a AAT Te AAW MUL ULVE INDUSTRIAL DIESEL ENGINE 2TNGGE*3TNGGE+3TNA72E*3TN75E+3TNC78E: 3TN82E+3TN82TE-4TN82E-4TN82TE*3TN84E- 3TN84TE-4TN84E-4TN84TEModels 2TN66E-3TN66E*3TNA72E*3TN75E*3TNC78E+ STN82E*3TN82TE:4TN82E*4TN82TE-3TN84E> 3TN84TE-4TN84E*4TN84TE 1 GENERAL wl 12 3. Performance Curves. as 4. CrossSectonal Views « rr 5. Dimensions ...... 1a 5. Maintenance 132 2. Seriat umber Location « 133 2 BASIC ENGINE 1. Cylinder block 24 2. Cylinder hens 228 3. Piston and piston pins . 3 4. Connecting rod. 247 5. Crankshaft and main beating... 220 Camshaft and rappers... 223 7. Timing gear. 228 2B. Flywhes 228 8. Sewice data. +230 20. Oversize and Undersize parts. 238 3 FUEL INJECTION EQUIPMENT 1. Fuel supply system « add 2 Disasembly, Reasembly and Inspection of Governor =... 343 43, Disassembly, Reassembly and lnspection of Fuel Injection Pump 3-23, 4, Adjustment of Fue i 38 5, Fuel feed pump 2347 6, Fuel injection nozale 3.49 17. Troubleshooting . sence MS 8. Tools .. . aT 9. Foelfiter 6.2... 389 110, Airventng system . 11, Service data 359 360 4 LUBRICATING SYSTEM Lubrication sytem ‘Lube il pump . , ‘Lube il filter & Oil pressure contol val Dit cooler Piston cooling moze Seve data. a0 x COOLING SYSTEM Cooling system . Radiator. Radiator fanbelt . Thermostat . Cooling water pump... AIR INDUCTION SYSTEM AND TURBOCHARGER Air cleaner - Ba ‘Turbocharger. 63 ELECTRICAL SYSTEM Wiring Diagram 2 Starter motor. : 74 Charging equipment... 229 Staring Aids 240 Battery . eo TAR Service ata. 2745; DISASSEMBLY AND REASSEMBLY Disassembly and Reasembly Precautions... Bt Disassembly and Reasembly Tools. 82 Dizassembly and Reasembly ag Bolt/nut tightening torque . Troubleshooting... Identification of Pars foreach Application Conversion Tables 829 830—_Chapter 1 General 2. Specifications 2. Specifications oan wee ainese Tuanae sae soenion = fle pe: -_@ ~-*[e[*=]«* 18 fee Tae oye watencooied da ee eontinion wen Sa pecomboin Cine aon eaten Tao fs otras z z verave | oe | tensa warez mare a Jeon wo | esrtsen | esotein ant ten ash tian Jovoncenen | tt, | 0439.28.70 ‘9688 4051 0879 380) ‘ose ens Fomine | wom cas |. | waco | | vaom |. [osrsm [rssaom owas $8888 3883 eases Rahim [am LEEE="n. arm | waren | Sagoee | earow | 127.000 ‘goon | 000 | oarane [a sn9%0 [rating ai 1173600 16.5/9600_ 2173600 12.7/1800_|26.8/3600 eanprnion 2 2 ma Tat ing eer 12 a rutinirion | ae arm inet rani eTs aa 7 [ming (FIO) (> TOC) ae" i weer w a stinieion [nent 76s 200 Teer urs 200 24 [een len es a7 0 rs 200 a4 bvesen ot lon Coons nd an Te oer te ot Five ig nm Ti cota or oo Fm [atin | __eetoen ooeen va vena er aaa] eT TERT] TB TaOT a 2 | gh 1a Fearon | wes a din | déo ah ese Ione | Se! s27 5,200 sa10 sa acon em Fare bein wih wOSTa Ban Moan Fm [aia | cewen [oon [vonon [ronan | van vag eapeCITY Ina wae 16 (1.69) 2212.33) | 3.03.17) | 2.4 (2.54) | 3.3(3.49) 3.1 (3.28) 5215.50) Irconnenan ot APL or DEAE 1030 300° 00 el Di ol RETA, ASTI DATE No.2 (Gtr HD biraer Dry oaer sone oer econ eg wer Krwcwnoor [own | _ oan tora | oana ro vane [ae [va — AN. ven Ton » |e !le les 12 >a )s las le 1a so ond oh | | he | ob | oe | am | am | eS | ak | om 7 on | 202s] ams) sa | ae | a | oe | os, |, | Ce . to | +] at | attdn | azen | atta | caso | acto | cso | cto bones |, oa) la a ee ee lS SS moa to_| ts] dei | edi | edien | ats | atin | aa | aun | atm a ea Tee) ae | ae | ze | Poe | zm | a to] he] he] eatin | eeen | etd | coon | cosa | ten | ceon Note: * shows the dimensions of ic engine from the fan to the fywheel. 12Chapter I General ME Specifications a i ries a es Eon emnee fn a ae onic are Eom — oisptacernent oh 1.148 169.93) 1.362 (83.11) 1.362 (83.11) mam [rerom] >| wanmo] zane] [pane [wanos ae cee Joi ins [ BSB aise [exe [_-_ [ae neneas i ri rea Eecuanieetion 19.61 MPa 200 (2844) a ein ear ee erate ea = seer ete leaner | a ea05 e338 exe Ettect use 1.301.374) 1.8 (1.90) 2.9 (222) 1.8 (1.90) ar See aaeeen Tarren nSTSo cea a eed sees Seana a = i ae an oleecieee Sane cet fe Pam [a] ae ot ae cea} ane Note: * shows the dimensions of Basic engine fram the fan to the flywheelChapter 1 General p TN Series, ‘2. Specifications ema mcr cz | si m7 a TS earned a — or ais sa omen ttt, | taecnoan amass care Sl seaen en | ee eons | enol Tames [arom levees ty fearon] szaes ae faten)| soe JS 5514 | ahr. HPimm | 40.5/3000 20.0/1500 | 40.5/3000 | 48/3000 | 24/1500 -31.573000 | 15.7/1500 | 31.5/3000 ES Poke ae iszjssl| aoa aie ot =e Pew Daw = timing (FID) te TDC) * 26" i od erator en oy Sry umes Etec | (thy 231249) 25268 23243) 180.80) 21222) swear [wear [santana sa [aa a baonen Seipecelnoule=oel eee onan es fa (eco as or Te eee Poe me sleet Pet a | a Palpeceieces ee oe pe = me) Note: * shows the dimensions of Batic engine from the fan tothe flywheel. 1aChapter 2 Basic Fein series 1. Cylinder Block Prteden Tease Tee eee wa ue wae Bore x sir tad (3314339) Gaie339 (331x339) [Displacement wm 1.429 (87.20) 1.906 (116.31) lass _[ecme, [wrimm | — | rans [seanomo | ~~] wean [anznom | ~~ saaw Terao owge site Haase [2a%3a0 sian [2.2 Sona (21860 JS 8514 Te. ‘HP irom | 38.0/3000 | ¥9.0/1600 | 38.0/3000 | 41.5/3000 | 21.0/1500 | 41.8/3000 | 0.773000 | 28.6/1800 | 60.7/3000 ig Soe [2988 Seana [205508 Sac [533088 caren [aint eo twee Sieeiontvowen Coun eh ied ra cooing Jere | stiy 202.113) 27 (2.859) 27 (2880) [cbsciy [Reser | ee [32a [120s | 22es| SSGn] Wissen SeEn] = = feecving |rusner | blade | 6.338 - - e370 | 6335 | 6370 | a7 - - tear [Ete [ly 1.8 (1.90) 24222) 2343) 25 (260) 231240) 25 (260) oo, Tecan enn eo feacermoes [ew var zona | sane_| 20n2 [zane [vant] bane tear aN wie vee Twi Incom em » ) as as) ee as Das me am ae om to om | om | oh | oh |e | el al ele ee 7 va es |, ) ae, | ee, ee ee Pee es : ti | dy | sh | ath | ot | eh | | es | es Pee [Dimer Ty 1 540 ‘540. 535 499 499 439, ‘S15. 515. 515 Note: * shows the dimensions of Basic engine from the fan to the flywheel 1s_Chaprer 1 Generat ‘3, Performance Curvesn n> Series STNATZE atm Nn od == 5 [490 4 poz 1 - 3 hoa 18.65] 25 14.92| 20 2 inaslis é ‘One hour rating output Output for « "2 pole generator continuous rating output 7.46] 10 — 373 5 ome sin § T 10 fear 5 = ==} 200 f2os = eat ieet hao |2ss 3 hao lasr 16 24 28 32 36 Engine speed (x 100 rpm) Conditions for performance curves are in accordance with JIS 88002, ISO 3046/1, BS5514, Intake air temperature: 27°C Barometric pressu 750 mmHg Relative humidity: 60% The curves show performance after 30 hours run-in. 18Chapter } 5. Performance Curve Series Output ewe 18.65| 25 14.92| 20 11.19) 15 7.46| 10 General 3TN75E htm kim ——— 6 [see [7 ~ + 8 — 5 |aao & 4 |39.2 earn a \ a F . f Z| 7 a (One hour rating output 7 Continuous rating output + 1 [ output or 4 pote generator I Jones gam hg0 [255 hao jaar h70 228 16 20 24 28 32 36 Engine speed (x 100.¢pm) 1° Conditions for performance curves are in accordance with JIS BB002, 1SO 3046/1, BSE514, Intake air temperature: 27°C. Barometric pressure: 750 mmHg Relative humidity: 60% The curves show performance after 30 hours run-in,Chapter 1 General 5. Performance Curves ris 3TNC7BE kom Nem 8 +785 aoe lees Tat 6 758.8 Medium seed spe. I 5 fas kw Ps 22074 30 \ \ 18.39} 25 8 é L owrput tor eco '2 pole generator ~] 03 15 110903 4 out for rast 10 pole generator rsh skh E poofass 8 peofzas = hoya 16 20 24 28 32 36 Engine speed (x 100 rpm) Conditions for performance curves are in accordance with JIS 88002, 1SO 3046/1, BS5514, Intake air temperature: 27°C Barometric pressure: 750 mmHg Relative humidity: 60% ‘The curves show performance after 30 hours rurvin. 140Chapter 1. General | — ees "3. Performance Curves’ 3TN82E ht tn 9 |a6.2 7 = shea & ==y 7 lea. Isa ‘ wow 4} 40 }35 2238] 30 (output for eI 2 pole generator 2 1865] 25 8 ‘One hour rating output Continuous rating output 14.92] 20 on 1 2 7 / ma gan 11.19] 15 2 utput for | + 190/255 § je generator 4 poe ne sf} ——foola 3 7.46] 10 = = H70 [a8 16 20 24 28 32 36 Engine speed (x 100 rpm) Conditions for performance curves are in accordance with JIS 88002, 1SO 3046/1, BS5514. Intake 2c Barometr 750 mmHg Relative humi 60%Chapter i General a SF Petformance Carve ers STNB2TE jkgt-m Nm 11 fro7za 10 }se1 = High speed spec. 2 kW HP + o laa = Medium speed spec. 2 —~, 8/785 7 | 686 I 29.83) 40] 1 7 * ‘ 22237) 30} Output for One hour rating output 2 pole generator 1431} 20 Cont. rating Output for 7.48| 10 ‘4 pole generator a/HP-h ghkWeh ng0}255 hao|2e 5 —T E = = 170/228 veoj215 = 2 & 16 20 4 28 32 36 ) Engine speed rpm x 100 Conditions for performance curves are in accordance ‘with JIS 88002, ISO 3046/1, 855514, Intake air temperature: 27°C. Barometric pressure: 750 mmHg Relative humidity: 580% The curves show performance after 30 hours 1,Chapter i Generai So iy Series "3. Performance Curves arNeze [ hors rofseo & : oles. \ 3731) 80 \ \ 1 29.84] 40 : outgu to : Pe ea 2 dn 3 One hour ng output Continous ang orput 1499| » ouput fr i 5 pole generator bes sawn asl 10 j-—tien ss § Pd 8 ofa prokas a a a Engine speed (x 100 rpm) Conditions for performance curves are in accordance ‘with JIS 88002, ISO 3046/1, BS5514. Intake air temperature: 27°C Barometric pressur 750 mmHg Relative humidity: 60% ‘The curves show performance after 30 hours run-in.—Chapter 1 General ‘3. Performance Curves 44.76 37.31 29.83 22.38 14.92 50 40 20 20 Engine speed (x 100 rpm) TN Series 4TN82TE 13") 1275 ~~ o-t--s= ? N2 razz & a 5 ~ 2 > 11 | 107.9 poaan output for 2 pole generator Ourput for 4 pote generator / aa anna § ¢- 190|255 E 7 Z A eo 2a1 8 = -T 3 => = 170228 g 16 20 24 28 32 36 ° Conditions for performance curves are in accordance with JIS BB002, ISO 3046/1, BS5514. Intake air temperature: 27°C Barometric pressure: 750 mmHg Relative humidity: 60% ‘The curves show performance after 30 hours run-in.oe 3. Performance Curves STNGAE afm Nim 9 | eas [7 11... 1) 8 i 8 | 75 = = — 7 |e & kW PS Medium speed spe. m 29.42] 40 = 2207/30 g le generator & out v4.ni|20 w 736 }10 (Grote generator output g/PSh ghkWh S 5 200] 272 8 190 | 258 2 : g = 180} 205 2 —— 170 | 231 Lu 0 16 20 Py 28 32 36 Engine speed rpm x 100 Conditions for performance curves are in accordance ‘with JIS 88002, ISO 3046/1, BS5514, Intake air temperature: 27°C Barometric pressure: 750 mmHg Relative humidity: 60% ‘The curves show performance after 30 hours run-inShaft output 2 4 —_— i. "3. Performance Curves STNB4TE kgfm Nem T 1/1078 2 ——4===E High speed spec. —} 10 | 98.1 © kW PS -T ~~ — = + rf 9 jas 2 Medium speed spec. 7 m 29.42/40 t — 1 9, Sd ; WHVyFis iN 22.07/30 ES ZHo> 2.pole generator SE output 14.7120 | 4:pole generator output 7.36/10 S/PSh ghkWh ¢ E ot 190} 258 Z = 180] 245 5 t 2 —— Si 10] 231 £ 160] 217 = 16 20 24 32 36 Engine speed rpm x100 Conditions for performance curves are in accordance with JIS BB002, ISO 3046/1, BS5514. Intake air temperature: 27°C Barometric pressure: 750 mmHg Relative humidity: 60%. The curves show performance after 30 hours run-in.kw 36.78 29.42 output 22.07 4 50 40 30 20 1 ban nitions £ rotor 2 o tees ¢y ote 7 \ \ uti High speed spec. z = 13 p72 > 12: 117.7 m Medium speed spec: ‘i ee 11: +:107.9 Kw Ps 4.13460 \ 36.784-60 a § 2.42440 é Output for 2 pole 2.07430 generator * Output for want A pole generator J _|orenrarwn & it Roopzns | & wot28 | 8 a 2 wop25 a 2 wots | & ~~ == O) o 16 20 26 23238 Engine speed rpm x100 Conditions for perfermance curves are ins accusslance with JIS 88002, ISO 3046/1, BS5514 Intake air temperature: 27°C Relative humiaity: 60%. ‘The curves show performance after 30 hours us 118—_Chapter i General "4. Cross Sectional Views 4. Cross Sectional Views 10 " 24 23 22 No, 3| Cooling tan (Cooling water pump Piston ring Piston pin Connecting roa Crank shaft Main bearing cap Lubricating ol intet pipe Main bearing 21 20 19 18 No. 2} No. 1/eylinder ‘arm shat support 3 20. Valve rocker arm shaft 21 Breath 22. Exhaust valve 23 Intake vale 28 Thermostat TN SeriesChapter i Generai oa Dn Sires '4. Cross Sectional Views LIN Ser 25 Fuolinjeeion pump «32. Starting motor 26 Fuel eed pump 33. Anernator 27 Dipstiek 34 Exnaust manifold 28 Lubricating it 35, Push oa 23 Oilpan 36. Vave rocker arm 30 Oil pan spacer 37 BY Gviinae block 38 120Chapter 1 General, 0, '5. Dimensions TN Series 5. Dimensions STNESE-STN Series Chapter 1 General 5. Dimensions va—Chapter 1 General, ‘5. Dimensions ry Series STNAT2E-S ‘STNA72E-G2 (Power pack) va5. DimensionsSTN75E-G2Series w—_Chapter i Generat 5. Dimensions ‘STNB2E-S| S$ ‘5. Dimensions TN Series STNS2E-G1 3TNB2E-G2 (Power pack)Chapter 1 General TW Series ‘5. Dimensions ATN82E-S 4TNB2E-G1 (Power—Chapier 1 Gener ‘5. Dimensions ATNB2E-G2Chapter 1 General Ss Dimensions a series MEMO: 130Chapter 1 General, ‘5. Dimensions ey i MEMO. 131IN Series | ‘oq poe sin feu ye ens, | “ wonsoit an © 12 span ‘nog put ane ye wat ete) ri g “apa Ks ‘4 fea) aways a seis pus ueig | auea ‘Sie * aaa oa BD | END 3 o = meq Bun009 wraw Oo S| aeeyea op Bue Ie o © woe i Fo wou e ° wang o ao E o Tone iy eyo aro ue UTD Teel ny wen Teawyper wnouny | AAS eng RO Torowo0s Marg | wroyooe hang _| wrowasr vara | enowoor Ama | now og Mang su Chapter 1 General, ‘6. Maintenance .adsuy sejna4 ‘sow jJe 18 soueWO}.od auyBua o94}-ajqnoss “wnus}xeW 24rst Binpayss soueuauIeW © eoueuaquleyy °9Chapter 1 General 7 "Serial Number Location —— << —$——<—<— — <<< ry series 7. SERIAL NUMBER LOCATION ‘The serial number is stamped on the engine name plate, Al- ways specify this number when inquiring about the order- ing parts in order to get correct parts for the engine being serviced, Engine name plate Ce Bh Serial number location of engine supplied to specific OEM vaaChapter 2 Basic J. Cylinder Block 1. Cylinder Block ‘The cylinder block Is thin-skinned, (low-weight), short ‘skirt type with rationally placed ribs. The side walls are wave shaped to maximize ridigity for strength and low noise. PY Series 141 Inspection of parts ‘Make a visual inspection to check for cracks on engines ‘that have frozen up, overtumed or otherwise been subject- ‘ed to undue stress. Perform a color check on any portions. ‘that appear to be cracked, and replace the cylinder block if the crack is not repairable. 1-2 Cleaning of oil holes Clean ail oll holes, making sure that none are clogged up ‘and the blind plugs do not come off. (coor cck wt Par cade No. 97550004560 24 1-3 Color check procedure (1) Clean the area to be Inspected. (@) Color check kit ‘The color check test kit consists of an aeroso! cleaner, ppenetrant and developer. (6) Clean the area to be inspected with the cleaner. Either spray the cleaner on directly and wipe, or wipe the area with a cloth moistened with cleaner. (4) Spray on ted penetrant After cleaning, spray on the red penetrant and allow 5 ~ 40 minutes for penetration. Spray on more red penetrant if It dries before it has been able to penetrate (6) Spray on developer Remove any residual penetrant on the surface after the ppenetrant has penetrated, and spray on the developer. IW there are any cracks in the surface, red dots or a red line will appear several minutes after the developer dries. Hold the developer 300 ~ 400mm (11.8110 ~ 15:7480in.) away from the area being inspected when spraying, ‘making sure to coat the surface uniformly. (©) Clean the surface with the cleaner. ‘Note..Be sure to read the instruction for the color kit ‘before use.“Chapter 2 Basic Engine 1, Cylinder Block TN Series 1-4 Cylinder bore measurement Measure the bore diameter with a cylinder gauge at the positions shown in the figure. Replace the cylinder bore when the measured value ex zeeds the wear limit. Measurement must be done at least ‘at 3 positions as shown in the figure, namely, top, middle ‘and bottom positions in both directions along the ‘rankshaft rotation and crankshaft center lines. Coytinder gare <| ‘oo positon Miia postion Sete gauge to z00 ‘Set tone yinder sm nd inner ameter = ane Cylinder bore dia, See separate service data Cylinder roundness (Page 230, 31) 22Chapter 2 Basie Bgime I sees 1. Cylinder Block 15 Sleeveless cylinder 145.1 Features of sleveless construction {1) Improved reliability for tightness of combustion gas, cooling water, and lubricating oi ‘The sleeveless design permits tightening a cylinder head gasket evenly between the flat surface of the cylinder block and of the cylinder head, thereby improving tightness. (2) The sleeveless design has eliminated increase in lubri- cating oil consumption and blow-by caused by deform- ed or defective sleeves, thus assuring stabilized engine performance. (3) “Sleeve! of the piston and ring, with enhanced engine dura v ‘cooling improves the cooling efficiency i= 1.5.2 Durability of the sleeveless engine ‘The conventional models of engine (T and TH Series) are ‘equipped with wet liners or sleeves to the standard specifi ‘cation. Tests in Yanmar Laboratory have proven that the sleeveless engine is improved in wear resistance by about 20% as compared with the conventional T and TH Series engine, which have long and widely been used and marked. fair durability in the market, A decision should be made as to whether the sleeveless 1e requires overhauling by checking increase in lubri- cating oil consumption or blow-by indicates rapid change, 1.5.3 Overhaul procedure Following figure shows the time of the first to third over- hauling and, the service life of the sleeveless cylinder to- ‘gether with necessary honing or boring. (1) How to re-hone the sleeveless cylinder Prepare a motor-driven drill, “Flex-Hone”, and honing fluid. Overhaul of Cylinder Servic life of sleeves cylinder block (Hy) 73H) ‘Time of redboring and rehoning (Ha) ‘Time of eenoning (Hy) 23 Incrense in LO. Inerest in LOC. or blow-by orbiow-by L, Sit Se PCChapter 2 Basic Eng “1. Gutinder Block Fenoraing| FLEXHONE [Appicabe 001] size | Grain | Granular grindstone | boring oa | mode | type | size type oom) 2STNGGE [6870] 63-70 [STNATIE farw7se [5°75] + soc] ‘Silconcarbide | 70-78 SINGTEE (tor easton) 3, 4TNBZE serwazre [S289 76-89 37ND Me The “Flex-Hone” is commercially available, and is ready for shipment from Yanmar on request. (Manufacturer: Brush Research Mfg. Co., Inc.) FLEXHONE GRIT 180 Engine oil Light oi! Oe Honing agent Applying the honing fluid to the Flex-Hone. Insert the Flex-Hone while turning it, and move it up and down for about 30 sec so that a cross hatch angle becomes 30° to 40°, Extract the Flex-Hone while turning it. Carry out fine boring before honing. Use a hone consisting of the GC grain (green carborun- dum) of grain size of #300, and vitrified bond (bond- ing agent). Select the revolutions and feed rate of hon- ing according to the following table. Revolutions el | FAL Mel III Jol 3 o é lo} ||] jo} NOTE: Commence honing when 1/3 ~ 1/4 of the length of the grinding wheel protrudes from the top of the cylinder, ‘nd continue unui 1/3 ~ 1/4 protrudes from the bottom: Finally bore the cylinder and hone to the cylinder inside diameter, D, in the following table. Cylinder. [evingerB10)] Length long after fine borng| ater honing eylinder 0.) (rom (com ‘cam Barneee | e622 | e250 | 1092 aiwarze | __ 7222 | 722690 | 227 STN7BE 722 | 7525808 | i987 arwcree vex | 70289 [1307 fsarweamie 8222 | waasrZ00 | isos BaTNBamTIE| 8822 —] gaa5°90 | veo Revolutions tom) | Feed Rave (wlnind zamese | _ 900-300 SINATIE 260 =310 ‘STNTSE eee STNC78E 250 ~ 290 Barsamiel aap Sérneane| 2-280 | (The above table provides a crom hatch angie of 35" 24ax Chapter 2° Basic Engine ey Series 1. Cylinder Block 15.4 Handling of FLEX-HONE ‘© Use the Flex Hone by mounting it on @ motor-driven {stepless variable speed,) drill. ‘¢ Use soluble type grinding fluid for grinding. Do not em. ploy dry type grinding. Use neither emulsion type grind- ing fluid nor patroleum-base (wash oil) grinding fluid. ‘© After grinding, be sure to clean the grain ball in warm water of about 30° — 40°C using a bristled brush or the like. Do not store the grain ball with chipping powder or wom grain particles left deposited. Other- wise, grinding capacity decreases. ‘9 The Flex Hone is intended only for wet type grinding. Nover use it for the dry type grinding purpose. Cleaning Sue ona 30°~40°C '* "Never keep the Flex Hone immersed in thinner, gasoline, 928 oil, etc. Be sure to keep it dry for storage. Other: wise, the binder of grain particles is inversely influenced. yl amet zg Creole tata 25 1.8.5 Calculation diagram for obtaining crosshatch angle Calculation diagram for obtaining erosshatch angle cross- hatching varies with circumferential speed and axial speed. ‘The following diagram is a calculation diagram for obtain: ing a crosshatch angle. [EXAMPLE] Where 2 workpiece is 100mm in inside diameter and is rotated at 2 head speed of 95 r.p.m., 8 broken line connecting the two extends to 29.8 m/min on the circumferential speed axis. Where a stroke is 200 mm in length and number of stroke reciprocations is 27.5/i ‘an axial speed of 11.0 m/min is obtained. When the point {298 m/min at an axial speed), a crosshatch angel of 40” is obtained in the center. Part list for Oversize piston and Oversize: 0.25 mm: ston ring Refer to the parts catalogs,Chapter 2B. “2. Cylinder Head 2. Cylinder Head “The eylinder head is 3- or 4-cylinder integral construction. IMPORTANT: ‘The area between the intake port and exhaust port is coo! Gylnder head assembly differs among envne models It ed by a water jet, incorrect cylinder head is installed, combustion performance a . will drop. Be sure to check the applicable engine model ‘identification mark (1. D. Mark) on the cylinder heed 25- sembly t0 insure use of the correct part. Yatve rocker arm shatt Je JYelve cocker arm shaft pring Applicable engine ‘model 1.0. mark Exhaust valve a arm i Ine ave "em PR f S co—8 Fuel injection nozzle Corer y a = Sh von he meee ye ‘Valve spring Ses stem seat ‘Valve guide= 2 Basie Fngine, 2. Cylinder Head 2-1 Inspecting the cylinder head ‘The cylinder head is subjected to severe operating condi- tions with repeated high pressure, high temperature and cooling. Thoroughly remove all the carbon and dirt after disassembly and carefully inspect all parts, 2.1.1 Distortion of the combustion surface Carefully check for cylinder head distortion as to gasket damage and compression leaks. (1) Clean the cylinder head surface. (2) Place a straight-edge along each of the four sides and ‘each diagonal. Measure the clearance between the straight-edge and combustion surface with a feeler ‘gauge. is leads Measurement procedure Straight-eege - TN Series 2.1.3 Checking the intak Check the surface and width of the valve seats. It they are too wide, orif the surfaces are rough, correct to the following standards: eater gauge’ meta) intake Tao Standard [Wear tit oe Exhaust 20" ‘See separate service data finder head distortion o ne (Page 230, 31) renting Seat width Siandara Wear tit 2.1.2 Checking for eracks in the combustion surface ea) ‘See separate service date Exhaust (Page 2-30, 31) Remove the fuel injection nozzle, intake and exhaust valve land clean the combustion surface. Check for discolora- tion or distortion and conduct a color check test to check for any cracks. 27Chapter 2 Basic Engine. .TN Senes y 6 . Cylinder Head 2:2 Valve seat correction procedure NOTE: Clean the valve and cylinder head with light oil or ‘The most common method for correcting unevenness of the equivalent after valve seat finishing is com- the reat surface with a seat grinder is as follows: pleted, and-make sure that there are no grindings (1) tse a seat grinder to make the surface even. remaining. First, use 70° grinder, then grind the seat to the stand- ard dimension with a 15° grinder. NOTE: 1. Insert adjusting shims between the valve spring ‘and cylinder head when seats have been re- finished with a seat grinder. 2.Measure valve distortion after valve seat re- finishing has been completed, and replace the valve and valve seat if it exceeds the tolerance. “Son grngor intake vane 3 s Exhaust vave a5 2:3 Intakefexhaust valves, valve guides NOTE: When seat adjustment is necessary, be sure to 23-1 Wearing and corrosion of valve stem check the vale and valve guide. 1! the clearance Replace the vale ifthe vale stem is excessively worn or exceeds the tolerance, replace the vale or the corroded. valve guide, and then grind the seat. (@)Knead valve compound with oil and finish the valve seat with a lapping tool. (8) Final finishing should be done with oil only. nmin) Yate ster an ea i ; outside a. Gad ee Lapping tool i Use a rubber cap type lapping {ntake See separate service data tool for cylinders without (Page 2:30, 31) Exhaust a lapping tool groove si 28"2. Cylinder Head 2.3.2 Inspection of valve seat wear and contact surface Inspect for valve seat scratches and excessive wear. ‘Check to make sure the contact surface is normal. The ‘seat angle must be checked and adjusted if the valve seat contact surface is smaller than the width of the valve seat. Note; Keep in mind that the intake and exhaust valve have different dimameters. 2.3.3 Valve sinking ‘Over long periods of use and repeated lappings, combus- tion efficiency may drop. Measure the sinking distance ‘and replace the valve and valve seat if the valve sink ex- ‘ceeds the tolerance. (2) Replacing the valve guide Use the insertion too! and tap in the guide with a mallet. Toot Nave guide Cylinder meas ‘The intake valve guide and exhaust valve guide are of different shapesidimensions. The one with a groove around it is the exhaust valve guide and the one without isthe intake valve guide. (3) Valve guide projection ‘The valve quide should project the following “ from the top of the cylinder head, < nmin) a a W ‘See separate service Vahe sink * (age 230, 31) 23.4 Valve guide (1) Measuring inner diameter of valve guide. Measure the Inner diameter of the valve guide and ‘eplace iti it exceeds the wear limit. Valve quide | See seperate service data mia) Brojection A, (Page 230, 31) ‘Standard [War tint Intake | See separate service data a (Page 2:30, 31) NOTE: The inner diameter standard dimensions assume @ pressure fit. 29Chapter 2 Basic Engine, 2, Cylinder Head (2) Valve stem seals The valve stem seals in the intakelexhaust valve guides ‘cannot be re-used once they are removed—be sure 0 replace them. When assembling the intakelexhaust valves, apply an adequate amount of engine oil on the valve stem before inserting them, AA | omens Vatve stem sea! vatve guide 2-4 Valve springs 24.1 Checking valve springs (1) Check the spring for scratches or corrosion. (2) Measure the free length of the spring (@) Measure inclination. { Square gauge 240 TN Series (4) Assembling valve springs The side with the smaller pitch (painted yellow) should tace down (cylinder head). Upsice jm mee NOTE: The pitch of the valve spring is not even. The side with the smaller pitch (yellow) should face down (cylinder head) when assembled. (6) Spring retainer and spring cotter Inspect the inside face of the spring retainer, the ‘outside surface of the spring cotter, the contact area of the spring cotter inside surface and the notch in the head of the valve stem. Replace the spring retainer and spring cotter when the contact area is less than 70%, ‘or when the spring cotter has been recessed because of wear, own se fChapter 2 Bas 2. Cylinder Head 2-5 Assembling the cylinder head Partially tighten the bolts in the specified order and then tighten to the specified torque, being careful not to dis- tort the head. (1) Clean out the cylinder head bolt holes. (2) Check for foreign matter on the cylinder head surface that comes in contact with the block. {@) Coat the head bolt threads and nut seats with lube oil, (4) Use the positioning pins to line up the head gasket with the cylinder block. (5) Match up the cylinder head with the head gasket and ‘mount. Flyheel side “Timing gear eave side Take manifol side 2 cylinder engine Exhaust manifold side Flywheel side “Timing gear cate wide ‘3Ovlinder engine Exhaust mand soe Flywheel sie {nzake manifold sae "E Cylinder engine Fist Tightening tone ‘See separate service data 2-6 Measuring top clearance (1) Place a high quality fuse (1.5mm (0.059tin), 10mm {0:3997in) long) in three positions on the flat part of the piston head. (@) Assemble the cylinder head gasket and the cylinder block and tighten the bolts in the specified order to the specified torque. (@)Turn the crank, (in the direction of engine revolution), and press the fuse against the piston until it breaks. (@) Remove the head and take out the broken fuse. (Page 230, 31) 2 (6) Measure the three positions where each fuse is broken ‘and calculate the average. (0:71 ~0.75mm (0.0280 ~ 0,0296in) is ideal) Fuse wire ‘See separate service data (Page 230, 31) 2:7 Intake and exhaust valve arms Valve arm and valve arm bushing wear may alter open inglciosing timing of the valve, and may in turn affect ‘engine performance according to the extent of the change. "Top clearance ? comstvdve 4 oan J reasevive monChapter 2. Rasic Fngine, “2. Cylinder Head (1) Valve arm shatt and valve arm bushing Measure the outer diameter of the shaft and the inner Giameter of the bearing, and replace if wear exceeds the limit, min) Wear tit Standard Intake and exhaust valve rocker arm Shaft outsige Intake and exhaust valve rocker arm Dushing insige da ‘assembled) Vane rocker arm shaft and bushing clearance ataseembly See separate service data (Page 2:30, 31) Replace the valve arm shaft bushing if it moves and replace the entire valve arm if there is no tightening clearance. (2)Vave arm spring ‘Check the valve arm spring and replace it ed or worn, (@) Valve arm and valve top retainer wear . Inspect the contact surface of the valve armand replace it if there is abnormal wear or flaking. (4) Inspect the contact surface of the valve clearance adjust: ‘ment screw and push rod and replace if there is abnor- ‘mal wear or flaking. itis corrod: 242 2-8 Adjustment of valve head clearance (1) Make adjustments when the engine is cool. ein) Ta an exit daranee [02 ToT) sag owemce ITN tect (2) Do not fail to adjust the opening and closing angles for both intake and exhaust valves when reassembling the timing gear. Toc proc, aoc Yes banc L abe. intake valve open [_b.7OC - ioake vale closed | a BDo | See separate service date Exhaust valve open_| _b.BDC (Page 2-30, 31) Exhaust valve closed | a TOCChapter 2 Basic Engine "3, Piston and Piston Pins 3. Piston and Piston Pins ‘The piston is made up of an aluminum alloy with less thermal expansion. ‘There is clearance between the outside diameter of the piston and the inside diameter of the cylinder. The clearance is an important factor that has influence on the lubricity between the piston and cylinder, lubricating oil consumption, the noise level of the cylinder {In Yanmar engines, both piston and cylinder have identifi cation marks to ensure proper clearance between the piston and cylinder on respective top surfaces. In Yanmar factory, the piston is assembled into the cylinder block with the same identification mark. ‘The following shows combinations of identification marks for the piston and cylinder block, Idesteton of pon Tm [ws [= tree fx | x linger a soo [xe Joe Now 1s Oves Fine SEER 23 TN Series 341 Piston 31.1. Piston head and combustion surface Remove the carbon that has accumulated on the piston hhead and combustion surface, taking eate no to scratch the piston. Check the combustion surface for any damage, '3:1.2_ Measurement of piston outside diameter/inspection (1) Replace the piston if the outside of the piston or ring grooves are worn, Measure the piston O.D. of location bottom at right angles to the piston pin, i) "from the men tind Wer fit Standard ‘See separate service data (Page 2:32, 23)3. Piston and Piston Pins TN Series pee 39 Paton toe temperature (coat with oil to make it slide in easily). from being kept on the thrust surface and in turn provides barat > D a UT] Bee 5 &-—— 59 “Tapered face ring col expanse 32 Piston pin Measure the outer diameter and replace the pin if it is excessively worn, 2.3.1 Measuring the rings Measure the thickness and width of the rings, and the” ting-to-groove clearance after installation. Replace if wear exceeds the limit nmtn) won] |G Sanda Wear iit Fajegin wer Peka pe See separate service data “Tiekness outside dia (Page 2-32, 33) Standard clearance 244S TN Series ‘3. Piston and Piston Pins mma} 33.3 Replacing the piston rings [Standard ——[Weartmit™ ——(1) Thoroughly clean the ring grooves when replacing Groove wih piston ang rest (2) The side with the manufacturer's mark near piston ring $item | ing win ap) should face up, os ca Spears Growin | ine da Second 20 separate service data Seen? [pine wm (Pape 292,93) i) Groove and eagtearee esd wih maar rove with ra tng | ing wath Gras and () Alter iting the piston rng, make sure it moves easily Sees ‘and smoothy. (a) Stagger the piston rings at 120° intervals, making sure 3.8.2 Measuring piston ring gap none of them line up with the piston. Press the piston ring onto a cylinder and measure the piston ring gap with a gauge. Press on the ring about 30 mm (1.1811 in.) from the bottom of the cylinder. ne ns ote oe mane 4 cael = if] a [aes ee Sao fatntontng a |e separate service date secede aw |” tegen a Olio we 245—Chapter 2 Basic Engine TN Series 3. Piston and Piston Pins 1st compression ring Direction ot piston pin Direction of sie pressure 120° 2nd compression ing (6) The oil ring is provided with a coil expander. The coil ‘expander joint should be opposite (staggered 180°) the oiling gap. soint ot cell expander 246spter 2 Basie Engine "4. Connecting Rod 4. Connecting Rod ‘The connecting rod is made of high-strength forged car- bon steel. ‘The large end with the special aluminumalloy metal ‘can be separated into two and the small end has a copper alloy coll bushing, Crank pin metal Seer Connecting tod bot 4-1 Inspecting the connection rod ‘4-1.TTwist and parallelism of the large and small ends {Insert the measuring too! into the large and small ends of the connecting rod. Measure the extent of twist and Parallelism and replace if they exceed the tolerancé, ton in butng | 247 Measuring twist ‘Connecting rod Wear limit {wist and paraleity ‘See separate service date (Page 2-32, 33) 4-1.2 Checking thrust clearance Fit the respective crank pins to the connecting rod and check to make sure that the clearance in the crankshaft irection is correct. mm tay Standard [Wear limit ‘Connecting red side clearance ‘See separate service data (Page 2-32, 33).Capt 4. Connecting Rod 42 Crank pin bushing 42.1 Checking crank pin bushing Check for flaking, melting or seizure on the contact surface, 42.2 Measuring erank pin oil clearance Procedure (1) Use the press gauge (Plastigage) for measuring oll clearance in the crank pin. (@) Mount the connecting rod on the crank pin (tighten to specified torque), ‘See separate ‘service data — (Page 2-32, 33)— Connecting rod tightening torque (3) Remove the connecting rod and measure the broken 4.2.3 Precautions on replacement of crank pin bushing (1) Wash the crank pin bushing, (2) Wash the large end cap, mount the crank pin bushing and make sure that it fits tightly on the large end cap. () When assembling the connecting rod, match up the large end and large end cap number. ‘Coat the bolts with engine oil and gradually tighten them alternately to the specified torque. a torque wrench is not available, make match marks fon the bolt heads and large end cap (to indicate the proper torque position) and retighten the bolts to those ‘ligament mask (Punched mary (4) Make sure there is no sand, metal cuttings or other foreign matter in the lube oil, and that the crankshaft is rot scratched. Take special care in cleaning the il holes. 4:3 Piston pin bushing (1) Measuring piston pin clearance Excessive piston pin bushing wear may result in ‘damage to the piston pin or the piston itself. cyinaer gavge-end Standard | Wear iit Piston pin bushing Inside dia. ‘See separate service data Piston pin and bushing (Page 2-32, 33) i caarance (@) Replacing piston pin bushing 1) When the bushing for the connecting rod piston pin is, either worn out or damaged, replace it by using the ton pin extracting tool” installed on a press. NOTE: Force the piston pin bushing into position so that its oil hole coincides with the hole on the small ‘end of the connecting rod. 219 ‘4-4 Assembling piston and connecting rod ‘The piston and connecting rod should be assembled so that the match mark on the connecting rod large end faces the fue! injection pump side and the combustion chamber above the piston is close to the fuel injection pump, Di engine Flywheel sce (Cam shat sige ~ vd Size mark 1.0. mark (TH 4m Fuel injection Gear case sie pump sie Mater, anwar ‘Aignent mar (erging mark) IDI engine ‘Cam shat se - Combustion ‘chamber Fut injection ume sidengine ‘Main Bearing 5. Crankshaft and Main Bearing The crank pin and crank journal have been high-frequency hardened for superior durability, and the crankshaft is provided with four balance weights for optimal balance. ‘The crankshaft main bearing is of the hanger type, with ‘the upper metal (cylinder block side) provided with an oil ‘groove, and with no oll groove on the lower metal (bearing ‘cap side). The bearing cap (location cap) of the flywheel, side has @ thrust metal which supports the thrust load, sans J~- WY J W) Ge beaing meta an erg tk f 54 Crankshatt P Jj (1) Color check of shaft Perform a color check after cleaning the crankshaft, Zh ‘Main bearing cap td vploce ine cank hat heres any Gage 6 considerable damage. 5 Main bearing bot 220Chapter 2. Basic Engine LIN Series 5. Crankshaft and Main Bearing 7 (2) Bending of the crankshaft Support the crankshaft with V-blocks at both ends of the journals. Measure the deflection of the center journal with a dial gauge while rotating the crankshaft to check the extent of crankshaft bending. Aen | (i Tat peu voce (Grankshalt bend ‘Less than 002mm (0.0007 ia) (@) Measuring the crank pin and journal ‘Measure the extent of journal wear (roundness, taper). Regrind it to the proper shape if itis within the outer diameter limit, and replace if not. rma ‘Standard [West ‘Outside da Crank pin Bushing inside da ‘Crank pn and bushing of Glearance ‘See separate service data om (Page 2:32, 33, 34, 25) Crank journal [Bushing inside da ‘rank journal and bushing 6 cearance Filet rounding of rank pin and journal 221Chapter 2 Basie Engine ‘5. Crankshaft and Main Be (4) Checking side clearance of the crankshaft After assembling the crankshaft, tighten the main bear- ing cap to the specified torque, shaft to one side, placing a dial gauge on one end of the shaft to measure thrust clearance. ‘This measurement can also be effected by inserting the gauge directly into the clearance between the thrust bearing and crankshaft thrust surface. Replace the thrust bearing if itis worn beyond the limit. meta) ‘Standard__[_Wear iit ‘See separate service data Page 2:34, 35) ‘Crankshaft side g3p 5:2 Main bearing (1) Inspecting the main bearing Check for flaking, seizure or burning of the contact surface and replace if necessary. (2) Measuring the inner diameter of metal Tighten the cap to the specified torque and measure the inner diameter of the meta ‘See separate service data (Page 2:34, 35) — Bearing cap bolt tightening torque TN Series Dial inaieator Ccrankenatt NOTE: When assembling the bearing cap, keep the follow- ing in mind. 1 The lower metal (cap side) has no oll groove. 2)The upper metal (cylinder block side) has an oil groove. 3) Check the cylinder block alignment No, 4)The "FW" on the cap lies on the flywheel side, Man bering meta (basi) YY) Main beving ca asi) __t = o “8 d Main bearing meta iy 222Chapter 2 Basic Engine “6. Camshaft and Tappets 6. Camshaft and Tappets 6-1 Camshaft The camshaft is normalized and the cam and bearing surfaces are surface hardened and ground. The cams have ‘a cure that izes the repeated shock on the valve seats and maximizes valve seat life. (1) Checking the camshaft side gap ‘The standard bearing near the end of the camshaft by the cam gear receives the load, resulting in rapid wear of the end of the bearing and enlargement of the side ‘9ap. Therefore, measure the thrust gap before disas- sembly. As the cam gear is shrink-ftted to the cam, be careful when replacing the thrust bearing. ‘camara gear Thrust metal L Camshalt side gap 223 _ TN Seri (2) Measure the camshaft height, and replace the cam if it is worn beyond the limit itt me in) Camshaft height Standard | Wear tit Tntake cam ‘See separate service date Exhaust cart (Page 234, 35)chapter 2 Basic Engine Camshaft and Tappets (0) Measure the camshatt outer diameter and the camshaft ‘bearing inner diameter. Replace if they exceed the wear limit or are damaged. mein) Sandard Gear case sie Wear kit Tatermediate| I Flywheel side ‘Camshaft journal outside dia ‘Camshaft journal bushing inside la. ‘See separate service data ‘ylinder block bearing inside dia (Page 2:34, 35) Oil clearance (4) Bending of the camshaft 6-2 Teppets ‘Support both ends of the camshaft with V-blocks, place a dial gauge against the central bearing areas and ‘measure bending. Replace if excessive. ial gauge NOTE: The reading on the dial gauge is divided by two to obtain the extent of bending. nmin) Wear iit ‘See separate service Gata (Page 2-34, 35) —— 224 (1) The tappets are offset to rotate during operation and thereby prevent uneven wearing. Check the contact of ‘each tappet and replace it excessively or unevenly ih SY 1 | it (ON Ta NOTE: When removing tappets, be sure to hep them separate for each cylinder and intake/exhaus! valve.Engine 6. Camshaft and Tappets 3 —_—————— ts {@) Measure the outer diameter of the tappet, and replace if ‘worn beyond the limit. Tappet stom outsie aa, Wpret aise rote sie | Gyno Boe “appelstem and guide tite ol ewan’ (©) Measuring push rods. Measure the length and bending ofthe push rods. ‘See separate service data (Page 234, 35) Siandard Wear limit Push rod length ————_ See separate service data easel (Page 2.34, 35) Push rod dia. 2257. Timing Gear The timing gear is helical type for minimum noise and specially treated for high durability. Fuel ington pump gxsr y cama gear xt 7 tae om ana dr Lupneateg ot pmo far mba) No.of Face | Helical Teetn_| wain | "oe Back ash titer tint Comsat gear tae gear Sauna gw See separate service data pi (Page 2:36, 37) Lubricating ot pump gear ale gear Fuel inection pump gear 7-1 Inspecting the gears (1) Inspect the gears and replace if the teeth are damaged) ding gear or worn, (2) Measure the backlash of all gears that mesh, and replace the meshing gears as a set if wear exceeds the lit. NOTE: If backlash is excessive it will not only result in ex- cessive noise and gear damage, but also lead to bad valve and fue! injection timing and a decrease in engine pertormance. 228 The bushing is pressure fitted into the idling gear Measure the bushing inner diameter and the outer diameter of the shaft, and replace the bushing or idling ‘gear shaft if the oil clearance exceeds the wear limit. A, B and C are inscribed on the end of the idling gear. ‘When assembling, these marks should align with those on the cylinder block.Chapter 2 Basic Engine, 7. Timing Gear TN Series STN7SE, STNC7BE, 2, STNEGE, 3TN72E B,ATNBQITIE, ZATNBATIE 00. B)/ 6 Q { . od Idle gear Jgle gear bushing a igiesexratt 5 2 1 @ ‘Ant ark 7 sent) late Sar [Standard [Wear iit {ale shaft ia tena | Seeseparate service data ae al bushing (Page 2334, 35) Tate shaft and bashing elicaararce 7-2 Gear timing marks ‘Match up the timing marks on each gear when assembling (Bando). Fal injection ump opr (Camstat goat Luicaing ot pum Se Direction of rotationChapter 2 Basic Engine, 8. Flywheel 8. Flywheel The flywheel used in the STNB2E, 3TNEZTE, STNBAE, and 3TN84TE incorporate an unbalance mass in order to reduce engine vibrations by Istmode inertia couple produced by the reciprocation of the piston assembly, piston pin and small end of the connecting rod. The TNGGE, STNGGE, STNA72E, 3TN75E, STNC7BE, ‘and 4TN series engines, however, employ a balanced flywheel. The timing marks are punched on the circum- ference of the flywheel. These marks are used for check- ing the fuel injection timing. 8:1 Position of top dead center and fuel injection timing (1) Marking Stambes etter tndweatng 8.6 ‘Stampea marking ine Stamped leter indicating marking evlinder number in Stamped marking Stamped marking =| fine indieating line indicating 0. iro Stamped marking ‘stamped eer fuel iiection tinder ner 4 evlinder engine 228. Flywheel {@) Matching mark. Fiywheet housing Ld NE A | athing mark “The matching mark is made at the hole of the flywheel housing. 9, Crankshaft pulley ‘The crankshaft pulley of the 3TN82E, 3TNS2TE, STNS4E, and 3TNBATE employ the unbalance mass design in order to reduce engine vibrations by offsetting ‘the Ist-mode inertia couple produced by the reciprocat- ing mass. The 2TNGGE, STNGSE, STNA72E, 3TN7SE, STNC7BE, and 4TN series engines, however, employ @ balanced pulley. Vo Lo t ‘Cntalance max Unbalanced pulley * Balanced pulley 229Chapter 2 Basic Engine 9. Service Data 9. Service Data ey series THE Tae Tae = a soot [| owes | rin ck y we | eoo-em | em | rew-mm | raw | aoc ea vind tov i _| eim=Seim | moe | cenazeen | aon | goacimy | sin on 308 on on 9-001 002 Cinder roxrtoans ind (0 -0.0004) 10001 (0 0.0004) 10.000 {0 - 0.0004) 10.008) espana nial [190 = 27 = 2077) i rina : aa] oases | 8] aati —] as} aati a "Hinder hex distortion in (0.002) 10.006) 10.002) (0.006) 10.002) 10.006) Trae 0 SI 7 S mH i Sesrseate chao oes. 90 = 20 = 90 = i ral Tar a Tae Ta as-is sewn o oo oom) om com | woman | roam a cee en ta 7 1a 277 196-187 277 o oo coors ore Ee a yam foo ra = = 20 5 = = ESS enn on # = © 5 ‘« = Ime wn] sai-308 | 50a} as -aoe | an | as 000} “a ates io | ars-or | eam | wms-ome | orm | ezscemo | am ose. aa] Sasa 3945-6980 —|~ 50 | — aot=eoss —| 005 i | eaw-ca | eam | oan-oam | ona | arene | omm Ta oo mmamgsonn | emi | zor 5 210980) = eon ~ Pein memuring pany | men! Te : scam : 50 (1.900) - vse sn intake tel so016) - 49.02) = 10.012 - 0.020) 10.099) Ica on ass ons a3=08 73 ca oan : om = | woa-sam | om hana ime $5= 8515] 5} Fs rane | a8] aes am pe (| waar | 2m | ozmencsen | orm | zeae | osm mee me [88-8516 | Sa ros ran | 78] rapa ho : i | wrscoam | ezm | wirmnaaen | osm | azne-ome | osm Tin panne h mia [eam é e1aase) S earn 5 [Free lenatn (Al co 0.102), - 3472) = 1.654) = mW 70 17 einai 8) | mtd : way E eos 2 maa io ee a ay aes we | msc | - | eracaien | — | aetecatom | - ow wn 3937 eo-es we) | aera | | wase=ston | - - wm | esa 081-070 is | woman | = | omozeann | — 2 irene ma ane wn | 997-099] vam | riae6~nnge | am Tease rm hoes i | wies-cmn | own | _tanzonn | won oem ae eka ae aT wwe | ta00= soma | som | —rano— ran] zon] —o00= eaao | tomo niente G_| wioor-cane | aan | wae-oen | am | woaoroan | wom ike kr oa aE rl oo1-om ans | aow-oom —] 0105 | —oove-oma —] 0108 igs smi | omot-cm | ean | wome-omn | woom | woomnomm | sos trate eteat he eee | “a ta | 02 Si 27 0m: = 02 008) 5 com TOE en Sa S 71 s w=7 5 iodo rm Baa s ea S 0-8) S Exh ae open rm aa s won = sei = Eonar tones TOC oo = = = = rer = 230Chapter 2. Basic Engine -' _——}—$ $$ er 9. Service Data Series TINGE SATNOREDATNOTTE TaN ATNOATE tn a weet | Stet co Sd pana wove m= | pepe mo-ae | a2 | anna | a vind br To _| eeeatem, Gam-so | eam | GSE | ls = = 208) @=091 7a 3-001 aa evn ruta | ok eete cow | ween | wen | oom espana mia | a9eren = 21077 = Bow a Sn Evin mat axon m= | anaes | oe | 7 Tosa —] OF : i am | eat ‘oon oom ‘oom ‘oom a= om ou=aem | wom | eoe-oom | oom Se cm ‘om ry 2 120145, 138 Tae 135, 73 . fo | 88-880 | dd | owmcan | corm | once | oom eaeae a ae = 5 = Si = s Soe era ee = S = s = 7 Ieee | gaan |g | 2om-79m8 | a0 | —vom—79m —] Ta es em im | S288 | dt | ese-oam | eam | wsszern | wan mires me] gee |e | 7988-791 —] 799 | —r985=79% —] 730 Gm | dei | de | aamnanw | eam | ear-oae | ean Peston som [oni | vonwn | - so0380 = meen : ee oo memwingoomy | mind | so1raem = ows = wan = nate = 38h 2 a3-05 1B w=05 1% a T_| ws2=880 | dts | wor-cem | wom | o-com | wom lem oa o3=08 2 33-05 73 o=OF 77 t_| ea8=8io | wii | woa-cem | wam | eo2-com | wom i me | 209-7018 —] 70 | —eo10-00%8 —] a0 | — so10=eoas —] 010 va aie T_| retin | ity | eseose | eam | eaie-eoim | am eee | 7a5-70% | en] aoise000 010 | — sa18-em00 —]— 810 i _| 02%~EEren | wim | gae-os | am | oare-ome | coat ama pam pension amie | __ awe 5 50m) s co s etn) mi Be S So fe oan fy va sring nection) renin) : ote, 7 (otto : (o'ste ge [First ue - ‘35-43 Bee wo) = | asm | - Fagan len we - een, psa Ps ~ | wlicthe [ me | 969-977 = a= 0m ‘e-OmF [rep cearenes in ‘fo.c248 — 0.0303) (0.0252 - 0.0323) = 10.0252 ~ 0.0323) - eres wom | gases onese | game | vsas0— seam —| ass | rsa0e= inane —| eas ee tr_| Gee=cSs | Get | emenoem | wm | wene—acem | xm rer perenne wen | ~ yeas seo | game] 16000 16am0 | 1ean0 | — teoo0=venz —| a0 rm ting nar 6 to _|_ Weeiees | S88 | eoroen | wan | tesm=cesn | wan vert om wee] ogi =g0se [033s [0016-00 onus | — aore-oasa —|_ ome Seton ey to _| 2688880 | 8z | iocmoe—oemn | wooo | woooe=soorm | roams, nae eet wivecerwna | ow | e3 0m) = 02 0007) = 22 0207 5 nae vv pe bTOE ee 3 5 19-29 S co = nis oe ou OE ot = a= S co = eben we comb 7 = sist s en 5 shea ae Saved TOS rm = co si ae 2 231_ Chapter 2 Basic Engine i eres 9. Service Data TN e vo eee ew ee — a a Pent mon fom | smn | | ee | = | ewan] fmneenteaeviom | im | aocene | com | esa | ona | casaen | oe romenaa seas en | Saori} Rarer ant mi] Gece [em | cecum | 2 [gece | oe a pos} tan — at cae meee | aS, aoe | eee | ee S| Mocs Barca acco noes Paonagg | Tee ctaas—} ooo i a ee ra ee Ceseance tind 10,0026 ~ 0.0039) (0.0073) {0,003 - 0.0043), 40.0079) 10,0028 — 0.0041) 0.0008) coon] eae eae a Basted coe ing fea wi int 400579 - 0.0567) = 10.058 - 0.059) = 1.0776 — 007%) = — Seana — — } Fl nee ee (ee Sree ice iad (0.1382 — 0.1388) = 10.138 - 0.139) = 10.158 - 0.1591 = Ciarance e008 oar» | ror | coooa—oooz | wooare) | _tao12—ooa20 | oor emzete [ein | esiceie | eee | Season | an a eae | os = cz a io9 e (0,006 - 0.014) 10.059) 10.006 — 0.014) 10.089) (0.008 - 0.016) (0.059) 3970-3590 > (ob |_cises—arern is6—013 (0860357 = en] —a000 = 9080 93, | 00050 | 02 0025-0080 02 toi | woooa-seom | wise | eooie-somn | oom | ronnie oarn | moor, apa mr 925-000 Tg, [,azs0ze00nas | 15 | ozozoane | 15 fi_|_waio-2a | wii fosiomeseaaremore| wos facewviesoreoaral (oes fa 025-040 78 020-035 15 030-040 15 are ti_| _wore-oo% | dim | eom=oa. | wasn | woos-core | iovsoy on im 370040 78 15 025-045 15 7 oe er = assy | woro-core | ones, Conon od [eres wi a me | agancomaies | ome | caxrcomanm | aon | ocanmomawn | 00 Join toi _|_“eooreatrr" | warm | “cooraaamn’ | oon | “oooassn | oon aogrod ct ore a 929-040, 55 | 020-040 oss 020-00 055; foment ted _| essi=B2ien_| wttin | wasore—aorsn | wortn | canons | worn wipmmeen | 2S 38=42 45-50 ~ 45-50 - Cemecina ro anng ee) | arabian |= | asa anie, 225323618) Sersrercsrsersy wer | aaaas—znae | fay | —0uns~zeooe | mai] —aaam—ze008 | 03 me = toi | @aae~ooon__| eae | doms—sorn | nam | cameron | cam nd big ol ra aor -90e | ax | a0as-onst | ass ‘ens—00si | 931 [eonnwnsnuninaciserwncs | ai | wasre=sacior | wast | roacro-cooam | 2s | ioonenacom | wenn Genta nd mabe ——| = ‘en man 002 = ‘es an 092 - ‘umn 0n2| ~ to ‘seen ‘acon oso) ae | —aen-aen | an | 9ge-0sn | oa | won-ean | om peewee od |_ fame=taoes | eam | doere=tocen | taney | tame tessa,_| nem nbn ini m= | am-aoa | ao | ssao-son | «tor | eaon-aon | «aor o Ec abohing tens | ter exe | ome-om0 | ar co38-o000 | 06 Ss 7 eH wies: | ronors—cams [oer | ronors-o0o9 | soe Petinent omic a ‘waosi—ase2 | «20 | ast—aaoe2 | 020 i to tioees ten | see) | tiger=toen | ase 9 ore boing ea so000- som | #010 | soom=snoes | 5030 na essed | ot tise tare [ora | tiseonssr | ra_Chapter 2 Basic Engine TN Series 9, Service Data FES Tae Ta em voit Sund i Sunder 4 ‘Sunda ve peer w=] aomo-oom | 018 | _omo-oom | 018 | _com-aema | 018 tr _| qoun-oarm | worse | weoe-ocom | ounsn | eoos-oomn | woos, em 30-33 ~ 30-33 ~ 25-38 to | eie-or0 e020 ormnaiso | ~ ae aa] — oaas=aass —] a3] — om -0a1 —] ons | a0-0a | om or to _| som-oom | om | wacom | oom | ean-com | worm in bmg om bar anog | sa 538 ~ 7-42 ~ 79-2 ec my | casetran 0105529 goansoan | - atta woe a wa 05-8 a rary aa Gores | oe 0 fm _| eom-oam | wo | woor-eme | wate | oow-coon | wot musa wen] 937-9003 —] 2975] — snos=ae05 | ag75 | —sesne—sezes | ona — to | diwltem | am | damsaen | ze | sects | asia wart | ooameem ven] — aaar=an0s | ms] mnas=ouas | ans | aness—anzes | ana | crmat | darn | dawntam | nam | saci | asin wm vem] a5 556 ‘macmae | o0as | mao ae owen to |_atenate Gamaien | aan | taectro | ogee tema ee veo] asa 35a maw-masr | as | aso-aas | as vera pte Sencieoe | sor] aes Ft ie to | datectate tmsteme | dsm | tre-10 | a7e0 vcore mn | 3680-96065 woo aa0es | ao | atone —asoss : i | ean teo item | am | tmotne evnger [Stennett = 5 5 5 5 = ec Pina a a fait to | tanta | ean | tarts | asm | nmecirm | ets eamnnan vem] —auo=team [981 | —wom—s00% | «an | —s500-«50m— | fie | Ft tom | wavetaie | wan | temas | osm | homairat wre] toW0 = 0986 0010-0. cow-0120 | aa event ta _| twooe-oae | - | ore-oom | - | eans-oomo | oom canis em] tome 0718 2065 0.8 > coes-0105 02 ace | womeoan | - | eomesoo ooors = aooes | sore cyan wom] 0000 8385 010-0005 = 7080-0100] 02 me a coors oom woos com | oom caer aie om tai-[ 202 8000 5 202 2601) 5 ‘029008 5 7 sa com | W7a5— ase —[ 1703 | oan7~aose | moos | tiavs—niano | vias eon com | erer-ore | ome | oar-oees | caw | toan-oam | aero ee woe] 00010 ‘as [nao—nvar | 2108 | —tamo- raare | 1aa5 ope el i tr _|_exer-ome | orm | xno | ne | tea-oam | aero Roses o ar ae ve] 0082-0088 ~ dao ~ ‘co10=000 | orem t_| sors coo ooore-o00%7 eons a0) can ee [Ta 8 a) =¥2 ‘wees was] = to | weamasn | - esos a ae ven] te 805 ‘es eanoars | ‘aw nmnoas | 03 he a ‘ow, 5 ‘soa “aoa ots oor Sear | s0167 : Zox07) = wioare 5 ee = va | waw-vome | s000 | sso | we aie i ren |_ome-orn | ome | ism-taim | cm ‘wm 2000-2002 2000-20021 “oo =a60%5 | 4503 ta a nee to _| trem | - | moma | - | ‘nancia | ara fact abana cm] ogn-onea —] ass} —omz-o0se [ore | _aoas-a07s [016 enews to _| won-com | oon | sooxe-oome | woo | wown—oorn | oon 238