate Cap Screw Torque . . . . . .40 (0. . .020) 28 (1. .20 (0. . . . . . . . .41 (0.2 (0. . . . . . . . . . . 0.213) . . . . . . . . . . . . . . . GROUP 20—Flywheel Item .. . . . . . . . . Valve Seat Angle Intake . . . . . . . . .Repair Specifications/Engine ENGINE: 3TN66 Item Standard mm (in. 90˚ . . . . . . . . . . . 0. . M12 Nut . . . . . . . . 49 N·m (36 lb-ft) . . . . . . . . . . . . . . . . . 0. . . . . . . Valve Spring Free Length (Approx. . . . . . . . .220) . . . Valve Seat Width Intake . . . . . .) 06 2 Cylinder Head Valve Recession Intake . . . . . . . . . . . . . . . . . . . .102) 17 (0. . 1.. . . . . .I. . Exhaust . .50 (0. . .. . .008) Flatness . . Valve Spring Test Length . . . . . .460—5. . . . . . . . . . . . . 7 (0. . .5—5. . . 5. . . . . . . . . . . . 0. . . . . . . . . . . . . Valve Guide I. 59 N·m (44 lb-ft) Flywheel Flatness . . . . . . . . . . . . .075) .15 (0. . . . . . .05 (0.276) . . . . Less than 0. . . . . . . . . . . . . .002) . . .. .. . . Cylinder Head Valve Stem O. . . . . . . .515 (0. . . .. . 34 N·m (25 lb-ft) Standard mm (in. .056) . . . . .. . . . . . . . . . . . . . . . . . . (Knurl) . . . . . . . . .TM306. . . . . . . .475 (0.008) . . . . . . . . . . . .215) . . .002) . . 0. . . . .. . . .

. . . . . . .33 (0. Ring End Gap (1st and Oil) Ring End Gap (2nd) .0039) . . . . . .. 0. Oil Pan to Seal Case . . . . . . . . . End-Cap Screw Torque . I. .0079—0. . .. . . . . 11 N·m (96 lb-in.045 (0.07 (1. .33 (0. 36.D.. . .15—0. . .7874) . . 54 N·m (40 lb-ft) .. ..1 (0. . .0028) .0039) . . .. . . . ..416—1.. .577) .011) . 0.. .597) 66.417—1. .001) GROUP 30—Crankshaft and Main Bearings Item Standard mm (in. . .98 (1. Pin Bushing I. . .095—0. . ... . . .. . .. . . .1 (0. . . 0.35 (0. .006—0.TM306. . .788) 0. . .. .) 39. . . . . . . . 20. .010—0. . . .787—0.08) 1. ..957 (2.15 (0. .02 (0. . .. .042 (1.5 (0. . .. .D. .0026—0. .786) 20. 0. . . . . 35. . . . . . . 0.00—36. . . Piston O. . .. Bearing Clearance (Piston Pin) Maximum Twist ... Second Ring .006) 0. Oil Ring .0217) . .08 (0.9 (1. . . . .065—0. 40.9 (0.. .. .025—20.789) 0—0. .07 (1....55 (0. . . . . Bearing Clearance (Crankpin) . . . . 0. . .020—0. . . .D. . .2—0. . . .. . . . . .. . . . .D.. . . . . . . . . . . . . . . . . .. .005) 0. . . .420) 06 3 .065—0. .. . ... Cylinder Block Cylinder Bore Maximum Piston Clearance Cylinder Out-of-Round . .788—0. .. . . .. . . . . .2 (0.5740) .. . 0... . Main Bearing I. .008 (0.047 (0.. . . .20 (2. . . .072 (0. . .0018) 65. . .D. .. .. .) Wear Limit mm (in. . . .417) . .. . . . . . .25—0.0007) . . . . .0157) 23 N·m (200 lb-in.000—20. ...2 (0. . .004—0. . . 19.00—40.) 9 N·m (78 lb-in. Pin Bore I. . . .2 (0. ..0072 (0. .013) . . . .0010—0. .) 0. . . . ..97—39.) Crankshaft End Play . .059) 1. .0059) . 0. . . .014) . Piston Pin O.. . . . .. Journal O. .. .0008—0. . . . . . .1 (0..D. .020—0. . .4 (0. . 0.. . .... . . .578) 5M4. . . . . . . . 0.3 -19-28AUG87 CTM3 (03JAN90) 06-3 3TN/4TN Series Yanmar Engines 010897 PN=12 . ..013) 0. .788) 0. . . .D. . .600) . . . . . . 20.15 (0. . 0. . . Main Bearing Journal O.92 (1.. . . Pin Bore Clearance .03 (2.) Connecting Rod Side Clearance . .. . . .02 (0. . . . . . Piston Pin Clearance . .. . . . . . ..Repair Specifications/Engine ENGINE: 3TN66 GROUP 25—Connecting Rods and Pistons Item Standard mm (in. . .0008—0. . . Bearing I.. . . . .. . .40 (0. . .. . .059) 19. .0039) . . .991—20.927—65. .025—0. . . . .. .0026—0. .08) 0. . . . . .593) 66.. . .0. . . . .D. .17 (0—0. ... . .596—2. . Piston Ring Groove Clearance Top Ring .606) 0.... . . . . . . . 0. . .5736—1. .0026—0.572) 40. . . .003) 35.00—66. .85 (2. (Crankpin) . . .0007) .599—2. Main Bearing Clearance . .. . . . .042 (1. .0 (0. . 39.. .. .. .) Wear Limit mm (in.045 (0.0019) . . .08) 0.. ..575—1. .0018) 20... 0.. .016) . . .5 (0. . .787—0. . .97—35. . . . . 65.419) .. . . . ..0028) 0.. .12 (0. . . . . .98 (1. . . . .. . .D. . . .791) 0. . . . .. .. .. Main Bearing Cap Screw Torque . . . Oil Seal Case Cap Screw Torque Seal Case to Block . .414) 36. .266 (0.1 (0. .038 (0. . . .. .. . . . .065—0.017 (0—0. .

786—0. . . . .010) (0. . .. .. . . . . . ..20 0. ...20 0. . . .791) Shaft Diameter .. . . .. .11—0. . .008) (0.04—0. 11 N·m (96 lb-in.0016—0.25 (0. .. 19. . .TM306.) Wear Limit mm (in.0043—0. . .008) Gear Gear Bushing Diameter . .. . . .9—24.. . . . .0016—0. . 11 N·m (96 lb-in. . . . . Timing Idler Idler Idler . ....19 0. . . .959—19. ..001—0.93 (0. . Crankshaft . 0.86—0.008) (0. . . . . .20 0. .11—0..785) Shaft Oil Clearance . . . . .. . .) Wear Limit mm (in. ... . . .787) . . .04—0.786—0. . .062 (0. . ...) Oil Pan-to-Gear Housing Cover Torque . .. .00—20.0043—0.20 (0.) Crankshaft Pulley Cap Screw Torque . . Outer Rotor-to-Pump Body Clearance . . ..008) (0.. . . . . 25 N·m (18 lb-ft) . . .. .. 9 N·m (78 lb-in.) of Shim Thickness .. .. . .. .. . . .96) Valve Spring Test Length . . . . . .12 0. . 14. . . . 21. . . .0016—0.. .12 0. . . . . 115 N·m (85 lb-ft) Timing Gear Backlash Fuel Injection Pump Idler . . . . ... . . . . .) 5M4. . .. ..19 (0. . . .08 (0. . . . .0047) (0.002) . . . .. 0. 19. ... . 20. . . . . .5 (0.. . . . .008) (0. . .25 0. .008) (0. . . . . .8 kPa (2 psi) Oil Pan Strainer Tube Attaching Cap Screw Torque .02—0. . Oil Pump . . . . . . . . . ..15 (0. . .021 (0. . . . . .039 in. .. . 0. .0075) . . .04—0. . . .010) (0. . Inner Rotor-to-Outer Rotor Clearance . . . . . Rotor Recess . .Repair Specifications/Engine ENGINE: 3TN66 GROUP 35—Gear Housing Item Standard mm (in. . . . . . 0..0075) . .. . .7 (0. .0043—0. . . . .980 (0. .010) Oil Pressure Regulating Valve Valve Spring Free Length (Approx. . ... 13. . . .58) Oil Pressure Change Per 1 mm (0.. .. . .. ... . .. 20. .) .. .25 0. . . .. . . 0. . . . .. . .. .12 0. . ..) Oil Pump Gear Backlash . .. . . Camshaft . .0047) (0. ..19 (0. . . . 0. . . . .0075) (0.. . . .788) .. 9 N·m (78 lb-in. . . Oil Pump Attaching Cap Screw Torque . .4 -19-28AUG87 CTM3 (03JAN90) 06-4 3TN/4TN Series Yanmar Engines 010897 PN=13 .. .) 06 4 Gear Housing Cap Screw Torque . . . . . . ..006) GROUP 49—Lubrication System Item Standard mm (in. . . .0047) (0...11—0.20 0. .) Oil Pan-to-Block Cap Screw Torque . .20 0. . .

.006) . . . . . . . . . . . .. . . . . . .. . . . .90 8. . . . . . . . . . . . . . . . . . . Camshaft Bearing Screw Torque . .. . .. . . . . . . .. . . . . .5 -19-28AUG87 CTM3 (03JAN90) 06-5 3TN/4TN Series Yanmar Engines 010897 PN=14 . . .5 in. . . . . . . . .. . . .20 7. . . . 85˚C (184˚F) Housing Cover Cap Screw Torque . 0. . .90 (0. . . . . .. . . . .TM306. . . . . . . 40 N·m (30 lb-ft) GROUP 55—Fuel Control and Governor Linkage Item Standard mm (in. . . Pulley Cap Screws Torque Attaching Cap Screws . . . . . . . . . . . . . . . . . . .12 (0. . . . .008) 88 N·m (65 lb-ft) . . . . . . . . . .. . . . . . .. . 10 Seconds @ 11032 kPa (1600 psi) Pressure @ 11032 kPa (1600 psi) Pressure Retaining Nut-to-Nozzle Body Torque . . . . . . . . . . . . . . . . . . . .. . . . . ... . .. . . . . . . . . ... Minus Shaft O. .D. . . . . . . . . . . . .) Water Pump Plate Screws Torque . . ..0016—0. . . . and Nozzles Item Standard mm (in. . . . . .) at 107 N (24 lb) Force applied midway between pulleys. . .) . . . . . . . . .. . . . . . . .) Wear Limit mm (in. . . .18 (0. . . . . . . . . . 40 N·m (30 lb-ft) Nozzle-to-Cylinder Head Torque . . . . . . . . . . . Camshaft. . . .D.) Fuel Injection Pump Pump Mounting Hardware Torque Gear Backlash .. . . . .D. . 9 N·m (78 lb-in. . .. . . . . . . .) 20 N·m (180 lb-in. . . . . . .) Fuel Control and Governor Linkage Governor Shaft O. . . . . .2 (0. . . . . . . . . . . .) 0. .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N·m (180 lb-in. . . . . . .. . . . . . . .. .311) (0. . . . . . . .. . . . . .. .323) (0.Repair Specifications/Engine ENGINE: 3TN66 GROUP 45—Cooling System Item Specification Thermostat Begin Opening Temperature . ... .311) . . . . . . . . . Sleeve Oil Clearance (Sleeve Bore I. . . .. . .0047) . . 30. . . . .. . . . . . . 71˚C (160˚F) Fully Open Temperature . . . Gear Attaching Nut Torque . . . . . . Fuel Control Linkage Bore I. . . . . . . . 50 N·m (37 lb-ft) Leak-Off Fitting-to-Nozzle Torque . . . . . . . . . . . . .D. . . . . . . Sleeve Shaft O. . .9 (1. . . . . Alternator Belt Deflection . . Pump Camshaft Lobe Height . .15 8. . . . . . . . . .. . . . . . 06 5 GROUP 50—Fuel Injection Pump.. . . . . . . . . . 0. . .D.) . . . . . . . . . . 7. . 0. . . . . 11 N·m (96 lb-in. .150 (0. . . . . . .. . .D. . . 11722 ± 480 kPa (1700 ± 70 psi) Minimum Leakage Time . . .) Governor Shaft Clearance Linkage Bore Minus Shaft O. . . . . . . . . . Sleeve Bore I. .. .) Fuel Injection Nozzles Nozzle Opening Pressure . . . . . .321) (0. . . . 26 N·m (226 lb-in. . . . . . . . . . . . .D. . .) . . . . . . . . . . . . .. . . .0071) GROUP 60—Starter See Starter Specifications in this Group GROUP 65—Alternator See Alternator Specifications in this Group 5M4. . . . . . Screw Torque .217) 20 N·m (180 lb-in. . 9 N·m (78 lb-in. . . . . .04—0. . .. . . 13 mm (0. . . . . . . . . . . .) Wear Limit mm (in. . . ..

0—40. . . . .824) Bore I.329) 40. . . . . . . . .94—39. .471—0. . 11. .) Wear Limit mm (in. . . . . .18 (0. 0.472—0. . . Attaching Cap Screw Torque . . 40. . .D. . . . 5 (0. .. .473) .) Intake Manifold Cap Screw Torque . . . . .09 (0. . . 0. . . . . . . . .054 . . 11. . .. . 39.824—0. . . (Flywheel Side) . . (Gearcase Side) . . . . .337—1. . . .825) . . 141. . . . .573) .6 -19-28AUG87 CTM3 (03JAN90) 06-6 3TN/4TN Series Yanmar Engines 010897 PN=15 .02 (0.85 (1. .935 (1. . . . . . (Intermediate) .D. 20. . . . . .572—1. .960 (0. .2 (0.D. . Valves. . .115 (0. . .) Manifold Exhaust Manifold Cap Scrw Torque .476) 12. . 0. . . . . . . . .0026—0. . .577) . . .577) . . . .D. .. . . .008) 39.197) Cam Follower O. . . .. . . . .40 (0. . . . .D.96 (1. . . .0016—0. . . . . . ..05 (0. . .0—21. .96 (1. . . . . 0.D. . . . . .. . .) Wear Limit mm (in. .0 (5. . . . . . . . . . . . . . . .. . .59) .569) 39. . . . . . . . . 20. . .) . . . . .93 (0. Journal O. . .016) . . . End Journal Clearance . 0.15 (0. . . . . 0. . .0045) 11 N·m (96 lb-in. . . .. .065—0. . . 141—142 (5. . . .. . . . . . .575—1. .579) 33.D. . . .. . .94—39.002—0. . . . .I. . Bushing I. . . .828) . . . . .472) 12. . .966—11.. . . . .075 (0. . . .0—40. . Journal O. . . 0. .13 (0. . .040—0.. 39. . . . .. . . . .R.085 (0. Journal O. . . .09 (0.005) . .569) 40. . . . . .472—0. . . . . . .85 (1. Lobe Height . .0033) . .984 (0. . . 21.579) 0. . . . . . . .. . (Gearcase Side) . . . .) Push Rod Maximum T..572) 39. . . . . . . . .003) Length .55—5. .579) 40..) 5M4. . 12. . . . . . . .341) .10 (1.571—1. . .02 (0. 26 N·m (226 lb-in. . . .829) Bore Clearance . . .05 (1. Rocker Arm Assembly Cap Screw and Nut Torque . .TM306.065 (1.007) 0.) 06 6 Valve Clearance . . . . . .1 (1. . .. . . . . . . Intermediate Journal Clearance . . . .471) 12. . . . . . . . . 0. . . . 18 N·m (160 lb-in..D. . .00—12.094 (0. . . 33. (Intermediate and Flywheel Side) . . .572—1. . . . . . . . . . . . . Arm I. .021 (0.10 (1. Gear Housing Cover Cap Screw Torque Fuel Shut-Off Solenoid Bracket Cap Screw Torque (Early Units) Crankshaft Pulley Cap Screw Torque . . .D. . . . . . . . 26 N·m (226 lb-in. . Shaft Support I. . . . . . . . . .55) Diameter . . . . .95—34. . . 40. .573) . . .910—39.) 9 N·m (78 lb-in.. .) 115 N·m (85 lb-ft) GROUP 15—Cylinder Head. . . . . . .476) 0. . . . . . . .065 (1. .0037) Camshaft End Play . . . . . . . .927—20. 21.. . . . . . . . . . . . . . . . . . . . . . Rocker Arm Cover Nut Torque . . .016—0.00—12. Maximum Gear Backlash Between Each Gear . . . . . . . . Bore I. . .20 (0. . .473) . Shaft Clearance . . .96 (0.006) .0016—0. .Repair Specifications/Engine ENGINE: 3TNA72 GROUP 10—Valve Train and Camshaft Item Standard mm (in. .04—0.827—0. .75 (1. . . . and Manifolds Item Standard mm (in. .575—1. . . . . . .05—0.D. .008) Rocker Arm Shaft O. 11 N·m (96 lb-in.

. . . . . GROUP 20—Flywheel Item . . .4 (1. . . . . Valve Spring Free Length Valve Spring Test Length . . . 59 N·m (44 lb-ft) Flywheel Flatness . . . . . Exhaust . . 6. . . 9. . . . . . . . . . . . . . Exhaust . . . . . .006—0. . . . .05 (0.. . 1. .354) . . .Repair Specifications/Engine ENGINE: 3TNA72 Item Standard mm (in. 0. . Exhaust . . . . . . . . . . . . . . .90 (0. Valve Guide Height . 83 N·m (61 lb-ft) . . . . . . . . . . .) .. . . . .. . Mill Cylinder Head No More Than .2758—0. Flywheel Housing or Shield Cap Screw or Nut Torque M10 . .. . . . . . .020) 0. . . .. . Valve Guide-to-Valve Stem Clearance: (Replace) . . 61 N·m (45 lb-ft) Standard mm (in. . 88 N·m (65 lb-ft) 5M4. . . . . . . . . . Valve Guide I. . . . . . . . . . . .) Wear Limit mm (in. 1.008) . . . . . . Starter-to-Mounting Plate Cap Screw Torque . . . . . 6. . .) Stub Shaft (If Equipped) Maximum T. .2764) . . . . . . . . . . . . ..20 (0. . .TM306. . . . . . .033) 37. . .50 (0. . . . . . . . . . . . . . .272) . . . . M8 . . . . . .. . . . . . . . . . . . . . . . . . . . . Attaching Cap Screw Torque Flywheel Housing Mounting Plate or Housing Cap Screw Torque . . . . . . .078) .960 (0. . . . . . . . . . . . . . . .. . . . . 2. . .008) Flatness .7 -19-28AUG87 CTM3 (03JAN90) 06-7 3TN/4TN Series Yanmar Engines 010897 PN=16 . . . . . . . . . .) Cylinder Head Valve Recession Intake . . 88 N·m (65 lb-ft) . 0. . . . . 22. . . . .070) . . . . . .273—0. . .. . . . . . . .. . . . . . . . .I. .05 (0. . . 0.5 (0. .005—7. . . . . . . . . . . 0. . . . . . . . . . . . . . . . .20 (0. . . . .R. . . . . . . . . . . . . (Knurl) .D. . . . . . .00 (0. 0. . . . 120˚ .) . . . . . . . . . . .. . . . .. . Valve Seat Angle Intake . . . ..77 (0. . . . .006) . . .87) 06 7 Valve Stem O. .057) . . . Valve Seat Width Intake . . . 0. .002) . . .D. . . . . . . . . (Approx. ...472) . M12 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N·m (226 lb-in. . .27 (0. .44 (0. . . .15—0. . . . . . . .5 (0. .. . . . .008) . . 1. . . . 6. . . . . . . . . . . . . . . . . . . . . . . . . . .85 (0. . . . . . . . . . . . . . . . . 90˚ .15 (0. . . . . . . . . . .002) . . .90 (0.008) . . . . . . . . . . 0. . . . . . . 7. . . . . . . . . . . . . . . . . . .20 (0. Less than 0. . . . . . .) Wear Limit mm (in. .98 (0. . . 49 N·m (36 lb-ft) .274) . . . . .089) . . . . Cylinder Head Flatness (Maximum Distortion) . . . . . . 49 N·m (36 lb-ft) . . . . . . . . . .. . . . . . .945—6. . . . .020 (0. . . . . .. . . . . . . . . . . . . . 0. . . . . . . .272) . . . . .20 (0. . Cylinder Head Cap Screw Torque In Sequence (Lubricated) . . . .002) Attaching Cap Screw Torque .

. . .10 (0. . .. 11 N·m (96 lb-in.. . . .97—39. .0030—0. . . . 72. .826) 21. .022) . 0. . . . .97—43. . . .TM306. .5 (0. . . . .07 (1. . . . .08 (0. . . .98 (1. . . .042 (1. . . 39. .0043) . . . . . .0158) . .047 (0. .8282) 0. . . . . . . . . . . .02 (0. .010) ..8 -19-28AUG87 CTM3 (03JAN90) 06-8 3TN/4TN Series Yanmar Engines 010897 PN=17 . . . . . .006) . .. . . Cylinder Block Cylinder Bore I. . . . .Repair Specifications/Engine ENGINE: 3TNA72 GROUP 25—Connecting Rods and Pistons Item Standard mm (in.20 (0. . .042 (1. . . .5736—1. . . . .016) . . . .010—0. . . . .) Crankshaft End Play . Pin O. . . . .02 (0. .92 (1. . . . . . .11 (0.833) .25—0.843) . .011) .578) .. . . . 72.0—40. . . Rind End Gap (2nd) .4 (0. .731—1. . .003) 39. . . . . .08278—0. . . . .) 43.) . . Minimum Journal O. .0—72. .. . .836) . (Crankpin) . . .047 (0.013) . . . . . . . .008) 1. . . . . . . . . . .92 (1. . . Ring End Gap (1st) . . . .. . . . .07 (1. . . . . . . . . . Maximum Twist . .038 (. .03 (2. .020—0. . . . . Piston O. . . . . . . . . . . . . Main Bearing Clearance . . . .006) 0. . . .D. .) 06 8 Connecting Rod Side Clearance . . .579) . .025—0. . .0 (0. . . . . .D. .81 (2. . . .1—0. .D. . .11 (0. . . .045 (0. . . . Bearing Clearance (Crankpin) . . . . . . . 21. .826—0.729) 44. . . . . .018 (0—0. Ring End Gap (oil) .0007) . . . . Bearing Clearance (Piston Pin) . .0079—0. . 0. . . 0.952 (2. . . . . . . . . .0010—0. .072 (0. . . . . . . 9 N·m (78 lb-in. . . Oil Pan to Seal Case .059) 1. . Oil Seal Case Cap Screw Torque Seal Case to Block . . . Main Bearing Cap Screw Torque .020—0. .. .004—0.. . . . . . . . . .09—0. 23 N·m (200 lb-in.15—0.5 (0.832—2. .004—0. . .0028) . 0. . .. ... . Pin Bushing I. . 79 N·m (58 lb-ft) . . . 20. . . . .D. . . 71. . . . . . .025—21.. . .. .072 (0. . . . . . . Pin Bushing Clearance . .0008—0. . .827) . . . . . .059) 1. . .271 (0.014) . . . . 0. . . . . . .735) 5M4.991—21. . .922—71. .732—1.734) . 0. . .572) 40. . . . .33 (0. . . . . . . . . . 43. . . . . . . .35 (0. . (Crankpin) Bearing I. Pin Bore I. 0. . .5 (0. . .0019) .) 0. . . . . . . .574) . Pin Bore Clearance . . .80 (0. .8271) . . . . . . . . . 0.011) .828) 0. . . . . . 0—0. . Maximum Piston Clearance Cylinder Out-of-Round .835—2. . . . .) 9 N·m (78 lb-in. . .0—21.0010—0. 44.20 (2. . . . . .0028) 0. . . . Main Bearing Journal O. .15 (0.11 (0. . .. . . . .732) . . . .55 (0. . ..009 (0. . .. . . .0043) 0.2—0. . . . . .D.831) 0. . . . . .025—0. . . . 0. .001) GROUP 30—Crankshaft and Main Bearings Item Standard mm (in.15 (0. . .004) 21. .075—0. 0.8268—0.D. . . . . . . 40.0018) 71. . . . . .. .D. . . . Main Bearing I. .28 (0. .) Wear Limit mm (in. . 0. .D. 21. 0. . . . . . . . . . 0.D.827) . . . 0.0—44. . . .) Wear Limit mm (in. . . .98 (1.98 (0. .0019) . .006—0. . End-Cap Screw Torque . . . .. . . . . . . . ..008—0.059) 20.25 (0.575—1. Piston Ring Groove Clearance All Rings .

. . ..25 (0. ... . .. .786—0. . . . .785) Shaft Oil Clearance .) Wear Limit mm (in. .. . .0075) (0. . 9 N·m (78 lb-in. . . ... .. .11—0.788) . (0..0075) . . . . ..04—0.. . .. .010) 0. .010) 0. . . . ... . . .008) (0. . . ... . . .. . . . . . .11—0.1 (0.. . .. ...20 0. . 0.004—0. . . . Inner Rotor-to-Outer Rotor Clearance 3TNA72 . . . . ..010) 0. .0075) .0047) (0. .010) (0. . 25 N·m (18 lb-ft) .. . Oil Pump ..010) . .. . Outer Rotor-to-Pump Body Clearance . . .....20 (0. . .010) . .. (0. .. . . . . ...008) (0. .. .11—0.. . . . 0.9 -19-28AUG87 CTM3 (03JAN90) 06-9 3TN/4TN Series Yanmar Engines 010897 PN=18 .15 (0. . . .0047) (0.. .010) (0..11—0..786—0. .) Oil Pump (Later 3TNA72) Gear Backlash 3TNA72 . . . .19 (0. . .. .25 (0. .. . 20.. . . . . . ... . . . . .. . . . .. . .008) (0. ..0016—0. . . . . .... .959—19. .. . . . . .. Rotor Recess .93 (0. . . ... . . . . . .. .. .80 (0. Oil Pump Attaching Cap Screw Torque .. . .. .. . .787) . ... . .004—0. .. . . .0—20. .. . . . . . 0... 3TNA72-UJB Only . .. . . Outer Rotor-to-Pump Clearance .. .. . .791) Shaft Diameter . ...498) 12.. . .. . . .002) . . .0043—0. . . . . .. .25 (0. . .. . .02—0. .25 (0. .20 0. . .. ..0075) . . .12 0. ..006) GROUP 40—Lubrication System Item Standard mm (in. 19. . . . . . . . .. . .. .25 (0. . .062 (0..20 0.25 (0. . . . 115 N·m (85 lb-ft) Timing Gear Backlash Fuel Injection Pump Idler .. . . . . . . . .. . . . ... .) Crankshaft Pulley Cap Screw Torque .0043—0.. . . . . . . . .. . . Timing Idler Idler Idler 06 9 . .20 0. 0. . .25 0. . . 0. ... ... . . . . 19. . .. . . 9 N·m (78 lb-in. . . .001—0.) Wear Limit mm (in.. . .. . . 20.0047) (0. . . .. .980 (0. . . . . . . . ..11—0. . .. . ... ... .. .. 0.08 (0.008) (0. . .19 0. Shaft-to-Bore Clearance .. .. .. Rotor Shaft Diameter ... .. . Rotor Recess. . ..004) 5M4. .. Camshaft . .. . 0. Oil Pump Attaching Cap Screw Torque Oil Pump (Early 3TNA72) Gear Backlash . .12 0. . .. . Inner Rotor-to-Outer Rotor Clearance .19 (0.. . . .. .008) (0.TM306. . . . .. . .010) 12. . . . Crankshaft . ... . .. . . . .15 (0.. . . . . . ... . . .20 0. . ..) .. 3TNA72-UJB Only . . . .. .. . . . .65 (0. .0043—0. .. . ..04—0.. . .. . . . . . .19 .. . . . . 0. . . .. . .0016—0. .. .. . . . .. .. . .. ..19 0. . . . .04—0. . .. . ... .008) Gear Wear Specifications Gear Bushing Diameter . . . . . . . . .0016—0. .) Gear Housing Cap Screw Torque .. 0..12 0.. . . . . . 0. . Shaft Bore Diameter Maximum .... Maximum .25 0. . . .0075) . .. . .006) .Repair Specifications/Engine ENGINE: 3TNA72 GROUP 35—Gear Housing Item Standard mm (in. . . .021 (0. .. .. .504) 0. . ... . . . . . .

) 26 N·m (226 lb-in. . . . . . . . . .7 lb) Force Oil Pressure Change per 1 mm (0.08 in. . . . . . . . .. . . . . .. . . . . . . . . . . . . .. . . . . . .5 mm (1. . . . . . . . . . . . 11 N·m (96 lb-in. . . . . . . ..) Valve Spring Test Length . . . .. .) .039 in. . .. .) @ 27. . . .. Fully Open Temperature .. . . .. .. . . .. . . . .. . . . . . . . . . . . . . .. . . . . . . . .6 ± 0.2 N (6. . .. . . . . . . . . .TM306. . . . . . . . . . 46 mm (1.. . . . . . . . .. . . . . .039 in. . . . . . . . . . .) . . . . .. . . . . .. . . . . . . . . 28 kPa (4 psi) Oil Pan Strainer Tube Attaching Cap Screw Torque . . . . . .. . . . . . . . . . . . . . . .) of Shim Thickness . . .) Valve Spring Test Length . . .6 psi) Oil Pressure Regulating Valve (3TNA72-UJB Only) Valve Spring Free Length (Approx.4 ± 3. . . .) Valve Spring Test Length .. . . . . . . . . . .. . . . . . . . . . . . . . . .7 lb) Force Oil Pressure Change Per 1 mm (0. . . . .5—40. . . . . . . . . . . . . . . . . . . . .10 -19-28AUG87 CTM3 (03JAN90) 06-10 3TN/4TN Series Yanmar Engines 010897 PN=19 . . .) of Shim Thickness . . .. . . . . .. 39. .. .. . . . . . . .55—1. . . . . . .. . . . . . 30 mm (1. . . . . . . . . Water Pump Plate Screws Torque 3TNA72 . . . . . . . . . . . . . . . . . . . .) @ 29. . . . . . .. .1 N (6. . . . . . . . .) Oil Pan-to-Gear Housing Cover Torque . . . ..) Oil Pan-to-Block Cap Screw Torque . . . . . . .5—48. . . .Repair Specifications/Engine ENGINE: 3TNA72 Item Specification 06 10 Oil Pressure Regulating Valve (Later 3TNA72) Valve Spring Free Length . . . . .. . . . . . Housing Cover Cap Screw Torque 3TNA72 3TNA72-UJB (Only) . 10. .) GROUP 45—Cooling System Item Specification Thermostat Begin Opening Temperature . .. . .. . .. . . .. . . 85˚C (184˚F) 20 N·m (180 lb-in. . 3TNA72-UJB (Only) . 27. . . . . . .59 in. . . . . Alternator Belt Deflection . . . . .) 5M4.. . .. . . . . . .) .5 mm (1. . . . . . .5 ± 3. . . .. . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . .. 11 N·m (96 lb-in.. . .) Force applied midway between pulleys . . . . . .71—1. .. . . .. . . . . . .. . .. . . . . . .. .. . . . .81 in. . . . . . . . ... . . .91 in.. . . . . . . .. . .. . . . 9 N·m (78 lb-in. .. . . . . 43.5 mm (0.. . . . .. . .. . . . . 11 N·m (96 lb-in. . . . .96 in. . .. . . . .1 lb) Force Oil Pressure Regulating Valve (Early 3TNA72) Valve Spring Free Length . .. . . . . . . .. . . . . .. . .) @ 20. . . . . . . 26 N·m (226 lb-in. . . . . . . . . ..5 mm (1. . . .. .18 in. . . .. . . . . . . . . . . . . Attaching Cap Screws . . . .. . . .) . . . . . . . . . . . . . . . . . . . . .. . .. . . . (24 lb) . . . . . . 11 N·m (96 lb-in. . . . .. . 13 mm (0. . Pulley Cap Screws Torque . . . . . . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . .. .1 N (4. . . . . 9 N·m (78 lb-in... . . . .5 in. . . . 24. . . . . . . .9 kPa (1. . . . . . . . .. . . . . . . . 71˚C (160˚F) . . . .. . . . .6 ± 0. . .) . . . . . . . . . . . . . . . . . ... .. . . . . . @ 107 N . . . . . . . . . . . .. . . .. . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30. . . . . . . . . .217) Camshaft Bearing Retaining Screw Torque 3TNA72 . and Nozzles Item Standard mm (in. . . . . . . . . . . . . . . Camshaft. . . . . . . .) Wear Limit mm (in. . . . . . . .12 (0. . . . . . . . . . . . . . . . . . . . . . . . . . . 50 N·m (37 lb-ft) 3TNA72-UJB (Only) . .9 (1.) 06 11 5M4. . . . . . . . . . 37 N·m (28 lb-ft) Fuel Leak-Off Fitting-to-Nozzle Torque 3TNA72 . . . . 11 N·m (96 lb-in. . . . . . . . . .) Fuel Injection Pump Pump Mounting Hardware Torque 3TNA72 . . . . . . 0. . . . . . . . . . . . . . . . . . . . . . . . 51 N·m (38 lb-ft) Nozzle-to-Cylinder Head Attaching Torque 3TNA72 . . . . . .0047) .008) Gear Attaching Nut Torque . 27 N·m (20 lb-ft) Maximum Gear Backlash . . 10 Seconds . . . . . . . . . . . . . . . . @ 11032 kPa (1600 psi) Pressure . 88 N·m (65 lb-ft) Pump Camshaft Minimum Lobe Height . . . . . . . . . . . . .TM306. . . . . . . . . . . . . . . . . . . 40 N·m (28 lb-ft) 3TNA72-UJB (Only) . . . . . . 40 N·m (30 lb-ft) 3TNA72-UJB (Only) . .) Fuel Injection Nozzles Nozzle Opening Pressure .Repair Specifications/Engine ENGINE: 3TNA72 GROUP 50—Fuel Injection Pump. . . .0016—0. . . . . . . . . . . . . . . 20 N·m (180 lb-in. . . . . . .) 3TNA72-UJB (Only) . . . . . . 0. . . 20 N·m (180 lb-in. . . . .04—0. . . . . . . (1600 psi) Pressure Retaining Nut-to-Nozzle Body Torque 3TNA72 . . . . . . . . . . . . . . . . . .2 (0. . . . . . . . . . . . . . . . 11722 ± 480 kPa (1700 ± 70 psi) Minimum Leakage Time . . . . . . . . . . 15 N·m (130 lb-in.) 3TNA72-UJB (Only) . . . . . . . . .11 -19-28AUG87 CTM3 (03JAN90) 06-11 3TN/4TN Series Yanmar Engines 010897 PN=20 .

. . . . . . . . . . . . . . . . . . . . . . . .) Governor Shaft Torque . . . . . . . .D.311) . . . . .12 -19-28AUG87 CTM3 (03JAN90) 06-12 3TN/4TN Series Yanmar Engines 010897 PN=21 . . . . . . . . . 9. . .311) . . . .D. . . . . .) GROUP 60—Starter See Starter Specifications in this Group GROUP 65—Alternator See Alternator Specifications in this Group TM4. .18 (0. . . . . . 8. .007) . 8. . . . . . . . . . . . Fuel Control Linkage Bore I. . . . . . .D. 0. . . . . . . . . . .D. . . . . . . . . . . . . 8. . . . . . . . . .D. . . .D. . 7. . . . . . . 8. . . . . . . .) Wear Limit mm (in. . Minus Shaft O. . Sleeve Bore I. . . . . . Governor Cover Cap Screw Torque . Sleeve Shaft O. . . . . .15 (0. . . . . . 7. .323) . . . . . . . . . . . . . .D.TM306. . . Governor Shaft Clearance (Fuel Control Linkage Bore Minus Shaft O. . . . . . . . . . . . . . . . 7. .350) . . . . . . . .D.20 (0. . . . . . 0. . . . . . . . . . . . . . .321) . . Fuel Control Linkage Bore I.D. . . . . . . . . . . . . . . . . . . .006) . . . . . . . . . . .D. . . . . . . . 49 N·m (36 lb-ft) . 0. . .15 (0. . . . . . . . Inner Rotor Shaft O. . . . . . . . . . .15 mm (0.15 (0. . . . . . . .) 06 12 Fuel Control and Governor Linkage (Later 3TNA72) Governor Shaft O. . . .18 (0. .90 (0. . . . 9 N·m (78 lb-in. . . .D. . . . . . . Sleeve Bore I. . . Inner Rotor Shaft Clearance (Sleeve Bore I. . . . . . . . . . . . . . . .20 (0. . . . . . . . . . . .90 (0. . .90 (0. . . . . . . .) Fuel Control and Governor Linkage (Early 3TNA72) Governor Shaft O. . . . . . . . . . . . . .D. .) . . . . . . . . . . . 0. . . . . . . Sleeve Oil Clearance (Sleeve Bore I. . . . . . . . . . . . . . . . Minus Shaft O. Governor Shaft Clearance Bore I. . . . . . . .D. . . . . . . . . . Minus Shaft O. . . . .007) . .D.90 (0. . . . . . . . .Repair Specifications/Engine ENGINE: 3TNA72 GROUP 55—Fuel Control and Governor Linkage Item Standard mm (in. . . . . . .311) . . . . . . . . . . . . . . . .321) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D.006) . . . . .362) . . . . . . . . . .

521—1. . .13 (0. . . . . . . . . . . . Arm I. . .990 (0. . . . . . .TM306. 146.) Manifold Exhaust Manifold Cap Screw Torque .473) .018 (0. . . . . .773) . 0. . 15. 0. . . 0. . . .) 5M4. . .471—0. . . .910—44.. 0.016—0. .055 (1. . . . . .008) Rocker Arm Shaft O. 146. .2 (0. . . 06 13 . .. . .D. . .776) 0. . .0039) 26 N·m (226 lb-in. .0045) 0. 0. . .D. . . . .130 (0. .0—45. . 44.050—0. . .0078) 0. . .20 (0. . . .. . ..2 (0.. . .D. . . . . . . . . . .) Push Rod Maximum T. . .631) .10 (1. . . . . .R. . .630—0. . . . . . . . PTO Journal Clearance .77) Diameter . . . . .040—0.) 26 N·m (226 lb-in. . . . . . . . . .0—16. . . . Valves. .633) 16. . 11. . . . . . . . . . . . . . .0—12. . . . . . . . . .D. .774) 45. . . . . . . . . . . .008) 44. . . 18 N·m (160 lb-in. . . .474) Bore Clearance . . . . . . .. . .2 (0..) Intake Manifold Cap Screw Torque . 0. . .) Wear Limit mm (in. . . . . . . Gear Housing Cover Cap Screw Torque Crankshaft Pulley Cap Screw Torque . . . . . . .D. . . . . . 0.0016) Camshaft End Play . .) Wear Limit mm (in. . . . . . . .0015—0. .315) Cam Follower O.. . 0. . . .0021) .526) 44. . . .008) . . .935 (1. ..801) . . .10 (1. . .633) 0. Intermediate Journal Clearance . . . . .016) . .. .628) 16.) 26 N·m (226 lb-in. .) Rocker Arm Cover Nut Torque . ..40 (0. .D. . . .470) Bore I. 12. . . . .005) . . . Idler Gear Shaft Cap Screw Torque . . . .010—0. . . .512) 45. .13 -19-28AUG87 CTM3 (03JAN90) 06-13 3TN/4TN Series Yanmar Engines 010897 PN=22 . . . . . .80 (1.93 (0. . . Intermediate and Flywheel End Bores I. . . . .770) 44. . . . . .65—147. . . . and Manifolds Item Standard mm (in.772—1. . . . . . . . . . . Bushing I.D. .02 (0.0003—0. . . . .065—0. . . . . . . Lobe Height . . . .764) 44. . .0050) 0. . . . . . . . . . 8 (0. .984 (0. . .075 (0. . . . . Flywheel Journal Clearance . .774—5. . . . . . . . . .115 (0.002—0. .0019—0. . . . . . . . . . . . . . .0—16. .769) 38. .631) .025 (1. . . . . . .2 (0. . . . 16. . . . . . . Maximum Gear Backlash Between Each Gear . . . . Rocker Arm Assembly Cap Screw and Nut Torque .. .09 (0. .Repair Specifications/Engine ENGINE: 3TN75 GROUP 10—Valve Train and Camshaft Item Standard mm (in. . . . . . . . . . 11. . ..D. .925—44. . . . . . . . . . . . . . . .. . . . . . . . . .. . Shaft Support I.6293) 16. . . . . . . . . Shaft Clearance . . . . . End Journals O.990—45.02 (0. Attaching Cap Screw Torque . .0025—0. . .472) .630—0. . . . . . .955 (0.35 (5. . 12. . . .20 (0. . ... Intermediate Journal O.6 (5.764) 38. . 15. . . .003) Length . . .043 (0. . .472—0.D. . . . .6286—0. .. .768—1. . . .765 (1. . . 26 N·m (226 lb-in. . .776) 45. .05—0. . . . .. . .) 115 N·m (85 lb-ft) . .769—1. . .771—1. .966—15. .950 (1.0078) 0.. .635—38. .054 90.975—11.0006—0. . .I. . . . . . .100 (0. . 26 N·m (226 lb-in. . . . . . 26 N·m (226 lb-in. .0078) GROUP 15—Cylinder Head.80 (1. . . . . . . . . .05 (0.40 (1. . . . .09 (0.) Valve Clearance .

. . . . 0. 83 N·m (61 lb-ft) . . . . . . . . .14 -19-28AUG87 CTM3 (03JAN90) 06-14 3TN/4TN Series Yanmar Engines 010897 PN=23 . . . . .I. 88 N·m (65 lb-ft) 5M4. . . . . . . . . . . . . . . Cylinder Head Cap Screw Torque In Sequence (Lubricated) . . . . Starter-to-Mounting Plate Cap Screw Torque .59 (0. . . . . . . . . . . . 1. . . . .006) .065—0. . .273—0. Valve Guide Height . . . .27 (0. . . . .) Wear Limit mm (in. . . . Exhaust . 25. . . . . . .0 (0. . . . . . . . . . . . . 6. . . . . . . .98 (0. 0. . . . . .00 (0. . . . . . . . . . . . Attaching Cap Screw Torque Flywheel Housing Mounting Plate or Housing Cap Screw Torque .078) . . . . . . . . . . . 0. . 1. . . .R. . . .089) .945—6. .008) Flatness . . . . . . . . . . . . . . .Repair Specifications/Engine ENGINE: 3TN75 Item Standard mm (in. . . . . .20 (0. . . . . (Knurl) . .15 (0. 49 N·m (36 lb-ft) . . . . . . . . .002) . . .2 (0.20 (0. . .05 (0. . 26 N·m (226 lb-in. . . . . . . .274) .36—1. . . . .87 90. . . .53 (0. . 0. . . . . . . . . . . . . .472) . . . .006—0. . . . .99) Valve Stem O. . . .15—0. Cylinder Head Flatness . Exhaust . . . . . . . . . . . . .008) . . . . . . 6. . 12. M8 . . . . . 2. . . . . . . . . . . . .008) . . . .D. .074) . . . . . . . . . . . . . . . . . 0. . . . . . . . .012—0.960 (0. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0. . . . . . . 0. . . 59 N·m (44 lb-ft) Flywheel Flatness . . . . . . . . . . . . .TM306. . . . . . . . . . . 88 N·m (65 lb-ft) . . . . . . . . .5 (1. . . . . . . . . .05 (0. . . . . . Valve Seat Angle Intake . 1.90 (0. . . . .) . . . . . . . . . .2 (0. . .002) . . . . . . . . . . .05 (0. . .) Wear Limit mm (in. . . . . . . . . .272) . . . . . . . Valve Guide-to-Valve Stem Clearance: (Replace) . . .63) Valve Spring Test Length . . . . . . . . . . . . . . .) . . . . . 0. . . . . 120˚ 90˚ Less than 0. . . . . . . . . . . . . M12 Nut . . . . . . .060) . . . . .054—0.66—1. . . .008) . . . . . . . Mill Cylinder Head No More Than . . . . GROUP 20—Flywheel Item Standard mm (in. 41. . . . . . . . . . . . . . . . . . . . . . . . . . 49 N·m (36 lb-ft) . . . . .30—0. . . . . . . . . . . . . . . . . . . . . . 69 N·m (51 lb-ft) Stub Shaft (If Equipped) Maximum T. . . . Flywheel Housing or Shield Cap Screw or Nut Torque M10 . .020) . . . . . . . . . . . . . . . . . . . . . . . . . . .) . . . . . . . . . . . . . . . . . .002) Attaching Cap Screw Torque . . . . . . . . . . . . . . . . . . . . 1.039) Valve Spring Free Length (Approx.) 06 14 Cylinder Head Intake and Exhaust Valve Recession . . . . Valve Seat Width Intake . . . . . .20 (0. . . .

018 (0—0. . . .008—0.004) 23. . .25 (0.0—43. . .038 (0. . .009) . . . . . . . . . . . . .33 (0. . . . . . . Main Bearing Journal O. . . . . . 42. . . . Bearing Clearance (Crankpin) . 74. .9070) 0.850—1.047 (0. . .. Bearing Clearance (Piston Pin) Maximum Twist .22) . . . . . .2—0. . . Maximum Piston Clearance Cylinder Out-of-Round . . . .059) 22. . . 22. . .03 (2. .0—47.. . . . . .047 (0. . 75. .. 39 N·m (29 lb-ft) 0. .0028) . . . .093 (0. .02 (0. .953—2. .0035) . .0037) .07 (1. . . . .4 (0. . ..0—23.09—0. .. .. . . .025—0. . . .50 (0.. . . . . . . .038—0. 0. . . Main Bearing I. . . .TM306.8485—1. . . . . . . . . . . . .070 (0. . .035—0.962 (1. . . . . .847) 47.0028—0. Pin Bore I. . . .D. 0.55 (0. . Main Bearing Cap Cap Screw Torque Main Bearing Clearance .909) 0. . . . . .0 (0.691—1.0019) . 0. . . .02 (0. . . . . . . . 0.6914) 43. . . 0.0007) .91 (1. . .943 (2. . . . .906) . . 0—0..0015—0. . .042 (1.030—0. . . . . . . .906) 0. . . . . . . . .0—75. .20 (2.006) . .004—0. . . . . . . 75.0158) . . . . 46.008) GROUP 30—Crankshaft and Main Bearings Item Standard mm (in.002) 74. . . .11 (0. . 0. . .693—1. . . . Piston Ring Groove Clearance Top Ring . . . . . . . .003) 42. . End-Cap Screw Torque . . . 0. 0. . Pin O.962 (1.696) 06 15 .9055—0. .D. . . . . . . . . . . . . . .11 (0. . . . . . . . 0.. . . . . . . .025—0. . 0. .952—42. .011) . . Bearing I. . .. .. .15 -19-28AUG87 CTM3 (03JAN90) 06-15 3TN/4TN Series Yanmar Engines 010897 PN=24 . . . . . . . . . . . . Pin Bore Clearance . . . . . .15 (0. 0.271 (0.8489) .9065—0. . Ring End Gap . . .16 (0. . . . . . . . . . . Pin Bushing I. . . .0012—0. . . . . .25 (0. . . .006) 0.045 (1. . . . . . .0043) 0. . .689) 43. . . Oil Ring . 0. .) 46.010) 0. . . . .852) . . . . . . .0015—0.695) . .060 (0. . . . . . .08 (0. . . . . ..22 (0.) Connecting Rod Side Clearance .913—74. . .008) 1. . . . .. . .D. . . . . . 78 N·m (57 lb-ft) . . . . . 0. . . . . .010) 0. .4 (0. . . .10 (0. . . . . . . . . Pin Bushing Clearance . . . .05 (0. (Crankpin) . . .) 9 N·m (78 lb-in. Oil Pan to Seal Case .. . . . ..961) . . 23. .0010—0. .) Wear Limit mm (in.0079—0. .991—23. . 47. . .D. .013) .0010—0. . . . . . . . . .D.905—0. . Piston O. .025—23. ..0014—0. . . .2—0. . . .. . . .10 (1. 26 N·m (226 lb-in. . . . . . . . . . . .009 (0. . . . . . . . . . Oil Seal Case Cap Screw Torque Seal Case to Block .854) 5M4. . .91 (1.038—0. . .952—46. . Cylinder Block Cylinder Bore I.0041) . . .. . . .9059) . .. .) Crankshaft End Play .D. . . . . . . . . .902) 23. .090 (0. .) Wear Limit mm (in. .0019) . 0. . .016) . . . . .0024) . .954) . .81 (2. . 23.945) . .951) . . . . . Journal O. . . .Repair Specifications/Engine ENGINE: 3TN75 GROUP 25—Connecting Rods and Pistons Item Standard mm (in. . . . .. .105 (0. . 0.D. . . . .D. . . . .90 (0. . . .D.. . . . . .949—2.070—0. . . .20 (0. . Second Ring . . . .

. .0075) (0.010) Oil Pressure Regulating Valve Valve Spring Free Length (Approx.950—45. .. . . . . . . .. .812) .. Outer Rotor-to-Pump Body Clearance .04—0. 25 N·m (18 lb-ft) .. . . .010) (0. . . . . .19 (0. . . .008) Gear Wear Specifications Gear Bushing Diameter .. .25 (0. . . ..0075) . . . . .11—0... . .. . . . .025—0... . . 46. . .0047) (0. 15.. . . ..20 0.. . 0.. . . . . . . ..) Wear Limit mm (in.04—0. . . . .) Wear Limit mm (in. .. 27..808) Shaft Oil Clearance .. 0. . . . . . .81) Valve Spring Test Length . . . . 26 N·m (226 lb-in. .6 lb) Force Oil Pressure Change Per 1 mm (0. ...) of Shim Thickness . .. . 26 N·m (226 lb-in. . ..12 0..11—0.. .25 0.. . 115 N·m (85 lb-ft) Timing Gear Backlash Fuel Injection Pump Idler . 46. . . 45.809—1. . . ... . .) 5M4... . . . . .0016—0. . . .) Crankshaft Pulley Cap Screw Torque .0075) . . .19 0. .. .0079) (0. .. . 0. . . ..0—46. . . .. 26 N·m (226 lb-in. .03 (1.. . 0. . .006) GROUP 40—Lubrication System Item Standard mm (in.. . . Oil Pump Attaching Cap Screw Torque . . .. .0043—0..0047) (0.008) (0.20 0. . . 26 N·m (226 lb-in. . .12 0.Repair Specifications/Engine ENGINE: 3TN75 GROUP 35—Gear Housing Item Standard mm (in. . . .. 0. . . . . . . .TM306.20 0. .008) (0.5 (1.) ..3 psi) Oil Pan Strainer Tube Attaching Cap Screw Torque .. . . . . . . . . . . . . .93 (1. . . .13 0. .15 (0. . .) Oil Pump Gear Backlash . ..20 (0. . . .. . . 0. .. .20 0. . . . Inner Rotor-to-Outer Rotor Clearance . . . 45.005) (0. . . . . . .19 (0.0043—0.. . . .. . .. ... . 46.0029) . . . .) 06 16 Gear Housing Cap Screw Torque .6 kPa (2.11—0. . . .04—0. .. . .. .0009—0. Timing Idler Idler Idler . .12 0. .0 (1. . . . . .975 (1. . . . . .039 in.075 (0.. . ..008) (0. .20 0. . .025 (1.. . .. . . .0043—0.0047) (0. . . . . . .16 -19-28AUG87 CTM3 (03JAN90) 06-16 3TN/4TN Series Yanmar Engines 010897 PN=25 . . ..812) Shaft Diameter . . .5 N (4. .. Camshaft . . Crankshaft . Oil Pump ..0016—0. . . .08) @ 20. .) Oil Pan-to-Gear Housing Cover Torque . ..0016—0. ..) Oil Pan-to-Block Cap Screw Torque ... . .. Rotor Recess . .810) .811—1. . . . . . . .008) (0. . .

008) Fuel Injection Nozzles Nozzle Opening Pressure . . . . . . . . . . . . . . . . .0016—0. . . . . . . . Plate Screws Torque . . . . . . . . . .2 (0. . .67 in. . . . . . 0. . 9 N·m (78 lb-in. . . . .04—0. . . . . . . . . . . . . . . . . . . . . . . . . . . 13 mm (0. . . 20 N·m (180 lb-in. . . . . . .TM306. . . . . . . 43 N·m (31 lb-ft) Nozzle-to-Cylinder Head Attaching Torque . . . . . . . . . . Camshaft. . . . . . . . . .0 mm (0.) . . . . 11 N·m (96 lb-in. . . . . .) in. . . . . . . . . 17 mm (0. . . . . . . . Pulley Cap Screws Torque . . . . . 19600 ± 480 kPa (2843 ± 70 psi) Minimum Leakage Time .) . . .0047) Gear Attaching Nut Torque .Repair Specifications/Engine ENGINE: 3TN75 GROUP 45—Cooling System Item Specification Thermostat Begin Opening Temperature . . . . . . . . .) 06 17 . . . . . . . . . . . . . . . . . . . . . . . 71˚C (160˚F) Fully Open Temperature . . . . . . . . . . . . .) at 107N (24 lb) Force applied midway between pulleys. . . . . . . . . . . . . . . 2. . . . . . . . . . . . . . . . . . . . . . . . .) . . . . . 15 N·m (130 lb-in. . . . . . . .12 (0. . . . . . . . . . . . . . . . . . . . . . . . 0. . . . . . . . . . .) Fuel Leak-Off Fitting-to-Nozzle Torque . .) Water Pump Bottom of Pulley Flange-to-Housing Distance . . . 45 N·m (39 lb-in. . . . .) Wear Limit mm (in. . . . .5 GROUP 50—Fuel Injection Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator Belt Deflection . . . . . . . . . Fuel Injection Pump Pump Mounting Hardware Torque . . . . 27 N·m (20 lb-ft) Gear Backlash . and Nozzles Item Standard mm (in. . . . . . . . . . . . . . . . . . . . 26 N·m (226 lb-in. . . . . . . Distance Top of Impeller is Below Housing . . . . . . . .17 -19-28AUG87 CTM3 (03JAN90) 06-17 3TN/4TN Series Yanmar Engines 010897 PN=26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 N·m (65 lb-ft) . . . . . . . . 5 Seconds @ 17640 kPa (2550 psi) Pressure Retaining Nut-to-Nozzle Body Torque . . . . . . . .08 in. . . . . 85˚C (184˚F) Housing Cover Cap Screw Torque . . . . . . .) GROUP 60—Starter See Starter Specifications in this Group GROUP 65—Alternator See Alternator Specifications in this Group 5M4. . . Attaching Cap Screws . . . . .) .

. . . .771—1. . . . . .990—45. .633) 0. . . . . . . . . . . . . . . . . . . . . . .D. . Gear Housing Cover Cap Screw Torque Crankshaft Pulley Cap Screw Torque .18 -19-28AUG87 CTM3 (03JAN90) 06-18 3TN/4TN Series Yanmar Engines 010897 PN=27 . . .Repair Specifications/Engine ENGINE: 3TN78 & 4TN78 GROUP 10—Valve Train and Camshaft Item Standard mm (in. . . . .2 (0. . . .950 (1. . . .050—0. . .631) . . .09 (0.774—5. . . . . .003) Length . . . .) 06 18 Valve Clearance .016—0.05—0. .. . ..016) .075 (0. . . . . . .628) 16. . . . . . . . . . . . . . . . . . . . .. . .768—1. . . . . . . . Shaft Support I. . . 146. 0. . . . . .0039) 26 N·m (226 lb-in. Lobe Height . .472) . . . . . . .635—38. . . . .. . . . .10 (1. . . .065—0. . . .. . . . . .0045) 0. . 11. . .D. . ..769) 38. . .008) 44. .470) Bore I. . . . . . . .773) . . .6293) 16. . . . .. . . . . . . .774) 45. . . . .984 (0. . .966—15. . .631) . . . . 26 N·m (226 lb-in. . . . . Bushing I. Idler Gear Shaft Cap Screw Torque .043 (0.D. . .10 (1.0003—0.526) 44. . . . .471—0. . . . . . . .13 (0.630—0. . . . .80 (1.115 (0. .) 115 N·m (85 lb-ft) . . . .005) Rocker Arm Assembly Cap Screw and Nut Torque . .0—12. . . ... . .315) Cam Follower O. . .521—1. . . . . .776) 0. . .) Manifold Exhaust Manifold Cap Screw Torque . . Intermediate Journal Clearance . . . .D. .0078) 0. . . . . . 26 N·m (226 lb-in. . . 0..) Rocker Arm Cover Nut Torque . . . . . . . . .) 5M4. . . . . . .. .) 26 N·m (226 lb-in. 44. . . . . . . . . Flywheel Journal Clearance . . . . . . .130 (0. . 0. .765 (1. . .77) Diameter . .2 (0. . .010—0.I. . . . .80 (1.770) 44. . . .02 (0.20 (0.0021) . 146. . . . . .0—16.910—44. . . .D.6286—0. . . 0. .025 (1. . . .) Intake Manifold Cap Screw Torque .0078) 0. . . . . . . . . 15. . . .975—11. . .. . . Maximum Gear Backlash between each gear . Valves. . . . . . 12.990 (0. . . . . . . . 0. . 15. . . . . .935 (1. . .. 8 (0. . . . . . . . .0—16. . . . .) Wear Limit mm (in. .955 (0.6 (5. .472—0. . .055 (1. . . . .. . . . . Intermediate Journal O. Intermediate and Flywheel End Bores I. . . .0025—0. . . . . . .) Wear Limit mm (in. . .0050) 0. . . . . . . .35 (5. .054 90. . .05 (0. . . . . . . .776) 45. . . . and Manifol ds Item Standard mm (in.801) .0006—0. . .630—0. .772—1. .) Push Rod Maximum T. . . .0078) ROUP 15—Cylinder Head. . . . . . . .512) 45. . . . . ..008) . . . 0. .0—45.002—0. . . . . . .D.09 (0. .R. 26 N·m (226 lb-in. .040—0. Attaching Cap Screw Torque .473) .. . . . 0. 0. . . . . .0016) Camshaft End Play . . .925—44. . . . .2 (0. . . . . . . . . . .633) 16. . . . .D. PTO Journal Clearance . . .. . .20 (0. .40 (0. Shaft Clearance ..018 (0. . . . . . .764) 44. .. Arm I. . . . . 16. . 11. .008) Rocker Arm Shaft O. . . . .2 (0.0015—0. . . . 18 N·m (160 lb-in. . . . . .764) 38.D. . . . . . . .93 (0. . . . .D. . . .65—147.474) Bore Clearance . End Journals O. ..0019—0. . . . .769—1. . .) 26 N·m (226 lb-in. . . . . .02 (0. . . . . 12.100 (0. . . . . . . .40 (1. .TM306. .

2. . . . .472) . . . . . . . . . . .36—1. . . 0. . . . . . . . . . . . . . 26 N·m (226 lb-in. . . . . . . . . . . . . . . . . . . . . (Knurl) . .2 (0. . . .I. .05 (0. . . . . . 1. M8 . .060) . . . . . .00 (0. . . . . . . . . . . . . . .) . . . . . . . . . . . . . . . . .15 (0. . Valve Seat Width Intake . . . . . . .273—0. . . . . . . . 6. . . . . . . . . . . . . . . 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120˚ 90˚ Less than 0. . . . . .272) . . . . . . .66—1.008) . . . . . . . . . . . . . . . . Exhaust . Starter-to-mounting Plate Cap Screw Torque . . . . . 1. .054—0. . . . .002) Attaching Cap Screw Torque . . . . . . . . . . Exhaust . . . . . . . .20 (0. . .945—6. . . . . . . . . . . . . . . . 0. . . Cylinder Head Cap Screw Torque In Sequence (Lubricated) . .20 (0.) Cylinder Head Intake and Exhaust Valve Recession . . . . . . . . . . . . . .19 -19-28AUG87 CTM3 (03JAN90) 06-19 3TN/4TN Series Yanmar Engines 010897 PN=28 . . . .2 (0. Valve Guide-to-Valve Stem Clearance: (Replace) . 6. . .074) . Attaching Cap Screw Torque Flywheel Housing Mounting Plate or Housing Cap Screw Torque . . . . . .274) . . . .30—0. . .TM306. . . . . . . . .05 (0. . . . . . . . . . 1. .05 (0. 0. .Repair Specifications/Engine ENGINE: 3TN78 & 4TN78 Item Standard mm (in. . . . . . . . . . . .99) @ 313 N (70 lb) Force Valve Stem O. Mill Cylinder Head No More Than . . . . . . .006) . . . 49 N·m (36 lb-ft) . . . .039) Valve Spring Free Length (Approx. 25. .002) . . . . .) Wear Limit mm (in. .D. . . . . . Flywheel Housing or Shield Cap Screw or Nut Torque M10 . . . .078) . .20 (0. . .5 (1. . . .90 (0. . 0. . 0. . . . . . . . . . Valve Seat Angle Intake . . . 0. . .008) . . . . . . . . GROUP 20—Flywheel Item Standard mm (in. . . . . . . . . . . . . . . . . Valve Guide Height . . . . . 88 N·m (65 lb-ft) 5M4. . . . . . .63) Valve Spring Test Length . . . .008) . . .0 (0. . .020) . . . . .012—0. . . . . 0. . . . . . . . . . . .R. Cylinder Head Flatness . . . . . . . . . . . . .008) Flatness . . . . . .) . . . . . . . . . . . .065—0. . . . . . .87 90. . . M12 Nut . . . . . 88 N·m (65 lb-ft) . . . . . . . . . . . . . . . . . .27 (0. . . . . . 83 N·m (61 lb-ft) . . 1.089) . . . . . . . . .15—0. . . . . . . . . . . . . . . 69 N·m (51 lb-ft) Stub Shaft (If Equipped) Maximum T. . . . . . . .) Wear Limit mm (in. . . . . . . . . . .006—0. .960 (0. . . . . 49 N·m (36 lb-ft) . . . . . . . . . . . . . . . . . . . . . . . 12. . . . . . . 59 N·m (44 lb-ft) Flywheel Flatness . . . . . .002) . . . . .98 (0. . . . . . . . .59 (0. . 41. . . . . . . . . . .) 06 19 . . . . . . . .53 (0. .

.696) . . . . .852) .. Main Bearing Journal O. 0. .691—1.11 (0. .) 9 N·m (78 lb-in.010) 0. . 0—0. . . . . . . . . . . . . . . 0. . .0041) .070 (0.0—78. . . . .6914) 43. . .0010—0.847) 47. .030—0.0019) . . 0. . . .0043) 0. (Crankpin) .. . .. . .2—0. . . . . 0. .962 (1. .0015—0. . Maximum Piston Clearance Cylinder Out-of-Round . . . . . . .025—23. . . . . . .TM306.9065—0. 42.02 (0. . . . . .925 (3. .004) 23. . Bearing I.079) . .047 (0. . . .695) .09—0. . 0. . . . . . . . .850—1.952—42. . . . . . . . 46. . .D. .010) 0. . Bearing Clearance (Crankpin) . .0015—0. . . .070—0. . . . .91 (1. .0010—0.059) 22. . . . . .. .D. . 0. . .. Second Ring .D. . .038 (0.038—0. . . . . . . . . . . . . . . . . . . . .909) 0. ... . . . .D.. . . . . . . . . .20 (0.22) . . 0.047 (0. . . . . . 39 N·m (29 lb-ft) 0. . .991—23.0158) . . .008—0.2—0.071—3.072) . 0. Pin Bore Clearance .0079—0. .906) 0.004—0. .02 (0. 22. .91 (1. . . .905—0. . . .03 (3. .0—23.. . .067—3. . .07 (1. . .902) 23. . . . . . . . . .025—0.962 (1. . . . . .045 (1. . . . . .9070) 0. . . . Pin Bore I. . . . . . . . . . . . . .009) . Oil Pan to Seal Case . .0—43. . . .. . Cylinder Block Cylinder Bore I. .D. . . . .25 (0. . . . Pin Bushing Clearance . . .008) 1. . . .. . Main Bearing Cap Cap Screw Torque Main Bearing Clearance . . . . .013) ..20 -19-28AUG87 CTM3 (03JAN90) 06-20 3TN/4TN Series Yanmar Engines 010897 PN=29 . . . . . . . .689) 43. . . . 23. . . . .33 (0.9055—0. . . . . . Ring End Gap . . . . 0. . . . . . . . . . . . 0.15 (0. Piston O. . . Pin O.10 (1. . .81 (3. . . . . .105 (0.0012—0. . .035—0. . . .. . Oil Ring . . . . . .) 46. . . . . . .002) 77. . . . . . .20 (3. . . . 78. . . .271 (0. .063) . .. .16 (0. . . 0. . .10 (0. .018 (0—0. . . .038—0. Oil Seal Case Cap Screw Torque Seal Case to Block . .9059) .. . 47. .25 (0.090 (0. .0028—0. .0007) . . . . . . . 23. . . Journal O. . . . . . .0024) .22 (0. 77. . . . . .093 (0. . . . . . . . . . .0037) . .693—1. . 26 N·m (226 lb-in. . 0. . . . .8489) . . 78.008) GROUP 30—Crankshaft and Main Bearings Item Standard mm (in. .0019) . . ..4 (0. . . . . . . .952—46. .906) .90 (0. .854) 5M4.) Wear Limit mm (in.0014—0. . . .006) 0. . .D. . Piston Ring Groove Clearance Top Ring .895—77.) 06 20 Connecting Rod Side Clearance . . . .. . .009 (0. . 78 N·m (57 lb-ft) . .8485—1. . . .006) .4 (0. . . . .060 (0. . .. . . . .0 (0. . .0028) . . .0035) . . . . . .003) 42. . . .068) . . . . . .D.D. .042 (1. . . . End-Cap Screw Torque . . . 0. . .Repair Specifications/Engine ENGINE: 3TN78 & 4TN78 GROUP 25—Connecting Rods and Pistons Item Standard mm (in.11 (0.D. . . . . .016) . . . . . .08 (0. . 0. . . . . . . .. . . . .05 (0.55 (0. . Main Bearing I. . . Pin Bushing I.50 (0.. . . . . .011) . 0. .. . . . . Bearing Clearance (Piston Pin) Maximum Twist .) Crankshaft End Play . . . . . . . .025—0.) Wear Limit mm (in. . . . . .0—47.

.0029) .25 (0. .81) 4TN78 . .11—0. . .20 0.12 0.0 (1. . . . . .025—0. . 46. . . . Camshaft . . .12 0. .. . . . . . . .0043—0. .20 0.008) Gear Wear Specifications Gear Bushing Diameter . .808) Shaft Oil Clearance . .. . . .19 0.. .) Oil Pan-to-Gear Housing Cover Torque . . . .91) Valve Spring Test Length 3TN78 . . . . . . . . ... . .TM306.0043—0.0047) (0. . . 45. . . .. .. . . 26 N·m (226 lb-in. .. . . . . .812) ... . .11—0. . .. . . .0016—0. . . .0016—0. . .. . . 48. Outer Rotor-to-Pump Body Clearance . .810) . .006) GROUP 40—Lubrication System Item Standard mm (in. . . . . ..12 0.025 (1. .. 24. . . 0. . ... . 45. .0016—0. . . .0009—0..) Crankshaft Pulley Cap Screw Torque . . . . Rotor Recess . .. . .. 0. .) 3TN78 . ... . 115 N·m (85 lb-ft) Timing Gear Backlash Fuel Injection Pump Idler . .. .005) (0. . . .0047) (0..1 lb) Force 4TN78 .. .. . . 26 N·m (226 lb-in. Inner Rotor-to-Outer Rotor Clearance .. . . . . . . . . . ..20 0. . . . .0075) . . .04—0.04—0.) Gear Housing Cap Screw Torque .20 0. .96) @ 27. . 26 N·m (226 lb-in.5 (1. . .21 -19-28AUG87 CTM3 (03JAN90) 06-21 3TN/4TN Series Yanmar Engines 010897 PN=30 .0047) (0. . . . . Oil Pump .11—0. 0.010) Oil Pressure Regulating Valve Valve Spring Free Length (Approx.075 (0. . . . .. . .0079) (0..0043—0. . . . . .15 (0. . ..Repair Specifications/Engine ENGINE: 3TN78 & 4TN78 GROUP 35—Gear Housing Item Standard mm (in. . 0. .13 0. . . . . .. . . .975 (1. . . . . . . .. .5 (0. . .) Wear Limit mm (in. 33 (1. 26 N·m (226 lb-in. . . . . .. . . ..008) (0. . .. .) Oil Pump Gear Backlash . .. ... . . . .. 25 N·m (18 lb-ft) . . . . . . .25 0. . . . .008) (0. . . 0. . ..19 (0.. . . . .. . . .008) (0.. . . . .2 N (6. . . . . . . ..950—45. . . . . . .811—1.. .. . . .. .. .. . . Oil Pump Attaching Cap Screw Torque . . . ..) 5M4. . . . 46. . ..008) (0. . . .. . . .809—1. . . . . . . . . .0—46. . .03 (1. .) Oil Pan-to-Block Cap Screw Torque . Crankshaft .. .20 0.. . . . . . . . . ... . . .. . . ... . . . . .. . . . . . .. 0.04—0.19 (0. Timing Idler Idler Idler 06 21 .0075) (0. . .. . 46. .0075) . . .20 (0. . .812) Shaft Diameter .93 (1. .010) (0. .) Wear Limit mm (in. . . . .. . .30) @ 80 N (18 lb) Force Oil Pan Strainer Tube Attaching Cap Screw Torque .

. . . . . . . Alternator Belt Deflection .. . . . . . . . . . . . . . . . . . . . . . 43 N·m (31 lb-ft) Nozzle-to-Cylinder Head Attaching Torque . GROUP 50—Fuel Injection Pump. . . . . . . . . . . . . . . . . .Repair Specifications/Engine ENGINE: 3TN78 & 4TN78 GROUP 45—Cooling System Item Specification 06 22 Thermostat Begin Opening Temperature . . . . . . . . . .. . Camshaft. . . 13 mm (0. . . . . . . . . . . . . . . . . . . . . . . . 19600 ± 480 kPa (2843 ± 70 psi) Minimum Leakage Time . .. .TM306. . . . . . . . . 85˚C (184˚F) 26 N·m (226 lb-in. . . . .. . . . . . . . . . . . .. . .2 (0. . . . . . . .. . . . . ... . . . . . . . . .008) Fuel Injection Nozzles Nozzle Opening Pressure . . . . . . . . . .. . . . .. . . . Housing Plate Cap Screw Torque . . . . .) 26 N·m (226 lb-in. . . . . .. .12 (0. . . . . . . . . . . . .) GROUP 60—Starter See Starter Specifications in this Group GROUP 65—Alternator See Alternator Specifications in this Group 5M4. . . .) 26 N·m (226 lb-in. .) Fuel Leak-Off Fitting-to-Nozzle Torque . . . . . . . . . . . . .. . . . . 15 N·m (130 lb-in. . . 27 N·m (20 lb-ft) Gear Backlash . .0047) Gear Attaching Nut Torque . . . .5 . . . . . . Housing Attaching Cap Screw Torque Housing Cover Cap Screw Torque . . . . .) Fuel Injection Pump Pump Mounting Hardware Torque . .) at 107N (24 lb) Force applied midway between pulleys. . ... . . 5 Seconds @ 17640 kPa (2550 psi) Pressure Retaining Nut-to-Nozzle Body Torque . .. . . .. . . . . . . 11 N·m (96 lb-in. . . . . . . . . . . . . . . . . . . 71˚C (160˚F) . 0. . . . . . . . . . Water Pump Plate Screws Torque . . . . . . . . . .. . 0. . .04—0. . . . . . . . . . .) . . . . . . . . . 59 N·m (43 lb-ft) . . . . . . .. 11 N·m (96 lb-in.0016—0. .22 -19-28AUG87 CTM3 (03JAN90) 06-22 3TN/4TN Series Yanmar Engines 010897 PN=31 . . . . . . 4. . . . ..) . . . . . . . . . . . . . . .) Wear Limit mm (in. . . . . . . . Fully Open Temperature . . . . . and Nozzles Item Standard mm (in. .. . . . . 11 N·m (96 lb-in. . . . . . . . . . . . .) in. . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . Pulley Cap Screws Torque Attaching Cap Screws . . . . .. .5 N·m (39 lb-in. . .) .

771—1. .D. . Bushing I.. . . . . PTO Journal Clearance . . . .05—0.10 (1. . .40 (0. Flywheel Journal Clearance . . . . .2 (0.80 (1. Gear Housing Cover Cap Screw Torque Crankshaft Pulley Cap Screw Torque . End Journals O. . .037) . .054 90.. 0.75 (7. . . . .772—1.0025—0. . . . .. . . .631) . . . . . . .065—0.) Valve Clearance . . . . . . .635—38. . . .10 (1. . . . . . . . .20 (0. . . . . . .008) Rocker Arm Shaft O. ..) Manifold Exhaust Manifold Cap Screw Torque .0021) . ..935 (1. 11. . . . . . . . . Attaching Cap Screw Torque . . . . .633) 16. Shaft Support I. . . 26 N·m (226 lb-in. . .100 (0. . . . .) 5M4. . . 12. and Manifolds Item Standard mm (in. .25—178.. . . .80 (1. . . . Arm I. . . . . . .628) 16. . .) 26 N·m (226 lb-in. . . .472) . . . .005) . . . .008) 44. .471—0. .D. . . . . .6293) 16.20 (0. . .0019—0.) Rocker Arm Cover Nut Torque . . . 16. . . . . 0.. . . . . Bore I. .. . 8 (0. . . . . . . . .D. . .93 (0. . .D. . . . . . .0045) 0. . .) Wear Limit mm (in. . . .055 (1. . . . . . . . ... . . . . .765 (1.776) 0. . . . . .. Rocker Arm Assembly Cap Screw and Nut Torque . . . . .40 (1. .315) .018 (0. . . .0078) 0. .. . . . . . . . . .008) . . .0006—0. . . . . . . . . . 178. . Idler Gear Shaft Cap Screw Torque . . . . . . . .910—44.770) 44. Length .. . . . .TM306. . . . . . .512) 45. .526) 44.0—12.) Push Rod Maximum T.. . Bore Clearance . 15. Intermediate Journal Clearance .130 (0. Diameter . . Cam Follower O. . . . . . . . . .003) . . . Intermediate Journal O. . . . . . .474) . ..) 26 N·m (226 lb-in. .521—1.. . . .D. . . . .018—7. . . . ..975—11. . . . . . . . . . 26 N·m (226 lb-in. . .776) 45. . .2 (0. . . .. 26 N·m (226 lb-in.075 (0. . . .769) 38. . . .473) . .02 (0.2 (7. . .984 (0. .D... . . .773) .) Intake Manifold Cap Screw Torque .990 (0. . . . . .. . . 0.955 (0.. ..13 (0. Intermediate and Flywheel End Bores I.D.769—1.. 18 N·m (160 lb-in. .016—0.633) 0.630—0. . .2 (0. .0—45. . . . . .D. . . . . .470) . . . . . 11. .768—1. . . . . .0016) Camshaft End Play . 0. . 44. .0039) 26 N·m (226 lb-in. . .0078) 0.774) 45. .. .0—16.. .0078) GROUP 15—Cylinder Head. . . . . . .050—0. .I.. . 0. . Shaft Clearance . . .. . . . . . .09 (0.990—45. . . .6286—0. 0.925—44. . . . .) 115 N·m (85 lb-ft) .630—0. 0..016) . . .025 (1.09 (0. .R. . 0. . . . . .0050) 0.631) . . . 178. .. . . . . . .. 15. . . Lobe Height . . . .) Wear Limit mm (in.02 (0. Valves. . . . . . . .0003—0. . . .2 (0. . . . . . . .. ..115 (0.02) . . . . Maximum Gear Backlash between each gear .23 -19-28AUG87 CTM3 (03JAN90) 06-23 3TN/4TN Series Yanmar Engines 010897 PN=32 .002—0. . . . . . .040—0. 06 23 . . . .010—0. . . . . . . . . . .472—0. . . . . . . 12. . . . . ..D.966—15. . . . . . . .. .Repair Specifications/Engine ENGINE: 3TN82 & 4TN82 GROUP 10—Valve Train and Camshaft Item Standard mm (in. . .764) 38.0015—0. . . . .043 (0.764) 44. . . .950 (1. . . . . . . . . . . . . . .05 (0.0—16. . .

D. . . . . . . . . . . . . . . .05 (0. .311) . (Knurl) . . . . . . . . 1. .74 (0. . . . Valve Guide Height . 1.15 (0. . . . . . . . . . . . . . . . . . Starter-to-Mounting Plate Cap Screw Torque . . . . . .314) . . . . . . .0 (0. . . . Valve Guide I. . . 1. .002) Attaching Cap Screw Torque . . . .012—0. . . . . . . . . . . . . . . . . . .24 (0. . . . .057) . . .20 (0. . . . . . . . . . . . . . . . . . . . . . . . . .591) Cylinder Head Cap Screw Torque In Sequence (Lubricated) . .I. . . . . . . . . . . . . .006) 0.049) . . . . . . . . . . .008) Wear Limit mm (in. . . . . . . .) . . . . . . . . . .3160) Valve Guide-to-Valve Stem Clearance: (Replace) . . .95) @ 319 N (72 lb) Force Valve Stem O.008) . . 0. . . . . . . . . . . . .020) . . . . Flywheel Housing or Shield Cap Screw or Nut Torque M10 . . .45 (0. . . . . . .042—0. . . 1. . .20 (0. . . . . . . . . . .24 -19-28AUG87 CTM3 (03JAN90) 06-24 3TN/4TN Series Yanmar Engines 010897 PN=33 . 49 N·m (36 lb-ft) . . . . . . . . . . . . . . . . . .) Cylinder Head (Continued) 06 24 Cylinder Head Intake and Exhaust Valve Recession . . . Valve Seat Width Intake .002) . . .049—0. . . . .Repair Specifications/Engine ENGINE: 3TN82 & 4TN82 Item Standard mm (in. . . . . . . . . . . .94 (0. Valve Spring Free Length (Approx. . . . . . . . . . . . . . . Less than 0. . . . . . . . . . .24—1. . . . .039) . . .15—0.069) .5 (1. . . . . . . 24. . .0 (0. . . . . . . . . 0. . . . 59 N·m (44 lb-ft) Flywheel Flatness . . . . . . . . . . . . . . . Exhaust . . 8. . . . . . . . . . . . . . .010—8. . Mill Cylinder Head No More Than . . . . . . 0. . .) Stub Shaft (If Equipped) Maximum T. . . . . 88 N·m (65 lb-ft) 5M4. .) Wear Limit mm (in. . . . . .20 (0. . . . Attaching Cap Screw Torque Flywheel Housing Mounting Plate or Housing Cap Screw Torque . . . . . . . . . . . . .) . . . . . 0. . . . .30—0. . . 7. . . . . . . . . . . M8 . . . . . 88 N·m (65 lb-ft) . .50 (0. . .076) . . . . . . . . . . 26 N·m (226 lb-in. . 40 (1. . . . . . 1. . . . 83 N·m (61 lb-ft) . .975 (0. . . . . . . . . . . .319) . . . . . . . . . . . . . . . 49 N·m (36 lb-ft) . . . . . . . . .90 (0. . . . .3154—0. . . 78 N·m (58 lb-ft) GROUP 20—Flywheel Item Standard mm (in. . . . .006—0. . . . . . 8.008) Flatness . . . . . . . . . . . . . . . Cylinder Head Flatness . . . .05 (0. 120˚ 90˚ 0. . . . . . . . . . . . . . . . . . M12 Nut . . . . .R. . . . . . . . .00 (0. . 39. . . . . . . . . Valve Spring Test Length . . . 0. . . . . .313—0. 15. . . . . . . .030 (0. . . .05 (0. . . . . .575) . . . .TM306. . . .07—1. . . . Exhaust . . . . . . . . . . . . . . . . . .D. .008) . . . .002) . . . . . . . . . . . . . . . . .55) . . . .960—7. 7.10 (0. . . . Valve Seat Angle Intake .20 (0. . .) . 0. . . . . . .

0. . .0236l1. .014) . . . . . . . 0. . . . . . . . .0010—0. . . . . . . . 0—0.15 (0. . . . .969—1. . . . . . . . . Main Bearing Cap Screw Torque . . . .028) 0. .0—48.898—81.090—0. . .) Crankshaft End Play . .) Connecting Rod Side Clearance . Pin Bore Clearance . . . .016) .90 (1. . . . . . . . . .D.228—3. . .0—82. .. 0. . . 0. . .011) .025—26. .9666—1.. .D.) 9 N·m (78 lb-in. . . . .0010—0.10 (0. . . . . . . . . . Ring End Gap (1st Ring) .962 (1.891) . . . . . . . .D. .55 (0. . . . . . . . .972) 5M4. . .004—0. . . .042 (1. . . . . .025—0. . 0. . . .024) .965) 50. .10 (1. . . . . . . . 0. .0246—1. Cylinder Block Cylinder Bore I.. . . . .0037) .230) .40 (0. .008) 1.91 (1. . ..D. . . . . .) Wear Limit mm (in. Piston O. . . Bearing Clearance (Piston Pin) Maximum Twist . . . 49. 47.0031) . . . .0020) . . . .0079—0. . . 0... . .008—0.0035) . . Maximum Piston Clearance .893) 06 25 Piston Ring Groove Clearance Top Ring . .08 (0.059) 1.952—47. . .25 -19-28AUG87 CTM3 (03JAN90) 06-25 3TN/4TN Series Yanmar Engines 010897 PN=34 . Second Ring . .002) 81. . . . . .006) 0. . . . . . . . 82. . . . .080 (0.. .928 (3. . . .003) 47. . . .038—0. . . .02 (1. . . . . . Oil Ring . . . .4 (0. . . . . . . . .051 (0.008) GROUP 30—Crankshaft and Main Bearings Item Standard mm (in. . .0041) . .8879—1.093 (0..11 (0. . . . . Pin Bushing I.962 (1.010—0. . . . .014) . .2—0. . . . . End-Cap Screw Torque . . 26. 0. . . . . .024) 0. 0. . . . . .0010—0. . Main Bearing Clearance . . .D.D. . . . .038—0. .07 (1. .D. . . .. 98 N·m (72 lb-ft) . . .004) 26. . . . . . .0024) . .090 (0. .075—0.05 (0. Journal O. . . . . . 25. .8883) 48.0028—0.9670) .105 (0. . . . . .236) . 81. .20 (3.987—26. Pin Bore I. .0240) . .271 (0. . . . . . . .0—50. 50. .16 (0. .0015—0.25 (0. . . . . . . .90 (1. . . 0. 0. . . . . . . Main Bearing Journal O. .0018—0. .022 (0—0. . .. . . .. . . . . 47 N·m (35 lb-ft) 0. .D. . . . Pin Bushing Clearance . .009 (1.25 (0. ... . . . . . . . . . . . . . .TM306. .023—1.013) . . . . . . . . . .50 (0.D.045 (1. . Bearing I. . . .0251) 0.220) .226) .025—0. .11 (0. . 26. . Oil Pan to Seal Case .. .02 (0. . . . . . . .038 (1. . (Crankpin) . . .. . . . . 26 N·m (226 lb-in. . .025—0. ..970) . Main Bearing I. . . . . . . . . .03 (3. .. .) Wear Limit mm (in. . . .0158) .886) 48. . . . . . 0. . . . . . .0—26.) 49. Bearing Clearance (Crankpin) . . 0. . . .020) 26. .0009) . .35 (0. . . .20—0. . .060 (0.80 (3. .. 82.. .952—49. . . . 0. . . . . . . Oil Seal Case Cap Screw Torque Seal Case to Block . . . . . . . . . . .010) 0. . Cylinder Out-of-Round .022) . .. . .224—3.0 (1. . . . . . .. . . .0019) . . . .888—1. . . . . .0015—0.0043) 0. . . . . 0.33 (0. .25—0. . .006) .50 (0. .20 (0. . . . . . . .35 (0. Ring End Gap (2nd and Oil Rings) Pin O. . . ..010) 0. .047 (0.Repair Specifications/Engine ENGINE: 3TN82 & 4TN82 GROUP 25—Connecting Rods and Pistons Item Standard mm (in. . . . . . . . . . . . .059) 25. . . .045—0. . . . . . 0.

0047) .) 5M4. . .. . .809—1. . .. . Camshaft .20 0. .1 lb) Force . . . .008) Gear Wear Specifications Gear Bushing Diameter .025 (1. . .. . . .13 0. .. . .. . . 26 N·m (226 lb-in.25 0. . .20 0. . . .. .. .5 (1. .. .0016—0. . . . . . . . .0047) (0. . 0. . Rotor Recess . .008) (0. . ..810) . 46... . 0.Repair Specifications/Engine ENGINE: 3TN82 & 4TN82 GROUP 35—Gear Housing Item Standard mm (in. . .26 -19-28AUG87 CTM3 (03JAN90) 06-26 3TN/4TN Series Yanmar Engines 010897 PN=35 . . . . . . . . . . .008) (0. . .. . .0016—0.. . . . . . .. 0. . 45. .. . .20 0.. . . .0047) .. . .04—0. . . . . .0 (1. . Valve Spring Test Length 3TN82-RJB (only) .. .. Inner Rotor-to-Outer Rotor Clearance . . Oil Pump Attaching Cap Screw Torque Oil Pressure Regulating Valve Valve Spring Free Length (Approx.6 lb) Force .006) .. . . . . 15. . ..TM306. . . .. . .) Crankshaft Pulley Cap Screw Torque .0016—0. . . .811—1.. . . .. . . . . . . 26 N·m (226 lb-in. . . . . . .. . ..) Wear Limit mm (in. .950—45. . . . . . . . . .04 (0. . . .. . .0016—0. . . .03 (1. .15 (0. . . ... . .) 3TN82-RJB (only) . . . 3TN82/4TN82 .6 kPa (2. . .2 N (6. 26 N·m (226 lb-in. .04—0.04—0.. . . . . . . .08) @ 20. .04—0. . .. . . .975 (1. . Oil Pressure Change Per 1 mm (0. . .. . . . . . . . ..0016—0.. .) of Shim Thickness . . ..12 (0. .008) (0.20 0.04—0.008) (0. .008) (0. .12 (0. . . . . . . .12 0. .) Oil Pump Gear Backlash .0 (1.15 (0.. . . .075 (0. . .0—46. . . 0. .93 (1. . 27. . . .025—0.) 06 26 Gear Housing Cap Screw Torque . 3TN82/4TN82 .. . . .20 (0. . . . . .5 (0.. .. . . 115 N·m (85 lb-ft) Timing Gear Backlash Fuel Injection Pump Idler . 0. . .0047) (0. . Timing Idler Idler Idler .. . . 46.005) (0. .12 0.. .. .96) @ 27. . . ..20 0. .5 N (4. . . .812) Shaft Diameter . . . .0047) (0.81) . . . ..808) Shaft Oil Clearance . . .. .812) . . .. . .) Oil Pan-to-Gear Housing Cover Torque . . . . . 26 N·m (226 lb-in. 25 N·m (18 lb-ft) .. .3 psi) Oil Pan Strainer Tube Attaching Cap Screw Torque . . . . .0047) (0. . . . .) Wear Limit mm (in. Outer Rotor-to-Pump Body Clearance . . . . 46. 46. . .. Crankshaft . .0029) . . . . 24.12 0. . .. .006) GROUP 40—Lubrication System Item Standard mm (in. . .0016—0.. .. .81) .010) (0. Oil Pump . . .. 45. 0.039 in.) Oil Pan-to-Block Cap Screw Torque . . . . .. . .12 0. . . .. . . . . . .0009—0. . .

. . .2 (0. . . . . . . . . . . . . . . . .0047) Gear Attaching Nut Torque . . . . . . .. . .. . . . . . . . . . . . . . . .. . . . . . . .. . . . Pulley Cap Screws Torque Attaching Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . ..04—0. . . GROUP 50—Fuel Injection Pump.. . . . . .. . . . . . . . . . . . . . . . . . . ... . . 5 Seconds @ 17640 kPa (2550 psi) Pressure Retaining Nut-to-Nozzle Body Torque . . . . . .. . . . . . . . . . . .. . . 85˚C (184˚F) 26 N·m (226 lb-in. . . . . . . . . .Repair Specifications/Engine ENGINE: 3TN82 & 4TN82 GROUP 45—Cooling System Item Specification Thermostat Begin Opening Temperature . . . ..) Wear Limit mm (in. . . .) at 107 N (24 lb) Force applied midway between pulleys. . . 71˚C (160˚F) . . . . . .0016—0. . . ..5 N·m (39 lb-in.) . . .. . . . .) . . . 0. . . . . .) 20 N·m (180 lb-in..27 -19-28AUG87 CTM3 (03JAN90) 06-27 3TN/4TN Series Yanmar Engines 010897 PN=36 . . ..12 (0. . .) . . Housing Plate Cap Screw Torque . .. . . . . . ... . . . . . 0. .. . . . .. . . . .. .. . . .. . . .. . . . . .) 06 27 . 4. .. . . . . . . . . . . . . . . . . . . . . . . . . . . Fully Open Temperature . ..5 in. . . . . . . . 11 N·m (96 lb-in. . . . .008) Fuel Injection Nozzles Nozzle Opening Pressure . . . . . 13 mm (0. . . . . . . . . .) Fuel Leak-Off Fitting-to-Nozzle Torque . . . . . . . . . . . 11 N·m (96 lb-in. . . . . . 15 N·m (130 lb-in. . .) GROUP 55—Fuel Control and Governor Linkage GROUP 60—Starter See Starter Specifications in this Group GROUP 65—Alternator See Alternator Specifications in this Group 5M4. . Alternator Belt Deflection . . . .. . .. . . 11 N·m (96 lb-in. . Housing Attaching Cap Screw Torque Housing Cover Cap Screw Torque .) 26 N·m (226 lb-in. . . . . 43 N·m (31 lb-ft) Nozzle-to-Cylinder Head Attaching Torque . Camshaft. . . . . .. . . . . . . . . 59 N·m (43 lb-ft) .. .. . . . . . . . . . . . .. . . . . . . . . . . . . . 19600 ± 480 kPa (2843 ± 70 psi) Minimum Leakage Time . Water Pump Plate Screws Torque . 27 N·m (20 lb-ft) Maximum Gear Backlash . . . . . . . . . . . . . . . . . . . . . . .TM306. . . . . and Nozzles Item Standard mm (in. . . . . . . . . . . . . . .. . . ..) Fuel Injection Pump Pump Mounting Hardware Torque . . . . . . . .. . . . .

. 26 N·m (226 lb-in.. 11. . . . . . . . . . . . . .990 (0. . .Repair Specifications/Engine ENGINE: 3TN84 & 4TN84 GROUP 10—Valve Train and Camshaft Item Standard mm (in. . Shaft Clearance . . . . . . .. . .. .) 26 N·m (226 lb-in.769—1. . . . Diameter .008) 44. . 0. . . . . . . .10 (1. . . . .765 (1.D. . .) Wear Limit mm (in.016—0. .472—0. .. . .025 (1.D. . .93 (0. . 12. . . . . . .80 (1. .115 (0. . . . . . . . . . . .75 (7. . Shaft Support I. . . .. . . . .984 (0. . . . .776) 0. 8 (0. . . .631) .TM306. . . .. . .950 (1.. . ..10 (1. . . . . . . .. Bore Clearance .0078) GROUP 15—Cylinder Head. . Cam Follower O.05 (0.) 06 28 Valve Clearance . . . . . . . . . .054 90..0—45.018 (0. .2 (0. . .. . . .975—11. 18 N·m (160 lb-in. . 178. .075 (0. . Length .628) 16. .. . . . . .20 (0. 26 N·m (226 lb-in. .764) 38. 0.774) 45. . . . . .770) 44. . .0025—0. . .769) 38.. . . . . .2 (0.) 5M4. .055 (1. . . ..315) . . . Intermediate Journal O. . . . .037) . . . 26 N·m (226 lb-in. .) Push Rod Maximum T.008) Rocker Arm Shaft O.0021) . . .005) Rocker Arm Assembly Cap Screw and Nut Torque . . . . . . 0.D. . .. .. . . . . .100 (0. . . .910—44. . . . . . .09 (0.0015—0. . .633) 0. . .2 (0. .28 -19-28AUG87 CTM3 (03JAN90) 06-28 3TN/4TN Series Yanmar Engines 010897 PN=37 .. . . . . . Flywheel Journal Clearance . 15.) Wear Limit mm (in. 16. . . . . . 178. .633) 16. .773) . . . . PTO Journal Clearance . . Idler Gear Shaft Cap Screw Torque . . . .474) . . 0. . . . . . . 11. . . .13 (0. . ..0—16.R.050—0. . . . . . ..512) 45.010—0.018—7. . . . .925—44.003) . . .002—0. . . . . .6293) 16.0045) 0. . . . . . . . . Lobe Height . . . . 44. Attaching Cap Screw Torque . . Bore I. . . .. . . . . . .D. . . .043 (0. . . . . . . . . . Maximum Gear Backlash between each gear .) Rocker Arm Cover Nut Torque .521—1.D. . . . . . . . . .472) . .0039) 26 N·m (226 lb-in. . Bushing I. . .2 (0. 0.25—178. . . Intermediate and Flywheel End Bores I.6286—0. .D.) 115 N·m (85 lb-ft) . . . . . . . . .D. . and Manifolds Item Standard mm (in. ..) Manifold Exhaust Manifold Cap Screw Torque . . . . Arm I. .631) . . . . . . . . . . Intermediate Journal Clearance . . . .0016) Camshaft End Play . . . . . . .05—0. . . .. .) Intake Manifold Cap Screw Torque .0019—0. 15. . .771—1.016) . . .. .20 (0. . . . . . .D. . . . . . .02 (0. .526) 44. 12. . .. . . . . . . . . . .630—0.008) . ..473) . . . . . . .02) . . .040—0..768—1. . . . . . . . . . . . .772—1.. Valves. Gear Housing Cover Cap Screw Torque Crankshaft Pulley Cap Screw Torque . . . .935 (1.470) . .. . . 0. .. .630—0.776) 45. . . . . . .) 26 N·m (226 lb-in. . .0006—0.I. . . ..0—12. . . End Journals O. . . . . . . .. . .0078) 0.02 (0. . . . .40 (0. . . . . . . . . .990—45..0003—0. .130 (0.635—38. .D. . . .0050) 0. .065—0. . . .0—16.764) 44. . . .955 (0. . . . .40 (1. . .. 0. . .2 (7. . . . . . . 0. . . .80 (1.0078) 0. . . . .471—0. . .966—15. . . . ... . . . .09 (0.

1. .) Wear Limit mm (in. . . . . . .. . . . 49 N·m (36 lb-ft) . Valve Spring Free Length (Approx. . . .) Cylinder Head (Continued) Cylinder Head Intake and Exhaust Valve Recession . . . . . . . . . . . . . . . . . . . . . . . . . . .. .002) Attaching Cap Screw Torque . 120˚ 90˚ 0. . Cylinder Head Cap Screw Torque In Sequence (Lubricated) . . .. . . . Valve Seat Width Intake . . . . . . . . . Starter-to-Mounting Plate Cap Screw Torque . . . . . . . . .0 mm (0.. . . . . . .. . . . . .591) . . .) 7. .Repair Specifications/Engine ENGINE: 3TN84 & 4TN84 Item Standard mm (in. (Knurl) . . . . .. . . .5 mm (1. . . .049—0. . .. . Valve Seat Angle Intake . . 7. . .008) . .. . . . .. . . . .TM306. . 59 N·m (44 lb-ft) Flywheel Flatness . . . . . . .. .. .002) . . . 78 N·m (58 lb-ft) Stub Shaft (If Equipped) Maximum T. .975 (0. .. .. . .030 (0. .10 (0. . . . . . . . . . . . . . . . .. . . . .05 (0. . 83 N·m (61 lb-ft) . Flywheel Housing or Shield Cap Screw or Nut Torque M10 . .. .20 (0. . .008) . . . . . . . . 8.006—0. . . .313—0. . . . . . . . . 15. . . . . . .) 24.. ..15—0.) Wear Limit mm (in. . . . Valve Guide Height .) 41. . .. .07—1.. . .. 1. . .006) 0. .. . .960—7. . . . . . . . . . . . . . . .. .50 mm (0. . . Valve Guide I. . . . .319) 06 29 . . . .042—0. . . . .24 (0. . . . .90 (0.. . . . . . . .. . . . . . . . .. .95 in. . . . . . . . . . . . .) . .008) Flatness . . . . . .. . . . . . . .. . . . . .29 -19-28AUG87 CTM3 (03JAN90) 06-29 3TN/4TN Series Yanmar Engines 010897 PN=38 . M8 . .20 (0. Exhaust . . . . . . . . . . 26 N·m (226 lb-in. . . 88 N·m (65 lb-ft) 5M4. ... . . . M12 Nut . .. .05 (0.. .30—0. .) . . . . . . . . . . 0. .. .. . . . .35 (0. . . . . . . . . . . . . 88 N·m (65 lb-ft) . GROUP 20—Flywheel Item Standard mm (in. . . . . 1. . . . . . . . . . ..012—0. .069) . .63 in. . . . . .05 (0. . . . Valve Guide-to-Valve Stem Clearance: (Replace) . . . .3154—0.008) . 0. . . . . . . . . . . . . . . .049) .20 (0. ... . . . . . .94 (0. . Exhaust . . . .. .. . . . . 49 N·m (36 lb-ft) . . . . . . . .. . . . .. . . . . . . .3160) . . .. . . . . . . . . . . . .20 (0. . . . . .020 in. . . Attaching Cap Screw Torque Flywheel Housing Mounting Plate or Housing Cap Screw Torque . . . .D. . . . . . .076) .I.15 (0. .. . . 1. . . . . Valve Stem O.. . . .002) . 0. .. .. . .. . . . .. .D. .010—8. . . . . . 0. . Valve Spring Test Length .. . . . . . .74 (0. .. . ... .053) . 0. . . . ..314) . . . . . . . . .) . . . . .00 (0. . . . Less than 0. . . . . Cylinder Head Flatness . . . . . . . . . . .R. . . . .24—1. . Mill Cylinder Head No More Than . 0. . .. .311) 8. . . . .. . .

0009) . . . . . . Cylinder Out-of-Round . . . 0. . . . . .0015—0.307—3. .. . . .970) . .D.) 49. .2—0.. .0—84. .45 (0. 50. ..0020) .15 (0. . 26 N·m (226 lb-in. . .025—0. . . .D. . . .038—0. . . . .0079—0. . .965) 50. . . . . .) 06 30 Connecting Rod Side Clearance . . . . . . .886) 48. 84.5 (0. .11 (0. 84. .0028—0. 0.50 (0. . . . . . . . .888—1. . . 0.010) 0. . . 0. .022 (0—0. . . .0 (1. . . . . . .. .038—0. . . . . . . . . Main Bearing Journal O. . 0. .898—83.D. .304) . . . . . .40 (0.. Journal O. . .33 (0. .20 (0. . . . . . . . . ..025—0. .0010—0.952—49. 98 N·m (72 lb-ft) .962 (1.080 (0. .0—50. . .0—48. . .011) . . Second Ring . Oil Ring .0041) . .952—47. . . . . 25. . . .20—0. . . . . . . . .972) 5M4. .0236l1. . 0. Main Bearing I.) 9 N·m (78 lb-in. . . . .. . .. . . . Pin Bore Clearance . 0.. . . .051 (0. . . . . . . . . . . . . . .045 (1. . . 0—0. .0246—1. . . . . . . . .090 (0. . . . . . . . .. .0—26. . .016) .308) . End-Cap Screw Torque . . . . . . .023—1. ..009 (1.9670) . . . . .9666—1. 49. . . . . .105 (0.014) . ..10 (0. . . . Bearing Clearance (Crankpin) . . . . . . . .90 (1. .. . . .11 (0. Pin O.4 (0. . . . . .987—26. .35 (0. Pin Bore I.042 (1.299) . .060 (0. . .20 (3. . 83. . Pin Bushing I. . . . . . .271 (0. . . .D. . .893) Piston Ring Groove Clearance Top Ring . . . .075—0.10 (1. . 0. . . .) Crankshaft End Play . . . . . . . . . . . . Pin Bushing Clearance . . . Oil Pan to Seal Case . . .315) . Cylinder Block Cylinder Bore I. .008—0. . . . . . . . . .018) . . . . . . ..30 -19-28AUG87 CTM3 (03JAN90) 06-30 3TN/4TN Series Yanmar Engines 010897 PN=39 . . Main Bearing Cap Screw Torque .047 (0.303—3.. . . .. .003) 47. 0. . . . . .004—0.010) 0.0037) . . .0043) 0.90 (1. . .006) . . . . . . . 0. 47 N·m (35 lb-ft) 0. (Crankpin) .0015—0.0031) . . . . .0240) . . .025—0. . .028) 0. . Piston O. . . . . . .0024) . . . . . .010—0. . . . Maximum Piston Clearance . . 0. Bearing Clearance (Piston Pin) Maximum Twist . .16 (0.059) 1. .024) ..25—0. . . .962 (1. . .022) . . .0158) . . . . . . . . . . . .) Wear Limit mm (in. .91 (1.8879—1.02 (0.0035) . . .020) 26. . Main Bearing Clearance . . . .0251) 0. . . .25 (0. . . . . .80 (3. . . . . . . Oil Seal Case Cap Screw Torque Seal Case to Block .05 (0.25 (0. .8883) 48. . . . . . .045—0. . .) Wear Limit mm (in.025—26.0010—0. . . . . . . . .08 (0. . . 0. .969—1. . 0.D. 26. . .002) 83. . . Bearing I. . Ring End Gap (1st and 2nd Rings) Ring End Gap (Oil Ring) . . .07 (1. . . . 0.Repair Specifications/Engine ENGINE: 3TN84 & 4TN84 GROUP 25—Connecting Rods and Pistons Item Standard mm (in. .. . . . . . . .D. . . 0. . . .006) 0.024) 0. . . . . . .D.013) .02 (1. .038 (1.. . . .. . . . . .891) . . . . . . . . . . .004) 26. . .0019) .008) 1. . . 47. . . . . . . .928 (3.TM306.0010—0. .008) GROUP 30—Crankshaft and Main Bearings Item Standard mm (in. .D.. . .059) 25.D. . 26.. . .03 (3. . . . . . .0018—0. . . .55 (0. . .093 (0. .090—0. . . . . . . . . 0. . . .

... .20 0. . . . . . . . .04 (0. .3 psi) Oil Pan Strainer Tube Attaching Cap Screw Torque . . .006) GROUP 40—Lubrication System Item Standard mm (in. .. . . . . .) 5M4.. .20 (0. . . .0009—0. . . .0047) (0. . . . . . . . . . .) Oil Pump Gear Backlash . .15 (0.03 (1.. . . .812) Shaft Diameter . . ..008) (0.) Oil Pan-to-Gear Housing Cover Torque . . . . . .04—0.. . . .) Wear Limit mm (in.08) @ 20. 46. . . . ..93 (1. . . .0047) (0. Oil Pump Attaching Cap Screw Torque . .6 lb) Force Oil Pressure Change Per 1 mm (0. . . .. 0..... . .. 0.0016—0. . . .0029) . .008) (0. . . . . .. . . . . . ..0 (1. . ..0016—0. . . . . . . .006) Oil Pressure Regulating Valve Valve Spring Free Length . . . . . . . . Rotor Recess .) Crankshaft Pulley Cap Screw Torque . . . .008) (0. . 0. . . . 26 N·m (226 lb-in. . . . . . . . . . . . .31 -19-28AUG87 CTM3 (03JAN90) 06-31 3TN/4TN Series Yanmar Engines 010897 PN=40 ..) of Shim Thickness .. . . .13 0. . . . . .0—46. .809—1.12 (0. .. . . .6 kPa (2. . . .. 0..TM306. . .. . .25 0.008) Gear Wear Specifications Gear Bushing Diameter .Repair Specifications/Engine ENGINE: 3TN84 & 4TN84 GROUP 35—Gear Housing Item Standard mm (in. Timing Idler Idler Idler 06 31 . . . .12 (0.811—1... . .0016—0. 27..20 0.0016—0. . ..075 (0. . . . . . 25 N·m (18 lb-ft) . . . .. .. . . .. . . .0016—0..0047) ....) Gear Housing Cap Screw Torque . . . . . . .) Oil Pan-to-Block Cap Screw Torque . . . . .04—0.0047) (0. . . . . ...810) . . . .81) Valve Spring Test Length .. 46. .. . . 15.975 (1. .5 N (4... . . . . . . . . 0. .. . . . . .15 (0.. . . . . . . . . . 26 N·m (226 lb-in. .12 0... . . . . . . . . . .. . Outer Rotor-to-Pump Body Clearance . 115 N·m (85 lb-ft) Timing Gear Backlash Fuel Injection Pump Idler . .812) .20 0. .. . . .20 0.) Wear Limit mm (in. 45. . . .20 0.. . ..010) (0. .0016—0. ..04—0. . 46. Oil Pump . . 0.005) (0. . Crankshaft . Camshaft .12 0. . 26 N·m (226 lb-in.950—45. .12 0. . . . . . .04—0.025 (1. .008) (0. .5 (1. . . .0047) . . ..0047) (0. .025—0. ..12 0.008) (0. .808) Shaft Oil Clearance .. .039 in. . 45. . . Inner Rotor-to-Outer Rotor Clearance . . 26 N·m (226 lb-in.04—0..

. .5 N·m (39 lb-in. . . . . . . . . . . . . . . . . .. . .. . 11 N·m (96 lb-in. . . . . . . . . . . .. . . . . . . . . . . . . Camshaft. . . . . 71˚C (160˚F) . . . . . . . . . . . . .0047) Gear Attaching Nut Torque . . . . . . .Repair Specifications/Engine ENGINE: 3TN84 & 4TN84 GROUP 45—Cooling System Item Specification 06 32 Thermostat Begin Opening Temperature . . . . . 85˚C (184˚F) 26 N·m (226 lb-in. .. . . . .008) Fuel Injection Nozzles Nozzle Opening Pressure . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 -19-28AUG87 CTM3 (03JAN90) 06-32 3TN/4TN Series Yanmar Engines 010897 PN=41 . . . . . . . . Alternator Belt Deflection . . . . 13 mm (0. . . 0. . . . . . . .. . . . .. . . . . . .. . . . .) Fuel Leak-Off Fitting-to-Nozzle Torque .. . . . . . . . . 19600 ± 480 kPa (2843 ± 70 psi) Minimum Leakage Time . . . . . . . .. . . . . . . . . . . . . .. 27 N·m (20 lb-ft) Maximum Gear Backlash . . . . . . . . . . . . .. .. . .... .) Fuel Injection Pump Pump Mounting Hardware Torque .12 (0. . . . . . . .. . . . .) .TM306. . . . . .) at 107 N (24 lb) Force applied midway between pulleys. . . . . 59 N·m (43 lb-ft) . . 11 N·m (96 lb-in. .) 26 N·m (226 lb-in. . . . .. .. . . . . 43 N·m (31 lb-ft) Nozzle-to-Cylinder Head Attaching Torque . . . . ... . .5 in. . . . .. . . and Nozzles Item Standard mm (in. . Housing Attaching Cap Screw Torque Housing Cover Cap Screw Torque . . . . . . . . . . .) . . . . . . . . . . . . . . . 5 Seconds @ 17640 kPa (2550 psi) Pressure Retaining Nut-to-Nozzle Body Torque . .) . .. . . . . . . . ... . Pulley Cap Screws Torque Attaching Cap Screws . . . . .) 20 N·m (180 lb-in. .04—0. . .. . . . . .. . . . . .0016—0. . . . . . . . .. . . . . 4.) Wear Limit mm (in. . . . . . . .. . GROUP 50—Fuel Injection Pump. . . .) . . . . .) GROUP 55—Fuel Control and Governor Linkage GROUP 60—Starter See Starter Specifications in this Group GROUP 65—Alternator See Alternator Specifications in this Group 5M4. . . .. . . . . Fully Open Temperature . . . .. . . . . . . .. . . . . . . . Water Pump Plate Screws Torque . . .. . . Housing Plate Cap Screw Torque . . . . .. .. . 11 N·m (96 lb-in. . . . . . . . . . . . .2 (0. . . 0. . . . . . 15 N·m (130 lb-in.. . . .

. . . . . . .D. . . . .. . . . . . . . . . . . . . . . . . .011 (0. . . . . . . . . . . .. . . .563 in. . . . . . . . . . . . . . . . . . . . 06 33 . . 26 N·m (226 lb-in. . . . . . . . . .I. . . . . . Maximum Gear Backlash . .30 mm (0. . . . . .. . . .) 0. .14 mm (0. . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .002 in.) Maximum Bore I. . . . . . . .TM306. . . Minimum Lobe Height . . . . . .05 mm (0. . . . . . . .17 in. . . . . . . . . . . . . . . Maximum Arm I. . . . . . . . . . . . . . . . . . . . . . . . .012 in. . . .. .. . . . . .. . . . . . . . . . . . . . . . . . .D. . . . . . . . . . . . 14. .D. . . .0 mm (7. . . . . .248 in. . .10 mm 57. .236 (1. .. . Maximum Shaft Support I. . . . . . . . . . . . . . . . . . . .. 0.. . . . . . .. .. .) 5M4. . . . . 115 N·m (85 lb-ft) GROUP 15—Cylinder Head. . . .248 in. . . . . . . . . .) in. . . . . . . . . . .. . . . Maximum Intermediate and Flywheel End Bores I. . . . . . . . . . . .35 mm (0. ..30 mm(0. . . . . . . . .. . .Repair Specifications/Engine ENGINE: 4TN100 GROUP 10—Valve Train and Camshaft Item Specification Valve Clearance . . . . . 0. . . . . . . 18 N·m (160 lb-in. .) in. . .25 mm 56. . . . . .. . . . . . .815 (2. . . 26 N·m (226 lb-in. . . . . . . . . . . . . . . . . .. Intermediate and Flywheel End . . .. . . . . . . . .. . . . . . . . . . . . .) Intake Manifold Cap Screw Torque . . . .732 in. . . . . . . . . . . . . . .. . . . . . ..558 in. .D. .) . . . . . .. . . . . . . . . . . . . . . . . . . .. . . . . . . . . .10 mm (0. . .006 in. . . .. . . . . . . . 0. . . . Maximum Shaft Clearance . . . . . . . 0.) in. . . . . . . . . . . . . . . .) 18. . . . . . . .R. . . . . . .. . . . . .. . . Valves. . . . . . . . . . ..17 mm (0. . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . 0. . . . . . . . . . . . . . . . . . . . . . . . 26 N·m (226 lb-in. . .. . . . . . . .. . . . . .. . . . . . . . . . . . . . . . .. .) Rocker Arm Minimum Shaft O. . . . .) in. . .10 mm (2. . 14. .D. . .. .) . . . . . . . . . . . . . . . . . . . . . . . . Rocker Arm Assembly Cap Screw Rocker Arm Cover Nut Torque . . Attaching Cap Screw Torque . . .60 mm (0. . . . . . . Maximum Journal Clearance Gear Case End . . . 182. . . .722 in. . . .. . . . Minimum Journal O. . . .) . . . . . .. . . . .. . . . . . . . . . . . . . .) Maximum Clearance . . . . . . . . . . . . . . 0.) . . . . . . . . . . . . . 18. . . . .D. . . . . . . . . . . . . . . . . . . 26 N·m (226 lb-in.06 mm (0. . . . . . . . . . . . . . . . .. . . . . .. . .. . 26 N·m (226 lb-in. . . . . . .) . . .29 mm .) .. . . .732 in.. . .) . . . . . .) Minimum Length . . . . . . . . . . . .) Cam Follower Minimum O. . . . . . . . . . . . . . . .D. . . . . . . . .30 mm (0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . Gear Housing Cover Cap Screw Torque Crankshaft Pulley Cap Screw Torque . . and Nut .80 mm 46. . .) 18. . . .. . . . . . . . . . . . . . . .) Push Rod Maximum T.. . . . . 57. . . . .012 in. . . . . . . . .. . Torque . . . . and Manifolds Item Specification Manifold Exhaust Manifold Cap Screw Torque . . . . . . . . . . . . . . . . . . . .) . Maximum Bushing I. . . . . .) Camshaft Maximum End Play . . . . .. . . . . .005 in. . . . . . . . . . 0. . . . . . . . .D. . . . . . .010 (2. . . . . . . . . . . . . .. . .12 mm (0. . . . . . . . . . . . .60 mm (0. . . . . . . . . . . . . . . . . . . . . . . .33 -19-28AUG87 CTM3 (03JAN90) 06-33 3TN/4TN Series Yanmar Engines 010897 PN=42 . . . . . .002 in. . .. . . . . . . . . . .. . . . . . . . .

. . . . . . . . . . . . . . . . . . . . .) . . . . . . . . . . .05 mm (0. . . . . . . .) @ 12.) Cylinder Head Cap Screw Torque In Sequence (Lubricated) . . . . . . . . M8 . . . . .TM306. . . . . . . . . . . . 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .008 in. . . . . . . . . . . . . . . . . . . . . . . . 26 N·m (226 lb-in. . . . . . . . . . . . . . . . .05 mm (0. . 30˚ Exhaust . . . . . . . . . . . . . 45˚ Intake Valve Angle . . . . . . . . . . . . . . . . . . . . . . . .15—0. . . . . . . . . . . . . 88 N·m (65 lb-ft) .006—0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .084 in. . . . . . . . . . . . . . .108 in. . . . . . . . . 157 N·m (116 lb-ft) GROUP 20—Flywheel Item Specification Flywheel Flatness . . . . . . . . . . . . .63 in. .Repair Specifications/Engine ENGINE: 4TN100 Item Specification 06 34 Cylinder Head Intake and Exhaust Valve Recession . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D. .350 in. . . . . . . . . . . . . . . . Attaching Cap Screw Torque Flywheel Housing Mounting Plate or Housing Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45˚ Cylinder Head Flatness . . . .) Maximum Valve Seat Width Intake . . . . . . . . . . . . . . . . . . . . . . . . . .) Exhaust Valve Angle . . . . . . . . . . . . . . . .5 mm (1. . .20 mm (0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 N·m (145 lb-ft) . . . . . . . . . . 9. .) (Knurl) . . . . 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.) Valve Seat Angle Intake . 0. . . . . . . . . . . . . . . .) . . . . . . . . . . . . . .) Valve Guide Height . . . . . . . . . . . . . . . . . .) Valve Spring Free Length (Approx. . . . . . . . . 49 N·m (36 lb-ft) . . . . . . . . . . 42. . . . . . . . . . . . . . . . . .12 mm (0. . . . . . . . . . . . . . . . . . . .90 mm (0. . . . . . . . . .002 in. 49 N·m (36 lb-ft) . . .6 N (2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel Housing or Shield Cap Screw or Nut Torque M10 . . . . . . . . . . . . . .358 in. . . . M12 Nut . . . . . . . . . . . . . .) Valve Guide-to-Valve Stem Clearance: (Replace) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 mm (0. . . . . . .008 in. .453 in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73 mm (0. . . . . . . . . . . . .D. . . . . . . . .) . . . . . . . . . . .002 in. . . . . Starter-to-Mounting Plate Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . 88 N·m (65 lb-ft) 5M4. . . . . . . . . . . . . . . . . . . . . . . .20 mm (0. . . . .) Mill Cylinder Head No More Than . . 8.67 in. 2. 0. . . . . . . . 0. . . . . . . . . . . . . . . . .008 in. .) Exhaust . . . . . . . 2.20 mm (0. . . . . . . . .50 mm (0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .071 in. . . . . . . . . . . . . . .) Valve Spring Test Length . . . . . . . . . . . . . . . . . .80 mm (0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30˚ Maximum Valve Guide I. . . . . . . . . 11. . . . . . . . . . .34 -19-28AUG87 CTM3 (03JAN90) 06-34 3TN/4TN Series Yanmar Engines 010897 PN=43 . . . . . . . . . . . . . . .8 lb) Force Minimum Valve Stem O. . . . . . . . . . . . . . . . . . . . . .5 mm (1. . . . . . . . . . . . .

) 60.20 mm (0. . . . . . . .35 mm (0. . . . . . .) 70. . . . . . . . . . . . . .79 mm (3. . . . . . . . . . . . . . . . . . . . . . . . . . . .006 0. . . . . . . . . . . . . . . . . . . . . . . . . . . 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TM306. . . . . . 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Seal Case Cap Screw Torque Seal Case to Block . . . .) 69. Minimum Piston O. . . . . . . .D. . .D. . . Maximum Ring End Gap . . . . . .) in. . . . . . . . . . . . . . . . . .059 33. . . . .D. . . . . . . . . . . .90 mm (2. . . . . . . . . . . . . . . . . .) 5M4. . End-Cap Screw Torque . . . .) in. . . . .15 mm (0. . . . . .366 in. . . . . . . . . . . 93 N·m (69 lb-ft) . . .760 in. . . . .D. . . . . . Maximum Cylinder Bore I. .90 mm (2. . . . . . . . . . . .011 in. . . . . . . . . . . . in. . . . . . .) in. . . .) in. . . . . . . . . . . . . . . . . . . . Main Bearing Cap Screw Torque .0024 34. . . . . . . . .) in. . . . . .) in. . . . . . . . . . . . . . . . . .018 in. . . . . . . . Minimum Main Bearing Journal O. .35 -19-28AUG87 CTM3 (03JAN90) 06-35 3TN/4TN Series Yanmar Engines 010897 PN=44 . .004 in. . . . . . .29 mm (0. Maximum Main Bearing Clearance . .) 06 35 Piston Maximum Ring Groove Clearance Top Ring . . . . . . . . .45 mm (0. . . . . . . . . . .) in.D. . . Maximum Pin Bushing Clearance Maximum Pin Bore I. . . . . . . .008 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum Piston Clearance . . . . . . . . . . . . . . . . . . . . 0. . . . . . . . . . . . .) . . . . . . 196 N·m (145 lb-ft) . . . . . . . . . . . . Maximum Main Bearing I. . . 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .006 1. . . . . . . . . . . . . . . . . . . 0. . .945 .) .001 99. . . . .15 mm (0. . . . .752 in. . . . . .10 mm (2. . . . . . . . . . . .20 mm (3. . . . . . . . .) . . .343 0. . . . . . . .Repair Specifications/Engine ENGINE: 4TN100 GROUP 25—Connecting Rods and Pistons Item Specification Connecting Rod Maximum Side Play . . . . . . . . . . .01 mm (1. . . . . . .358 in. . . . . . . . . .) in. . . .D. . . . . . . . . . . . Maximum Bearing I. . . . . . . . . . . . .D. . . . . . . . .50 mm (0. Minimum Pin O. . . . . . . . . . . . . . . . . . . . . . . . . Oil Ring . . . . . . . . .338 34. . . .D. . . . . . . . . . . . . . .014 . . . . . . .D. . . . . . . . . . . . . . . .) in. . . . . . . . . . . . . . . . .09 mm (0. . . Second Ring . . Maximum Pin Bore Clearance . . . .09 mm (0. . . . Maximum Pin Bushing I. . . . . . .339 . . . . . . . . . . . . . . .06 mm (0. .) in. . . .02 mm (0. . . . . . . . . .929 100. . . . . . . . . . . . . . . . . . . . . .10 mm (2. . . . . Oil Pan to Seal Case . 26 N·m (226 lb-in.10 mm (1. . . . . . . . . . . . . 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum Bearing Clearance Minimum Journal O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0. . . .) GROUP 30—Crankshaft and Main Bearings Item Specification Crankshaft Maximum End Play . . . 21 N·m (180 lb-in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99 mm (1. .) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) 59. . . . .004 in. . . . . . . . . . . . . . . . . . .) in. . . . .

. . . . . Oil Pan Spacer-to-Block Cap Screw Torque M8 . . . . . . . . . . . Oil Pan Spacer-to-Crankshaft Seal Case . . .25 0. . . . . . . . .) in. . . Oil Pump Body Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) . . . . . . . . . . . . .006 in. . . . . . . . . . . . . . . . . . . . . . .) . . . . .) GROUP 40—Lubrication System Item Specification Oil Pump Gear Backlash. . . . . . . . . .) Crankshaft Pulley Cap Screw Torque . . . . 0. . . . .010 in. . . . . . . .) . . 50. . 26 N·m (226 lb-in. . . . . . . . .25 mm (0. .) Shaft Oil Clearance . . . . . . . . . . . . 21 N·m (180 lb-in. .0 mm (2. . . . . . . . . . . . . . . . . .25 mm (0. . . . . . . . . . . . . . . . . . . 26 N·m (226 lb-in. . . . . . . . . Maximum . . . . . . . . . . . . . . . .) 5M4. . . . . . . . . . . . . . . . . . . . 45. . .25 mm mm mm mm mm (0. . . . . . .808 in. . . . .25 0.) in. . .008 in. . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pan-to-Block Cap Screw Torque . . . . . . . . . 46. . . . . . . . 0. . . . . Valve Spring Test Length . . . . . . . . . . .) . . Oil Pump . . . . . . . . . . . . . .010 in. . . . . . .4 N·m (1. . . . . . . . . . . . . . . . . . . . .) in. . . . . . . . . . . . . . .010 (0. . . . . . . . . . . . . . . .) Gear Wear Specifications Gear Bushing Diameter . . . . . . . . . . . . . . . .08 mm (1. . . . . . . 0.25 mm (0. . . . . . . . . . . . . . . . . . Maximum . .010 in. . . . . .) 5. . . Timing Idler Idler Idler 115 N·m (85 lb-ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . @ Oil Pan Strainer Tube Attaching Cap Screw Torque . . . . . . . .) . . . . . . . . . . . . . . . . . . .) . . . . . . . . . . . . . . . . . . . . . .Repair Specifications/Engine ENGINE: 4TN100 GROUP 35—Gear Housing Item Specification 06 36 Gear Housing Cap Screw Torque . . . . . . M12 . 88 N·m (65 lb-ft) .010 in. . . . . . . . . . . . . . . . . . . .TM306. . . . . . . . . . . . . . . . . . Oil Pump Attaching Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . Timing Gear Backlash Fuel Injection Pump Idler . Maximum Outer Rotor-to-Pump Body Maximum Clearance Inner Rotor-to-Outer Rotor Maximum Clearance Shaft-to-Bore Clearance. . . . .) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) . . . . . . . . . . . . . . . . . . . . . . .97 in. . . . . . . .2 mm (0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N·m (221 lb-ft) Oil Pressure Regulating Valve Valve Spring Free Length (Approx. . . . . . . . . . . . . . . . . . . . 26 N·m (226 lb-in. 26 N·m (226 lb-in. . . . . . . Oil Pan-to-Gear Housing Cover Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .010 (0. . . . . . . . . .36 -19-28AUG87 CTM3 (03JAN90) 06-36 3TN/4TN Series Yanmar Engines 010897 PN=45 . . . . . . . . . . . . . . . . . . . . .) . . . . . . . . . . . . . . . . . . . . . . . .010 (0. . . . . . . . . . . . . .2 lb) Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51. . . . . . . . . . Crankshaft . .0 mm (1. . . .25 0. . . 0. . . . . . . . . . . . . . .15 mm (0. . . . . .25 0. . . . . Camshaft . . . . . . .814 in. . .93 mm (1. . . . . . .) Shaft Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .010 (0. . . . . . . . . . . 21 N·m (180 lb-in. . . . . .) in. .) 0. . . . . . 6 N·m (53 lb-in. . . . . . . . . . . . . . . . . . . . . . . . . . .) . . . . . . . . . . . . . . . . . . . 0. . . . . . Rotor Recess. .01 in. .

. .75 N (0. . . . . . . . . . . . . .1 mm (0.37 -19-28AUG87 06-37 3TN/4TN Series Yanmar Engines 010897 PN=46 . . . . . . . . . . . . . . . . .. . . . . .5 GROUP 50—Fuel Injection Pump. . . . . . . . . . .45 in. .) . . 88 N·m (65 lb-ft) Fuel Injection Nozzles Nozzle Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 mm (0. . . . . . Camshaft. . . 9 N·m (78 lb-in. . . . Clearance Between Impeller and Pump Body . . .) Water Pump Bottom of Pulley Flange-to-Housing Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .043 in. . . . . . . . . . . . . . . . . . . . . . .) Gear Attaching Nut Torque . . . Pulley Cap Screws Torque . . . . . . . . . . . . .Repair Specifications/Engine ENGINE: 4TN100 GROUP 40—Lubrication System (Continued) Item Specification Oil Cooler-to-Oil Cooler Housing Nuts Torque Oil Cooler Housing Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . Plate Screws Torque . . . . . . . . . . . 71˚C (160˚F) Fully Open Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . and Nozzles Item Specification . . .. 4. .) . . . . . . . . . . . . . . .0 mm (2. . . Attaching Cap Screws . . Alternator Belt Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) . . . . . . 27 N·m (20 lb-ft) Maximum Gear Backlash . . . . . . . . . . . . . . .) . . . . . . .008 in. . 24 N·m (212 lb-in. . . . . . . 5 Seconds @ 18100 kPa (2625 psi) Pressure Retaining Nut-to-Nozzle Body Torque . . . . . . . . . . . . . .) in. . . . . . . .) GROUP 55—Fuel Control and Governor Linkage Fuel Supply Pump Pump Mounting Nuts Torque . . . . . . . . . . . . . . . . . . . .48 in. . . . . . 13 mm (0. .. 63. . . 43 N·m (31 lb-ft) Nozzle-to-Cylinder Head Attaching Torque . . . .) at 107N (24 lb) Force applied midway between pulleys. . . . 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0. . .) . . . . .50 in. . . . . . 11 N·m (96 lb-in. . . . . . . . . . . . . . . . . . .) GROUP 60—Starter See Starter Specifications in this Group GROUP 65—Alternator See Alternator Specifications in this Group CTM3 (03JAN90) 5M4. . . . . @ . . .2 mm (0. . . . . . . Fuel Injection Pump Pump Mounting Hardware Torque . . . . . . . . . . . . . . . . . . . . .) By-Pass Valve Spring Test Length . 49 N·m (36 lb-ft) . . . . . . . . . . . . . . . By-Pass Valve Spring Free Length (Approx. . . 37. . . . . . . . . .012—0. . . . . . . . . . . . . . . 20 N·m (180 lb-in. . . . . . .5 N·m (39 lb-in. . . . . . . . . . . . . . . . . . . 20100 ± 490 kPa (2915 ± 71 psi) Minimum Leakage Time . . . . . . . . . . . . . . . .0 mm (1. . . . .) . . . . . .. . . .3—1. . . . . . . . . . . . . . 85˚C (184˚F) Housing Cover Cap Screw Torque . . .TM306. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) 3.84 lb) Force 06 37 GROUP 45—Cooling System Item Specification Thermostat Begin Opening Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N·m (96 lb-in. . . . . . . . . . . . . . . . . 26 N·m (226 lb-in. . . . . . .

Repair Specifications/Engine 06 38 CTM3 (03JAN90) 06-38 3TN/4TN Series Yanmar Engines 010897 PN=47 .

Name Use Feeler Gauge Outside Micrometer Telescoping Gauge Valve Inspect Center Vernier Calipers Strap Wrench 13-Ton Puller Set Magnetic Base with Adjustable Arm Dial Indicator Magnetic Follower Holder Kit Measure valve clearance Measure engine components Measure engine components Measure pushrod TIR Measure pushrod length Hold crankshaft pulley Remove crankshaft pulley To hold dial indicator Measure gear and shaft end play To hold cam followers in place when removing camshaft To service bushings. Some tools may be available from a local supplier.Group 10 Valve Train and Camshaft SERVICE EQUIPMENT AND TOOLS NOTE: Order tools from the U. To seal gear case cover. and oil seals To service camshaft gear 10 1 Bushing. Bearing. SERVICEGARD™ Catalog or from the European Microfiche Tool Catalog (MTC). LOCTITE is a trademark of the Loctite Corp. M21.1 -19-05FEB86 OTHER MATERIAL Number Name Use PT502 T43512 John Deere GASKET MAKER® John Deere LOCTITE® Thread Lock and Sealer (Medium Strength) John Deere Form-In-Place Gasket (RTV rubber silicone sealant) To seal camshaft plug Apply to threads of crankshaft pulley cap screw.TM310.TM310. bearings. and Seal Driver Set Press M21.2 -19-23JUL87 CTM3 (03JAN90) 10-1 3TN/4TN Series Yanmar Engines 010897 PN=48 .S. PT94 GASKET MAKER is a trademark of the Permatex Corp.

Remove crankcase breather cover (D).TM310. Remove oil fill cap (B) and O-ring (C).3 -19-17MAR86 REMOVE AND DISASSEMBLE ROCKER ARM COVER 1.Valve Train and Camshaft/Rocker Arm SERVICE PARTS KITS The following kits are available through your parts catalog: Cylinder Block Gasket Kit. A—Baffle B—O-Ring C—Crankcase Breather Tube D—Crankcase Breather Cover 3TN75 Shown M21. 10 2 M21. Remove O-ring (A) from special nuts.TM310. Cylinder Head Gasket Kit.7 -19-04AUG87 4. Remove screws and lock washers to remove baffle (A). -UN-29AUG88 M21. 5. Remove rocker arm cover. Remove O-ring or gasket (B) and crankcase breather tube (C). 2.8 -19-23JUL87 CTM3 (03JAN90) 10-2 3TN/4TN Series Yanmar Engines 010897 PN=49 M37498 -UN-29AUG88 M35328 -UN-29AUG88 M35327 . 3.TM310.

M21. -UN-29AUG88 3TN75 Shown M21.1 cylinder intake valve (A) opens. NOTE: Number one cylinder is closest to the flywheel end.TM310. packing (A) and O-ring (B). Remove screen.TM310.9 -19-23JUL87 MEASURE AND ADJUST VALVE CLEARANCE (ALL EXCEPT 4TN100) 1.10 -19-24JUL87 CTM3 (03JAN90) 10-3 3TN/4TN Series Yanmar Engines 010897 PN=50 M35255 -UN-29AUG88 M37499 -UN-29AUG88 M35329 10 3 . Turn crankshaft clockwise until No.Valve Train and Camshaft/Rocker Arm 6. Wash packing in a safe solvent and blow dry with air pressure. Remove gasket from baffle. If packing comes apart or is deteriorated. replace it.

(TDC on compression stroke).TM310. 1 Timing Mark B—Index Arrow C—No. A—No. 1 Timing Mark D—Index Mark on Flywheel Housing E—No.Valve Train and Camshaft/Rocker Arm NOTE: TDC—Top Dead Center (the piston at its highest point). 1 Timing Mark F—Index Mark 3TNA72UJ Engine (Early Units) Engines with Flywheel Housing Engines Without Flywheel Housing M21. 2. 1 timing mark lines up with index mark. Continue turning crankshaft until No.11 -19-14SEP87 CTM3 (03JAN90) 10-4 3TN/4TN Series Yanmar Engines 010897 PN=51 M37501 -UN-29AUG88 M37500 -UN-29AUG88 M35256 10 4 -UN-29AUG88 .

. . . . Hold screw while tightening nut.20 mm (0. . . . . . . .) 4. . . .008 in. . . .20 mm (0. . A—Intake Valve B—Exhaust Valve C—Nut D—Adjusting Screw 10 5 View From Flywheel End M21. .12 -19-17FEB86 CTM3 (03JAN90) 10-5 3TN/4TN Series Yanmar Engines 010897 PN=52 M35257 -UN-29AUG88 .TM310. 0. To adjust valves (A and B). . . . . . . . loosen nut (C) and turn adjusting screw (D) to proper clearance.) Exhaust valves (B) . . . . . . 0. . .008 in. . . . . . . . . Measure valve clearance. VALVE CLEARANCE SPECIFICATIONS Intake valves (A) .Valve Train and Camshaft/Rocker Arm 3. .

2 timing mark on flywheel with mark on flywheel housing or mounting plate. -UN-29AUG88 M21. 1 cylinder TDC mark (A) aligns with the timing mark (3) on the flywheel housing. 2 cylinder intake valve (C) opens. For 4 cylinder engine. Turn crankshaft until No. For 4 cylinder engine. c. 2 timing mark on crankshaft pulley with arrow on gear housing cover. Continue turning crankshaft to align the No.A1 -19-27JUL87 View From Flywheel End MEASURE AND ADJUST VALVE CLEARANCE (4TN100) 1. 4 timing mark on flywheel with mark on mounting plate.TM310.Valve Train and Camshaft/Rocker Arm 5. Turn crankshaft pulley cap screw clockwise until No. continue turning crankshaft to align the No. 4 cylinder intake valve opens. Remove plug from timing hole on flywheel housing.13 -19-27JUL87 M21. NOTE: “Top Dead Center (TDC)” is the piston at its highest point. To adjust remaining valves (A and B): a. See Step 4 to adjust intake and exhaust valve. CTM3 (03JAN90) 10-6 3TN/4TN Series Yanmar Engines 010897 PN=53 M51561 -UN-31AUG88 M35258 .TM310. continue turning crankshaft to align the No. turn crankshaft until No. 10 6 b. 2. For 3TNA72UJ engine (early unit).

) A—Intake Valve B—Exhaust Valve C—Nut D—Adjusting Screw 6. Install plug in timing hole on flywheel housing. 10. . 0. . CTM3 (03JAN90) 10-7 3TN/4TN Series Yanmar Engines 010897 PN=54 M51593 M51592 10 7 . .30 mm (0. . .TM310. 9. . 4 cylinder at TDC on compression stroke. If both rocker arm push rods are loose the piston is at TDC on compression stroke. . . . . VALVE CLEARANCE SPECIFICATIONS Intake valves (A) . . rotate flywheel one revolution (360˚). .) Exhaust valves (B) . .A2 -19-28AUG87 7. . . . Turn crankshaft pulley cap screw clockwise to turn flywheel one revolution (360˚). Measure intake (A) and Exhaust (B) valve clearances.Valve Train and Camshaft/Rocker Arm 3. . . . Install rocker arm cover and gasket. . . To adjust valves. See Step 5 to adjust valves. M21. . 0. loosen nut (C) and turn adjusting screw (D) until proper clearance is obtained. 1 cylinder is the closest to the flywheel.TM310. . . -UN-31AUG88 4. Measure intake (A) and exhaust (B) valve clearance. . . .30 mm (0. This puts No. . . Try to move both No. . . .A3 -19-27JUL87 8. . . . . If rocker arm pushrods are not loose. -UN-31AUG88 M21. 5. . . .012 in. 1 cylinder rocker arms or push rods. NOTE: No. .012 in. Hold screw while tightening lock nut. . . Remove rocker arm cover.

15 -19-27JUL87 M21. go to Step 4. -UN-29AUG88 3TN75 Shown M21.14 -19-27JUL87 NOTE: For all engines except 3TN66/3TNA72. Remove snap ring and parts (A—F). Remove set screw and parts (A—H). A—Exhaust Rocker Arm B—Support C—Intake Rocker Arm D—Spring E—Nut F—Adjusting Screw -UN-29AUG88 M21.16 -19-17FEB86 3. 2.TM310. Remove rocker arm assembly.TM310.Valve Train and Camshaft/Rocker Arm REMOVE AND DISASSEMBLE ROCKER ARM ASSEMBLY 1. A—Support B—Intake Rocker Arm C—Spring D—Exhaust Rocker Arm E—Nut F—Adjusting Screw G—Rocker Arm Shaft H—Snap Ring CTM3 (03JAN90) 10-8 3TN/4TN Series Yanmar Engines 010897 PN=55 M35261 -UN-29AUG88 M35260 M37503 -UN-29AUG88 M35259 10 8 .TM310.

96 mm (0. . . . . . . . . . . . .96 mm (0. . .TM310.) 4TN100 . . . . . . . . . . . 11. . 9. . A—Support B—Rocker Arm C—Spring D—Nut E—Adjusting Screw F—Rocker Arm Shaft G—Cap Screw -UN-29AUG88 All except 3TN66/3TNA72/4TN100 M21.722 in. .Valve Train and Camshaft/Rocker Arm 4. . . . . . 18.628 in. SPECIFICATIONS (MIN) 3TN66 . . . . . Remove snap ring and cap screw (G). . . . Remove parts (A—F).) 3TN75/3TN78/3TN82/3TN84/ 4TN78/4TN82/4TN84 . . . . . . . Remove three studs using two M8 nuts. .392 in. .TM310. . . . .17 -19-14SEP87 5. . . . . .471 in. . . . . . . . .) -UN-29AUG88 M21. replace shaft. . Remove parts (A—F). . . . . . . . ROCKER ARM SHAFT O. . . . . . . . . . CTM3 (03JAN90) 10-9 3TN/4TN Series Yanmar Engines 010897 PN=56 M35262 M51562 -UN-31AUG88 M37504 10 9 . . . . . .D.96 mm (0.) 3TNA72 . . .18 -19-14SEP87 If rocker arm shaft diameter is less than wear tolerance. 15. . . . . Measure shaft at each rocker arm location. .35 mm (0. . . . . . .

. . . . . .) 4TN100 . .20 -19-04AUG87 If rocker arm shaft support diameter exceeds wear tolerance. . . . .19 -19-28AUG87 M21. . . . . .D. . .D. . . . . . . . . rocker arm.D. . .) 3TNA72 . . . . 12. . . . . . . . . . . . . replace rocker arm shaft. . .09 mm (0. . . . . . . . . .633 in. 18. . . . 10. . . . . . . . 12.06 mm (0.) 3TNA72 . . . . . (Max) 3TN66 . . . . .005 in. . . . . . SPECIFICATIONS (MAX) 3TN66 . . . .) 4TN100 . . . . . . . . . . . . . . . . . .) If rocker arm bore diameter exceeds wear tolerance. . . . . . . .60 mm (0.002 in. . . . minus rocker arm shaft O. .397 in. . . . . If shaft clearance exceeds wear tolerance. .09 mm (0. . Measure each support. . .) 3TN75/3TN78/3TN82/3TN84/ 4TN78/4TN82/4TN84 . . . . . . . . . . . . . .09 mm (0. . . . Measure each rocker arm inside diameter and determine rocker arm shaft clearance (rocker arm I. . . .) 3TN75/3TN78/3TN82/3TN84/ 4TN78/4TN82/4TN84 .) 4TN100 . . . . ROCKER ARM SHAFT SUPPORT I. .476 in. . 7.) Shaft Clearance (Max) All except 4TN100 . . . 10. 0. . .60 mm (0. . . . . . . . . . . .09 mm (0. . . . 16. . . . 18. ROCKER ARM SPECIFICATIONS Arm I.D. . . . . . . . .09 mm (0. . . . . . . . . . .13 mm (0.Valve Train and Camshaft/Rocker Arm 6. . . . .) -UN-29AUG88 M21. . . replace rocker arm. . . . . .TM310. or both. . .397 in. 16.TM310. . CTM3 (03JAN90) 10-10 3TN/4TN Series Yanmar Engines 010897 PN=57 M35264 M35263 10 10 . . . . . . . . 0. .09 mm (0. . . . . . . . . . .476 in. . . . . -UN-29AUG88 Inspect rocker arm to valve surface and adjusting screw for metal flakes or wear. . . . .732 in. . . . . . . replace support.633 in. . .). . . . . .732 in. . .

. . . . . 3. . .0 mm (7. . . . . . . 114. . . .30 mm (0. . . . . . . .55 in. . -UN-29AUG88 M21. . .) 3TNA72 . . . . . . . . . . . . 178.77 in. . . . . . . . . . . . . . .0 mm (4. . . .) -UN-29AUG88 If pushrod length is less than wear tolerance. . . . . . . . . Measure pushrod TIR (Total Indicator Runout) using Valve Inspection Center. .012 in. . . . . . . .30 mm (0. .TM310. . . . . . . Remove pushrods. . . 182. .6 mm (5. . . .) 3TN82/3TN84/ 4TN82/4TN84 . . .49 in. . . . . . . 0. 141. . . .Valve Train and Camshaft/Rocker Arm REMOVE AND INSPECT PUSHRODS AND CAM FOLLOWERS 1. . . .) -UN-06SEP88 M21. . . . . . . . . . . . .23 -19-04AUG86 If pushrod TIR exceeds 0.012 in. . . . SPECIFICATION Pushrod TIR (Max) . . . . replace it. . 146. .21 -19-17FEB86 2.). . . PUSHROD LENGTH SPECIFICATIONS (MIN) 3TN66 . . . .TM310. . . . .22 -19-22APR86 M21. . . . Measure pushrod length.0 mm (5. . . . . .17 in. . . . .02 in. . .) 3TN75/3TN78/4TN78 . CTM3 (03JAN90) 10-11 3TN/4TN Series Yanmar Engines 010897 PN=58 M35266 M35400 M35265 10 11 . . . . . . . . .) 4TN100 . .TM310. . replace it.2 mm (7. .

. . .824 in.) 3TNA72 . .93 mm (0. (See Group 15 in this manual). . 9. . .TM310.93 mm (0. . . . -UN-06SEP88 3TN75 Shown M21. .) -UN-29AUG88 If cam follower diameter is less than wear tolerance. . .) 3TN75/3TN78/3TN82/3TN84/ 4TN78/4TN82/4TN84 . . . . . . For all other engines. M21.25 -19-28AUG87 CTM3 (03JAN90) 10-12 3TN/4TN Series Yanmar Engines 010897 PN=59 M37510 M35268 M35267 10 12 -UN-29AUG88 .558 in. 11.D. . . . . . . . . CAM FOLLOWER O. . . . .24 -19-04AUG87 8. Put a mark on each cam follower and cylinder block bore to aid in assembly. SPECIFICATIONS (MIN) 3TN66 . . . .93 mm (0. . . . . . . . . . replace it. . . . . . . . . . . . 3TN75 Shown 7. . 6. . (See Group 10 and 40 in this manual. Inspect cam follower-to-camshaft surface for uneven wear or damage. . .TM310. . . . . . remove cylinder head. . . . Remove cam followers.470 in. . . 20. 14. . remove camshaft and oil pan. . Measure cam followers outside diameter. . . . . For 3TN66 or 3TNA72 engine only.706 in. .) IMPORTANT: Cam followers must be installed in the same bores from which they were removed.Valve Train and Camshaft/Rocker Arm 4. . . . . 5. . . . replace as necessary. . .) 4TN100 . . 17. . . . . . . . . . . . .17 mm (0. . .

D. . . . .) 3TN75/3TN78/3TN82/3TN84/ 4TN78/4TN82/4TN84 . . .) 4TN100 . . minus cam follower O. . . . .006 in. . .05 mm (0. . . . . . . . . . . . . . . . . . . . 0. . . . If cam follower clearance exceeds wear tolerance. . . . . . . . . . . . . . . . . . 0. .D.) 3TNA72 . . . . . . .05 mm (0. 21. . . . . . . .) -UN-29AUG88 M21. .30 mm (0. . . . . . . cylinder block or both. . . . .711 in. . . . . . . .05 mm (0. . .TM310. . . .) 3TNA72 . 0.15 mm (0. . . 18. . . . CTM3 (03JAN90) 10-13 3TN/4TN Series Yanmar Engines 010897 PN=60 M35269 10 13 . CAM FOLLOWER BORE SPECIFICATIONS Bore I. replace cylinder block. . . Measure cam follower bore inside diameter and determine cam follower clearance (cam follower bore I. (Max) 3TN66 .004 in. . . . . . . . . 14. . .474 in. . .563 in.26 -19-04AUG87 If cam follower bore diameter exceeds wear tolerance.05 mm (0. . . . . .829 in. . . . .) 4TN100 . replace cam follower. . . .002 in. . . . 12. . . . . . . . .) Clearance (Max) All except 3TNA72/4TN100 . . . . . .Valve Train and Camshaft/Rocker Arm 10. . . . . . . .10 mm (0. . .D. . . . . . . . . .). . .

. (See Groups 10 and 40 in this manual.TM310. Install cam followers. M21. IMPORTANT: Cam followers must be installed in the same bores from which they were removed. Install the pushrods.) 4. install camshaft and oil pan. -UN-29AUG88 3. install cylinder head. For all other engines.27 -19-28AUG87 5. For 3TN66/3TNA72 engines only.) 3TN75 Shown M21.28 -19-17FEB86 CTM3 (03JAN90) 10-14 3TN/4TN Series Yanmar Engines 010897 PN=61 M35265 -UN-29AUG88 M37509 -UN-29AUG88 M35267 10 14 2. (See Group 15 in this manual.TM310. Put clean engine oil on cam followers.Valve Train and Camshaft/Rocker Arm INSTALL PUSH RODS AND CAM FOLLOWERS 1.

A—Support B—Intake Rocker Arm C—Spring D—Exhaust Rocker Arm E—Nut F—Adjusting Screw G—Rocker Arm Shaft H—Snap Ring -UN-29AUG88 M21.TM310. Install parts (A—H) on rocker arm shaft.29 -19-08AUG87 M21. Install and tighten set screw. A—Exhaust Rocker Arm B—Support C—Intake Rocker Arm D—Spring E—Nut F—Adjusting Screw -UN-29AUG88 CTM3 (03JAN90) 10-15 3TN/4TN Series Yanmar Engines 010897 PN=62 M35260 M35261 10 15 . go to step 5.TM310.Valve Train and Camshaft/Rocker Arm ASSEMBLE AND INSTALL ROCKER ARM ASSEMBLY NOTE: For all engines except 3TN66/3TNA72. 2.30 -19-17FEB86 3. Install snap ring. 1. Align set screw hole in support with center hole in rocker arm shaft. 4. Install parts (A—F) on rocker arm shaft.

31 -19-28AUG87 CTM3 (03JAN90) 10-16 3TN/4TN Series Yanmar Engines 010897 PN=63 M51562 -UN-31AUG88 M37504 10 16 -UN-29AUG88 . Install and tighten three studs using two M8 nuts.TM310. Install and tighten cap screw (G). Align hole in last support with hole in rocker arm shaft.Valve Train and Camshaft/Rocker Arm 5. Install snap ring. Install parts (A—F) on rocker arm shaft. A—Support B—Rocker Arm C—Spring D—Nut E—Adjusting Screw F—Rocker Arm Shaft G—Cap Screw All except 3TN66/3TNA72/4TN100 4TN100 M21.

. . . . . . .) Exhaust Valves (B) . . .Valve Train and Camshaft/Rocker Arm 7. .30 mm (0. . . . .30 mm (0. . . Be sure adjusting screws (A) are in push rod sockets. . . . . . Install and tighten eight cap screws to 26 N·m (226 lb-in.008 in. 8. . . . . .). . . . . .20 mm (0. .33 -19-17FEB86 CTM3 (03JAN90) 10-17 3TN/4TN Series Yanmar Engines 010897 PN=64 M35257 -UN-29AUG88 M37505 -UN-29AUG88 M35297 10 17 . .) Exhaust Valves (B) . . . . . .) VALVE CLEARANCE SPECIFICATIONS All Except 4TN100 Intake Valves (A) . . . 0. .012 in. . . . -UN-29AUG88 All except 3TN66/3TNA72 M21.) 4TN100 Intake Valves (A) .TM310. .32 -19-28AUG87 9. . 0. . . . . . . (See Measure and Adjust Valve Clearance in this section. . . Measure valve clearance. . Install rocker arm assembly. . . . .008 in. . . . . . . . . . .20 mm (0. . . .) A—Intake Valve B—Exhaust Valve C—Nut D—Adjusting Screw M21. 0.012 in. .TM310. Install and tighten two nuts and cap screw to 26 N·m (226 lb-in. . .). . 0. . .

Install a new O-ring (B) in crankcase breather cover. 3. Install packing (A) and screen.TM310.34 -19-04AUG87 2. -UN-29AUG88 3TN75 Shown M21.Valve Train and Camshaft/Rocker Arm ASSEMBLE AND INSTALL ROCKER ARM COVER 1. A—Baffle B—O-Ring C—Crankcase Breather Tube D—Crankcase Breather Cover 3TN75 Shown M21.35 -19-04AUG87 CTM3 (03JAN90) 10-18 3TN/4TN Series Yanmar Engines 010897 PN=65 M37498 -UN-29AUG88 M35328 -UN-29AUG88 M37499 -UN-29AUG88 M35329 10 18 . Install a new gasket on baffle. Install baffle (A) and fasten with four lock washers and screws. Install crankcase breather tube (C) and O-ring or gasket (B). Install crankcase breather cover (D) and fasten with two cap screws.TM310.

.TM310.TM310.36 -19-28AUG87 M21.016 in. . 0. . . . . . .40 mm (0. . If end play exceeds specifications. . 3. CAMSHAFT END PLAY SPECIFICATIONS (MAX) All except 4TN100 .) 5.) 4. . . . Install rocker arm cover. .) 4TN100 .) -UN-29AUG88 2. . . . . . . . . . . . Install O-ring (C) on oil fill cap (B). . . . . 0. . . . . . . Remove timing gear cover. .011 in. . . . . . (See Group 10 in this manual. 7. . . Measure camshaft end play. . . .) -UN-06SEP88 CTM3 (03JAN90) 10-19 3TN/4TN Series Yanmar Engines 010897 PN=66 M37512 M35270 M35298 10 19 . . and pushrods.Valve Train and Camshaft/Camshaft 4. alternator belt. . . rocker arm assembly. -UN-29AUG88 M21. . replace camshaft thrust plate.29 mm (0. if equipped. 18 N·m (160 lb-in.43A -19-05AUG87 6. Remove fan.TM310. . . 5. . Install an O-ring (A) on each special nut. . .) REMOVE CAMSHAFT 1. . Remove rocker arm cover. . . . . . . . . . . (See Machine Technical Manual. . install cap screws and tighten to specification. (See Group 35 in this manual. install special nuts and tighten to specification. . . . . . . . . . . TORQUE SPECIFICATIONS All except 4TN100 . . . . . and alternator. 26 N·m (226 lb-in. . . . . . For 4TN100 engine. . . . For all engines except 4TN100. . .37A -19-04AUG87 M21. . . . Remove engine. . . . . Install oil fill cap. . .) 4TN100 .

IMPORTANT: DO NOT allow camshaft lobes to hit bearing surfaces while removing camshaft.TM310. turn engine until oil pan is upward. Hold cam followers away from camshaft using a magnetic follower holder kit such as JT01783.TM310. CTM3 (03JAN90) 10-20 3TN/4TN Series Yanmar Engines 010897 PN=67 M35279 -UN-29AUG88 M37514 M37513 10 20 -UN-06SEP88 . 9. Remove two cap screws and carefully remove camshaft.) M21. (See Group 35 in this manual for backlash specifications. measure camshaft gear backlash. Check backlash of other timing gears.Valve Train and Camshaft/Camshaft 6. -UN-06SEP88 M21. Turn engine on engine stand with flywheel side down.44A -19-05AUG87 NOTE: If a magnetic follower holder kit is not available.TM310. If end play is correct. 8. to hold cam followers away from camshaft. Machined surfaces can be damaged. replace these gears as necessary.45A -19-05AUG87 M21.46A -19-05AUG87 7.

. . . . . . . .TM310. . . . . . . M35280 10 21 . . . SPECIFICATIONS (MIN) 3TN66 . . . . the camshaft has only one intermediate journal. . . . . Remove thrust plate (B). replace if necessary. . 39.80 mm (1. . . . . . . . . . CTM3 (03JAN90) 10-21 3TN/4TN Series Yanmar Engines 010897 PN=68 M35282 -UN-29AUG88 NOTE: For some engines. . . . CAMSHAFT END AND INTERMEDIATE JOURNAL O.Valve Train and Camshaft/Camshaft DISASSEMBLE AND INSPECT CAMSHAFT 1. . . . . . . . . . .80 mm (2. . . .) 3TN75/3TN78/3TN82/3TN84/ 4TN78/4TN82/4TN84 . . . . . . Remove gear using 11/16-in. 2. 40. .48 -19-28AUG87 4.D. . . . . . .) 4TN100 . . . . . . .) If end journal diameter or intermediate journal diameter is less than wear tolerance replace camshaft. . . . . . . .764 in. . and intermediate journal diameter (B). . . . . . . . . . .569 in. . . . -UN-29AUG88 M21. .TM310. Measure camshaft end journal diameter (A). 35.47 -19-18FEB86 M21. . .1 (1.411 in. 3.) 3TNA72 . . 44. . .) 3TNA72 (Flywheel End) . .236 in. . . . . . . . . . . . .579 in. Inspect gear for chipped or broken teeth. driver disk (A) and a press. 56. . . . . . . . . . . IMPORTANT: Be sure to hold camshaft while removing camshaft gear.85 mm (1.85 mm (1. .

Use a chisel to remove bushing. . . . . . . . . . . . . . . . . . . . . . 38. . . 57. . . . . . . . . .) 3TN75/3TN78/3TN82/3TN84/ 4TN78/4TN82/4TN84 . 33. . .) 3TNA72 . . . . CAMSHAFT BUSHING I. . .) 3TNA72 . . . .776 in. . .10 mm (1. . . .815 in. . . . . . . . . . . . . . .171 in. . 40. .D. . . . . Be careful not to push bushing inside of engine. . . . . . . . . . replace camshaft. . . . .10 mm (1. . .) -UN-01NOV88 M21. . . . . . . . .10 mm (1. . . . .40 mm (1.512 in. . . .50 -19-28AUG87 If height is less than wear tolerance. . . 45. . . . . . . . . . . . .TM310. . . . . . . . . . .) 4TN100 . . . . . . . .75 mm (1. . .49 -19-28AUG87 M21. . . replace bushing. . . . . . . . . .10 mm (2. 46. . . . 6. . . . . . . . . Measure gear housing side camshaft bushing diameter. . . .TM310. 29.) 3TN75/3TN78/3TN82/3TN84/ 4TN78/4TN82/4TN84 . . . . . . . . . . .) -UN-29AUG88 If diameter exceeds wear tolerance. .329 in. . . . -UN-29AUG88 CTM3 (03JAN90) 10-22 3TN/4TN Series Yanmar Engines 010897 PN=69 M35285 M35284 T81262 10 22 . . .) 4TN100 . . .579 in. . . . . .75 mm (1. . .Valve Train and Camshaft/Camshaft 5.10 mm (1. Measure camshaft lobe height. CAMSHAFT LOBE HEIGHT SPECIFICATIONS (MIN) 3TN66 . SPECIFICATIONS (MAX) 3TN66 . . .248 in. . . . . . .421 in. . . . . 36. . . . .

. 45. . . . . . . . .10 mm (2. . . . Remove plug using a wooden dowel. . . . . . .10 mm (1. Remove plug from gear housing side. . 36. . 40. . . . . . . . .10 mm (1. . .) -UN-29AUG88 M21.D. . . SPECIFICATIONS (MAX) 3TN66 .51 -19-18FEB86 If diameter exceeds wear tolerance.) b. . . . . .) 4TN100 . replace cylinder block. 57. . . . . Remove flywheel assembly.TM310. . . CAMSHAFT BORE I. . . Measure camshaft intermediate bore diameter. . . . . 8. . . .) 3TNA72 .248 in. CTM3 (03JAN90) 10-23 3TN/4TN Series Yanmar Engines 010897 PN=70 M35287 -UN-29AUG88 M35286 10 23 . . . . . . . .10 mm (1. . . . .Valve Train and Camshaft/Camshaft 7. . . (See Group 15 in this (manual. . . . . . . . .) 3TN75/3TN78/3TN82/3TN84/ 4TN78/4TN82/4TN84 .421 in. . . . . .776 in. . . . . .TM310. . . . . . .579 in. . . . .64 -19-28AUG87 M21. . . . . Measure the other intermediate and flywheel side camshaft bore diameters using the following procedure: a. .

. .) -UN-29AUG88 .) d. .10 mm (1. . . cylinder block. . . . . . .TM310. . . . . . . . . . . . . . . . . . . . . . . . .) Intermediate and Flywheel End Clearance . . . . . . . . . . c. . . .421 in. . . . . . . . . . . . . . 45. If clearance exceeds wear tolerance replace camshaft. 0. . . .14 mm (0. . . . . .) 4TN100 Gearcase End . .52 -19-28AUG87 CTM3 (03JAN90) 10-24 3TN/4TN Series Yanmar Engines 010897 PN=71 M35288 10 24 3TNA72 .) 3TN75/3TN78/3TN82/3TN84/ 4TN78/4TN82/4TN84 . . . . . . . .10 mm (1. . . . . . . CAMSHAFT BORE I. . . 0. . . . .006 in. . . . 40. . . . . . . or both. . . Measure intermediate and flywheel side camshaft bore diameters. . . . 36. 57. .18 mm (0. . . . . . replace cylinder block. . . .10 mm (2. . . . .005 in. . .) 4TN100 .D. . . . . . . .) If diameter exceeds wear tolerance. .10 mm (1. . . . . . .776 in. . .579 in. . . . . .248 in. . . . . . . . .007 in. . . CAMSHAFT JOURNAL CLEARANCE SPECIFICATIONS (MAX) All except 4TN100 . 0. Determine camshaft journal clearance (bushing. SPECIFICATIONS (MAX) 3TN66 . .12 mm (0. .Valve Train and Camshaft/Camshaft NOTE: Some engines do not have an intermediate journal on the flywheel side. . . . . . . . M21. . . . . or bore diameter minus journal diameter).

Align slot in gear with key in shaft.53 -19-28AUG87 M21.54 -19-19FEB86 CAUTION: DO NOT heat oil over 182˚C (360˚F). 2. Heat the oil in a well-ventilated area. driver disk (A) and a press. 3. Use a cylinder block and cylinder head gasket kit when assembling the engine. 2. Install thrust plate (B) on camshaft. remove gear and repeat steps 1—5. if it does not. Use a thermometer. Do not allow a flame or heating element to come in direct contact with the oil. Put gear with timing mark side downward on press table. 4. Plan a safe handling procedure to avoid burns. Thoroughly clean and dry all parts. Push camshaft gear tight against camshaft shoulder using 1 11/16 in. Install plug flush with surface of cylinder block. Apply gasket maker or an equivalent on outer edge of plug.TM310.Valve Train and Camshaft/Install ASSEMBLE CAMSHAFT N -UN-23FEB89 M21.TM310. 5. 1. Thrust plate must spin freely on camshaft. IMPORTANT: Be sure thrust plate is not between camshaft gear and camshaft shoulder while installing gear. 6. 3. T81191 10 25 INSTALL CAMSHAFT 1. CTM3 (03JAN90) 10-25 3TN/4TN Series Yanmar Engines 010897 PN=72 M35287 -UN-29AUG88 M35281 -UN-29AUG88 . Oil fumes or oil can ignite above 193˚C (380˚F). Heat camshaft gear to approximately 150˚C (300˚F).

) 5.TM310.55 -19-28AUG87 CTM3 (03JAN90) 10-26 3TN/4TN Series Yanmar Engines 010897 PN=73 M35291 M35289 10 26 Engine (B) Size (in.Valve Train and Camshaft/Install 4. Align oil holes (A) in bushing and cylinder block.) (C) -UN-29AUG88 . Install bushing flush with surface of cylinder block using the correct driver disks (B and C). (See Group 15 in this manual. DISK DIAMETERS 3TN66 3TNA72 3TN75/3TN78/3TN82/ 3TN84/4TN78/ 4TN82/4TN84 4TN100 1 7/16 1 9/16 1 1/2 1 11/16 1 3/4 2 1/4 1 7/8 2 3/8 -UN-29AUG88 M21. Install flywheel assembly.

-UN-06SEP88 IMPORTANT: DO NOT allow camshaft lobes to hit bearing surfaces while installing camshaft. Remove snap ring (C) and washer (D) to remove idler gear (B). Install idler gear shaft. Put clean engine oil on camshaft bearing journals. Carefully install camshaft (E). Remove idler gear (B). Align timing marks (A) and install idler gear. Remove two cap screws (F) to remove idler gear shaft (G) and idler gear (B).TM310. Align timing marks (A) and install idler gear. 8. Carefully install camshaft (E). Install washer and snap ring.Valve Train and Camshaft/Install 6. Align timing marks (A) and install idler gear. Carefully install camshaft (E). Machined surfaces can be damaged.56 -19-28AUG87 CTM3 (03JAN90) 10-27 3TN/4TN Series Yanmar Engines 010897 PN=74 M37518 -UN-06SEP88 M37517 -UN-06SEP88 M37516 -UN-06SEP88 M37515 10 27 . Align timing marks (A) and install idler gear. Carefully install camshaft (E). Install and tighten two cap screws to 26 N·m (226 lb-in. Remove snap ring (C) and washer (D) to remove idler gear (B). Turn engine on engine stand with flywheel side down.) A—Timing Marks B—Idler Gear C—Snap Ring D—Washer E—Camshaft F—Cap Screws G—Idler Gear Shaft 3TNA72 (Early Units) 3TNA72 3TN66 All except 3TN66/3TNA72 M21. Install washer and snap ring. 7.

.Valve Train and Camshaft/Install 9. Install and tighten two cap screws to specifications. . and rocker arm cover. . . . .57A -19-28AUG87 . . . Install timing gear cover. . .) -UN-29AUG88 M21. . . . . . . (See Group 10 in this manual. . rocker arm assembly. . . .TM310. 26 N·m (226 lb-in. .) 11. . . . . CAMSHAFT CAP SCREW TORQUE SPECIFICATIONS 3TN66/3TNA72 . . (See Group 35 in this manual. . . . .) CTM3 (03JAN90) 10-28 3TN/4TN Series Yanmar Engines 010897 PN=75 M35292 10 28 10. . . .) . . . . . Install push rods. All except 3TN66/3TNA72 11 N·m (96 lb-in. . . .

SERVICEGARD™ Catalog or from the European Microfiche Tool Catalog (MTC). Valves.1 -19-05AUG87 CTM3 (03JAN90) 15-1 3TN/4TN Series Yanmar Engines 010897 PN=76 . and Manifolds ESSENTIAL TOOLS NOTE: Order tools from the U.Group 15 Cylinder Head. Some tools may be available from a local supplier.S. Number Name Use D-20018WI Valve Guide Knurler To knurl valve guides on 3TNA72/3TN75 engines To knurl valve guides on 3TN82/3TN84/4TN82/4TN84 engines To ream valve guides on 3TNA72/3TN75 engines To ream valve guides on 3TN82/3TN84/4TN82/4TN84 engines Remove and install valve guide on 3TNA72/3TN75/3TN82/3TN84/4TN82/4TN84 engines Remove and install valve guides on 3TN66 engines To knurl valve guides on 4TN100 engine To ream valve guides on 4TN100 engine D-20019WI Valve Guide Knurler D-20020WI Valve Guide Reamer 15 1 D-20021WI Valve Guide Reamer JDE-118 Valve Guide Driver JDG-504 Valve Guide Driver 9 mm Knurler 9 mm Reamer M21.TM315.

Cylinder Head. Valves. Remove four nuts to remove exhaust pipe or muffler and gasket (A).2 -19-22APR86 15 2 Outside Micrometer Valve Guide Brush Ball Gauge Vernier Calipers Valve Seat Grinder Feeler Gauge Spring Compression Tester SERVICE PART KITS The following kits are available through your parts catalog: Cylinder Head Gasket Kit M21.TM315. AND INSTALL EXHAUST MANIFOLD 1.TM315. and Manifolds/Exhaust Manifold SERVICE EQUIPMENT AND TOOLS NOTE: Order tools from the U. SERVICEGARD™ Catalog or from the European Microfiche Tool Catalog (MTC). M21.S.6 -19-19FEB86 CTM3 (03JAN90) 15-2 3TN/4TN Series Yanmar Engines 010897 PN=77 M35482 -UN-06SEP88 .TM315. Some tools may be available from a local supplier. Name Use Depth Gauge Valve Spring Compressor Valve Inspection Center Measure valve recession Remove and install valves Measure valve out-of-round Measure valves Clean valve guide internal bores Measure valve guide internal bores Measure Valve seat width Recondition valve seat Measure cylinder head flatness Check valve springs M21.3 -19-19FEB86 REMOVE. REPAIR.

. . Inspect manifold and gasket for cracks and holes. Tighten nuts and cap screws to specifications. Remove cap screws.7 -19-19FEB86 M35443 15 3 5. .TM315.) -UN-06SEP88 M21. 7. . . .9 -19-22APR86 All except 3TN66 . 3. . Fasten exhaust pipe or muffler with four nuts. . -UN-06SEP88 CTM3 (03JAN90) 15-3 3TN/4TN Series Yanmar Engines 010897 PN=78 M35482 -UN-06SEP88 M35483 M35444 . . . .Cylinder Head. . and exhaust manifold. . . After engine is at normal operating temperature. . and Manifolds/Exhaust Manifold NOTE: Exhaust manifold can be removed with engine in the tractor. . . . . . . . . Start engine and check exhaust system for leaks. .8 -19-05AUG87 M21. . .TM315. . . 11 N·m (96 lb-in. . . Install a new gasket (A). Install gasket. Remove gasket material. . retighten exhaust manifold cap screws and nuts to specifications. . . 4. . . Valves. . . Replace or repair as necessary. -UN-06SEP88 M21. . . . Tighten nuts. .TM315. 26 N·m (226 lb-in. . and cap screws.) 6. manifold. . . nuts. 8. nuts. . . . . . . . . 2. EXHAUST MANIFOLD CAP SCREW AND NUT TORQUE SPECIFICATIONS 3TN66 .

Tighten cap screws to specifications. AND INSTALL INTAKE MANIFOLD NOTE: Intake manifold can be removed with engine in the tractor. M35446 M21. . . . .) CTM3 (03JAN90) 15-4 3TN/4TN Series Yanmar Engines 010897 PN=79 M35448 -UN-06SEP88 M35447 -UN-06SEP88 .10 -19-19FEB86 M21. Replace or repair as necessary. . Remove cap screws and intake manifold.) -UN-06SEP88 . . INTAKE MANIFOLD CAP SCREW TORQUE SPECIFICATIONS 3TN66/3TNA72 . . . . 26 N·m (226 lb-in. . . . . REPAIR. . . . . Remove gasket material. .Cylinder Head. . . All except 3TN66/3TNA72 11 N·m (96 lb-in. . Install new gasket. Valves. . .TM315. . . . . 2. and cap screws. manifold. . . . . . and Manifolds/Intake Manifold REMOVE. . 3.11 -19-05AUG87 15 4 4. . . Inspect manifold for cracks and holes.TM315. . . . 1. . .

12 -19-05AUG87 7.Cylinder Head. Remove cover (B). Valves.) 4. M21.13 -19-19FEB86 8. and Manifolds/Cylinder Head REMOVE CYLINDER HEAD NOTE: Cylinder head can be removed with engine in the tractor. if equipped. Remove lines (G) and nozzles (F).) 6.14 -19-19FEB86 CTM3 (03JAN90) 15-5 3TN/4TN Series Yanmar Engines 010897 PN=80 M35300 -UN-29AUG88 M35401 -UN-06SEP88 M35299 -UN-29AUG88 . (See Group 10 in this manual. 1.TM315. Remove manifold (E). (See Group 50 in this manual. If cylinder head is removed for valve service only. and F). rocker arm assembly. (See Group 15 in this manual. M21. and pushrods. Remove glow plugs (D). 5. D. do not remove parts (A. Remove pump (C).) 2. Remove valve caps.) 3. (See Group 45 in this manual.TM315. E. (See Group 15 in this manual.TM315.) A—Exhaust Manifold B—Rocker Arm Cover C—Water Pump D—Glow Plugs E—Intake Manifold F—Fuel Injection Nozzles G—Fuel Injection Lines 15 5 M21. if equipped. Remove manifold (A). Remove cap screws to remove cylinder head and gasket.

TM315. Valves. Remove two lifting brackets. remove studs using exhaust manifold nuts.15 -19-05AUG87 M21.16 -19-05AUG87 CTM3 (03JAN90) 15-6 3TN/4TN Series Yanmar Engines 010897 PN=81 M35302 -UN-29AUG88 M35301 .TM315.Cylinder Head. If equipped. -UN-29AUG88 15 6 2. and Manifolds/Cylinder Head DISASSEMBLE CYLINDER HEAD 1. M21.

Remove retainers.18 -19-19FEB86 Inspect retainers for groove.) 0.00 mm (0.) Wear Tolerance (MAX) -UN-29AUG88 0.50 mm (0.85 mm (0.039 in.) 0.40 mm (0.039 in.012—0. VALVE RECESSION SPECIFICATIONS Intake 3TN66 3TNA72 3TN75/3TN78/ 3TN82/3TN84/ 4TN78/4TN82/ 4TN84 Standard 0.071 in.Cylinder Head.020 in.TM315.) 1. Measure valve recession.071 in.50 mm (0.033 in.020 in. Release spring pressure and remove compressor.) Standard 0.50 mm (0.30—0.80 mm (0.020 in.30—0.) 1. -UN-29AUG88 M21.033 in. Compress valve springs using a valve spring compressor.00 mm (0.17 -19-28AUG87 4. CTM3 (03JAN90) 15-7 3TN/4TN Series Yanmar Engines 010897 PN=82 M35304 .012—0. Valves. or damage on outside surface and wear or damage to inside tang. wear. and Manifolds/Cylinder Head 3.85 mm (0.) M35303 15 7 Wear Tolerance (MAX) 4TN100 Exhaust 3TN66 3TNA72 3TN75/3TN78/ 3TN82/3TN84/ 4TN78/4TN82/ 4TN84 0.) 1.) 1.80 mm (0.016 in. Replace retainers as necessary.TM315.) 4TN100 M21.

) 24 mm (0.) 4TN100 42.992 in. SPRING SPECIFICATIONS Engine 3TN66 Measurement Free length (approx) Test length at 125 N (28 lb) Force Free length (approx) Test length at 299 N (67 lb) Force Free length (approx) Test length at 313 N (70 lb) Force Free length (approx) Test length at 319 N (72 lb) Force Free length (approx.) Test length at 12.591 in.5 mm (1.9 mm (1.19 -19-28AUG87 CTM3 (03JAN90) 15-8 3TN/4TN Series Yanmar Engines 010897 PN=83 M35305 -UN-29AUG88 .) 3TN82/3TN84/ 4TN82/4TN84 41.) 25. If spring strength is not correct.634 in.5 mm (0.) 17 mm (0.) 3TN75/ 3TN78/ 4TN78 41.5 mm (1.945 in.) M21. Remove spring retainers (A) and springs.5 mm (1. and Manifolds/Cylinder Head 5.634 in. Inspect springs for damaged or weak coils.) 22.453 in. 6.673 in. Check spring using a spring compression tester.) 15 8 3TNA72 36. Valves.Cylinder Head.) 41.083 in.5 mm (1.TM315. install new spring.634 in.7 lb) Force Wear Tolerance (MAX) 27.6 N (5.886 in.5 mm (1.2 mm (0.

. . . 10. bent.311 in. . . M21. .) 3TN82/4TN82/4TN84 . . . Remove scratches from valve stems using steel wool or crocus cloth. . . . . . . . 7. . .Cylinder Head. . . . .90 mm (0. . .TM315. . . . . . . . . M21. or warped condition using a valve inspection center. . . .40 mm (0.272 in. corrosion. . . . . . . .90 mm (0. . Remove intake and exhaust valves. 5. . Inspect valve for damage. 9. . . . . . Valves. . and stem using a soft wire wheel on a bench grinder. . . SPECIFICATIONS (MIN) 3TN66 . . . 11.TM315. . . .90 mm (0. 6. . 8. Check valve for out-of-round. .TM315. .21 -19-19FEB86 12. .22 -19-28AUG87 CTM3 (03JAN90) 15-9 3TN/4TN Series Yanmar Engines 010897 PN=84 M35308 M35307 -UN-29AUG88 .20 -19-19FEB86 M35306 -UN-29AUG88 15 9 8. .) 4TN100 . Clean carbon from valve face. or burned face. . . . . .) -UN-29AUG88 M21. . . pitting. . VALVE STEM O. . . . .213 in. . and Manifolds/Cylinder Head 7. . . . . . . . . . . .) 3TNA72/3TN75/3TN78/4TN78 . . . head. Measure valve stem diameter.350 in. . .D.

. . . .Cylinder Head. . If valve face margin (B) is less than 0. . . . . . . 30˚ -UN-29AUG88 M21. . . . .TM315. . . . . . . .TM315.) after grinding. If necessary. . . . . . VALVE ANGLE Exhaust Valve . 14.51 mm (0. . . . . . .020 in. . . . . grind valves to proper face angle (A) following manufacturers instructions. . Valves.25 -19-19FEB86 15 10 IMPORTANT: Do not reuse valve stem seals if seals are removed. . CTM3 (03JAN90) 15-10 3TN/4TN Series Yanmar Engines 010897 PN=85 M35310 -UN-29AUG88 M35309 -UN-29AUG88 M36267 . . and Manifolds/Cylinder Head 13. . . . . 15. . . . . remove valve stem seal and discard. If valve faces are worn. . . . . Clean valve guides using a valve guide brush. . . . . .23 -19-22APR86 M21. . 45˚ Intake Valve . . . . .24 -19-22APR86 M21. . .TM315. . . . burned or pitted. . replace valve. . .

4TN100 . .27 -19-28AUG87 If clearance exceeds 0.20 mm (0. knurl or replace valve guide. . . . . and Manifolds/Cylinder Head 16. .279 in. . 18. . . . -UN-29AUG88 M21.26 -19-05AUG87 M21.).319 in. 3TNA72/3TN75/3TN78/4TN78 3TN82/3TN84/ 4TN82/4TN84 . VALVE GUIDE KNURLERS Engine 3TN72/ 3TN75/3TN78/ 4TN78 3TN82/3TN84/ 4TN82/4TN84 4TN100 Number D-20018WI D-20020WI D-20019WI D-20021WI 9 mm 9 mm Item Knurler Reamer Knurler Reamer Knurler Reamer M35312 -UN-29AUG88 CTM3 (03JAN90) 15-11 3TN/4TN Series Yanmar Engines 010897 PN=86 M35311 . . . .20 mm (0.008 in. . . . . . .220 in. . . replace valve guide.D.58 mm (0. . . . VALVE GUIDE SPECIFICATIONS Guide I. .10 mm (0.TM315. . . 17. 9.Cylinder Head.006 in. . . . . 7. . . . . . knurl valve guide. . . . . . . . . .006 in. . . .008 in. .) 15 11 If valve guide diameter exceeds wear tolerance. . . . . . . determine guide-to-stem clearance (guide diameter minus stem diameter). . . . . .) . . If diameter is correct. . 8. .15 mm (0. .358 in. . . . . . . . . . . . If clearance exceeds 0. . .) but is less than 0. Follow tool manufacture’s instructions. . .10 mm (0. . . . (MAX) 3TN66 . . .). .) Clearance (MAX) All Engines . . . Measure valve guide diameter. . . . . . . . . . . . . . Knurl valve guide using a valve guide knurler. . .15 mm (0. 5. Valves. .08 mm (0. 0. .TM315.) . .) . . .

pits.) 1.) 1.108 in.) 1. 22.27 mm (0.16 mm (0. remove valve guides using JDE-118 or JDG-504 (3TN66UJ Engine only) Valve Guide Driver.94 mm (0. or excessive wear.) Wear Limit (MAX) 1.057 in.070 in.28 -19-20FEB86 Intake Exhaust If necessary.44 mm (0. 15 12 20. Measure valve seat width. VALVE SEAT WIDTH SPECIFICATIONS Engine 3TN66 Valve Intake Exhaust 3TNA72/ 3TN75/3TN78/ 4TN78 3TN82/ 3TN84/ 4TN82/4TN84 4TN100 Intake Exhaust Intake Exhaust Nominal 1.065 in.35 mm (0.91 mm (0.084 in.) 2. Clean carbon from valve seats using a wire brush and an electric drill.47 mm (0.) 1.01 mm (0.058 in.) 2.73 mm (0.056 in.) M21. Inspect valve seats for cracks.) 1.41 mm (0.075 in.076 in.045 in.TM315.) 1.29 -19-28AUG87 CTM3 (03JAN90) 15-12 3TN/4TN Series Yanmar Engines 010897 PN=87 M35314 -UN-29AUG88 M35313 -UN-29AUG88 . 21.) 1.079 in.) 2.74 mm (0. and Manifolds/Cylinder Head 19. M21.TM315.) 1.046 in.053 in.98 mm (0. grind valve seats to recondition or to meet specifications.) 2. If necessary.069 in. Valves.15 mm (0.Cylinder Head.) 1.089 in.77 mm (0.078 in.) 1.12 mm (0.65 mm (0.

26. Grind intake valve seat using a 30˚ seat grinder and exhaust valve seat using a 45˚ seat grinder. -UN-30NOV88 CTM3 (03JAN90) 15-13 3TN/4TN Series Yanmar Engines 010897 PN=88 RW539 -UN-30NOV88 NOTE: Valve seat inserts are available for 3TNA72 and 3TN75 engines only. Measure valve seat width after grinding. Grind upper seat surface using a 15˚ Seat grinder (B) until seat width (A) is narrowed to specifications. If valve recession exceeds maximum specifications or seats cannot be reconditioned. Valve seats should be ground and lapped. and Manifolds/Cylinder Head IMPORTANT: Valve seats should never be cut. measure valve recession and check contact pattern between the seat and valve with bluing dye. Cutting a valve seat can damage its sealing surface. valve seats and/or cylinder head. RW538 R26143N . Valves. replace valves.Cylinder Head. If seat is too wide after grinding. grind lower seat surface using a 70˚ seat grinder (B) until seat width (A) is close to specifications.TM315. 23. Follow tool manufactures instructions.30 -19-22APR86 M21. which may result in leaks or valve/seat failure. If valve seats are ground. -UN-09DEC88 M21. 25.31 -19-22APR86 15 13 24. NOTE: LIGHTLY grind valve seats for a few seconds only to avoid excessive valve seat width.TM315.

.00 mm (0. . . . -UN-29AUG88 M21. 15. .Cylinder Head. . . . . . . . . . . . . . .15 mm (0. . . . . .32 -19-28AUG87 M21. . . . . . . . . . . . .002 in. . with grooves upward. .) 4TN100 . . . . . but do not remove more than 0. VALVE GUIDE HEIGHT SPECIFICATIONS 3TN66 . 11. . . and Manifolds/Cylinder Head 27.354 in. . Use a cylinder head gasket kit when assembling the engine. . 29.) 3TNA72 . 9. . .). . . .591 in. . . . .50 mm (0. . . . . . . . . ASSEMBLE CYLINDER HEAD 1. . . . . . . . Measure cylinder head flatness in several directions. . Thoroughly clean and dry all parts. . . . . . . .) 3TN82/3TN84/ 4TN82/4TN84 . . . . . . using JDE-118 or JDG-504 (3TN66 Engine only) Valve Guide Driver. . . . . . . . . . .008 in. . . Install valve guides. . .00 mm (0.20 mm (0. Inspect cylinder head for cracks or discoloration.33 -19-29AUG87 28. . CYLINDER HEAD FLATNESS SPECIFICATIONS (MAX) All except 4TN100 . . Thoroughly clean cylinder head in solvent. . . resurface or replace cylinder head. .006 in. .05 mm (0. . . . . . . .00 mm (0. 12. . . . . . . . .) M37520 -UN-06SEP88 -UN-29AUG88 CTM3 (03JAN90) 15-14 3TN/4TN Series Yanmar Engines 010897 PN=89 M35313 M35316 . . Carefully clean carbon deposits from combustion chamber and gasket surface with a soft wire brush. . . . . . . .472 in.) 15 14 If cylinder head distortion exceeds specification. . . .453 in. . . Push valve guide down until top of valve guide is specified distance above machined surface of cylinder head. 0. If cylinder head is milled down to head flatness specification. .00 mm (0. . . . . . . .) 3TN75/3TN78/4TN78 .) 4TN100 . Remove only enough metal to make cylinder head flat. . Valves. . .276 in.TM315. . . . . . . . . 0. . . . . . .TM315. . . . measure valve recession. . . . . . 2. . . 7. . . . . . . . .

37 -19-20FEB86 If new valves are installed. -UN-29AUG88 M21. 7. If necessary.TM315.Cylinder Head.34 -19-20FEB86 M35318 15 15 IMPORTANT: Do not reuse valve stem seals if seals were removed. CTM3 (03JAN90) 15-15 3TN/4TN Series Yanmar Engines 010897 PN=90 M35305 -UN-29AUG88 M35306 M35319 .TM315. Install intake and exhaust valves -UN-29AUG88 M21. and Manifolds/Cylinder Head 3.TM315.TM315. and spring retainers (A).36 -19-20FEB86 M21. Valves. Grind valve seats as required. measure valve recession. -UN-29AUG88 M21. with smaller pitch end (paint mark) toward cylinder head. Put clean engine oil on valve stems. 8. Measure new valve guide diameter. ream inside diameter of valve guides to specifications using a valve guide reamer. Install springs. Install new valve stem seals. 4. 5.35 -19-20FEB86 6.

Use exhaust manifold nuts to turn studs until studs bottom out. M21. with short threaded end in cylinder head. install studs.TM315. -UN-29AUG88 M21. and Manifolds/Cylinder Head 9. Valves. Install two lifting brackets.TM315.38 -19-20FEB86 M21.TM315. Install retainers.Cylinder Head. M21.39 -19-20FEB86 11. Hit valve stems lightly to seat the retainers. Release spring pressure and remove compressor. If used. Compress valve springs using a valve spring compressor.40 -19-06AUG87 12. -UN-29AUG88 15 16 10.41 -19-06AUG87 CTM3 (03JAN90) 15-16 3TN/4TN Series Yanmar Engines 010897 PN=91 M35301 -UN-29AUG88 M35302 M35320 -UN-29AUG88 M35304 .TM315.

. 78 N·m (58 lb-ft) 4TN100 . . . . . . . . . . . . . IMPORTANT: Cylinder head cap screws must be checked for proper torque after 50 hours of engine operation. . . . . . . 69 N·m (51 lb-ft) 3TN82/3TN84/ 4TN82/4TN84 . . . . . . and Manifolds/Cylinder Head INSTALL CYLINDER HEAD IMPORTANT: Oil passage (A) in gasket must be located over oil passage in block. . . . . . . . . . . . . . . . . . . . . . in three stages of gradually-increasing torque: • First stage—tighten all cap screws to 31% of specified torque. . . . . . . . . . . . . . 3-Cylinder Engines • Third stage—tighten all cap screws to final specified torque. . . Tighten cap screws. . .Cylinder Head. . .43 -19-06AUG87 CTM3 (03JAN90) 15-17 3TN/4TN Series Yanmar Engines 010897 PN=92 -UN-06SEP88 M35322 -UN-29AUG88 . . . . . . 34 N·m (25 lb-ft) 3TNA72 .42 -19-22APR86 M35321 15 17 2. . . . . 3. • Second stage—tighten all cap screws to 62% of specified torque. . . . . Install cap screws. . . . . . -UN-29AUG88 M21. . .TM315. . Install new gasket on cylinder block. Be sure to keep gasket dry. . . . 61 N·m (45 lb-ft) 3TN75/3TN78/4TN78 . . . . . . . . . . . . . . .TM315. Dip entire cylinder head cap screws in clean engine oil. . . . . . . . . . 157 N·m (116 lb-ft) M37521 4-Cylinder Engines A—Flywheel End M21. . . . . . . . Valves. . Install cylinder head on cylinder block. in the sequence shown. . . . . 1. . . . . . . CYLINDER HEAD CAP SCREW TORQUE SPECIFICATIONS 3TN66 . . . . . . .

Install nozzles (F) and lines (G). Valves. Install pushrods. (See Group 15 in this manual. and Manifolds/Cylinder Head 4. Install glow plugs (D).44 -19-06AUG87 M21. (See Group 45 in this manual. (See Group 10 in this manual.) A—Exhaust Manifold B—Rocker Arm Cover C—Water Pump D—Glow Plugs E—Intake Manifold F—Fuel Injection Nozzles G—Fuel Injection Lines M21. (See Group 50 in this manual. Install pump (C). and cover (B).TM315.Cylinder Head.) 7. Install manifold (E). If equipped.TM315. rocker arm assembly. install valve caps. 15 18 5.) 10.45 -19-20FEB86 CTM3 (03JAN90) 15-18 3TN/4TN Series Yanmar Engines 010897 PN=93 M35299 -UN-29AUG88 M35401 -UN-06SEP88 . Install manifold (A). 8.) 9. (See Group 15 in this manual.) 6.

remove four cap screws to remove stub shaft. 5.).1 -19-22APR86 REMOVE FLYWHEEL HOUSING AND FLYWHEEL 1.).20 mm (0.008 in. Name Use Dial Indicator Magnetic Base with Adjustable Arm Feeler Gauge Measure stub shaft TIR To hold dial indicator Measure flywheel flatness M21. While turning crankshaft.) 2. Maximum TIR is 0.S.TM320. If equipped. SERVICEGARD™ Catalog or from the European Microfiche Tool Catalog (MTC). If equipped. -UN-29AUG88 NOTE: Turn engine crankshaft using crankshaft pulley cap screw.TM320. remove nuts and cap screws to remove flywheel housing or flywheel shield.) 3. replace stub shaft. If equipped.Group 20 Flywheel SERVICE EQUIPMENT AND TOOLS NOTE: Order tools from the U. CTM3 (03JAN90) 20-1 3TN/4TN Series Yanmar Engines 010897 PN=94 M35332 -UN-29AUG88 M35331 M35330 .TM320. Remove engine (See Machine Technical Manual. measure stub shaft TIR (total indicator runout) using a dial indicator.3 -19-06AUG87 M21. Some tools may be available from a local supplier.5 -19-06AUG87 20 1 4.20 mm (0.TM320. (See Machine Technical Manual. -UN-29AUG88 M21.4 -19-06AUG87 M21. remove electric clutch assembly.008 in. If stub shaft TIR exceeds 0.

7 -19-06AUG87 9.TM320. M21. Remove cap screws to remove flywheel. Remove large-headed cap screws to remove mounting plate and seal (A).6 -19-03MAR86 7. Remove large-headed cap screws to remove mounting plate or housing.8 -19-06AUG87 CTM3 (03JAN90) 20-2 3TN/4TN Series Yanmar Engines 010897 PN=95 M37681 -UN-06SEP88 M35335 -UN-29AUG88 M35334 M35333 -UN-29AUG88 . If equipped remove two pins or studs (A). 3TN75 Shown M21. -UN-29AUG88 M21.TM320. 20 2 8.Flywheel/Flywheel Housing and Flywheel 6. Remove nuts or cap screws to remove starter.TM320.

3. inspect pilot bearing (A) for wear and smooth rotation.002 in. Replace bearing as necessary. Inspect flywheel ring gear for chipped or broken teeth.02 mm (0.Flywheel/Flywheel Housing and Flywheel INSPECT FLYWHEEL AND STUB SHAFT 1. -UN-29AUG88 M35336 M21. Check flywheel and stub shaft flatness using a straight edge and feeler gauge. Replace flywheel as necessary.0008 in. For 4TN100 engine. 4.) for stub shaft and 0.) for flywheel.05 mm (0.TM320.9 -19-28AUG87 CTM3 (03JAN90) 20-3 3TN/4TN Series Yanmar Engines 010897 PN=96 M51563 -UN-31AUG88 M35338 -UN-29AUG88 M35337 -UN-29AUG88 20 3 . 2. New part flatness specification is 0.

Install mounting plate. Install foam seal (3TN66/3TNA72 engines only).TM320.TM320.10 -19-06AUG87 20 4 2. Tighten cap screws to 49 N·m (36 lb-ft). -UN-06SEP88 3TN75 Shown M21.Flywheel/Flywheel Housing and Flywheel INSTALL FLYWHEEL AND FLYWHEEL HOUSING 1. Install mounting plate or housing. Tighten cap screws to 49 N·m (36 lb-ft). -UN-29AUG88 3TN66/3TNA72 M21.11 -19-06AUG87 CTM3 (03JAN90) 20-4 3TN/4TN Series Yanmar Engines 010897 PN=97 M37682 M35342 -UN-29AUG88 M35341 .

49 N·m (36 lb-ft) All except 3TN66 . 196 N·m (145 lb-ft) M35344 M21. Apply clean engine oil to cap screw threads and under head. . . Install starter and two nuts or cap screws. . . .TM320. IMPORTANT: Install new cap screws each time flywheel is removed. . Install flywheel and cap screws. . . . . FLYWHEEL CAP SCREW TORQUE SPECIFICATIONS All except 4TN100 . . . . . . . . . . . install two pins or studs (A). . . . . . . . . . . . . . . . Align hole (A) in flywheel with pin (B) in crankshaft. . . Tighten cap screws to specifications. . . . . STARTER CAP SCREW OR NUT TORQUE SPECIFICATIONS 3TN66 . . . 83 N·m (61 lb-ft) 4TN100 . . . 6. . .Flywheel/Flywheel Housing and Flywheel 3. . . .13 -19-06AUG87 -UN-29AUG88 CTM3 (03JAN90) 20-5 3TN/4TN Series Yanmar Engines 010897 PN=98 M35345 -UN-29AUG88 . . . . . . . . . . . . . . . . . . . . Tighten nuts or cap screws to specifications. . . . . . . . . . . 88 N·m (65 lb-ft) M35343 -UN-29AUG88 20 5 M21. . . . . . . . . . . . . If equipped. . . . . . 4. . .12 -19-28AUG87 5.TM320. . . . . . . . .

) 49 N·m (36 lb-ft) 26 N·m (226 lb-in. .) 88 N·m (65 lb-ft) 49 N·m (36 lb-ft) 26 N·m (226 lb-in. install stub shaft and four cap screws. 59 N·m (44 lb-ft) -UN-29AUG88 M21. . . . If equipped. . . STUB SHAFT CAP SCREW TORQUE SPECIFICATION All Engines . . nuts. . . .14 -19-06AUG87 M21. .) -UN-29AUG88 3TNA72 3TN75 CTM3 (03JAN90) 20-6 3TN/4TN Series Yanmar Engines 010897 PN=99 M35347 M35346 .TM320. .Flywheel/Flywheel Housing and Flywheel 7.15 -19-06AUG87 20 6 8. . . Tighten cap screws to specification. . . . FLYWHEEL HOUSING OR SHIELD TORQUE Engine 3TN66 Item Cap Screw (A) (2 used) Cap Screw (B) (6 used) Cap Screw (A) (2 used) Cap Screw (B) (5 used) Nut (C) (2 used) Cap Screw (A) (5 used) Cap Screw (B) (3 used) Specification 49 N·m (36 lb-ft) 26 N·m (226 lb-in. . . and cap screws. . .TM320. install flywheel housing or flywheel shields. . . . . If equipped. . .

3 -19-03MAR86 CTM3 (03JAN90) 25-1 3TN/4TN Series Yanmar Engines 010897 PN=100 . Measure piston bore I. Cylinder Head Gasket Kit.TM325.D.D.Group 25 Connecting Rods and Pistons SERVICE EQUIPMENT AND TOOLS NOTE: Order tools from the U. M21.TM325. Name Use Feeler Gauge Outside Micrometer Cylinder Bore Ridge Reamer Telescoping Gauge Piston Ring Expander Bushing. SERVICEGARD™ Catalog or from the European Microfiche Tool Catalog (MTC). To deglaze cylinder bores Install pistons in cylinder block M21.S. Bearing.1 -19-06AUG87 25 1 OTHER MATERIALS Name Use PLASTIGAGE® Measure connecting rod bearing clearance PLASTIGAGE is a trademark of the TRW Corporation M21.TM325.2 -19-22APR86 SERVICE PART KITS The following kits are available through your parts catalog: Cylinder Block Gasket Kit. and Seal Driver Set Vernier Calipers Inside Micrometer Flex Hone Piston Ring Compressor Measure clearances Measure engine components To remove ridge from top of cylinder bore Measure engine components Remove and install piston rings Remove and install connecting rod bushing Measure piston O. Some tools may be available from a local supplier.

9 -19-06AUG87 5. . . . . . . . . . .) -UN-29AUG88 M21. . . 0. . . . . . . . CONNECTING ROD SIDE PLAY SPECIFICATIONS (MAX) All except 4TN100 .) 3. . . 0. . Measure connecting rod side play. .) 2.022 in.) 4. Remove flywheel assembly (B).) 25 2 M21. . . . .45 mm (0. . .TM325.TM325. . .Connecting Rods and Pistons/Measure Side Play MEASURE CONNECTING ROD SIDE PLAY 1. . Remove engine. . remove electric clutch assembly (A). (See Machine Technical Manual. . replace connecting rod and connecting rod cap. .10 -19-28AUG87 If side play exceeds wear tolerance. . CTM3 (03JAN90) 25-2 3TN/4TN Series Yanmar Engines 010897 PN=101 M35349 M35453 -UN-06SEP88 . If equipped. . .55 mm (0. . Remove oil pan (C). .) 4TN100 . . . . . . . . (See Machine Technical Manual. . (See Group 40 in this manual. (See Group 20 in this manual.018 in. .

. M21. .13 -19-06AUG87 CTM3 (03JAN90) 25-3 3TN/4TN Series Yanmar Engines 010897 PN=102 M35352 M35351 . . . . . .Connecting Rods and Pistons/Measure Bearing Clearance MEASURE CONNECTING ROD BEARING CLEARANCE Measure each connecting rod bearing clearance. . . 23 N·m (200 lb-in. . . Turn crankshaft about 30˚ from BDC (bottom dead center). . . . . . .12 -19-03MAR86 25 3 4. . .TM325.) off center. . . . 2. . . Wipe oil from bearing insert and crankshaft journal. -UN-29AUG88 M21. . . .) 3TN75/3TN78/4TN78 . Put PLASTIGAGE (A) or an equivalent on the full length of the bearing insert about 6 mm (0. . . . . . . . . using the following PLASTIGAGE method or by measuring after the pistons have been removed: PLASTIGAGE Method IMPORTANT: Connecting rod end caps must be installed on the same connecting rod and in the same direction to prevent crankshaft and connecting rod damage. . . . . . . . . . . . . .25 in.TM325. 93 N·m (69 lb-ft) -UN-29AUG88 M21. . . 47 N·m (35 lb-ft) 4TN100 . . 39 N·m (29 lb-ft) 3TN82/3TN84/ 4TN82/4TN84 . . . . . . . . . . . . . . . . . . Tighten cap screws to specifications CONNECTING ROD CAP SCREW TORQUE SPECIFICATIONS 3TN66/3TNA72 . . 1. .TM325. . . . . . . . . . . . . . Install connecting rod cap and cap screws. Remove connecting rod cap. . . . . . .11 -19-22APR86 M35350 -UN-29AUG88 3. . . . . . . . . . .

Use the graduation marks on the envelope to compare the width of the flattened PLASTIGAGE at its WIDEST point. . . . .) 25 4 If clearance exceeds wear tolerance.15 -19-04MAR86 CTM3 (03JAN90) 25-4 3TN/4TN Series Yanmar Engines 010897 PN=103 M35353 -UN-29AUG88 . .) 3. .) M21. . . . . . . Install and tighten cap screws to specifications. If clearance is correct.TM325. 0. . . M21.006 in. Remove flywheel assembly (B). . 7. . . . . . . 0.14 -19-28AUG87 REMOVE PISTONS AND CONNECTING RODS 1.) Remove cylinder head. (See Machine Technical Manual.TM325. Remove engine. . . replace bearings. . (See Group 15 in this manual. . . . Determine bearing clearance. . . . . .) 2. CONNECTING ROD BEARING CLEARANCE SPECIFICATIONS 3TN66/3TNA72 . (See Group 20 in this manual.15 mm (0. Remove cap screws and connecting rod cap. (See Machine Technical Manual. . install connecting rod caps. 8. . . . .006 in. (See Group 40 in this manual. .09 mm (0. 0. . .) 4TN100 . . The number within the graduation marks indicates the bearing clearance in inches or in millimeters depending on which side of the envelope is used. Remove PLASTIGAGE. 6.16 mm (0. . . .) 3TN75/3TN78/3TN82/3TN84/ 4TN78/4TN82/4TN84 . . . . . . . The flattened PLASTIGAGE will be found on either the bearing or crankshaft journal.) 4. . . .Connecting Rods and Pistons/Pistons and Connecting Rods 5. If equipped. .004 in. . . . remove electric clutch assembly (A). . . . Remove oil pan (C).

M35354 -UN-29AUG88 25 5 M21. 9. CTM3 (03JAN90) 25-5 3TN/4TN Series Yanmar Engines 010897 PN=104 M35357 -UN-29AUG88 M35356 .16 -19-04MAR86 6.TM325. and dipstick (B). -UN-29AUG88 M21.TM325. Remove two cap screws to remove connecting rod cap. Remove two cap screws. Before piston removal. These ridges can cause damage to piston if ridge is not removed. If necessary. M21.17 -19-04MAR86 IMPORTANT: Connecting rod caps must be installed on the same connecting rod they were removed from. remove ridge from top of cylinder bore using a ridge reamer. check cylinder bore for ridges.18 -19-04FEB86 M21.19 -19-22APR86 8. 7.TM325.Connecting Rods and Pistons/Pistons and Connecting Rods 5. Push piston and connecting rod out of cylinder bore using a wooden dowel. oil suction strainer (A).TM325.

. . . . . . . .358 in. Measure crankshaft connecting rod journal diameter.010 in. . . 59. .92 mm (1. . . .20 -19-06AUG87 CTM3 (03JAN90) 25-6 3TN/4TN Series Yanmar Engines 010897 PN=105 M35358 2. . . . 35. . . . 39. 42. . . . NOTE: If engine has had a previous major overhaul.D.) 3TN75/3TN78/4TN78 . . .414 in. . . . . . . .25 mm (0. . . . Bearing inserts are available in 0. . . .90 mm (2. . . .) undersize. . . .91 mm (1.) If journals are ground. . . . .) 3TN82/3TN84/ 4TN82/4TN84 .Connecting Rods and Pistons/Pistons and Connecting Rods INSPECT PISTONS AND CONNECTING RODS 1. . .) 25 6 4TN100 . . . M21. . . connecting rod journals may have been ground and undersize bearing inserts installed. .886 in. . . .91 mm (1. If journal diameter is less than wear tolerance. . . . . . . .572 in. . . . . . .) 3TNA72 . . -UN-29AUG88 . . . . Measure several places around each journal and each side of every journal. . . CONNECTING ROD JOURNAL O. . . . . . . . . . . . . . . . . replace crankshaft or have journals ground undersize by a qualified machine shop. . . .TM325. . .689 in. . . . . 47. . . . . SPECIFICATIONS (MIN) 3TN66 . . . . undersize bearing inserts must be installed. . . . . . . .92 mm (1. . . . . .

. . . . . . . . . . . . . . . . grind crankshaft connecting rod journals and install undersize bearing inserts. . .006 in. . . 0. . . . . . . . .) 3TN75/3TN78/3TN82/3TN84/ 4TN78/4TN82/4TN84 . . . replace bearing inserts. . . .Connecting Rods and Pistons/Pistons and Connecting Rods 3. 60.420 in. . . bearings can be reused. 48. . .D. . . . 47 N·m (35 lb-ft) 4TN100 . . Tighten connecting rod cap screws to specifications. If bearing diameter and clearance are within specifications and bearings are not damaged. . . . . . CONNECTING ROD CAP SCREW TORQUE SPECIFICATIONS 3TN66/3TNA72 . . . . . . . minus journal O. 3TN75/3TN78/4TN78 3TN82/3TN84/ 4TN82/4TN84 . . . . 93 N·m (69 lb-ft) CONNECTING ROD BEARING SPECIFICATIONS -UN-29AUG88 M21. . . . . . . . . . . . . . . . 36. . . . . . . . . . . .07 mm (1. . . . . .578 in. . . . . . . 23 N·m (200 lb-in. . . Measure connecting rod bearing diameter and connecting rod bearing clearance (bearing I. . 39 N·m (29 lb-ft) 3TN82/3TN84/ 4TN82/4TN84 . . .07 mm (1. . . .07 mm (1. . . . . . . . . . . . . . . . . .) . . . . . . CTM3 (03JAN90) 25-7 3TN/4TN Series Yanmar Engines 010897 PN=106 M35359 Bearing I. . . . . 3TNA72 . . . . .) 4TN100 . . . . . . . . . . . .D. . . . . . . . .21 -19-28AUG87 Clearance (MAX) 3TN66/3TNA72 . (MAX) 3TN66 . . . . .) 25 7 . .TM325. .) 3TN75/3TN78/4TN78 . . . . .006 in. . . . . . . .) . . .10 mm (2. . . . . If bearing clearance exceeds wear tolerance. or replace bearing inserts and crankshaft. . . . . . . . . . . . . 0. . . . . . . . . .366 in. . . .16 mm (0. 43.) . . . . 4TN100 . . . 0. . 40. . . . . . . . . . .15 mm (0. . . . . . . . . .) . 4. .893 in. . . Install connecting rod cap and bearing insert on connecting rod. . . . .07 mm (1. . .696 in. . . .) If bearing diameter exceeds wear tolerance. . . . . .004 in.). . . . . . . . . . . . . . . . . . . . . . . .09 mm (0. . . .D.

006 in.23 -19-04FEB86 CTM3 (03JAN90) 25-8 3TN/4TN Series Yanmar Engines 010897 PN=107 M35361 -UN-29AUG88 M35360 -UN-29AUG88 If clearance exceeds wear tolerance. Measure piston ring groove clearance.008 in. M21. or the end of a piston ring filed to a sharp point. . clean piston ring groove with a piston ring groove cleaner.20 mm (0. 7.) (Top Ring and Second Ring) (Oil Ring) (Top Ring) (Second and Oil Rings) 25 8 M21.TM325.20 mm (0. PISTON RING GROOVE CLEARANCE SPECIFICATIONS Engine 3TN66/ 3TNA72 3TN75/3TN78/3TN82/ 3TN84/4TN78/ 4TN82/4TN84 4TN100 Measurement (All Rings) Wear Tolerance (MAX) 0. Remove piston rings using a piston ring expander.008 in.15 mm (0. If necessary.Connecting Rods and Pistons/Pistons and Connecting Rods 5.008 in.TM325.) 0.) 0.25 mm (0.010 in.22 -19-28AUG87 6.) 0. Measure several places around each piston. replace rings or piston.) 0.20 mm (0.

24 -19-28AUG87 M35362 If end gap exceeds wear tolerance. replace rings. .50 mm (0.) -UN-29AUG88 -UN-29AUG88 M21. -UN-29AUG88 M21. . . . CTM3 (03JAN90) 25-9 3TN/4TN Series Yanmar Engines 010897 PN=108 M35364 M35363 . Remove piston pin using a wooden dowel. 10.25 -19-04MAR86 9. . . . . . . . 11. 1. Remove two snap rings.Connecting Rods and Pistons/Pistons and Connecting Rods 8. PISTON RING END GAP SPECIFICATIONS (MAX) All Engines .TM325. . . Put a mark on each piston and connecting rod for proper identification to aid in assembly. . . . Push ring into cylinder bore until ring is approximately 30 mm (1. .TM325. . . Measure piston ring end gap.181 in.) from bottom of cylinder bore. .059 in. . . . . . 25 9 IMPORTANT: Pistons must be installed in the same direction and on the same connecting rod they were removed from.

3TNA72 . . . . . . replace bushing.) -UN-29AUG88 M21. . . . If bushing clearance exceeds wear tolerance. . . .) . .D. .791 in. . . . . . . . . .10 mm (0. . . . . . 34. . . CTM3 (03JAN90) 25-10 3TN/4TN Series Yanmar Engines 010897 PN=109 M35366 -UN-29AUG88 M35365 . . . .338 in. .26 -19-28AUG87 M21. . . . .D. . . 23.020 in.831 in. 26. . .826 in. . . . . . . . . .). 33.) . .99 mm (1. . . . . . . . . .10 mm (1. . . . . . .10 mm (0. .TM325. .98 mm (0. .902 in.) Clearance (MAX) All except 4TN100 . . . .98 mm (0.) 4TN100 . piston pin.) 3TN75/3TN78/4TN78 . . . Measure diameter of piston pin at six places. . . .004 in. . . . Measure piston pin bushing and piston pin bushing clearance (bushing I. . . . . . . . . . . . . 20. . replace pin. . . . . . . . . . . . 20. .909 in. . 19. . . . . . . . . . . . . . SPECIFICATIONS (MIN) 3TN66 . 4TN100 . . . or both. . . 25. . . . . . . . . replace bushing. . . . . . . . . .Connecting Rods and Pistons/Pistons and Connecting Rods 12. . . . . . .786 in. . . 21.060 mm (0. . . .90 mm (1.) 3TNA72 . . . . . . .343 in. . . 25 10 13. . . . . .10 mm (1. minus pin O.27 -19-28AUG87 If pin diameter is less than wear tolerance. . . . . PISTON PIN BUSHING SPECIFICATIONS Bushing I.D. . . . . . .11 mm (0. . . . . . . . . . . . . . . . .D. . .10 mm (0. . . . . . . . . . . . . .) If bushing diameter exceeds wear tolerance. . . . . . . . . PISTON PIN O. . . . . . . . . 0.) . . . . .) . . . .TM325.0024 in. . . .90 mm (0. . . . .028 in. . 3TN75/3TN78/4TN78 3TN82/3TN84/ 4TN82/4TN84 . . . . . . . . . . . . . . . (MAX) 3TN66 . 22. . .) 3TN82/3TN84/ 4TN82/4TN84 . . . . . . . . . . two measurements 90˚ apart at each end and two measurements 90˚ at center.) 4TN100 . . . 0. . . . . . . . . . .

PISTON PIN BORE SPECIFICATIONS Bore I. . . or both. . 25 11 M21. . .) Clearance (MAX) All except 4TN100 . . . . .02 mm (0. . .) -UN-29AUG88 M21.D.001 in. . . . . . . . .TM325. . .02 mm (0. .828 in. .024 in. . . . .05 mm (0.28 -19-06AUG87 15. 0. . . . . . 34. . . . . replace piston.) . . . . .) If piston pin bore diameter exceeds wear tolerance. . . . . . .) . .788 in. . . .) 4TN100 . . . . . . 4TN100 . . . . . . 21. . . . . . . replace piston. . . . . . . . . . . . 23. .02 mm (1. . . . 3TNA72 . . . . .906 in. . . .Connecting Rods and Pistons/Pistons and Connecting Rods 14. . . .D. . . . .D. Measure piston pin bore in piston and piston pin clearance (bore I. .TM325. . . . . . .002 in. . . . . 0. -UN-06SEP88 M37683 . . .02 mm (0.) . . . . . . DISKS FOR BUSHING REMOVAL Engine (A) 3TN66 3TNA72 3TN75/3TN78/4TN78 3TN82/3TN84/ 4TN82/4TN84 4TN100 13/16 15/16 15/16 Size (in. . 20. Remove bushing using driver disks (A and B). . . piston pin. .). . . . . . . . . . . (MAX) 3TN66 . . . . .02 mm (0. . . . .) . .01 mm (1. . If piston pin clearance exceeds wear tolerance. . . . . . . . . minus pin O. . 3TN75/3TN78/4TN78 3TN82/3TN84/ 4TN82/4TN84 . . . .29 -19-28AUG87 (B) 3/4 13/16 7/8 1 1/16 1 3/8 1 1 5/16 CTM3 (03JAN90) 25-11 3TN/4TN Series Yanmar Engines 010897 PN=110 M35368 . . . 26. . .339 in.

D.197 in.00 mm (0. CTM3 (03JAN90) 25-12 3TN/4TN Series Yanmar Engines 010897 PN=111 M35369 .004 in.30 -19-06AUG87 3TNA72 3TN75 25 12 3TN78/4TN78 3TN82/4TN82 3TN84/4TN84 4TN100 If piston diameter is less than wear tolerance. and pin bores.) 83.) O.81 mm (3.00 mm (0.) 74. PISTON (STANDARD) SPECIFICATIONS Engine 3TN66 Measurement O. at 8.) O.00 mm (1.) O.220 in.D.85 mm (2.299 in.866 in. NOTE: If engine has had a previous major overhaul.) 99. oversize pistons and rings may have been installed.866 in.315 in.) O.79 mm (3.00 mm (0. perpendicular to piston bore at approximate specified distance from bottom of piston.) 81.50 mm (1.) 77.81 mm (2.) 71.827 in. at 29. skirts.80 mm (3. at 22.80 mm (3.D.593 in.25 mm (0.D.) O.492 in.) O.D. at 5.) Wear Tolerance (MIN) 65.TM325. at 12.00 mm (0.D. at 22.50 mm (0.010 in. replace as necessary. Pistons and rings are available in 0.81 mm (2.D.929 in.142 in.D. at 25.Connecting Rods and Pistons/Pistons and Connecting Rods 16.) -UN-29AUG88 M21.) oversize. install a new piston.063 in. Inspect piston for scuffling or scoring.945 in. Inspect piston for cracks at ring lands. Measure piston O.

079 in.) 75.) 82.D.00—78.45 mm (3.954 in.) 100.) 82.) 100.20 mm (3.616 in.03 mm (3. oversize pistons and rings may have been installed. middle. (OVERSIZE) SPECIFICATIONS Engine 3TN66 3TNA72 3TN75 3TN78/ 4TN78 3TN82/ 4TN82 3TN84/ 4TN84 4TN100 Nominal 66.) 78.600 in.970 in.TM325.) 75.00—82.955 in.31 -19-28AUG87 3TN78/4TN78 25 13 3TN82/4TN82 3TN84/4TN84 4TN100 CYLINDER BORE I.D.) 72.) 75.25 mm (2.25 mm (3.25 mm (3.) 78.20 mm (3.230 in.25 mm (2.961 in.) CTM3 (03JAN90) 25-13 3TN/4TN Series Yanmar Engines 010897 PN=112 M35370 .03 mm (2.071—3.00—84. CYLINDER BORE I.) 84. (STANDARD) SPECIFICATIONS Engine 3TN66 Nominal 66.325 in.03 mm (3.) 72.45 mm (3.) 3TNA72 3TN75 -UN-29AUG88 M21.238 in.) 72.03 mm (2.852 in.45 mm (2.598—2.) 100.45 mm (2.947 in.953—2.) 84.) 82. two measurements 90˚ apart at top.) 84.20 mm (2.315 in.945 in.963 in.937—3.25 mm (3.228—3.03 mm (2. NOTE: If engine has had a previous major overhaul.317 in.081 in. Measure piston bore I.00—72.606 in.307—3.) 100.072 in.03 mm (3.D.20 mm (2.308 in.) Wear Tolerance (MAX) 66.20 mm (3.) 72. and bottom of ring travel.608 in.) Wear Tolerance (MAX) 66.) 75.089 in.844 in.45 mm (3.236 in.25 mm (2.00—66.) 78.00—100.843 in.) 84.45 mm (2.) 82.20 mm (3.25 mm (3.835—2.938 in.) 78.836 in. at six places.45 mm (3.20 mm (2.Connecting Rods and Pistons/Pistons and Connecting Rods 17.03 mm (3.00—75.246 in.

. piston or both. . . .25 mm (0. . . .A1 -19-25MAY89 DEGLAZE CYLINDER BORES IMPORTANT: If cylinder bores are to be deglazed with crankshaft installed in engine. . . . . . . . . . . . . . 1. . . . . . . . . . . . . . .010 in. . . . Pistons and rings are available in 0. 0. . minus piston O. .011 in.D.TM325. . replace cylinder block or have cylinder rebored by a qualified machine shop.32 -19-04MAR86 CTM3 (03JAN90) 25-14 3TN/4TN Series Yanmar Engines 010897 PN=113 M35371 -UN-29AUG88 . . or rebore cylinder and install oversize piston and rings. . . .014 in. MX.). .010 in.TM325. . M21. . . . . . . . . . . . . . .D.30 mm (0. . 0. . . . . . . . . . . . PISTON/CYLINDER BORE CLEARANCE SPECIFICATIONS (MAX) 3TN66 . . . .) If cylinder bore exceeds wear tolerance. . . . . .) 4TN100 . . . . . . . .) 3TN78/3TN82/3TN84/4TN78/ 4TN82/4TN84 . . . . 0.35 mm (0. . . . . . . . . . . . . . . . . oversize piston and rings must be installed. . . .) 3TN75 .) oversize. Deglaze cylinder bores using a flex-hone with 180 grit stones. put clean shop towels over crankshaft to protect journal and bearing surfaces from any abrasives. 25 14 If piston clearance exceeds wear tolerance. .009 in.22 mm (0. . 0. . replace cylinder block.) 3TNA72 . .012 in. . .25 mm (0. . . . . . . . . . 0.28 mm (0. . If cylinder is rebored. . . . . . . Measure piston clearance (piston bore I.Connecting Rods and Pistons/Pistons and Connecting Rods 18. . . . . .

Clean cylinder walls using clean white rags and warm soapy water. 3. Use flex-hone as instructed by manufacturer to obtain 30—40˚ crosshatch pattern as shown. Remove excess abrasive residue from cylinder walls using a clean dry rag. kerosene. Continue to clean cylinder until white rags show no discoloration. M21. or commercial solvents to clean cylinder bores. Solvents will not remove all abrasives from cylinder walls.TM325.Connecting Rods and Pistons/Pistons and Connecting Rods 2.33 -19-04MAR86 M52958 -UN-05APR89 25 15 CTM3 (03JAN90) 25-15 3TN/4TN Series Yanmar Engines 010897 PN=114 . IMPORTANT: Do not use gasoline.

010 in. MX. It should have a 30—40˚ crosshatch pattern. specifications. -UN-05APR89 4. Solvents will not remove all metal particles and abrasives produced during honing. Dry cylinder and apply engine oil. 10. 9.001 in.) of desired size. 3. 6.Connecting Rods and Pistons/Pistons and Connecting Rods REBORE CYLINDER BLOCK NOTE: The cylinder block can be rebored to use 0. Clean cylinder thoroughly using warm soapy water until clean white rags show no discoloration. Use a flex hone with 180 grit stones for honing to final size. Run drill press at about 250 RPM. Remove rigid hone when cylinder is within 0. NOTE: Finish should not be smooth. (See this group for cylinder bore I. Align center of bore to drill press center. Hone should turn by hand. 2.A2 -19-25MAY89 CTM3 (03JAN90) 25-16 3TN/4TN Series Yanmar Engines 010897 PN=115 M52959 NOTE: Measure bore when cylinder is cool. 7. (See this group. Adjust hone so lower end is even with lower end of cylinder bore. Adjust if too tight. taper and out-of-round. IMPORTANT: Check stone for wear or damage. Stop press and check cylinder diameter several times during rebore procedure. 8. Adjust rigid hone stones until they contact narrowest point of cylinder. . 25 16 5.25 mm (0. 11.) 1. Move hone up and down in order to obtain a 30—40˚ crosshatch pattern.03 mm (0.) oversize pistons and rings. Use a rigid hone with 300 grit stones. Check bore for size.) IMPORTANT: Do not use solvents to clean cylinder bore.D. Coat cylinder with honing oil.TM325.

34 -19-06AUG87 IMPORTANT: Pistons must be installed on connecting rods from which they were removed. Install pin through piston and connecting rod. Be sure snap rings are fastened in groove all around.35 -19-04MAR86 CTM3 (03JAN90) 25-17 3TN/4TN Series Yanmar Engines 010897 PN=116 M35364 -UN-29AUG88 M37685 . 4. Turn bushing so oil holes in bushing and connecting rod are aligned. Put clean engine oil on piston pin. Install snap rings. 3.) (B) 3/4 13/16 7/8 M35368 1 5/16 1 1/2 1 1 5/16 -UN-29AUG88 25 17 M21. 2.TM325. DISKS FOR BUSHING INSTALLATION Engine (A) 3TN66 3TNA72 3TN75/3TN78/4TN78 3TN82/3TN84/ 4TN82/4TN84 4TN100 1 1 1 1/4 Size (in.TM325. Identification marks on piston must be the same side as marks on connecting rod.Connecting Rods and Pistons/Pistons and Connecting Rods ASSEMBLE PISTONS AND CONNECTING RODS 1. 5. Install bushing using driver disks (A and B). -UN-06SEP88 M21. assemble piston to connecting rod with piston recess (A) opposite bearing insert groove (B). If a new piston or connecting rod is used.

CTM3 (03JAN90) 25-18 3TN/4TN Series Yanmar Engines 010897 PN=117 M37686 -UN-06SEP88 M35372 -UN-08SEP88 IMPORTANT: Piston rings must be installed with chamfer (A). toward top of piston. Turn ring until gap is 120˚ away from second ring gap. Turn oil ring so ends are on opposite side of piston from the expander ends.36 -19-04MAR86 M21. Install rings with identification mark (B) toward top of piston.TM325. Identification mark (B) may be a “T”. Install oil ring expander in bottom piston ring groove. Turn expander so ends are above either end of piston pin -UN-29AUG88 M21. or “RN”.Connecting Rods and Pistons/Pistons and Connecting Rods 6. “R”. Install oil ring over expander with a piston ring expander. 25 18 8.TM325. Turn ring until gap is 120˚ away from second ring gap. Install chrome ring in top groove. M35361 .37 -19-28AUG87 7. if present. Install second ring in middle groove.

7.TM325.Connecting Rods and Pistons/Pistons and Connecting Rods INSTALL PISTONS AND CONNECTING RODS IMPORTANT: Pistons must be installed in cylinders from which they were removed and in the same direction.TM325. Push pistons down until top ring is in cylinder. Pull connecting rod to crankshaft. and cylinder bore. Install bearing insert in connecting rod with tang (B) in groove (A). 5. For 4TN100 engine. 2. 1. Put clean engine oil on insert. Install bearing insert in connecting rod cap with tang (A) in groove (B). rings. Put clean engine oil on insert and crankshaft journal. CTM3 (03JAN90) 25-19 3TN/4TN Series Yanmar Engines 010897 PN=118 M35375 M35374 M51565 . -UN-06SEP88 6.40 -19-04MAR86 M37687 -UN-06SEP88 25 19 IMPORTANT: Do not touch the bearing insert surface. Be careful not to damage crankshaft rod journal while installing piston.39 -19-04MAR86 M21.38 -19-06AUG87 M21. -UN-08SEP88 3. Oil and acid from your finger will corrode the bearing surface. insert piston with size mark (A) toward camshaft. Oil and acid from your finger will corrode the bearing surface. IMPORTANT: Do not touch the bearing insert surface. A—Piston Size Mark B—Fuel Injection Pump Side C—Gear Case Side -UN-31AUG88 M21.TM325. 4. Install pistons with piston recess (A) toward fuel injection pump using a piston ring compressor. Put clean engine oil on pistons.

. . . . . . . . . . . 98 N·m (69 lb-ft) 11.42 -19-28AUG87 M21. . . . . . . CONNECTING ROD CAP SCREW TORQUE SPECIFICATIONS 3TN66/3TNA72 . . 8. 39 N·m (29 lb-ft) 3TN82/3TN84/ 4TN82/4TN84 . . . .43 -19-04MAR86 IMPORTANT: Never reuse connecting rod cap screws. . . . . . . . .Connecting Rods and Pistons/Pistons and Connecting Rods IMPORTANT: Connecting rod caps must be installed on the same connecting rod they were removed from and in the same direction. . -UN-06SEP88 M21. . . . . . . . . . . Tighten cap screws to specifications. . .) 3TN75/3TN78/4TN78 . . . -UN-06SEP88 CTM3 (03JAN90) 25-20 3TN/4TN Series Yanmar Engines 010897 PN=119 M35378 M35377 -UN-06SEP88 M35376 . . . . . . 23 N·m (200 lb-in. . . . . Dip entire connecting rod cap screw in clean engine oil. . .TM325. . . . . . . . . 9. . . .41 -19-04MAR86 M21. . . . . . . . Install cap on connecting rod with tangs (A) to same side. . . stamp a number corresponding to the cylinder number on the connecting rod cap and connecting rod. . . . . . . . .TM325. . . . . 25 20 10. . . . If a new piston and connecting rod have been installed. . .TM325. Install cap screws in connecting rods. . . 47 N·m (35 lb-ft) 4TN100 . . . . . .

) 16.TM325. Install oil pan. Install engine. Install dipstick (B).) 14. (See Group 15 in this manual.Connecting Rods and Pistons/Pistons and Connecting Rods 12. Install cylinder head. oil suction strainer (A).) M35379 M21. (See Group 40 in this manual. (See Machine Technical Manual.44 -19-23APR86 -UN-06SEP88 25 21 CTM3 (03JAN90) 25-21 3TN/4TN Series Yanmar Engines 010897 PN=120 . and two cap screws. Install flywheel assembly. 13.) 17. (See Group 20 in this manual.) 15. (See Machine Technical Manual. If equipped. install electric clutch assembly.

. . . . Place three 10 mm (0.) 3TNA72 . .59—0. . . . . . .4 in.) 3. .63—0. .A3 -19-25MAY89 CTM3 (03JAN90) 25-22 3TN/4TN Series Yanmar Engines 010897 PN=121 M52960 -UN-05APR89 . . .023—0. . . . . Install cylinder head and gasket to engine block. .77 mm (0. . . . . . . 4. .82 mm (0. Tighten cylinder head cap screws in proper sequence to specified torque.030 in.032 in. . . . . . . .74 mm (0. . 0. .06 in. . . . .59—0. . . . . . . .TM325.) 3TN75 . . .)-long pieces of 1. Slowly turn crankshaft one complete revolution.035 in. . . . . .031 in.) MX. . 25 22 If clearance is below specification replace parts as necessary to correct.023—0. .029 in.Connecting Rods and Pistons/Pistons and Connecting Rods MEASURE PISTON-TO-CYLINDER HEAD CLEARANCE 1. . . . . . . . 2. .79 mm (0. . .) 5.5 mm (0. . . 0. . 0.) 3TN82/4TN82 . . . . Compute average thickness of wires and compare to specifications.71—0. .028—0. . . . . . . . Remove cylinder head.030 in. . . 0.89 mm (0.024—0. . .61—0. . . . 0.) diameter soft wire (A) in three positions on flat part of piston crown. . PISTON TO CYLINDER HEAD CLEARANCE SPECIFICATIONS (NOMINAL) 3TN66 .025—0. .) 3TN84/4TN84 4TN100 . . . .64—0. . Measure thickness of flattened section of each piece of wire. .77 mm (0. . (See Group 15. . . . . . .) 3TN78/4TN78/ . (See Group 15. 0.025—0.

Name Use Dial Indicator Magnetic Base with Adjustable Arm Bushing. and Seal Driver Set 13-Ton Puller Set Press Outside Micrometer Telescoping Gauge Measure crankshaft end play To hold dial indicator Remove and install seals Remove crankshaft gear To service crankshaft gear Measure crankshaft journals Measure crankshaft bearing bore M21. M21.1 -19-05MAR86 SERVICE PART KITS The following kits are available through your parts catalog: Cylinder Block Gasket Kit Cylinder head Gasket Kit 30 1 M21. Some tools may be available from a local supplier.3 -19-06AUG87 CTM3 (03JAN90) 30-1 3TN/4TN Series Yanmar Engines 010897 PN=122 .TM330.2 -19-23APR86 OTHER MATERIAL Number Name Use PLASTIGAGE® Measure crankshaft bearing clearance To seal oil seal case PT94 John Deere Form-In-Place Gasket (RTV rubber silicone sealant) PLASTIGAGE is a trademark of the TRW Corporation LOCTITE is a trademark of the LOCTITE Corp. Bearing.TM330.Group 30 Crankshaft and Main Bearings SERVICE EQUIPMENT AND TOOLS NOTE: Order tools from the U.S. SERVICEGARD™ Catalog or from the European Microfiche Tool Catalog (MTC).TM330.

0. remove crankshaft and inspect thrust bearings for wear.29 mm (0.6 -19-28AUG87 MX. . Drain engine oil. . 2. . IMPORTANT: Rotate crankshaft to find marks or mark a tooth on balancer gear and crankshaft gear before removing balancer. . . . . . Remove oil pan. . . . .) 4TN100 . . 3. . . 3. Locate and align balancer-to-crankshaft timing marks (A). .1 -19-06OCT89 IMPORTANT: Do not use excessive force when moving crankshaft to avoid damaging bearings. 30 2 REMOVE ENGINE BALANCER ASSEMBLY—4TN82/84 1. . . . Fasten dial indicator to engine. . . .011 in. 2. . Push crankshaft toward front then toward rear. . .TM330Z. . CTM3 (03JAN90) 30-2 3TN/4TN Series Yanmar Engines 010897 PN=123 M48268 -UN-01NOV89 M35380 .Crankshaft and Main Bearings/Balancer Assembly—4TN82/84 MEASURE CRANKSHAFT END PLAY 1. 0. .33 mm (0. . . . . . . . -UN-06SEP88 M21. .013 in. . . . . . . .TM330.) If crankshaft end play exceeds wear tolerance. (Extension housing removed for photographic purposes). . . CRANKSHAFT END PLAY SPECIFICATIONS (MAX) All except 4TN100 . . . Measure crankshaft end play. . . .

Check gear teeth for chipping of excessive wear. cap screws (B) and shafts (C). M48309 MX. check crankshaft gear and replace as necessary. If gear (F) is damaged. See crankshaft removal. Clean and check oil passages for debris or blockage. 3. -UN-01NOV89 MX. Remove oil pickup cap screws (A). 5.Crankshaft and Main Bearings/Balancer Assembly—4TN82/84 4.TM330Z. Carefully remove balancer. Balancer gears (E) are pressed on shafts. Inspect bushing (D) for signs of wear or scoring. Disassemble balancer by removing nut (A).2 -19-06OCT89 DISASSEMBLE AND INSPECT BALANCER—4TN82/84 1. 2.TM330Z.3 -19-06OCT89 CTM3 (03JAN90) 30-3 3TN/4TN Series Yanmar Engines 010897 PN=124 M48311 -UN-01NOV89 30 3 . Remove cap screws (B).

5.4 -19-01OCT89 4. MX.5 -19-06OCT89 CTM3 (03JAN90) 30-4 3TN/4TN Series Yanmar Engines 010897 PN=125 M48354 -UN-01NOV89 M48312 M48353 -UN-01NOV89 . align hole in bushings with oil passage ports (C). Tighten nut to 106 N·m (78 lb-ft). 3. Install new o-ring (B). Install balancer assembly and tighten cap screws to 27 N·m (20 lb-ft).TM330Z. flush with beveled edge. When installing new bushings. aligning timing marks (A). Install drive gear and nut (A). 30 4 -UN-01NOV89 MX. Press gears (B) on shaft.Crankshaft and Main Bearings/Balancer Assembly—4TN82/84 ASSEMBLE AND INSTALL BALANCER 1. Coat bushings with oil and install balancer shafts. Tighten retaining bolts to 27 N·m (20 lb-ft).TM330Z. 2.

. . . . . . . . . . . Extension housing-to-timing cover . . . TORQUE SPECIFICATIONS Extension housing-to-block . . 27 N·m (20 lb-ft) . . Remove three rear bearing-to-extension housing cap screws (B). (Front extension housing-to-timing gear cover cap screws not shown). . . . 2. . Rear bearing housing-toextension housing . . . . . Apply a bead of Form-in-Place Gasket or equivalent on sealing surface and reinstall housing. . . . . . . . . . 22 N·m (16 lb-ft) . Clean gasket surfaces. . . . . . . .6 -19-06OCT89 CTM3 (03JAN90) 30-5 3TN/4TN Series Yanmar Engines 010897 PN=126 . . . . . . . . . . . . . Remove all external cap screws (C).TM330Z. 49 N·m (36 lb-ft) . . . . 4. . . . . . . 5. . . 27 N·m (20 lb-ft) . . . . . . . . . . . . . 3. . Remove all internal cap screws (D) and remove housing. . . . . . . . . . . . . . . . . . . Rear plate-to-extension housing Oil pan cap screws .Crankshaft and Main Bearings/Balancer Assembly—4TN82/84 REMOVE AND INSTALL CRANKCASE EXTENSION HOUSING 1. . . . 27 N·m (20 lb-ft) M48310 -UN-01NOV89 30 5 MX. . . . Remove two rear plate-to-extension housing cap screws (A). . .

If equipped. (See Machine Technical Manual. and dipstick (B). Remove engine. (See Group 40 in this manual.) M21.TM330. (See Group 20 in this manual. 3.8 -19-06AUG87 CTM3 (03JAN90) 30-6 3TN/4TN Series Yanmar Engines 010897 PN=127 M35354 -UN-29AUG88 M35453 30 6 -UN-06SEP88 .TM330. remove electric clutch assembly (A). M21. Remove oil suction strainer (A).7 -19-05MAR86 5.) 4.Crankshaft and Main Bearings/Measure Crankshaft Bearing Clearance MEASURE CRANKSHAFT BEARING CLEARANCE 1.) 2. Remove flywheel assembly (B). Remove oil pan (C). (See Machine Technical Manual).

. MAIN BEARING CAP SCREW TORQUE SPECIFICATIONS 3TN66 . . . . . . . . . . . . . . . . . . . Tighten cap screws to specifications. . . . .) off center. . . . b. . Put a piece of PLASTIGAGE (A) or an equivalent on the full length of the bearing insert about 6 mm (1/4 in. . Remove main bearing cap. a. . . . .TM330. . . . -UN-06SEP88 M21. 54 N·m (40 lb-ft) 3TN75/3TNA72/3TN78/4TN78 . . . . . Install main bearing cap and cap screws. . . . . 196 N·m (145 lb-ft) -UN-06SEP88 M21. . Measure reach crankshaft bearing clearance using the following PLASTIGAGE method or by measuring after the crankshaft has been removed. . . . . . . . . . . . . 98 N·m (72 lb-ft) 4TN100 . . . . . . . . . . . . . . . . . .10 -19-05MAR86 30 7 d. .TM330. . Wipe oil from bearing insert and crankshaft journal. .TM330. . . . .9 -19-05MAR86 M35381 PLASTIGAGE method: IMPORTANT: Main bearing caps must be installed on the same main bearing from which they were removed. -UN-06SEP88 M21. . c. . . . . Arrows on bearing caps point toward flywheel end of block. . . . 79 N·m (58 lb-ft) 3TN82/3TN84/ 4TN82/4TN84 . . . .Crankshaft and Main Bearings/Measure Crankshaft Bearing Clearance 6.11 -19-28AUG87 CTM3 (03JAN90) 30-7 3TN/4TN Series Yanmar Engines 010897 PN=128 M35383 M35382 . . . . . . . . .

Crankshaft and Main Bearings/Measure Crankshaft Bearing Clearance
e. Remove cap screws and main bearing cap. f. The flattened PLASTIGAGE will be found on either the bearing or crankshaft journal. g. Use the graduation marks on the envelope to compare the width of the flattened PLASTIGAGE at its WIDEST point. h. Determine main bearing clearance. The number within the graduation marks on the envelope indicates the bearing clearance in thousandths of an inch or in millimeters depending on which side of the envelope is used. Remove PLASTIGAGE.
MAIN BEARING CLEARANCE SPECIFICATIONS 3TN66/3TNA72 . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.) 3TN75/3TN78/4TN78/ 3TN82/4TN82/ 3TN84/4TN84 . . . . . . . . . . . . . . . . . . . . . . . 0.16 mm (0.006 in.) 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.09 mm (0.004 in.)

If clearance is correct, install main bearing caps and tighten cap screws to specifications.

M21,TM330,12

-19-28AUG87

CTM3 (03JAN90)

30-8

3TN/4TN Series Yanmar Engines
010897

PN=129

M35384

30 8

If clearance exceeds wear tolerance, remove crankshaft.

-UN-06SEP88

Crankshaft and Main Bearings/Crankshaft Oil Seal

REMOVE CRANKSHAFT OIL SEAL
1. Remove engine. (See Machine Technical Manual.) 2. If equipped, remove electric clutch (A). (See Machine Technical Manual). 3. Remove flywheel assembly (B). (See Group 20 in this manual.)

-UN-06SEP88 M21,TM330,13 -19-05MAR86

4. Remove attaching cap screws. 5. Remove oil seal case.
-UN-06SEP88 M21,TM330,14 -19-05MAR86

CTM3 (03JAN90)

30-9

3TN/4TN Series Yanmar Engines
010897

PN=130

M35405

-UN-06SEP88

M35404

M35452

30 9

Crankshaft and Main Bearings/Crankshaft Oil Seal
6. Remove oil seal using driver disks (A and B). 7. Remove old gasket material from plate.
DISKS FOR SEAL REMOVAL Engine (A) 3TN66/3TNA72 3TN75/3TN78/3TN82/3TN84/ 4TN78/4TN82/4TN84 4TN100 3-13/16 Size (in.) (B) 2-5/16
M35387 M21,TM330,15 -19-06AUG87 M21,TM330,16 -19-06AUG87 -UN-06SEP88

3-1/2 4-1/2

2-7/8 3-3/4

INSTALL CRANKSHAFT OIL SEAL

30 10

If crankshaft is grooved at oil seal contact point, seal can be installed 3.0 mm (0.12 in.) farther into oil seal case.
DISKS FOR SEAL INSTALLATION Engine (A) 3TN66/3TNA72 3TN75/3TN78/3TN82/3TN84/ 4TN78/4TN82/4TN84 4TN100 3-13/16 Size (in.) (B) 2-5/16

3-1/2 4-1/2

2-7/8 3-3/4

CTM3 (03JAN90)

30-10

3TN/4TN Series Yanmar Engines
010897

PN=131

M35387

-UN-06SEP88

1. Install seal, with lip of seal, toward cylinder block. Use driver disks (A and B) to push seal even with surface of oil seal case.

Crankshaft and Main Bearings/Crankshaft Oil Seal
2. Apply RTV rubber silicone sealant or an equivalent on the oil seal case. 3. Align oil seal case with dowel pins on the cylinder block. 4. Install and tighten cap screws to specifications.
OIL SEAL CASE CAP SCREW TORQUE SPECIFICATIONS Engine 3TN66/3TNA72 Item Seal case to block Oil pan to seal case Specification 11 N·m (96 lb-in.) 9 N·m (78 lb-in.)
M35406 M35407 M21,TM330,17 -19-06AUG87 -UN-06SEP88

3TN75/3TN78/ 3TN82/3TN84/ 4TN78/4TN82/ 4TN84 4TN100

Seal case to block Oil pan to seal case

26 N·m (226 lb-in.) 21 N·m (180 lb-in.)

5. Install flywheel assembly. (See Group 20 in this manual.) 6. If equipped, install electric clutch. (See Machine Technical Manual). 7. Install engine. (See Machine Technical Manual.)

-UN-06SEP88

30 11

CTM3 (03JAN90)

30-11

3TN/4TN Series Yanmar Engines
010897

PN=132

Crankshaft and Main Bearings/Crankshaft

REMOVE CRANKSHAFT
1. Remove engine. (See Machine Technical Manual.) 2. Measure crankshaft end play. (See Group 30 in this manual.) 3. Remove cylinder head (A) and cam followers. (See Group 15 in this manual.) 4. Remove camshaft (B). (See Group 15 in this manual.) 5. Remove gear housing (C). (See Group 35 in this manual.) 6. Remove flywheel assembly (E). (See Group 20 in this manual.) 7. Remove oil pan (D). (See Group 40 in this manual.)
-UN-29AUG88 M21,TM330,18 -19-23APR86

8. Remove attaching cap screws. 9. Remove oil seal case.
-UN-06SEP88 M21,TM330,19 -19-05MAR86

CTM3 (03JAN90)

30-12

3TN/4TN Series Yanmar Engines
010897

PN=133

M35386

-UN-06SEP88

M35385

M35323

30 12

Crankshaft and Main Bearings/Crankshaft
10. Remove oil seal using driver disks (A and B). 11. Remove old gasket material from plate.
DISKS FOR SEAL REMOVAL Engine (A) 3TN66/3TNA72 3TN75/3TN78/3TN82/3TN84/ 4TN78/4TN82/4TN84 4TN100 3-13/16 Size (in.) (B) 2-5/16
M35387 M21,TM330,20 -19-07AUG87 -UN-06SEP88

3-1/2 4-1/2

2-7/8 3-3/4

12. Remove oil suction strainer (A), and dipstick (B).

30 13
-UN-29AUG88 M21,TM330,21 -19-07AUG87

IMPORTANT: Connecting rod end caps must be installed on the same connecting rod from which they were removed.
-UN-29AUG88 M21,TM330,22 -19-05MAR86

13. Remove cap screws and connecting rod caps. 14. Push pistons and connecting rod away from crankshaft but not out of the block.

CTM3 (03JAN90)

30-13

3TN/4TN Series Yanmar Engines
010897

PN=134

M35356

M35354

Crankshaft and Main Bearings/Crankshaft
IMPORTANT: Main bearing caps must be installed on the same main bearings from which they were removed.
-UN-06SEP88 M21,TM330,23 -19-07AUG87 M21,TM330,24 -19-05MAR86 M21,TM330,25 -19-05MAR86 M21,TM330,26 -19-05MAR86

15. Remove cap screws and main bearing caps (A). 16. Remove two cap screws, main bearing cap (B), and thrust bearing set.

17. Remove crankshaft.

18. Remove thrust bearings.

DISASSEMBLE AND INSPECT CRANKSHAFT
1. Inspect gear for chipped or broken teeth; replace if necessary. IMPORTANT: Be sure to hold crankshaft while removing crankshaft gear. 2. Remove gear using a 1-in. driver disk (A), bearing puller attachment, and a press.
-UN-06SEP88

CTM3 (03JAN90)

30-14

3TN/4TN Series Yanmar Engines
010897

PN=135

M35391

M35390

-UN-06SEP88

M35389

30 14

-UN-06SEP88

M35388

. . . .752 in. . .010 in. . . . . . . .) 4TN100 .91 mm (1. . 49. . . see Pistons and Connecting Rods in Group 25.92 mm (1. . . . .25 mm (0. . . . . 39. M35392 4. .D. . . . . .) 3TN75/3TN78/4TN78 .) 3TNA72 . .90 mm (1. . .) 3TN82/3TN84/ 4TN82/4TN84 . . . . . . . . .92 mm (1. Measure several places around each journal and each side of every journal. . . 69. . . . If journals are ground. .572 in. . . . . . . .729 in. . . . . . . . . . . . . . . . . .TM330. Measure crankshaft main bearing journal diameter. .) undersize. . . . . . . . . Bearing inserts are available in 0. . . -UN-06SEP88 NOTE: If engine has had a previous major overhaul. . . . . . . . . . . . . . . . replace crankshaft or have journals ground undersize by a qualified machine shop. . . crankshaft journals may have been ground and undersize bearing inserts installed.Crankshaft and Main Bearings/Crankshaft 3. . SPECIFICATIONS (MIN) 3TN66 . . . .965 in. 43.27 -19-07AUG87 CTM3 (03JAN90) 30-15 3TN/4TN Series Yanmar Engines 010897 PN=136 . . . . .847 in. . . . . . . . . . . undersize bearing inserts must be installed.) If journal diameter is less than wear tolerance. . 30 15 M21. . .90 mm (2. 46. MAIN BEARING JOURNAL O. For connecting rod journal specifications. .

.). . . . . . . .) . . . .) . 79 N·m (58 lb-ft) 3TN82/3TN84/ 4TN82/4TN84 . . . . . If journals are ground. . . . . . . . minus journal O. . . . . replace bearing inserts. .TM330. . .578 in. . . . . . . . . . . . . bearings can be reused. . . . . .10 mm (1.Crankshaft and Main Bearings/Crankshaft 5. . . . .D. . . . . CTM3 (03JAN90) 30-16 3TN/4TN Series Yanmar Engines 010897 PN=137 M35408 . . . . . .07 mm (1. .854 in. . . .972 in. . .) . 4TN100 . . . . . . . . . . . . . . .010 in. If bearing diameter and clearance are within specifications and bearings are not damaged. . . . . 40. . . .004 in. . . . .D. . . . . . 47. . . . . . .D. -UN-06SEP88 M21. . . . . . 54 N·m (40 lb-ft) 3TNA72/3TN75/3TN78/4TN78 . .) If bearing diameter exceeds wear tolerance. . Measure main bearing diameter and main bearing clearance (bearing I. . . Bearing inserts are available in 0. . . . . . . . .) .735 in. . Install main bearing cap and bearing insert on main bearing. . . . . 44. . . . . . .09 mm (0. .15 mm (0.004 in. . . . . . . . 0. . . . .10 mm (1. . . . . . . .) 30 16 Clearance (MAX) All except 4TN100 .25 mm (0.) undersize. . . . .) 4TN100 . . . Tighten main bearing cap screws to specifications. . . . . . . . . . . . . . . .006 in. . . . . replace bearing inserts and crankshaft. . . . . If bearing clearance exceeds wear tolerance. . . . . . .28 -19-28AUG87 6. . . . . . . . . . . . . . .09 mm (0. . . . or have crankshaft main bearing journals ground undersize by a qualified machine shop.07 mm (1. . . . . 50. . . MAIN BEARING CAP SCREW TORQUE SPECIFICATIONS 3TN66 . . 196 N·m (145 lb-ft) MAIN BEARING SPECIFICATIONS Bearing I. 3TNA72 . . . . . . 0. . . . . . . . . . . . . . . . . . . 98 N·m (72 lb-ft) 4TN100 . . . . . . 3TN75/3TN78/4TN78 3TN82/3TN84/ 4TN82/4TN84 . . . 0. undersize bearing inserts must be installed. . (MAX) 3TN66 . . . . . . . . . . . . . . . . .

Clean and inspect oil passages in main bearing journals. Use a thermometer. Oil and acid from your finger will corrode the bearing surface. Heat crankshaft gear to approximately 150˚C (300˚F). Use a piece of wire to clean oil passages if necessary. 2.TM330. Install bearing inserts in crankshaft bearing bores with tang (A) in groove (B). Use a 1-11/16 in. 4. Heat the oil in a well-ventilated area. CTM3 (03JAN90) 30-17 3TN/4TN Series Yanmar Engines 010897 PN=138 M35396 -UN-06SEP88 . -UN-06SEP88 M21. 8. driver disk (A) and a press. 2.Crankshaft and Main Bearings/Crankshaft 7.TM330.31 -19-05MAR86 M35394 ASSEMBLE CRANKSHAFT N CAUTION: DO NOT heat oil over (182˚C) 360˚F. Do not allow a flame or heating element to come in direct contact with the oil.TM330. 3.29 -19-05MAR86 -UN-23FEB89 M21. replace crankshaft as necessary. Plan a safe handling procedure to avoid burns. Install gear (B) with timing mark “A” or dot on press table. Put clean engine oil on inserts.30 -19-28AUG87 M21. Push crankshaft into gear until gear is tight against crankshaft shoulder. Oil fumes or oil can ignite above (193˚C) 380˚F. Align slot in gear with key in shaft. Inspect crankshaft for cracks or other damage. connecting rod journals. 1. T81191 30 17 INSTALL CRANKSHAFT IMPORTANT: Do not touch the bearing insert surface. 1. and main bearing bores in cylinder block.

33 -19-05MAR86 M21. Put clean engine oil on insert. 6. M21.TM330.32 -19-05MAR86 IMPORTANT: Do not touch the bearing insert surface. in the number “1” main bearing bore. Install thrust bearings. 5. Oil and acid from your finger will corrode the bearing surface. Put clean engine oil on crankshaft main bearing journals.34 -19-05MAR86 4.TM330. Install crankshaft in cylinder block.TM330. with oil grooves to the outside. -UN-06SEP88 CTM3 (03JAN90) 30-18 3TN/4TN Series Yanmar Engines 010897 PN=139 M35389 M35397 30 18 M35390 -UN-06SEP88 . -UN-06SEP88 M21. 7. Install bearing inserts in main bearing caps with tang (A) in groove (B).Crankshaft and Main Bearings/Crankshaft 3.

-UN-06SEP88 M21. Install main thrust bearing. Caps and cylinder block are numbered. 11.TM330. in the number “1” main bearing bore. Arrows (A) must point toward flywheel side of engine. Lightly hit the front end of the crankshaft with a soft-faced hammer.Crankshaft and Main Bearings/Crankshaft IMPORTANT: Main bearing caps must be installed on the same main bearing from which they were removed. 10. Install cap screws in main bearing cap. -UN-06SEP88 M35398 30 19 M21. Install main bearing caps in cylinder block. with oil grooves to the outside. 8. so caps can be installed in their original locations. Tighten cap screws tight. Main bearing caps and cylinder block are numbered.36 -19-05MAR86 CTM3 (03JAN90) 30-19 3TN/4TN Series Yanmar Engines 010897 PN=140 M35409 .35 -19-05MAR86 12. then the rear end of the crankshaft to align the main thrust bearing halves. 9.TM330. Dip entire main bearing cap screws in clean engine oil.

. 79 N·m (58 lb-ft) 3TN82/3TN84/ 4TN82/4TN84 . . . . If it does not turn easily. . . . . . . . . . . . . .37 -19-07AUG87 M21. . . . . . . -UN-06SEP88 M21. . . . 98 N·m (72 lb-ft) 4TN100 . . . -UN-06SEP88 CTM3 (03JAN90) 30-20 3TN/4TN Series Yanmar Engines 010897 PN=141 M35376 M35410 . . . . .TM330. . . . . disassemble parts and find the cause. Turn crankshaft by hand. . . . . . . . . 14. . . . . . . .Crankshaft and Main Bearings/Crankshaft IMPORTANT: DO NOT use high speed power tools or air wrenches to tighten main bearing cap screws. . . . . . . . . . . .38 -19-05MAR86 13. . . . . . . . 54 N·m (40 lb-ft) 3TNA72/3TN75/3TN78/4TN78 . . . . MAIN BEARING CAP SCREW TORQUE SPECIFICATIONS 3TN66 . . . . .TM330. . . Tighten main bearing cap screws to specifications. . . . . . . . . . . . Install cap on connecting rod with tang (A) to same side. . . . . 196 N·m (145 lb-ft) 30 20 IMPORTANT: Connecting rod caps must be installed on the same connecting rod they were removed from and in the same direction. . . . . . .

. 93 N·m (69 lb-ft) M35377 -UN-06SEP88 30 21 M21. and oil suction strainer (A). . . . . . . . . . . . .39 -19-28AUG87 17. . . . . . CONNECTING ROD CAP SCREW TORQUE SPECIFICATIONS 3TN66/3TNA72 . . . . . . . . . . Install dipstick (B). 39 N·m (29 lb-ft) 3TN82/3TN84/ 4TN82/4TN84 . . . . . . . M21. . . . . . . . . . . 23 N·m (200 lb-in. . . . .40 -19-07AUG87 CTM3 (03JAN90) 30-21 3TN/4TN Series Yanmar Engines 010897 PN=142 M35379 -UN-06SEP88 . . . . . . . . . . . . . . . . 15. . . .TM330. . . 47 N·m (35 lb-ft) 4TN100 . . . . . . . .Crankshaft and Main Bearings/Crankshaft IMPORTANT: Never reuse connecting rod cap screws. . . . . . . . . 16.) 3TN75/3TN78/4TN78 . . . . . . . . . . . . Install cap screws in connecting rods. . Dip entire connecting rod cap screw in clean engine oil. . . Tighten cap screws to specifications.TM330. . . .

Crankshaft and Main Bearings/Crankshaft
18. Install seal with lip of seal toward cylinder block. Use driver disks (A and B) to push seal even with surface of oil seal case.
-UN-06SEP88 M21,TM330,41 -19-07AUG87

If crankshaft is grooved at oil seal contact point, seal can be installed 3.0 mm (0.12 in.) farther into oil seal case.
DISKS FOR SEAL INSTALLATION Engine (A) 3TN66/3TNA72 3TN75/3TN78/3TN82/3TN84/ 4TN78/4TN82/4TN84 4TN100 3-13/16 Size (in.)

2-5/16

3-1/2 4-1/2

2-7/8 3-3/4

30 22

CTM3 (03JAN90)

30-22

3TN/4TN Series Yanmar Engines
010897

PN=143

M35387

(B)

Crankshaft and Main Bearings/Crankshaft
19. Apply RTV rubber silicone sealant or an equivalent on the oil seal case. 20. Align oil seal case with dowel pins on the cylinder block. 21. Install and tighten cap screws to specifications.
OIL SEAL CASE CAP SCREW TORQUE Engine 3TN66/3TNA72 Item Seal case to block Oil pan to seal case Specification 11 N·m (96 lb-in.) 9 N·m (78 lb-in.)
M35411

All except 3TN66/3TNA72

Seal case to block

26 N·m (226 lb-in.)

22. Install oil pan. (See Group 40 in this manual.) 23. Install flywheel assembly. (See Group 20 in this manual.) 24. If equipped, install electric clutch assembly. (See Machine Technical Manual.) 25. Install gear housing. (See Group 35 in this manual.) 26. Install camshaft. (See Group 15 in this manual.) 27. Install cam followers and cylinder head. (See Group 15 in this manual.) 28. Install engine. (See Machine Technical Manual.)

-UN-06SEP88

30 23

M21,TM330,42

-19-28AUG87

CTM3 (03JAN90)

30-23

3TN/4TN Series Yanmar Engines
010897

PN=144

Crankshaft and Main Bearings/Crankshaft

30 24

CTM3 (03JAN90)

30-24

3TN/4TN Series Yanmar Engines
010897

PN=145

Group 35

Gear Housing
SERVICE EQUIPMENT AND TOOLS
NOTE: Order tools from the U.S. SERVICEGARD™ Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier.
Name Use

Strap Wrench 13-Ton Puller Set Bushing, Bearing, and Seal Driver Set Dial Indicator Telescoping Gauge Outside Micrometer Belt Tension Gauge O-Ring Seal Tool Set

Remove crankshaft pulley Remove crankshaft pulley and gears Remove and install seals Measure timing gear backlash Measure idler gear bushing diameter Measure idler shaft diameter Check belt tension Remove and install O-rings

M21,TM335,1

-19-23MAY86

OTHER MATERIAL
Number Name Use

35 1

PT94

John Deere Form-In-Place Gasket (RTV rubber silicone sealant) John Deere LOCTITE Thread Lock and Sealer (Low Strength) John Deere LOCTITE Thread Lock and Sealer (Medium Strength)

To seal gear housing cover and gear housing. Apply to threads of gear housing studs. Apply to threads of crankshaft pulley cap screw.

AT52853

T43512

LOCTITE is a trademark of the LOCTITE Corp.

M21,TM335,2

-19-07AUG87

CTM3 (03JAN90)

35-1

3TN/4TN Series Yanmar Engines
010897

PN=146

Gear Housing/Timing Gear Cover

REMOVE TIMING GEAR COVER
1. Remove engine. (See Machine Technical Manual.)
-UN-29AUG88 M21,TM335,5 -19-07AUG87 M21,TM310,38 -19-18FEB86 M21,TM310,39 -19-18FEB86 M21,TM310,40 -19-18FEB86

2. Remove fan, if equipped. 3. Remove alternator belt and alternator. 4. Hold crankshaft pulley using a strap wrench. Remove cap screw and washer.

5. Remove crankshaft pulley using puller, shaft protector, and two 8 mm cap screws.

35 2

NOTE: For all engines except 3TNA72UJ (Early Units) go to step 8.
6. Remove cotter pin and washer (A) to disconnect fuel shut-off solenoid linkage.

7. Remove two nuts and one cap screw to remove bracket and fuel shut-off solenoid.

CTM3 (03JAN90)

35-2

3TN/4TN Series Yanmar Engines
010897

PN=147

M35273

-UN-29AUG88

M35272

-UN-29AUG88

M37508

-UN-29AUG88

M35270

Gear Housing/Timing Gear Cover
8. Remove cap screws to remove gear housing cover. Remove gasket material from cover and gear housing.

M21,TM310,41

-19-18FEB86

9. Remove seal using the correct driver disks (A and B) or screwdriver.
DISKS FOR SEAL REMOVAL Engine (A) 3TN66 3TNA72 3TN75/3TN78/3TN82/3TN84/ 4TN78/4TN82/4TN84 4TN100 1 11/16 1 3/4 Size (in.) (B) 2 3/8 2 7/16
-UN-29AUG88 M35275

2 1/8 1 5/8

2 3/4 2 3/8

M37511

-UN-06SEP88

35 3

M21,TM310,42

-19-07AUG87

CTM3 (03JAN90)

35-3

3TN/4TN Series Yanmar Engines
010897

PN=148

Gear Housing/Timing Gear Cover

INSTALL TIMING GEAR COVERS
1. Thoroughly clean and dry all parts. Use new gaskets, O-rings, and oil seals when assembling the engine. 2. Install seal with lip of seal toward inside of gear housing cover. Use the correct driver disks (A and B) to install seal flush with surface of gear housing cover.
DISKS FOR SEAL INSTALLATION Engine (A) 3TN66 3TNA72 3TN75/3TN78/3TN82/3TN84/ 4TN78/4TN82/4TN84 4TN100 1 11/16 1 3/4 Size (in.) (B) 2 1/2 2 9/16
M35275 -UN-29AUG88 M21,TM335,6 -19-07AUG87 M21,TM335,7 -19-07AUG87

2 1/8 1 5/8

2 7/8 2 1/2

35 4

3. Apply a bead of plastic gasket or equivalent on sealing surface of gear housing cover. 4. Install gear housing cover and fasten with cap screws. Tighten cap screws to specifications.
GEAR HOUSING COVER CAP SCREW TORQUE 3TN66/3TNA72 . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N·m (78 lb-in.) All except 3TN66/3TNA72 . . . . . . . . . . . . . . . . . 26 N·m (226 lb-in.)

CTM3 (03JAN90)

35-4

3TN/4TN Series Yanmar Engines
010897

PN=149

M37519

-UN-06SEP88

M21. alternator belt.TM335. Tighten cap screw to 115 N·m (85 lb-ft). Install pulley. Install engine. Install washer and cap screw.10 -19-01SEP87 8. Apply thread lock and sealer (medium strength) on threads of cap screw. -UN-29AUG88 M21. Install bracket and fuel shut-off solenoid. Fasten fuel shut-off solenoid linkage with washer and cotter pin.TM335.TM335. Install alternator. 5. if equipped.) CTM3 (03JAN90) 35-5 3TN/4TN Series Yanmar Engines 010897 PN=150 M35296 M35295 -UN-29AUG88 . Install and tighten two nuts and cap screws to 9 N·m (78 lb-in. and fan.8 -19-07AUG87 6.Gear Housing/Timing Gear Cover NOTE: For all engines except 3TNA72UJ (Early Units).). Align pin (A) (if equipped) in crankshaft pulley with hole (B). 10. 35 5 M21.TM335. go to step 7.11 -19-07AUG87 9.9 -19-01SEP87 M35272 -UN-29AUG88 M35294 -UN-29AUG88 7. M21. (See Machine Technical Manual.

TIMING GEAR BACKLASH SPECIFICATIONS (MAX) Fuel Injection Pump (A) . . replace if necessary. . . .12 -19-23APR86 M21.) Crankshaft (D) .TM335. .). Measure bushing inside diameter. .) If backlash exceeds the wear tolerance specifications.008 in. . . Inspect gear for chipped or broken teeth. . .20 mm (0. . .20 mm (0. Remove idler gear. . . . . . . . . . . . -UN-26AUG88 CTM3 (03JAN90) 35-6 3TN/4TN Series Yanmar Engines 010897 PN=151 M35492 M35491 -UN-26AUG88 M35489 . .008 in. . 3.13 -19-07FEB86 M21. . . .791 in. .08 mm (0. . . . . . . . . If diameter exceeds 20. replacing bushing. . . . . . 0. . . . . 0. 0.Gear Housing/Timing Gears (Early 3TNA72UJ) REMOVE AND INSPECT TIMING GEARS (EARLY 3TNA72UJ) 1. .) Idler (B) . . . . . . replace gears as necessary. timing marks will only align periodically. . 0. . . . . . . . . . . . . . . . . Measure backlash between gears. . .20 mm (0. . . . . . . . -UN-06SEP88 M21.14 -19-07FEB86 NOTE: Due to the odd number of teeth on the idler gear. . . . .TM335. . . . . .20 mm (0. . . .TM335. . . . . . . . . .008 in. . . .) Oil Pump (E) . . . . . . . . 35 6 2.) Camshaft (C) . . . . . .25 mm (0. 0.010 in. .008 in. . Number one cylinder is closest to the flywheel.

remove bushing using a 7/8 in. A—Gear Housing Cover Cap Screw B—Washer C—Bearing Puller D—H-Bar E—Slide Hammer M21. If diameter is less than 19.16 -19-07FEB86 M35494 M35493 -UN-26AUG88 7.TM335.15 -19-07FEB86 5. driver disk (B).). replace idler shaft.TM335.17 -19-07FEB86 8. driver disk (A) and 3/4 in.TM335.15 mm (0.18 -19-07FEB86 CTM3 (03JAN90) 35-7 3TN/4TN Series Yanmar Engines 010897 PN=152 M35496 -UN-26AUG88 M35495 -UN-26AUG88 . replace idler shaft.006 in. -UN-26AUG88 M21.Gear Housing/Timing Gears (Early 3TNA72UJ) 4. or both. 6. Determine idler shaft clearance (bushing diameter minus shaft diameter).3 mm (0.TM335.).785 in. If necessary. Remove set screw. Measure idler shaft diameter. idler bushing. M21. Remove idler shaft using a slide hammer and puller. If clearance exceeds 0. 35 7 M21.

20 -19-07FEB86 M21. driver disk (A) and 3/4 in. Idler shaft flange must be tight against bottom of cylinder block bore. 35 8 4.21 -19-07FEB86 2.TM335. Align holes in bushing and idler gear.TM335.TM335. Install bushing even with surface of idler gear using a 1-in. -UN-26AUG88 CTM3 (03JAN90) 35-8 3TN/4TN Series Yanmar Engines 010897 PN=153 M35493 M35495 -UN-26AUG88 M35497 . 3. Install idler shaft with flange toward cylinder block. Install and tighten set screw. driver disk (B). -UN-26AUG88 M21. 5.Gear Housing/Timing Gears (Early 3TNA72UJ) INSTALL TIMING GEARS (EARLY 3TNA72UJ) 1. Thoroughly clean and dry all parts.19 -19-07FEB86 M21.

. . . .008 in. 0. . . . . . . . . .20 mm (0. 0. TIMING MARKS Timing Mark “A—A” “B—B” “C—C” Gear Crankshaft-to-idler Engine Camshaft-to-idler Fuel Injection Pump Camshaft-to-Idler M21.010 in. . . . Number one cylinder is closest to the flywheel. . CTM3 (03JAN90) 35-9 3TN/4TN Series Yanmar Engines 010897 PN=154 M37832 .22 -19-23APR86 M52956 -UN-05APR89 REMOVE AND INSPECT TIMING GEARS (3TN66/LATER 3TNA72) 1. . . . . . fuel injection pump. . .) 35 9 If backlash exceeds the wear tolerance specifications. . . .20 mm (0. . . . . . . . .TM335. . . . . 8. Carefully install idler gear. . . . . . . . Measure backlash between gear. . 0. . .) Crankshaft (D) . . . . 7. . . . . . . .25 mm (0. Later 3TNA72) 6. . . . . Install gears. . . . . . . .TM335. 0. . . . TIMING GEAR BACKLASH SPECIFICATIONS (MAX) Fuel Injection Pump (A) . .) Camshaft (C) . .) Oil Pump (E) . . replace gears as required. . idler.20 mm (0. . . . . . . . .008 in. Align timing marks between crankshaft. . . . . timing marks will only align periodically. . . -UN-29AUG88 M21. . . . .008 in. . . . . . 0. .20 mm (0. .Gear Housing/Timing Gears (3TN66. . . .008 in. . . . . . NOTE: Number one cylinder is closest to flywheel. . . .) Idler (B) . .23 -19-08AUG87 NOTE: Due to the odd number of teeth on the idler gear. . and camshaft gears. if removed. .

TM335.15 mm (0.14 -19-07FEB86 35 10 4. -UN-26AUG88 M21. replace idler shaft. -UN-29AUG88 M21. Measure bushing inside diameter. -UN-29AUG88 M21. Measure idler shaft diameter.15 -19-07FEB86 5.006 in. If diameter exceeds 20. 6. Remove snap ring and washer (A) to remove idler gear. remove bushing using a 7/8 in. If clearance exceeds 0. driver disk (B). idler bushing.25 -19-23APR86 CTM3 (03JAN90) 35-10 3TN/4TN Series Yanmar Engines 010897 PN=155 M37834 M35493 -UN-26AUG88 M35492 M37833 . Inspect gear for chipped or broken teeth.93 mm (0. If diameter is less than 19.TM335. replace idler shaft. or both. replace if necessary.785 in.24 -19-07FEB86 3. replacing bushing.).Gear Housing/Timing Gears (3TN66. M21.791 in. Later 3TNA72) 2.08 mm (0.TM335.). If necessary.TM335.). driver disk (A) and 3/4 in. Determine idler shaft oil clearance (bushing diameter minus shaft diameter).

4.TM335. Align oil holes in bushing and idler gear.TM335. -UN-29AUG88 M21. -UN-26AUG88 M21. M21. Thoroughly clean and dry all parts. Install idler shaft and three cap screws. Later 3TNA72) 7. 2.Gear Housing/Timing Gears (3TN66.27 -19-08AUG87 M37835 M37835 -UN-29AUG88 3.28 -19-07FEB86 35 11 CTM3 (03JAN90) 35-11 3TN/4TN Series Yanmar Engines 010897 PN=156 M35493 . driver disk (B). Tighten cap screws.26 -19-07FEB86 INSTALL TIMING GEARS (3TN66/LATER 3TNA72) 1. Install bushing even with surface of idler gear using a 1 in.TM335. driver disk (A) and 3/4 in. Remove three cap screws to remove idler shaft.

B. Install gears.Gear Housing/Timing Gears (3TN66. and C) between crankshaft. Align timing marks (A. 6.29 -19-23APR86 CTM3 (03JAN90) 35-12 3TN/4TN Series Yanmar Engines 010897 PN=157 M37806 -UN-29AUG88 M37805 -UN-29AUG88 .TM335. Install idler gear. if removed. NOTE: Number one cylinder is closest to the flywheel. and snap ring. washer. idler. Later 3TNA72) 5. (Later 3TNA72UJ) (3TN66UJ) 35 12 M21. 7. fuel injection pump and camshaft gears.

replace gears as required. . Measure backlash between gears. . . . . . . . . . . . . . . . .20 mm (0. . . 0. 0. .25 mm (0. . . . . . .010 in. . .20 mm (0. 0. . . . . . . .010 in. . .20 mm (0. .20 mm (0. . . Inspect gear for chipped or broken teeth. . . . . .) Oil Pump (E) . .008 in. . . . .) 4TN100 Fuel Injection Pump (A) . .25 mm (0. 0.) Camshaft (C) . . . . . 35 13 NOTE: Due to the odd number of teeth on the idler gear. . .) Crankshaft (D) . . . replace if necessary. -UN-29AUG88 M21. . . . . . 0. . . . . . . .25 mm (0.) Crankshaft (D) . . . .Gear Housing/Timing Gears (All Except 3TN66/3TNA72 REMOVE AND INSPECT TIMING GEARS (ALL EXCEPT 3TN66/3TNA72) 1. M21. . . . . .010 in. . . . . . . . . . . .008 in. . . . . . . . . . . .25 mm (0. . . . . . . . . . . . . . . . . . . .30 -19-08AUG87 2. . . .) Camshaft (C) . . 0. . . . . . 0. .) If backlash exceeds the wear tolerance specifications. . . . . . . . . TIMING GEAR BACKLASH SPECIFICATIONS (MAX) 3TN75/3TN78/3TN82/3TN84/4TN78/4TN82/4TN84 Fuel Injection Pump (A) . . . . . . 0. . . . . . .25 mm (0. . . . . . . . . . . . . . .008 in. 0. . . . . . . . . .31 -19-07FEB86 CTM3 (03JAN90) 35-13 3TN/4TN Series Yanmar Engines 010897 PN=158 M37837 .010 in. . . . .TM335. .) Idler (B) . . . . . 0. Remove two cap screws to remove idler shaft and idler gear. . . . . . . .TM335. .010 in. . . .20 mm (0. . .) -UN-29AUG88 M37836 Idler (B) . .008 in. . . timing marks will only align periodically. . . .) Oil Pump (E) . . . . . . . Number one cylinder is closest to the flywheel. . .008 in. . . . . . . . . . .

15 mm (0. -UN-29AUG88 CTM3 (03JAN90) 35-14 3TN/4TN Series Yanmar Engines 010897 PN=159 M37839 M37840 M37839 -UN-29AUG88 M37838 . If diameter is less than 45.TM335.TM335. Thoroughly clean and dry all parts. driver disk (B). driver disk (A) and 1 13/16 in.35 -19-10AUG87 INSTALL TIMING GEARS (ALL EXCEPT 3TN66/3TNA72) 1. If diameter exceeds 46.814 in. 2.Gear Housing/Timing Gears (All Except 3TN66/3TNA72 3.). If necessary.32 -19-23APR86 4. or both. -UN-29AUG88 M21.808 in.).TM335. If oil clearance exceeds 0. remove bushing using a 1 15/16 in. replace idler shaft. Align oil holes in bushing and idler gear. 3. Measure idler shaft diameter.) replace idler shaft.33 -19-07FEB86 35 14 5. M21. idler bushing. Measure bushing inside diameter.08 mm (1.TM335.006 in. driver disk (A) and 1 13/16 in. 6. Install bushing even with surface of idler gear using a 2 1/4 in. replace bushing.93 mm (1.34 -19-07FEB86 M21. driver disk (B). Determine idler shaft oil clearance (bushing diameter minus shaft diameter). -UN-29AUG88 M21.

5. if removed.82. fuel injection pump. Align timing marks (A.TM335. 6.84 “A—A” “B—B” “C—C” Crankshaft-to-idler Fuel Injection Pump-to-idler Engine camshaft-to-idler M37841 -UN-29AUG88 35 15 4TN100 M21.78. Install gears. 7.82.84/4TN78. B. and camshaft gear. Tighten cap screws TIMING MARKS Timing Mark “A—A” “B—B” “C—C” Gear Engine Camshaft-to-idler Fuel Injection Pump-to-idler Crankshaft-to-idler 3TN75. Install idler shaft and two cap screws.Gear Housing/Timing Gears (All Except 3TN66/3TNA72 4. Carefully install idler gear.36 -19-10AUG87 CTM3 (03JAN90) 35-15 3TN/4TN Series Yanmar Engines 010897 PN=160 M51564 -UN-31AUG88 . idler. and C) between crankshaft.

Remove governor linkage (B).TM335. Remove throttle linkage (A). (See Group 35 in this manual). See Group 55 in this manual. Remove fuel injection pump and camshaft (A).Gear Housing/Gear Housing REMOVE GEAR HOUSING 1.37 -19-10AUG87 NOTE: For all engines except early 3TNA72U go to step 12. (See Group 35 in this manual). 2. Remove engine camshaft and gear (C). (See Group 40 in this manual. (See Group 50 in this manual).) A—Throttle Linkage B—Governor Linkage C—Oil Pump Cover D—Oil pump M21. 6. (See Group 10 in this manual).TM335.) 8. 3.38 -19-07FEB86 CTM3 (03JAN90) 35-16 3TN/4TN Series Yanmar Engines 010897 PN=161 M35502 -UN-26AUG88 M37842 -UN-29AUG88 .) A—Injection Pump Camshaft/Gear B—Idler Gear C—Engine Camshaft/Gear D—Oil Pump/Gear Later 3TNA72UJ Shown 35 16 M21. 4. (See Group 40 in this manual. Remove oil pump assembly (D). Remove idler gear (B). 7. Remove oil pump cover (C) and oil pump (D). 5. (See Group 55 in this manual). Remove timing gear cover.

Remove cap screws to remove gear housing. Remove cover and gasket (A).41 -19-07FEB86 NOTE: Early 3TNA72UJ: be careful not to lose special screws (A) while removing gear housing. Remove old gasket material from gear housing and cylinder block.TM335.40 -19-11MAR86 M35504 -UN-26AUG88 M35503 -UN-26AUG88 11.39 -19-07FEB86 10.42 -19-07FEB86 3TNA72UJ Shown CTM3 (03JAN90) 35-17 3TN/4TN Series Yanmar Engines 010897 PN=162 M35506 M35505 -UN-26AUG88 . 13. Remove seven studs and two spring pins (A). 35 17 M21. -UN-26AUG88 M21. M21.TM335.TM335. Remove two cap screws to remove bracket.TM335. M21.Gear Housing/Gear Housing 9. 12.

. . .44 -19-07FEB86 3. Install bracket and fasten with two cap screws.) 35 18 NOTE: For all engines except early 3TNA72UJ go to step 13. . 2. . . . . . . . . .) Aluminum . -UN-26AUG88 CTM3 (03JAN90) 35-18 3TN/4TN Series Yanmar Engines 010897 PN=163 M35505 M35506 NOTE: Early 3TNA72: Install special screw (A) before installing gear housing. . . . .TM335. . . O-rings. . . . . . . . . . . 5. . . Apply plastic gasket or an equivalent on the gear housing. .) All except 3TN66/3TNA72 Cast Iron . Thoroughly clean and dry all parts. . . .Gear Housing/Gear Housing INSTALL GEAR HOUSING 1. . . . . . 25 N·m (220 lb-in. . . . . . . . . . 4. . . . 11 N·m (96 lb-in. . . CAP SCREW TORQUE SPECIFICATIONS 3TN66/3TNA72 Cast Iron . and oil seals when assembling the engine. Install and tighten cap screws. . . . . . . . . . . . . . . . . . . . . . . . Install gear housing. .TM335. .) Aluminum . .43 -19-10AUG87 M21. . 20 N·m (177 lb-in. . . . . . . . . . . . . . Use new gaskets. . . . . Align gear housing holes with dowel pins on the cylinder block. 9 N·m (78 lb-in. . . -UN-26AUG88 M21. . . . . . .

) 12. Install oil pump (D) and oil pump cover (C). -UN-26AUG88 M21.47 -19-23APR86 35 19 CTM3 (03JAN90) 35-19 3TN/4TN Series Yanmar Engines 010897 PN=164 M35502 -UN-26AUG88 .TM335. Apply thread lock and sealer (low strength) on the threads of studs. 7.Gear Housing/Gear Housing 6. Install throttle linkage (A).46 -19-07FEB86 M35503 -UN-26AUG88 M35504 9.45 -19-07FEB86 M21. (See Group 40 in this manual. Install governor linkage (B). Install seven studs with short-threaded end in gear housing. Install two spring pins (A).) A—Throttle Linkage B—Governor Linkage C—Oil Pump Cover D—Oil Pump M21.) 11. 8.TM335. (See Group 55 in this manual.TM335. (See Group 55 in manual. Install new gasket (A) and cover. 10.

) 15. (See Group 35 in this manual.) IMPORTANT: Make sure to align timing marks between crankshaft. (See Group 10 in this manual.) 16. injection pump. Install timing gear cover (See Group 35 in this manual.TM335. Install camshaft (B).) 17. idler. Install injection pump camshaft (C). Install idler gear (A).48 -19-07FEB86 35 20 CTM3 (03JAN90) 35-20 3TN/4TN Series Yanmar Engines 010897 PN=165 M35501 -UN-26AUG88 . (See Group 40 in this manual. Install oil pump (D). 14.Gear Housing/Gear Housing 13. (See Group 50 in this manual. and camshaft gears.) A—Idler Gear B—Engine Camshaft/Gear C—Injection Pump Camshaft/Gear D—Oil Pump/Gear M21.

2 -19-28AUG87 CTM3 (03JAN90) 40-1 3TN/4TN Series Yanmar Engines 010897 PN=166 . and oil pan. oil pan spacer.TM340. PT94 LOCTITE is a trademark of the Loctite Corp. and Seal Driver Set Dial Indicator Depth Micrometer Outside Micrometer Telescoping Gauge Vernier Calipers Belt Tension Gauge Spring Compression Tester O-Ring Seal Tool Set Remove crankshaft pulley Remove crankshaft pulley and gears Remove and install seals Measure oil pump gear backlash Measure oil pump body depth Measure oil pump components Measure oil pump components Measure rotor ring diameter Check belt tension Check oil pressure regulating valve spring Remove and install O-rings 40 1 M21. Some tools may be available from a local supplier. M21.TM340.Group 40 Lubrication System SERVICE EQUIPMENT AND TOOLS NOTE: Order tools from the U. To seal gear housing cover. crankshaft seal case. Bearing. SERVICEGARD™ Catalog or from the European Microfiche Tool Catalog (MTC). Name Use Strap Wrench 13-Ton Puller Set Bushing.1 -19-28AUG87 OTHER MATERIAL Number Name Use T43512 John Deere LOCTITE® Thread Lock and Sealer (Medium Strength) John Deere Form-In-Place Gasket (RTV rubber silicone sealant) Apply to threads of crankshaft pulley cap screw.S.

To avoid oil leakage install new seal. Clean and dry gasket application surfaces. Remove old gasket material from oil pan and engine block (or spacer).A14 -19-25MAY89 CTM3 (03JAN90) 40-2 3TN/4TN Series Yanmar Engines 010897 PN=167 M35632 -UN-26AUG88 M35581 . Apply plastic gasket. 7.TM340. 4.Lubrication System/Remove and Install Oil Pump REMOVE AND INSTALL OIL PAN 1. Remove cap screws to remove oil strainer tube and seal. Remove cap screws to remove oil pan spacer. 9. Install seal and oil strainer tube. Remove old gasket material from spacer and engine block. 3TNA72 Shown 3TNA72 Shown 40 2 MX. 8. (See Machine Technical Manual for engine oil capacity specifications. -UN-26AUG88 NOTE: For all engines except 4TN100. IMPORTANT: DO NOT reuse oil strainer tube seal. go to step 9. Remove engine oil dipstick. Remove cap screws (A and B) to remove oil pan.) 2. Clean and dry gasket application surfaces. Tighten cap screws to specifications. Install spacer. 3. 10. Tighten cap screws to specifications. 5. 6. Drain engine oil. to spacer. or an equivalent.

. . . . . . . . . . . . . . .) 40 3 MX. .TM340. . . . . . . . .Lubrication System/Oil Pump (Early 3TNA72UJ) 11. . . . . .TM340. (See Section 20 in Machine Technical Manual. . . . . . .A14A -19-12JUL89 REMOVE OIL PUMP (EARLY 3TNA72UJ ENGINES) 1. Remove engine. . .) Oil Pan-to-Gear Housing Cover 3TN66/3TNA72 . . 9 N·m (78 lb-in. 21 N·m (180 lb-in. . . . . . . . . . . .) 3TN75/3TN78/3TN82/3TN84/ 4TN78/4TN82/4TN84 . . . . . .5 -19-23APR86 CTM3 (03JAN90) 40-3 3TN/4TN Series Yanmar Engines 010897 PN=168 M35630 -UN-26AUG88 . . Install dipstick. . . . . .) M12 . . . . . . . . . . . . . . . . .) Oil Pan-to-Block 3TN66/3TNA72 . . . . . . . (See Machine Technical Manual for type and capacity of engine oil. . . . . . . . . . . . . . . . 26 N·m (226 lb-in. . . . . . . .) 4TN100 . . . . . .) All except 3TN66/3TNA72 . . . 21 N·m (180 lb-in. . . . 26 N·m (226 lb-in. . 12. . Tighten cap screws to specifications. . 13. . . . . .) All except 3TN66/3TNA72 . . Apply plastic gasket. . . . 11 N·m (96 lb-in. . . .) 2. . . . . . 88 N·m (65 lb-ft) Oil Pan Spacer-to-Crankshaft Seal Case 4TN100 . . . . . . . . . . Install oil pan.) Oil Pan Spacer-to-Block 4TN100 M8 . . . . . M21. . . . . . . .) CAP SCREW TORQUE SPECIFICATIONS Strainer Tube 3TN66/3TNA72 . . . . . . . . . . . . . . . 11 N·m (96 lb-in. . 26 N·m (226 lb-in. . . . . . . . . Fill engine with oil to specifications. 3. . . . . 26 N·m (226 lb-in. . or an equivalent. Remove alternator belt. . to oil pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove fuel injection lines (A) and fuel injection pump (B) as instructed in Group 50. . . . . . .

Lubrication System/Oil Pump (Early 3TNA72UJ) 4. Use a puller.TM340.TM340. -UN-26AUG88 M21. Remove 17 cap screws to remove gear housing cover. shaft protector. Disconnect shut-off linkage. If backlash exceeds 0. Remove crankshaft pulley cap screw and washer.11—0. New backlash specification is 0. and a strap wrench.). (See Group 35 in this manual.9 -19-05MAR86 9.20 mm (0. Check backlash of other gears in gear housing. Remove old gasket material from cover and gear housing.6 -19-05MAR86 6. Measure oil pump gear backlash using a dial indicator. 10.008 in.19 mm (0. Remove two nuts and cap screw to remove fuel shut-off solenoid bracket. Remove crankshaft pulley. M21.004—0.TM340. replace gear.TM340.8 -19-05MAR86 8.7 -19-05MAR86 40 4 7.008 in. M21. two cap screws from water pump.) CTM3 (03JAN90) 40-4 3TN/4TN Series Yanmar Engines 010897 PN=169 M35533 M35532 M35273 -UN-29AUG88 M35271 -UN-29AUG88 .) -UN-26AUG88 M21. 5.

TM340.13 -19-23APR86 CTM3 (03JAN90) 40-5 3TN/4TN Series Yanmar Engines 010897 PN=170 M35537 M35536 . M35535 -UN-26AUG88 M35534 -UN-26AUG88 40 5 -UN-26AUG88 M21.Lubrication System/Oil Pump (Early 3TNA72UJ) 11.TM340.12 -19-05MAR86 IMPORTANT: DO NOT allow fuel injection pump camshaft lobes to hit bearing surfaces while removing camshaft.11 -19-05MAR86 13.TM340. M21. Loosen lock nut. Carefully remove injection pump camshaft assembly.TM340. -UN-26AUG88 M21. Remove idler gear. Machined surfaces may be damaged. 14. M21. Remove bearing retaining screw. Put a shop towel between gear teeth.10 -19-05MAR86 12. Use a slide hammer puller and two cap screws from the housing cover.

Remove two cap screws and nut to remove cover and gasket (A). 16. Remove two cap screws to remove bracket and four washers (A). Disconnect spring from governor linkage.15 -19-05MAR86 M21. 40 6 -UN-26AUG88 21.TM340. Remove sealing wire (A).17 -19-05MAR86 18. Remove oil filter and oil dipstick tube. 19.14 -19-23APR86 -UN-26AUG88 M21.Lubrication System/Oil Pump (Early 3TNA72UJ) 15.16 -19-05MAR86 M21.TM340. CTM3 (03JAN90) 40-6 3TN/4TN Series Yanmar Engines 010897 PN=171 M35542 -UN-26AUG88 M35541 M35540 M35539 .TM340. A—Washer (4 used) B—Cap Screw (4 used) C—Cover D—Gasket M21. 17.TM340. Remove two cap screws (B) to remove cover (C) and gasket (D). Loosen nut (B). Turn slow idle adjusting screw (C) counterclockwise several turns. -UN-26AUG88 20.

Remove nut.19 -19-05MAR86 24.TM340.TM340.Lubrication System/Oil Pump (Early 3TNA72UJ) 22. -UN-26AUG88 M21.21 -19-05MAR86 CTM3 (03JAN90) 40-7 3TN/4TN Series Yanmar Engines 010897 PN=172 M35546 M35545 . Remove oil pump gear using a three-jaw puller. M21. Replace as necessary. M35544 -UN-26AUG88 M35543 -UN-26AUG88 40 7 -UN-26AUG88 M21. M21.TM340. Inspect gear for chipped or broken teeth. Remove governor shaft and washer (A).18 -19-05MAR86 23. Remove governor shaft lever.20 -19-05MAR86 25.TM340. 26.

.23 -19-05MAR86 INSPECT OIL PUMP ASSEMBLY (EARLY 3TNA72UJ) 40 8 ROTOR-TO-PUMP BODY SPECIFICATIONS Difference of two measurements (new parts) . . . . 0. . M21. -UN-26AUG88 M21. . .) NOTE: The measurement between 0.006 in.010 in.TM340. . . see Remove Oil Pressure Regulating Valve in this group. . M35548 -UN-26AUG88 M35547 -UN-26AUG88 NOTE: For repair of oil pressure regulating valve (B).15—0. . If rotor clearance exceeds the maximum specification. . .25 mm (0.TM340. M21. .22 -19-05MAR86 28. . . Remove four cap screws and nut to remove oil pump cover and gasket (A). . .006—0.24 -19-10AUG87 CTM3 (03JAN90) 40-8 3TN/4TN Series Yanmar Engines 010897 PN=173 M35550 M35549 -UN-26AUG88 1. replace gear housing. . . . .25 mm (0.Lubrication System/Oil Pump (Early 3TNA72UJ) 27. .TM340. . 0.08—0.15 mm (0. .003—0. Remove oil pump assembly.) Maximum difference allowed . .) indicates a tolerable wear difference that could affect pump efficiency. . .010 in. . Measure rotor-to-pump body clearance (pump body depth minus rotor depth). . . . .

INNER ROTOR-TO-ROTOR RING SPECIFICATIONS Difference of two measurements (new parts) . . . . . . . If inner rotor clearance exceeds the maximum specification.25 mm (0. .) -UN-26AUG88 M21.15 mm (0.006 in. . . . .) -UN-26AUG88 M21. .TM340.15 mm (0.) Maximum difference allowed . . ROTOR RING-TO-PUMP BODY SPECIFICATIONS Difference of two measurements (new parts) . .010 in. . .26 -19-06MAR86 40 9 NOTE: The measurement between 0.010 in. .25 -19-05MAR86 M35552 -UN-26AUG88 M35551 NOTE: The measurement between 0. . . . . .010 in. .010 in. . replace gear housing. . . . . . . Measure inner rotor-to-rotor ring clearance (rotor ring diameter minus inner rotor diameter). . . 0. . If rotor ring clearance exceeds the maximum specification. .) indicates a tolerable wear difference that could affect pump efficiency.25 mm (0. . . .15—0. . . . . . .) indicates a tolerable wear difference that could affect pump efficiency. . . . 0. .Lubrication System/Oil Pump (Early 3TNA72UJ) 2.) Maximum difference allowed . . .006 in. . . . . . . replace oil pump assembly.10—0. 0. Measure rotor ring-to-pump body clearance (pump body diameter minus rotor ring diameter).25 mm (0.25 mm (0. 0.10—0. .15—0. CTM3 (03JAN90) 40-9 3TN/4TN Series Yanmar Engines 010897 PN=174 M35554 -UN-26AUG88 M35553 . 3.004—0. .TM340.006—0.004—0. . . .006—0. . . . .

replace gear housing. replace gear housing and oil pump assembly. OIL PUMP BORE SPECIFICATIONS Bore diameter (new parts) .27 -19-06MAR86 5. . 0. . . .0039 in. . . . . .) NOTE: The measurement between 0.4988—0.67—12. .) Bore diameter (maximum) .) Maximum difference allowed . . . 12. . . . .499 in.048—0. Measure inner rotor shaft clearance (oil pump bore diameter minus inner rotor shaft diameter).015—0. 12. . .685 mm (0. .TM340. . .718 mm (0. . . .5—0. 12. . . .100 mm (0.048 mm (0. . .0019—0. INNER ROTOR SHAFT CLEARANCE SPECIFICATIONS 40 10 Difference of two measurements (new parts) . . .8 mm (0. . . . . 12.5007 in. . . . . -UN-26AUG88 . .65 mm (0. . replace oil pump assembly.0006—0. . .100 mm (0.Lubrication System/Oil Pump (Early 3TNA72UJ) 4.28 -19-06MAR86 CTM3 (03JAN90) 40-10 3TN/4TN Series Yanmar Engines 010897 PN=175 M35556 If bore diameter exceeds the maximum specification. . . . . . . . -UN-26AUG88 M35555 If shaft diameter is less than the minimum specification. .) Shaft Diameter (minimum) . M21. .7—12. 0. . . . . .) indicates a tolerable wear difference that could affect pump efficiency. . . .0039 in. Measure oil pump bore diameter. .) M21. . If inner rotor shaft clearance exceeds specifications. .0019 in.) 6. . . . . . . . . . . Measure inner rotor shaft diameter. .504 in. . .TM340.4980 in. INNER ROTOR SHAFT SPECIFICATIONS Shaft Diameter (new parts) . . . .

Lubrication System/Oil Pump (Early 3TNA72UJ) INSTALL OIL PUMP (EARLY 3TNA72UJ) 1.TM340. Use new gaskets and seals when assembling the engine. IMPORTANT: Marks (A) on inner rotor and rotor ring must be installed toward gear housing. 2.TM340. Thoroughly clean and dry all parts.30 -19-06MAR86 CTM3 (03JAN90) 40-11 3TN/4TN Series Yanmar Engines 010897 PN=176 M35558 -UN-26AUG88 . Install rotor ring (B) and inner rotor shaft (C) in gear housing. Put clean engine oil on all sides and surfaces of oil pump rotors. governor weights. -UN-26AUG88 M21. 3. Install thrust washer. and sleeve (D) on rotor shaft. Align splines on inner rotor shaft (A) with splines in thrust washer (B) and governor weights (C). A—Inner Rotor Shaft B—Thrust Washer C—Governor Weights D—Sleeve 40 11 M21.29 -19-10AUG87 M35557 4.

).32 -19-28AUG86 8.TM340.TM340. -UN-26AUG88 M21. Install oil pump cover. 40 12 -UN-26AUG88 M21.34 -19-06MAR86 CTM3 (03JAN90) 40-12 3TN/4TN Series Yanmar Engines 010897 PN=177 M35545 -UN-26AUG88 M35561 M35560 -UN-26AUG88 M35559 .33 -19-06MAR86 9.TM340.Lubrication System/Oil Pump (Early 3TNA72UJ) 5. Install oil pump gear. M21. Install and tighten four cap screws and nut to 9 N·m (78 lb-in. Install gasket. Install nut.31 -19-06MAR86 7. M21. Align spring pins (A) in cover with holes (B) in gear housing.TM340. 6.

36 -19-28AUG86 14.TM340.TM340. 40 13 -UN-26AUG88 M21.37 -19-06MAR86 CTM3 (03JAN90) 40-13 3TN/4TN Series Yanmar Engines 010897 PN=178 M35542 -UN-26AUG88 M35563 . 13. M21. 11.TM340. Tighten governor shaft to 49 N·m (430 lb-in.).Lubrication System/Oil Pump (Early 3TNA72UJ) 10. Install washer (A) on governor shaft (B). -UN-26AUG88 M21. Connect spring to internal lever and then to governor assembly. Install governor shaft through governor shaft lever. Install governor shaft lever (C).35 -19-06MAR86 M35562 -UN-26AUG88 M35544 12.

39 -19-10AUG87 19.TM340. two each over hole location. 40 14 20.40 -19-06MAR86 21. bracket (C).TM340.Lubrication System/Oil Pump (Early 3TNA72UJ) 15. IMPORTANT: DO NOT allow fuel injection pump camshaft lobes to hit bearing surfaces while installing camshaft. -UN-26AUG88 M21. Carefully install fuel injection pump camshaft assembly. Install cover and fasten with two cap screws and nut. cover.41 -19-06MAR86 CTM3 (03JAN90) 40-14 3TN/4TN Series Yanmar Engines 010897 PN=179 M35568 -UN-26AUG88 M35538 M35566 -UN-26AUG88 M35564 . and two cap screws (D). Push bearings to bottom of gear housing bore. Install dipstick tube (B) and fasten with cap screw. 22. 16. M21.TM340. Tighten cap screws and nut to 9 N·m (78 lb-in. Put washers between cover and bracket. Install four washers (B). A—Cap Screw (2 used) B—Washer (4 used) C—Bracket D—Cap Screw (2 used) M21.). -UN-26AUG88 M21. and two cap screws (A). Install oil filter (A).TM340. 18. Install gasket. Tighten four cap screws to 9 N·m (78 lb-in.). Machined surfaces may be damaged. Install gasket. Apply clean engine oil on fuel injection pump camshaft bearings.38 -19-10AUG87 17.

Timing Marks Timing Mark “A—A” “B—B” “C—C” Gear Crankshaft-to-Idler Camshaft-to-Idler Fuel Injection Pump Camshaft-to-Idler -UN-05APR89 M52957 M35569 -UN-26AUG88 40 15 M21.).Lubrication System/Oil Pump (Early 3TNA72UJ) 23. M21. and camshaft gears.TM340. M21.44 -19-10AUG87 CTM3 (03JAN90) 40-15 3TN/4TN Series Yanmar Engines 010897 PN=180 M35570 -UN-26AUG88 . idler.42 -19-10AUG87 24. Tighten lock nut to 88 N·m (65 lb-ft).TM340. Put a shop towel between gear teeth.TM340.43 -19-06MAR86 26. 25. Carefully install idler gear. fuel injection pump. Align timing marks between crankshaft. Install and tighten bearing retaining screw to 20 N·m (180 lb-in.

29. Apply plastic gasket or an equivalent on gear housing cover.TM340.).Lubrication System/Oil Pump (Early 3TNA72UJ) 27. M21.TM340. Tighten cap screws to 9 N·m (78 lb-in.46 -19-28AUG87 30.TM340. driver disk (A) and 2-3/8 in.48 -19-06MAR86 CTM3 (03JAN90) 40-16 3TN/4TN Series Yanmar Engines 010897 PN=181 M35272 -UN-29AUG88 M35294 M35571 -UN-26AUG88 M35275 -UN-29AUG88 . M21.47 -19-28AUG87 31.TM340. 40 16 -UN-29AUG88 M21. replace front crankshaft oil seal using a 1-3/4 in.). If necessary. Connect fuel shut-off solenoid linkage. M21.45 -19-06MAR86 28. Install new seal with lip toward inside of gear housing. Fasten linkage with washer (A) and cotter pin. Install fuel shut-off solenoid bracket. driver disk (B). Install and tighten two nuts and cap screw to 9 N·m (78 lb-in. Install gear housing cover and fasten with 17 cap screws. Install flush with face of housing cover.

apply force ONLY to rear alternator housing (near the belt) to prevent alternator damage. Hold crankshaft pulley using a strap wrench.Lubrication System/Oil Pump (Early 3TNA72UJ) 32. -UN-29AUG88 M21. Apply force against alternator housing and tighten cap screw. Install alternator belt. Align pin (A) in crankshaft pulley with hole (B) in crankshaft.51 -19-06MAR86 CTM3 (03JAN90) 40-17 3TN/4TN Series Yanmar Engines 010897 PN=182 M35667 . Alternator belt must deflect 13 mm (0. Apply thread lock and sealer (medium strength) on threads of cap screw. 36. 35. M21. IMPORTANT: When adjusting belt tension. Install washer and cap screw.5 in.49 -19-06MAR86 33.50 -19-10AUG87 34. loosen cap screw and adjust belt tension. M35296 M35295 -UN-29AUG88 40 17 -UN-26AUG88 M21.TM340.TM340.TM340. If necessary.) at 107 N (24 lb) Force applied halfway between pulleys. Install pulley. Check belt tension using a belt tension gauge. Tighten cap screw to 88 N·m (65 lb-ft).

(See Section 230 in Machine Technical Manual.) 38. Remove cap screw and washer. Bleed fuel injection system. -UN-29AUG88 5.53 -19-10AUG87 M21. Remove crankshaft pulley.Lubrication System/Oil Pressure Regulating Valve (Early 3TNA72UJ) 37. Check and adjust slow idle setting.TM340. (See Group 50 in this manual. Remove 17 gear housing cap screws and remove gear housing cover. 40 18 4. and a strap wrench. shaft protector.55 -19-06MAR86 REMOVE OIL PRESSURE REGULATING VALVE (EARLY 3TNA72UJ) 1. (See Machine Technical Manual.TM340.) 40. Hold crankshaft pulley with strap wrench.) -UN-26AUG88 M21. (See Machine Technical Manual. 6.TM340. (See Section 20 in Machine Technical Manual. Install fuel injection pump (B) and fuel injection lines (A). two cap screws from water pump. Use a puller. Disconnect fuel shut-off linkage. CTM3 (03JAN90) 40-18 3TN/4TN Series Yanmar Engines 010897 PN=183 M35273 -UN-29AUG88 M35271 M35270 -UN-29AUG88 M35630 . Remove fan belt. Remove engine. Remove two nuts and cap screw to remove fuel shut-off solenoid bracket.54 -19-06MAR86 M21. 3.TM340. Install engine.) 2.) 39.52 -19-06MAR86 M21.

. .4 ± 3. spring (B). . .56 -19-06MAR86 IMPORTANT: If oil pressure regulating valve is being disassembled to be cleaned. . .5—40. .55—1. .57 -19-06MAR86 CTM3 (03JAN90) 40-19 3TN/4TN Series Yanmar Engines 010897 PN=184 . . if equipped. Remove shims (A).18 in. Check spring (B) using spring compression tester. . . Inspect valve and housing bore for wear or damage. 9. . 8. . .Lubrication System/Oil Pressure Regulating Valve (Early 3TNA72UJ) 7. and valve (C). 39. . . .6 ± 0.TM340. . . 40 19 M21. NEW SPRING SPECIFICATIONS Free Length . M21. 30.59 in. . . .) Test Length at Force of 29. the same number and thicknesses of shims must be installed when assembled. .) M35573 -UN-26AUG88 M35572 -UN-26AUG88 10. . . . . Valve must slide freely in bore.7 lb) .1 N (6. .0 mm (1. . . . . Remove spring retainer. . Replace parts as necessary.5 mm (1.TM340. .

until the oil pressure is 365 ± 69 kPa (53 ± 10 psi). IMPORTANT: If oil pressure regulating valve was disassembled to be cleaned. 40 20 5.008 in. 3.85 psi) change in oil pressure.) of shim thickness.20 mm (0. (See Section 220 in Machine Technical Manual. After assembling the oil pressure regulating valve. Apply clean engine oil on valve. Install and tighten spring retainer.012 in.3 psi) -UN-26AUG88 M21.58 -19-28AUG87 M21.30 mm (0. check the oil pressure. Thoroughly clean and dry all parts.) SHIM PACK Shim Size 0. CTM3 (03JAN90) 40-20 3TN/4TN Series Yanmar Engines 010897 PN=185 M35572 -UN-26AUG88 M35573 . 2. there is approximately a 6 kPa (0.) Approximate Pressure Change 6 kPa (0.008 in. 4. Install valve (C) and spring (B) in housing bore.) 0.20 mm (0.TM340. Install the required amount of shims (A) from shim pack. the same number and thicknesses of shims must be installed.59 -19-06MAR86 NOTE: For every 0.TM340.Lubrication System/Oil Pressure Regulating Valve (Early 3TNA72UJ) INSTALL OIL PRESSURE REGULATING VALVE (EARLY 3TNA72UJ) 1.85 psi) 9 kPa (1.

TM340. Install gear housing cover and fasten with 17 cap screws.63 -19-06MAR86 CTM3 (03JAN90) 40-21 3TN/4TN Series Yanmar Engines 010897 PN=186 M35295 -UN-29AUG88 M35294 . Tighten cap screws to 9 N·m (78 lb-in. M21. M21.Lubrication System/Oil Pressure Regulating Valve (Early 3TNA72UJ) 6.61 -19-10AUG87 9. replace front crankshaft oil seal using a 1 3/4 in. Install fuel shut-off solenoid with bracket and connect shut-off linkage. Apply plastic gasket or an equivalent on gear housing cover.60 -19-06MAR86 7. driver disk (A) and a 2 3/8 in. Install new seal with lip facing inside of gear housing. If necessary.TM340. Press seal flush with face of housing cover. Install pulley.TM340. disk (B). M35498 -UN-26AUG88 M35275 -UN-29AUG88 40 21 -UN-29AUG88 M21.). M21.TM340. 8. Align pin (A) in crankshaft pulley with hole (B) in crankshaft.62 -19-06MAR86 10.

Tighten cap screw to 88 N·m (65 lb-ft). Apply thread lock and sealer (medium strength) on threads of cap screw. loosen cap screw and adjust belt tension.25 mm (0. IMPORTANT: When adjusting belt tension. 13. Check oil pump gear backlash. If necessary. (See Section 20 of Machine Technical Manual. CTM3 (03JAN90) 40-22 3TN/4TN Series Yanmar Engines 010897 PN=187 M37772 -UN-29AUG88 M35667 -UN-26AUG88 M35296 . Remove gear housing cover as instructed in Remove Timing Gears. -UN-29AUG88 M21.65 -19-23APR86 M21. Apply force against alternator housing and tighten cap screw. (See Section 220 of Machine Technical Manual.64 -19-06MAR86 M21.) 40 22 REMOVE AND INSPECT OIL PUMP (ALL EXCEPT EARLY 3TNA72UJ/4TN100) 1. Hold crankshaft pulley using a strap wrench.010 in.66 -19-28AUG87 12. 14. Check and adjust engine oil pressure.Lubrication System/Oil Pump (All Engines Except Early 3TNA72UJ) 11. 15. 2.TM340.) 17.) at 107 N (24 lb) Force applied halfway between pulleys. Alternator belt must deflect 13 mm (0. Replace gear if backlash is more than 0.5 in.TM340.TM340.). Install washer and cap screw. Install engine. Install alternator belt. Group 35. Check belt tension using a belt tension gauge. apply force ONLY to rear alternator housing (near the belt) to prevent alternator damage. 16.

TM340.10 in.68 -19-06MAR86 5.69 -19-28AUG87 M37774 -UN-29AUG88 M37773 -UN-29AUG88 40 23 0.) .Lubrication System/Oil Pump (All Engines Except Early 3TNA72UJ) 3.TM340. Remove oil pump attaching hardware and remove oil pump. M21.) CTM3 (03JAN90) 40-23 3TN/4TN Series Yanmar Engines 010897 PN=188 M37775 0. replace rotor assembly.005 in.TM340. If rotors are recessed below face of pump housing more than listed below. Check rotor recess.25 mm (0.13 mm (0.67 -19-06MAR86 4. M21. Carefully remove backing plate from pump. Engine 3TN66UJ/3TNA72UJ/3TNA72-UJB/ 3TN78-RJB/3TN82-RJB/4TN78T-RJB 3TN75RJ/3TN82ESP/3TN84/ 4TN82ESP/4TN84 Maximum Recess -UN-29AUG88 M21.

Place gear on flat surface. 40 24 IMPORTANT: Hold oil pump shaft while pressing from gear. Support oil pump gear on a knife edge puller. replace rotor assembly.010 in.) 0.72 -19-23APR86 M21.TM340. replace oil pump.006 in.25 mm (0. Press shaft with rotor and pump body into gear until it bottoms. Engine 3TNA72-UJ/3TN78-RJB/ 3TN82-RJB/4TN78T-RJB All other engines Maximum Recess -UN-29AUG88 M21.TM340.TM340. Check outer rotor-to-pump body clearance. Remove outer rotor from pump body.70 -19-06MAR86 7. If clearance is more than listed below. If clearance is more than 0. Use a cap screw (A) to press shaft from gear.15 mm (0.TM340. -UN-29AUG88 M21.) 8.010 in.25 mm (0.71 -19-28AUG87 M21.73 -19-10AUG87 0. CTM3 (03JAN90) 40-24 3TN/4TN Series Yanmar Engines 010897 PN=189 M37779 -UN-29AUG88 M37778 M37777 M37776 . Check inner-to-outer rotor clearance.).Lubrication System/Oil Pump (All Engines Except Early 3TNA72UJ) 6. 9. -UN-29AUG88 ASSEMBLE AND INSTALL OIL PUMP (ALL EXCEPT EARLY 3TNA72UJ/4TN100) 1.

Remove three attaching cap screws (A). M21. 2. -UN-29AUG88 M21. -UN-29AUG88 M21. Remove housing with valve from engine.75 -19-01SEP87 SERVICE OIL PRESSURE REGULATING VALVE (3TN66UJ/LATER 3TNA72UJ/ 3TNA72-UJB/3TN75RJ/3TN78-RJB/3TN82E-SP/ 3TN84/4TN78T-RJB/4TN82E-SP4TN84 1.TM340. Install oil pump on engine using new gasket. 3.TM340. Tighten hardware to 25 N·m (18 lb-ft). Install backing plate onto pump body. Coat all parts with clean engine oil.TM340.Lubrication System/Oil Pressure Regulating Valve 2.74 -19-06MAR86 4.76 -19-01SEP87 M37773 -UN-29AUG88 M37780 40 25 CTM3 (03JAN90) 40-25 3TN/4TN Series Yanmar Engines 010897 PN=190 M37781 . Remove oil filter. Install outer rotor with identification mark (A) facing inside of housing.

CTM3 (03JAN90) 40-26 3TN/4TN Series Yanmar Engines 010897 PN=191 M37783 40 26 -UN-29AUG88 NOTE: If removing valve to adjust engine oil pressure.Lubrication System/Oil Pressure Regulating Valve 3.TM340.0 psi) 10.77 -19-23APR86 M21. Remove valve from housing. M37782 . attaching nut need not be removed.8 kPa (2. Each 1 mm (0. If adjusting pressure only.6 psi) -UN-29AUG88 M21.039 in. Remove valve attaching nut (A).6 kPa (2.TM340.78 -19-06MAR86 15. remove cap (A) and add shims to inside of cap.9 kPa (1.) of shim thickness increases oil pressure as listed: Engine 3TN66UJ 3TNA72UJ 3TN75RJ/3TN82ESP/3TN84/ 4TN82ESP/4TN84 Pressure Increase 13.3 psi) 4.

58 in.) at 20.96 in. Remove valve plug (A).79 -19-01SEP87 CTM3 (03JAN90) 40-27 3TN/4TN Series Yanmar Engines 010897 PN=192 .Lubrication System/Oil Pressure Regulating Valve 5.5 mm (0.0 mm (1.30 in.71—1. Inspect parts for wear or damage. Replace complete regulating valve if any components are defective.5—48.) at 27.2 N (6.) 48.5 mm (0.7 mm (0.) at 80 N (18 lb) Force 40 27 4TN78T-RJB NOTE: Valve components are not serviced individually.0 N (2.91 in.) COMPRESSED LENGTH SPECIFICATIONS Engine 3TN66 Specification 14. M21.6 lb) Force 3TNA72-UJB/3TN78-RJB/ 3TN82-RJB 24.) 43.81 in. and valve (D) from valve body.) M37784 -UN-29AUG88 Later 3TNA72 3TNA72-UJB/3TN78-RJB/3TN75/ 3TN82/3TN82-RJB/3TN84/ 4TN82/4TN84 4TN78T-RJB A—Valve Cap B—Shims C—Spring D—Valve 46.9—24.) at 12.0 mm (1.TM340.7 lb) Force Later 3TNA72/3TN75/3TN82ESP/ 3TN84/4TN82/4TN84 27. shims (B).5 N (4.5 mm (1.91 in.96 in. spring (C). 7. 6.1 lb) Force 33. FREE LENGTH SPECIFICATIONS Engine 3TN66 Specification 21.5 mm (1.08 in. Check spring free and compressed length.86—0.5 mm (1.

Pressure test cooler for leaks.TM340Z. 10. -UN-01NOV89 MX. Tighten nut to 30 N·m (22 lb-ft). 2. spring. Remove engine oil filter. 5. Inspect rear of oil cooler for pitting in sealing area. 3.Lubrication System/Remove. Replace o-rings (E).TM340. M21. and shims into valve body. Install oil filter. Install cooler. Install valve. Install retaining nut (A) and tighten to 30 N·m (22 lb-ft). 6. screw valve body into housing. 9. Install housing with valve onto engine. Refill cooling system and check for leaks. Remove nut (C) and oil cooler (D). Remove clamps (B) from coolant hoses. Inspect and Install Oil Cooler (3TN84UJ) 8. 4.1 -19-24OCT89 40 28 7. Drain cooling system (A). Reinstall hoses and clamps. If removed. 8.80 -19-06MAR86 REMOVE. (See this group). INSPECT AND INSTALL OIL COOLER (ETN84UJ) 1. A—Coolant Drain B—Hose Clamps C—Cooler Nut D—Oil Cooler E—O-Rings CTM3 (03JAN90) 40-28 3TN/4TN Series Yanmar Engines 010897 PN=193 M48395 -UN-01NOV89 M48394 M37783 -UN-29AUG88 . Install valve cap and stake to valve body.

Check for regular intervals of air bubbles. 3. Coat with oil before installing. 7.TM340Z. indicating a leak. 5. 6. Apply regulated air pressure 206—483 kPa (30—70 psi) to the other coolant passage. Optional test: If leak did not appear. Remove three cap screws (B) and pressure control valve housing (C). 3. Install new o-rings and oil cooler. If malfunction exists. Leave in water several minutes to disperse air that may have been trapped. Dip oil cooler into water. Remove oil cooler. Remove control valve (D) from housing. Install new gasket between control valve housing and block.) 2. Tighten cap screws to 27 N·m (20 lb-ft). Replace o-ring (E). Tighten cooler nut to 27—34 N·m (20—25 lb-ft). 8.3 -19-24OCT89 CTM3 (03JAN90) 40-29 3TN/4TN Series Yanmar Engines 010897 PN=194 M48397 -UN-01NOV89 M48396 40 29 . A—O-Ring B—Cap Screws C—Control Valve Housing D—Control Valve E—O-Ring -UN-01NOV89 MX. Individual parts are not available. (See this group. 2. MX. Control valve is serviced as an assembly. replace control valve. Plug one of the coolant inlet or outlet passages.2 -19-24OCT89 REMOVE. INSPECT. 4.TM340Z.Lubrication System/Remove/Inspect/Install Oil Pressure Control Valve ENGINE OIL COOLER LEAK TEST 1. AND INSTALL OIL PRESSURE CONTROL VALVE 1. use hot water bath to possibly open crack. Install control valve housing. Remove and replace o-rings (A).

Lubrication System/4TN100RJF Lubrication System REMOVE AND INSPECT OIL PUMP (4TN100-RJF) 1. Check rotor recess. Remove four cap screws (A) to separate pump from housing.20 mm (0.A1 -19-01SEP87 NOTE: Do not remove gear to remove cap screws.A3 -19-10AUG87 6. If rotor is below face of pump housing more than 0. 3. If clearance is more than 0.TM340. Remove cap screws (A) to remove oil pump and gasket from engine. replace entire assembly. M51569 M51568 -UN-31AUG88 .008 in.). Check oil pump gear backlash. M21. M21. -UN-31AUG88 M21. 4. if worn or damaged.).TM340.). 2.010 in.TM340. Replace gear if backlash is more than 0.25 mm (0.010 in.TM340. Group 35. replace as an assembly. 40 30 M21. replace rotor.25 mm (0. Check rotor shaft outer diameter and the rotor cover hole diameter.A4 -19-10AUG87 CTM3 (03JAN90) 40-30 3TN/4TN Series Yanmar Engines 010897 PN=195 M51571 -UN-31AUG88 M51570 -UN-31AUG88 5. Remove gear housing cover and idler gear as instructed in Remove Timing Gears.A2 -19-01SEP87 NOTE: Do not disassemble rotor shaft assembly (A).

-UN-31AUG88 M21. M51573 -UN-31AUG88 M51572 40 31 -UN-31AUG88 M21. M21. Install new gasket and oil pump. Check inner-to-outer rotor clearance. Install outer rotor with identification mark (A) facing toward rotor shaft assembly.25 mm (0.010 in.A8 -19-10AUG87 3.TM340. 4. Group 35. CTM3 (03JAN90) 40-31 3TN/4TN Series Yanmar Engines 010897 PN=196 M51568 -UN-31AUG88 M51574 .A6 -19-10AUG87 ASSEMBLE AND INSTALL OIL PUMP (4TN100-RJF) 1. Check outer rotor-to-pump body clearance.TM340.).010 in. 2. Install idler gear and gear housing cover as instructed in Install Timing Gears. replace rotor assembly.TM340. Coat all parts with clean engine oil. If clearance is more than 0. Install rotor shaft assembly onto pump housing and tighten cap screws to 6 N·m (53 lb-in.TM340.).A7 -19-10AUG87 M21. replace oil pump. Tighten cap screws (A) to 25 N·m (18 lb-ft). If clearance is more than 0.).Lubrication System/4TN100RJF Lubrication System 7.25 mm (0.A5 -19-10AUG87 8.

Remove fuel injection pump as instructed in Remove Fuel Injection Pump.TM340. replace if necessary. 4. M21.TM340. Group 50. Push oil cooler on water pump. Remove four nuts to separate oil cooler (A) from housing (B). M51576 -UN-31AUG88 M51575 -UN-31AUG88 . 2. Group 50. Install oil cooler (A) and gaskets in housing (B). Install oil cooler and gasket on engine. 4. M21.A9 -19-01SEP87 ASSEMBLE AND INSTALL OIL COOLER (4TN100-RJF) 40 32 2.Lubrication System/4TN100RJF Lubrication System REMOVE AND INSPECT OIL COOLER (4TN100-RJF) 1. Remove 21 caps screws to remove oil cooler assembly from engine. Replace O-ring (C) if damaged. 3. Inspect oil cooler for leaks or cracks. Tighten cap screws to 24 N·m (18 lb-ft). 3.A10 -19-10AUG87 CTM3 (03JAN90) 40-32 3TN/4TN Series Yanmar Engines 010897 PN=197 M51577 -UN-31AUG88 M51576 -UN-31AUG88 1. Tighten nuts to 49 N·m (36 lb-ft). Install fuel injection pump as instructed in Install Fuel Injection Pump.

SPRING LENGTH SPECIFICATION Length Free Compressed Specification 51. and valve plug in oil cooler.48 in. Inspect parts for wear or damage.2 lb) Force A—Valve Plug B—Washer C—Spring D—Valve M51578 -UN-31AUG88 40 33 -UN-31AUG88 Oil Cooler Removed for Clarity 4. spring. Remove plug (A).84 lb) Force A—Valve Plug B—Washer C—Spring D—Valve Oil Cooler Removed for Clarity 4.) @ 5. spring.A12 -19-01SEP87 CTM3 (03JAN90) 40-33 3TN/4TN Series Yanmar Engines 010897 PN=198 M51579 . 3.0 mm (1.4 N (1. spring (C). spring (C). washer. Replace parts as needed. M21. Inspect parts for wear or damage.75 N (0. washer. and valve (D). Check valve seat surfaces for nicks or scratches.45 in. Check spring free and compressed lengths.) @ 3. Replace parts as needed.A11 -19-10AUG87 INSPECT OIL PRESSURE CONTROL VALVE (4TN100-RJF) 1. Install valve. 2.01 in. and valve (D).TM340. and plug in oil cooler. washer (B).) 37. install between spring and plug. Install valve. Check valve seat surfaces for nicks or scratches.TM340.0 mm (2. washer (B). If shims are used. M21. Check spring free and compressed lengths.Lubrication System/4TN100RJF Lubrication System INSPECT OIL COOLER BY-PASS VALVE (4TN100-RJF) 1.0 mm (2. Remove plug (A).0 mm (1. 2. 3. SPRING LENGTH SPECIFICATION Length Free Compressed Specification 63. Check for shims between spring and plug.97 in.) 50.

Lubrication System/4TN100RJF Lubrication System

INSPECT PISTON COOLING NOZZLES (4TN100-RJF)
1. Remove oil pan and spacer. (See Group 40 in this manual.) 2. Remove piston cooling nozzle (A). 3. Inspect nozzle hole for dirt or other foreign material. Clean if necessary. Check the nozzle piping for looseness, for damage or cracks. Replace if necessary. 4. Install nozzle with pin (B) in locating hole of cylinder block. Tighten cap screw.
-UN-31AUG88 M21,TM340,A13 -19-10AUG87

5. Install oil pan spacer and oil pan. (See Group 40 in this manual.)

40 34

CTM3 (03JAN90)

40-34

3TN/4TN Series Yanmar Engines
010897

PN=199

M51581

M51580

-UN-31AUG88

Group 45

Cooling System
ESSENTIAL TOOLS
NOTE: Order tools from the U.S. SERVICEGARD™ Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier.
Number Name Use

JDE-152 JDG-506

Bearing Driver Bearing Driver

Remove and install water pump bearing shaft on 3TN75RJ/early 3TNA72UJ engines. Remove and install water pump bearing shaft on 3TN66UJ/3TNA72UJ/3TN82E-SP/3TN84/ 4TN82E-SP/4TN84 engines.
M21,TM345,1 -19-23APR86

SERVICE EQUIPMENT AND TOOLS
NOTE: Order tools from the U.S. SERVICEGARD™ Catalog or from the European Microfiche Tool Catalog (MTC). Some tools may be available from a local supplier.
Name Use

Thermostat Tester Strap Wrench 13-Ton Puller Set Press O-ring Seal Tool Set

Check thermostat opening temperature Hold water pump pulley Remove water pump pulley flange Remove and install water pump components Remove and install water pump seals and O-rings Install water pump components Check Belt Tension

Bushing, Bearing, and Seal Driver Set Belt Tension Gauge

45 1

M21,TM345,2

-19-23APR86

CTM3 (03JAN90)

45-1

3TN/4TN Series Yanmar Engines
010897

PN=200

Cooling System/Thermostat and Housing

REMOVE THERMOSTAT AND THERMOSTAT HOUSING

N

1. Open radiator and engine drain valves to drain coolant. 2. Disconnect water pump outlet hose. 3. Remove thermostat cover and gasket (A).

4TN82E-SP
M21,TM345,5 -19-11AUG87

NOTE: Gasket is only used on some engines.
4. Remove thermostat and gasket (A), if equipped.
-UN-26AUG88

45 2

4TN82E-SP
M21,TM345,6 -19-11OCT87

CTM3 (03JAN90)

45-2

3TN/4TN Series Yanmar Engines
010897

PN=201

M37844

-UN-29AUG88

M35634

M37843

-UN-29AUG88

M35633

-UN-26AUG88

CAUTION: DO NOT remove thermostat until engine is cool to the touch.

Cooling System/Thermostat and Housing
5. Check thermostat using a thermostat tester. Heat thermostat in water to check opening temperature.
THERMOSTAT SPECIFICATIONS Begin Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71˚ C (160˚ F) Fully Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85˚ C (184˚ F)
-UN-26AUG88 M21,TM345,7 -19-06MAR86

NOTE: Steps 6—10 apply to 4TN82E-SP engines only.
6. Loosen cap screw (A) to loosen alternator belt.
-UN-29AUG88

7. Loosen clamp (B) and remove hose (C). 8. Disconnect temperature sender wiring lead. 9. Remove three cap screws to remove thermostat housing and gasket (D).
A—Cap Screw B—Clamp C—Hose D—Gasket

4TN82E-SP

M21,TM345,8

-19-23APR86

M37845

M35635

If thermostat is not fully open at 85˚C (184˚F), replace thermostat.

10. Remove two cap screws to remove plate and gasket (A). 11. If necessary, remove parts (B—F).
A—Gasket B—Fitting C—Plug D—Washer (2 used) E—Plug F—Temperature Sender
-UN-29AUG88

45 3

4TN82E-SP

M21,TM345,9

-19-06MAR86

CTM3 (03JAN90)

45-3

3TN/4TN Series Yanmar Engines
010897

PN=202

M37846

Cooling System/Thermostat and Housing

INSTALL THERMOSTAT AND THERMOSTAT HOUSING
1. Thoroughly clean and dry all parts.

NOTE: For all engines except 4TN82E-SP, go to step 11.
2. Apply pipe sealant on threads of fitting (A). 3. Install parts (A—E). 4. Install a new gasket on thermostat housing. 5. Install plate and two cap screws. Tighten cap screws to 9 N·m (78 lb-in.).
4TN82E-SP

A—Fitting B—Plug C—Washer (2 used) D—Plug E—Temperature Sender
M21,TM345,10 -19-11OCT87

6. Install a new gasket. 7. Install thermostat housing and three cap screws. Tighten cap screws to 26 N·m (226 lb-in.). 8. Connect temperature sender wiring lead. Connect hose (A) and fasten with clamp (B). 9. Pull alternator to tighten belt and tighten cap screw (C). 10. Check belt tension using a belt tension gauge. Alternator belt must deflect 13 mm (0.5 in.) at 107 N (24 lb) Force applied halfway between pulleys.
-UN-29AUG88

45 4

4TN82E-SP
M21,TM345,11 -19-11OCT87

CTM3 (03JAN90)

45-4

3TN/4TN Series Yanmar Engines
010897

PN=203

M37850

-UN-29AUG88

M37849

M37847

-UN-29AUG88

Cooling System/Thermostat and Housing NOTE: Gasket is only used on some engines.
11. Install new gasket (A), if equipped and thermostat.
-UN-26AUG88

4TN82R-SE
M21,TM345,12 -19-11OCT87

12. Install new gasket.

-UN-26AUG88

M37844

-UN-29AUG88

M35634

45 5

4TN82E-SP
M21,TM345,13 -19-06MAR86

CTM3 (03JAN90)

45-5

3TN/4TN Series Yanmar Engines
010897

PN=204

M37851

-UN-29AUG88

M35636

Cooling System/Thermostat and Housing
13. Install thermostat housing. Tighten cap screws to specifications.
THERMOSTAT HOUSING CAP SCREW TORQUE SPECIFICATIONS 3TN66UJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N·m (78 lb-in.) 3TNA72-UJB/3TN78-RJB/ 3TN82-RJB/4TN78T-RJB . . . . . . . . . . . . . . . . . 26 N·m (226 lb-in.) 3TNA72UJ/3TN75RJ/3TN82E-SP/ 3TN84/4TN82E-SP/4TN84/ 4TN100-RJF . . . . . . . . . . . . . . . . . . . . . . . 20.3 N·m (180 lb-in.)
-UN-26AUG88

14. Connect water pump outlet hose. Tighten hose clamp. 15. Fill cooling system with proper coolant to proper level.

4TN82E-SP
M21,TM345,14 -19-01SEP87

45 6

CTM3 (03JAN90)

45-6

3TN/4TN Series Yanmar Engines
010897

PN=205

M37852

-UN-29AUG88

M35637

5. 3. 3TNA72UJ Shown 4. Disconnect inlet and outlet coolant lines from water pump. -UN-29AUG88 1. Open the radiator and engine drain valve to drain coolant. 2. Disconnect coolant temperature sender wire.15 -19-01SEP87 M37855 M37854 45 7 CTM3 (03JAN90) 45-7 3TN/4TN Series Yanmar Engines 010897 PN=206 . -UN-29AUG88 3TN75RJ Shown M21. Loosen cap screw and remove alternator belt (A). Remove four cap screws (B) to remove fan (C) if equipped.Cooling System/Water Pump REMOVE WATER PUMP N CAUTION: DO NOT remove water pump until engine is cool to the touch. Move alternator away from water pump area.TM345.

Loosen hose clamp (B) and remove hose (C).16 -19-11AUG87 CTM3 (03JAN90) 45-8 3TN/4TN Series Yanmar Engines 010897 PN=207 M51566 45 8 -UN-31AUG88 M37858 -UN-29AUG88 M37857 . five for 4TN100) cap screws to remove water pump and gasket (A).TM345. -UN-29AUG88 4TN82E-SP 4TN100 M21. Remove four (three for 3TN66.Cooling System/Water Pump 6.

2.TM345.17 -19-11AUG87 M37859 -UN-29AUG88 M35641 NOTE: Gasket is only used on some engines. Remove thermostat and gasket (A). go to step 5 3TNA72UJ Shown 3TN75RJ Shown M21.TM345.18 -19-11AUG87 45 9 CTM3 (03JAN90) 45-9 3TN/4TN Series Yanmar Engines 010897 PN=208 M35642 .Cooling System/Water Pump DISASSEMBLE WATER PUMP 1. if equipped. but the disassembly procedure is the same. -UN-26AUG88 M21. NOTE: For 4TN82E-SP engines. Remove thermostat housing and gasket (A). -UN-26AUG88 NOTE: Water pump housings differ slightly.

19 -19-11AUG87 4.Cooling System/Water Pump 3. M21. Hold pulley using a strap wrench. Remove temperature sender and washer (A).20 -19-10MAR86 45 10 CTM3 (03JAN90) 45-10 3TN/4TN Series Yanmar Engines 010897 PN=209 M35852 -UN-26AUG88 M37899 -UN-29AUG88 . 3TNA72UJ Shown M21. Remove four cap screws to remove pulley. Remove cap screws (A).TM345.TM345.

Cooling System/Water Pump 3TN75RJ/3TN82-ESP/3&4TN84/4TN100RJF Early 3TNA72UJ 3TN66UJ/3TNA72UJ -UN-29AUG88 M37901 -UN-29AUG88 M35644 -UN-26AUG88 45 11 5. Remove three screws to remove plate and gasket (A). 10 for 4TN100RJF Engine) cap screws and remove parts (A—E).TM345. Remove three screws to remove plate and gasket (A).21 -19-01SEP87 CTM3 (03JAN90) 45-11 3TN/4TN Series Yanmar Engines 010897 PN=210 M37903 M37902 . 4TN82E-SP M21. -UN-29AUG88 Remove four (eight for 3TN82E-SP 3TN84/4TN84 Engines. Remove five screws to remove plate and gasket (A).

) 45 12 M21.TM345.24 -19-10MAR86 CTM3 (03JAN90) 45-12 3TN/4TN Series Yanmar Engines 010897 PN=211 M35647 M35646 -UN-26AUG88 M35645 -UN-26AUG88 . Remove bearing shaft (A) using the correct size bearing driver (B).23 -19-11AUG87 IMPORTANT: Impeller bore is tapered.TM345. Remove impeller (A) using a bearing puller (B).Cooling System/Water Pump 6. Remove pulley flange (A) using a puller (B) and small nuts (C). and a press. Allow enough clearance between cap screw and impeller bore to prevent cap screw from binding. M21. 7. -UN-26AUG88 M21.22 -19-10MAR86 NOTE: Be sure press blocks do not hit impeller. (Use JDE-152 or JDG-506 Bearing Driver. cap screw (C).TM345. 8. 3/8 in.

-UN-26AUG88 M21. Remove O-ring. 12. Remove shaft seal. Remove ceramic seal. -UN-26AUG88 M21. Replace parts as necessary. M21.TM345. M21.26 -19-10MAR86 11. Install new O-ring.Cooling System/Water Pump 9. if equipped.27 -19-10MAR86 M35649 -UN-26AUG88 M35648 -UN-26AUG88 45 13 ASSEMBLE WATER PUMP 1.TM345. if equipped.TM345.25 -19-10MAR86 10. Thoroughly clean and inspect all parts.28 -19-10MAR86 CTM3 (03JAN90) 45-13 3TN/4TN Series Yanmar Engines 010897 PN=212 M35650 M35650 .TM345.

M21. using correct size bearing driver (A) and a press.Cooling System/Water Pump 2. Press shaft into pump body until bearing surface (B) is flush with housing surface (C). 45 14 M21.31 -19-10MAR86 CTM3 (03JAN90) 45-14 3TN/4TN Series Yanmar Engines 010897 PN=213 M35653 -UN-26AUG88 M35652 -UN-26AUG88 M35651 -UN-26AUG88 . socket (B) and a press.TM345. Install new shaft seal over impeller side of shaft.) 3. Use a 25 mm or 1 in. long end down.30 -19-10MAR86 5. (Use JDE-152 or JDG-506 Bearing Driver.TM345. M21.TM345. Install bearing shaft. Push shaft seal (A) to the bottom of its bore.29 -19-11AUG87 4.

-UN-26AUG88 M21.67 in. Use a ram adapter (C) and a press. push pulley flange (B) on bearing shaft until bottom of flange is 13 mm (0.32 -19-11AUG87 IMPORTANT: DO NOT touch lapped sealing surface of ceramic insert with bare hands: it must be clean and dry. -UN-26AUG88 6. CTM3 (03JAN90) 45-15 3TN/4TN Series Yanmar Engines 010897 PN=214 M35655 M37905 .) from top of housing.06 in.TM345. Push pulley flange (B) on bearing shaft until flange is flush with end of shaft.50 in.) from top of housing. Use a ram adapter (C) and a press. Use a 1-in. DO NOT support on housing or you could damage the housing. 7. driver disk (C) and a press. Push pulley flange (B) on bearing shaft until bottom of flange is 17 mm (0. For 4TN100RJF.Cooling System/Water Pump IMPORTANT: Support pump on bearing shaft only.33 -19-10MAR86 8. Support pump on bearing shaft using a driver disk (A).) from top of housing. Install new ceramic seal (shaft seal assembly) in impeller. 3TN66/3TNA72 3TN75RJ/3TN82E-SP/3TN84/4TN84 -UN-29AUG88 M37904 -UN-29AUG88 Push pulley flange (B) on bearing shaft until top of flange is 27 mm (1. M35654 45 15 4TN82E-SP M21.TM345.

012—0.Cooling System/Water Pump 9. Push impeller on bearing shaft until top of impeller is even with end of shaft. Use a 1 in. Use a ram adapter (B) and a press. 10.) below housing.1 mm (0.04 in. driver disk (B) and a press. Use a ram adapter (B) and press.3—1. Push impeller on bearing shaft until top of impeller is 2 mm (0.TM345. Use a ram adapter and a press to push impeller on bearing shaft until clearance between impeller and pump body is 0.) below housing.) -UN-29AUG88 3TN66UJ/3TNA72UJ 3TN75RJ/3TN82E-SP/3TN84/4TN84 45 16 4TN82E-SP 4TN100RJF M21.043 in.08 in. Push impeller on bearing shaft until top of impeller is 1 mm (0. Install impeller (A) with ceramic seal toward the shaft seal.34 -19-11AUG87 CTM3 (03JAN90) 45-16 3TN/4TN Series Yanmar Engines 010897 PN=215 M51567 -UN-31AUG88 M37907 -UN-29AUG88 M37906 M35656 -UN-26AUG88 .

Cooling System/Water Pump 11.TM345. 4TN82E-SP M21. Install new gasket on water pump housing.35 -19-10MAR86 M37908 -UN-29AUG88 M35657 -UN-26AUG88 45 17 CTM3 (03JAN90) 45-17 3TN/4TN Series Yanmar Engines 010897 PN=216 .

Install plate and five screws. Install plate and three screws. Tighten screws to 9 N·m (78 lb-in.TM345. Tighten screws to 9 N·m (78 lb-in. Install plate and three screws. 10 for 4TN100 RJF Engine) cap screws to 9 N·m (78 lb-in.36 -19-01SEP87 CTM3 (03JAN90) 45-18 3TN/4TN Series Yanmar Engines 010897 PN=217 M37911 -UN-29AUG88 M37910 -UN-29AUG88 M37909 -UN-29AUG88 M35658 -UN-26AUG88 .) Install parts (A—D).). Tighten screws to 9 N·m (78 lb-in.). A—Plate B—Adapter C—O-Ring D—Gasket 3TN66UJ/3TNA72UJ 45 18 3TN75RJ/3TN82ESP/3&4TN84/4TN100RJF 4TN82E-SP Engine M21.). Early 3TNA72UJ NOTE: For 4TN82E-SP engines.Cooling System/Water Pump 12. steps 13—17 are not used. Install and tighten four (eight for 3TN82E-SP/3TN84/4TN84 Engines.

15. Hold pulley using strap wrench.TM345. Install washer (A) and temperature sender. Tighten cap screws to 11 N·m (96 lb-in. Install new gasket (A). -UN-26AUG88 M21.38 -19-11AUG87 NOTE: Gasket is only used on some engines. Install cap screws (A). Install pulley and four cap screws. -UN-26AUG88 M21.39 -19-11AUG87 M37899 -UN-29AUG88 M35853 45 19 CTM3 (03JAN90) 45-19 3TN/4TN Series Yanmar Engines 010897 PN=218 M35659 . 3TNA72UJ Shown M21. if equipped and thermostat.Cooling System/Water Pump 13.37 -19-11AUG87 14.).TM345.TM345.

) -UN-26AUG88 3TNA72UJ Shown 3TN75RJ Shown M21.) Torque 26 N·m (226 lb-in. Install thermostat housing.Cooling System/Water Pump 16. THERMOSTAT HOUSING CAP SCREW SPECIFICATIONS Engine 3TN66UJ 3TNA72UJ/3TN75RJ/ 3TN82E-SP/ 3TN84/ 4TN82E-SP/4TN84/ 4TN100RJF 3TNA72-UJB/3TN78-RJB/ 3TN82-RJB/ 4TN78T-RJB Measurement Torque Specifications 9 N·m (78 lb-in. 17.40 -19-01SEP87 CTM3 (03JAN90) 45-20 3TN/4TN Series Yanmar Engines 010897 PN=219 M37912 45 20 -UN-29AUG88 M35661 . Tighten cap screws to specifications.) M35660 -UN-26AUG88 Torque 20 N·m (180 lb-in. Install new gasket.TM345.

Cooling System/Install INSTALL WATER PUMP 1.TM345.). Install water pump and three cap screws. Thoroughly clean and dry all parts. 3. Install new gasket. -UN-29AUG88 -UN-29AUG88 M37914 -UN-29AUG88 M37913 2. Tighten cap screws to 26 N·m (226 lb-in. Install hose (A) and fasten with hose clamp (B). Install new gasket.). 4TN82E-SP 4TN82E-SP M21. Tighten cap screws to 26 N·m (226 lb-in. Install water pump.41 -19-01SEP87 CTM3 (03JAN90) 45-21 3TN/4TN Series Yanmar Engines 010897 PN=220 M37916 -UN-29AUG88 M37915 45 21 .

Tighten cap screws to 11 N·m (96 lb-in. Install alternator belt (A).42 -19-01SEP87 45 22 CTM3 (03JAN90) 45-22 3TN/4TN Series Yanmar Engines 010897 PN=221 M37855 -UN-29AUG88 M37854 -UN-29AUG88 . 3TNA72UJ Shown 3TN75RJ Shown M21. 5.).TM345. Pull alternator to tighten belt and tighten cap screw.Cooling System/Install 4. Install fan (C) if equipped and four cap screws (B).

Connect coolant temperature sender wire. Connect inlet and outlet coolant lines and fasten with hose clamps. If necessary. loosen cap screw and adjust belt tension. 8. 7.TM345. Close the radiator and engine drain valves. 6. 10.) at 107 N (24 lb) Force applied halfway between pulleys.Cooling System/Install IMPORTANT: When adjusting belt tension. Fill cooling system with proper coolant to proper level. -UN-26AUG88 M21.5 in.43 -19-10MAR86 M35667 45 23 CTM3 (03JAN90) 45-23 3TN/4TN Series Yanmar Engines 010897 PN=222 . Check belt tension using a belt tension gauge. apply force ONLY to rear alternator housing (near the belt) to prevent alternator damage. Alternator belt must deflect 13 mm (0. 9.

Cooling System/Install 45 24 CTM3 (03JAN90) 45-24 3TN/4TN Series Yanmar Engines 010897 PN=223 .

2 -19-23APR86 CTM3 (03JAN90) 50-1 3TN/4TN Series Yanmar Engines 010897 PN=224 .1 -19-23APR86 SERVICE EQUIPMENT AND TOOLS NOTE: Order tools from the U. and oil seals To service fuel injection pump camshaft Measure fuel injection pump camshaft gear backlash Measure fuel injection pump camshaft lobe height Bushing.S. SERVICEGARD™ Catalog or from the European Microfiche Tool Catalog (MTC).Group 50 Fuel Injection Pump. Bearing.TM350. bearings. Some tools may be available from a local supplier. SERVICEGARD™ Catalog or from the European Microfiche Tool Catalog (MTC). and Nozzles ESSENTIAL TOOLS NOTE: Order tools from the U.S.TM350. and Seal Driver Set Press Dial Indicator Outside Micrometer 50 1 M21. Name Use Strap Wrench 13-Ton Puller Set To hold crankshaft pulley To remove crankshaft pulley and to service fuel injection pump camshaft To service bushing. Some tools may be available from a local supplier. Camshaft. Number Name Use D—01109AA D—01110AA 23622 Diesel Fuel Injection Nozzle Tester Adapter Set Straight Adapter To test nozzles To connect nozzle to nozzle tester To connect nozzle to nozzle tester M21.

TM350. and Nozzles/Service Part Kits OTHER MATERIAL Number Name Use PT94 John Deere Form-In-Place Gasket (RTV rubber silicone sealant) John Deere LOCTITE Thread Lock and Sealer (medium strength) To seal gear housing cover T43512 Apply on threads of Crankshaft pulley cap screw LOCTITE is a trademark of the Loctite Corp.4 -19-07FEB86 50 2 CTM3 (03JAN90) 50-2 3TN/4TN Series Yanmar Engines 010897 PN=225 .3 -19-01SEP87 SERVICE PART KITS The following kits are available through your parts catalog. M21.Fuel Injection Pump. Cylinder Block Gasket Kit Fuel Injection Pump Shim Pack Fuel Injection Nozzle Shim Pack M21. Camshaft.TM350.

Relieve pressure before disconnecting hydraulic or other lines.Fuel Injection Pump. it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result.6 -19-01SEP87 IMPORTANT: Never steam clean or pour cold water on injection pump while the pump is running or warm. Turning fittings may damage pump internally. Camshaft. Use a piece of cardboard or paper to search for leaks. See Fuel Injection Pump Timing Adjustment in Machine Technical Manual. 4. Do not use your hand. Doing so can damage the pump. Remove two screws and clamp from injection lines. and area around the pump using a parts cleaning solvent or steam cleaner. Section 220. Close all openings with caps and plugs to keep dirt out of the fuel system. Remove fuel injection lines. If ANY fluid is injected into the skin.TM350. M21. M37785 M21. 2.7 -19-23APR86 -UN-29AUG88 X9811 -UN-23AUG88 50 3 CTM3 (03JAN90) 50-3 3TN/4TN Series Yanmar Engines 010897 PN=226 . and Nozzles/Fuel Injection Pump (3TN66. Loose fuel injection line connectors slightly to release pressure in the fuel system. When loosening connectors. Keep hands and body away from pinholes and nozzles which eject fluids under high pressure.TM350. 1. IMPORTANT: When removing injection lines. N CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. 3. Clean the injection pump lines. Tighten all connections before applying pressure. DO NOT turn pump delivery valve fittings. use another wrench to keep injectors from loosening. 3TNA72) REMOVE FUEL INJECTION PUMP (3TN66/3TNA72) NOTE: If the fuel injection pump is being removed to check timing.

Remove four nuts to remove cover (A) with solenoid. Remove cotter pin (B) to disconnect solenoid linkage.TM350.9 -19-08FEB86 CTM3 (03JAN90) 50-4 3TN/4TN Series Yanmar Engines 010897 PN=227 M37787 M37786 -UN-29AUG88 M35886 . Remove pin (A) to disconnect linkage (B). Remove cover and gasket (A).TM350.8 -19-23APR86 8. -UN-26AUG88 Early 3TNA72UJ 3TN66UJ/Later 3TNA72UJ M21. and Nozzles/Fuel Injection Pump (3TN66. 6. Remove two cap screws and nut. 7.Fuel Injection Pump. Camshaft. 3TNA72) 5. 50 4 -UN-29AUG88 M21.

have the pump serviced only by a qualified fuel injection repair shop. Install governor linkage (B) over arm on injection pump rack and fasten with pin (A). 3TNA72) IMPORTANT: If injection pump is being removed to be serviced or replaced.10 -19-08FEB86 INSTALL FUEL INJECTION PUMP (3TN66/3TNA72) IMPORTANT: If a serviced or replacement fuel injection pump is installed. measure old shim thickness and install new shims of the same thickness. If repair is necessary.Fuel Injection Pump. M21.TM350. Remove four nuts to remove fuel injection pump and shims (A). Align controller rack (A) and governor linkage fork (B). IMPORTANT: DO NOT disassemble fuel injection pump except for fuel delivery valves. or replace pump. 9.TM350. Install fuel injection pump and shims into housing. Early 3TNA72UJ M35888 -UN-26AUG88 M37788 -UN-29AUG88 3TN66UJ/Later 3TNA72UJ M21. the same number and thickness of new shims must be installed when pump is assembled. and Nozzles/Fuel Injection Pump (3TN66.11 -19-23APR86 CTM3 (03JAN90) 50-5 3TN/4TN Series Yanmar Engines 010897 PN=228 M37787 -UN-29AUG88 50 5 . Camshaft. 1.

Connect fuel shut-off linkage and fasten with cotter pin (B). Install new gasket. 3TNA72) 2.Fuel Injection Pump. and Nozzles/Fuel Injection Pump (3TN66.) M21. -UN-26AUG88 Install cover (A) with fuel shut-off solenoid and fasten with four stud nuts. 4. Camshaft. Install and tighten four nuts to 20 N·m (180 lb-in.TM350.TM350.13 -19-23APR86 CTM3 (03JAN90) 50-6 3TN/4TN Series Yanmar Engines 010897 PN=229 M37786 -UN-29AUG88 M35890 M37789 -UN-29AUG88 . Install cover and fasten with two cap screws and nut. Early 3TNA72UJ 50 6 3TN66UJ/Later 3TNA72UJ M21.12 -19-08FEB86 3.

6. 7. Connect fuel inlet hose. 5. and Nozzles/Fuel Injection Pump (3TN66. DO NOT turn pump delivery valve fittings. Install injection lines using two wrenches. Turning fittings may damage pump internally. Camshaft. -UN-29AUG88 M21.Fuel Injection Pump. See Section 220 of the appropriate Machine Technical Manual.TM350.14 -19-01SEP87 M37785 50 7 CTM3 (03JAN90) 50-7 3TN/4TN Series Yanmar Engines 010897 PN=230 . Bleed fuel system and check injection pump timing. 3TNA72) IMPORTANT: When installing injection lines.

Keep hands and body away from pinholes and nozzles which eject fluids under high pressure.TM350. use another wrench to keep injectors from loosening. 1.Fuel Injection Pump.15 -19-01SEP87 N CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Loosen fuel injection line connectors slightly to release pressure in the fuel system. Camshaft. -UN-23AUG88 M21. Relieve pressure before disconnecting hydraulic or other lines. Clean the injection pump lines. Do not use your hand. Tighten all connections before applying pressure. 2. Doing so can damage the pump. When loosening connectors. 50 8 CTM3 (03JAN90) 50-8 3TN/4TN Series Yanmar Engines 010897 PN=231 X9811 . and Nozzles/Fuel Injection Pump (3TN75/3TN78/3TN82/3TN84/4TN78/4TN82/4TN84 REMOVE FUEL INJECTION PUMP (3TN75/3TN78/3TN82/3TN84/ 4TN78/4TN82/4TN84) IMPORTANT: Never steam clean or pour cold water on injection pump while the pump is running or warm. and area around the pump using a parts cleaning solvent or steam cleaner. it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result. Use a piece of cardboard or paper to search for leaks. If ANY fluid is injected into the skin.

16 -19-08FEB86 4. 5. Remove injection lines (A) and access cover (B). Camshaft. Note position of timing mark (B) for installation.TM350. M21. -UN-29AUG88 CTM3 (03JAN90) 50-9 3TN/4TN Series Yanmar Engines 010897 PN=232 M37792 M37791 50 9 .Fuel Injection Pump. Disconnect external lube line (A).17 -19-08FEB86 M21. 8.TM350. Use chalk or paint to mark injection pump gear to idler gear (A). and Nozzles/Fuel Injection Pump (3TN75/3TN78/3TN82/3TN84/4TN78/4TN82/4TN84 3.18 -19-23APR86 6.TM350. M37790 -UN-29AUG88 7. -UN-29AUG88 M21. Remove the 3 attaching stud nuts (C). Remove special nut (B).

Fuel Injection Pump. Install puller onto injection pump gear through access hole. Remove injection pump. and Nozzles/Fuel Injection Pump (3TN75/3TN78/3TN82/3TN84/4TN78/4TN82/4TN84 9. CTM3 (03JAN90) 50-10 3TN/4TN Series Yanmar Engines 010897 PN=233 M37792 50 10 M37794 M37793 -UN-29AUG88 . Put injection pump onto back of gear housing. Be sure to align gear timing marks (A) made during removal. Assemble a suitable two jaw puller similar to the one shown.21 -19-13AUG87 1. Align key on shaft with keyway in gear.TM350. 11.19 -19-23APR86 10. M21. 2. Tighten to 90 N·m (66 lb-ft). Camshaft.20 -19-08FEB86 INSTALL INJECTION PUMP (3TN75/3TN78/3TN82/3TN84/ 4TN78/4TN82/4TN84) -UN-29AUG88 M21. -UN-29AUG88 M21. Pull gear from shaft.TM350. Install special nut (B).TM350.

Install external lube line (A).TM350. check and adjust timing as instructed in Section 220 of the Machine Technical Manual.Fuel Injection Pump. 4. Camshaft. Bleed fuel system as instructed in Machine Technical Manual. 50 11 CTM3 (03JAN90) 50-11 3TN/4TN Series Yanmar Engines 010897 PN=234 . -UN-29AUG88 M21. Tighten to 26 N·m (19 lb-ft). 6. and Nozzles/Fuel Injection Pump (3TN75/3TN78/3TN82/3TN84/4TN78/4TN82/4TN84 3. Align timing marks to same place as when removed. Install the three mounting stud nuts (C). Install injection lines and gear access cover. 5.22 -19-01SEP87 M37791 If new injection pump is being installed.

and area around the pump using a parts cleaning solvent or steam cleaner. fuel filter hoses (B) and external lube line (C).TM350. Loosen fuel injection line connectors slightly to release pressure in the fuel system. 3. Keep hands and body away from pinholes and nozzles which eject fluids under high pressure. Camshaft. When loosening connectors. If ANY fluid is injected into the skin. Relieve pressure before disconnecting hydraulic or other lines. Do not use your hand.Fuel Injection Pump. use another wrench to keep injectors from loosening. 4. Score a line (D) to mark injection pump position on gear case housing. N CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. and Nozzles/Fuel Injection Pump (4TN100RJF) REMOVE FUEL INJECTION PUMP (4TN100RJF) IMPORTANT: Never steam clean or pour cold water on injection pump while the pump is running or warm. 2.A1 -19-01SEP87 CTM3 (03JAN90) 50-12 3TN/4TN Series Yanmar Engines 010897 PN=235 M51582 -UN-31AUG88 X9811 -UN-23AUG88 . it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result. Doing so can damage the pump 1. Clean the injection pump lines. A—Injection Lines B—Hoses C—Lube-Line D—Line 50 12 M21. Remove injection lines (A). Tighten all connections before applying pressure. Use a piece of cardboard or paper to search for leaks.

Install oil filler neck and gasket. Install six cap screws (A).TM350. Put injection pump onto gear housing. M21.A2 -19-13AUG87 7. Align gear timing marks (C) made during removal. Install O-ring (B) on injection pump. Remove oil filler neck assembly. 2.TM350. 3. Camshaft. -UN-31AUG88 M21.Fuel Injection Pump. Use chalk or paint to mark injection pump gear to notch (A) on gear case housing. 6.A4 -19-13AUG87 M51584 -UN-31AUG88 M51583 CTM3 (03JAN90) 50-13 3TN/4TN Series Yanmar Engines 010897 PN=236 M51585 50 13 .TM350. -UN-31AUG88 M21.A3 -19-13AUG87 INSTALL FUEL INJECTION PUMP (4TN100RJF) 1. Remove six cap screw (A) to remove injection pump. and Nozzles/Fuel Injection Pump (4TN100RJF) 5.

) 2. Bleed fuel system as instructed in Machine Technical Manual.TM350. If new injection pump is being installed. 5.Fuel Injection Pump. M21. (See Section 20 in Machine Technical Manual. check and adjust timing as instructed in Section 230 or 9010 of the Machine Technical Manual. 50 14 3. Loosen alternator and remove alternator belt (B). Camshaft.23 -19-13AUG87 CTM3 (03JAN90) 50-14 3TN/4TN Series Yanmar Engines 010897 PN=237 M35973 -UN-29AUG88 M51582 -UN-31AUG88 . Install external lube line (C). and Nozzles/Fuel Injection Pump Camshaft 4.TM350. Align marks (D) to same place as when removed. 6. Remove fuel injection pump (A).A5 -19-01SEP87 REMOVE FUEL INJECTION PUMP CAMSHAFT (EARLY 3TNA72UJ) 1. Tighten mounting cap screws to 27 N·m (20 lb-ft). Install injection lines. as instructed earlier in this group. Remove engine. A—Injection B—Hoses C—Lube Line D—Line M21.

26 -19-24MAR86 M35271 -UN-29AUG88 M35270 -UN-29AUG88 7.TM350. Remove cap screw and washer.25 -19-24MAR86 6. two cap screws from water pump. Remove two nuts and one cap screw to remove bracket and fuel shut-off solenoid. M21. Hold crankshaft pulley using a strap wrench.24 -19-24MAR86 5.TM350. and strap wrench. and Nozzles/Fuel Injection Pump Camshaft 4. Camshaft. M21. shaft protector.Fuel Injection Pump. Remove crankshaft pulley using puller.TM350.TM350. M21. Remove cotter pin and washer (A) to disconnect fuel shut-off solenoid linkage.27 -19-24MAR86 CTM3 (03JAN90) 50-15 3TN/4TN Series Yanmar Engines 010897 PN=238 M35273 -UN-29AUG88 M35272 50 15 . -UN-29AUG88 M21.

005 in.). and Nozzles/Fuel Injection Pump Camshaft 8.04—0.008 in. replace gear.002—0.TM350.31 -19-24MAR86 If backlash exceeds 0.TM350.Fuel Injection Pump. CTM3 (03JAN90) 50-16 3TN/4TN Series Yanmar Engines 010897 PN=239 M35901 -UN-26AUG88 M35900 50 16 M35275 -UN-29AUG88 M35532 . driver disk (A) and 2 3/8 in.30 -19-24MAR86 M21.28 -19-24MAR86 9. Loosen lock nut. Remove 17 cap screws to remove gear housing cover.20 mm (0. Remove seal using 1 3/4 in. Put a shop towel between gear teeth.TM350. -UN-26AUG88 M21. M21. Remove old gasket material from cover and gear housing.29 -19-24MAR86 10. Measure fuel injection pump gear backlash using a dial indicator. driver disk (B). Camshaft.12 mm (0. New backlash specification is 0.TM350. -UN-26AUG88 M21. 11.).

3.32 -19-24MAR86 13. Carefully remove fuel injection pump camshaft assembly. 14.33 -19-24MAR86 IMPORTANT: DO NOT allow fuel injection pump camshaft lobes to hit bearing surfaces while removing camshaft. Camshaft. 2. Remove governor housing and flyweight assembly as instructed in Group 60. Remove special screw.Fuel Injection Pump. M21. Machined surfaces may be damaged.TM350.TM350. and Nozzles/Fuel Injection Pump Camshaft 12. CTM3 (03JAN90) 50-17 3TN/4TN Series Yanmar Engines 010897 PN=240 M35537 50 17 . Remove idler gear.35 -19-01SEP87 M35536 -UN-26AUG88 M35535 -UN-26AUG88 REMOVE FUEL INJECTION PUMP CAMSHAFT (3TN66/LATER 3TNA72) 1. Use a slide hammer puller and two cap screws from the gear housing cover.TM350.34 -19-24MAR86 M21. -UN-26AUG88 M21. Remove fuel injection pump as instructed earlier in this group.TM350. M21. Remove gear housing cover.

and Nozzles/Fuel Injection Pump Camshaft 4. Camshafts on 3TN66 and later 3TNA72 engines are not tapered Service procedures are the same.Fuel Injection Pump.38 -19-01SEP87 CTM3 (03JAN90) 50-18 3TN/4TN Series Yanmar Engines 010897 PN=241 M37797 50 18 -UN-29AUG88 M37796 -UN-29AUG88 M37795 -UN-29AUG88 . Inspect camshaft gear for chipped. IMPORTANT: Hold camshaft while removing gear. broken or worn teeth. Camshaft. M21.TM350. 2. Tap the rear of camshaft (A) with plastic hammer to remove from housing.37 -19-23APR86 DISASSEMBLE AND INSPECT FUEL INJECTION PUMP CAMSHAFT 1. M21. Remove camshaft bearing retaining screw (A) and idler gear (B). M21.TM350.36 -19-08FEB86 5.TM350. NOTE: Early 3TNA72 injection pump camshafts are tapered on the gear end. Support gear on knife edge puller and press shaft from gear.

Measure height of each camshaft lobe. 3. and Nozzles/Fuel Injection Pump Camshaft IMPORTANT: Hold camshaft while removing bearings. Camshaft.Fuel Injection Pump.217 in.TM350.) M37799 -UN-29AUG88 M37798 -UN-29AUG88 50 19 -UN-26AUG88 M21.39 -19-08FEB86 4. Front Bearing Rear Bearing M21. Replace camshaft if lobe height is less than 30. Support bearings on knife edge puller and press shaft from bearings.9 mm (1.TM350.40 -19-08FEB86 CTM3 (03JAN90) 50-19 3TN/4TN Series Yanmar Engines 010897 PN=242 M35905 .

deep well socket and press camshaft into bearing until it bottoms on bearing race.41 -19-08FEB86 M21. -UN-29AUG88 M21. CTM3 (03JAN90) 50-20 3TN/4TN Series Yanmar Engines 010897 PN=243 M37801 50 20 -UN-29AUG88 M37800 . and Nozzles/Fuel Injection Pump Camshaft ASSEMBLE AND INSTALL FUEL INJECTION PUMP CAMSHAFT 1.41A -19-19MAR86 3.TM350. 2. Support large bearing on a 3/4 in. Camshaft. Support camshaft in knife edge puller. Press smaller bearing onto rear end of camshaft using a 3/4 in.Fuel Injection Pump.TM350. deep well socket. Press until bearing race bottoms on camshaft shoulder.

8.42 -19-23APR86 5.44 -19-08FEB86 6.). and Nozzles/Fuel Injection Pump Camshaft 4. damage or indications that bearing has spun in support. On 3TN66/later 3TNA72 engines. -UN-29AUG88 M21. Press camshaft with bearings into gear. Camshaft.Fuel Injection Pump. If necessary. CTM3 (03JAN90) 50-21 3TN/4TN Series Yanmar Engines 010897 PN=244 M37804 -UN-29AUG88 M37803 50 21 . M37802 -UN-29AUG88 7. Install injection pump as instructed earlier in this group. Install governor assembly and flyweights as instructed in Group 60. replace gear housing if bearing bores are damaged. remove three cap screws (A) and replace support.43 -19-13AUG87 M21. M21. Inspect camshaft front bearing support. Tighten to 20 N·m (180 lb-in.TM350.TM350. Install bearing retaining screw (A). Put camshaft gear on a flat surface. Press until gear face is flush with end of shaft.TM350. Check for cracks. 9. On early 3TNA72UJ engines. 10. Slide camshaft assembly into housing. Tap camshaft gear with plastic hammer to seat bearings in bores.

Tighten to 88 N·m (65 lb-ft). On early 3TNA72UJ engines. and C).45 -19-13AUG87 50 22 12.TM350. NOTE: Number one cylinder is closest to flywheel. -UN-26AUG88 M21. Camshaft. and Nozzles/Fuel Injection Pump Camshaft 11. B.TM350. Install lock washer and nut.Fuel Injection Pump. Install idler gear and align timing marks (A. put a shop towel between gear teeth. -UN-29AUG88 3TNA72 3TN66 M21.46 -19-08FEB86 CTM3 (03JAN90) 50-22 3TN/4TN Series Yanmar Engines 010897 PN=245 M35909 M37806 -UN-29AUG88 M37805 .

and Nozzles/Fuel Injection Pump Camshaft 13.49 -19-08FEB86 M35571 -UN-26AUG88 M35275 Install new seal with lip facing inward. 16. disk (B).TM350. Install and connect fuel shut-off solenoid. Install gear housing cover. disk (A) and 2-3/8 in. If necessary. Camshaft.Fuel Injection Pump.48 -19-08FEB86 -UN-29AUG88 M21. Use 1-3/4 in.47 -19-08FEB86 M21.) 15. replace front crankshaft oil seal. Tighten cap screws to 9 N·m (80 lb-in. If equipped. Install flush with front face of gear housing cover. CTM3 (03JAN90) 50-23 3TN/4TN Series Yanmar Engines 010897 PN=246 M35295 50 23 . -UN-29AUG88 M21.TM350. align index pin (A) with hole in crankshaft gear (B). 14.TM350.

18. 19. It is different from the hole type nozzle in that it is threaded into the cylinder head. See section 20 of Machine Technical Manual. Install engine.51A -19-13AUG87 CTM3 (03JAN90) 50-24 3TN/4TN Series Yanmar Engines 010897 PN=247 T6333AJ -19-05JAN89 M35296 -UN-29AUG88 . When the fuel pressure reaches specified pressure it overcomes the nozzle spring tension. 21. Install fan and fan belt. Pressure builds beneath the nozzle valve.50 -19-08FEB86 PINTLE TYPE FUEL INJECTION NOZZLE OPERATION (3TN66/3TNA72) The pintle type nozzle is used on indirect injection engines 3TN66 and 3TNA72.TM350. See section 230 of Machine Technical Manual. Leakage (return fuel) flows from beyond the nozzle valve and nozzle body to the hole on top of the nozzle spring through the return pipe fitting and back into the fuel tank.TM350. 20. and Nozzles/Pintle Type Fuel Injection Nozzle 17. Camshaft. M21. The nozzle valve retracts into the nozle body and fuel is injected into the engine. Apply medium strength thread lock and sealer to pulley cap screw. 50 24 M21. The nozzle valve is shim adjustable to regulate the opening pressure. Bleed fuel system. Hold pulley with strap wrench and tighten cap screw to 88 N·m (65 lb-ft). The nozzle valve is automatically pushed down by the nozzle spring and closed after fuel is injected. High pressure fuel from the injection pump flows through a fuel inlet passage.Fuel Injection Pump.

Do not use your hand.TM350.52A -19-01SEP87 IMPORTANT: When removing injection lines. and Nozzles/Pintle Type Fuel Injection Nozzle REMOVE PINTLE TYPE FUEL INJECTION NOZZLES (3TN66/3TNA72) N CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. IMPORTANT: Never steam clean or pour cold water on injection pump while the pump is running or warm. If ANY fluid is injected into the skin.TM350. Use two wrenches to loosen fuel line fittings enough to release any pressure in the fuel system. Turning fittings may damage pump internally. it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result. Relieve pressure before disconnecting hydraulic or other lines. 2. and area around the nozzles using a parts cleaning solvent or a steam cleaner. lines. Doing so can damage the pump. Use a piece of cardboard or paper to search for leaks. Disconnect fuel lines from injection nozzles and remove lines. M21. 4. Keep hands and body away from pinholes and nozzles which eject fluids under high pressure. -UN-26AUG88 M21.53 -19-08FEB86 X9811 -UN-23AUG88 50 25 CTM3 (03JAN90) 50-25 3TN/4TN Series Yanmar Engines 010897 PN=248 M35883 . injection nozzles. Cap all openings to keep dirt out of the fuel system. Tighten all connections before applying pressure.Fuel Injection Pump. Clean the injection pump. Camshaft. DO NOT turn pump delivery valve fittings. 3. 1.

Remove clamps to remove hoses (A) and fittings (B). Remove three nuts to remove leak-off line (B).Fuel Injection Pump. CTM3 (03JAN90) 50-26 3TN/4TN Series Yanmar Engines 010897 PN=249 M35912 50 26 M35911 -UN-26AUG88 M35910 .55 -19-08FEB86 M21. -UN-26AUG88 11. Test injection nozzles. 6.TM350.TM350. Remove and discard bronze gaskets. Loosen clamp and disconnect fuel return hose (A).56 -19-08FEB86 IMPORTANT: To prevent possible leakage DO NOT reuse bronze gasket material. 7.TM350. and Nozzles/Pintle Type Fuel Injection Nozzle 5. Camshaft. -UN-26AUG88 M21. Remove fuel injection nozzles. Remove and discard bronze gaskets. 9. 10. 8.54 -19-08FEB86 M21.

it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result. . . . and Nozzles/Pintle Type Fuel Injection Nozzle TEST PINTLE TYPE FUEL INJECTION NOZZLES (3TN66/3TNA72) This test checks the opening pressure. . . If pressure reading does not meet specifications. . . a. . . Use a piece of cardboard or paper to search for leaks. Test the nozzle before disassembly to determine condition and necessary repair. N CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. chatter.TM350. . Connect fuel injection nozzle (D) to D-01109AA Diesel Fuel Injection Nozzle Tester (F). leakage. B. Keep hands and body away from pinholes and nozzles which eject fluids under high pressure. . . . (See Disassemble Fuel Injection Nozzles in this section. disassemble injection nozzle and inspect nozzle assembly for contamination or stuck valve. . . 1. b. Record pressure reading when nozzle valve opens. . -UN-26AUG88 M35913 2. Tighten all connections before applying pressure. Relieve pressure before disconnecting hydraulic or other lines. . and G) from D-01110AA Adapter Set and fitting (C). . Do not use your hand.57 -19-01SEP87 CTM3 (03JAN90) 50-27 3TN/4TN Series Yanmar Engines 010897 PN=250 . Use fittings (A. and spray pattern of the fuel injection nozzle. . Test fuel injection nozzle opening pressure following the tool manufacturer’s instructions. .) NOZZLE VALVE OPENING PRESSURE SPECIFICATIONS 3TN66/3TNA72 . IMPORTANT: Use clean filtered diesel fuel when testing fuel injection nozzles to get best test results. . add or remove shims to change opening pressure. If ANY fluid is injected into the skin. . Camshaft.Fuel Injection Pump. If necessary. 11 722 ± 480 kPa (1700 ± 70 psi) A—23617 90˚ Adapter B—23621 Straight Adapter C—23622 Straight Adapter D—Fuel Injection Nozzle E—Container F—D-01109AA Diesel Fuel Injection Nozzle G—36352 Fuel Line Assembly X9811 -UN-23AUG88 50 27 M21. .

. . .59 -19-08FEB86 CTM3 (03JAN90) 50-28 3TN/4TN Series Yanmar Engines 010897 PN=251 . .Fuel Injection Pump. . . . . If nozzle leakage time is low. . Inspect valve seating surface. Camshaft. . . 10 seconds d. Inspect valve seating surface. . . a. chatter sound Slow Hand Lever Movement . check nozzle for contamination. . . . . . .TM350. c. . . Test fuel injection nozzle leakage following the tool manufacturer’s instructions. . M21. . . . . Dry nozzle completely using a lint-free cloth. . 11 722 ± 480 kPa (1700 ± 70 psi) Slow Hand Lever Movement . replace nozzle assembly as required. . .58 -19-08FEB86 4. Test fuel injection nozzle chatter and spray pattern following the tool manufacturer’s instructions. a. . . Pressurize nozzle to test specifications. . . . . . b. NOZZLE PRESSURE TEST SPECIFICATIONS 3TN66/3TNA72 . . . . check nozzle for contamination. fine atomized spray pattern 50 28 If nozzle does not chatter or spray pattern is toward one side only and not finely atomized. . . . . replace nozzle assembly as required. . . . . . . . . . Pressurize nozzle to test specifications. . . . . . Listen for “chatter” sound and watch spray pattern. . fine stream spray pattern Fast Hand Lever Movement .TM350. . Watch for leakage from nozzle spray orifice NOZZLE LEAKAGE 3TN66/3TNA72 TEST SPECIFICATIONS Nozzle Pressure . b. . . . . . M21. . . . and Nozzles/Pintle Type Fuel Injection Nozzle 3. . . . 11 032 kPa (1600 psi) Minimum Nozzle Leakage Time .

M21. valve (B). Remove O-ring (A). and nozzle body (C).63 -19-08FEB86 IMPORTANT: If injector nozzles are being disassembled to be cleaned. Remove retainer (C). Inspect 45˚ valve seating surfaces. the same number and thicknesses of shims must be installed when nozzles are assembled. Separate injector assembly. replace part. spring (B). work area. 2. -UN-26AUG88 5.61 -19-08FEB86 4. Camshaft. Remove valve (A). replace nozzle assembly as required.TM350. 1.TM350.TM350.Fuel Injection Pump. 6. and Nozzles/Pintle Type Fuel Injection Nozzle DISASSEMBLE PINTLE TYPE FUEL INJECTION NOZZLES (3TN66/3TNA72) NOTE: Disassemble fuel injection nozzles in a clean. All internal service parts must have a shiny surface. -UN-26AUG88 M21. M35914 M21.TM350.62 -19-08FEB86 M35915 -UN-26AUG88 M21.60 -19-01SEP87 3. and shims (A). CTM3 (03JAN90) 50-29 3TN/4TN Series Yanmar Engines 010897 PN=252 M35917 -UN-26AUG88 M35916 50 29 . If surface is dull. lint-free.

Fuel Injection Pump.64 -19-14SEP87 CTM3 (03JAN90) 50-30 3TN/4TN Series Yanmar Engines 010897 PN=253 M35918 50 30 -UN-26AUG88 . Camshaft.TM350. and Nozzles/Pintle Type Fuel Injection Nozzle CROSS SECTION OF PINTLE TYPE FUEL INJECTION NOZZLE (3TN66/3TNA72) A—Injector Body B—O-Ring C—Bronze Gasket D—Shim (as required) E—Nozzle Fitting F—Nozzle Body G—Valve H—Nozzle Assembly I—Seat J—Retainer K—Spring M21.

Fuel Injection Pump, Camshaft, and Nozzles/Pintle Type Fuel Injection Nozzle

CLEAN AND INSPECT PINTLE TYPE FUEL INJECTION NOZZLES (3TN66/3TNA72)
IMPORTANT: Never use a steel brush or abrasives to clean nozzles. Doing so will damage the spray hole. 1. Remove carbon from used nozzles, and clean by washing in clean diesel fuel. If parts are coated with hardened carbon or lacquer, it may be necessary to use a brass wire brush from the JDF-13 Nozzle Cleaning Kit.

NOTE: A worn, damaged, or contaminated nozzle assembly will cause nozzle leakage. This condition usually will be noticed when testing the fuel injection nozzle.
2. Inspect nozzle assembly components for wear or damage. All internal service parts must have a shiny surface. If surface is dull, replace part. 3. Inspect the nozzle assembly by performing a slide test. Use the following procedure: a. Dip the valve (A) in clean diesel fuel. Insert valve in nozzle body (B). b. Hold nozzle assembly vertical and pull valve out about 1/3 of its engaged length. c. Release valve. Valve should slide down to its seat by its own weight. Always replace a nozzle assembly if the valve does not slide freely to its seat.

M35919

-UN-26AUG88

50 31
M21,TM350,65 -19-01SEP87

ASSEMBLE PINTLE TYPE FUEL INJECTION NOZZLES (3TN66/3TNA72)
NOTE: Assemble fuel injection nozzles in a clean,lint-free, work area.
1. Put clean diesel fuel on all internal parts. 2. Install valve (A) in nozzle body (B). Valve must slide freely in nozzle body.

M21,TM350,66

-19-14AUG87

CTM3 (03JAN90)

50-31

3TN/4TN Series Yanmar Engines
010897

PN=254

M35919

-UN-26AUG88

Fuel Injection Pump, Camshaft, and Nozzles/Pintle Type Fuel Injection Nozzle
3. Install nozzle assembly (B and C) and seat (A).

M21,TM350,67

-19-24MAR86

IMPORTANT: If injection nozzles were disassembled to be cleaned, the same number and thicknesses of shims must be installed. 4. Install the required amount of shims (A) from shim pack, until the nozzle valve opening pressure is 11 722 ± 480 kPa (1700 ± 70 psi). After assembling fuel injection nozzles, test opening pressure. (See Fuel Injection Nozzle Test in this section.)
SHIM PACK Shim Size 0.15 0.40 0.50 0.60 0.70 0.80 mm mm mm mm mm mm (0.006 (0.016 (0.020 (0.024 (0.028 (0.031 in.) in.) in.) in.) in.) in.) Approximate Pressure Change 2170 kPa (315 psi) 5790 kPa (840 psi) 7240 kPa (1050 psi) 8690 kPa (1260 psi) 10 140 kPa (1470 psi) 11 580 kPa (1680 psi)
-UN-26AUG88 M21,TM350,68 -19-23APR86

NOTE: For every 0.10 mm (0.004 in.) of shim thickness, there is approximately a 1450 kPa (210 psi) change in nozzle valve opening pressure.

50 32

5. Install spring (B) and retainer (C).

CTM3 (03JAN90)

50-32

3TN/4TN Series Yanmar Engines
010897

PN=255

M35915

M35916

-UN-26AUG88

Fuel Injection Pump, Camshaft, and Nozzles/Pintle Type Fuel Injection Nozzle
6. Assemble nozzle assembly. Tighten to 40 N·m (30 lb-ft). 7. Install new O-ring (A).
-UN-26AUG88 M21,TM350,69 -19-14AUG87

INSTALL PINTLE TYPE FUEL INJECTION NOZZLES (3TN66/3TNA72)
1. Install new bronze gaskets.
-UN-26AUG88 M21,TM350,70 -19-14AUG87

2. Install and tighten injection nozzle into cylinder head to 50 N·m (37 lb-ft).

-UN-26AUG88 M21,TM350,71 -19-14AUG87

M35921

M35920

3. Install hoses (A) and fittings (B). Fasten with clamps.

M21,TM350,72

-19-08FEB86

CTM3 (03JAN90)

50-33

3TN/4TN Series Yanmar Engines
010897

PN=256

M35911

-UN-26AUG88

M35922

50 33

Fuel Injection Pump, Camshaft, and Nozzles/Pintle Type Fuel Injection Nozzle
4. Install new bronze gaskets (A). 5. Install fuel leak-off line and nuts. Tighten nuts to no more than 40 N·m (30 lb-ft). 6. Connect fuel return line (B) and fasten with clamp.
-UN-26AUG88 M21,TM350,73 -19-14AUG87 M21,TM350,74 -19-08FEB86

IMPORTANT: When installing injection lines, DO NOT turn pump outlet fittings. Turning fittings may damage pump internally.
-UN-26AUG88

7. Install injection lines using two wrenches. 8. Install line clamp and two screws. 9. Bleed the fuel system. (See Section 30 of the appropriate Technical Manual.)

CTM3 (03JAN90)

50-34

3TN/4TN Series Yanmar Engines
010897

PN=257

M35885

50 34

M35924

-UN-26AUG88

M35923

Fuel Injection Pump, Camshaft, and Nozzles/Hole Type Fuel Injection Nozzle

HOLE TYPE FUEL INJECTION NOZZLE OPERATION (ALL EXCEPT 3TN66/3TNA72)
The hole type nozzle is used on direct injection engines 3TN75 and larger. It is different from the pintle type nozzle in that it is held in the cylinder head by a retaining bracket instead of being threaded. High pressure fuel from the injection pump flows through a fuel inlet passage. Pressure builds beneath the nozzle valve. When the fuel pressure reaches specified pressure it overcomes the nozzle spring tension. The nozzle valve retracts into the nozzle body and fuel is injected into the engine. The nozzle valve is shim adjustable to regulate the opening pressure. The nozzle valve is automatically pushed down by the nozzle spring and closed after fuel is injected. Leakage (return fuel) flows from between the nozzle valve and nozzle body to the hole on top of the nozzle spring through the return pipe fitting and back into the fuel tank.
-19-05JAN89 M21,TM350,75A -19-01SEP87 T6333AI

50 35

CTM3 (03JAN90)

50-35

3TN/4TN Series Yanmar Engines
010897

PN=258

Fuel Injection Pump, Camshaft, and Nozzles/Hole Type Fuel Injection Nozzle

REMOVE HOLE TYPE FUEL INJECTION NOZZLES (ALL EXCEPT 3TN66/3TNA72)

N

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Keep hands and body away from pinholes and nozzles which eject fluids under high pressure. Use a piece of cardboard or paper to search for leaks. Do not use your hand. If ANY fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result.

IMPORTANT: Never steam clean or pour cold water on injection pump while the pump is running or warm. Doing so can damage the pump. 1. Clean the injection pump, injection nozzles, lines, and area around the nozzles using a parts cleaning solvent or a steam cleaner.

M21,TM350,52B -19-14AUG87

50 36

IMPORTANT: When removing injection lines, DO NOT turn pump delivery valve fittings. Turning fittings may damage pump internally. 2. Use two wrenches to loosen fuel line fittings enough to release any pressure in the fuel system. 3. Disconnect fuel lines from injection nozzles and remove lines. 4. Cap all openings to keep dirt out of the fuel system.
-UN-26AUG88 M21,TM350,53 -19-08FEB86

CTM3 (03JAN90)

50-36

3TN/4TN Series Yanmar Engines
010897

PN=259

M35883

X9811

-UN-23AUG88

Fuel Injection Pump, Camshaft, and Nozzles/Hole Type Fuel Injection Nozzle
5. Remove nuts from studs and remove retaining plates (A) from nozzles. 6. Remove leak-off lines (B).
-UN-29AUG88 M21,TM350,76 -19-08FEB86

7. If nozzles are stuck in cylinder head: Grind the head of a cap screw (A) so it fits inside a nut from (B), from an old injection line. Use double nuts to attach a large flat washer (C) to the cap screw. Install the assembly onto nozzle and use a suitable puller and slide hammer to pull nozzles from head.
-UN-29AUG88 M21,TM350,77 -19-08FEB86 -UN-29AUG88 M21,TM350,78 -19-08FEB86 M37808

8. When removing nozzles, check to see if teflon seal and ring (A) is removed with nozzle. If heat protector stays in cylinder head, thread a cap screw into it and pull from cylinder head. 3. Test injection nozzles.

M37807

CTM3 (03JAN90)

50-37

3TN/4TN Series Yanmar Engines
010897

PN=260

M37809

50 37

Test fuel injection nozzle opening pressure following the tool manufacturer’s instructions.79 -19-01SEP87 CTM3 (03JAN90) 50-38 3TN/4TN Series Yanmar Engines 010897 PN=261 M35913 X9811 -UN-23AUG88 .) NOZZLE VALVE OPENING PRESSURE SPECIFICATIONS 3TN75/3TN78/3TN82/3TN84/4TN78 4TN82/4TN84 . and G) from D01110AA Adapter Set and fitting (C). IMPORTANT: Use clean filtered diesel fuel when testing fuel injection nozzles to get best test results. add or remove shims to change opening pressure. Use fittings (A. Test the nozzle before disassembly to determine condition and necessary repair. Do not use your hand. . .TM350. . . Connect fuel injection nozzle (D) to D-01109AA Diesel Fuel Injection Nozzle Tester (F). . . If ANY fluid is injected into the skin. . . chatter. . If necessary. . Record pressure reading when nozzle valve opens. 1. If pressure reading does not meet specifications. it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result. . a. . . . . . Keep hands and body away from pinholes and nozzles which eject fluids under high pressure. .Fuel Injection Pump. . . and Nozzles/Hole Type Fuel Injection Nozzle TEST HOLE TYPE FUEL INJECTION NOZZLES (ALL EXCEPT 3TN66/3TNA72) This test checks the opening pressure. . . . . B. N CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. . 20 100 ± 490 kPa (2915 ± PSI) A—23617 90˚ Adapter B—23621 Straight Adapter C—23622 Straight Adapter D—Fuel Injection Nozzle E—Container F—D-011-09AA Diesel Fuel Injection Nozzle Tester G—36352 Fuel Line Assembly 50 38 M21. leakage. . . 19 600 ± 480 kPa (2843 ± 70 psi) 4TN100 . . and spray pattern of the fuel injection nozzle. . b. . . Camshaft. -UN-26AUG88 2. Use a piece of cardboard or paper to search for leaks. . disassemble injection nozzle and inspect nozzle assembly for contamination or stuck valve. (See Disassemble Fuel Injection Nozzles in this section. .

. . . . . . . . . . . NOZZLE LEAKAGE TEST SPECIFICATIONS 3TN75/3TN78/3TN82/3TN84/4TN78/4TN82/4TN84 Nozzle Pressure . . NOZZLE PRESSURE TEST SPECIFICATIONS 3TN75/3TN78/3TN82/3TN84/ 4TN78/4TN82/4TN84 .81 -19-01SEP87 CTM3 (03JAN90) 50-39 3TN/4TN Series Yanmar Engines 010897 PN=262 . . . . . . . . . . chatter sound Slow Hand Lever Movement . If nozzle leakage time is low. . . . . . . . . . . 18 100 kPa (2625 psi) Minimum Nozzle leakage Time . . replace nozzle assembly as required. . . . . . . . . . . replace nozzle assembly as required. . c. Inspect valve seating surface. . . fine stream spray pattern Fast Hand Lever Movement . . . check nozzle for contamination. . . . . . . . . . . . . . . .TM350. Inspect valve seating surface. . . 19 600 ± 480 kPa (2843 ± 70 psi) 4TN100 . . M21. b. b. . . . . . Test fuel injection nozzle leakage following the tool manufacturer’s instructions. . . . . . . . Dry nozzle completely using a lint-free cloth. . . 17 640 kPa (2550 psi) Minimum Nozzle Leakage Time . 20 100 ± 490 kPa (2915 ± 71 psi) Slow Hand Lever Movement . . . . . . . Listen for “chatter” sound and watch spray pattern. . Test fuel injection nozzle chatter and spray pattern following the tool manufacturer’s instructions. Pressurize nozzle to test specifications. . . .Fuel Injection Pump. 5 seconds 4TN100 Nozzle Pressure . . . . .80 -19-01SEP87 4. M21. . . . . . . . a. . fine atomized spray pattern 50 39 If nozzle does not not chatter or spray pattern is toward one side only and not finely atomized. Pressurize nozzle to test specifications. a. . Camshaft. . . check nozzle for contamination. . . . . . . . 5 seconds d. . . . . Watch for leakage from nozzle spray orifice. .TM350. . . . . . . . . and Nozzles/Hole Type Fuel Injection Nozzle 3. . . . . . . . . .

Fuel Injection Pump. Remove nozzle retaining nut (A). Remove separator plate and index pins (C). 50 40 CTM3 (03JAN90) 50-40 3TN/4TN Series Yanmar Engines 010897 PN=263 M37811 -UN-29AUG88 M37810 .82 -19-14AUG87 M21. Remove spring seat (A).TM350. Remove nozzle assembly (B). spring (B).TM350. 2. 3.83 -19-08FEB86 1. Camshaft. 4. and shims (C). and Nozzles/Hole Type Fuel Injection Nozzle DISASSEMBLE HOLE TYPE FUEL INJECTION NOZZLES (ALL EXCEPT 3TN66/3TNA72) -UN-29AUG88 M21.

Inspect the piston (large) part of nozzle valve (A) to see that it is not scratched or scored and that lower (tip) end of valve is not broken. Camshaft. RG2233 -UN-20APR89 50 41 M21. 5. This condition usually will be noted when performing “Leakage Test” described in this group. Remove carbon from used nozzles. If any of these conditions are present. and pull valve out about 1/3 of its engaged length (C). Further inspect the nozzle assembly by performing a slide test.Fuel Injection Pump. NOTE: A bad nozzle valve seat will cause fuel to drip from the nozzle.84 -19-14AUG87 CTM3 (03JAN90) 50-41 3TN/4TN Series Yanmar Engines 010897 PN=264 . 3. Valve should slide down to its seat by its own weight. Use the following procedure: a. Contact area of seat (both parts) must not be scored or pitted. inspect the lapped machine surface (D) for nicks or scratches. b. Release valve. and clean by washing in diesel fuel. 4. and Nozzles/Hole Type Fuel Injection Nozzle CLEAN AND INSPECT HOLE TYPE INJECTION NOZZLE COMPONENTS (ALL EXCEPT 3TN66/3TNA72) 1.TM350. replace the nozzle assembly. Inspect condition of seat for nozzle valve and nozzle. it may be necessary to use a brass wire brush (supplied in JDF-13 Nozzle Cleaning Kit). 6. Use an inspection magnifier (No. 2. Remove anti-corrosive grease from new or reconditioned nozzles by washing them thoroughly in diesel fuel. Always replace a nozzle assembly if the valve does not slide freely to its seat. After removing carbon or lacquer from the exterior of nozzle. 7. Hold nozzle vertical. c. Insert valve in nozzle (B). 16487 or equivalent) to aid making the inspection. If parts are coated with hardened carbon or lacquer. IMPORTANT: Never use a steel brush to clean nozzles as this will distort the spray hole. Dip the nozzle valve (A) in clean diesel fuel.

85 -19-14SEP87 CTM3 (03JAN90) 50-42 3TN/4TN Series Yanmar Engines 010897 PN=265 M37684 -UN-06SEP88 .TM350. Camshaft.Fuel Injection Pump. and Nozzles/Hole Type Fuel Injection Nozzle CROSS SECTION OF HOLE TYPE FUEL INJECTION NOZZLE (ALL EXCEPT 3TN66/3TNA72) A—Fuel Return Pipe B—Dowel Pin (3 used) C—Seat D—Nozzle Nut E—Valve F—Nozzle Body G—Nozzle Assembly H—Retainer I—Spring J—Shim (as required) K—Injector Body 50 42 M21.

TM350. 7. Tighten nuts to 4.TM350.87 -19-08FEB86 M37809 -UN-29AUG88 M37812 6. 2. -UN-29AUG88 M21. and Nozzles/Hole Type Fuel Injection Nozzle ASSEMBLE AND INSTALL HOLE TYPE FUEL NOZZLES (ALL EXCEPT 3TN66/3TNA72) 1.TM350. Install retaining plates and nuts. 8. Install nozzle assembly (B) and retaining nut (C).5 N·m (39 lb-in. Tighten retaining nut to 43 N·m (31 lb-ft).). Install nozzles into cylinder head. Camshaft.86 -19-01SEP87 M21. 11. 5. 10. Install new teflon seal (A) into old retaining ring. -UN-29AUG88 M21. Refer to section 30 of the appropriate Technical Manual. Install leak-off lines and injection lines. test nozzles and adjust opening pressure. Install separator plate and index pins (A). 3. Install shims as needed into nozzle body. 9.Fuel Injection Pump.88 -19-08FEB86 50 43 CTM3 (03JAN90) 50-43 3TN/4TN Series Yanmar Engines 010897 PN=266 M37813 . If any parts were replaced. Bleed fuel system. Install spring and spring seat into nozzle body. 4.

Fuel Injection Pump. Camshaft. and Nozzles/Hole Type Fuel Injection Nozzle 50 44 CTM3 (03JAN90) 50-44 3TN/4TN Series Yanmar Engines 010897 PN=267 .

and Seal Driver Set To remove throttle lever bushing To measure speed control linkage components To measure speed control linkage components To install throttle lever bushing M21.3 -19-08FEB86 CTM3 (03JAN90) 55-1 3TN/4TN Series Yanmar Engines 010897 PN=268 .2 -19-23APR86 SERVICE PART KITS The following kits are available through your parts catalog: Cylinder Block Gasket Kit Fuel Injection Pump Shim Pack 55 1 M21.TM355.S.TM355. Some tools may be available from a local supplier.Group 55 Fuel Control and Governor Linkage SERVICE EQUIPMENT AND TOOLS NOTE: Order tools from the U. Name Use Blind-Hole Puller Set Outside Micrometer Telescoping Gage Bushing.TM355. SERVICEGARD™ Catalog or from the European Microfiche Tool Catalog (MTC).1 -19-23APR86 OTHER MATERIAL Number Name Use AT52853 John Deere LOCTITE® Thread Lock and Sealer (Low Strength) Apply on threads of fuel shut-off lever set screw M21. Bearing.

TM355. Remove sealing wire (A). 6. 3. 5. Disconnect throttle cable (B).5 -19-01SEP87 7.TM355. 2. Remove fuel injection pump (A). A—Washer (4 used) B—Cap Screw (2 used) C—Cover D—Gasket M21. 8. Remove cap screw (B) to remove slow idle screw bracket (C).7 -19-14FEB86 55 2 9.) 4.Fuel Control and Governor Linkage/Fuel Control and Governor Linkage (Early 3TNA72UJ) REMOVE FUEL CONTROL AND GOVERNOR LINKAGE (EARLY 3TNA72UJ) 1. A—Fuel Injection Pump B—Throttle Cable C—Fuel Shut-Off Linkage D—Oil Filter E—Dipstick Tube M21. Remove two cap screws (B) to remove cover (C) and gasket (D).TM355. 11. Remove cap nuts (D). Remove oil filter (D) and dipstick tube (E). Disconnect fuel shut-off linkage (C). Remove two cap screws and four washers (A) to remove bracket. A—Sealing Wire B—Cap Screw C—Slow Idle Screw Bracket D—Cap Nuts -UN-26AUG88 M21. Remove grille and left side panel.8 -19-14FEB86 CTM3 (03JAN90) 55-2 3TN/4TN Series Yanmar Engines 010897 PN=269 M35929 M35928 -UN-26AUG88 M35927 -UN-26AUG88 . Disconnect battery negative (—) cable. (See Group 50 in this manual. 10.

M21.TM355. M21. Loosen lock nut to remove fast idle adjusting screw (A) and seals (B).12 -19-14FEB86 CTM3 (03JAN90) 55-3 3TN/4TN Series Yanmar Engines 010897 PN=270 M35934 -UN-26AUG88 .TM355.TM355. throttle lever (A). Disconnect spring from throttle lever. Remove nut to remove lever.9 -19-14FEB86 13. M21. 55 3 M21.TM355. Loosen lock nut to remove fuel controller (A) and seals (B).Fuel Control and Governor Linkage/Fuel Control and Governor Linkage (Early 3TNA72UJ) 12.10 -19-24MAR86 14.11 -19-14FEB86 M35933 -UN-26AUG88 M35932 -UN-26AUG88 M35930 -UN-26AUG88 15. and O-ring.

M21. M21.15 -19-14FEB86 55 4 IMPORTANT: DO NOT reuse bronze gasket. remove bushing using a 7/16-in. If necessary. Inspect bushing for wear or damage. Remove set screw to remove fuel shut-off lever. and spacer. M21. Remove O-ring. 17. 20.TM355. -UN-26AUG88 M21. Remove governor shaft. Do not remove bushing unless replacement is necessary. blind-hole puller.Fuel Control and Governor Linkage/Fuel Control and Governor Linkage (Early 3TNA72UJ) 16. snap ring (A).TM355.16 -19-14FEB86 CTM3 (03JAN90) 55-4 3TN/4TN Series Yanmar Engines 010897 PN=271 M35938 M35937 -UN-26AUG88 M35936 -UN-26AUG88 M35935 -UN-26AUG88 .14 -19-24MAR86 19.TM355. bronze gasket.13 -19-14FEB86 18.TM355. and spring (B).

. Remove fuel control linkage assembly. . M21. . 7.TM355. . . . M21. Measure governor shaft outside diameter. . . .) If diameter is less than minimum specification.D. . GOVERNOR SHAFT O. .TM355. .17 -19-14FEB86 22.18 -19-14FEB86 M35941 -UN-26AUG88 M35939 -UN-26AUG88 M35940 -UN-26AUG88 55 5 CTM3 (03JAN90) 55-5 3TN/4TN Series Yanmar Engines 010897 PN=272 . . . replace governor shaft. . . .90 mm (0.311 in. Turn governor weights until one weight is toward the engine. . SPECIFICATION (MIN) Shaft Diameter . . . . .Fuel Control and Governor Linkage/Fuel Control and Governor Linkage (Early 3TNA72UJ) 21. .

. M21.TM355.18 mm (0. 8. . . .321 in.21 -19-14FEB86 CTM3 (03JAN90) 55-6 3TN/4TN Series Yanmar Engines 010897 PN=273 M35944 -UN-26AUG88 M35943 -UN-26AUG88 M35942 -UN-26AUG88 .TM355. . GOVERNOR SHAFT CLEARANCE SPECIFICATION (MAX) Governor Shaft Clearance . Measure fuel control linkage bore inside diameter. . replace fuel control linkage assembly. M21.Fuel Control and Governor Linkage/Fuel Control and Governor Linkage (Early 3TNA72UJ) 23. . 0.) If bore diameter is greater than maximum specification. . . . .TM355. fuel control linkage assembly. SPECIFICATION (MAX) Bore Diameter . pin (A).) If clearance is greater than maximum specification. . . . . . . replace governor shaft.D. M21. . . and spring (B). . . .20 -19-14FEB86 55 6 26. FUEL CONTROL LINKAGE BORE I.007 in. . . . or both. Determine governor shaft clearance (fuel control linkage bore diameter minus governor shaft diameter). .15 mm (0. . . . . 24. . . . . .19 -19-14AUG87 25. Remove snap ring. . . . Remove spring pin.

. . .15 mm (0. . . governor weights (B). 9. . .TM355. .20 mm (0. . Inspect splines on shaft for chipped or broken teeth. . . . M21. . . . .350 in. replace shaft. .90 mm (0. .D. . . . . replace shaft. . . .) M35947 -UN-26AUG88 M35946 -UN-26AUG88 M35945 -UN-26AUG88 55 7 If clearance is greater than maximum specification. . . or both. . . and thrust washer (C). .24 -19-14AUG87 CTM3 (03JAN90) 55-7 3TN/4TN Series Yanmar Engines 010897 PN=274 . .) If shaft diameter is less than minimum specification. . .23 -19-14FEB86 29. . . Determine inner rotor shaft clearance (sleeve bore diameter minus inner rotor shaft diameter).Fuel Control and Governor Linkage/Fuel Control and Governor Linkage (Early 3TNA72UJ) 27. 0. Remove sleeve (A).22 -19-14FEB86 28. (See Group 40 in manual. . . . . . . replace sleeve. .TM355. .006 in. . . . . . . . .) If bore diameter is greater than maximum specification.D. . . M21. If necessary. SPECIFICATION (MAX) Bore Diameter . .TM355. replace sleeve. . . . INNER ROTOR SHAFT CLEARANCE SPECIFICATION (MAX) Shaft Clearance . . inner rotor shaft. . SPECIFICATION (MIN) Shaft Diameter . 8. . . Measure sleeve bore inside diameter. . . . . . Measure inner rotor shaft outside diameter. INNER ROTOR SHAFT O. M21. . SLEEVE BORE I.362 in.) 30. .

-UN-26AUG88 M21. Install spring (B). Align splines on inner rotor shaft (A) with splines in thrust washer (C) and governor weights (B). Install thrust washer. governor weights. 4. Install pin (A) and fasten with snap ring. Use new gaskets when assembling the engine.TM355.25 -19-23APR86 5.27 -19-14FEB86 CTM3 (03JAN90) 55-8 3TN/4TN Series Yanmar Engines 010897 PN=275 M35948 -UN-26AUG88 M35944 M35945 -UN-26AUG88 . 2. and sleeve on inner rotor shaft. 55 8 M21.26 -19-14FEB86 7. Install spring pin. M21.TM355. Put clean engine oil on all internal parts.Fuel Control and Governor Linkage/Fuel Control and Governor Linkage (Early 3TNA72UJ) INSTALL FUEL CONTROL AND GOVERNOR LINKAGE (EARLY 3TNA72UJ) 1.TM355. 6. Thoroughly clean and dry all parts. 3.

TM355. Tighten governor shaft to 49 N·m (36 lb-ft). 9. 11. Install governor shaft through fuel control linkage assembly. -UN-26AUG88 M21.29 -19-14FEB86 M35949 -UN-26AUG88 M35939 -UN-26AUG88 M35940 12.Fuel Control and Governor Linkage/Fuel Control and Governor Linkage (Early 3TNA72UJ) 8. Turn governor weights until one weight is toward the engine.TM355.28 -19-14FEB86 10. 55 9 M21.30 -19-24APR86 CTM3 (03JAN90) 55-9 3TN/4TN Series Yanmar Engines 010897 PN=276 M43379 -UN-20NOV89 .TM355. Install fuel control linkage assembly. M21. Install spacer (A) and new bronze gasket (B) on governor shaft.

33 -19-14FEB86 55 10 18.TM355. Install and tighten set screw. driver disk.32 -19-14FEB86 16. Install fuel shut-off lever.31 -19-14FEB86 14. Apply thread lock and sealer (low strength) on threads on set screw. and new O-ring on fuel shut-off lever. 17. 15.TM355.34 -19-14FEB86 CTM3 (03JAN90) 55-10 3TN/4TN Series Yanmar Engines 010897 PN=277 M35952 M35936 M35951 -UN-08SEP88 M35937 -UN-26AUG88 . Be sure groove is visible through hole (B). M21. Install spring (B). Push bushing even with surface of gear housing. -UN-08SEP88 M21. chamfered end first into gear housing using a 7/8-in. If removed.TM355. install bushing.TM355.Fuel Control and Governor Linkage/Fuel Control and Governor Linkage (Early 3TNA72UJ) 13. M21. Align groove (A) in fuel shut-off lever with hole (B) in gear housing. snap ring (A). -UN-26AUG88 M21.

Fuel Control and Governor Linkage/Fuel Control and Governor Linkage (Early 3TNA72UJ) 19. Install new O-ring on throttle lever. CTM3 (03JAN90) 55-11 3TN/4TN Series Yanmar Engines 010897 PN=278 M35932 .35 -19-24MAR86 20.37 -19-14FEB86 M35933 -UN-26AUG88 M35934 -UN-26AUG88 M35953 -UN-29AUG88 22. M21. Install throttle lever (A) and lever. Install and tighten nut.36 -19-14FEB86 21. Connect spring to throttle lever and then to fuel control linkage assembly. -UN-26AUG88 M21. 23. Install fuel controller assembly.38 -19-14FEB86 55 11 NOTE: DO NOT install cap nut at this time. M21. M21.TM355.TM355. Install seals (B) and lock nuts on fuel controller (A).TM355.TM355.

cover.41 -19-14AUG87 27.TM355. M21. Tighten four cap screws to 9 N·m (78 lb-in. Install new gasket. 29. Install two washers (B) between bracket (C) and cover in alignment with holes. Install seals (B) and lock nut on fast idle adjusting screw (A). 25.Fuel Control and Governor Linkage/Fuel Control and Governor Linkage (Early 3TNA72UJ) 24. Install slow idle screw bracket (A) so the stop (B) on the lever contacts the slow idle screw (C). -UN-29AUG88 M21. Install fuel shut-off lever spring on slow idle screw bracket.).40 -19-14FEB86 M21.39 -19-14FEB86 26. Install bracket and two cap screws. Install and tighten cap screw. NOTE: DO NOT install cap nut or sealing wire at this time.TM355. 28. 55 12 -UN-29AUG88 CTM3 (03JAN90) 55-12 3TN/4TN Series Yanmar Engines 010897 PN=279 M35955 M35566 -UN-26AUG88 M35954 M35930 -UN-26AUG88 .TM355. and two cap screws (A). Install fast idle adjusting screw assembly.

43 -19-14AUG87 M37786 -UN-29AUG88 M35956 38.42 -19-23APR86 M21. Check and adjust slow and fast idle setting.) REMOVE FUEL CONTROL AND GOVERNOR LINKAGE (3TN66/LATER 3TNA72) 1. 55 13 M21. (See Machine Technical Manual.TM355. Install fuel injection pump (E).) -UN-29AUG88 M21. 3. Install dipstick tube (D) and fasten with cap screw.TM355. 32. 31. Check and adjust fuel shut-off lever. Install oil filter (C). Connect fuel shut-off linkage (B). Connect throttle cable (A). Bleed fuel injection system.) 37.) 35. 33.TM355. Remove cotter pin (B) to disconnect solenoid. 36. (See Technical Manual. Remove pin (A) to disconnect linkage (B). Remove four nuts to remove cover assembly (A).44 -19-23APR86 CTM3 (03JAN90) 55-13 3TN/4TN Series Yanmar Engines 010897 PN=280 M37787 -UN-29AUG88 .Fuel Control and Governor Linkage/Fuel Control & Governor Linkage (3TN66 & Later 3TNA72) 30. (See Group 50 in this manual. 2. Connect battery negative (—) cable. (See Technical Manual. 34.

. .Fuel Control and Governor Linkage/Fuel Control & Governor Linkage (3TN66 & Later 3TNA72) 4. . . Remove three cap screws to remove bracket (A).TM355.TM355. . 5.47 -19-14FEB86 6.D. 8. Remove four remaining cap screws to remove the linkage housing (C). 8. . . . -UN-29AUG88 M21.45 -19-14FEB86 M21. .) If bore diameter is greater than maximum specification. . Remove sleeve. . . . 55 14 CTM3 (03JAN90) 55-14 3TN/4TN Series Yanmar Engines 010897 PN=281 M37756 -UN-29AUG88 M37755 -UN-29AUG88 M37754 . Remove cap screw to remove dipstick (B). . Measure sleeve bore inside diameter. .46 -19-14FEB86 M21. . . 7. replace sleeve. . .20 mm (0.323 in. .TM355. SPECIFICATION (MAX) Bore Diameter . . SLEEVE BORE I. . .

. .D. 0. . Replace if necessary.006 in. . . 10. SHAFT O. . Remove seal and sealing wire (B). Inspect governor weights for damage or any binding.15 mm (0. CTM3 (03JAN90) 55-15 3TN/4TN Series Yanmar Engines 010897 PN=282 M37759 . .311 in. M37757 DISASSEMBLE FUEL CONTROL AND GOVERNOR LINKAGE (3TN66/LATER 3TNA72) -UN-29AUG88 M21. .90 mm (0. 2. . .) If clearance is greater than maximum specification. .Fuel Control and Governor Linkage/Fuel Control & Governor Linkage (3TN66 & Later 3TNA72) 9. . . .TM355. . Remove spring (A). . Determine oil clearance (sleeve bore diameter minus shaft diameter. . -UN-29AUG88 M21. . OIL CLEARANCE SPECIFICATION (MAX) Oil clearance . . .48 -19-14AUG87 11. . SPECIFICATION (MIN) Shaft Diameter . . . shaft or both. . 7. -UN-29AUG88 M21. . .TM355. . . . replace shaft. Remove nut (A) to remove weights (B). . . . . . .50 -19-14AUG87 55 15 1. . replace sleeve.49 -19-14FEB86 M37758 Inspect keyway in shaft and alignment tooth in the governor weights for wear or damage. . . . . . Measure shaft outside diameter. . . . .TM355.) If shaft diameter is less than minimum specification. . .

fuel control linkage assembly (B) and shims (C). 4. M21. Remove set screw (B) to remove fuel shut-off lever (C).53 -19-14FEB86 CTM3 (03JAN90) 55-16 3TN/4TN Series Yanmar Engines 010897 PN=283 M37762 -UN-29AUG88 M37761 -UN-29AUG88 M37760 -UN-29AUG88 .51 -19-14FEB86 6.52 -19-14FEB86 55 16 7. Remove shaft (A).TM355. Remove O-ring (A) and spring (B). Remove retaining cap screw (D). A—Retaining Cap Screw B—Set Screw C—Fuel Shut-Off Lever D—Retaining Cap Screw E—Lever M21.TM355. 5.TM355. M21. Remove retaining cap screw (A). Remove nut to remove lever (E).Fuel Control and Governor Linkage/Fuel Control & Governor Linkage (3TN66 & Later 3TNA72) 3.

8. . . . . . . -UN-29AUG88 M21. .) If diameter is less than minimum specification.311 in. . GOVERNOR SHAFT O.TM355. .55 -19-14FEB86 M37763 -UN-29AUG88 55 17 CTM3 (03JAN90) 55-17 3TN/4TN Series Yanmar Engines 010897 PN=284 M37764 . . . . . . . . .54 -19-01SEP87 11.TM355. .D. . . .18 mm (0.90 mm (0. replace governor shaft. replace fuel control linkage assembly. Measure fuel control linkage bore inside diameter. . .321 in. . 7. . . 9. .15 mm (0. Remove spring pin (A). . . SPECIFICATION (MIN) Shaft Diameter . . . . . . . . .) If clearance is greater than maximum specification. 10. M21. fuel control linkage assembly. FUEL CONTROL LINKAGE BORE I. . . . . . . .Fuel Control and Governor Linkage/Fuel Control & Governor Linkage (3TN66 & Later 3TNA72) 8. . . . . GOVERNOR SHAFT CLEARANCE SPECIFICATION (MAX) Shaft Clearance . . . . 0. . . . . . Measure governor shaft outside diameter. . . . . or both. .007 in.) If bore diameter is greater than maximum specification. . . . Determine governor shaft clearance (fuel control linkage bore diameter minus governor shaft diameter). SPECIFICATION (MAX) Bore Diameter . . replace governor shaft. . .D. .

Rotate shaft and lever assembly as shown.TM355. and D).TM355. M21. Remove cover assembly (A) and fuel control stops (B. Remove snap ring. 14. 15. A—Cover Assembly B—Slow Idle Stop C—Fuel Controller D—Fast Idle Stop 55 18 CTM3 (03JAN90) 55-18 3TN/4TN Series Yanmar Engines 010897 PN=285 M37767 -UN-29AUG88 M37766 M37765 -UN-29AUG88 . and spring (B). C. -UN-29AUG88 M21. Remove tapered pin (B) from tapered hole using a punch. Remove shaft (A) and lever (C).TM355.58 -19-23APR86 16.Fuel Control and Governor Linkage/Fuel Control & Governor Linkage (3TN66 & Later 3TNA72) 12.57 -19-14FEB86 M21. pin (A).56 -19-14FEB86 13.

A—Cover Assembly B—Slow Idle Stop C—Fuel Controller D—Fast Idle Stop 4. 5. and D) and cover assembly (A). C.TM355. Use new gaskets when assembling linkage housing. Rotate shaft (A) until rounded side (D) of shaft is toward the retaining cap screw.60 -19-01SEP87 M37768 -UN-29AUG88 M37767 1. Put clean engine oil on all internal parts. 2.TM355. Thoroughly clean and dry all parts. 3. Position lever (C) as shown and install tapered pin (B) in tapered hole. Install fuel control stops (B.Fuel Control and Governor Linkage/Fuel Control & Governor Linkage (3TN66 & Later 3TNA72) ASSEMBLE FUEL CONTROL AND GOVERNOR LINKAGE (3TN66/LATER 3TNA72) -UN-29AUG88 M21.59 -19-01SEP87 -UN-29AUG88 M21. A—Shaft B—Tapered Pin C—Lever D—Rounded Side 55 19 CTM3 (03JAN90) 55-19 3TN/4TN Series Yanmar Engines 010897 PN=286 M37769 . Install shaft (A) and lever (C).

M21. Install O-ring (A) and spring (B) on fuel shut-off lever.TM355. M21.64 -19-14FEB86 CTM3 (03JAN90) 55-20 3TN/4TN Series Yanmar Engines 010897 PN=287 M37761 -UN-29AUG88 M37762 -UN-29AUG88 M37764 -UN-29AUG88 M37765 -UN-29AUG88 .Fuel Control and Governor Linkage/Fuel Control & Governor Linkage (3TN66 & Later 3TNA72) 6. M21. M21. Install pin (A).61 -19-14FEB86 7.63 -19-14FEB86 55 20 9. snap ring and spring (B).TM355. shims (C).62 -19-14FEB86 8.TM355. Install fuel control linkage assembly (B).TM355. and shaft (A). Install spring pin (A).

Use new gaskets when assembling the engine. Put clean engine oil all internal parts. 55 21 M21.66 -19-14FEB86 M37770 -UN-29AUG88 M37760 INSTALL FUEL CONTROL LINKAGE (3TN66/LATER 3TNA72) 1. Thoroughly clean and dry all parts. Install fuel shut-off lever. and sleeve (C).TM355. Install spring (A).65 -19-23APR86 15. Apply threadlock and sealer (low strength) on threads of set screw. 12. 3. 2.67 -19-14AUG87 CTM3 (03JAN90) 55-21 3TN/4TN Series Yanmar Engines 010897 PN=288 M37771 -UN-29AUG88 . Install governor weight (A). M21. Install lever (E) and nut. 13.TM355. A—Retaining Cap Screw B—Set Screw C—Fuel Shut-Off Lever D—Retaining Cap Screw E—Lever -UN-29AUG88 M21. 11.Fuel Control and Governor Linkage/Fuel Control & Governor Linkage (3TN66 & Later 3TNA72) 10. Fasten with retaining cap screw (D). Align tooth in governor weight with slot in shaft. nut (B). Install retaining cap screw (A). 14. Install and tighten set screw.TM355. Align groove in fuel shut-off lever with set screw hole in housing. Be sure groove is visible through hole.

TM355. Install linkage housing (C). M21. 8. 6. 7. (See Machine TM). Check and adjust slow and fast idle settings. 55 22 2. M21. to prevent dirt from entering the fuel system. M21. fitting (B) and hand primer assembly (C). Thoroughly clean the supply pump body and surrounding area before loosening and fittings. it must be serviced by a qualified fuel injection repair shop. After all adjustments are made install new lead seal wire and crimp using JDF-10 Sealing Wire Pliers. Tighten cap screws. 9. (See Machine TM). and dipstick (B). 5. If unit is in need of repair.Fuel Control and Governor Linkage/Fuel Supply Pump (4TN100RJF) 4. Check and adjust fuel shut-off lever. Bleed fuel injection system (See Section 30 in Machine TM).TM335. (See Machine TM). or the fuel injection pump assembly must be replaced.69 -19-14AUG87 REMOVE AND INSPECT FUEL SUPPLY PUMP (4TN100RJF) 1. bracket (A).TM355. Check and adjust fuel controller.A1 -19-18AUG87 CTM3 (03JAN90) 55-22 3TN/4TN Series Yanmar Engines 010897 PN=289 M51586 -UN-31AUG88 M37754 -UN-29AUG88 . Remove fuel line (A).68 -19-23APR86 SERVICE FUEL CONTROL AND GOVERNOR LINKAGE (ALL EXCEPT 3TN66/3TNA72) Do not attempt to service the fuel control and governor linkage.

foreign material or pitting. 4.A2 -19-14AUG87 5.A3 -19-14AUG87 M51589 -UN-31AUG88 M51588 -UN-31AUG88 M51587 -UN-31AUG88 55 23 CTM3 (03JAN90) 55-23 3TN/4TN Series Yanmar Engines 010897 PN=290 . 6. Inspect valve seat surfaces for scratches. nicks. Inspect valves and springs for excessive wear or damage. Remove plug (A) and inspect parts (A—E) for wear or damage.Fuel Control and Governor Linkage/Fuel Supply Pump (4TN100RJF) 3. Remove three mounting nuts to remove pump body from engine. A—Plug B—Washer C—Spring D—Plunger E—Rod M21.TM355.TM355. Replace if necessary. M21.

Replace if necessary. Install cam roller assembly into pump body with small hole in holder towards bottom of pump body.A5 -19-14AUG87 CTM3 (03JAN90) 55-24 3TN/4TN Series Yanmar Engines 010897 PN=291 M51590 -UN-31AUG88 M51591 -UN-31AUG88 M51591 -UN-31AUG88 M51590 -UN-31AUG88 .TM355.A4 -19-14AUG87 ASSEMBLE AND INSTALL FUEL SUPPLY PUMP (4TN100RJF) 1. Assemble cam roller assembly (B—F). A—Wire Retainer B—Shaft C—Roller D—Slide Pivot (2 used) E—Washer (2 used) F—Holder 55 24 M21. Install wire retainer (A). 8. Inspect cam roller assembly (B—F) for wear or damage. A—Wire Retainer B—Shaft C—Roller D—Slide Pivot (2 used) E—Washer (2 used) F—Holder M21.Fuel Control and Governor Linkage/Fuel Supply Pump (4TN100RJF) 7.TM355. Lift wire retainer (A) to remove pump cam roller assembly. 2.

fitting (B) and fuel line (A).TM355.A6 -19-14AUG87 5. M21.TM355.Fuel Control and Governor Linkage/Fuel Supply Pump (4TN100RJF) 3. Install pump on engine and tighten nuts to 11 N·m (96 lb-in.A7 -19-14AUG87 M51586 -UN-31AUG88 M51588 -UN-31AUG88 M51589 55 25 CTM3 (03JAN90) 55-25 3TN/4TN Series Yanmar Engines 010897 PN=292 . Install plunger parts (A—E) in pump body. -UN-31AUG88 M21.). Install hand primer assembly (C). 4. Tighten plug (A).

Fuel Control and Governor Linkage/Fuel Supply Pump (4TN100RJF) 55 26 CTM3 (03JAN90) 55-26 3TN/4TN Series Yanmar Engines 010897 PN=293 .

-UN-29AUG88 M21. Some tools may be available from a local supplier.) To help identify the Nippon Denso starters.33 -19-01SEP87 STARTER APPLICATION CHART The various starters covered in this group are identified by manufacturer and output rating. Install retaining wire and use two pliers to press pinion stopper (A) over retaining wire.0 mm (3. M37831 60 1 M21. SERVICEGARD™ Catalog or from the European Microfiche Tool Catalog (MTC).1 -19-14JUN85 ASSEMBLE HITACHI 0.0 kW 1. Name Use Volt-Ohm-Amp Meter Armature Growler 13-Ton Puller Set Check continuity Check starter armature Remove armature shaft bearings M21. Install clutch assembly on armature. measure the outside diameter of the motor yoke. Install pinion stopper over shaft.S.0 -19-01SEP87 CTM3 (03JAN90) 60-1 3TN/4TN Series Yanmar Engines 010897 PN=294 .00 in.4010R.) 76.8 KILOWATT STARTER 1.0 mm (2.8 kW 1. Manufacture Rated Output Motor Yoke Outside Diameter Hitachi Nippon Denso Nippon Denso 0.TM360.TM360.Group 60 Starter SERVICE EQUIPMENT AND TOOLS NOTE: Order tools from the U.68 in.4 kW —— 68. 2.

Starter/Bench Test Starter (All Engines) BENCH TEST STARTER 1. either the pull-in winding is open-circuited or mechanical parts are sticking.4010R.TM360. starter should engage and run. Connect a remote start switch (D) between switch terminal (E) and battery terminal (B). It should turn freely clockwise only. When switch is activated. 7. Remove starter from engine. clutch assembly is defective. and field windings. but motor does not run. M21. 8. perform starter no load running test. armature.5 -19-14JUN85 CTM3 (03JAN90) 60-2 3TN/4TN Series Yanmar Engines 010897 PN=295 RW2159 . Disassemble solenoid to determine cause of problem. reduction gears. 3. -UN-01DEC88 NOTE: The solenoid cannot be repaired although mechanical parts may be replaced. check main contact points. brushes. To check for sticking. If solenoid only chatters. 5. If solenoid engages properly. If nothing happens. NOTE: A short piece of wire with a small clip on the end will allow a more positive connection at the switch terminal.1 -19-14AUG87 NOTE: Do not conduct the no-load test unless the armature turns freely. 2. Connect a 12-volt battery (A) to starter battery terminal (B) and starter frame (C). hold-in winding is open-circuited. remove solenoid end cover and push plunger by hand. 6. A—12-Volt Battery B—Battery Terminal C—Starter Frame D—Remote Start Switch E—Switch Terminal 60 2 M21. Use heavy duty cables. bearings. If gear turns freely both directions. Turn pinion gear by hand. If pinion turns freely. 4.

Remove brush holder assembly from field coil assembly.4010R.7 -19-14JUN85 M21.30 in. 4. the entire field coil assembly must be replaced.Starter/Nippon Denso 1. 5.6 -19-14AUG87 M21.). 7. If field coil brushes are worn. Use a screwdriver to pry springs away. replace the entire brush holder. If negative side brushes mounted on brush holder are worn.5 mm (0. Remove two bolts (B) and separate motor from solenoid. Remove field coil brushes (A) from brush holder. Brush assembly will remain attached to field coil. Remove armature assembly. Pry springs away and pull negative side brushes (B) back about 6 mm (0. 6.4010R. 60 3 -UN-29AUG88 M21.0 KILOWATT STARTER 1. Remove two screws to remove end frame (A).8 -19-14JUN85 M36754 -UN-29AUG88 M36753 -UN-29AUG88 M36752 3. 2. -UN-29AUG88 M21. Replace if worn below minimum length of 8.9 -19-14JUN85 CTM3 (03JAN90) 60-3 3TN/4TN Series Yanmar Engines 010897 PN=296 M36755 .4010R.25 in.).4010R.0 kW Starter DISASSEMBLE AND SERVICE NIPPON DENSO 1. Release springs to hold negative brushes in place. Disconnect field lead (A). Measure brush length.

Test for grounded field winding using an ohmmeter or test light. Inspect springs. Touch one probe of tester to field coil brush and other probe to field frame. the coil is grounded and the field frame assembly must be replaced. the field coil is open and the field frame assembly must be replaced. -UN-29AUG88 60 4 CTM3 (03JAN90) 60-4 3TN/4TN Series Yanmar Engines 010897 PN=297 M36758 M36757 -UN-29AUG88 9. If there is continuity.10 -19-14JUN85 M21. -UN-29AUG88 M21.4010R. Test for open field coil by touching a probe to each field coil brush.4010R. If there is no continuity. replace if weak or distorted.Starter/Nippon Denso 1. M36756 . If there is continuity. Touch one probe of tester to negative brush holder and other probe to field brush holder.0 kW Starter 8.11 -19-14JUN85 M21.4010R. Test the brush holder using an ohmmeter or test light.12 -19-14JUN85 10. replace the brush holder. Be sure the brush lead is not touching the frame.

Clean all dust from armature when finished. a winding is grounded and the armature must be replaced. Look for signs of dragging against pole shoes.4010R. Armature windings are connected in series.0 kW Starter IMPORTANT: Do not clean armature with solvent. Use only mineral spirits and a brush. If necessary. Solvent can damage insulation on windings. Touch probes on two different commutator bars. Touch probes on commutator bar and armature shaft.4010R. burned bars. there is an open circuit and the armature must be replaced. -UN-29AUG88 M21. 12. 14. Inspect armature. so only one commutator bar needs to be checked. Test for open circuited windings using an ohmmeter or test light. Inspect commutator. If test shows no continuity. clean and touch up with 400 sandpaper.15 -19-14JUN85 M36760 -UN-29AUG88 M36759 13.4010R.13 -19-17JUL85 M21. NEVER use emery cloth. 11. If test shows continuity. Look for roughness. Test for grounded windings using an ohmmeter or test light.Starter/Nippon Denso 1. or any material which might cause short circuits between bars. CTM3 (03JAN90) 60-5 3TN/4TN Series Yanmar Engines 010897 PN=298 M36761 60 5 .14 -19-14JUN85 -UN-29AUG88 M21.

the blade will vibrate on the slot.4010R. If test indicates short circuited windings. If the test still indicates a short circuit. replace the armature. Replace if defective. CTM3 (03JAN90) 60-6 3TN/4TN Series Yanmar Engines 010897 PN=299 M36763 M36762 -UN-29AUG88 RW2168 -UN-01DEC88 . clean the commutator of dust and filings.0 KILOWATT) -UN-29AUG88 M21. Check the armature again.0 kW Starter 15.Starter/Nippon Denso 1. Remove bearings by using a knife edge bearing puller.4010R. Inspect front and rear armature bearings for smooth quiet operation. If coil is shorted. Put armature in growler and hold a hacksaw blade above each slot while slowly rotating armature.16 -19-14JUN85 17. M21.17 -19-14JUN85 60 6 INSPECT AND REPAIR GEAR TRAIN AND OVERRUNNING CLUTCH (NIPPON DENSO 1.18 -19-14AUG87 1. 16. 18. M21. Remove two screws. Test for short circuited windings using a growler. NOTE: A short circuit most often occurs because of copper dust or filings between two commutator segments.4010R.

Remove steel ball from end of clutch shaft. 6.21 -19-14JUN85 M36764 -UN-29AUG88 60 7 CTM3 (03JAN90) 60-7 3TN/4TN Series Yanmar Engines 010897 PN=300 M36766 . Remove pinion (A). Remove clutch assembly from housing.19 -19-14JUN85 4.4010R. 3. retainer (B). M21. Be sure rear vise jaw is against shaft and front jaw is against pinion. -UN-29AUG88 M21.Starter/Nippon Denso 1.4010R. Remove snap ring and retainer. Replace if worn or pitted. 9. 8.20 -19-14JUN85 M36765 Inspect pinion. rollers. Hold clutch housing as shown and lift solenoid housing from clutch. Put clutch assembly in a soft jaw vise. and retainer. 7. Push retainer (A) back until snap ring is exposed. 5. -UN-29AUG88 M21. and five rollers. Tighten vise slowly until pinion compresses.4010R. Remove plunger spring (A).0 kW Starter 2.

22 -19-14JUN85 M21. 12.0 KILOWATT) 1.Starter/Nippon Denso 1. Inspect shaft spring and replace if broken or distorted.23 -19-14JUN85 M21. 11. -UN-29AUG88 M21.4010R. and washer (C). Replace entire assembly if bearings are defective. Replace if defective.0 kW Starter N CAUTION: Shaft could be propelled from clutch unit with considerable force if spring is not allowed to extend fully while in vise. spring (B). Turn toothed washer (A) to remove it from shaft. -UN-29AUG88 Inspect clutch bearings for flat spots in rotation. Inspect shaft for excessive wear or damage. Inspect pinion for excessive wear or damage. slowly open vise until all spring compression is relieved.4010R. -UN-29AUG88 CTM3 (03JAN90) 60-8 3TN/4TN Series Yanmar Engines 010897 PN=301 M36769 60 8 M36768 M36767 . Remove three screws to remove cover and gasket.4010R. While holding clutch assembly. INSPECT AND REPAIR SOLENOID (NIPPON DENSO 1. Replace if defective.24 -19-01SEP87 10. Remove shaft and spring from clutch. Push shaft against spring in clutch assembly. Remove pinion (A). Replace spring if broken or distorted.

0 kW Starter 2. Be sure smaller contact plate is on left side. If it is defective.Starter/Nippon Denso 1. 1. 3.0 KILOWATT STARTER Assemble Solenoid NOTE: The assembly sequence of the left and right terminals is similar. remove terminals. Remove parts in order as shown from each terminal: A—Nut B—Washer C—O-Ring D—Insulator E—Bushing F—Contact Plate G—Terminal Bolt ASSEMBLE NIPPON DENSO 1. Inspect plunger spring.25 -19-14JUN85 M21. Install parts (A—H). Clean burnt areas to improve electrical contact. If it is necessary to replace contact plates. Replace plunger if broken. -UN-29AUG88 M21.4010R.26 -19-14JUN85 M36771 -UN-29AUG88 M36771 -UN-29AUG88 M36770 Inspect copper washer (A) on plunger and contact plates (B) on solenoid. The solenoid is not serviceable. Remove plunger.4010R.4010R. A—Nut B—Washer C—O-Ring D—Insulator E—Bushing F—Contact Plate G—Terminal Bolt H—Solenoid Lead Terminal 60 9 M21. Replace contacts or plunger if either shows excessive burning or pitting. Be sure solenoid terminal lead (H) is installed between bolt (G) and contact plate (F).27 -19-01SEP87 CTM3 (03JAN90) 60-9 3TN/4TN Series Yanmar Engines 010897 PN=302 . replace the solenoid housing assembly.

28 -19-14JUN85 3. M21. Apply bearing grease to the steel ball. Install gasket and cover. Assemble parts (A—J) in sequence order. springs.30 -19-14AUG87 1.0 kW Starter 2. A—Steel Ball B—Shaft C—Clutch Spring D—Clutch E—Toothed Washer F—Washer G—Pinion Spring H—Pinion I—Retainer J—Snap Ring 60 10 CTM3 (03JAN90) 60-10 3TN/4TN Series Yanmar Engines 010897 PN=303 M36774 M36773 -UN-29AUG88 M36783 -UN-29AUG88 .0 KILOWATT) -UN-29AUG88 M21.Starter/Nippon Denso 1.4010R. shaft. Fasten with three screws. M21. Install solenoid plunger.4010R.29 -19-14JUN85 ASSEMBLE GEAR TRAIN AND OVERRUNNING CLUTCH (NIPPON DENSO 1. and bearings.4010R. Be sure wire retaining clip (A) is installed as shown.

6. Hold clutch assembly and slowly open vise. Install washer (C). M21. 3. Install retainer and five rollers. 7. 11. Be sure rear vise jaw is against shaft and front jaw is against pinion. Slide the retainer over the snap ring. and five rollers. Push shaft against spring and install toothed washer (A). Install clutch spring and clutch assembly on shaft. retainer (B).34 -19-14JUN85 M36767 -UN-29AUG88 M36768 -UN-29AUG88 60 11 CTM3 (03JAN90) 60-11 3TN/4TN Series Yanmar Engines 010897 PN=304 M36776 . 8. Be sure flange on washer is pointing outward.4010R.31 -19-14JUN85 4.4010R. Tighten vise slowly until pinion compresses.32 -19-14JUN85 5.Starter/Nippon Denso 1. 10. Apply grease to pinion (A).33 -19-14JUN85 M36775 9. Install both into housing at the same time. Hold pinion (A) and clutch assembly with teeth meshed. Install steel ball in end of shaft. and pinion (A). Put clutch assembly in a soft jaw vise. Install retainer (A) with the cupped side outward.0 kW Starter 2. Install snap ring.4010R.4010R. -UN-29AUG88 M21. -UN-29AUG88 M21. M21. pinion spring (B). Use grease to hold it in place. Turn toothed washer below the shaft splines to hold clutch in place.

12.37 -19-17JUL85 CTM3 (03JAN90) 60-12 3TN/4TN Series Yanmar Engines 010897 PN=305 M36777 -UN-29AUG88 14. Be sure to drive only on inner race.4010R. Assemble solenoid housing to clutch housing. 60 12 M21. Install new bearing on splined end of armature shaft using a piece of 5/8-in. M21.Starter/Nippon Denso 1.35 -19-18JUN85 13.4010R. M21. M36763 -UN-29AUG88 M36764 -UN-29AUG88 . Make sure bearing is tight against shoulder of shaft. Install plunger spring (A).D.36 -19-14JUN85 IMPORTANT: Install both armature bearings with the sealed side toward the armature. I. pipe.0 kW Starter NOTE: Be sure steel ball is in the end of the clutch shaft.4010R. Fasten with two screws.

40 -19-14JUN85 18. Apply a light film of grease to the felt washer. -UN-29AUG88 M21. Replace springs to hold brushes in place.4010R.38 -19-14JUN85 16.39 -19-14JUN85 17.0 kW Starter 15.41 -19-10JUN85 M36780 M36779 M36778 60 13 CTM3 (03JAN90) 60-13 3TN/4TN Series Yanmar Engines 010897 PN=306 M36781 . Use a screwdriver to pry springs away.Starter/Nippon Denso 1.4010R. Be sure felt washer (A) is in place on spline end of armature.4010R. -UN-29AUG88 M21. -UN-29AUG88 M21. Install field coil brushes in brush holder. -UN-29AUG88 M21. Install brushes.4010R. driver to install bearing tight against shoulder of shaft. Install bearing on commutator end of armature shaft with sealed side of bearing toward commutator. Release springs to hold brushes in place. Use a 1/2 in. Use a screwdriver to pry springs away from brush holder. Install armature in field coil.

4010R. Install end frame (A) and fasten with two screws. Apply grease to the bearing cup inside the end frame. 22. Tighten nuts to 88 N·m (65 lb-ft). Fasten motor to clutch assembly with two bolts (B). Turn brush holder slightly to take up slack in brush wires.43 -19-14JUN85 21. be sure field coil brush wires do not touch end frame. M21. 60 14 CTM3 (03JAN90) 60-14 3TN/4TN Series Yanmar Engines 010897 PN=307 M36752 M36753 -UN-29AUG88 IMPORTANT: When installing end frame. -UN-29AUG88 M21.4010R. M21.42 -19-14JUN85 20. M36754 -UN-29AUG88 . Connect field lead (A). Install starter. Press wires inward to clear the end frame.0 kW Starter 19.44 -19-14FEB86 23. Release brush springs to allow field coil brushes (A) and negative side brushes (B) to contact commutator.Starter/Nippon Denso 1.4010R.

8 kW DISASSEMBLE AND SERVICE HITACHI 0.Starter/Hitachi 0. Remove “E” clip (C) and shim pack (D).8 KILOWATT STARTER 1.22 -19-14AUG87 M21. Disconnect wire (A) from solenoid. 2. Remove the two field coil brushes from holders and remove brush holder assembly. remove cover bushing (A) with blind hole puller. 4. Pry plastic cap (B) from rear cover. Pry brush spring (A) away and pull negative brush (B) up enough to allow spring to hold in place. CTM3 (03JAN90) 60-15 3TN/4TN Series Yanmar Engines 010897 PN=308 M37875 60 15 . 7.TM360. If necessary. Remove cover. 6.23 -19-15FEB86 -UN-29AUG88 M21. Install new bushing with suitable size driver disks until bushing bottoms in cover. Remove the two phillips screws and two through bolts from rear cover.24 -19-15FEB86 M37874 -UN-29AUG88 -UN-29AUG88 5. A—Solenoid Wire B—Plastic Cap C—E-Clip D—Shim Pack M37873 M21.TM360.TM360. 3.

Test for grounded field winding using an ohmmeter or test lights. Touch one probe of tester to field coil brush and other probe to field frame.37 -19-08APR86 M21. replace the entire brush holder. Inspect springs. the coil is grounded and the field frame assembly must be replaced.TM360. Measure brush length. M37876 -UN-29AUG88 M36755 -UN-29AUG88 M36756 . replace if weak or distorted. If there is continuity.7 mm (0. Replace if worn below minimum length of 7.TM360.). the entire field coil assembly must be replaced. If field coil brushes are worn. -UN-29AUG88 M21. 60 16 CTM3 (03JAN90) 60-16 3TN/4TN Series Yanmar Engines 010897 PN=309 M36757 -UN-29AUG88 11. replace the brush holder.39 -19-15FEB86 9.TM360.Starter/Hitachi 0.8 kW 8.10 -19-14JUN85 M21.4010R. Be sure the brush lead is not touching the frame. 10.25 -19-15FEB86 M21. Remove field coil housing from armature. If negative side brushes mounted on brush holder are worn. If there is continuity. Touch one probe of tester to negative brush holder and other probe to field brush holder. Test the brush holder using an ohmmeter or test light.30 in.

8 kW 12.27 -19-15FEB86 M37878 -UN-29AUG88 M37877 15. M36758 60 17 -UN-29AUG88 M21. Replace clutch assembly as needed.26 -19-15FEB86 M21. -UN-29AUG88 M21. the field coil is open and the field frame assembly must be replaced.TM360.28 -19-15FEB86 CTM3 (03JAN90) 60-17 3TN/4TN Series Yanmar Engines 010897 PN=310 M37879 .TM360. Test for open field coil by touching a probe to each field coil brush.TM360. Remove retaining wire (A).Starter/Hitachi 0. 18. Pull solenoid (B) and armature assemblies (C) from housing. 17. 14. if there is not continuity. pinion stopper (B) and clutch assembly (C) from armature shaft.40 -19-15FEB86 13. 16. Remove the two solenoid attaching cap screw.TM360. Remove rubber plug (A). Inspect clutch gear for damage it should rotate only in one direction. -UN-29AUG88 M21. Use a piece of pipe or a deep well socket to drive pinion stopper (A) down from retaining wire.

TM360. Touch probes on two different commutator bars. If test indicates short circuited windings. If the test still indicates a short circuit. 60 18 M21. the blade will vibrate on the slot. Check the armature again. 22. If test shows no continuity. there is an open circuit and the armature must be replaced. NOTE: A short circuit most often occurs because of copper dust or filings between tow commutator segments. so only one commutator bar needs to be checked.Starter/Hitachi 0.8 kW 19. M21.29 -19-15FEB86 20. Test for grounded windings using an ohmmeter or test light.TM360.TM360. If coil is shorted. clean the commutator of dust and filings. Touch probes on commutator bar and armature shaft.30 -19-15FEB86 21. Armature windings are connected in series.31 -19-15FEB86 CTM3 (03JAN90) 60-18 3TN/4TN Series Yanmar Engines 010897 PN=311 RW2168 -UN-01DEC88 M36761 -UN-29AUG88 M36760 -UN-29AUG88 . a winding is ground and the armature must be replaced. Put armature in growler and hold a hacksaw blade above each slot while slowly rotating armature. M21. If test shows continuity. Test for short circuited windings using a growler. replace the armature. Test for open circuited windings using an ohmmeter or test light.

-UN-29AUG88 M21.TM360. Install rubber plug (A) in notched area of housing.TM360. A—Clutch Fork Pivot B—Solenoid Plunger C—Spring D—Solenoid ASSEMBLE HITACHI 0. 3. 4.Starter/Hitachi 0. Install solenoid making sure spring pivot seats in notch (C) in clutch fork. Install pinion stopper over shaft. Place armature with clutch assembly into housing. Replace solenoid if indicated in bench test.33 -19-01SEP87 M21.32 -19-23APR86 M21.TM360. 6. Install retaining wire and use two pliers to press pinion stopper (A) over retaining wire. Be sure spring pivot (A) is installed in solenoid and install clutch fork (B) over clutch and through solenoid plunger. 60 19 -UN-29AUG88 M21.8 KILOWATT STARTER 1. 2.35 -19-24MAR86 CTM3 (03JAN90) 60-19 3TN/4TN Series Yanmar Engines 010897 PN=312 M37882 . Remove and inspect solenoid components. Assemble in reverse order. 7. Install clutch assembly on armature.TM360. 5. Install two solenoid attaching cap screws. earlier in this group.8 kW 23.34 -19-15FEB86 M37881 -UN-29AUG88 M37831 -UN-29AUG88 M37880 24.

Install field coil brushes (B) in brush holder. 14. M37923 -UN-29AUG88 DISASSEMBLE AND SERVICE NIPPON DENSO 1.4 kW Starter 8. Remove motor assembly from starter. Install rear cover two through bolts. Install wiring onto solenoid.Starter/Nippon Denso 1.TM360. 2. Install “E” clip (A) and plastic cover (B).38 -19-15FEB86 M21. Install brush holder over armature and release springs to allow brushes to seat on commutator ring. -UN-29AUG88 M21.2 -19-15AUG87 9. 13.4 KILOWATT STARTER 1. Hold springs (A) back to keep brushes off armature. Tighten hardware to 49 N·m (36 lb-ft). Install two phillips screws to secure brush holder. Install field coil housing.TM360.36 -19-15FEB86 M21. Remove two hex-head screws and remove end cap (A) and shims (B) as shown. 10.TM360. 11. CTM3 (03JAN90) 60-20 3TN/4TN Series Yanmar Engines 010897 PN=313 M37820 60 20 3. Remove two phillips-head screws and two through-bolts from rear of starter. 12. Install starter on engine. -UN-29AUG88 M37875 . Remove rear cover. Install same number and thickness of shims as removed.

25 in. Test for grounded field winding using an ohmmeter or test light. the entire field coil assembly must be replaced. If there is continuity.9 -19-14JUN85 8. Test the brush holder using an ohmmeter or test light. 5.4010R.8 -19-14JUN85 7. M36755 -UN-29AUG88 M36754 -UN-29AUG88 60 21 .4010R.10 -19-14JUN85 M36756 M21. Remove field coil brushes (A) from brush holder. Replace if worn below minimum length of 8. replace the entire brush holder.30 in.4010R.). Measure brush length.5 mm (0. -UN-29AUG88 M21. Pry springs away and pull negative side brushes (B) back about 6 mm (0. replace the brush holder. Release springs to hold negative brushes in place. If field coil brushes are worn. If there is continuity. 6.Starter/Nippon Denso 1. Remove brush holder assembly from field coil assembly. If negative side brushes mounted on brush holder are worn.4 kW Starter 4. Be sure the brush lead is not touching the frame. Touch one probe of tester to negative brush holder and other probe to field brush holder. Use a screwdriver to pry springs away. M21. M21. the coil is grounded and the field frame assembly must be replaced.4010R.11 -19-14JUN85 CTM3 (03JAN90) 60-21 3TN/4TN Series Yanmar Engines 010897 PN=314 M36757 -UN-29AUG88 9. replace if weak or distorted. Inspect springs. Touch one probe of tester to field coil brush and other probe to field frame.).

13 -19-17JUL85 M21. 12. a winding is grounded and the armature must be replaced. Armature windings are connected in series.4010R. Touch probes on commutator bar and armature shaft. If there is no continuity. or any material which might cause short circuits between bars. 11.Starter/Nippon Denso 1. burned bars. Use only mineral spirits and a brush. If necessary.14 -19-14JUN85 13. Inspect armature. Look for signs of dragging against pole shoes. Test for grounded windings using an ohmmeter or test light.12 -19-14JUN85 IMPORTANT: Do not clean armature with solvent.4010R.4010R. Inspect commutator. Look for roughness. CTM3 (03JAN90) 60-22 3TN/4TN Series Yanmar Engines 010897 PN=315 M36760 60 22 -UN-29AUG88 M36759 M36758 . NEVER use emery cloth. Test for open field coil by touching a probe to each field coil brush. so only one commutator bar needs to be checked. the field coil is open and the field frame assembly must be replaced.4 kW Starter 10. Solvent can damage insulation on windings. -UN-29AUG88 M21. If test shows continuity. -UN-29AUG88 M21. clean and touch up with 400 sandpaper. Clean all dust from armature when finished.

If the test still indicates a short circuit. M21. Put armature in growler and hold a hacksaw blade above each slot while slowly rotating armature.Starter/Nippon Denso 1.4 kW Starter 14. 18.17 -19-14JUN85 CTM3 (03JAN90) 60-23 3TN/4TN Series Yanmar Engines 010897 PN=316 M36762 . there is an open circuit and the armature must be replaced. NOTE: A short circuit most often occurs because of copper dust or filings between two commutator segments. replace the armature. 16.4010R.4010R.16 -19-14JUN85 17. M21. If test shows no continuity. clean the commutator of dust and filings. Touch probes on two different commutator bars. Test for open circuited windings using an ohmmeter or test light.15 -19-14JUN85 15. Replace if defective. Remove bearings by using a knife edge bearing puller. If test indicates short circuited windings. Check the armature again. Inspect front and rear armature bearings for smooth quiet operation.4010R. the blade will vibrate on the slot. Test for short circuited windings using a growler. RW2168 -UN-01DEC88 M36761 -UN-29AUG88 60 23 -UN-29AUG88 M21. If coil is shorted.

TM360. Inspect bearing (A) and seal (B).TM360. M21.6 -19-15FEB86 CTM3 (03JAN90) 60-24 3TN/4TN Series Yanmar Engines 010897 PN=317 M37821 M37824 M37823 M37822 -UN-29AUG88 . Remove shims from ring gear shaft.TM360. -UN-29AUG88 M21. Remove three cap screws (A) and remove rear bearing housing. Replace defective parts as needed. Remove two cap screws and remove plunger with spring (A). remove bearing with a suitable blind hole puller. and solenoid (C).4 KILOWATT) 1.4 kW Starter SERVICE GEAR TRAIN (NIPPON DENSO 1.5 -19-15FEB86 4.3 -19-15AUG87 2. If necessary. shims (B).TM360.Starter/Nippon Denso 1. 60 24 -UN-29AUG88 M21. Install new bearing flush with housing surface.4 -19-15FEB86 3. -UN-29AUG88 M21.

6. M21.TM360. Inspect ring gear (D) for chipped or broken teeth.TM360.7 -19-23APR86 7. Remove clutch fork pivot bolt (A) to remove fork and clutch assembly (B).4 kW Starter 5. replace fork as needed. Remove retaining wire (A).9 -19-15FEB86 10. 9. Use a piece of pipe or suitable size deep well socket to drive pinion stopper (A) down from retaining wire. pinion stopper (B). Remove snap ring (A) from clutch assembly.TM360.Starter/Nippon Denso 1.10 -19-15FEB86 CTM3 (03JAN90) 60-25 3TN/4TN Series Yanmar Engines 010897 PN=318 M37828 .TM360.8 -19-23APR86 8. A—Retaining Wire B—Pinion Stopper C—Clutch Assembly D—Ring Gear and Shaft M21. Replace as needed. and clutch assembly (C) from ring gear shaft. Inspect “SHOES” on clutch fork. M21. M37827 -UN-29AUG88 M37826 -UN-29AUG88 M37825 -UN-29AUG88 60 25 -UN-29AUG88 M21.

4 KILOWATT STARTER 60 26 2. Install pinion stopper over shaft. -UN-29AUG88 M21. Install clutch fork pivot bolt (A) and nut.TM360. -UN-29AUG88 ASSEMBLE NIPPON DENSO 1.4 kW Starter 11.TM360. M37830 M37831 M37829 -UN-29AUG88 . Inspect end frame bushing (A). Inspect clutch parts and replace as needed. CTM3 (03JAN90) 60-26 3TN/4TN Series Yanmar Engines 010897 PN=319 M37825 -UN-29AUG88 1. Install clutch assembly on ring gear shaft. Use two pliers to press pinion stopper (A) over retaining wire. Install new bushing flush with face of housing. Assemble in reverse order. 14.13 -19-15FEB86 M21.11 -19-15FEB86 12. Install retaining wire in groove of shaft.Starter/Nippon Denso 1.14 -19-15AUG87 15. 13. Install fork (B) over clutch and install assembly into housing.12 -19-15FEB86 M21.TM360. A—Washer B—Spring Cap C—Spring D—Clutch M21.TM360. Replace using suitable size driver disks.

same shims (B) as removed and solenoid (C).4 kW Starter 3. M21.TM360. M21. M21. Install same number and thickness of ring gear shims as removed.16 -19-15FEB86 5.Starter/Nippon Denso 1. Install three cap screws (A).TM360.18 -19-15FEB86 CTM3 (03JAN90) 60-27 3TN/4TN Series Yanmar Engines 010897 PN=320 M36780 .TM360. Pry brush spring back and install field coil brushes into brush holder.15 -19-15FEB86 4.TM360.17 -19-15FEB86 6. Secure with two cap screws. M37822 -UN-29AUG88 M37824 -UN-29AUG88 M37821 -UN-29AUG88 60 27 -UN-29AUG88 M21. Install rear bearing housing. Install plunger with spring (A).

TM360. Install the rear cover and secure with two long through-bolts.TM360. -UN-29AUG88 M21.21 -19-15FEB86 60 28 CTM3 (03JAN90) 60-28 3TN/4TN Series Yanmar Engines 010897 PN=321 M37820 M36754 -UN-29AUG88 M36781 -UN-29AUG88 . M21. 11. Install the two phillip-head screws. Install starter on engine.4 kW Starter 7. Install motor assembly onto gear train. M21.Starter/Nippon Denso 1.TM360.19 -19-15FEB86 8. 10. Install end frame cap (A) with same number and thickness of shims (B) as removed.20 -19-15FEB86 9. Install armature (A) into field coil. 12. Release springs to allow brushes (A and B) to contact commutator. Tighten nut to 88 N·m (65 lb-ft).

50 in.0 mm (0.30 in. Name Use Volt-Ohm-Amp Meter 13-Ton Puller Set Check continuity Remove rotor shaft bearing M21.S.4005R.) 54 N·m (40 lb-ft) 27 N·m (20 lb-ft) Belt Deflection All Engines 13 mm (1/2 in.TM365.22 in.14A -19-15AUG87 65 1 CTM3 (03JAN90) 65-1 3TN/4TN Series Yanmar Engines 010897 PN=322 . M21. Some tools may be available from a local supplier.5 mm (0.Group 65 Alternator SERVICE EQUIPMENT AND TOOLS NOTE: Order tools from the U.) at 107 N (24 lb) Force between pulleys.) 33. SERVICEGARD™ Catalog or from the European Microfiche Tool Catalog (MTC).1 -19-17JUL85 SPECIFICATIONS Item Alternator Specification Minimum Exposed Brush Length Maximum Exposed New Brush Length Distance From Stator-toRectifier Pulley Nut Torque All 5.) Nippon Denso 35A Nippon Denso 35 A Hitachi 25A Nippon Denso 35A Kokosan 20A Hitachi 25A 13.5 mm (1.

-UN-29AUG88 6. Do not separate stator from drive end assembly. Use a soldering gun with at least 120 watt capacity to disconnected terminals (A). 4.5 -19-15FEB86 M21.4005R. us ONLY 60—40 rosin-core solder. Remove alternator from engine. 2.Alternator/Nippon Denso Alternator REPLACE VOLTAGE REGULATOR (NIPPON DENSO ALTERNATOR) 1. Remove nut (A) and nuts with insulators (B and C).40054.6 -19-14JUN85 M21.4005R. 65 2 NOTE: If additional solder is needed. IMPORTANT: Do not pry against stator wires. -UN-29AUG88 M21.7 -19-14JUN85 3. CTM3 (03JAN90) 65-2 3TN/4TN Series Yanmar Engines 010897 PN=323 M36728 M36727 -UN-29AUG88 M36726 -UN-29AUG88 M36725 . Install new voltage regulator and solder the terminals.4005R.4 -19-01SEP87 M21. Use a screwdriver to pry end frame (A) from alternator. Remove three attaching screws as shown. Remove voltage regulator (B). 5.

4005R. Install nut (A). 10. Remove screws.4005R.4005R. DISASSEMBLE NIPPON DENSO ALTERNATOR 1. IMPORTANT: Do not pry against stator wires. Install end frame. 65 3 CTM3 (03JAN90) 65-3 3TN/4TN Series Yanmar Engines 010897 PN=324 M36729 .9 -19-17JUL85 M21. 9. Install insulators and nuts (B and C). 8.4005R. Use a screwdriver to separate drive end frame (A) from stator housing (B). Install and tighten three screws.10 -19-01SEP87 -UN-29AUG88 M21.Alternator/Nippon Denso Alternator 7. 2. Install insulting washers on terminals (B and C) before installing end frame.11 -19-14JUN85 M36725 -UN-29AUG88 M36725 -UN-29AUG88 M36726 11. -UN-29AUG88 M21.8 -19-17JUL85 M21.

M21. polish the surface of the slip rings using No.Alternator/Nippon Denso Alternator 3.4005R. Touch the probes of an ohmmeter (A) to slip rings (B).4005R. If necessary. Remove rotor assembly (A) from stator assembly (B). Replace rotor if test indicates no continuity (no needle movement). Repeat for other slip ring. Touch the probes of the ohmmeter (A) to the shaft (B) and one of the slip rings (C). Replace rotor if test shows continuity (needle movement).14 -19-14JUN85 65 4 CTM3 (03JAN90) 65-4 3TN/4TN Series Yanmar Engines 010897 PN=325 RW10034 RW10033 -UN-01DEC88 M36730 -UN-29AUG88 .13 -19-14JUN85 3. 00 sandpaper or 400-grit silicon carbide paper.4005R. M21.12 -19-14JUN85 DISASSEMBLE AND TEST ROTOR 1. 2. or out of roundness. rough spots. -UN-01DEC88 M21. Inspect the rotor slip rings for dirt build-up.

Inspect rotor shaft rear bearing by spinning bearing on shaft. Inspect rotor shaft front bearing by spinning rotor in housing.4005R. Remove nut (A). Replace bearing is defective.4005R.17 -19-15AUG87 RW2126 7.16 -19-14JUN85 -UN-01DEC88 M21. pull bearing from shaft. and fan (C). pulley (B). 5.15 -19-14JUN85 6. -UN-01DEC88 M21.Alternator/Nippon Denso Alternator 4. Use a soft hammer to remove rotor shaft. put rotor in a soft-jaw vise. Listen for any sounds indicating bearing failure. If necessary. To replace bearing. M36731 -UN-29AUG88 65 5 CTM3 (03JAN90) 65-5 3TN/4TN Series Yanmar Engines 010897 PN=326 RW10038 . To replace bearing. Listen for any sounds indicating bearing failure. 8.4005R. put front frame on open jaws of vise. Replace bearing if defective. lock washer. M21.

Remove nut (A). M21. A—Retainer B—Bearing C—Washer D—Felt Washer E—Bushing F—Front Frame M21. 3.21 -19-14JUN85 65 6 IMPORTANT: Do not pry against stator wires. Use a screwdriver to pry end frame from stator.4005R.20 -19-14JUN85 DISASSEMBLE AND TEST STATOR AND RECTIFIER 1. Remove retainer (A).Alternator/Nippon Denso Alternator 9. washer (C). CTM3 (03JAN90) 65-6 3TN/4TN Series Yanmar Engines 010897 PN=327 M36726 M36734 -UN-29AUG88 M36733 -UN-29AUG88 M36732 -UN-29AUG88 .4005R. felt washer (D).18 -19-14JUN85 10. bearing (B). M21. Remove three screws to remove bearing retainer (A). 2. Remove spacer from rotor shaft.4005R. -UN-29AUG88 M21. Remove nuts and insulators (B and C).4005R. Inspect bearing for tight spots in rotation. Replace if defective.19 -19-14JUN85 11. and bushing (E) from front frame (F). Inspect other parts and service as necessary.

Inspect brush holder and brushes for damage. Brushes must slide freely and the springs must hold the brushes firmly against the slip ring of the rotor. M21.4005R. To replace brushes. 5.25 -19-14JUN85 CTM3 (03JAN90) 65-7 3TN/4TN Series Yanmar Engines 010897 PN=328 . Use an ohmmeter or a test light to check for continuity.23 -19-14JUN85 7.4005R. Melt solder joints (A) to remove voltage regulator (B). Use soldering gun with at least a 120 watt capacity.) Replace.22 -19-14JUN85 M21.4005R. 9. melt solder from brush lead connections (A) and remove brushes and springs. 65 7 M21. M36737 -UN-29AUG88 M36736 -UN-29AUG88 6. There should be no continuity. Inspect springs to be sure they are not broken collapsed. Replace brush holder-rectifier assembly if there is no continuity.24 -19-14JUN85 IMPORTANT: Do not heat connections longer than necessary to melt solder as excess heat will damage rectifier assembly.5 mm (0. M21. Minimum exposed length must be 5.4005R.Alternator/Nippon Denso Alternator 4. Check between the two brushes (A) and between each brush and ground (B). 8. Replace as needed. Measure brushes for wear.22 in.

Repeat for each wire. 13. -UN-29AUG88 M21.4005R. Inspect stator for defective insulation. Move probes so all terminals are cross checked. discoloration or a burned odor. Touch the probes of an ohmmeter to each pair of stator wires. Touch one probe of the ohmmeter to the bare metal surface of stator and the other probe to a bare stator lead wire. 10. Equal continuity readings should be observed between each pair of leads.29 -19-14JUN85 NOTE: Use an ohmmeter that is sensitive to resistance of 0 to 1 ohm. Replace the rectifier if test shows no continuity. Pull stator wire from pipe.26 -19-14JUN85 11. M21. replace stator. 14. Replace stator if test indicates continuity. Test the three inner terminals (A) using an ohmmeter. open the flattened pipe with a needle nose pliers. -UN-29AUG88 NOTE: The three inner terminals (A) are connected by a printed circuit in the rectifier.Alternator/Nippon Denso Alternator NOTE: Stator must be removed from rectifier to test. While solder is hot. 12. 65 8 CTM3 (03JAN90) 65-8 3TN/4TN Series Yanmar Engines 010897 PN=329 M36742 -UN-29AUG88 M36741 M36740 M36739 -UN-29AUG88 .27 -19-14JUN85 M21. If readings are not equal.28 -19-14JUN85 M21.4005R. If any of these defects are found.4005R. replace stator.4005R. Melt solder inside the connecting pipes.

31 -19-17JUL85 M36744 -UN-29AUG88 M36743 15.30 -19-14JUN85 M21. There should be continuity in only one direction between each terminal (B) and the output post (A). There should be continuity in only one direction between each terminal (B) and the ground post (A). 16. 18. 17. An open diode would have no continuity in either direction. Switch the probes and check each terminal again. Replace the rectifier if any of the six diodes are defective. 65 9 CTM3 (03JAN90) 65-9 3TN/4TN Series Yanmar Engines 010897 PN=330 .Alternator/Nippon Denso Alternator NOTE: Each of the three outer terminals (B) on the rectifier is connected to two diodes permitting current flow in only one direction. -UN-29AUG88 M21.4005R. Test the diodes by touching probes to output post (A) and the three outer terminals (B). A shorted diode would have continuity in both directions. Test the diodes by touching probes to ground post (A) and the three outer terminals (B).4005R. Switch the probes and check each terminal again.

32 -19-01SEP87 NOTE: The three pair of lead wires on the stator are not evenly spaced.33 -19-14JUN85 CTM3 (03JAN90) 65-10 3TN/4TN Series Yanmar Engines 010897 PN=331 M36746 -UN-29AUG88 M36745 -UN-29AUG88 .) from stator to rectifier. Push brush lead wire through spring.30 in. 4. Install the three inner lead wires on stator through inner terminal pipes. Insert spring and brush in brush holder with lead protruding through hole in brush holder. 6. Connect the six terminals using a soldering gun with at least a 120 watt capacity. If additional solder is needed.50 in. Adjust the length of the stator lead wires 33. use ONLY 60-40 rosin core solder. A—Brush B—Brush Holder C—Brush Lead D—Washers E—Insulator M21. Cut off excess length of leads (C).4005R.4005R.) 3. 2. 5. Be sure insulating washers (D) and insulator (E) are in place. Hold brushes in position so that exposed length is 13 mm (0. Rotate the rectifier until the terminal pipes align with the stator leads. Make sure the longest side of brush (A) is on side of brush holder with raised lip (B). 65 10 M21. Install the three outer lead wires on stator through outer terminal pipes. Solder brush leads in this position.5 mm (1.Alternator/Nippon Denso Alternator ASSEMBLE STATOR AND RECTIFIER (NIPPON DENSO ALTERNATOR) 1.

Install insulators and nuts (B and C).4005R. -UN-29AUG88 M21. Install bushing (E) in felt washer (D). 8.4005R. 9. Fasten with nut (A). Install washer (C). Install end frame. Apply a small amount of grease to the felt washer (D). 2. Install voltage regulator (B). bearing (B). and retainer (A).Alternator/Nippon Denso Alternator 7. Connect and solder joints (A).4005R.34 -19-14JUN85 IMPORTANT: Be sure six stator lead wires do not contact end frame when installed.35 -19-14JUN85 M21. Install bushing and felt washer in front frame (F).36 -19-15AUG87 M36734 -UN-29AUG88 M36726 ASSEMBLE ROTOR (NIPPON DENSO ALTERNATOR) 1. A—Retainer B—Bearing C—Washer D—Felt Washer E—Bushing F—Front Frame M36738 -UN-29AUG88 65 11 CTM3 (03JAN90) 65-11 3TN/4TN Series Yanmar Engines 010897 PN=332 . M21.

4005R. Hold rotor in a soft-jaw vise.38 -19-14JUN85 5. -UN-29AUG88 65 12 CTM3 (03JAN90) 65-12 3TN/4TN Series Yanmar Engines 010897 PN=333 M36747 RW2126 M36732 -UN-29AUG88 M36733 -UN-29AUG88 .37 -19-17JUL85 4. M21. Install bearing on rotor shaft until bearing is flush with end of shaft. 6. pulley (B). Install rotor shaft in front frame assembly. Tighten nut (A) to 54 N·m (40 lb-ft).4005R. Press only on inner race of bearing. Fasten retainer (A) with three screws. lock washer.4005R. -UN-01DEC88 M21.Alternator/Nippon Denso Alternator 3.40 -19-14JUN85 7. Install fan (C). M21. 8.4005R. Apply a thin film of grease to the bearing.39 -19-14JUN85 M21. Install bushing on rotor shaft. and nut (A).

Alternator/Service 20A Kokosan Alternator 9.1 -19-01SEP87 -UN-29NOV88 M21. Support alternator on open jaws of vise. Clamp pulley in a soft jaw vise. -UN-31AUG88 M21.4005R.41 -19-01SEP87 10. 13.TM365. Push alternator brushes (A) into brush holder. Remove nut (A) and washers. Apply a small amount of grease on the rear of the rotor shaft. 12.4005R. 3.42 -19-15AUG87 SERVICE 20A KOKOSAN ALTERNATOR 1. Use a soft hammer to tap shaft and flywheel from body.TM365.2 -19-15FEB86 M46059 2. -UN-29AUG88 M36748 65 13 CTM3 (03JAN90) 65-13 3TN/4TN Series Yanmar Engines 010897 PN=334 RW117 . Assemble the rotor assembly to the stator assembly and fasten with three screws (A). Remove alternator from engine. Remove wire (B) from rear of end frame. -UN-29AUG88 M21. 11. Install alternator on engine and adjust belt tension. M36749 M21. Install a wire (B) through access hole in rear of end frame to lock brushes in place.

TM365. Install shaft with pulley until pulley bottoms on flywheel face. Install washer and spacer over shaft. Support flywheel on press. M21. 5.6 -19-15FEB86 CTM3 (03JAN90) 65-14 3TN/4TN Series Yanmar Engines 010897 PN=335 M37816 -UN-29AUG88 M37815 -UN-29AUG88 M37814 -UN-29AUG88 RW120 -UN-15DEC88 .TM365.4 -19-15FEB86 7. Replace flywheel if magnets are missing or damaged. Inspect bearing (B) for damage or tight spots in rotation. If necessary to replace bearing.5 -19-15FEB86 8. 65 14 M21.Alternator/Service 20A Kokosan Alternator 4.TM365. support flywheel on press and push shaft from bearing and flywheel. M21.3 -19-15FEB86 6. M21.TM365. Inspect magnets (A) in flywheel.

use a press and a spark plug socket to remove bearing.9 -19-23APR86 12. socket to press new bearing into coil plate until it bottoms in bore. -UN-29AUG88 M21. Support coil plate on press. always install a new bearing. M21.10 -19-17AUG87 M37819 -UN-29AUG88 M37818 -UN-29AUG88 NOTE: Bearing will be damaged when removed. Use a 9/16 in. Use a 1 in.TM365.TM365. If necessary to replace coil plate bearing.Alternator/Service 20A Kokosan Alternator 9.TM365. remove harness clamp (A) and remove connector (B) from leads. If necessary to replace stator..7 -19-15FEB86 10.8 -19-15FEB86 11.drive deep socket TURNED UPSIDE DOWN to press new bearing onto shaft until it bottoms on spacer. 1/2 in. M21. Support flywheel on press. -UN-08SEP88 M21. M37817 65 15 CTM3 (03JAN90) 65-15 3TN/4TN Series Yanmar Engines 010897 PN=336 M46061 .TM365.

16.TM365. Remove two screws and remove stator.TM365. Test alternator output as instructed in Section 240 of the Machine Technical Manual.Alternator/Hitachi 24V/25A Alternator 13.11 -19-15FEB86 14.12 -19-15FEB86 REPLACE VOLTAGE REGULATOR (HITACHI 24V/25A ALTERNATOR) 1. Install stator with two screws and install harness connector.TM365. Remove four nuts (A) and nut (B) with insulator. Remove alternator from engine.14 -19-17AUG87 3. -UN-31AUG88 M21. Remove four attaching screws as shown. Install flywheel onto coil plate.TM365. M21. 65 16 CTM3 (03JAN90) 65-16 3TN/4TN Series Yanmar Engines 010897 PN=337 M51595 -UN-31AUG88 M51594 RW121 -UN-15DEC88 . M21. 15. Install two washers and tighten nut to 27 N·m (20 lb-ft).13 -19-17AUG87 M21. 2.

Alternator/Hitachi 24V/25A Alternator IMPORTANT: Do not pry against stator wires.TM365. 4. use ONLY 60-40 rosin-care solder. 9.6 -19-14JUN85 5. 10. M21. Install new regulator and solder terminals. 6. Push two capscrews (C) out of brush housing to remove IC regulator (B). -UN-31AUG88 M21. Do not separate stator from drive end assembly.TM365.15 -19-17AUG87 M21. Install insulating washer on terminal (B) before installing end frame. Install insulator and nut (B). A—Regulator Terminals B—Regulator C—Cap Screws D—Insulator 7. 8. Install end frame. Use a screwdriver to pry end frame (A) from alternator. Use a soldering gun with at least 120 watt capacity to disconnect five terminals (A). Install four nuts (A).4005R. M36727 -UN-29AUG88 65 17 CTM3 (03JAN90) 65-17 3TN/4TN Series Yanmar Engines 010897 PN=338 . Remove insulator (D).16 -19-17AUG87 M51595 -UN-31AUG88 M51602 NOTE: If additional solder is needed.

Use a screwdriver to separate drive end frame (A) from stator housing (B). 2.12 -19-14JUN85 CTM3 (03JAN90) 65-18 3TN/4TN Series Yanmar Engines 010897 PN=339 M36730 -UN-29AUG88 M36729 M36725 M36725 -UN-29AUG88 . 65 18 M21. -UN-29AUG88 M21.TM365. Remove rotor assembly (A) from stator assembly (B).4005R.TM365.4005R. -UN-29AUG88 M21.11 -19-14JUN85 3.18 -19-17AUG87 IMPORTANT: Do not pry against stator wires. M21.17 -19-17AUG87 DISASSEMBLE HITACHI 24V/25A ALTERNATOR 1.Alternator/Hitachi 24V/25A Alternator 11. Install and tighten four screws. Remove four screws.

Alternator/Hitachi 24V/25A Alternator DISASSEMBLE AND TEST ROTOR 1.4005R.4005R. Repeat for other slip ring. 2. Replace rotor if test indicates no continuity (no needle movement). -UN-01DEC88 M21. Inspect rotor shaft rear bearing by spinning bearing on shaft. -UN-29AUG88 M21.14 -19-14JUN85 4. polish the surface of the slip rings using No. pull bearing from shaft. 00 sandpaper or 400-grit silicon carbide paper. Touch the probes of an ohmmeter (A) to slip rings (B). Listen for any sounds indicating bearing failure.13 -19-14JUN85 3. Replace bearing if defective. 5. If necessary.4005R. To replace bearing.15 -19-14JUN85 RW10034 RW10033 -UN-01DEC88 65 19 CTM3 (03JAN90) 65-19 3TN/4TN Series Yanmar Engines 010897 PN=340 M36731 . Replace rotor if test shows continuity (needle movement). Touch the probes of the ohmmeter (A) to the shaft (B) and one of the slip rings (C). rough spots. Inspect the rotor slip rings for dirt build-up. M21. or out of roundness.

-UN-01DEC88 M21. If necessary. 9.4005R.4005R. Use a soft hammer to remove rotor shaft.17 -19-15AUG87 M21. To replace bearing. Replace bearing if defective. put front frame on open jaws of vise. 65 20 CTM3 (03JAN90) 65-20 3TN/4TN Series Yanmar Engines 010897 PN=341 M36732 -UN-29AUG88 RW10038 -UN-01DEC88 M51596 -UN-31AUG88 RW2126 . Remove bushing from shaft.Alternator/Hitachi 24V/25A Alternator 6. put rotor in a soft-jaw vise.19 -19-17AUG87 M21.18 -19-14JUN85 7. Remove spacer from rotor shaft. Listen for sounds indicating bearing failure. pulley (B).TM365. and fan (C). Remove nut (A). lock washer. Inspect rotor shaft front bearing by spinning rotor in housing. 8.

M51597 -UN-31AUG88 M36733 -UN-29AUG88 65 21 CTM3 (03JAN90) 65-21 3TN/4TN Series Yanmar Engines 010897 PN=342 M36735 . Minimum exposed length must be 5.19 -19-14JUN85 11. Replace brushes as necessary.TM365. 3.21 -19-17AUG87 -UN-29AUG88 M21. M21. Brushes must slide freely and the springs must hold the brushes firmly against the slip rings of the rotor.) or to wear limit line on brushes.Alternator/Hitachi 24V/25A Alternator 10.5 mm (0. Inspect bearing for tight spots in rotation.4005R. Measure brushes for wear. M21. Replace if defective.20 -19-17AUG87 DISASSEMBLE AND TEST STATOR AND RECTIFIER 1.TM365. Remove nut and insulator (B). Use a screwdriver to pry end frame from stator.TM365. Remove three screws to remove bearing retainer (A). Remove four nuts (A). Inspect brush holder and brushes for damage. 2. Remove retainer (A) and bearing (B) from front frame (C). IMPORTANT: Do not pry against stator wires.22 in.22 -19-17AUG87 M51595 4. 5. -UN-31AUG88 M21.

TM365. NOTE: Stator must be removed from rectifier to test. To replace brushes.24 -19-17AUG87 M21. -UN-31AUG88 65 22 CTM3 (03JAN90) 65-22 3TN/4TN Series Yanmar Engines 010897 PN=343 M51605 M51604 M51603 M36736 -UN-29AUG88 .23 -19-17AUG87 IMPORTANT: Do not heat connections longer than necessary to melt solder as excess heat will damage rectifier assembly. Melt five solder joints (A) to remove voltage regulator (B). Check between the two brushes (A) and between each brush and ground (B).25 -19-01SEP87 8. There should be no continuity. Use soldering gun with at least a 120 watt capacity.Alternator/Hitachi 24V/25A Alternator 6. Use an ohmmeter or a test light to check for continuity. -UN-31AUG88 M21. melt solder from connection (A).23 -19-14JUN85 7. Remove IC regulator (B) if necessary. M21.TM365. 9.4005R. -UN-31AUG88 M21. See Replace Voltage Regulator in this group. Melt solder at three connections (A) to remove rectifier. Replace brush holder-rectifier assembly if there is no continuity.TM365.

Test the diodes by touching probes to ground post (A) and the three outer terminals (B). There should be continuity in only one combination of each terminals (B) and the ground post (A).TM365. replace stator. Replace stator if test indicates continuity. If any of these defects are found. -UN-31AUG88 M21. replace stator. Touch one probe of the ohmmeter to the bare metal surface of stator and the other probe to a bare stator lead wire. If readings are not equal.26 -19-17AUG87 M21. 65 23 CTM3 (03JAN90) 65-23 3TN/4TN Series Yanmar Engines 010897 PN=344 . Continuity should read approximately 0. 13.TM365.Alternator/Hitachi 24V/25A Alternator 10. Inspect stator for defective insulation.TM365. discoloration or a burned odor. 11.26 ohms. 14. Repeat for each wire. Switch the probes and check each terminal again.27 -19-17AUG87 M21.28 -19-17AUG87 M51600 -UN-31AUG88 M51599 -UN-31AUG88 M51598 NOTE: Use an ohmmeter that is sensitive to resistance of 0 to 1 ohm. Touch probes of an ohmmeter to wires of stator in three possible combinations. 12.

Test the diodes by touching probes to output post (A) and the three outer terminals (B).30 -19-01SEP87 2. If additional solder is needed.) from stator to rectifier. If IC regulator (B) was removed.TM365. M21. install and solder five connections (A).TM365. A shorted diode would have continuity in both directions.5 mm (1. An open diode would have no continuity in either direction. Switch the probes and check each terminal again.Alternator/Hitachi 24V/25A Alternator 15.31 -19-17AUG87 65 24 CTM3 (03JAN90) 65-24 3TN/4TN Series Yanmar Engines 010897 PN=345 M51604 -UN-31AUG88 M51605 -UN-31AUG88 M51601 -UN-31AUG88 .29 -19-17AUG87 ASSEMBLE STATOR AND RECTIFIER (HITACHI 24V/25A ALTERNATOR) 1. M21. use ONLY 60-40 rosin care solder.TM365. Adjust the length of the stator lead wires 33.30 in. M21. Connect the three terminals using a soldering gun with at least a 120 watt capacity. Replace the rectifier assembly if any of the six diodes are defective. 16. There should be continuity in only one combination of each terminal (B) and the output post (A).

4005R. 4. 3. Install insulator and nut (B).38 -19-14JUN85 M36733 -UN-29AUG88 M51597 -UN-31AUG88 M51595 ASSEMBLE ROTOR (HITACHI 24V/25A ALTERNATOR) 1. Install end frame. 65 25 CTM3 (03JAN90) 65-25 3TN/4TN Series Yanmar Engines 010897 PN=346 M36732 . Fasten with four nuts (A).37 -19-17JUL85 -UN-29AUG88 M21. 3.4005R. Install bushing on rotor shaft. Install bearing (B) in front frame (C).33 -19-17AUG87 M21. 4.32 -19-12AUG87 M21. 2.Alternator/Hitachi 24V/25A Alternator IMPORTANT: Be sure stator lead wires do not contact end frame when installed.TM365. -UN-31AUG88 M21. Fasten retainer (A) with three screws. Install retainer (A).TM365.

Install fan (C). M21. Install a wire (B) through access hole in rear of end frame to lock brushes in place.34 -19-17AUG87 6. -UN-01DEC88 M21.4005R. Push alternator brushes (A) into brush holder.35 -19-01SEP87 8. Install rotor shaft in front frame assembly.40 -19-14JUN85 9. Tighten nut (A) to 54 N·m (40 lb-ft). Apply a thin film of grease to the bearing.TM365.41 -19-01SEP87 65 26 CTM3 (03JAN90) 65-26 3TN/4TN Series Yanmar Engines 010897 PN=347 M36748 M36747 RW2126 M51596 -UN-31AUG88 . pulley (B). Install bearing on rotor shaft until bearing is flush with end of shaft. 7. -UN-29AUG88 M21. Hold rotor in a soft-jaw vice.Alternator/Hitachi 24V/25A Alternator 5. lock washer.TM365. Install bushing. -UN-29AUG88 M21. Press only on inner race of bearing. and nut (A).4005R.

11. Assemble the rotor assembly to the stator assembly and fasten with three screws (A). 12. 13. M36749 M21.4005R. Remove wire (B) from rear of end frame.42 -19-15AUG87 -UN-29AUG88 65 27 CTM3 (03JAN90) 65-27 3TN/4TN Series Yanmar Engines 010897 PN=348 . Install alternator on engine and adjust belt tension.Alternator/Hitachi 24V/25A Alternator 10. Apply a small amount of grease on the rear of the rotor shaft.

Alternator/Hitachi 24V/25A Alternator 65 28 CTM3 (03JAN90) 65-28 3TN/4TN Series Yanmar Engines 010897 PN=349 .

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