TNV Direct Inj Service Manual 3tne & 4tnv

TNV DI Service Manual
TNV series
SERVICE MANUAL
3TNV82A
3TNV84 3TNV84T 3TNV88
4TNV84 4TNV84T 4TNV88
4TNV94L
4TNV98 4TNV98T
4TNV106 4TNV106T
P/N: 0BTNV0-G0000
INDUSTRIAL
ENGINES
This Service Manual has been developed for the exclusive use of service and repair professionals such as
Yanmer authorized Distributors and Yanmar authorized Dealers. It is written with these professionals in mind
and may not contain the necessary detail or safety statements that may be required for a non-professional to
perform the service or repair properly and / or safely. Please contact an authorized Yanmar repair or service
professional before working on your Yanmar product.
Disclaimers:
All information, illustrations and specifications in this manual are based on the latest information available at
the time of publishing. The illustrations used in this manual are intended as representative reference views
only. Moreover, because of our continuous product improvement policy, we may modify information,
illustrations, and / or specifications to explain and / or exemplify a product, service, or maintenance
improvement. We reserve the right to make any change at any time.
Yanmar and are registered trademarks of Yanmar Co., Ltd. in Japan, the United States and / or
other countries.
All Rights Reserved:
No part of this publication may be reproduced or used in any form by any means - graphic, electronic, or
mechanical, including photocopying, recording, taping, or information storage and retrieval systems - without
the written permission of Yanmar Co., Ltd.
2005 Yanmar Co. Ltd.
ii TNV DI Service Manual

TABLE OF
CONTENTS
Introduction ......................................................................................... 1-1
Yanmar Warranties.............................................................................. 2-1
Safety.................................................................................................... 3-1
General Service Information .............................................................. 4-1
Periodic Maintenance ......................................................................... 5-1
Engine .................................................................................................. 6-1
Fuel System ......................................................................................... 7-1
Cooling System ................................................................................... 8-1
Lubrication System ............................................................................. 9-1
Turbocharger ..................................................................................... 10-1
Starter Motor...................................................................................... 11-1
Alternator ........................................................................................... 12-1
Electric Wiring ................................................................................... 13-1
Troubleshooting ................................................................................ 14-1
iii
TABLE OF CONTENTS
This Page Intentionally Left Blank
iv
Section 1
INTRODUCTION
This Service Manual describes the service
procedures for the TNV series direct injection
engines. These engines are certified by the U.S.
EPA, California ARB and/or the 97/68/EC Directive
for industrial use.
Please use this manual for accurate, quick and safe
servicing of the engine. Since the directions in this
manual are for a typical engine, some
specifications and components may be different
from your engine. Refer to the documentation
supplied by the optional equipment manufacturer
for specific service instructions.
Yanmar products are continuously undergoing
improvement. This Service Manual might not
address possible field modifications to the
equipment. Contact an authorized Yanmar
industrial engine dealer or distributor for answers to
any questions relating to field modifications.
TNV DI Service Manual 1-1

INTRODUCTION
1-2 TNV DI Service Manual

Section 2
YANMAR
WARRANTIES
Page
Yanmar Limited Warranty................................................................ 2-3
What is Covered by this Warranty? .......................................... 2-3
How Long is the Warranty Period? ........................................... 2-3
What the Engine Owner Must Do: ............................................ 2-3
To Locate an Authorized Yanmar Industrial Engine
Dealer or Distributor: ................................................................. 2-4
What Yanmar Will Do: ............................................................... 2-4
What is Not Covered by this Warranty? ................................... 2-4
Warranty Limitations: ................................................................ 2-5
Warranty Modifications: ............................................................ 2-5
Questions: ................................................................................. 2-5
Retail Purchaser Registration.................................................... 2-5
Emission System Warranty ............................................................. 2-6
Yanmar Co., Ltd. Limited Emission Control System
Warranty - USA Only....................................................................... 2-6
Your Warranty Rights and Obligations: ..................................... 2-6
Manufacturers Warranty Period:............................................... 2-6
Warranty Coverage: .................................................................. 2-7
Warranted Parts: ....................................................................... 2-7
Exclusions: ................................................................................ 2-8
Owners Warranty Responsibilities:........................................... 2-8

YANMAR WARRANTIES

YANMAR WARRANTIES
YANMAR LIMITED WARRANTY

What is Covered by this Warranty?
Yanmar warrants to the original retail purchaser that a new Yanmar TNV Series Industrial Engine will be
free from defects in material and / or workmanship for the duration of the warranty period.
Note: Yanmar engines may be equipped with external components including, but not limited to: wiring
harnesses, electrical devices, control panels, radiators, air filters, fuel filters, and/or exhaust systems
that are supplied and/or installed by manufacturers other than Yanmar. For warranty information on
such external components, please contact the machine or component manufacturer directly or see
your authorized Yanmar dealer or distributor.
THIS WARRANTY IS PROVIDED IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED.
YANMAR SPECIFICALLY DISCLAIMS ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE, except where such disclaimer is prohibited by law. IF SUCH
DISCLAIMER IS PROHIBITED BY LAW, THEN IMPLIED WARRANTIES SHALL BE LIMITED IN
DURATION TO THE LIFE OF THE EXPRESS WARRANTY.
How Long is the Warranty Period?

The Yanmar standard limited warranty period runs for a period of twenty-four (24) months or two-
thousand (2000) engine operation hours, whichever occurs first. An extended limited warranty of thirty-
six (36) months or three thousand (3000) engine operating hours, whichever occurs first, is provided for
these specific parts only: the cylinder block, cylinder head, crankshaft forging, connecting rods, flywheel,
flywheel housing, camshaft, timing gear, and gear case. The Warranty Period for both the standard limited
warranty and the extended limited warranty (by duration or operation hours) begins on the date of delivery
to the original retail purchaser and is valid only until the applicable warranted duration has passed or the
operation hours are exceeded, whichever comes first.
What the Engine Owner Must Do:

If you believe your Yanmar engine has experienced a failure due to a defect in material and / or
workmanship, you must contact an authorized Yanmar industrial engine dealer or distributor within thirty
(30) days of discovering the failure. You must provide proof of ownership of the engine, proof of the date of
the engine purchase and delivery, and documentation of the engine operation hours. Acceptable forms of
proof of delivery date include, but are not limited to: the original warranty registration or sales receipts or
other documents maintained in the ordinary course of business by Yanmar dealers and / or distributors,
indicating the date of delivery of the Yanmar product to the original retail purchaser. This information is
necessary to establish whether the Yanmar product is still within the warranty period. Thus, Yanmar
strongly recommends you register your engine as soon as possible after purchase in order to facilitate any
future warranty matters.
You are responsible for the transportation of the engine to and from the repair location as designated by
Yanmar.

YANMAR WARRANTIES
Yanmar Limited Warranty - Continued
To Locate an Authorized Yanmar Industrial Engine Dealer or Distributor:

You can locate your nearest authorized Yanmar industrial engine dealer or distributor by visiting the Yanmar
Corp., LTD. website at:
http://www.yanmar.co.jp (The Japanese language page will be displayed.) For English language click on
English Page.)
Click on Network in the website heading to view the Yanmar Worldwide Network.
Choose and Click on the desired product group.
Click on the Icon closest to your region.
Click on the desired country or Associate company to locate your nearest authorized Yanmar industrial
engine dealer or distributor.
You may also contact Yanmar by clicking on Inquiry in the website heading and typing in your question
or comment.
What Yanmar Will Do:

Yanmar warrants to the original retail purchaser of a new Yanmar engine that Yanmar will make such
repairs and / or replacements at Yanmars option, of any part(s) of the Yanmar product covered by this
Warranty found to be defective in material and / or workmanship. Such repairs and / or replacements will be
made at a location designated by Yanmar at no cost to the purchaser for parts or labor.
What is Not Covered by this Warranty?

This Warranty does not cover parts affected by or damaged by any reason other than defective materials or
workmanship including, but not limited to, accident, misuse, abuse, Acts of God, neglect, improper
installation, improper maintenance, improper storage, the use of unsuitable attachments or parts, the use
of contaminated fuels, the use of fuels, oils, lubricants, or fluids other than those recommended in your
Yanmar Operation Manual, unauthorized alterations or modifications, ordinary wear and tear, and rust or
corrosion. This Warranty does not cover the cost of parts and / or labor required to perform normal /
scheduled maintenance on your Yanmar engine. This Warranty does not cover consumable parts such as,
but not limited to, filters, belts, hoses, fuel injector nozzles, lubricants and cleaning fluids. This Warranty
does not cover the cost of shipping the product to or from the Warranty repair facility.

YANMAR WARRANTIES
Yanmar Limited Warranty - Continued
Warranty Limitations:
The foregoing is Yanmars only obligation to you and your exclusive remedy for breach of warranty.
Failure to follow the requirements for submitting a claim under this Warranty may result in a waiver of all
claims for damages and other relief. In no event shall Yanmar or any authorized industrial engine
dealer or distributor be liable for incidental, special or consequential damages. Such consequential
damages may include, but not be limited to, loss of revenue, loan payments, cost of rental of substitute
equipment, insurance coverage, storage, lodging, transportation, fuel, mileage, and telephone costs. The
limitations in this Warranty apply regardless of whether your claims are based on breach of contract, tort
(including negligence and strict liability) or any other theory. Any action arising hereunder must be brought
within one (1) year after the cause of action accrues or it shall be barred. Some states and countries do not
allow certain limitations on warranties or for breach of warranties. This Warranty gives you specific legal
rights, and you may also have other rights which vary from state to state and country to country.
Limitations set forth in this paragraph shall not apply to the extent that they are prohibited by law.
Warranty Modifications:
Except as modified in writing and signed by the parties, this Warranty is and shall remain the complete and
exclusive agreement between the parties with respect to warranties, superseding all prior agreements,
written and oral, and all other communications between the parties relating to warranties. No person or
entity is authorized to give any other warranty or to assume any other obligation on behalf of
Yanmar, either orally or in writing.
Questions:
If you have any questions or concerns regarding this Warranty, please call or write to the nearest
authorized Yanmar industrial engine dealer or distributor or other authorized facility.
Retail Purchaser Registration
It is very important for the original retail purchaser to register the Yanmar product. Registration enables
Yanmar to provide the best support for your Yanmar product.
At the time of purchase, Yanmar highly recommends registering the retail purchasers information through
the website http://www.yanmar.co.jp as soon as possible.
If it is not possible to access the website, please contact the nearest authorized Yanmar industrial engine
dealer or distributor.

YANMAR WARRANTIES
EMISSION SYSTEM WARRANTY
YANMAR CO., LTD. LIMITED EMISSION CONTROL SYSTEM

WARRANTY - USA ONLY
Your Warranty Rights and Obligations:
California
The California Air Resources Board (CARB), the Environmental Protection Agency (EPA) and Yanmar Co.,
Ltd. hereafter referred to as Yanmar, are pleased to explain the emission control system warranty on
your industrial compression-ignition engine. In California, model year 2000 or later off-road compression-
ignition engines must be designed, built and equipped to meet the States stringent anti-smog standards. In
all states, 1998 and later non-road compression-ignition engines must be designed, built and equipped to
meet the United States EPA emissions standards. Yanmar warrants the emission control system on your
engine for the periods of time listed below provided there has been no abuse, neglect or improper
maintenance of your engine.
Your emission control system may include parts such as the fuel injection system and the air induction
system. Also included may be hoses, belts, connectors and other emission-related assemblies.
Where a warrantable condition exists, Yanmar will repair your non-road compression-ignition engine at no
charge to you including diagnosis, parts and labor.
Manufacturers Warranty Period:

The model year 1998 or later certified and labeled non-road compression-ignition engines are warranted
for the periods listed below. If any emission-related part on your engine is found to be defective during the
applicable warranty period, the part will be replaced by Yanmar.
Engine Type Warranty Period by Number of Years or Hours of Operation

The warranty period is five (5) years or 3,000 hours of use, whichever occurs first.
Constant speed engines rated at or above
In the absence of a device to measure the hours of use, the engine has a
50 hp SAE (37 kW)
warranty period of five (5) years.
Constant speed engines rated under 50 hp The warranty period is two (2) years or 3,000 hours of use, whichever occurs first.
SAE (37 kW) with rated speeds greater than In the absence of a device to measure the hours of use, the engine has a
or equal to 3,000 rpm warranty period of two (2) years.
The warranty period is five (5) years or 3,000 hours of use, whichever occurs first.
Engines rated at or above 26 hp SAE
In the absence of a device to measure the hours of use, the engine has a
(19 kW)
warranty period of five (5) years.
The warranty period is two (2) years or 3,000 hours of use, whichever occurs first.
Engines rated under 26 hp SAE (19 kW) In the absence of a device to measure the hours of use, the engine has a
warranty period of two (2) years.

YANMAR WARRANTIES
Limited Emission Control System Warranty - USA Only - Continued
Warranty Coverage:
This warranty is transferable to each subsequent purchaser for the duration of the warranty period. Repair
or replacement of any warranted part will be performed at an authorized Yanmar industrial engine dealer or
distributor.
Warranted parts not scheduled for replacement as required maintenance in the Operation Manual shall be
warranted for the warranty period. Warranted parts scheduled for replacement as required maintenance in
the operation manual are warranted for the period of time prior to the first scheduled replacement. Any part
repaired or replaced under warranty shall be warranted for the remaining warranty period.
During the warranty period, Yanmar is liable for damages to other engine components caused by the failure
of any warranted part during the warranty period.
Any replacement part which is functionally identical to the original equipment part in all respects may be
used in the maintenance or repair of your engine, and shall not reduce Yanmars warranty obligations. Add-
on or modified parts that are not exempted may not be used. The use of any non-exempted add-on or
modified parts shall be grounds for disallowing a warranty.
Warranted Parts:
This warranty covers engine components that are a part of the emission control system of the engine as
delivered by Yanmar to the original retail purchaser. Such components may include the following:
Fuel Injection System
Cold Start Enrichment System
Intake Manifold
Turbocharger Systems
Exhaust Manifold
Positive Crankcase Ventilation System
Hoses, belts, connectors and assemblies associated with emission control systems
Since emissions-related parts may vary slightly between models, certain models may not contain all of
these parts and other models may contain the functional equivalents.

YANMAR WARRANTIES
Limited Emission Control System Warranty - USA Only - Continued
Exclusions:
Failures other than those arising from defects in material and / or workmanship are not covered by this
warranty. The warranty does not extend to the following: malfunctions caused by abuse, misuse, improper
adjustment, modification, alteration, tampering, disconnection, improper or inadequate maintenance or use
of non-recommended fuels and lubricating oils; accident-caused damage, and replacement of expendable
items made in connection with scheduled maintenance. Yanmar disclaims any responsibility for incidental
or consequential damages such as loss of time, inconvenience, loss of use of equipment / engine or
commercial loss.
Owners Warranty Responsibilities:

As the engine owner, you are responsible for the performance of the required maintenance listed in
your owners manual. Yanmar recommends that you retain all documentation, including receipts, covering
maintenance on your non-road compression-ignition engine, but Yanmar cannot deny warranty solely for
the lack of receipts, or for your failure to ensure the performance of all scheduled maintenance.
Yanmar may deny your warranty coverage of your non-road compression-ignition engine if a part has failed
due to abuse, neglect, improper maintenance or unapproved modifications.
Your engine is designed to operate on diesel fuel only. Use of any other fuel may result in your engine no
longer operating in compliance with applicable emissions requirements.
You are responsible for initiating the warranty process. You must present your engine to a Yanmar dealer as
soon as a problem exists. The warranty repairs should be completed by the dealer as expeditiously as
possible. If you have any questions regarding your warranty rights and responsibilities, or would like
information on the nearest Yanmar dealer or authorized service center, you should contact Yanmar
America Corporation at 1-800-872-2867.

Section 3
SAFETY
Page
Safety Statements ........................................................................... 3-3
Safety Precautions .......................................................................... 3-4

SAFETY

SAFETY
SAFETY STATEMENTS
A CAUTION
Yanmar is concerned for your safety and your Caution (the word CAUTION is in black
machines condition. Safety statements are one of letters with a yellow rectangle behind it)
the primary ways to call your attention to the indicates a potentially hazardous
potential hazards associated with Yanmar TNV situation which, if not avoided, may
engine operation. Follow the precautions listed result in minor or moderate injury.
throughout the manual before operation, during
0000001en
operation and during periodic maintenance
procedures for your safety, the safety of others and
to protect the performance of your engine. Keep the CAUTION
labels from becoming dirty or torn and replace Caution without the safety alert symbol
them if they are lost or damaged. Also, if you need indicates a potentially hazardous
to replace a part that has a label attached to it, situation that can cause damage to the
make sure you order the new part and label at the machine, personal property and / or the
same time. environment or cause the machine to
operate improperly.
This safety alert symbol appears 0000001en
A
with most safety statements. It
means attention, become alert,
your safety is involved! Please read
and abide by the message that
follows the safety alert symbol.
A DANGER
Danger (the word DANGER is in white
letters with a red rectangle behind
it) - indicates an imminently hazardous
situation which, if not avoided, will
result in death or serious injury. Danger
is limited to the most extreme
situations.
0000001en
A WARNING
Warning (the word WARNING is in
black letters with an orange rectangle
behind it) indicates a potentially
hazardous situation which, if not
avoided, could result in death or serious
injury.
0000001en

SAFETY
SAFETY PRECAUTIONS
A DANGER
A DANGER
FIRE AND EXPLOSION HAZARD!

Diesel fuel is flammable and explosive
under certain conditions.
SCALD HAZARD!
When you remove any fuel system
NEVER remove the radiator cap if the
component to perform maintenance
engine is hot. Steam and hot engine
(such as changing the fuel filter) place
coolant will spurt out and seriously
an approved container under the
burn you. Allow the engine to cool
opening to catch the fuel.
down before you attempt to remove
the radiator cap. NEVER use a shop rag to catch the
fuel. Vapors from the rag are
Tighten the radiator cap securely after
flammable and explosive.
you check the radiator. Steam can
spurt out during engine operation if Wipe up any spills immediately.
the cap is loose. Wear eye protection. The fuel system
ALWAYS check the level of the engine is under pressure and fuel could spray
coolant by observing the reserve tank. out when you remove any fuel system
component.
Failure to comply will result in death or
serious injury. Failure to comply will result in death or
0000002en
serious injury.
0000009en
A DANGER
A DANGER
EXPLOSION HAZARD! FIRE AND EXPLOSION HAZARD!

Keep the area around the battery well- Only use the key switch to start the
ventilated. While the engine is running engine.
or the battery is charging, hydrogen
gas is produced which can be easily NEVER jump-start the engine. Sparks
ignited. caused by shorting the battery to the
starter terminals may cause a fire or
Keep sparks, open flame and any other explosion.
form of ignition away while the engine
is running or battery is charging. Failure to comply will result in death or
serious injury.
0000004en
serious injury.
0000003en

SAFETY
A DANGER A DANGER
FIRE AND EXPLOSION HAZARD! FIRE AND EXPLOSION HAZARD!

Diesel fuel is flammable and explosive Diesel fuel is flammable and explosive
under certain conditions. under certain conditions.
If the unit has an electric fuel pump, Only fill the fuel tank with diesel fuel.
when you prime the fuel system, turn Filling the fuel tank with gasoline may
the key switch to the ON position for result in a fire and will damage the
10 to 15 seconds to allow the electric engine.
fuel pump to prime the system.
NEVER refuel with the engine running.
If the unit has a mechanical fuel pump,
when you prime the fuel system, Wipe up all spills immediately.
operate the fuel priming lever of the Keep sparks, open flames or any other
mechanical fuel pump several times form of ignition (match, cigarette,
until the fuel filter cup is filled with static electric source) well away when
fuel. refueling.
Failure to comply will result in death or NEVER overfill the fuel tank.
serious injury. Fill the fuel tank. Store any containers
0000010en
containing fuel in a well-ventilated
area, away from any combustibles or
sources of ignition.
serious injury.
0000005en

SAFETY
A DANGER A DANGER

Diesel fuel is extremely flammable and CRUSH HAZARD!
explosive under certain conditions. When you need to transport an engine
for repair, have a helper assist you to
Be sure to place the diesel fuel
attach it to a hoist and load it on a
container on the ground when
truck.
transferring the diesel fuel from the
pump to the container. Hold the hose NEVER stand under a hoisted engine.
nozzle firmly against the side of the If the hoist mechanism fails, the
container while filling it. This prevents engine will fall on you, causing death
static electricity buildup which could or serious injury.
cause sparks and ignite fuel vapors. Failure to comply will result in death or
NEVER place diesel fuel or other serious injury.
flammable material such as oil, hay or 0000008en
dried grass close to the engine during

engine operation or shortly after
shutdown.
A DANGER
serious injury.
0000014en

Before you operate the engine, check
for fuel leaks. Replace rubberized fuel
hoses every two years or every 2000
hours of engine operation, whichever
comes first, even if the engine has
been out of service. Rubberized fuel
lines tend to dry out and become
brittle after two years or 2000 hours of
engine operation, whichever comes
first.
serious injury.
0000015en

SAFETY
A DANGER A DANGER

EXPLOSION HAZARD! Diesel fuel is flammable and explosive
NEVER check the remaining battery under certain conditions.
charge by shorting out the terminals.
NEVER use diesel fuel as a cleaning
This will result in a spark and may
agent.
cause an explosion or fire. Use a
hydrometer to check the remaining Failure to comply will result in death or
battery charge. serious injury.
0000012en
If the electrolyte is frozen, slowly warm
the battery before you recharge it.
serious injury.
0000007en
A DANGER

NEVER remove the fuel cap with the
engine running.
serious injury.
0000011en

SAFETY
A WARNING A WARNING
SEVER HAZARD! EXHAUST HAZARD!

Keep hands and other body parts NEVER operate the engine in an
away from moving / rotating parts enclosed area such as a garage,
such as the cooling fan, flywheel or tunnel, underground room, manhole or
PTO shaft. ships hold without proper ventilation.
Wear tight-fitting clothing and keep NEVER block windows, vents, or other
your hair short or tie it back while the means of ventilation if the engine is
engine is running. operating in an enclosed area. All
Remove all jewelry before you operate internal combustion engines create
or service the machine. carbon monoxide gas during
operation. Accumulation of this gas
NEVER start the engine in gear. within an enclosure could cause
Sudden movement of the engine and / illness or even death.
or machine could cause death or
serious personal injury. Make sure that all connections are
tightened to specifications after repair
NEVER operate the engine without the is made to the exhaust system.
guards in place.
Failure to comply could result in death
Before you start the engine make sure or serious injury.
that all bystanders are clear of the 0000003en
area.
Keep children and pets away while the
engine is operating.
A WARNING
Check before starting the engine that
any tools or shop rags used during
maintenance have been removed from
the area.
Failure to comply could result in death ALCOHOL AND DRUG HAZARD!
or serious injury.
0000002en
NEVER operate the engine while you
are under the influence of alcohol or
drugs.
NEVER operate the engine when you
are feeling ill.
or serious injury.
0000004en

SAFETY
A WARNING A WARNING
BURN HAZARD!
EXPOSURE HAZARD! If you must drain the engine oil while it
is still hot, stay clear of the hot engine
Wear personal protective equipment
oil to avoid being burned.
such as gloves, work shoes, eye and
hearing protection as required by the ALWAYS wear eye protection.
task at hand. Failure to comply could result in death
NEVER wear jewelry, unbuttoned or serious injury.
cuffs, ties or loose-fitting clothing 0000011en
when you are working near moving /

rotating parts such as the cooling fan,
flywheel or PTO shaft.
A WARNING
ALWAYS tie back long hair when you
are working near moving / rotating
parts such as a cooling fan, flywheel,
or PTO shaft.
NEVER operate the engine while BURN HAZARD!
wearing a headset to listen to music or Batteries contain sulfuric acid. NEVER
radio because it will be difficult to hear allow battery fluid to come in contact
the alert signals. with clothing, skin or eyes. Severe
Failure to comply could result in death burns could result. ALWAYS wear
or serious injury. safety goggles and protective clothing
0000005en
when servicing the battery. If battery
fluid contacts the eyes and / or skin,
immediately flush the affected area
with a large amount of clean water and
obtain prompt medical treatment.
or serious injury.
0000007en

SAFETY
A WARNING A WARNING
HIGH-PRESSURE HAZARD! ENTANGLEMENT HAZARD!

Avoid skin contact with the Stop the engine before you begin to
high-pressure diesel fuel spray caused service it.
by a fuel system leak such as a broken
fuel injection line. High-pressure fuel NEVER leave the key in the key switch
can penetrate your skin and result in when you are servicing the engine.
serious injury. If you are exposed to Someone may accidentally start the
high-pressure fuel spray, obtain engine and not realize you are
prompt medical treatment. servicing it. This could result in a
serious injury.
NEVER check for a fuel leak with your
hands. ALWAYS use a piece of wood If you must service the engine while it
or cardboard. Have your authorized is operating, remove all jewelry, tie
Yanmar industrial engine dealer or back long hair, and keep your hands,
distributor repair the damage. other body parts and clothing away
from moving / rotating parts.
or serious injury. Failure to comply could result in death
0000008en
or serious injury.
0000010en
A WARNING
A WARNING
SHOCK HAZARD! BURN HAZARD!

Turn off the battery switch (if Wait until the engine cools before you
equipped) or disconnect the negative drain the engine coolant. Hot engine
battery cable before servicing the coolant may splash and burn you.
electrical system.
Check the electrical harnesses for or serious injury.
cracks, abrasions, and damaged or 0000016en
corroded connectors. ALWAYS keep
the connectors and terminals clean.
or serious injury.
0000009en

SAFETY
A WARNING A WARNING
SUDDEN MOVEMENT HAZARD!
Engaging the transmission or PTO at
an elevated engine speed could result
in unexpected movement of the
equipment.
FUME / BURN HAZARD!
Failure to comply could result in death Always read and follow safety related
or serious injury. precautions found on containers of
0000006en
hazardous substances like parts
cleaners, primers, sealants and
A WARNING sealant removers.
or serious injury.
0000014en
BURN HAZARD! A WARNING

Never apply over 40 psi (2.8 kgf/cm) to
Keep your hands and other body parts
the waste gate actuator.
away from hot engine surfaces such
0000026en
as the muffler, exhaust pipe,
turbocharger (if equipped) and engine
block during operation and shortly A WARNING
after you shut the engine down. These Never inject fuel toward you. Since the
surfaces are extremely hot while the fuel is injected at high pressure from
engine is operating and could the nozzle, it may penetrate the skin,
seriously burn you. resulting in injury.
Failure to comply could result in death Never inject fuel toward a fire source.
or serious injury. Atomized fuel is highly flammable and
0000015en may cause a fire or burn skin.
0000028en
A WARNING
To prevent possible eye injury, always

wear SAFETY GLASSES while servicing
the engine.
0000013en

SAFETY
A CAUTION A CAUTION
COOLANT HAZARD! PINCH HAZARD!

Wear eye protection and rubber gloves Carefully rotate the alternator toward the
when you handle long life or extended cylinder block while loosening the
life engine coolant. If contact with the V-belt. Failure to comply may result in
eyes or skin should occur, flush eyes minor or moderate injury.
and wash immediately with clean 0000014en
water.
Failure to comply may result in minor
or moderate injury.
A CAUTION
If any oil pump component clearance
0000005en
exceeds its limit, the oil pump must be
replaced as an assembly.
A CAUTION 0000015en
CAUTION
Only use diesel fuels recommended by
Yanmar for the best engine
performance, to prevent engine
damage and to comply with EPA / ARB
FLYING OBJECT HAZARD! warranty requirements.
ALWAYS wear eye protection when Only use clean diesel fuel.
servicing the engine and when using
compressed air or high-pressure NEVER remove the primary strainer (if
water. Dust, flying debris, compressed equipped) from the fuel tank filler port.
air, pressurized water or steam may If removed, dirt and debris could get
injure your eyes. into the fuel system causing it to clog.
0000004en
or moderate injury.
0000003en
CAUTION
NEVER attempt to adjust the low or high
A CAUTION idle speed limit screw. This may impair
the safety and performance of the
Be sure to secure the engine solidly to machine and shorten its life. If
prevent injury or damage to parts due to adjustment is ever required, contact
the engine falling during work on the your authorized Yanmar industrial
engine. engine dealer or distributor.
0000009en
0000045en

SAFETY
CAUTION CAUTION
If any problem is noted during the visual Observe the following environmental
check, the necessary corrective action operating conditions to maintain engine
should be taken before you operate the performance and avoid premature
engine. engine wear:
0000021en
Avoid operating in extremely dusty
conditions.
CAUTION Avoid operating in the presence of
NEVER hold the key in the START chemical gases or fumes.
position for longer than 15 seconds or Avoid operating in a corrosive
the starter motor will overheat. atmosphere such as salt water spray.
0000007en
NEVER install the engine in a
floodplain unless proper precautions
CAUTION are taken to avoid being subject to a
Make sure the engine is installed on a flood.
level surface. If a continuously running NEVER expose the engine to the rain.
engine is installed at an angle greater 0000003en
than 30 (in any direction) or if an engine
runs for short periods of time (less than
three minutes) at an angle greater than CAUTION
35 (in any direction) engine oil may Observe the following environmental
enter the combustion chamber causing operating conditions to maintain engine
excessive engine speed and white performance and avoid premature
exhaust smoke. This may cause serious engine wear:
engine damage.
The standard range of ambient
0000010en
temperatures for the normal operation
of Yanmar engines is from +5F (-15C)
CAUTION to +113F (+45C).
Make sure the engine is installed on a If the ambient temperature exceeds
level surface. If a continuously running +113F (+45C) the engine may
engine is installed at an angle greater overheat and cause the engine oil to
than 30 (in any direction) or if an engine break down.
runs for short periods of time (less than If the ambient temperature is below
three minutes) at an angle greater than +5F (-15C) the engine will be hard to
35 (in any direction) engine oil may start and the engine oil may not flow
enter the combustion chamber causing easily.
excessive engine speed and white
exhaust smoke. This may cause serious Contact your authorized Yanmar
engine damage. industrial engine dealer or distributor
0000010en
if the engine will be operated outside
of this standard temperature range.
0000065en

SAFETY
CAUTION CAUTION
The illustrations and descriptions of Only use the engine coolant specified.
optional equipment in this manual, such Other engine coolants may affect
as the operators console, are for a warranty coverage, cause an internal
typical engine installation. Refer to the buildup of rust and scale and / or
documentation supplied by the optional shorten engine life.
equipment manufacturer for specific Prevent dirt and debris from
operation and maintenance instructions. contaminating the engine coolant.
0000018en
Carefully clean the radiator cap and
the surrounding area before you
CAUTION remove the cap.
If any indicator illuminates during NEVER mix different types of engine
engine operation, stop the engine coolants. This may adversely affect the
immediately. Determine the cause and properties of the engine coolant.
repair the problem before you continue 0000006en
to operate the engine.

0000029en
CAUTION
NEVER overfill the engine with engine
CAUTION oil.
Only use the engine oil specified. ALWAYS keep the oil level between the
Other engine oils may affect warranty upper and lower lines on the oil cap /
coverage, cause internal engine dipstick.
components to seize and / or shorten
0000015en
engine life.
Prevent dirt and debris from
CAUTION
contaminating the engine oil. Carefully
clean the oil cap / dipstick and the For maximum engine life, Yanmar
surrounding area before you remove recommends that when shutting the
the cap. engine down, you allow the engine to
idle, without load, for five minutes. This
NEVER mix different types of engine will allow the engine components that
oil. This may adversely affect the operate at high temperatures, such as
lubricating properties of the engine oil. the turbocharger (if equipped) and
NEVER overfill. Overfilling may result exhaust system, to cool slightly before
in white exhaust smoke, engine the engine itself is shut down.
overspeed or internal damage. 0000008en
0000005en
CAUTION
NEVER use an engine starting aid such
as ether. Engine damage will result.
0000009en

SAFETY
CAUTION CAUTION
New Engine Break-in:
On the initial engine start-up, allow the
engine to idle for approximately 15
minutes while you check for proper
engine oil pressure, diesel fuel leaks,
ALWAYS be environmentally engine oil leaks, coolant leaks, and for
responsible. proper operation of the indicators
Follow the guidelines of the EPA or and / or gauges.
other governmental agencies for the During the first hour of operation, vary
proper disposal of hazardous the engine speed and the load on the
materials such as engine oil, diesel engine. Short periods of maximum
fuel and engine coolant. Consult the engine speed and load are desirable.
local authorities or reclamation facility. Avoid prolonged operation at
NEVER dispose of hazardous minimum or maximum engine speeds
materials irresponsibly by dumping and loads for the next four to five
them into a sewer, on the ground, or hours.
into ground water or waterways. During the break-in period, carefully
Failure to follow these procedures may observe the engine oil pressure and
seriously harm the environment. engine temperature.
0000013en During the break-in period, check the
engine oil and coolant levels
CAUTION frequently.
0000011en
NEVER engage the starter motor while
the engine is running. This may damage
the starter motor pinion and / or ring CAUTION
gear. NEVER attempt to modify the engines
0000012en design or safety features such as
defeating the engine speed limit
control or the fuel injection quantity
control.
Failure to comply may impair the
engines safety and performance
characteristics and shorten the
engines life. Any alterations to this
engine may affect the warranty
coverage of your engine. See Yanmar
Limited Warranty in Warranty Section.
0000044enTNVDISM

SAFETY
CAUTION CAUTION
Protect the air cleaner, turbocharger (if If any indicator fails to illuminate when
equipped) and electric components the key switch is in the ON position, see
from damage when you use steam or your authorized Yanmar industrial
high-pressure water to clean the engine. engine dealer or distributor for service
0000014en before operating the engine.
0000028en
CAUTION
NEVER use high-pressure water or CAUTION
compressed air at greater than 28 psi Establish a periodic maintenance plan
(193 kPa; 19 686 mm Aq) or a wire brush according to the engine application and
to clean the radiator fins. Radiator fins make sure you perform the required
damage easily. periodic maintenance at the intervals
0000016en indicated. Failure to follow these
guidelines will impair the engines safety
and performance characteristics,
CAUTION shorten the engines life and may affect
NEVER attempt to adjust the low or high the warranty coverage on your engine.
idle speed limit screw. This may impair
See Yanmar Limited Warranty in
the safety and performance of the
Warranty Section.
machine and shorten its life. If the idle
speed limit screws require adjustment, Consult your authorized Yanmar dealer
see your authorized Yanmar industrial or distributor for assistance when
engine dealer or distributor. checking items marked with a z.
0000017en 0000024enTNVDISM
CAUTION CAUTION
The tightening torque in the Standard If the fuel filter / water separator is
Torque Chart (see General Service positioned higher than the fuel level in
Information section) should be applied the fuel tank, water may not drip out
only to the bolts with a 7 head. (JIS when the fuel filter / water separator
strength classification: 7T) drain cock is opened. If this happens,
turn the air vent screw on the top of the
Apply 60% torque to bolts fuel filter / water separator 2-3 turns
that are not listed. counterclockwise.
Apply 80% torque when Be sure to tighten the air vent screw
tightened to aluminum alloy. after the water has drained out.
0000023enTNVDISM 0000025en

SAFETY
CAUTION CAUTION
When the engine is operated in dusty Do not loosen or remove the four bolts
conditions, clean the air cleaner retaining the fuel injection pump drive
element more frequently. gear to the fuel injection pump hub. Do
NEVER operate the engine with the air not disassemble the fuel injection pump
cleaner element(s) removed. This may drive gear from the hub. Correct fuel
allow foreign material to enter the injection timing will be very difficult or
engine and damage it. impossible to achieve.
0000031en
0000026en
CAUTION CAUTION
The maximum air intake restriction, in The starter motor can be damaged if
terms of differential pressure operated continuously longer than
measurement, must not exceed 0.90 psi 10 seconds while performing the
(6.23 kPa; 635 mmAq). Clean or replace no-load test.
the air cleaner element if the air intake 0000034en
restriction exceeds the above

mentioned value. CAUTION
0000046en
Do not short-circuit the charging system
between alternator terminals IG and L.
CAUTION Damage to the alternator will result.
It is important to perform daily checks. 0000035en
Periodic maintenance prevents

unexpected downtime, reduces the CAUTION
number of accidents due to poor Do not connect a load between
machine performance and helps extend alternator terminals L and E. Damage to
the life of the engine. the alternator will result.
0000060en 0000036en
CAUTION CAUTION
If the oil pump must be replaced, replace Do not remove the positive (+) battery
it as an assembly only. Do not replace cable from alternator terminal B while
individual components. the engine is operating. Damage to the
0000030en alternator will result.
0000037en
CAUTION
Do not turn the battery switch OFF while
the engine is operating. Damage to the
alternator will result.
0000038en

SAFETY
CAUTION CAUTION
Do not operate the engine if the Do not use a high-pressure wash
alternator is producing unusual sounds. directly on the alternator. Water will
Damage to the alternator will result. damage the alternator and result in
0000039en inadequate charging.
0000049en
CAUTION
If the engine coolant pump must be CAUTION
replaced, replace the engine coolant Do not reverse the positive (+) and
pump as an assembly only. Do not negative (-) ends of the battery cable.
attempt to repair the engine coolant The alternator diode and stator coil will
pump or replace individual components. be damaged.
0000041en 0000050en
CAUTION CAUTION
Use a new special O-ring between the When the battery indicator goes out, it
engine coolant pump and the joint. Be should not come on again. The battery
sure to use the special O-ring for each indicator only comes on during
engine model. Although the O-ring operation if the alternator fails or if the
dimensions are the same as a V-belt breaks. However, if an LED is
commercially available O-ring, the used in the battery indicator, the LED
material is different. will shine faintly during normal
0000042en operation.
0000051en
CAUTION
Remove or install the high-pressure fuel CAUTION
injection lines as an assembly whenever Using a non-specified V-belt will cause
possible. Disassembling the inadequate charging and shorten the
high-pressure fuel injection lines from belt life. Use the specified belt.
the retainers or bending any of the fuel 0000052en
lines will make it difficult to reinstall the
fuel lines.
CAUTION
0000047en
Agricultural or other chemicals,
especially those with a high sulfur
CAUTION content, can adhere to the IC regulator.
After marking the position of the pump This will corrode the conductor and
drive gear, do not rotate the engine result in battery over-charging (boiling)
crankshaft. Rotating the crankshaft will and charging malfunctions. Consult
cause the fuel injection pump to become Yanmar before using the equipment in
misaligned. such an environment or the warranty is
0000048en voided.
0000053en

SAFETY
CAUTION CAUTION
Make sure that the combined total Removing the battery cables or the
resistance of the battery cable in both battery while the engine is operating
directions between the starter motor may cause damage to the current limiter
and the battery is within the value depending on the electrical equipment
indicated on the wiring diagram. The being used. This situation could cause
starter motor will malfunction or break loss of control of output voltage. The
down if the resistance is higher than the continuous high voltage of 23-24 volts
specified value. (for 5000 rpm dynamo) will damage the
0000054en current limiter and other electrical
equipment.
CAUTION 0000058en
The starter motor is water-proofed

according to JIS D 0203, R2 which CAUTION
protects the motor from rain or general Reversing the battery cable connections
cleaning. Do not use high-pressure at the battery or on the engine will
wash or submerse the starter motor in destroy the SCR diode in the current
water. limiter. This will cause the charging
0000055en system to malfunction and may cause
damage to the electrical harnesses.
CAUTION 0000059en
Use a specialized battery charger to

recharge a battery with a voltage of CAUTION
8 volts or less. Booster starting a battery Avoid damage to the turbocharger or the
with a voltage of 8 volts or less will engine. Do not spray blower wash fluid
generate an abnormally high voltage or water too quickly.
and destroy electrical equipment. Use short strokes from a spray bottle to
0000056en
inject blower wash fluid or water into the
turbocharger.
CAUTION Spraying too much wash fluid or water,
Make sure that the combined total or spraying too quickly will damage the
resistance of the battery cable in both turbocharger.
directions between the starter motor 0000063en
and the battery is within the value

indicated in the Battery Cable
CAUTION
Resistance chart in the Electric Wiring
Section of this manual. The starter Do not allow any material to fall into the
motor will malfunction and fail if the oil lines or the oil inlet and outlet ports
resistance is higher than the specified of the turbocharger.
value. 0000064en
0000057en

SAFETY
CAUTION CAUTION
If the waste valve does not meet Do not rotate the crankshaft with the
specifications, replace the turbocharger injection pump removed.
or have it repaired by a qualified repair 0000083en
facility.
0000078en
CAUTION
Keep the piston pin parts, piston
CAUTION assemblies, and connecting rod
NEVER attempt to modify the engines assemblies together to be returned to
design or safety features such as the same position during the
defeating the engine speed limit reassembly process. Label the parts
control or the diesel fuel injection using an appropriate method.
quantity control. 0000088en
Modifications may impair the engines

safety and performance CAUTION
characteristics and shorten the
Do not allow the honing tool to operate
engines life. Any alterations to this
in one position for any length of time.
engine may void its warranty. Be sure
Damage to the cylinder wall will occur.
to use Yanmar genuine replacement
Keep the tool in constant up-and-down
parts.
motion.
0000079en
0000090en
CAUTION CAUTION
Identify all parts and their location using
Any part which is found defective as a
an appropriate method. It is important
result of inspection or any part whose
that all parts are returned to the same
measured value does not satisfy the
position during the reassembly process.
standard or limit must be replaced.
0000080en
0000119en
CAUTION CAUTION
Each pressure adjusting shim removed
Any part determined to not meet the
or added changes the pressure
service standard or limit before the next
threshold by approximately 275 psi
service, as determined from the state of
(1.9 MPa, 19 kgf/cm2). Adding adjusting
current rate of wear, should be replaced
shims increases the threshold pressure.
even though the part currently meets the
Removing adjusting shims reduces the
service standard limit.
pressure threshold.
0000120en
0000081en

SAFETY
CAUTION
NEVER remove or attempt to remove
the tamper-proof devices from the
full-load fuel adjusting screw or the
high-speed throttle limit screw on the
fuel injection pump and governor
assembly. These adjustments have
been made at the factory to meet all
applicable emissions regulations and
then sealed.
NEVER attempt to make any
adjustments to these sealed
adjustment screws. If adjustments are
required, they can be made only by a
qualified fuel injection shop that will
ensure the injection pump continues
to meet all applicable emissions
regulations and then replace the
tamper-proof seals.
Tampering with or removing these
devices may void the Yanmar Limited
Warranty.
0000146en
CAUTION
Never use a steel wire brush to clean
fuel injectors. Damage to the nozzle and
other components is likely to result.
0000172en
CAUTION
Allow the engine to warm-up for at least
five minutes and the idle speed of the
engine to return to normal before
engaging the transmission or any PTOs.
Engaging the transmission or PTO at an
elevated engine speed could result in an
unexpected movement of the
equipment.
0000159en

SAFETY

Section 4
GENERAL SERVICE
INFORMATION
Page
Component Identification................................................................. 4-3
Location of Labels ........................................................................... 4-4
Engine Nameplate (Typical) ...................................................... 4-4
Emission Control Regulations ......................................................... 4-5
EPA / ARB Regulations - USA Only .......................................... 4-5
Emission Control Labels.................................................................. 4-5
The 97/68/EC Directive Certified Engines....................................... 4-6
Engine Family.................................................................................. 4-6
Function of Major Engine Components ........................................... 4-7
Function of Cooling System Components ....................................... 4-8
Diesel Fuel ...................................................................................... 4-9
Diesel Fuel Specifications ......................................................... 4-9
Filling The Fuel Tank ............................................................... 4-10
Priming the Fuel System ......................................................... 4-12
Engine Oil...................................................................................... 4-12
Engine Oil Specifications ........................................................ 4-12
Engine Oil Viscosity................................................................. 4-13
Checking Engine Oil ................................................................ 4-13
Adding Engine Oil.................................................................... 4-14
Engine Oil Capacity (Typical) .................................................. 4-14
Engine Coolant.............................................................................. 4-15
Engine Coolant Specifications................................................. 4-16
Filling Radiator with Engine Coolant........................................ 4-16
Engine Coolant Capacity (Typical) .......................................... 4-17

GENERAL SERVICE INFORMATION
Specifications ................................................................................. 4-18
Description of Model Number................................................... 4-18
Engine Speed Specifications.................................................... 4-18
Engine General Specifications ................................................. 4-19
Principal Engine Specifications ...................................................... 4-20
3TNV82A.................................................................................. 4-20
3TNV84 .................................................................................... 4-22
3TNV84T .................................................................................. 4-24
3TNV88 .................................................................................... 4-26
4TNV84 .................................................................................... 4-28
4TNV84T .................................................................................. 4-30
4TNV88 .................................................................................... 4-32
4TNV94L .................................................................................. 4-34
4TNV98 .................................................................................... 4-36
4TNV98T .................................................................................. 4-38
4TNV106 .................................................................................. 4-40
4TNV106T ................................................................................ 4-42
Engine Service Standards.............................................................. 4-44
Tightening Torques for Standard Bolts and Nuts ........................... 4-45
Abbreviations and Symbols............................................................ 4-47
Abbreviations............................................................................ 4-47
Symbols.................................................................................... 4-47
Unit Conversions ............................................................................ 4-48
Unit Prefixes ............................................................................. 4-48
Units of Length ......................................................................... 4-48
Units of Volume ........................................................................ 4-48
Units of Mass............................................................................ 4-48
Units of Force ........................................................................... 4-48
Units of Torque......................................................................... 4-48
Units of Pressure...................................................................... 4-48
Units of Power .......................................................................... 4-48
Units of Temperature................................................................ 4-48

COMPONENT IDENTIFICATION
Figure 4-2 shows where the major engine components are located.
(1) (2) (20)

(19)
(3)
(18)
(4)
(17)
(16)
(15)
(5) (21)
(14)
(25)
(6)
(13)
(24)
(22)
(23)
0000015B
(12) (11) (10) (9) (8) (7)
1 Lifting Eye (Flywheel End) 14 Governor Lever
2 Turbocharger* 15 Intake Manifold
3 Lifting Eye (Engine Cooling Fan End) 16 Fuel Filter
4 Engine Coolant Pump 17 Fuel Inlet
5 Engine Cooling Fan 18 Fuel Return to Fuel Tank
6 Crankshaft V-Pulley 19 Top Filler Port (Engine Oil)
7 V-Belt 20 Rocker Arm Cover
8 Side Filler Port (Engine Oil) 21 Air Intake Port (From Air Cleaner)
9 Drain Plug (Engine Oil)** 22 Flywheel
10 Fuel Injection Pump 23 Starter Motor
11 Engine Oil Cooler*** 24 Exhaust Manifold
12 Engine Oil Filter 25 Alternator
13 Dipstick (Engine Oil)
Figure 4-1
* Only applies to 3TNV84T, 4TNV84T, 4TNV98T, 4TNV106T

** The engine oil drain plug location may vary based on oil pan options.
*** Not standard on all direct injection models

LOCATION OF LABELS
Figure 4-2 shows the location of regulatory and safety labels on Yanmar TNV series engines.
(1) (4) (3)

(4) (2)
0000019A
Figure 4-2
The typical location of the emission control Engine Nameplate (Typical)

information label is shown for 4TNV84, 4TNV84T
and 4TNV88 engines (Figure 4-2, (1)).
The typical location of the emission control 3TNV82A - DSA
information label is affixed to the exhaust side of kW
the rocker arm cover for 3TNV82A, 3TNV84, 3000
3TNV84T and 3TNV88 engines (Figure 4-2, (2)).
1.33 l
The typical location of the emission control 06532
information label is affixed to the exhaust side of
the rocker arm cover for 4TNV94L, 4TNV98,
4TNV98T, 4TNV106 and 4TNV106T engines
(Figure 4-2, (3)).
The typical location of the engine nameplate is
shown for various Yanmar TNV engines
(Figure 4-2, (4)).
0002132

EMISSION CONTROL EMISSION CONTROL LABELS

REGULATIONS Since emission control regulations are being issued
on a global basis, it is necessary to identify which
EPA / ARB Regulations - USA Only regulations a particular engine complies with. We
have listed several different types of labels you
Yanmar TNV engines meet Environmental
might find on your engine.
Protection Agency (EPA) (U. S. Federal) emission
control standards as well as the California Air EPA / ARB Labels
Resources Board (ARB, California) regulations.
Only engines that conform to ARB regulations can
be sold in the State of California.
Refer to the specific EPA / ARB installation " "
(page 5-16) and maintenance (page 5-16) in the
Periodic Maintenance Schedule section of this
manual. Also refer to the Emission System
Warranty on page 2-6.
(EPA) Less Than 50 HP SAE (37kW)
" US-2D " FUEL
(EPA) Greater Than or Equal To 50 HP SAE (37kW)
(EPA & ARB)

THE 97/68/EC DIRECTIVE

CERTIFIED ENGINES 97/68/EC DIRECTIVE
The engines described in this manual have been

certified by the 97/68/EC Directive.
To identify the engines that meet this certification,
the 97/68/EC emission control label is affixed on
(97/68/EC)
the engines.
ENGINE FAMILY
The EPA / ARB labels and the 97/68/EC label all have an Engine Family field. The following is an
explanation of the Engine Family designation:
5 YDX L 1.33 M 3 N
Method of air aspiration
Number of cylinders
Engine speed specifications
Displacement (liter)
Non-road / Off-road engine
Yanmar Diesel
*2005 Model Year
5*: 2005
6: 2006
7: 2007

FUNCTION OF MAJOR ENGINE COMPONENTS

Components Functions
The air cleaner prevents airborne contaminants from entering the engine. Since
the air cleaner is application specific, it must be carefully selected by an application
Air Cleaner engineer. It is not part of the basic engine package as shipped from the Yanmar
factory. Periodic replacement of the air cleaner filter element is necessary. See the
Periodic Maintenance Schedule on page 5-17 for the replacement frequency.
The alternator is driven by a V-belt which is powered by the crankshaft V-pulley.
Alternator The alternator supplies electricity to the engine systems and charges the battery
while the engine is running.
The engine oil dipstick is used to determine the amount of engine oil in the
Dipstick (Engine Oil)
crankcase.
The electric fuel pump makes sure there is a constant supply of diesel fuel to the
fuel injection pump. The electric fuel pump is electro-magnetic and runs on
Electric Fuel Pump
12 VDC. It must be installed on every application. This is standard equipment with
every engine.
The engine oil filter removes contaminants and sediments from the engine oil.
Engine Oil Filter Periodic replacement of the engine oil filter is necessary. See the Periodic
Maintenance Schedule on page 5-17 for the replacement frequency.
The engine oil cooler helps to keep the engine oil cool. Engine coolant from the
Engine Oil Cooler
cooling system is circulated through an adapter at the base of the engine oil filter
(If Equipped)
assembly and then returned to the cylinder block.
The fuel filter removes contaminants and sediments from the diesel fuel. Periodic
replacement of the fuel filter is necessary. See the Periodic Maintenance Schedule
Fuel Filter
on page 5-17 for the replacement frequency. Please note that the word diesel
is implied throughout this manual when the word fuel is used.
The fuel filter / water separator removes contaminants, sediments and water from
the diesel fuel going to the fuel filter. This is a required component of the fuel
Fuel Filter / Water Separator system. This is standard equipment with every engine. The separator is installed
between the fuel tank and the electric fuel pump. Periodically drain the water from
the fuel filter / water separator.
The fuel tank is a reservoir that holds diesel fuel. When the fuel leaves the fuel tank
it goes to the fuel filter / water separator. Next the fuel is pumped to the fuel filter
by the electric fuel pump. Then the fuel goes to the fuel injection pump. Since the
Fuel Tank fuel is used to keep the fuel injection pump cool and lubricated, more fuel than
necessary enters the injection pump. When the injection pump pressure reaches
a preset value, a relief valve allows the excess fuel to be returned back to the fuel
tank. The fuel tank is a required engine component.
You can fill the crankcase with engine oil from either the side or the top filler port
Side and Top Filler Port (Engine Oil)
depending upon which one is most convenient.
The starter motor is powered by the battery. When you turn the key switch in the
Starter Motor operators console to the START position, the starter motor engages with the ring
gear installed on the flywheel and starts the flywheel in motion.
Turbocharger
The turbocharger pressurizes the air coming into the engine. It is driven by a
(Only applies to 3TNV84T, 4TNV84T,
turbine that is energized by exhaust gases.
4TNV98T, 4TNV106T)

FUNCTION OF COOLING SYSTEM COMPONENTS

Components Functions
The TNV engine is liquid-cooled by means of a cooling system. The cooling system
consists of a radiator, radiator cap, engine cooling fan, engine coolant pump,
thermostat, and reserve tank. Note that all cooling system components are
Cooling System required for proper engine operation. Since some of the components are
application specific, they must be carefully selected by an application
engineer. The application specific items are not part of the basic engine
package as shipped from the Yanmar factory.
The engine cooling fan is driven by a V-belt which is powered by the crankshaft
Engine Cooling Fan V-pulley. The purpose of the engine cooling fan is to circulate air through the
radiator.
The engine coolant pump circulates the engine coolant through the cylinder block
Engine Coolant Pump
and the cylinder head and returns the engine coolant to the radiator.
The radiator acts as a heat exchanger. As the engine coolant circulates through
the cylinder block it absorbs heat. The heat in the engine coolant is dissipated in
Radiator
the radiator. As the engine cooling fan circulates air through the radiator, the heat
is transferred to the air.
The radiator cap controls the cooling system pressure. The cooling system is
pressurized to raise the boiling point of the engine coolant. As the engine coolant
temperature rises, the system pressure and the coolant volume increases. When
the pressure reaches a preset value, the release valve in the radiator cap opens
Radiator Cap
and the excess engine coolant flows into the reserve tank. As the engine coolant
temperature is reduced, the system pressure and volume is reduced and the
vacuum valve in the radiator cap opens allowing the engine coolant to flow from
the reserve tank back into the radiator.
The reserve tank contains the overflow of engine coolant from the radiator. If you
Reserve Tank need to add engine coolant to the system, add it to the reserve tank; not the
radiator.
A thermostat is placed in the cooling system to prevent the engine coolant from
circulating into the radiator until the engine coolant temperature reaches a preset
temperature. When the engine is cold, no engine coolant flows through the
Thermostat radiator. Once the engine reaches its operating temperature, the thermostat opens
and allows the engine coolant to flow through the radiator. By letting the engine
warm up as quickly as possible, the thermostat reduces engine wear, deposits and
emissions.

DIESEL FUEL The ash content must not exceed 0.01% by

volume.
Diesel Fuel Specifications The carbon residue content must not exceed
Diesel fuel should comply with the following 0.35% by volume. Less than 0.1% is preferred.
specifications. The table lists several worldwide
The total aromatics content should not exceed
specifications for diesel fuels.
35% by volume. Less than 30% is preferred.
Diesel Fuel Specification Location The PAH (polycyclic aromatic hydrocarbons)
No. 2-D, No. 1-D, content should be below 10% by volume.
USA
ASTM D975-94 The metal content of Na, Mg, Si, and Al should be
European equal to or lower than 1 mass ppm. (Test analysis
EN590:96
Union method JPI-5S-44-95)
ISO 8217 DMX International Lubricity: The wear mark of WS1.4 should be
United Max. 0.018 in (460 m) at HFRR test.
BS 2869-A1 or A2
Kingdom
Bio-Diesel Fuels
JIS K2204 Grade No. 2 Japan
In Europe and in the United States, as well as some
KSM-2610 Korea
other countries, non-mineral oil based fuel
GB252 China resources such as RME (Rapeseed Methyl Ester)
and SOME (Soybean Methyl Ester), collectively
Additional Technical Fuel Requirements known as FAME (Fatty Acid Methyl Esters), are
The fuel cetane number should be equal to 45 or being used as extenders for mineral oil derived
higher. diesel fuels.
The sulfur content must not exceed 0.5% by Yanmar approves the use of bio-diesel fuels that do
volume. Less than 0.05% is preferred. not exceed a blend of 5% (by volume) of FAME with
95% (by volume) of approved mineral oil derived
Bio-Diesel fuels. See Bio-Diesel Fuels on diesel fuel. Such bio-diesel fuels are known in the
page 4-9. marketplace as B5 diesel fuels.
NEVER mix kerosene, used engine oil, or These B5 diesel fuels must meet certain
residual fuels with the diesel fuel. requirements.
The water and sediment in the fuel should not 1. The bio-fuels must meet the minimum
exceed 0.05% by volume. specifications for the country in which they are
used.
Keep the fuel tank and fuel-handling equipment
In Europe, bio-diesel fuels must comply with
clean at all times.
the European Standard EN14214.
Poor quality fuel can reduce engine performance In the United States, bio-diesel fuels must
and / or cause engine damage. comply with the American Standard
Fuel additives are not recommended. Some fuel ASTM D-6751.
additives may cause poor engine performance. 2. Bio-fuels should be purchased only from
Consult your Yanmar representative for more recognized and authorized diesel fuel suppliers.
information.

Precautions and concerns regarding the use of Filling The Fuel Tank
bio-fuels:
1. Free methanol in FAME may result in corrosion A DANGER
of aluminum and zinc FIE components.
2. Free water in FAME may result in plugging of
fuel filters and increased bacterial growth.
3. High viscosity at low temperatures may result in
fuel delivery problems, injection pump seizures, FIRE AND EXPLOSION HAZARD!
and poor injection nozzle spray atomization.
4. FAME may have adverse effects on some under certain conditions.
elastomers (seal materials) and may result in
fuel leakage and dilution of the engine Only fill the fuel tank with diesel fuel.
lubricating oil. Filling the fuel tank with gasoline may
result in a fire and will damage the
5. Even bio-diesel fuels that comply with a suitable
engine.
standard as delivered, will require additional
care and attention to maintain the quality of the NEVER refuel with the engine running.
fuel in the equipment or other fuel tanks. It is Wipe up all spills immediately.
important to maintain a supply of clean, fresh
fuel. Regular flushing of the fuel system, and / Keep sparks, open flames or any other
or fuel storage containers, may be necessary. form of ignition (match, cigarette,
static electric source) well away when
6. The use of bio-diesel fuels that do not comply refueling.
with the standards as agreed to by the diesel
engine manufacturers and the diesel fuel NEVER overfill the fuel tank.
injection equipment manufacturers, or bio- Fill the fuel tank. Store any containers
diesel fuels that have degraded as per the containing fuel in a well-ventilated
precautions and concerns above, may affect area, away from any combustibles or
the warranty coverage of your engine. See sources of ignition.
Yanmar Limited Warranty on page 2-3.
serious injury.
0000005en

A DANGER A DANGER

Diesel fuel is extremely flammable and Diesel fuel is flammable and explosive
explosive under certain conditions. under certain conditions.
Be sure to place the diesel fuel Before you operate the engine, check
container on the ground when for fuel leaks. Replace rubberized fuel
transferring the diesel fuel from the hoses every two years or every 2000
pump to the container. Hold the hose hours of engine operation, whichever
nozzle firmly against the side of the comes first, even if the engine has
container while filling it. This prevents been out of service. Rubberized fuel
static electricity buildup which could lines tend to dry out and become
cause sparks and ignite fuel vapors. brittle after two years or 2000 hours of
engine operation, whichever comes
NEVER place diesel fuel or other
first.
flammable material such as oil, hay or
dried grass close to the engine during Failure to comply will result in death or
engine operation or shortly after serious injury.
shutdown. 0000015en

serious injury. CAUTION
0000014en
warranty requirements.
Only use clean diesel fuel.
NEVER remove the primary strainer (if
equipped) from the fuel tank filler port.
If removed, dirt and debris could get
into the fuel system causing it to clog.
0000004en

Note that a typical fuel tank is shown. The fuel tank 2. NEVER use the starter motor to crank the
on your equipment may be different. engine in order to prime the fuel system. This
may cause the starter motor to overheat and
1. Clean the area around the fuel cap damage the coils, pinion and / or ring gear.
(Figure 4-3, (1)).
2. Remove the fuel cap (Figure 4-3, (1)) from the
fuel tank (Figure 4-3, (2)). ENGINE OIL
3. Observe the fuel level sight gauge
(Figure 4-3, (3)) and stop fueling when the CAUTION
gauge shows the fuel tank is full. NEVER
overfill the fuel tank. Only use the engine oil specified.
Other engine oils may affect warranty
4. Replace the fuel cap (Figure 4-3, (1)) and hand coverage, cause internal engine
tighten. Over-tightening the fuel cap will components to seize and / or shorten
damage it. engine life.
(1) Prevent dirt and debris from
clean the oil cap / dipstick and the
surrounding area before you remove
(2) the cap.
NEVER mix different types of engine
oil. This may adversely affect the
lubricating properties of the engine oil.
(3)
NEVER overfill. Overfilling may result
in white exhaust smoke, engine
0000002A
overspeed or internal damage.
Figure 4-3 0000005en
Priming the Fuel System Engine Oil Specifications

The fuel system needs to be primed under certain Use an engine oil that meets or exceeds the
conditions: following guidelines and classifications:
Before starting the engine for the first time. Service Categories
After running out of fuel and fuel has been added API Service Categories CD or higher
to the fuel tank.
ACEA Service Categories E-3, E-4, and E-5
After fuel system maintenance such as changing
JASO Service Category DH-1
the fuel filter and draining the fuel filter / water
separator, or replacing a fuel system component. Definitions
To prime the fuel system: API Classification (American Petroleum Institute)
1. Turn the key to the ON position for 10 - 15 ACEA Classification (Association des
seconds. This will allow the electric fuel pump Constructeurs Europens d'Automobilies)
to prime the fuel system.
JASO (Japanese Automobile Standards
Organization)

Notes: Checking Engine Oil
Be sure the engine oil, engine oil storage 1. Make sure the engine is level.
containers, and engine oil filling equipment are 2. Remove the dipstick (Figure 4-5, (1)) and wipe
free of sediment and water. it with clean cloth.
Change the engine oil after the first 50 hours of 3. Fully reinsert the dipstick.
operation and then every 250 hours thereafter. 4. Remove the dipstick. The oil level should be
Select the oil viscosity based on the ambient between the upper (Figure 4-5, (2)) and lower
temperature where the engine is being operated. (Figure 4-5, (3)) lines on the dipstick.
See the SAE Service Grade Viscosity Chart 5. Fully reinsert the dipstick.
(Figure 4-4).
(4)
Yanmar does not recommend the use of engine
oil additives.
Additional Technical Engine Oil

Requirements:
The engine oil must be changed when the Total
Base Number (TBN) has been reduced to 2.0. TBN
(mgKOH/g) test method; JIS K-201-5.2-2 (HCI),
ASTM D4739 (HCI).
Engine Oil Viscosity (4)

Select the appropriate engine oil viscosity based on
the ambient temperature and use the SAE Service (5)
Grade Viscosity Chart in Figure 4-4.
SAE 10W (2)

SAE 20W (1)
SAE 10W-30
SAE 15W-40
(3)
SAE 20
SAE 30 0000007C
SAE 40
Figure 4-5
SAE 20W - 50
-4F 14F 32F 50F 68F 86F 104F 122F

(-20C) (-10C) (0C) (10C) (20C) (30C) (40C) (50C)
0000005A
Figure 4-4

Adding Engine Oil Engine Oil Capacity (Typical)
1. Make sure the engine is level. Note: These are the engine oil capacities
2. Remove the oil cap (Figure 4-5, (4)). associated with a deep standard oil
pan. The oil capacity will vary dependant
3. Add the indicated amount of engine oil at the upon which optional oil pan is used.
top or the side engine oil filler port Refer to the operation manual provided
(Figure 4-5, (5)). by the driven machine manufacturer for
4. Wait three minutes and check the oil level. the actual engine oil capacity of your
5. Add more oil if necessary. machine.
6. Reinstall the oil cap (Figure 4-5, (4)) and The following are the engine oil capacities for
hand-tighten. Over-tightening may damage the various Yanmar TNV engines.
cap.
Dipstick Upper Limit /
Engine Model
Lower Limit
5.8 / 3.8 qt
3TNV82A
(5.5 / 3.6 L)
7.1 / 4.1 qt
3TNV84, 3TNV84T
(6.7 / 3.9 L)
7.1 / 4.1 qt
3TNV88
(6.7 / 3.9 L)
7.8 / 4.2 qt
4TNV84, 4TNV84T
(7.4 / 4.0 L)
7.8 / 4.2 qt
4TNV88
(7.4 / 4.0 L)
11.1 / 6.3 qt
4TNV94L
(10.5 / 6.0 L)
11.1 / 6.3 qt
4TNV98, 4TNV98T
(10.5 / 6.0 L)
4TNV106(CL), 14.8 / 5.3 qt
4TNV106T(CL) (14.0 / 5.0 L)
4TNV106(VM), 14.8 / 6.9 qt
4TNV106T(VM) (14.0 / 6.5 L)

ENGINE COOLANT
A CAUTION
A DANGER
COOLANT HAZARD!
Wear eye protection and rubber gloves
SCALD HAZARD!
when you handle long life or extended
NEVER remove the radiator cap if the life engine coolant. If contact with the
engine is hot. Steam and hot engine eyes or skin should occur, flush eyes
coolant will spurt out and seriously and wash immediately with clean
burn you. Allow the engine to cool water.
the radiator cap.
or moderate injury.
Tighten the radiator cap securely after 0000005en
spurt out during engine operation if
the cap is loose. CAUTION
ALWAYS check the level of the engine Only use the engine coolant specified.
coolant by observing the reserve tank. Other engine coolants may affect
warranty coverage, cause an internal
Failure to comply will result in death or buildup of rust and scale and / or
serious injury. shorten engine life.
0000002en
contaminating the engine coolant.
A WARNING Carefully clean the radiator cap and
remove the cap.
coolants. This may adversely affect the
properties of the engine coolant.
BURN HAZARD! 0000006en
Wait until the engine cools before you
drain the engine coolant. Hot engine
coolant may splash and burn you.
or serious injury.
0000016en

Engine Coolant Specifications Filling Radiator with Engine Coolant
Use a Long Life Coolant (LLC) or an Extended Life Fill the radiator and reserve tank as follows. This
Coolant (ELC) that meets or exceeds the following procedure is for filling the radiator for the first time
guidelines and specifications: or refilling it after it is flushed. Note that a typical
radiator is illustrated (Figure 4-6).
Additional Technical Coolant
Specifications:
(2)
ASTM D6210, D4985 (US)
(5)
JIS K-2234 (Japan)
SAE J814C, J1941, J1034 or J2036 (3)
(International)
(6) FULL
Alternative Engine Coolant LOW
(4)
If an Extended or Long Life Coolant is not available,
alternatively, you may use an ethylene glycol or
propylene glycol based conventional coolant
(green). (1)
0000029A
Notes:
Figure 4-6
ALWAYS use a mix of coolant and water.
NEVER use water only. 1. Check to be sure the radiator drain plug is
Mix the coolant and water per the mixing installed and tightened or the drain cock
instructions on the coolant container. (Figure 4-6, (1)) is closed. Also make sure the
coolant drain plug (Figure 4-7, (1)) in the
Water quality is important to coolant cylinder block is closed or the oil coolant hoses
performance. Yanmar recommends that soft, (Figure 4-8, (1)) are installed at the oil cooler.
distilled, or demineralized water be used to mix
with coolants.
NEVER mix extended or long life coolants and
conventional (green) coolants.
NEVER mix different types and / or colors of
extended life coolants.
Replace the coolant every 1000 engine hours
or once a year.
(1)
0000027B
Figure 4-7

Engine Coolant Capacity (Typical)
Note: The capacities listed are for the engine
only without a radiator. Refer to the
operation manual provided by the driven
machine manufacturer for the actual
engine coolant capacity on your
machine.
The following are the engine coolant capacities for
various Yanmar TNV engines.
Engine Coolant
Engine Model
(1) 0001579B Capacity
3TNV82A 1.9 qt (1.8 L)
Figure 4-8
3TNV84, 3TNV84T 2.1 qt (2.0 L)
2. Remove the radiator cap (Figure 4-6, (2)) by 3TNV88 2.1 qt (2.0 L)
turning it counter-clockwise about 1/3 of a turn. 4TNV84, 4TNV84T 2.9 qt (2.7 L)
3. Pour the engine coolant slowly into the radiator 4TNV88 2.9 qt (2.7 L)
until it is even with the lip of the engine coolant 4TNV94L 4.4 qt (4.2 L)
filler port. Make sure that air bubbles do not
4TNV98, 4TNV98T 4.4 qt (4.2 L)
develop as you fill the radiator.
4TNV106, 4TNV106T 6.3 qt (6.0 L)
4. Reinstall the radiator cap (Figure 4-6, (2)).
Align the tabs on the back side of the radiator
cap with the notches on the engine coolant filler
port. Press down and turn the cap clockwise
about 1/3 of a turn.
5. Remove the cap on the reserve tank
(Figure 4-6, (3)), and fill it to the LOW (COLD)
mark (Figure 4-6, (4)) with engine coolant.
Reinstall the cap.
6. Check the hose (Figure 4-6, (5)) that connects
the reserve tank (Figure 4-6, (3)) to the
radiator. Be sure it is securely connected and
there are no cracks or damage. If the hose is
damaged, the engine coolant will leak out
instead of going into the reserve tank.
7. Run the engine until it is at operating
temperature. Check the level of engine coolant
in the reserve tank. When the engine is running
and the engine coolant is at normal
temperature, the coolant level in the tank should
be at the FULL (HOT) mark (Figure 4-6, (6)). If
the engine coolant is not at the FULL (HOT)
mark (Figure 4-6, (6)), add additional engine
coolant to the reserve tank to bring the level to
the FULL (HOT) mark.

SPECIFICATIONS
Description of Model Number
4 TNV 84 T - 0 0000
Customer Code
Rated rpm
Turbocharged (No symbol indicates naturally aspirated)
Cylinder Bore (mm)
Engine Series
No. of Cylinders
When ordering parts or making an inquiry about the engine you are working on, be sure to include the
complete model and serial numbers as shown on the engine nameplate. See Location of Labels on
page 4-4.
Engine Speed Specifications

Notation Available Engine Speed Intended Uses
-1)
VM 2000 - 3000 rpm (min Agricultural, Constructive, Industrial Machines
CL 1500 or 1800 rpm (min-1) 4-pole Generator Sets, Irrigation Pumps
VM: Variable Medium Speed

CL: Constant Low Speed

Engine General Specifications
Type Vertical In-line, Water Cooled, 4-Cycle Diesel Engine
Combustion System Direct Injection
Starting System Electric Starting
Cooling System Radiator
Lubricating System Forced Lubrication with Trochoid Pump
PTO Position Flywheel End
Direction of Rotation Counterclockwise Viewed from the Flywheel End
Note: The information described in Principal Engine Specifications is for a standard engine. To obtain the
information for the engine installed in your driven machine, please refer to the manual provided by
the driven machine manufacturer. Engine rating conditions are as follows (SAE J1349, ISO 3046/1):
Atmospheric Condition: Room temperature 77F (25C), Atmospheric pressure 29.53 in Hg (100 kPa,
750 mm Hg), Relative humidity 30%
Fuel Temperature at Fuel Injector Pump Inlet: 104F (40C)
With Cooling Fan, Air Cleaner, Muffler: Yanmar Standard
After Engine Break-In Period; Output Allowable Deviation: 3%
1 PS = 0.7355 kW
1 hp SAE (Society of Automotive Engineers) = 0.7457 kW

PRINCIPAL ENGINE SPECIFICATIONS

3TNV82A
Engine Model 3TNV82A
Version CL VM
Type Vertical In-line Diesel Engine
Aspiration Natural
No. of Cylinders 3
Bore Stroke 3.228 x 3.307 in. (82 84 mm)
Displacement 81.208 cu in. (1.331 L)
rpm
1500 1800
(min-1)
Continuous Rated hp SAE 13.3 16.1
Output
kW 9.9 12.0
PS 13.5 16.3
rpm
1500 1800 2000 2200 2400 2600 2800 3000
(min-1)
Max. Rated Output (Net) hp SAE 14.7 17.7 19.6 21.5 23.5 25.4 27.4 29.4
kW 11.0 13.2 14.6 16.0 17.5 19.0 20.4 21.9
PS 14.9 17.9 19.9 21.8 23.8 25.8 27.8 29.8
rpm 1600 1895 2205 2420 2615 2810 2995 3210
High Idling
(min-1) 25 25 25 25 25 25 25 25

Engine Model 3TNV82A

Version CL VM
Engine Weight (Dry)
304.3 lb (138 kg) 282.2 lb (128 kg)
with Flywheel Housing*
Firing Order 1-3-2-1 (No. 1 Cylinder on the Flywheel End)
Fuel Injection Timing See Checking and Adjusting Fuel Injection Timing on page 7-26.
Direction of Rotation Counterclockwise Viewed From the Flywheel End
Cooling System Liquid-Cooled with Radiator
Normal Oil Pressure at
42 - 57 psi (0.29 - 0.39 MPa; 2.96 - 3.98 kgf/cm2)
the Rated Engine Speed
8.8 psi (0.06 MPa; 0.6 kgf/cm2) or greater
the Low Idle Speed
Electric Starting - Starter Motor: DC12V, 1.6 hp (1.2 kW)
Starting System Alternator: DC12V, 40A**
Recommended Battery Capacity: 12V, 52 Amp-Hour (5h rating)
21.77 x 19.25 x 22.24 in. 20.79 x 9.25 x 22.24 in.
Dimensions (L W H)*
(553 489 565 mm) (528 x 489 x 565 mm)
Engine Oil Pan 5.8 / 3.8 qt (5.5 / 3.6 L)
Capacity*** (Dipstick Upper Limit / Lower Limit)
Engine Coolant Capacity 0.5 gal (1.8 L) Engine Only
Standard Cooling Fan 13.19 in. (335 mm) O.D., 6 Blades Pusher Type
* Engine specifications without radiator
** May vary depending on the application.
*** Engine oil capacity for a deep standard oil pan. Refer to the operation manual provided by the driven machine
manufacturer for the actual engine oil capacity of your machine.

3TNV84
Engine Model 3TNV84
Version CL VM
Aspiration Natural
No. of Cylinders 3
Bore Stroke 3.307 x 3.543 in. (84 x 90 mm)
rpm
1500 1800
(min-1)
Output
kW 11.3 13.5
PS 15.3 18.3
rpm
1500 1800 2000 2200 2400 2600 2800 3000
(min-1)
kW 12.4 14.8 16.4 18.1 19.7 21.3 23.0 24.6
PS 16.8 20.1 22.3 24.6 26.8 29.0 31.3 33.5
rpm 1600 1895 2205 2420 2615 2810 2995 3210
High Idling
(min-1) 25 25 25 25 25 25 25 25

Engine Model 3TNV84

Version CL VM
Engine Weight (Dry)
355.0 lb (161 kg) 341.8 lb (155 kg)
Fuel Injection Timing See Checking and Adjusting Fuel Injection Timing on page 7-26
42 - 57 psi (0.29 - 0.39 MPa; 2.96 - 3.98 kgf/cm2)
the Low Idle Speed
23.19 x 19.13 x 24.49 in 22.20 x 19.13 x 24.49 in
Dimensions (L W H)*
(589 x 486 x 622 mm) (564 x 486 x 622 mm)
Engine Oil Pan
7.1 / 4.1 qt (6.7 / 3.9 L) (Dipstick Upper Limit / Lower Limit)
Capacity***

3TNV84T
Engine Model 3TNV84T
Version CL VM
Aspiration Turbocharged
No. of Cylinders 3
rpm
1500 1800
(min-1)
Output
kW 14.0 16.5
PS 19.0 22.5
rpm
1500 1800 2000 2200 2400 2600 2800 3000
(min-1)
kW 15.8 18.8 21.0 22.8 25.0 26.8 29.1 30.9
PS 21.5 25.5 28.5 31.0 34.0 36.5 39.5 42.0
rpm 1600 1895 2205 2420 2615 2810 2995 3210
High Idling
(min-1) 25 25 25 25 25 25 25 25


Version CL VM
Engine Weight (Dry)
355.0 lb (161 kg) 341.8 lb (155 kg)
42 - 57 psi (0.29 - 0.39 MPa; 2.96 - 3.98 kgf/cm2)
the Low Idle Speed
Electric Starting - Starter Motor: DC12 V, 1.6 hp (1.2 kW)
23.19 x 19.13 x 24.49 in. 22.20 x 19.13 x 24.49 in.
Dimensions (L W H)*
(589 x 486 x 622 mm) (564 x 486 x 622 mm)
Engine Oil Pan
Capacity***

3TNV88
Engine Model 3TNV88
Version CL VM
Aspiration Natural
No. of Cylinders 3
rpm
1500 1800
(min-1)
Output
kW 12.3 14.8
PS 16.7 20.1
rpm
1500 1800 2000 2200 2400 2600 2800 3000
(min-1)
kW 13.5 16.3 18.0 19.9 21.6 23.5 25.2 27.1
PS 18.4 22.1 24.5 27.0 29.4 31.9 34.2 36.8
rpm 1600 1895 2205 2420 2615 2810 2995 3210
High Idling
(min-1) 25 25 25 25 25 25 25 25

Engine Model 3TNV88

Version CL VM
Engine Weight (Dry)
355.0 lb (161 kg) 341.8 lb (155 kg)
42 - 57 psi (0.29 - 0.39 MPa; 2.96 - 3.98 kgf/cm2)
the Low Idle Speed
23.19 x 19.13 x 24.49 in. 22.20 x 19.13 x 24.49 in.
Dimensions (L W H)*
(589 x 486 x 622 mm) (564 x 486 x 622 mm)
Engine Oil Pan
Capacity***
* Engine specifications without radiator.

4TNV84
Engine Model 4TNV84
Version CL VM
Aspiration Natural
No. of Cylinders 4
rpm
1500 1800
(min-1)
Output
kW 14.9 17.7
PS 20.3 24.1
rpm
1500 1800 2000 2200 2400 2600 2800 3000
(min-1)
kW 16.4 19.5 21.9 24.1 26.3 28.5 30.7 32.9
PS 22.3 26.5 29.8 32.8 35.8 38.7 41.7 44.7
rpm 1600 1895 2205 2420 2615 2810 2995 3210
High Idling
(min-1) 25 25 25 25 25 25 25 25

Engine Model 4TNV84

Version CL VM
Engine Weight (Dry)
403.5 lb (183 kg) 374.9 lb (170 kg)
Firing Order 1-3-4-2-1 (No. 1 Cylinder on the Flywheel End)
42 - 57 psi (0.29 - 0.39 MPa; 2.96 - 3.98 kgf/cm2)
the Low Idle Speed
26.89 x 19.63 x 24.29 in. 25.91 x 19.63 x 24.29 in.
Dimensions (L W H)*
(683 x 498.5 x 617 mm) (658 x 498.5 x 617 mm)
Engine Oil Pan
Capacity***
Standard Cooling Fan 14.57 in (370 mm) O.D., 6 Blades Pusher Type

4TNV84T
Version CL VM
No. of Cylinders 4
rpm
1500 1800
(min-1)
Output
kW 19.1 24.3
PS 26.0 33.0
rpm
1500 1800 2000 2200 2400 2600 2800 3000
(min-1)
kW 21.3 26.9 27.9 30.5 33.5 35.7 38.6 41.2
PS 29.0 36.5 38.0 41.5 45.5 48.5 52.5 56.0
rpm 1600 1895 2205 2420 2615 2810 2995 3210
High Idling
(min-1) 25 25 25 25 25 25 25 25


Version CL VM
Engine Weight (Dry)
403.5 lb (183 kg) 374.9 lb (170 kg)
42 - 57 psi (0.29 - 0.39 MPa; 2.96 - 3.98 kgf/cm2)
the Low Idle Speed
26.89 x 19.63 x 28.07 in. 25.55 x 19.63 x 28.07 in.
Dimensions (L W H)*
(683 x 498.5 x 713 mm) (649 x 498.5 x 713 mm)
Engine Oil Pan
Capacity***

4TNV88
Engine Model 4TNV88
Version CL VM
Aspiration Natural
No. of Cylinders 4
rpm
1500 1800
(min-1)
Output
kW 16.4 19.6
PS 22.3 26.7
rpm
1500 1800 2000 2200 2400 2600 2800 3000
(min-1)
kW 18.0 21.6 24.1 26.5 28.8 31.3 33.7 35.4
PS 24.5 29.4 32.7 36.0 39.2 42.5 45.8 48.1
rpm 1600 1895 2205 2420 2615 2810 2995 3210
High Idling
(min-1) 25 25 25 25 25 25 25 25

Engine Model 4TNV88

Version CL VM
Engine Weight (Dry)
403.5 lb (183 kg) 374.9 lb (170 kg)
42 - 57 psi (0.29 - 0.39 MPa; 2.96 - 3.98 kgf/cm2)
the Low Idle Speed
Starting System Alternator: DC12V, 40**
26.89 x 19.63 x 24.33 in. 25.91 x 19.63 x 24.33 in.
Dimensions (L W H)*
(683 x 498.5 x 618 mm) (658 x 498.5 x 618 mm)

4TNV94L
Engine Model 4TNV94L
Version CL VM
Aspiration Natural
No. of Cylinders 4
Bore Stroke 3.701 x 4.331 in (94 x 110 mm)
Displacement 186.333 cu in (3.054 L)
rpm
1500 1800
(min-1)
Output
kW 26.1 31.3
PS 35.5 42.5
rpm
1500 1800 2000 2200 2400 2500
(min-1)
Max. Rated Output (Net) hp SAE 39.0 46.4 47.3 51.3 55.7 57.7
kW 29.1 34.6 35.3 38.2 41.6 43.0
PS 39.5 47.0 48.0 52.0 56.5 58.5
rpm
High Idling 1600 25 1895 25 2205 25 2420 25 2615 25 2725 25
(min-1)

Engine Model 4TNV94L

Version CL VM
Engine Weight (Dry)
540.2 lb (245 kg) 518.2 lb (235 kg)
42 - 57 psi (0.29 - 0.39 MPa; 2.96 - 3.98 kgf/cm2)
the Low Idle Speed
28.31 x 19.61 x 29.21 in.
Dimensions (L W H)*
(719 x 498 x 742 mm)

4TNV98
Engine Model 4TNV98
Version CL VM
Aspiration Natural
No. of Cylinders 4
rpm
1500 1800
(min-1)
Output
kW 30.9 36.8
PS 42.0 50.0
rpm
1500 1800 2000 2200 2400 2500
(min-1)
kW 34.6 41.2 41.9 45.6 49.3 51.1
PS 47.0 56.0 57.0 62.0 67.0 69.5
rpm
High Idling 1600 25 1895 25 2205 25 2420 25 2615 25 2725 25
(min-1)

Engine Model 4TNV98

Version CL VM
Engine Weight (Dry)
546.8 lb (248 kg) 518.2 lb (235 kg)
42 - 57 psi (0.29 - 0.39 MPa; 2.96 - 3.98 kgf/cm2)
the Low Idle Speed
28.31 x 19.61 x 29.21 in.
Dimensions (L W H)*
(719 x 498 x 742 mm)

4TNV98T
Version CL VM
No. of Cylinders 4
rpm
1500 1800
(min-1)
Output
kW 37.9 45.6
PS 51.5 62.0
rpm
1500 1800 2000 2200 2400 2500
(min-1)
kW 41.9 50.4 50.7 55.5 60.3 62.5
PS 57.0 68.5 69.0 75.5 82.0 85.0
rpm
High Idling 1600 25 1895 25 2205 25 2420 25 2615 25 2725 25
(min-1)


Version CL VM
Engine Weight (Dry)
568.9 lb (258 kg) 540.2 lb (245 kg)
57 - 71 psi (0.39 - 0.49 MPa; 3.98 - 5.00 kgf/cm2)
the Low Idle Speed
28.31 x 22.64 x 31.65 in.
Dimensions (L W H)*
(719 x 575 x 804 mm)
Capacity*** (Dipstick Upper Limit / Lower limit)
Standard Cooling Fan 16.93 in. (430 mm) O.D., 8 Blades Suction Type

4TNV106
Engine Model 4TNV106
Version CL VM
Aspiration Natural
No. of Cylinders 4
rpm
1500 1800
(min-1)
Output
kW 41.2 49.3
PS 56.0 67.0
rpm
1500 1800 2000 2200 2400 2500
(min-1)
kW 45.6 54.4 56.6 61.4 65.5 67.7
PS 62.0 74.0 77.0 83.5 89.0 92.0
rpm
High Idling 1600 25 1895 25 2205 25 2420 25 2615 25 2725 25
(min-1)

Engine Model 4TNV106

Version CL VM
Engine Weight (Dry)
727.7 lb (330 kg)
With balancer 49 - 64 psi
45 - 71 psi
Normal Oil Pressure at (0.34 - 0.44 MPa; 3.47 - 4.49 kgf/cm2)
(0.31 - 0.49 MPa;
the Rated Engine Speed Without balancer 57 - 71 psi
3.16 - 5.00 kgf/cm2)
(0.39 - 0.49 MPa; 3.98 - 5.00 kgf/cm2)
the Low Idle Speed
31.81 x 24.69 x 31.61 in. 30.63 x 24.69 x 31.61 in.
Dimensions (L W H)*
(808 x 627 x 803 mm) (778 x 627 x 803 mm)
Engine Oil Pan 14.8 / 5.3 qt (14.0 / 5.0 L) 14.8 / 6.9 qt (14.0 / 6.5 L)
Capacity*** (Dipstick Upper Limit / Lower Limit) (Dipstick Upper Limit / Lower Limit)
Engine Coolant Capacity 1.6 gal (6 L) Engine Only
19.68 in. (500 mm) O.D. 19.68 in. (500 mm) O.D.
Standard Cooling Fan
7 Blades Pusher Type 7 blades suction type

4TNV106T
Version CL VM
No. of Cylinders 4
rpm
1500 1800
(min-1)
Output
kW 51.5 61.8
PS 70.0 84.0
rpm
1500 1800 2000 2200
(min-1)
Max. Rated Output (Net) hp SAE 76.1 91.2 93.7 96.6
kW 56.8 68.0 69.9 72.0
PS 77.2 92.5 95.0 97.9
rpm
High Idling 1600 25 1875 25 2205 25 2420 25
(min-1)


Version CL VM
Engine Weight (dry)
749.7 lb (340 kg)
Direction of Rotation Counter-clockwise Viewed From the Flywheel End
With balancer 49 - 64 psi
45 - 71 psi
Normal Oil Pressure at (0.34 - 0.44 MPa; 3.47 - 4.49 kgf/cm2)
(0.31 - 0.49 MPa;
the Rated Engine Speed Without balancer 57 - 71 psi
3.16 - 5.00 kgf/cm2)
(0.39 - 0.49 MPa; 3.98 - 5.00 kgf/cm2)
the Low Idle Speed
31.81 x 24.76 x 34.09 in. 30.63 x 24.76 x 34.09 in.
Dimensions (L W H)*
(808 x 629 x 866 mm) (778 x 629 x 866 mm)
Engine Oil Pan 14.8 / 5.3 qt (14.0 / 5.0 L) 14.8 / 6.9 qt (14.0 / 6.5 L)
Capacity*** (Dipstick Upper Limit / Lower Limit) (Dipstick Upper Limit / Lower Limit)
Engine Coolant Capacity 1.6 gal (6 L) Engine Only
19.68 in (500 mm) O.D. 19.68 in (500 mm) O.D.
Standard Cooling Fan
7 Blades Pusher Type 7 Blades Suction Type

ENGINE SERVICE STANDARDS

Reference
Inspection Item Standard Limit
page
All models
except 0.006 - 0.010 in. See Measuring
-
4TNV106 and (0.15 - 0.25 mm) and Adjusting
Intake / Exhaust Valve Clearance 4TNV106T Valve Clearance
4TNV106 and 0.010 - 0.014 in. on page 6-62
-
4TNV106T (0.25 - 0.35 mm)
Fuel Injection
See Checking and Adjusting Fuel Injection Timing on page 7-26.
Timing
Fuel Injection
See Test and Adjustment Specifications on page 7-8.
Pressure
443 - 473 psi 340 - 370 psi
3TNV82A (3.06 - 3.26 MPa; (2.35 - 3.55 MPa;
30 - 32 kgf / cm) 24 - 26 kgf / cm)
455 - 485 psi 355 - 385 psi See
Compression 3TNV84, 4TNV84 (3.14 - 3.34 MPa; (2.45 - 2.65 MPa; Troubleshooting
Pressure at 32 - 34 kgf / cm) 25 - 27 kgf / cm) By Measuring
250 rpm 411 - 441 psi 340 - 370 psi Compression
(250 min) 3TNV84T, 4TNV84T (2.84 - 3.04 MPa; (2.35 - 2.55 MPa; Pressure on
29 - 31 kgf / cm) 24 - 26 kgf / cm) page 14-4
3TNV88, 4TNV88, 4TNV94L, 483 - 513 psi 384 - 414 psi
4TNV98, 4TNV98T, 4TNV106, (3.33 - 3.53 MPa; (2.65 - 2.85 MPa;
4TNV106T 34 - 36 kgf / cm) 27 - 29 kgf / cm)
29 - 43 psi
Deviation Between Cylinders All Models (0.2 - 0.3 MPa; - -
2 - 3 kgf/cm)
5.8 - 8.8 psi
Oil Pressure Switch Operating Pressure (0.04 - 0.06 MPa; - -
0.4 - 0.6 kgf / cm)
Valve Opening Full Opening Lift
Temperature Temperature
0.32 in (8 mm) or
157F - 163F
All Models above See Thermostat
Thermostat (70C - 73C)
185F (85C) on page 8-10
0.39 in (10 mm) or
All Models 176F - 183F
above
Option (80C - 84C)
203F (95C)
See
225F - 235F Temperature
Coolant Temperature Switch -
(107C - 113C) Switch on
page 8-10

TIGHTENING TORQUES FOR STANDARD BOLTS AND NUTS

Use the correct amount of torque when you tighten
the fasteners on the machine. Applying excessive CAUTION
torque may damage the fastener or component and The tightening torque in the Standard
not enough torque may cause a leak or component Torque Chart (see General Service
failure. Information section) should be applied
only to the bolts with a 7 head. (JIS
strength classification: 7T)
Apply 60% torque to bolts

that are not listed.
Apply 80% torque when
tightened to aluminum alloy.
0000023enTNVDISM
Nominal Thread
Item x Pitch Tightening Torque Remarks
Diameter
7 - 9 ft-lb
(87 -104 in.-lb,
M6 x 1.0 mm
9.8 -11.8 Nm,
1.0 -1.2 kgfm)
17 - 21 ft-lb
M8 x 1.25 mm (200 - 251 in.-lb,
22.6 - 28.4 Nm,
2.3 - 2.9 kgfm)
33 - 40 ft-lb Use 80% of the value at left
M10 x 1.5 mm (44.1 - 53.9 Nm, when the tightening part is
Hexagon Bolt (7T) and
Nut 4.5 - 5.5 kgfm) aluminum.
Use 60% of the value at left for
58 - 72 ft-lb 4T bolts and lock nuts.
M12 x 1.75 mm (78.4 - 98.0 Nm,
8.0 - 10 kgfm)
94 - 108 ft-lb
M14 x 1.5 mm (127.5 - 147.1 Nm,
13 - 15 kgfm)
159 - 174 ft-lb
M16 x 1.5 mm (215.7- 235.4 Nm,
22 - 24 kgfm)
1/8 mm 7 ft-lb
(87 in.-lb, 9.8 Nm, 1.0 kgfm)
14 ft-lb
1/4 mm
(173 in.-lb, 19.6 Nm, 2.0 kgfm)
PT PLug -
22 ft-lb
3/8 mm (29.4 Nm, 3.0 kgfm)
1/2 mm 43 ft-lb
(58.8 Nm, 6.0 kgfm)

Nominal Thread
Item x Pitch Tightening Torque Remarks
Diameter
9 - 12 ft-lb
(112 - 148 in.-lb,
M8
12.7 - 16.7 Nm,
1.3 - 1.7 kgfm)
14 - 19 ft-lb
M10 (173 - 225 in.-lb,
19.6 - 18.734 Nm,
2.0 - 3.5 kgfm)
Pipe Joint Bolt 18 - 25 ft-lb -
M12 (24.5 - 34.3 Nm,
2.5 - 3.5 kgfm)
29 - 36 ft-lb
M14 (39.2 - 49.0 Nm,
4.0 - 5.0 kgfm)
36 - 43 ft-lb
M16 (49.0 - 58.8 Nm,
5.0 - 6.0 kgfm)
Note: Torque values shown in this manual are for clean, non-lubricated fasteners unless otherwise
specified.

ABBREVIATIONS AND k kelvin

kg kilogram
SYMBOLS kgf/cm kilogram force per square centimeter
kgf/m kilogram force per meter
Abbreviations km kilometers
kPa kilopascal
A ampere kW kilowatt
AC alternating current L liter
ACEA Association des Constructeurs L/hr liter per hour
Europens dAutomobilies lb pound
Ah ampere-hour lbf pound force
API American Petroleum Institute m meter
mL milliliter
ARB Air Resources Board
mm millimeter
ATDC after top dead center
mmAq millimeter Aqueous
BDC bottom dead center
MPa megapascal
BTDC before top dead center mV millivolt
C degree Celsius N newton
CARB California Air Resources Board Nm newton meter
CCA cold cranking amp No. number
cfm cubic feet per minute O.D. outside diameter
cm centimeter oz ounce
cm cubic centimeter Pa pascal
cm/min cubic centimeter per minute PS horsepower (metric)
psi pound per square inch
cu in. cubic inch
qt quart (U.S.)
D diameter
R radius
DC direct current
rpm revolutions per minute
DI direct injection SAE Society of Automotive Engineers
DVA direct volt adapter sec. second
EPA Environmental Protection Agency t short ton 2000 lb
ESG electronic speed governor TBN total base number
F degree Fahrenheit TDC top dead center
fl oz fluid ounce (U.S.) V volt
fl oz/min fluid ounce (U.S.) per minute VAC volt alternating current
ft foot VDC volt direct current
W watt
ft-lb foot pound
ft-lbf/min foot pound force per minute
g gram
Symbols
gal gallon (U.S.) degree
gal/hr gallon (U.S.) per hour
+ plus
gal/min gallon (U.S.) per minute
- minus
GL gear lubricant
hp horsepower (U.S.)
plus or minus
ohm
hr hour
micro
I.D. inside diameter
% percent
ID identification
IDI indirect injection
in. inch
inHg inches Mercury
in.-lb inch pound
j joule
JASO Japanese Automobile Standards
Organization

UNIT CONVERSIONS Units of Torque

ft-lb x 1.3558 = Nm
Unit Prefixes ft-lb x 0.1383 = kgf/m
Prefix Symbol Power in.-lb x 0.1130 = Nm
mega M x 1,000,000 in.-lb x 0.0115 = kgf/m
kilo k x 1,000 kgf/m x 7.2330 = ft-lb
centi c x 0.01 kgf/m x 86.8000 = in.-lb
milli m x 0.001 kgf/m x 9.8070 = Nm
micro x 0.000001 Nm x 0.7376 = ft-lb
Nm x 8.8510 = in.-lb
Units of Length Nm x 0.1020 = kgf/m
mile x 1.6090 = km Units of Pressure
ft x 0.3050 =m
in. x 2.5400 = cm psi x 0.0689 = bar
in. x 25.4000 = mm psi x 6.8950 = kPa
km x 0.6210 = mile psi x 0.0703 = kg/cm
m x 3.2810 = ft bar x 14.5030 = psi
cm x 0.3940 = in. bar x 100.0000 = kPa
mm x 0.0394 = in. bar x 29.5300 = inHg (60F)
kPa x 0.1450 = psi
Units of Volume kPa x 0.0100 = bar
kPa x 0.0102 = kg/cm
gal (U.S.) x 3.78540 =L
kg/cm x 98.0700 = psi
qt (U.S.) x 0.94635 =L
kg/cm x 0.9807 = bar
cu in. x 0.01639 =L
kg/cm x 14.2200 = kPa
cu in. x 16.38700 = mL
inHg (60) x 0.0333 = bar
fl oz (U.S.) x 0.02957 =L
inHg (60) x 3.3770 = kPa
fl oz (U.S.) x 29.57000 = mL
inHg (60) x 0.0344 = kg/cm
cm x 1.00000 = mL
cm x 0.03382 = fl oz (U.S.) Units of Power
Units of Mass hp (metric x 0.9863201 = hp SAE
or PS)
lb x 0.45360 = kg
hp (metric x 0.7354988 = kW
oz x 28.35000 =g
or PS)
kg x 2.20500 = lb
hp SAE x 1.0138697 = hp (metric or PS)
g x 0.03527 = oz
hp SAE x 0.7456999 = kW
Units of Force kW x 1.3596216 = hp (metric or PS)
kW x 1.3410221 = hp SAE
lbf x 4.4480 =N
lbf x 0.4536 = kgf Units of Temperature
N x 0.2248 = lbf
F = (1.8 x C) + 32
N x 0.1020 = kgf
C = 0.556 x (F - 32)
kgf x 2.2050 = lbf
kgf x 9.8070 =N

Section 5
PERIODIC
MAINTENANCE
Page
Before You Begin Servicing ............................................................ 5-3
Introduction.................................................................................... 5-16
The Importance of Periodic Maintenance................................ 5-16
Performing Periodic Maintenance ........................................... 5-16
Yanmar Replacement Parts .................................................... 5-16
Required EPA / ARB Maintenance -USA Only........................ 5-16
EPA / ARB Installation Requirements - USA Only .................. 5-16
Periodic Maintenance Schedule.................................................... 5-17
Periodic Maintenance Procedures ................................................ 5-19
After Initial 50 Hours of Operation ........................................... 5-19
Every 50 Hours of Operation ................................................... 5-23
Every 250 Hours of Operation ................................................. 5-26
Every 500 Hours of Operation ................................................. 5-31
Every 1000 Hours of Operation ............................................... 5-35

PERIODIC MAINTENANCE

BEFORE YOU BEGIN

A DANGER
SERVICING
A DANGER
SCALD HAZARD!
EXPLOSION HAZARD! engine is hot. Steam and hot engine
NEVER check the remaining battery burn you. Allow the engine to cool
charge by shorting out the terminals. down before you attempt to remove
This will result in a spark and may the radiator cap.
hydrometer to check the remaining Tighten the radiator cap securely after
battery charge. you check the radiator. Steam can
If the electrolyte is frozen, slowly warm the cap is loose.
ALWAYS check the level of the engine
Failure to comply will result in death or coolant by observing the reserve tank.
serious injury.
0000007en
serious injury.
0000002en
A DANGER

Only use the key switch to start the
engine.
NEVER jump-start the engine. Sparks
caused by shorting the battery to the
starter terminals may cause a fire or
explosion.
serious injury.
0000004en

A DANGER A DANGER

Diesel fuel is flammable and explosive Diesel fuel is flammable and explosive
under certain conditions. under certain conditions.
Only fill the fuel tank with diesel fuel. Before you operate the engine, check
Filling the fuel tank with gasoline may for fuel leaks. Replace rubberized fuel
result in a fire and will damage the hoses every two years or every 2000
engine. hours of engine operation, whichever
comes first, even if the engine has
NEVER refuel with the engine running.
been out of service. Rubberized fuel
Wipe up all spills immediately. lines tend to dry out and become
Keep sparks, open flames or any other brittle after two years or 2000 hours of
form of ignition (match, cigarette, engine operation, whichever comes
static electric source) well away when first.
refueling. Failure to comply will result in death or
NEVER overfill the fuel tank. serious injury.
0000015en
Fill the fuel tank. Store any containers
containing fuel in a well-ventilated
area, away from any combustibles or A DANGER
sources of ignition.
serious injury.
0000005en

NEVER remove the fuel cap with the
engine running.
serious injury.
0000011en

A DANGER A DANGER

Diesel fuel is extremely flammable and CRUSH HAZARD!
explosive under certain conditions. When you need to transport an engine
for repair, have a helper assist you to
Be sure to place the diesel fuel
attach it to a hoist and load it on a
container on the ground when
truck.
transferring the diesel fuel from the
pump to the container. Hold the hose NEVER stand under a hoisted engine.
nozzle firmly against the side of the If the hoist mechanism fails, the
container while filling it. This prevents engine will fall on you, causing death
static electricity buildup which could or serious injury.
cause sparks and ignite fuel vapors. Failure to comply will result in death or
NEVER place diesel fuel or other serious injury.
flammable material such as oil, hay or 0000008en
dried grass close to the engine during

engine operation or shortly after
shutdown.
serious injury.
0000014en
A DANGER

NEVER use diesel fuel as a cleaning
agent.
serious injury.
0000012en

A DANGER A DANGER

Diesel fuel is flammable and explosive Diesel fuel is extremely flammable and
under certain conditions. explosive under certain conditions.
When you remove any fuel system Place an approved container under the
component to perform maintenance air bleed port when you prime the fuel
(such as changing the fuel filter) place system. Never use a shop rag to catch
an approved container under the the fuel. Wipe up any spills
opening to catch the fuel. immediately. ALWAYS close the air
NEVER use a shop rag to catch the bleed port after you complete priming
fuel. Vapors from the rag are the system.
flammable and explosive. Wear eye protection. The fuel system
Wipe up any spills immediately. is under pressure and fuel could spray
out when you open the air bleed port.
Wear eye protection. The fuel system
is under pressure and fuel could spray If the unit has an electric fuel pump,
out when you remove any fuel system turn the key switch to the ON position
component. for 10 to 15 seconds, or until the fuel
coming out of the air bleed port is free
Failure to comply will result in death or of bubbles, to allow the electric fuel
serious injury. pump to prime the system.
0000009en
If the unit has a mechanical fuel pump,
operate the fuel priming pump several
times until the fuel coming out of the
air bleed port is free of bubbles.
serious injury.
0000006en

A WARNING A WARNING
EXHAUST HAZARD! SEVER HAZARD!

NEVER operate the engine in an Keep hands and other body parts
enclosed area such as a garage, away from moving / rotating parts
tunnel, underground room, manhole or such as the cooling fan, flywheel or
ships hold without proper ventilation. PTO shaft.
NEVER block windows, vents, or other Wear tight-fitting clothing and keep
means of ventilation if the engine is your hair short or tie it back while the
operating in an enclosed area. All engine is running.
internal combustion engines create Remove all jewelry before you operate
carbon monoxide gas during or service the machine.
operation. Accumulation of this gas
within an enclosure could cause NEVER start the engine in gear.
illness or even death. Sudden movement of the engine and /
or machine could cause death or
Make sure that all connections are serious personal injury.
is made to the exhaust system. NEVER operate the engine without the
guards in place.
or serious injury. Before you start the engine make sure
0000003en
that all bystanders are clear of the
area.
Keep children and pets away while the
engine is operating.
Check before starting the engine that
any tools or shop rags used during
maintenance have been removed from
the area.
or serious injury.
0000002en

A WARNING A WARNING
equipment.
ALCOHOL AND DRUG HAZARD!
or serious injury. NEVER operate the engine while you
0000006en
are under the influence of alcohol or
drugs.
A WARNING NEVER operate the engine when you

are feeling ill.
or serious injury.
0000004en
BURN HAZARD!
block during operation and shortly
after you shut the engine down. These
surfaces are extremely hot while the
engine is operating and could
seriously burn you.
or serious injury.
0000015en

A WARNING A WARNING
BURN HAZARD!
EXPOSURE HAZARD! Batteries contain sulfuric acid. NEVER
allow battery fluid to come in contact
Wear personal protective equipment
with clothing, skin or eyes. Severe
such as gloves, work shoes, eye and
burns could result. ALWAYS wear
hearing protection as required by the
safety goggles and protective clothing
task at hand.
NEVER wear jewelry, unbuttoned fluid contacts the eyes and / or skin,
cuffs, ties or loose-fitting clothing immediately flush the affected area
when you are working near moving / with a large amount of clean water and
rotating parts such as the cooling fan, obtain prompt medical treatment.
flywheel or PTO shaft.
ALWAYS tie back long hair when you or serious injury.
are working near moving / rotating 0000007en
parts such as a cooling fan, flywheel,
or PTO shaft.
A WARNING
NEVER operate the engine while
wearing a headset to listen to music or
radio because it will be difficult to hear
the alert signals.
HIGH-PRESSURE HAZARD!
or serious injury.
0000005en
Avoid skin contact with the
high-pressure diesel fuel spray caused
by a fuel system leak such as a broken
fuel injection line. High-pressure fuel
can penetrate your skin and result in
serious injury. If you are exposed to
high-pressure fuel spray, obtain
prompt medical treatment.
hands. ALWAYS use a piece of wood
or cardboard. Have your authorized
Yanmar industrial engine dealer or
distributor repair the damage.
or serious injury.
0000008en

A WARNING A WARNING
BURN HAZARD!
SHOCK HAZARD!
If you must drain the engine oil while it
Turn off the battery switch (if
equipped) or disconnect the negative
battery cable before servicing the
electrical system. ALWAYS wear eye protection.
Check the electrical harnesses for Failure to comply could result in death
cracks, abrasions, and damaged or or serious injury.
corroded connectors. ALWAYS keep 0000011en

Failure to comply could result in death A WARNING
or serious injury.
0000009en
A WARNING
BURN HAZARD!
Wait until the engine cools before you
ENTANGLEMENT HAZARD! Failure to comply could result in death
Stop the engine before you begin to or serious injury.
service it. 0000016en
NEVER leave the key in the key switch

when you are servicing the engine.
Someone may accidentally start the
engine and not realize you are
servicing it. This could result in a
serious injury.
If you must service the engine while it
is operating, remove all jewelry, tie
back long hair, and keep your hands,
other body parts and clothing away
or serious injury.
0000010en

A CAUTION CAUTION
warranty requirements.
COOLANT HAZARD! Only use clean diesel fuel.
Wear eye protection and rubber gloves NEVER remove the primary strainer (if
when you handle long life or extended equipped) from the fuel tank filler port.
life engine coolant. If contact with the If removed, dirt and debris could get
eyes or skin should occur, flush eyes into the fuel system causing it to clog.
and wash immediately with clean 0000004en
water.
Failure to comply may result in minor CAUTION
or moderate injury. Only use the engine oil specified.
0000005en
coverage, cause internal engine
A CAUTION components to seize and / or shorten
engine life.
the cap.
FLYING OBJECT HAZARD! NEVER mix different types of engine
ALWAYS wear eye protection when oil. This may adversely affect the
servicing the engine and when using lubricating properties of the engine oil.
compressed air or high-pressure NEVER overfill. Overfilling may result
water. Dust, flying debris, compressed in white exhaust smoke, engine
air, pressurized water or steam may overspeed or internal damage.
injure your eyes. 0000005en

or moderate injury.
0000003en

CAUTION CAUTION
Only use the engine coolant specified. Observe the following environmental
Other engine coolants may affect operating conditions to maintain engine
warranty coverage, cause an internal performance and avoid premature
buildup of rust and scale and / or engine wear:
shorten engine life. Avoid operating in extremely dusty
Prevent dirt and debris from conditions.
contaminating the engine coolant. Avoid operating in the presence of
Carefully clean the radiator cap and chemical gases or fumes.
remove the cap. Avoid operating in a corrosive
atmosphere such as salt water spray.
coolants. This may adversely affect the NEVER install the engine in a
properties of the engine coolant. floodplain unless proper precautions
0000006en
are taken to avoid being subject to a
flood.
CAUTION NEVER expose the engine to the rain.

0000003en
NEVER attempt to modify the engines
design or safety features such as
defeating the engine speed limit CAUTION
control or the diesel fuel injection Observe the following environmental
quantity control. operating conditions to maintain engine
Modifications may impair the engines performance and avoid premature
safety and performance engine wear:
characteristics and shorten the The standard range of ambient
engines life. Any alterations to this temperatures for the normal operation
engine may void its warranty. Be sure of Yanmar engines is from +5F (-15C)
to use Yanmar genuine replacement to +113F (+45C).
parts.
If the ambient temperature exceeds
0000079en
+113F (+45C) the engine may
overheat and cause the engine oil to
break down.
If the ambient temperature is below
+5F (-15C) the engine will be hard to
start and the engine oil may not flow
easily.
Contact your authorized Yanmar
industrial engine dealer or distributor
if the engine will be operated outside
of this standard temperature range.
0000065en

CAUTION CAUTION
NEVER hold the key in the START New Engine Break-in:
position for longer than 15 seconds or On the initial engine start-up, allow the
the starter motor will overheat. engine to idle for approximately 15
0000007en
minutes while you check for proper
engine oil pressure, diesel fuel leaks,
CAUTION engine oil leaks, coolant leaks, and for
proper operation of the indicators
For maximum engine life, Yanmar
and / or gauges.
recommends that when shutting the
engine down, you allow the engine to During the first hour of operation, vary
idle, without load, for five minutes. This the engine speed and the load on the
will allow the engine components that engine. Short periods of maximum
operate at high temperatures, such as engine speed and load are desirable.
the turbocharger (if equipped) and Avoid prolonged operation at
exhaust system, to cool slightly before minimum or maximum engine speeds
the engine itself is shut down. and loads for the next four to five
0000008en hours.
During the break-in period, carefully
CAUTION observe the engine oil pressure and
engine temperature.
NEVER use an engine starting aid such
as ether. Engine damage will result. During the break-in period, check the
0000009en
engine oil and coolant levels
frequently.
0000011en
CAUTION
Make sure the engine is installed on a
level surface. If a continuously running
CAUTION
engine is installed at an angle greater NEVER engage the starter motor while
than 30 (in any direction) or if an engine the engine is running. This may damage
runs for short periods of time (less than the starter motor pinion and / or ring
three minutes) at an angle greater than gear.
35 (in any direction) engine oil may 0000012en
enter the combustion chamber causing

excessive engine speed and white CAUTION
exhaust smoke. This may cause serious
engine damage. It is important to perform daily checks.
0000010en Periodic maintenance prevents
unexpected downtime, reduces the
number of accidents due to poor
machine performance and helps extend
the life of the engine.
0000060en

CAUTION CAUTION
NEVER use high-pressure water or
compressed air at greater than 28 psi
(193 kPa; 19 686 mm Aq) or a wire brush
to clean the radiator fins. Radiator fins
damage easily.
ALWAYS be environmentally 0000016en
responsible.
Follow the guidelines of the EPA or CAUTION
other governmental agencies for the NEVER attempt to adjust the low or high
proper disposal of hazardous idle speed limit screw. This may impair
materials such as engine oil, diesel the safety and performance of the
fuel and engine coolant. Consult the machine and shorten its life. If the idle
local authorities or reclamation facility. speed limit screws require adjustment,
NEVER dispose of hazardous see your authorized Yanmar industrial
materials irresponsibly by dumping engine dealer or distributor.
them into a sewer, on the ground, or 0000017en
into ground water or waterways.

Failure to follow these procedures may CAUTION
seriously harm the environment. Establish a periodic maintenance plan
0000013en according to the engine application and
make sure you perform the required
CAUTION periodic maintenance at the intervals
indicated. Failure to follow these
Protect the air cleaner, turbocharger (if
equipped) and electric components
from damage when you use steam or
shorten the engines life and may affect
high-pressure water to clean the engine.
the warranty coverage on your engine.
0000014en
Warranty Section.
CAUTION
Consult your authorized Yanmar dealer
NEVER overfill the engine with engine or distributor for assistance when
oil. checking items marked with a z.
ALWAYS keep the oil level between the 0000024enTNVDISM
upper and lower lines on the oil cap /
dipstick.
0000015en

CAUTION
If the fuel filter / water separator is
positioned higher than the fuel level in
the fuel tank, water may not drip out
when the fuel filter / water separator
drain cock is opened. If this happens,
fuel filter / water separator 2-3 turns
counterclockwise.
Be sure to tighten the air vent screw
after the water has drained out.
0000025en
CAUTION
When the engine is operated in dusty
conditions, clean the air cleaner
element more frequently.
NEVER operate the engine with the air
cleaner element(s) removed. This may
allow foreign material to enter the
engine and damage it.
0000026en
CAUTION
The maximum air intake restriction, in
terms of differential pressure
measurement, must not exceed 0.90 psi
(6.23 kPa; 635 mmAq). Clean or replace
the air cleaner element if the air intake
restriction exceeds the above
mentioned value.
0000046en

INTRODUCTION Perform periodic maintenance procedures in an

open, level area free from traffic. If possible,
This section of the Service Manual describes the perform the procedures indoors to prevent
procedures for proper care and maintenance of the environmental conditions, such as rain, wind, or
engine. snow, from damaging the machine.
The Importance of Periodic Yanmar Replacement Parts
Maintenance Yanmar recommends that you use genuine Yanmar
Engine deterioration and wear occurs in proportion parts when replacement parts are needed.
to length of time the engine has been in service and Genuine replacement parts help ensure long
the conditions the engine is subject to during engine life.
operation. Periodic maintenance prevents
unexpected downtime, reduces the number of Required EPA / ARB Maintenance -
accidents due to poor machine performance and USA Only
helps extend the life of the engine.
To maintain optimum engine performance and
Performing Periodic Maintenance compliance with the Environmental Protection
Agency (EPA) Regulations Non-road Engines and
the California Air Resources Board (ARB,
A WARNING California), it is essential that you follow the
Periodic Maintenance Schedule on page 5-17 and
Periodic Maintenance Procedures on page 5-19.
EPA / ARB Installation

EXHAUST HAZARD! Requirements - USA Only
NEVER operate the engine in an The following are the installation requirements for
enclosed area such as a garage, the EPA / ARB. Unless these requirements are met,
tunnel, underground room, manhole or the exhaust gas emissions will not be within the
ships hold without proper ventilation. limits specified by the EPA and ARB.
NEVER block windows, vents, or other Maximum Exhaust Gas Restriction shall be:
means of ventilation if the engine is
3TNV84T: 1.42 psi (9.81 kPa; 1000 mm Aq) or
operating in an enclosed area. All
less
internal combustion engines create
carbon monoxide gas during 4TNV84T and 4TNV98T: 1.71 psi (11.77 kPa;
operation. Accumulation of this gas 1200 mm Aq) or Iess
within an enclosure could cause
illness or even death. 3TNV82A, 3TNV84, 3TNV88, 4TNV94, 4TNV88,
4TNV94L, and 4TNV98: 2.22 psi (15.3 kPa;
Make sure that all connections are 1560 mm Aq) or Iess
is made to the exhaust system. Maximum air intake restriction shall be 0.90 psi
Failure to comply could result in death (6.23 kPa; 635 mm Aq) or less. Clean or replace
or serious injury. the air cleaner element if the air intake restriction
exceeds the above mentioned value.
0000003en

SCHEDULE
Daily and periodic maintenance is important to
keep the engine in good operating condition. The
following is a summary of maintenance items by
periodic maintenance intervals. Periodic
maintenance intervals vary depending on engine
application, loads, diesel fuel and engine oil used
and are hard to establish definitively. The following
should be treated only as a general guideline.
CAUTION
Establish a periodic maintenance plan
according to the engine application and
make sure you perform the required
periodic maintenance at the intervals
indicated. Failure to follow these
shorten the engines life and may affect
the warranty coverage on your engine.
Warranty Section.
Consult your authorized Yanmar dealer
or distributor for assistance when
checking items marked with a z.
0000024enTNVDISM

c:Check :Replace z: Contact your authorized Yanmar industrial engine dealer or distributor
Periodic Maintenance Interval
System Check Item Daily Every Every Every Every Every Every
50 250 500 1000 1500 2000
hours hours hours hours hours hours
Check and Refill Engine Coolant c
Check and Clean Radiator Fins c
c
c 2nd
Cooling Check and Adjust Cooling Fan V-Belt
1st time and
System after
or
Drain, Flush and Refill Cooling System every year
with New Coolant whichever
comes first
Cylinder Adjust Intake / Exhaust Valve Clearance z
Head Lap Intake / Exhaust Valve Seats z
Electrical Check Indicators c
Equipment Check Battery c
Check Engine Oil Level c
Drain and Fill Engine Oil
Engine Oil 2nd
Replace Engine Oil Filter 1st time and
after
Engine
Check and Adjust Governor Lever and
Speed c c
Engine Speed Control
Control
Inspect, Clean and Test Fuel Injectors z
Emission Inspect Turbocharger (Blower wash as
Control necessary) 3TNV84T, 4TNV84T, z
Warranty 4TNV98T, and 4TNV106T
Inspect Crankcase Breather System z
Check and Refill Fuel Tank Level c
Drain Fuel Tank c
Drain Fuel Filter / Water Separator c
Fuel
Check Fuel Filter / Water Separator c
Clean Fuel Filter / Water Separator c
Replace Fuel Filter
z or
Replace Fuel System and
Hoses every 2
Cooling System Hoses
years
Intake and
Clean or Replace Air Cleaner Element c
Exhaust
Complete
Overall Visual Check Daily c
Engine
Note: These procedures are considered normal maintenance and are performed at the owners expense.

PERIODIC MAINTENANCE CAUTION

PROCEDURES Only use the engine oil specified.
After Initial 50 Hours of Operation coverage, cause internal engine
Perform the following maintenance after the initial engine life.
50 hours of operation. Prevent dirt and debris from
Replace Engine Oil and Engine Oil Filter contaminating the engine oil. Carefully
Check and Adjust Cooling Fan V-Belt surrounding area before you remove
the cap.
Replace Engine Oil and Engine Oil
Filter
A WARNING
0000005en
BURN HAZARD! CAUTION

ALWAYS wear eye protection.
ALWAYS be environmentally
or serious injury.
responsible.
0000011en
Follow the guidelines of the EPA or
other governmental agencies for the
A WARNING proper disposal of hazardous
SUDDEN MOVEMENT HAZARD! materials such as engine oil, diesel
fuel and engine coolant. Consult the
Engaging the transmission or PTO at local authorities or reclamation facility.
in unexpected movement of the NEVER dispose of hazardous
equipment. materials irresponsibly by dumping
them into a sewer, on the ground, or
Failure to comply could result in death into ground water or waterways.
or serious injury.
0000006en
Failure to follow these procedures may
seriously harm the environment.
0000013en

The engine oil in a new engine becomes 7. After all oil has been drained from the engine,
contaminated from the initial break-in of internal reinstall the oil drain plug (Figure 5-2, (1)) and
parts. It is very important that the initial oil and filter tighten to 14 - 17 ftlb (19.6 - 23.5 Nm;
change is performed as scheduled. 2.0 - 2.4 kgfm).
Note: The oil drain plug may be in another 8. Dispose of used oil properly.
location if an optional oil pan is used. Remove the engine oil filter as follows:
Drain the engine oil as follows: 1. Turn the engine oil filter (Figure 5-2, (2))
counterclockwise (Figure 5-2, (3)) using a filter
1. Make sure the engine is level.
wrench.
2. Start the engine and bring it up to operating
temperature. (3)
3. Stop the engine.
(4)
4. Remove one of the oil filler caps
(Figure 5-1, (1)) to vent the engine crankcase
and allow the engine oil to drain more easily.
5. Position a container under the engine to collect
waste oil.
(2)
(1)
(1)
0000062B
Figure 5-2
(1) 0000084 2. Clean the engine oil filter mounting face.
3. Lightly coat the gasket on the new oil filter with
engine oil. Install the new engine oil filter
manually by turning it clockwise
(Figure 5-2, (4)) until it contacts the mounting
surface. Tighten an additional 3/4 of a turn
using the filter wrench.
Applicable Engine Oil Filter Part No.
3TNV82A, 3TNV84, 3TNV84T,
3TNV88, 4TNV84, 4TNV84T,
129150-35152
0000084B 4TNV88, 4TNV94L
4TNV98, 4TNV98T
Figure 5-1
4TNV106, 4TNV106T 119005-35100
6. Remove the oil drain plug (Figure 5-2, (1)) from
the engine oil pan. Allow oil to drain.

4. Add new engine oil to the engine as specified in 9. Reinstall the oil filler cap (Figure 5-3, (4)). If
Adding Engine Oil on page 4-14. any engine oil is spilled, wipe it away with a
clean cloth.
CAUTION
Check and Adjust Cooling Fan V-Belt
NEVER overfill the engine with engine
oil. The V-belt will slip if it does not have the proper
tension. This will prevent the alternator from
ALWAYS keep the oil level between the generating sufficient power. Also, the engine will
upper and lower lines on the oil cap / overheat due to the engine coolant pump pulley
dipstick. slipping.
0000015en
Check and adjust the V-belt tension (deflection) as
5. Warm up the engine by running it for five follows:
minutes and check for any engine oil leaks.
1. Press the V-belt down with your thumb with a
6. After engine is warm, shut it off and let it sit for
force of approximately 22 ftlb (98 Nm; 10 kgf)
10 minutes.
to check the deflection.
7. Recheck the engine oil level.
There are three positions to check for V-belt
8. Add engine oil (Figure 5-3, (5)) as needed until tension (Figure 5-4, (A), (B) and (C)). You can
the level is between the upper (Figure 5-3, (2)) check the tension at whichever position is the
and lower lines (Figure 5-3, (3)) shown on the most accessible. The proper deflection of a used
dipstick (Figure 5-3, (1)). V-belt at each position is:
(4)
Used V-Belt Tension
A B C
3/8 - 1/2 in. 1/4 - 3/8 in. 5/16 - 1/2 in.
(10 - 14 mm) (7 - 10 mm) (9 - 13 mm)
Note: A Used V-Belt refers to a V-belt which

has been used on a running engine for
five minutes or more.
(B)
(4)
(5)
(2) (A)
(1) (C)
(3) 0000063B
0000007C
Figure 5-4
Figure 5-3

2. If necessary, adjust the V-belt tension. Loosen 4. Check the V-belt for cracks, oil or wear. If any of
the adjusting bolt (Figure 5-5, (1)) and move these conditions exist, replace the V-belt.
the alternator (Figure 5-5, (2)) with a pry bar 5. Install the new V-belt. Refer to the table for
(Figure 5-5, (3)) to tighten the V-belt to the proper tension.
desired tension. Then tighten the adjusting bolt.
New V-Belt Tension
A B C
5/16 - 7/16 in. 3/16 - 5/16 in. 1/4 - 7/16 in.
(3) (8 - 12 mm) (5 - 8 mm) (7 - 11 mm)
(1) 6. After adjusting, run the engine for 5 minutes or

more. Check the tension again using the
specifications for a used V-belt.
(2) 0000064B Used V-Belt Tension
Figure 5-5 A B C
3/8 - 1/2 in. 1/4 - 3/8 in. 5/16 - 1/2 in.
3. Tighten the V-belt to the proper tension. There (10 - 14 mm) (7 - 10 mm) (9 - 13 mm)
must be clearance (Figure 5-6, (1)) between
the V-belt and the bottom of the pulley groove. If
there is no clearance (Figure 5-6, (2)) between
the V-belt and the bottom of the pulley groove,
replace the V-belt.
(2)
(1)
0000584
Figure 5-6

Every 50 Hours of Operation CAUTION

After you complete the initial 50 hour maintenance positioned higher than the fuel level in
procedures, perform the following procedures every the fuel tank, water may not drip out
50 hours thereafter. when the fuel filter / water separator
Drain Fuel Filter / Water Separator
Check Battery fuel filter / water separator 2-3 turns
counterclockwise.
Drain Fuel Filter / Water Separator Be sure to tighten the air vent screw
A DANGER 0000025en
CAUTION

When you remove any fuel system ALWAYS be environmentally
component to perform maintenance responsible.
proper disposal of hazardous
NEVER use a shop rag to catch the materials such as engine oil, diesel
fuel. Vapors from the rag are fuel and engine coolant. Consult the
flammable and explosive. local authorities or reclamation facility.
Wipe up any spills immediately. NEVER dispose of hazardous
Wear eye protection. The fuel system materials irresponsibly by dumping
is under pressure and fuel could spray them into a sewer, on the ground, or
out when you remove any fuel system into ground water or waterways.
component. Failure to follow these procedures may
Failure to comply will result in death or seriously harm the environment.
serious injury. 0000013en
0000009en
Drain the fuel filter / water separator whenever
there are contaminants, such as water, collected in
the bottom of the cup. NEVER wait until the
scheduled periodic maintenance if contaminants
are discovered.

The cup of the separator is made from semi- 5. Open the fuel cock (Figure 5-7, (3)).
transparent material. In the cup is a red colored 6. Be sure to prime the diesel fuel system when
float ring. The float ring will rise to the surface of the you are finished. Priming the Fuel System on
water to show how much needs to be drained. Also, page 4-12.
some optional fuel filter / water separators are
equipped with a sensor to detect the amount of 7. Check for leaks.
contaminants. This sensor sends a signal to an
Check Battery
indicator to alert the operator.
Drain the fuel filter / water separator as follows: A DANGER
1. Position an approved container under the fuel
filter / water separator (Figure 5-7, (1)) to
collect the contaminants.
(2) EXPLOSION HAZARD!

NEVER check the remaining battery
charge by shorting out the terminals.
(3) This will result in a spark and may
(1)
hydrometer to check the remaining
battery charge.
If the electrolyte is frozen, slowly warm
(4) 0000012C
Figure 5-7 serious injury.
2. Close (Figure 5-7, (2)) the fuel cock 0000007en
(Figure 5-7, (3)).

3. Loosen the drain cock (Figure 5-7, (4)) at the
bottom of the fuel filter / water separator. Drain
any water collected inside.
4. Hand-tighten the drain cock.
CAUTION
positioned higher than the fuel level in
the fuel tank, water may not drip out
when the fuel filter / water separator
fuel filter / water separator 2-3 turns
counterclockwise.
Be sure to tighten the air vent screw
0000025en

When the amount of fluid nears the lower limit
A WARNING (Figure 5-8, (1)), fill with distilled water
(Figure 5-8, (2)) so it is at the upper limit
(Figure 5-8, (3)). If operation continues with
insufficient battery fluid, the battery life is
shortened, and the battery may overheat and
explode. During the summer, check the fluid level
BURN HAZARD! more often than specified.
Batteries contain sulfuric acid. NEVER
allow battery fluid to come in contact (3)
with clothing, skin or eyes. Severe
burns could result. ALWAYS wear (2)
safety goggles and protective clothing
fluid contacts the eyes and / or skin, (1)
immediately flush the affected area
with a large amount of clean water and
obtain prompt medical treatment.
Failure to comply could result in death 0000067A
or serious injury.
0000007en
Figure 5-8
If the engine cranking speed is so slow that the
CAUTION engine does not start, recharge the battery.
If the engine still will not start after charging, have
your authorized Yanmar industrial engine dealer
or distributor check the battery and the engines
starting system.
If operating the machine where the ambient
temperature could drop to 5F (-15C) or less,
responsible.
remove the battery from the machine at the end
Follow the guidelines of the EPA or of the day. Store the battery in a warm place until
other governmental agencies for the the next use. This will help start the engine easily
proper disposal of hazardous at low ambient temperatures.
materials such as engine oil, diesel
local authorities or reclamation facility.
NEVER dispose of hazardous
materials irresponsibly by dumping
0000013en

Every 250 Hours of Operation CAUTION
Perform the following maintenance every 250 hours

of operation.
Drain Fuel Tank
Replace Engine Oil and Engine Oil Filter ALWAYS be environmentally
responsible.
Check and Clean Radiator Fins
Check and Adjust Cooling Fan V-Belt other governmental agencies for the
Check and Adjust the Governor Lever and proper disposal of hazardous
Engine Speed Control materials such as engine oil, diesel
Clean Air Cleaner Element local authorities or reclamation facility.
Drain Fuel Tank
A DANGER into ground water or waterways.
0000013en
FIRE AND EXPLOSION HAZARD! Note that a typical fuel tank is illustrated.
Diesel fuel is flammable and explosive 1. Position an approved container under the diesel
under certain conditions. fuel tank (Figure 5-9, (1)) to collect the
When you remove any fuel system contaminates.
component to perform maintenance 2. Remove the fuel cap (Figure 5-9, (3)).
3. Remove the drain plug (Figure 5-9, (2)) of the
fuel tank to drain the contaminates (water, dirt,
etc.) from the bottom of the tank.
NEVER use a shop rag to catch the
fuel. Vapors from the rag are (3)
Wipe up any spills immediately.
(1)
is under pressure and fuel could spray
out when you remove any fuel system
component.
serious injury. (2)
0000009en 0000065A
Figure 5-9

4. Drain the tank until clean diesel fuel with no
water and dirt flows out. Reinstall and tighten CAUTION
the drain plug firmly.
5. Reinstall the fuel cap.
6. Check for leaks.
Replace Engine Oil and Engine Oil

Filter ALWAYS be environmentally
responsible.
CAUTION Follow the guidelines of the EPA or
Only use the engine oil specified. other governmental agencies for the
Other engine oils may affect warranty proper disposal of hazardous
coverage, cause internal engine materials such as engine oil, diesel
components to seize and / or shorten fuel and engine coolant. Consult the
engine life. local authorities or reclamation facility.
Prevent dirt and debris from NEVER dispose of hazardous
contaminating the engine oil. Carefully materials irresponsibly by dumping
clean the oil cap / dipstick and the them into a sewer, on the ground, or
surrounding area before you remove into ground water or waterways.
the cap. Failure to follow these procedures may
NEVER mix different types of engine seriously harm the environment.
oil. This may adversely affect the 0000013en

Change the engine oil every 250 hours of operation
NEVER overfill. Overfilling may result after the initial change at 50 hours. Replace the
in white exhaust smoke, engine engine oil filter at the same time. See Replace
overspeed or internal damage. Engine Oil and Engine Oil Filter on page 5-19.
0000005en

Check and Clean Radiator Fins
A CAUTION
(1)
FULL
LOW
FLYING OBJECT HAZARD!

ALWAYS wear eye protection when 0000085A
Figure 5-10
compressed air or high-pressure
water. Dust, flying debris, compressed Check and Adjust Cooling Fan V-Belt
air, pressurized water or steam may
injure your eyes. Check and adjust the cooling fan V-belt every 250
hours of operation after the initial 50 hour V-belt
Failure to comply may result in minor maintenance. See Check and Adjust Cooling Fan
or moderate injury. V-Belt on page 5-21.
0000003en
Check and Adjust the Governor Lever

Dirt and dust adhering to the radiator fins reduce
and Engine Speed Control
the cooling performance, causing overheating.
Make it a rule to check the radiator fins daily and The governor lever and engine speed control
clean as needed. (throttle lever, pedal, etc.) of the machine are
connected together by a throttle cable or rod. If the
Note that a typical radiator is shown in Figure 5-10 cable becomes stretched, or the connections
for illustrative purposes only. loosen, the governor lever may not respond to
change of engine speed control position. This may
Blow off dirt and dust from fins and radiator with
make operation of the machine unsafe. Check the
28 psi (0.19 MPa; 2 kgf/cm2) or less of
cable periodically and adjust if necessary.
compressed air (Figure 5-10, (1)). Be careful not
to damage the fins with the compressed air. NEVER force the throttle cable or pedal to move.
This may deform the governor lever or stretch the
If there is a large amount of contamination on the
cable and cause irregular operation of the engine
fins, apply detergent, thoroughly clean and rinse
speed control.
with tap water.
CAUTION
NEVER use high-pressure water or
compressed air at greater than 28 psi
(193 kPa; 19 686 mm Aq) or a wire brush
to clean the radiator fins. Radiator fins
damage easily.
0000016en

Checking and adjusting the governor lever: Clean Air Cleaner Element
1. Check that the governor lever (Figure 5-11, (1)) Note that a typical air cleaner is shown in
makes uniform contact with the high idle Figure 5-12 and Figure 5-13 for illustrative
(Figure 5-11, (2)) and low idle purposes only.
(Figure 5-11, (3)) speed limit screws when the The engine performance is adversely affected
engine speed control is in the high idle speed or when the air cleaner element is clogged with dust.
low idle speed position. Be sure to clean the air filter element periodically.
1. Unlatch and remove the air cleaner cover
(Figure 5-12, (1)).
(3) (6) (4)

(2) (2)
(5)
(3)
(1)
(1)
(4)
0000070A
0000069A
Figure 5-12
Figure 5-11 2. Remove the element (Figure 5-12, (2)) (outer
element if equipped with two elements).
2. If the governor lever does not make contact with
the high idle or low idle speed limit screw, adjust
the throttle cable.
A CAUTION
3. In some engine speed control applications,
loosen the throttle cable lock nut
(Figure 5-11, (4)) and adjust the cable so the
governor lever makes proper contact with the
high / low idle speed limit screw.
CAUTION FLYING OBJECT HAZARD!

NEVER attempt to adjust the low or high ALWAYS wear eye protection when
idle speed limit screw. This may impair servicing the engine and when using
the safety and performance of the compressed air or high-pressure
machine and shorten its life. If the idle water. Dust, flying debris, compressed
speed limit screws require adjustment, air, pressurized water or steam may
see your authorized Yanmar industrial injure your eyes.
engine dealer or distributor. Failure to comply may result in minor
0000017en or moderate injury.
0000003en

3. Blow air (Figure 5-12, (3)) through the element 6. Replace the element with a new one if the
from the inside out using 42 - 71 psi element is damaged, excessively dirty or oily.
(0.29 - 0.49 MPa; 3.0 - 5.0 kgf/cm2) 7. Clean inside of the air cleaner cover.
compressed air to remove the particulates. Use 8. Install the element into the air cleaner case
the lowest possible air pressure to remove the (Figure 5-12, (4)).
dust without damaging the element.
9. Reinstall the air cleaner cover making sure you
4. If the air cleaner is equipped with a double match the arrow (Figure 5-12, (5)) on the cover
element, only remove and replace the inner with the arrow on the case (Figure 5-12, (6)).
element (Figure 5-13, (1)) if the engine lacks
power or the dust indicator actuates (if 10. Latch the air cleaner cover to the case.
equipped).
CAUTION
When the engine is operated in dusty
conditions, clean the air cleaner
element more frequently.
NEVER operate the engine with the air
cleaner element(s) removed. This may
(1) allow foreign material to enter the
engine and damage it.
0000026en
0000071A
Figure 5-13
5. The inner element should not be removed when
cleaning or replacing the outer element. The
inner element is used to prevent dust from
entering the engine while servicing the outer
element.

Replace Fuel Filter
Every 500 Hours of Operation
A DANGER
Perform the following maintenance every 500 hours
of operation.
Replace Air Cleaner Element
Replace Fuel Filter
Clean Fuel Filter / Water Separator Diesel fuel is flammable and explosive
Replace Air Cleaner Element
CAUTION component to perform maintenance
The maximum air intake restriction, in an approved container under the
terms of differential pressure opening to catch the fuel.
measurement, must not exceed 0.90 psi
(6.23 kPa; 635 mmAq). Clean or replace NEVER use a shop rag to catch the
the air cleaner element if the air intake fuel. Vapors from the rag are
restriction exceeds the above flammable and explosive.
mentioned value. Wipe up any spills immediately.
0000046en
Replace the air cleaner element (Figure 5-12, (2)) is under pressure and fuel could spray
every 500 hours even if it is not damaged or dirty. out when you remove any fuel system
component.
When replacing the element, clean the inside of the
air cleaner case (Figure 5-12, (4)).
serious injury.
If the air cleaner is equipped with a double element, 0000009en
only remove and replace the inner element

(Figure 5-13, (1)) if the engine lacks power or the CAUTION
dust indicator actuates (if equipped). This is in
addition to replacing the outer element. For maximum engine life, Yanmar
engine down, you allow the engine to
will allow the engine components that
operate at high temperatures, such as
the turbocharger (if equipped) and
exhaust system, to cool slightly before
the engine itself is shut down.
0000008en

CAUTION
responsible.
(1) (2)
proper disposal of hazardous 0000072A
fuel and engine coolant. Consult the Figure 5-14
local authorities or reclamation facility. 4. Clean the filter mounting surface and apply a
NEVER dispose of hazardous small amount of diesel fuel to the gasket of the
materials irresponsibly by dumping new fuel filter.
them into a sewer, on the ground, or 5. Install the new fuel filter. Turn to the right
into ground water or waterways. (Figure 5-14, (2)) and hand-tighten it only until
Failure to follow these procedures may it comes in contact with the mounting surface.
seriously harm the environment. Use a filter wrench to tighten it one additional
0000013en turn.
Replace the fuel filter at specified intervals to Applicable Fuel Filter Part No.
prevent contaminants from adversely affecting the All models except 119802-55800
diesel fuel flow. 4TNV98T, 4TNV106,
1. Stop the engine and allow it to cool. 4TNV106T
2. Close the fuel cock of the fuel filter / water 4TNV98T, 4TNV106, 123907-55800
separator. 4TNV106T
3. Remove the fuel filter with a filter wrench, 6. Open the fuel cock of the fuel filter / water
turning it to the left (Figure 5-14, (1)). When separator.
removing the fuel filter, carefully hold it to
prevent the fuel from spilling. Wipe up all spilled 7. Prime the fuel system. See Priming the Fuel
fuel. System on page 4-12.
8. Check for leaks.

Clean Fuel Filter / Water Separator
CAUTION
A DANGER
FIRE AND EXPLOSION HAZARD! ALWAYS be environmentally

responsible.
under certain conditions. Follow the guidelines of the EPA or
NEVER use diesel fuel as a cleaning proper disposal of hazardous
agent. materials such as engine oil, diesel
Failure to comply will result in death or fuel and engine coolant. Consult the
serious injury. local authorities or reclamation facility.
0000012en NEVER dispose of hazardous
A DANGER them into a sewer, on the ground, or
0000013en

component to perform maintenance
NEVER use a shop rag to catch the
fuel. Vapors from the rag are
Wipe up any spills immediately.
is under pressure and fuel could spray
out when you remove any fuel system
component.
serious injury.
0000009en

Periodically clean the fuel filter / water separator 6. Remove the float ring (Figure 5-15, (8)) from
element and inside cup. the cup. Pour the contaminants into the
container and dispose of it properly.
1. Position an approved container under the cup
(Figure 5-15, (1)) of the fuel filter / water 7. Clean the element (Figure 5-15, (9)) and inside
separator to collect the contaminants. cup. Replace the element if it is damaged.
(5) (9) Applicable Element Part No.

All Models 119802-55710
(2)
8. Install the element and O-ring in the bracket.
(10) 9. Position the float ring in the cup.
(3) (6) 10. Check the condition of the cup O-ring. Replace
if necessary.
11. Install the cup to the bracket by tightening the
(8) retaining ring to the right (Figure 5-15, (6)) to a
(1)
torque of 11 - 15 ftlb (15 - 20 Nm;
(4) 1.5 - 2.0 kgfm).
12. Close the drain cock. Reconnect the sensor
wire if equipped.
13. Open the fuel cock (Figure 5-15, (3)).
14. Prime the fuel system. See Priming the Fuel
System on page 4-12.
15. Check for leaks.
(7)
0000073A
Figure 5-15
2. Close (Figure 5-15, (2)) the fuel cock
(Figure 5-15, (3)).
3. Loosen the drain cock (Figure 5-15, (4)) and
drain the contaminants. See Drain Fuel Filter /
Water Separator on page 5-23.
4. Turn the retaining ring (Figure 5-15, (5)) to the
left (Figure 5-15, (10)) and remove the cup
(Figure 5-15, (6)). If equipped, disconnect the
sensor wire (Figure 5-15, (7)) from the cup
before removing the cup.
5. Carefully hold the cup to prevent fuel from
spilling. If you spill any fuel, clean up the spill
completely.

Every 1000 Hours of Operation A WARNING

Perform the following maintenance every 1000
hours of operation.
Drain, Flush and Refill Cooling System With
New Coolant BURN HAZARD!
Adjust Intake / Exhaust Valve Clearance Wait until the engine cools before you
Drain, Flush and Refill Cooling System coolant may splash and burn you.
With New Coolant
or serious injury.
A DANGER 0000016en
A CAUTION
SCALD HAZARD!
engine is hot. Steam and hot engine
COOLANT HAZARD!
burn you. Allow the engine to cool Wear eye protection and rubber gloves
down before you attempt to remove when you handle long life or extended
the radiator cap. life engine coolant. If contact with the
eyes or skin should occur, flush eyes
Tighten the radiator cap securely after
and wash immediately with clean
water.
the cap is loose. Failure to comply may result in minor
or moderate injury.
ALWAYS check the level of the engine
0000005en
coolant by observing the reserve tank.
serious injury.
0000002en

CAUTION
(1)
FULL
LOW
responsible.
materials such as engine oil, diesel (2) 0000074A
Figure 5-16
NEVER dispose of hazardous 4. Drain the coolant from the engine block.
materials irresponsibly by dumping On models not equipped with an oil cooler,
them into a sewer, on the ground, or remove the coolant drain plug
into ground water or waterways. (Figure 5-17, (1)) from the engine block.
0000013en
Engine coolant contaminated with rust or scale

reduces the cooling effect. Even when extended life
engine coolant is properly mixed, the engine
coolant gets contaminated as its ingredients
deteriorate. Drain, flush and refill the cooling
system with new coolant every 1000 hours or once (1)
a year, whichever comes first.
1. Allow engine and coolant to cool. 0000027B
2. Remove the radiator cap (Figure 5-16, (1)). Figure 5-17

3. Remove the drain plug or open the drain cock
(Figure 5-16, (2)) at the lower portion of the
radiator and drain the engine coolant.

On models equipped with an oil cooler, remove
the coolant hose (Figure 5-18, (1)) at the oil Every 1500 Hours of Operation
cooler.
Perform the following maintenance every 1500
hours of operation.
Inspect, Clean and Test Fuel Injectors
Inspect Turbocharger (Blower Wash as
Necessary) - 3TNV84T, 4TNV84T, 4TNV98T
and 4TNV106T
Inspect Crankcase Breather System
Inspect, Clean and Test Fuel Injectors
A WARNING
(1) 0001579B
Figure 5-18
5. After draining the engine coolant, flush the
radiator and engine block to remove any rust, HIGH-PRESSURE HAZARD!
scale and contaminants. Then reinstall and Avoid skin contact with the
tighten the drain plug or close the drain cock in high-pressure diesel fuel spray caused
the radiator. Reinstall and tighten the cylinder by a fuel system leak such as a broken
block drain plug or reconnect the coolant hose fuel injection line. High-pressure fuel
at the oil cooler. can penetrate your skin and result in
6. Fill radiator and engine with engine coolant. serious injury. If you are exposed to
See Filling Radiator with Engine Coolant on high-pressure fuel spray, obtain
page 4-16. prompt medical treatment.
Adjust Intake / Exhaust Valve
hands. ALWAYS use a piece of wood
Clearance or cardboard. Have your authorized
Proper adjustment is necessary to maintain the Yanmar industrial engine dealer or
correct timing for opening and closing the valves. distributor repair the damage.
Improper adjustment will cause the engine to run
noisily, resulting in poor engine performance and
or serious injury.
engine damage. See Intake / Exhaust Valve and
0000008en
Guide on page 6-7.
Proper operation of the fuel injectors is required to
obtain the optimum injection pattern for full engine
performance. The EPA / ARB requires that the fuel
injectors are inspected, cleaned and tested every
1500 hours. See Testing of Fuel Injectors on
page 7-33.

This procedure is considered normal maintenance To inspect the diaphragm and spring
and is performed at the owners expense. This (Figure 5-19, (3)):
procedure is not covered by the Yanmar Limited
Warranty. 1. Remove the bolts retaining the diaphragm cover
(Figure 5-19, (4)).
Inspect Turbocharger (Blower Wash
(4)
as Necessary) - 3TNV84T, 4TNV98T,
4TNV84T, and 4TNV106T (3)
Turbocharger service is required by the EPA / ARB (5)
every 1500 hours. Inspect, clean and blower wash
the unit if necessary (see Periodic Inspection on (1)
page 10-13). If you notice that the engine seems
(2)
sluggish or the exhaust color is abnormal NEVER
wait until the next service interval.
Inspect Crankcase Breather System

Proper operation of the crankcase breather system
is required to maintain the emission requirements
of the engine. The EPA / ARB requires that the
crankcase breather system is inspected every 1500 0002135
hours.
Figure 5-19
There are three different crankcase breather
systems used on the TNV engines. Only the non- 2. Remove the diaphragm cover, spring,
turbo TNV engines crankcase breather system diaphragm plate (Figure 5-19, (5)) and
requires periodic maintenance. diaphragm.
3. Inspect the diaphragm for tears. Inspect the
The non-turbo TNV engines use a crankcase
spring for distortion. Replace components if
breather system that has a spring-backed
necessary.
diaphragm (Figure 5-19, (1)) in the valve cover
(Figure 5-19, (2)). When the crankcase pressure 4. Reinstall the diaphragm, diaphragm plate,
reaches a predetermined value, the diaphragm spring and diaphragm cover. Tighten the
opens a passage that allows crankcase fumes to diaphragm bolts to specified torque.
be routed to the intake manifold. Failure of the diaphragm and / or spring will cause
the loss of pressure control and allow an excessive
amount of crankcase fumes to be routed to the
intake manifold. This could result in excessive
deposits in the intake system, high engine exhaust
smoke levels, excessive engine oil consumption,
and / or engine run-on due to the burning of the
engine oil.

Lap the Intake and Exhaust Valves
Every 2000 Hours of Operation
Adjustment is necessary to maintain proper contact
of the valves and seats. See Inspection of Intake
Perform the following maintenance every 2000 and Exhaust Valves on page 6-39.
hours of operation.
Check and Replace Fuel Hoses and Engine
Coolant Hoses
Lap the Intake and Exhaust Valves
Check and Replace Fuel Hoses and

Engine Coolant Hoses
CAUTION
responsible.
0000013en
Regularly check the fuel system and engine coolant

system hoses. If they are cracked or degraded,
replace them. Replace the hoses at least every two
years.


Section 6
ENGINE
Page
Introduction...................................................................................... 6-6
Cylinder Head Specifications .......................................................... 6-6
Adjustment Specifications ......................................................... 6-6
Cylinder Head............................................................................ 6-6
Intake / Exhaust Valve and Guide ............................................. 6-7
Push Rod................................................................................... 6-8
Valve Spring .............................................................................. 6-9
Rocker Arm and Shaft ............................................................... 6-9
Camshaft and Timing Gear Train Specifications........................... 6-10
Camshaft ................................................................................. 6-10
Idler Gear Shaft and Bushing .................................................. 6-12
Timing Gear Backlash ............................................................. 6-12
Crankshaft and Piston Specifications............................................ 6-13
Crankshaft ............................................................................... 6-13
Thrust Bearing ......................................................................... 6-14
Piston....................................................................................... 6-15
Piston Ring .............................................................................. 6-17
Connecting Rod....................................................................... 6-21
Tappet ..................................................................................... 6-22
Cylinder Block Specifications ........................................................ 6-22
Cylinder Block.......................................................................... 6-22
Special Torque Chart .................................................................... 6-23
Torque for Bolts and Nuts........................................................ 6-23
Special Service Tools.................................................................... 6-26
Measuring Instruments.................................................................. 6-30

ENGINE
2-Valve Cylinder Head ................................................................... 6-32
2-Valve Cylinder Head Components ........................................ 6-32
Disassembly of 2-Valve Cylinder Head .................................... 6-33
Cleaning of Cylinder Head Components .................................. 6-37
Inspection of Cylinder Head Components................................ 6-37
Reassembly of Cylinder Head.................................................. 6-42
4-Valve Cylinder Head ................................................................... 6-46
4-Valve Cylinder Head Components ........................................ 6-46
Disassembly of 4-Valve Cylinder Head .................................... 6-47
Cleaning of Cylinder Head Components .................................. 6-52
Inspection of Cylinder Head Components................................ 6-52
Reassembly of Cylinder Head.................................................. 6-57
Measuring and Adjusting Valve Clearance .................................... 6-62
2-Valve Cylinder Heads............................................................ 6-63
4-Valve Cylinder Heads............................................................ 6-64
Crankshaft and Camshaft Components ......................................... 6-68
Disassembly of Engine............................................................. 6-69
Disassembly of Camshaft and Timing Components ................ 6-70
Disassembly of Crankshaft and Piston Components ............... 6-75
Inspection of Crankshaft and Camshaft Components.............. 6-79
Honing and Boring.................................................................... 6-85
Reassembly of Crankshaft and Piston Components................ 6-86
Reassembly of Camshaft and Timing Components ................. 6-91
Final Reassembly of Engine..................................................... 6-94

ENGINE
BEFORE YOU BEGIN

A WARNING
SERVICING
A WARNING
FUME / BURN HAZARD!

Always read and follow safety related
precautions found on containers of
To prevent possible eye injury, always cleaners, primers, sealants and
wear SAFETY GLASSES while servicing sealant removers.
the engine.
0000013en
or serious injury.
A WARNING
0000014en
A CAUTION
ENTANGLEMENT HAZARD!
Stop the engine before you begin to
service it.
NEVER leave the key in the key switch FLYING OBJECT HAZARD!
when you are servicing the engine. ALWAYS wear eye protection when
Someone may accidentally start the servicing the engine and when using
engine and not realize you are compressed air or high-pressure
servicing it. This could result in a water. Dust, flying debris, compressed
serious injury. air, pressurized water or steam may
If you must service the engine while it injure your eyes.
is operating, remove all jewelry, tie Failure to comply may result in minor
back long hair, and keep your hands, or moderate injury.
other body parts and clothing away 0000003en
Failure to comply could result in death A CAUTION
or serious injury.
Be sure to secure the engine solidly to
0000010en
prevent injury or damage to parts due to
the engine falling during work on the
engine.
0000009en

ENGINE
CAUTION CAUTION
Only use the engine oil specified. Any part which is found defective as a
Other engine oils may affect warranty result of inspection or any part whose
coverage, cause internal engine measured value does not satisfy the
components to seize and / or shorten standard or limit must be replaced.
engine life. 0000119en

contaminating the engine oil. Carefully CAUTION
Any part determined to not meet the
the cap.
NEVER mix different types of engine current rate of wear, should be replaced
oil. This may adversely affect the even though the part currently meets the
lubricating properties of the engine oil. service standard limit.
NEVER overfill. Overfilling may result 0000120en

overspeed or internal damage. CAUTION
0000005en
Remove or install the high-pressure fuel
injection lines as an assembly whenever
CAUTION possible. Disassembling the
Only use the engine coolant specified. high-pressure fuel injection lines from
Other engine coolants may affect the retainers or bending any of the fuel
warranty coverage, cause an internal lines will make it difficult to reinstall the
buildup of rust and scale and / or fuel lines.
shorten engine life. 0000047en

contaminating the engine coolant. CAUTION
Carefully clean the radiator cap and Do not loosen or remove the four bolts
the surrounding area before you retaining the fuel injection pump drive
remove the cap. gear to the fuel injection pump hub. Do
NEVER mix different types of engine not disassemble the fuel injection pump
coolants. This may adversely affect the drive gear from the hub. Correct fuel
properties of the engine coolant. injection timing will be very difficult or
0000006en
impossible to achieve.
0000031en
CAUTION
Identify all parts and their location using
an appropriate method. It is important
0000080en

ENGINE
CAUTION
assemblies, and connecting rod
assemblies together to be returned to
the same position during the
reassembly process. Label the parts
using an appropriate method.
0000088en
CAUTION
motion.
0000090en

ENGINE
INTRODUCTION
This section of the Service Manual describes servicing of the engine.
CYLINDER HEAD SPECIFICATIONS

Adjustment Specifications
Valve Bridge Clearance
Model Valve Clearance
(4-Valve Head Only)
0.006 - 0.010 in.
All except 4TNV106, 4TNV106T 0
(0.15 - 0.25 mm)
0.010 - 0.014 in.
4TNV106, 4TNV106T 0
(0.25 - 0.35 mm)
Cylinder Head
Reference
Page
0.0020 in. 0.0059 in.
Combustion Surface Distortion (Flatness)
(0.05 mm) or less (0.15 mm)
0.0138 - 0.0217 in.
Intake 0.0315 in. (0.8 mm)
3TNV82A (0.35 - 0.55 mm)
(2-Valve Head) 0.0118 - 0.0197 in.
Exhaust 0.0315 in. (0.8 mm)
(0.30 - 0.50 mm)
3TNV84, 3TNV84T, 0.0118 - 0.0197 in.
Intake 0.0315 in. (0.8 mm)
3TNV88, 4TNV84, (0.30 - 0.50 mm)
4TNV84T, 4TNV88 See Valve
(2-Valve Head) 0.0118 - 0.0197 in. Recession on
4TNV84T (4-Valve Exhaust 0.0315 in. (0.8 mm)
(0.30 - 0.50 mm) page 6-40
Valve Recession Head) and 6-55.
0.0142 - 0.0220 in.
4TNV94L, 4TNV98, Intake 0.0315 in. (0.8 mm)
(0.36 - 0.56 mm)
4TNV98T
(4-Valve Head) 0.0138 - 0.0217 in.
(0.35 - 0.55 mm)
0.0197 - 0.0276 in.
Intake 0.0394 in. (1.0 mm)
4TNV106, 4TNV106T (0.50 - 0.70 mm)
(4-Valve Head) 0.0276 - 0.0354 in.
(0.70 - 0.90 mm)
Intake 120 - See Valve
Seat Angle Face and
Valve Seat Exhaust 90 -
Valve Seat
(2-Valve, 4-Valve)
Seat Correction Angle 40, 150 - on page 6-40
and 6-55.

ENGINE
Intake / Exhaust Valve and Guide
Reference
Page
0.2756 - 0.2762 in. 0.2787 in.
Guide Inside Diameter
(7.000 - 7.015 mm) (7.08 mm)
Valve Stem Outside 0.2734 - 0.2740 in. 0.2717 in.
Intake
Diameter (6.945 - 9.960 mm) (6.90 mm)
0.0016 - 0.0028 in. 0.0071 in. See
Valve Stem Bend Inspection of
3TNV82A (0.040 - 0.070 mm) (0.18 mm)
Valve Guides
(2-Valve Head) 0.2756 - 0.2762 in. 0.2787 in.
Guide Inside Diameter on
(7.000 - 7.015 mm) (7.08 mm) page 6-39.
Exhaust
Diameter (6.940 - 6.955 mm) (6.90 mm)
0.0018 - 0.0030 in. 0.0071 in.
Valve Stem Bend
(0.045 - 0.075 mm) (0.18 mm)
0.3154 - 0.3159 in. 0.3189 in.
(8.010 - 8.025 mm) (8.10 mm)
Intake
Diameter (7.955 - 7.975 mm) (7.90 mm)
0.0014 - 0.0028 in. 0.0071 in. See
4TNV84, Valve Stem Bend
(0.035 - 0.070 mm) (0.18 mm) Inspection of
3TNV84, 3TNV84T,
Valve Guides
4TNV88, 4TNV88 0.3156 - 0.3161 in. 0.3189 in.
(2-Valve Head) (8.015 - 8.030 mm) (8.10 mm) page 6-39.
Valve Stem Outside 0.3132 -.3134 in. 0.3110 in.
Exhaust
Diameter (7.955 - 7.960 mm) (7.90 mm)
0.0018 - 0.0030 in. 0.0071 in.
Valve Stem Bend
(0.045 - 0.075 mm) (0.18 mm)
0.2362 - 0.2368 in. 0.2394 in.
(6.000 - 6.015 mm) (6.08 mm)
Intake
Diameter (5.960 - 5.975 mm) (5.90 mm)
0.0010 - 0.0022 in. 0.0059 in. See
4TNV84T (0.025 - 0.055 mm) (0.15 mm)
Valve Guides
(4-Valve Head) 0.2362 - 0.2368 in. 0.2394 in.
(6.000 - 6.015 mm) (6.08 mm) page 6-39.
Exhaust
Diameter (5.945 - 5.960 mm) (5.90 mm)
0.0016 - 0.0028 in. 0.0067 in.
Valve Stem Bend
(0.040 - 0.070 mm) (0.17 mm)

ENGINE
(Intake / Exhaust Valve and Guide Cont.)
Reference
Page
0.2756 - 0.2762 in. 0.2787 in.
(7.000 - 7.015 mm) (7.08 mm)
Intake
Diameter (6.945 - 6.960 mm) (6.90 mm)
0.0016 - 0.0028 in. 0.0067 in. See
4TNV94L Oil Clearance Inspection of
(0.040 - 0.070 mm) (0.17 mm)
4TNV98, 4TNV98T Valve Guides
(4-Valve Head) 0.2756 - 0.2762 in. 0.2787 in. on
(7.000 - 7.015 mm) (7.08 mm) page 6-39.
Exhaust
Diameter (6.940 - 6.955 mm) (6.90 mm)
0.0018 - 0.0030 in. 0.0067 in.
Valve Stem Bend
(0.045 - 0.075 mm) (0.17 mm)
0.2759 - 0.2764 in. 0.2787 in.
(7.008 - 7.020 mm) (7.08 mm)
Intake
Diameter (6.945 - 6.960 mm) (6.92 mm)
0.0019 - 0.0030 in. 0.0063 in. See
4TNV106T (0.048 - 0.075 mm) (0.16 mm)
Valve Guides
(4-Valve Head) 0.2759 - 0.2764 in. 0.2787 in.
(7.008 - 7.020 mm) (7.08 mm) page 6-39.
Exhaust
Diameter (6.960 - 6.975 mm) (6.90 mm)
0.0013 - 0.0024 in. 0.0071 in.
Valve Stem Bend
(0.033 - 0.060 mm) (0.18 mm)
0.4606 - 0.4724 in.
3TNV82A -
(11.70 - 12.00 mm)
3TNV84, 3TNV84T, 0.5791 -0.5905 in.
-
4TNV84, 4TNV88 (14.71 - 5.00 mm) See
Valve Guide Projection From 0.3228 - 0.3346 in. Reassembly
4TNV84T - of Valve
Cylinder Head (8.20 - 8.50 mm)
Guides on
4TNV94L, 4TNV98, 0.3819 - 0.3937 in. page 6-42
-
4TNV98T (9.70 - 10.00 mm) and 6-57.
0.5276 - 0.5354 in.
4TNV106, 4TNV106T -
(13.40 - 13.60 mm)
Valve Guide Installation Method Cold-fitted -
Push Rod
Reference
Page
See Push
Less than 0.0012 in. Rod Bend on
Push Rod Bend - All Models
0.0012 in. (0.03 mm) (0.03 mm) page 6-38
and 6-53.

ENGINE
Valve Spring
Reference
Inspection Item Model Standard Limit
Page
1.7480 in. 1.7283 in.
3TNV82A (2-Valve Head)
(44.4 mm) (43.9 mm)
4TNV84, 3TNV84, 3TNV84T, 4TNV88 1.6535 in. 1.6339 in.
(2-Valve Head) (42.0 mm) (41.5 mm)
1.4724 in. 1.4528 in.
Free Length 4TNV84T (4-Valve Head)
(37.4 mm) (36.9 mm)
4TNV94L, 4TNV98, 4TNV98T (4-Valve 1.5630 in. 1.5433 in.
Head) (39.7 mm) (39.2 mm)
See
1.9921 in. 1.9724 in. Inspection of
4TNV106, 4TNV106T (4-Valve Head)
(50.6 mm) (50.1 mm) Valve
0.0551 in. Springs on
3TNV82A (2-Valve Head) - page 6-41
(1.4 mm)
and 6-56.
4TNV84, 3TNV84, 3TNV84T, 0.0551 in.
-
4TNV88 (2-Valve Head) (1.4 mm)
0.0551 in.
Squareness 4TNV84T (4-Valve Head) -
(1.3 mm)
4TNV94L, 4TNV98, 4TNV98T (4-Valve 0.0551 in.
-
Head) (1.4 mm)
0.0551 in.
4TNV106, 4TNV106T (4-Valve Head) -
(1.5 mm)
Rocker Arm and Shaft

Reference
Model Inspection Item Standard Limit
Page
0.6299 - 0.6307 in. 0.6327 in.
Arm Shaft Hole Diameter
3TNV82A, 3TNV84, (16.000 - 16.020 mm) (16.07 mm)
3TNV84T, 3TNV88, 0.6286 - 0.6293 in. 0.6276 in.
Shaft Outside Diameter
4TNV84, 4TNV84T, (15.966 - 15.984 mm) (15.94 mm)
See
4TNV88 0.0006 - 0.0021 in. 0.0051 in.
Oil Clearance Inspection of
(0.016 - 0.054 mm) (0.13 mm) Rocker Arm
0.7283 - 0.7291 in. 0.7311 in. Assembly on
Arm Shaft Hole Diameter page 6-38
(18.500 - 18.520 mm) (18.57 mm)
4TNV94L, 4TNV98, and 6-53.
0.7272 - 0.7280 in. 0.7260 in.
4TNV98T, 4TNV106, Shaft Outside Diameter
(18.470 - 18.490 mm) (18.44 mm)
4TNV106T
0.0004 - 0.0020 in. 0.0051 in.
Oil Clearance
(0.010 - 0.050 mm) (0.13 mm)

ENGINE
CAMSHAFT AND TIMING GEAR TRAIN SPECIFICATIONS

Camshaft
Reference
Page
See Removal
0.0020 - 0.0079 in. 0.0118 in. of Camshaft
End Play
(0.05 - 0.20 mm) (0.030 mm) on
page 6-73.
0 - 0.0008 in. 0.0020 in.
Bend (1/2 the dial gauge reading)
(0 - 0.02 mm) (0.05 mm)
3TNV82A, 3TNV84,
1.5197 - 1.5276 in. 1.5098 in. See
3TNV84T, 3TNV88, 4TNV84,
4TNV84T, 4TNV88
Camshaft on
Cam Lobe Height 4TNV94L, 4TNV98, 1.7087 - 1.7165 in. 1.6988 in. page 6-84.
4TNV98T (43.400 - 43.600 mm) (43.150 mm)
2.0039 - 2.0118 in. 1.9941 in.
4TNV106, 4TNV106T
(50.900 - 51.100 mm) (50.650 mm)
Shaft Outside Diameter / Bearing Inside Diameter
1.7713 - 1.7738 in. 1.7768 in.
Bushing Inside Diameter
(44.990 - 45.055 mm) (45.130 mm)
1.7687 - 1.7697 in. 1.7673 in.
Gear End Camshaft Outside Diameter
(44.925 - 44.950 mm) (44.890 mm)
0.0016 - 0.0051 in. 0.0094 in.
Oil Clearance
(0.040 - 0.130 mm) (0.240 mm)
3TNV82A, 1.7716 - 1.7726 in. 1.7756 in.
3TNV84, Bore Inside Diameter
(45.000 - 45.025 mm) (45.100 mm) See
3TNV84T,
1.7681 - 1.7691 in. 1.7667 in. Inspection of
3TNV88, Intermediate Camshaft Outside Diameter
(44.910 - 44.935 mm) (44.875 mm) Camshaft on
4TNV84,
0.0026 - 0.0045 in. 0.0089 in. page 6-84.
4TNV84T, Oil Clearance
4TNV88 (0.065 - 0.115 mm) (0.225 mm)
1.7716 - 1.7726 in. 1.7756 in.
Bore Inside Diameter
(45.000 - 45.025 mm) (45.100 mm)
1.7687 - 1.7697 in. 1.7673 in.
Flywheel End Camshaft Outside Diameter
(44.925 - 44.950 mm) (44.890 mm)
0.0020 - 0.0039 in. 0.0083 in.
Oil Clearance
(0.050 - 0.100 mm) (0.210 mm)

ENGINE
(Camshaft Cont.)
Reference
Page
1.9681 - 1.9707 in. 1.9736 in.
(49.990 - 50.055 mm) (50.130 mm)
1.9655 - 1.9665 in. 1.7673 in.
(49.925 - 49.950 mm) (49.890 mm)
0.0016 - 0.0051 in. 0.0094 in.
Oil Clearance
(0.040 - 0.130 mm) (0.240 mm)
1.9685 - 1.9695 in. 1.9724 in.
(50.000 - 50.025 mm) (50.100 mm)
4TNV94L,
1.9650 - 1.9659 in. 1.9636 in.
4TNV98, Intermediate Camshaft Outside Diameter
(49.910 - 49.935 mm) (49.875 mm)
4TNV98T
0.0026 - 0.0045 in. 0.0089 in;
Oil Clearance
(0.065 - 0.115 mm) (0.225 mm)
1.9685 - 1.9695 in. 1.9724 in.
(50.000 - 50.025 mm) (50.100 mm)
1.9655 - 1.9665 in. 1.7673 in.
(49.925 - 49.950 mm) (49.890 mm)
0.0020 - 0.0039 in. 0.0083 in. See
Oil Clearance
2.2827 - 2.2854 in. 2.2876 in. Camshaft on
Bushing Inside Diameter page 6-84.
(57.980 - 58.050 mm) (58.105 mm)
2.2799 - 2.2811 in. 2.2785 in.
(57.910 - 57.940 mm) (57.875 mm)
0.0016 - 0.0055 in. 0.0098 in.
Oil Clearance
(0.040 - 0.140 mm) (0.250 mm)
2.2835 - 2.2846 in. 2.2876 in.
(58.000 - 58.030 mm) (58.105 mm)
4TNV106, 2.2793 - 2.2805 in. 2.2779 in.
Intermediate Camshaft Outside Diameter
4TNV106T (57.895 - 57.925 mm) (57.860 mm)
0.0030 - 0.0053 in. 0.0096 in.
Oil Clearance
(0.075 - 0.135 mm) (0.245 mm)
2.2835 - 2.2846 in. 2.2876 in.
(58.000 - 58.030 mm) (58.105 mm)
2.2799 - 2.2811 in. 2.2785 in.
(57.910 - 57.940 mm) (57.875 mm)
0.0020 - 0.0047 in. 0.0091 in.
Oil Clearance
(0.050 - 0.120 mm) (0.230 mm)

ENGINE
Idler Gear Shaft and Bushing
Reference
Page
1.8091 - 1.8100 in. 1.8071 in.
Shaft Outside Diameter See
(45.950 - 45.975 mm) (45.900 mm)
Inspection of
1.8110 - 4.8120 in. 1.8140 in.
Bushing Inside Diameter Idler Gear
(46.000 - 46.025 mm) (46.075 mm)
and Shaft on
0.0010 - 0.0030 in. 0.0069 in. page 6-84.
Oil Clearance
(0.025 - 0.075 mm) (0.175 mm)
Timing Gear Backlash

Reference
Page
3TNV82A
3TNV84, 3TNV84T, Crank Gear, Cam Gear, Idler Gear,
0.0028 - 0.0059 in. 0.0067 in.
3TNV88, 4TNV84, Fuel Injection Pump Gear and PTO
(0.07 - 0.15 mm) (0.17 mm)
4TNV84T, Gear
4TNV88 See
Crank Gear, Cam Gear, Idler Gear, Checking
0.0031 - 0.0055 in. 0.0063 in. Timing Gear
Fuel Injection Pump Gear and PTO
4TNV94L (0.08 - 0.14 mm) (0.16 mm) Backlash on
Gear
4TNV98, 4TNV98T, page 6-70.
0.0035 - 0.0059 in. 0.0067 in.
4TNV106, Lubricating Oil Pump Gear
(0.09 - 0.15 mm) (0.17 mm)
4TNV106T
Balancer Drive Gear 0.0047 - 0.0071 in. 0.0079 in.
(Only for 4TNV106T) (0.12 - 0.18 mm) (0.20 mm)

ENGINE
CRANKSHAFT AND PISTON SPECIFICATIONS

Crankshaft
Note: Check appropriate parts catalog for various sizes of replacement main bearing inserts.
Reference
Page
0.0008 in.
Bend (1/2 the dial gauge reading) -
(0.02 mm)
Journal Outside 1.6910 - 1.6914 in. 1.6891 in.
Diameter (42.952 - 42.962 mm) (42.902 mm)
Bearing Inside 1.6929 - 1.6946 in.
-
Diameter (43.000 - 43.042 mm)
3TNV82A
Bearing Insert 0.0585 -.0591 in.
-
Thickness (1.487 - 1.500 mm)
0.0015 - 0.0035 in. 0.0059 in.
Oil Clearance
(0.038 - 0.090 mm) (0.150 mm)
Diameter (47.952 - 47.962 mm) (47.902 mm)
3TNV84,
3TNV84T, Bearing Inside 1.8898 - 1.8909 in.
-
3TNV88, Diameter (48.000 - 48.026 mm)
4TNV84, Bearing Insert 0.0587 - 0.0591 in.
4TNV84T - See
Thickness (1.492 - 1.500 mm)
4TNV88 Inspection of
0.0015 - 0.0029 in. 0.0059 in.
Oil Clearance Crankshaft
Connecting Rod (0.038 - 0.074 mm) (0.150 mm)
on
Journals Journal Outside 2.2816 - 2.2820 in. 2.2796 in. page 6-83.
Diameter (57.952 - 57.962 mm) (57.902 mm)
4TNV94L, -
Diameter (58.000 - 58.026 mm)
4TNV98,
4TNV98T Bearing Insert 0.0587 - 0.0591 in.
-
Thickness (1.492 - 1.500 mm)
0.0015 - 0.0029 in. 0.0059 in.
Oil Clearance
(0.038 - 0.074 mm) (0.150 mm)
Diameter (63.952 - 63.962 mm) (63.902 mm)
-
4TNV106, Diameter (64.016 - 64.042 mm)
-
Thickness (1.984 - 1.992 mm)
0.0021 - 0.0035 in. 0.0059 in.
Oil Clearance
(0.054 - 0.090 mm) (0.150 mm)

ENGINE
(Crankshaft Cont.)
Reference
Page
Diameter (46.952 - 46.962 mm) (46.902 mm)
-
Diameter (47.000 - 47.032 mm)
3TNV82A
Bearing Insert 0.0782 - 0.0787 in.
-
Thickness (1.987 - 2.000 mm)
0.0015 - 0.0031 in. 0.0059 in.
Oil Clearance
(0.038 - 0.080 mm) (0.150 mm)
Journal Outside 1.9666-1.9670 in. 1.9646 in.
Diameter (49.952-49.962 mm) (49.902 mm)
3TNV84,
3TNV84T, Bearing Inside 1.9685 - 1.9693 in.
-
3TNV88, Diameter (50.000 - 50.020 mm)
4TNV84, Bearing Insert 0.0785 - 0.0791 in.
4TNV84T -
Thickness (1.995 - 2.010 mm)
4TNV88 See
0.0015 - 0.0027 in. 0.0059 in.
(0.038 - 0.068 mm) (0.150 mm)
Main Bearing Journal Crankshaft
Journal Outside 2.5572 - 2.5576 in. 2.5552 in. on
Diameter (64.952 - 64.962 mm) (64.902 mm) page 6-83.
4TNV94L, -
Diameter (65.000 - 65.020 mm)
4TNV98,
-
Thickness (1.995 - 2.010 mm)
0.0015 - 0.0027 in. 0.0059 in.
Oil Clearance
(0.038 - 0.068 mm) (0.150 mm)
Diameter (75.952 - 75.962 mm) (75.902 mm)
-
4TNV106, Diameter (76.014 - 76.034 mm)
-
Thickness (2.488 - 2.503 mm)
0.0020 - 0.0032 in. 0.0059 in.
Oil Clearance
(0.052 - 0.082 mm) (0.150 mm)
Thrust Bearing
Reference
Page
See Removal
0.0051 - 0.0091 in. 0.0110 in. of Crankshaft
Crankshaft End Play - All Models
(0.13 - 0.23 mm) (0.28 mm) on
page 6-77.

ENGINE
Piston
Reference
Page
3.2264 - 3.2275 in. 3.2246 in.
3TNV82A
(81.950 - 81.980 mm) (81.905 mm)
3TNV84, 3TNV84T, 3.3047 - 3.3059 in. 3.3029 in.
4TNV84, 4TNV84T (83.940 - 83.970 mm) (83.895 mm)
3.4622 - 3.4634 in. 3.4604 in.
3TNV88,4TNV88
Piston Outside Diameter (87.940 - 87.970 mm) (87.895 mm)
(Measure at 90 to the Piston Pin.) 3.6982 - 3.6994 in. 3.6968 in.
4TNV94L
(93.935 - 93.965 mm) (93.900 mm)
3.8555 - 3.8567 in. 3.8541 in.
4TNV98, 4TNV98T
(97.930 - 97.960 mm) (97.895 mm) See
4TNV106, 4TNV106T Pistons,
(105.930 - 105.960 mm) (105.880 mm)
Piston Rings
0.6299 in. and Wrist Pin
3TNV82A -
(16 mm) on
3TNV84, 3TNV84T, 0.9449 in. page 6-80.
-
4TNV84, 4TNV84T (24 mm)
0.9449 in.
Piston Diameter Measure Location 3TNV88,4TNV88 -
(24 mm)
(Upward From the Bottom of the
Piston.) 0.8661 in.
4TNV94L -
(22 mm)
0.8661 in.
4TNV98, 4TNV98T -
(22 mm)
1.1811 in.
4TNV106, 4TNV106T -
(30 mm)

ENGINE
(Piston Cont.)
Reference
Page
0.9055 - 0.9059 in. 0.9070 in.
Hole Inside Diameter
(23.000 - 23.009 mm) (23.039 mm)
0.9053 - 0.9055 in. 0.9041 in.
3TNV82A Pin Outside Diameter
(22.995 - 23.000 mm) (22.965 mm)
0.0000 - 0.0006 in. 0.0029 in.
Oil Clearance
(0.000 - 0.014 mm) (0.074 mm)
3TNV84, 1.0236 - 1.0240 in. 1.0252 in.

3TNV84T, (26.000 - 26.009 mm) (26.039 mm)
3TNV88, 1.0234 - 1.0236 in. 1.0222 in.
Pin Outside Diameter
4TNV84, (25.995 - 26.000 mm) (25.965 mm) See
4TNV84T 0.0000 - 0.0006 in. 0.0029 in. Inspection of
4TNV88 Oil Clearance Pistons,
(0.000 - 0.014 mm) (0.074 mm)
Piston Pin Piston Rings
1.1811 - 1.1815 in. 1.1826 in. and Wrist Pin
(30.000 - 30.009 mm) (30.039 mm) on
4TNV94L,
1.1807 - 1.1811 in. 1.1795 in. page 6-80.
4TNV98, Pin Outside Diameter
(29.989 - 30.000 mm) (29.959 mm)
4TNV98T
0.0000 - 0.0008 in. 0.0031 in.
Oil Clearance
(0.000 - 0.020 mm) (0.080 mm)
1.4567 - 1.4571 in. 1.4582 in.
(37.000 - 37.011 mm) (37.039 mm)
4TNV106, 1.4563 - 1.4567 in. 1.4551 in.
Pin Outside Diameter
4TNV106T (36.989 - 37.000 mm) (36.959 mm)
0.0000 - 0.0009 in. 0.0031 in.
Oil Clearance
(0.000 - 0.022 mm) (0.080 mm)

ENGINE
Piston Ring
Reference
Page
0.0813 - 0.0819 in.
Ring Groove Width -
(2.065 - 2.080 mm)
0.0776 - 0.0783 in. 0.0768 in.
Ring Width
(1.970 - 1.990 mm) (1.950 mm)
Top Ring
0.0030 - 0.0043 in.
Side Clearance -
(0.075 - 0.110 mm)
0.0079 - 0.0157 in. 0.0193 in.
End Gap
(0.200 - 0.400 mm) (0.490 mm)
0.0801 - 0.0807 in. 0.0846 in.
Ring Groove Width
(2.035 - 2.050 mm) (2.150 mm) See
3TNV82A, 0.0776 - 0.0783 in. 0.0768 in. Inspection of
3TNV84, Ring Width Pistons,
(1.970 - 1.990 mm) (2.150 mm)
3TNV84T, Second Ring Piston Rings
4TNV84, 0.0018 - 0.0031 in. 0.0079 in. and Wrist
Side Gap
4TNV84T (0.045 - 0.080 mm) (0.200 mm) Pin on
0.0079 - 0.0157 in. 0.0193 in. page 6-80.
End Gap
(0.200 - 0.400 mm) (0.490 mm)
0.1581 - 0.1587 in. 0.1626 in.
Ring Groove Width
(4.015 - 4.030 mm) (4.130 mm)
0.1563 - 0.1571 in. 0.01555 in.
Ring Width
(3.970 - 3.990 mm) (3.950 mm)
Oil Ring
0.0010 - 0.0024 in. 0.0071 in.
Side Clearance
(0.025 - 0.060 mm) (0.180 mm)
0.0079 - 0.0157 in. 0.0193 in.
End Gap
(0.200 - 0.400 mm) (0.490 mm)

ENGINE
(Piston Ring Cont.)
Reference
Page
0.0811 - 0.0817 in.
Ring Groove Width -
(2.060 - 2.075 mm)
0.0776 - 0.0783 in. 0.0768 in.
Ring Width
(1.970 - 1.990 mm) (1.950 mm)
Top Ring
0.0028 - 0.0041 in.
Side Clearance -
(0.070 - 0.105 mm)
0.0079 - 0.157 in. 0.0193 in.
End Gap
(0.200 -.0400 mm) (0.490 mm)
0.0797 - 0.0803 in. 0.0843 in.
Ring Groove Width
(2.025 - 2.040 mm) (2.140 mm) See
0.0776 -- 0.0783 in. 0.0768 in. Inspection of
Ring Width Pistons,
3TNV88, (1.970 - 1.990 mm) (1.950 mm)
Second Ring Piston Rings
4TNV88 0.0014 - 0.0028 in. 0.0075 in.
Side Clearance and Wrist
(0.035 - 0.070 mm) (0.190 mm) Pin on
0.0079 - 0.0157 in. 0.0193 in. page 6-80.
End Gap
(0.200 - 0.400 mm) (0.490 mm)
0.1581 - 0.1587 in. 0.1626 in.
Ring Groove Width
(4.015 - 4.030 mm) (4.130 mm)
0.1563 -.1571 in. 0.1555 in.
Ring Width
(3.970 - 3.990 mm) (3.950 mm)
Oil Ring
0.0010 - 0.0024 in. 0.0071 in.
Side Clearance
(0.025 - 0.060 mm) (0.180 mm)
0.0079 - 0.0157 in. 0.0193 in.
End Gap
(0.200 - 0.400 mm) (0.490 mm)

ENGINE
(Piston Ring Cont.)
Reference
Page
0.0803 - 0.0811 in.
Ring Groove Width -
(2.040 - 2.060 mm)
0.0764 - 0.0772 in. 0.0756 in.
Ring Width
(1.940 - 1.960 mm) (1.920 mm)
Top Ring
0.0031 - 0.0047 in.
Side Clearance -
(0.080 - 0.120 mm)
0.0098 - 0.0177 in. 0.0213 in.
End Gap
(0.250 - 0.450 mm) (0.540 mm)
0.0819 - 0.0825 in. 0.0864 in.
Ring Groove Width
(2.080 - 2.095 mm) (2.195 mm) See
4TNV94L, Ring Width Pistons,
(1.970 - 1.990 mm) (1.950 mm)
4TNV98, Second Ring Piston Rings
4TNV98T 0.0035 - 0.0049 in. 0.0096 in. and Wrist
Side Clearance
(0.090 - 0.125 mm) (0.245 mm) Pin on
0.0177 - 0.0256 in. 0.0287 in. page 6-80.
End Gap
(0.450 - 0.650 mm) (0.730 mm)
0.1187 - 0.1193 in. 0.1232 in.
Ring Groove Width
(3.015 - 3.030 mm) (3.130 mm)
0.1169 - 0.1177 in. 0.1161 in.
Ring Width
(2.970 - 2.990 mm) (2.950 mm)
Oil Ring
0.0010 - 0.0024 in. 0.0071 in.
Side Clearance
(0.025 - 0.060 mm) (0.180 mm)
0.0098 - 0.0177 in. 0.0217 in.
End Gap
(0.250 - 0.450 mm) (0.550 mm)

ENGINE
(Piston Ring Cont.)
Reference
Page
0.0992 - 0.1000 in.
Ring Groove Width -
(2.520 - 2.540 mm)
0.0961 - 0.0969 in. 0.0953 in.
Ring Width
(2.440 - 2.460 mm) (2.420 mm)
Top Ring
0.0024 - 0.0039 in.
Side Clearance -
(0.060 - 0.100 mm)
0.0118 - 0.0177 in. 0.0213 in.
End Gap
(0.300 - 0.450 mm) (0.540 mm)
0.0815 - 0.0821 in. 0.0860 in.
Ring Groove Width
(2.070 - 2.085 mm) (2.185 mm) See
Ring Width Pistons,
4TNV106, (1.970 - 1.990 mm) (1.950 mm)
Second Ring Piston Rings
4TNV106T 0.0031 - 0.0045 in. 0.0093 in.
Side Clearance and Wrist
(0.080 - 0.115 mm) (0.235 mm) Pin on
0.0177 - 0.0236 in. 0.0268 in. page 6-80.
End Gap
(0.450 - 0.600 mm) (0.680 mm)
0.1187 - 0.1193 in. 0.1232 in.
Ring Groove Width
(3.015 - 3.030 mm) (3.130 mm)
0.1169 - 0.1177 in. 0.1161 in.
Ring Width
(2.970 - 2.990 mm) (2.950 mm)
Oil Ring
0.0010 - 0.0024 in. 0.0071 in.
Side Clearance
(0.025 - 0.060 mm) (0.180 mm)
0.0118 - 0.0197 in. 0.0236 in.
End Gap
(0.300 - 0.500 mm) (0.600 mm)

ENGINE
Connecting Rod
Connecting Rod Small End
Reference
Page
Wrist Pin Bushing 0.9065 - 0.9070 in. 0.9082 in.
Inside Diameter (23.025 - 23.038 mm) (23.068 mm)
Wrist Pin Outside 0.9053 - 0.9055 in. 0.9042 in.
3TNV82A
Diameter (22.995 - 23.000 mm) (22.967 mm)
0.0010 - 0.0017 in. 0.0040 in.
Oil Clearance
(0.025 - 0.043 mm) (0.101 mm)
3TNV84, 3TNV84T, 3TNV88, Wrist Pin Outside 1.0234 - 1.0236 in. 1.0223 in.
4TNV84, 4TNV84T, 4TNV88 Diameter (25.995 - 26.000 mm) (25.967 mm)
0.0010 - 0.0017 in. 0.0040 in. See
(0.025 - 0.043 mm) (0.101 mm)
Connecting
Wrist Pin Bushing 1.1821 - 1.1826 in. 1.1838 in. Rod on
Inside Diameter (30.025 - 30.038 mm) (30.068 mm) page 6-82.
4TNV94L, 4TNV98, 4TNV98T
Diameter (29.987 - 30.000 mm) (29.959 mm)
0.0010 - 0.0020 in. 0.0043 in.
Oil Clearance
(0.025 - 0.51 mm) (0.109 mm)
4TNV106, 4TNV106T
Diameter (36.989 - 37.000 mm) (36.961 mm)
0.0010 - 0.0019 in. 0.0042 in.
Oil Clearance
(0.025 - 0.049 mm) (0.107 mm)
Connecting Rod Big End

Reference
Page
See
Inspection of
0.0079 - 0.0157 in.
Side Clearance - All Models - Connecting
(0.20 - 0.40 mm)
Rod on
page 6-82.
See Special Torque Chart on page 6-23 for other specifications.

ENGINE
Tappet
Reference
Page
Tappet Bore (Block) Inside 0.4724 - 0.4734 in. 0.4742 in.
3TNV82A, 3TNV84, Diameter (12.000 - 12.025 mm) (12.045 mm)
3TNV84T, 3TNV88, 0.4715 - 0.4720 in. 0.4707 in.
Tappet Stem Outside Diameter
4TNV84, 4TNV84T, (11.975 - 11.990 mm) (11.955 mm)
4TNV88 0.0004 - 0.0020 in. 0.0035 in.
Oil Clearance
(0.010 - 0.050 mm) (0.090 mm)
Diameter (12.000 - 12.018 mm) (12.038 mm) See
4TNV94L, 4TNV98, 0.4715 - 0.4720 in. 0.4707 in. Inspection of
Tappet Stem Outside Diameter
4TNV98T (11.975 - 11.990 mm) (11.955 mm) Tappets on
0.0004 - 0.0017 in. 0.0033 in. page 6-82.
Oil Clearance
(0.010 - 0.043 mm) (0.083 mm)
Diameter (14.000 - 14.018 mm) (14.038 mm)
0.5498 - 0.5505 in. 0.5491 in.
4TNV106, 4TNV106T Tappet Stem Outside Diameter
(13.966 - 13.984 mm) (13.946 mm)
0.0006 - 0.0020 in. 0.0036 in.
Oil Clearance
(0.015 - 0.052 mm) (0.092 mm)
CYLINDER BLOCK SPECIFICATIONS

Cylinder Block
Reference
Inspection Item Model Standard Limit
Page
3.2283 - 3.2295 in. 3.2362 in.
3TNV82A
(82.000 - 82.030 mm) (82.200 mm)
3TNV84, 3TNV84T, 3.3071 - 3.3083 in. 3.3150 in.
4TNV84, 4TNV84T (84.000 - 84.030 mm) (84.200 mm)
3.4646 - 3.4657 in. 3.4724 in.
3TNV88, 4TNV88
(88.000 - 88.030 mm) (88.200 mm) See
Cylinder Inside Diameter Inspection of
3.7008 - 3.7020 in. 3.7059 in.
4TNV94L Cylinder
(94.000 - 94.030 mm) (94.130 mm)
Block on
3.8583 - 3.8594 in. 3.8634 in. page 6-80.
4TNV98, 4TNV98T
(98.000 - 98.030 mm) (98.130 mm)
4.1732 - 4.1744 in. 4.1783 in.
4TNV106, 4TNV106T
(106.000 - 106.030 mm) (106.130 mm)
Roundness 0.0004 in. (0.01 mm) 0.0012 in.
Cylinder Bore
Taper or less (0.03 mm)

ENGINE
SPECIAL TORQUE CHART

Torque for Bolts and Nuts
Lubricating Oil
Thread Diameter Application
Component Model Torque
and Pitch (Thread Portion and
Seat Surface)
46 - 49 ft-lb
3TNV82A M9 x 1.25 mm (61.7 - 65.7 Nm;
6.3 - 6.7 kgf/m)
3TNV82A, 3TNV84,
63 - 67 ft-lb
3TNV84T, 3TNV88,
M10 x 1.25 mm (85.3 - 91.1 Nm;
4TNV84, 4TNV84T,
Cylinder 8.7 - 9.3 kgf/m)
4TNV88 Applied
Head Bolt
76 - 83 ft-lb
4TNV94L, 4TNV98,
M11 x 1.25 mm (103.1 - 112.9 Nm;
4TNV98T
10.5 - 11.5 kgf/m)
139 - 146 ft-lb
4TNV106, 4TNV106T M13 x 1.5 mm (188.0 - 112.9 Nm;
19.0 - 20.0 kgf/m)
27 - 30 ft-lb
3TNV82A M8 x 1.0 mm (37.2 - 41.2 Nm;
3.8 - 4.2 kgf/m)
3TNV82A, 3TNV84,
33 - 36 ft-lb
3TNV84T, 3TNV88,
M9 x 1.0 mm (44.1 - 49.0 Nm;
4TNV84, 4TNV84T,
Connecting 4.5 - 5.0 kgf/m)
4TNV88 Applied
Rod Bolt
40 - 43 ft-lb
4TNV94L, 4TNV98,
M10 x 1.0 mm (53.9 - 58.8 Nm;
4TNV98T
5.5 - 6.0 kgf/m)
58 - 62 ft-lb
4TNV106, 4TNV106T M11 x 1.0 mm (78.5 - 83.4 Nm;
8.0 - 8.5 kgf/m)
3TNV82A, 3TNV84,
61 - 65 ft-lb
3TNV84T, 3TNV88,
M10 x 1.25 mm (83.3 - 88.2 Nm;
4TNV84, 4TNV84T,
Flywheel 8.5 - 9.0 kgf/m)
4TNV88 Applied
Bolt
4TNV94L, 4TNV98, 137 - 152 ft-lb
4TNV98T, 4TNV106, M14 x 1.5 mm (186.2 - 205.8 Nm;
4TNV106T 19 - 21 kgf/m)
83 - 91 ft-lb
EPA Flange
4TNV106, 4TNV106T M8 x 1.5 mm (113 - 123 Nm; Not Applied
Bolt
11.5 - 12.5 kgf/m)

ENGINE
(Torque for Bolts and Nuts Cont.)
Lubricating Oil
Seat Surface)
56 - 60 ft-lb
3TNV82A M10 x 1.25 mm (76.4 - 80.4 Nm;
7.8 - 8.2 kgf/m)
3TNV84, 3TNV84T, 69 - 72 ft-lb
3TNV88, 4TNV84, M12 x 1.5 mm (93.2 - 98.1 Nm;
Main Bearing Cap 4TNV84T, 4TNV88 9.5 - 10.5 kgf/m)
Applied
Bolt 80 - 87 ft-lb
4TNV94L, 4TNV98,
M11 x 1.25 mm (108.1 - 117.9 Nm;
4TNV98T
11.0 - 12.0 kgf/m)
137 - 152 ft-lb
4TNV106, 4TNV106T M14 x 1.5 mm (186.2 - 205.8 Nm;
19 - 21 kgf/m)
3TNV82A, 3TNV84,
83 - 91 ft-lb
3TNV84T, 3TNV88,
M14 x 1.5 mm (112.7 - 122.7 Nm;
4TNV84, 4TNV84T,
Crankshaft Pulley 11.5 - 12.5 kgf/m)
4TNV88 Applied
Bolt
4TNV94L, 4TNV98, 80 - 94 ft-lb
4TNV98T, 4TNV106, M14 x 1.5 mm (107.9 - 127.5 Nm;
4TNV106T 11.0 - 13.0 kgf/m)
3TNV82A, 3TNV84,
18 - 21 ft-lb
3TNV84T, 3TNV88,
M8 x 1.25 mm (24.4 - 28.4 Nm;
4TNV84, 4TNV84T,
Fuel Injector 2.5 - 2.9 kgf/m)
4TNV88 Not Applied
Bolt
4TNV94L, 4TNV98, 17 - 21 ft-lb
4TNV98T, 4TNV106, M8 x 1.25 mm (22.6 - 28.4 Nm;
4TNV106T 2.3 - 2.9 kgf/m)
3TNV82A, 3TNV84,
58 - 65 ft-lb
3TNV84T, 3TNV88,
M14 x 1.5 mm (78 - 88 Nm;
4TNV84, 4TNV84T,
Fuel Pump Drive 8 - 9 kgf/m)
4TNV88 Not Applied
Gear Nut
4TNV94L, 4TNV98, 83 - 90 ft-lb
4TNV98T, 4TNV106, M18 x 1.5 mm (113 - 123 Nm;
4TNV106T 11.5 - 12.5 kgf/m)
3TNV82A, 3TNV84,
22 - 25 ft-lb
3TNV84T, 3TNV88,
M12 x 1.5 mm (29.4 - 34.3 Nm;
4TNV84, 4TNV84T,
High-Pressure 3.0 - 3.5 kgf/m)
4TNV88 Not Applied
Fuel Lines Bolt
4TNV94L, 4TNV98, 174 - 217 in.-lbin.-lb
4TNV98T, 4TNV106, M12 x 1.5 mm (19.6 - 24.5 Nm;
4TNV106T 2.0 - 2.5 kgf/m)

ENGINE
(Torque for Bolts and Nuts Cont.)
Lubricating Oil
Seat Surface)
4TNV94L, 4TNV98, 70 - 86 in.-lb
Fuel Return Line
4TNV98T, 4TNV106, M6 x 1.0 mm (7.8 - 9.8 Nm; Not Applied
Joint Bolt
4TNV106T 0.8 - 1.0 kgf/m)
Rocker Arm 148 - 199 in.-lb
Cover 4TNV106, 4TNV106T M8 x 1.25 mm (16.7 - 22.5 Nm; Not Applied
Bolt 1.7 - 2.3 kgf/m)
See Tightening Torques for Standard Bolts and Nuts on page 4-45 for standard hardware torque values.

ENGINE
SPECIAL SERVICE TOOLS

No. Tool Name Applicable Model and Tool Size Illustration
Model L1 L2 d1 d2
3TNV82A
4TNV94L,
4TNV98, 0.787 in. 2.953 in. 0.256 in. 0.394 in.
0000827
4TNV98T (20 mm) (75 mm) (6.5 mm) (10 mm)
4TNV106,
Valve Guide Tool 4TNV106T
1 (For Removing
Valve Guide) 4TNV84,
3TNV84,
0.787 in. 2.953 in. 0.295 in. 0.433 in.
3TNV84T,
(20 mm) (75 mm) (7.5 mm) (11 mm)
3TNV88,
4TNV88
0.787 in. 2.953 in. 0.217 in. 0.354 in.
4TNV84T
(20 mm) (75 mm) (5.5 mm) (9 mm)
Locally Manufactured
Model L1 L2 d1 d2
0.472 in. 2.362 in. 0.256 in. 0.394 in.
3TNV82A
(12 mm) (60 mm) (6.5 mm) (10 mm)
4TNV84,
3TNV84,
0.591 in. 2.559 in. 0.551 in. 0.787 in.
3TNV84T, 0000828
(15 mm) (65 mm) (14 mm) (20 mm)
Valve Guide Tool 4TNV88,
2 (For Installing 4TNV88
Valve Guide) 0.335 in. 2.362 in. 0.433 in. 0.669 in.
4TNV84T
(8.5 mm) (60 mm) (11 mm) (17 mm)
4TNV94L,
0.276 in. 2.362 in. 0.512 in. 0.630 in.
4TNV98,
(7 mm) (60 mm) (13 mm) (16 mm)
4TNV98T
4TNV106, 0.535 in. 2.559 in. 0.512 in. 0.630 in.
4TNV106T (13.6 mm) (65 mm) (13 mm) (16 mm)
Fuel Injector
3 Removal Tool Yanmar Part No. 129470-92305
(2-Valve Head)

ENGINE
(Special Service Tools Cont.)
Model L1 L2 d1 d2
0.984 in. 3.346 in. 0.906 in. 1.024 in.
3TNV82A
(25 mm) (85 mm) (23 mm) (26 mm)
3TNV84,
Connecting Rod
3TNV84T,
Bushing
3TNV88, 0.787 in. 3.937 in. 1.024 in. 1.142 in.
Replacer 0000829
4TNV84, (20 mm) (100 mm) (26 mm) (29 mm)
4 (For Removal/
4TNV84T,
Installation of
4TNV88,
Connecting Rod
Bushing) 4TNV94L,
0.787 in. 3.937 in. 1.181 in. 1.299 in.
4TNV98,
(20 mm) (100 mm) (30 mm) (33 mm)
4TNV98T
4TNV106, 0.787 in. 3.937 in. 1.457 in. 1.575 in.
4TNV106T (20 mm) (100 mm) (37 mm) (40 mm)
Valve Spring
Compressor
Yanmar Part No.
5 (For Removal/
129100-92630
Installation of 0000830
Valve Spring)
Model d1 d2 d3 L1 L2 L3
0.598 0.827 0.472 0.622 2.559 0.157
in. in. in. in. in. in.
3TNV82A
(15.2 (21 (12 (15.8 (65 (4
mm) mm) mm) mm) mm) mm)
3TNV84,
0.638 0.866 0.531 0.740 2.559 0.157
3TNV84T,
3TNV88,
(16.2 (22 (13.5 (18.8 (65 (4
4TNV84,
Stem Seal 4TNV88
Installer 0.508 0.748 0.453 0.394 2.559 0.157
6
(for Installing in. in. in. in. in. in.
Valve Stem Seal) 4TNV84T
(12.9 (19 (11.5 (10 (65 (4
0.598 0.827 0.472 0.465 2.559 0.157
4TNV94L, 0000820
4TNV98,
(15.2 (21 (12 (11.8 (65 (4
4TNV98T
0.598 0.827 0.472 0.610 2.559 0.157
4TNV106, in. in. in. in. in. in.
4TNV106T (15.2 (21 (12 (15.5 (65 (4

ENGINE

Filter Wrench
(For Removal /
7 Available Locally
Installation of
Engine Oil Filter) 0000821
Model L1 L2 d1 d2
3TNV82A,
3TNV84,
3TNV84T,
0.709 in. 2.756 in. 1.772 in. 1.890 in.
3TNV88,
Camshaft (18 mm) (70 mm) (45 mm) (48 mm)
4TNV84,
Bushing Tool 0000822
4TNV84T,
8 (For Extracting 4TNV88
Camshaft
4TNV94L,
Bushing) 0.709 in. 2.756 in. 1.968 in. 2.087 in.
4TNV98,
(18 mm) (70 mm) (50 mm) (553 mm)
4TNV98T
4TNV106, 0.709 in. 2.756 in. 2.283 in. 2.402 in.
4TNV106T (18 mm) (70 mm) (58 mm) (61 mm)
Allowance: d1 d2
Model Yanmar Part No. Cylinder Bore

3.071 - 3.307 in.
3TNV82A 129400-92420
(78 - 84 mm)
3TNV88,
Flex-Hone 3.268 - 3.740 in.
4TNV88, 129400-92430
9 (For Preparation (83 - 95 mm)
4TNV94L
of Cylinder Walls) 0000823
3.504 - 3.976 in.
4TNV98 129400-92440
(89 - 101 mm)
4TNV106, 3.740 - 4.252 in.
129400-92450
4TNV106T (95 - 108 mm)
Piston Ring
Yanmar Part No. 95550-002476
Compressor
10 The Piston Insertion Tool is Applicable for
(For Installing
2.362 - 4.921 in. (60 - 125 mm) Diameter Pistons
Piston)
0000824
Piston Ring
Expander
11 (For Removal / Available Locally
Installation of
Piston Ring) 0000825

ENGINE
Locally Manufactured 0000826

(1)
Crankshaft Pulley
12 (4TNV94L only)
Installing Tool
(Knurl knob (1))
0002134

ENGINE
MEASURING INSTRUMENTS
No. Instrument Name Application Illustration
1 Dial Indicator Locally Available Measure shaft bend and end play
0000831
Measurements of narrow or deep portions that

2 Test Indicator Locally Available
cannot be measured by dial gauge
0000832
3 Magnetic Stand Locally Available For holding the dial gauge when measuring
0000833
For measuring the outside diameters of

4 Micrometer Locally Available
crankshaft, pistons, piston pins, etc.
0000834
Cylinder Bore For measuring the inside diameters of cylinder

5 Locally Available
Gauge liners, bearing bores, etc.
0000835
For measuring outside diameters, depth,

6 Calipers Locally Available
thickness and width
0000836
7 Depth Micrometer Locally Available For measuring of valve recession
0000837
For measuring valve spring inclination and

8 Square Locally Available
straightness of parts
0000838

ENGINE
9 V-Block Locally Available For measuring shaft bend
0000839
For tightening nuts and bolts to the specified

10 Torque Wrench Locally Available
torque
0000840
For measuring piston ring gaps, piston ring

11 Feeler Gauge Locally Available
clearance, and valve adjustment clearance
0000841

ENGINE
2-VALVE CYLINDER HEAD

2-Valve Cylinder Head Components
(3)
(1)
(2) (4)
(5)
(6) (7)
(34)
(8)
(32)
(33)
(9) (10)
(11)
(12)
(29)
(17) (13)
(30) (18) (14)
(28) (31) (15)
(19)
(20) (16)
(27)
(21)
(22)
(23)
(26)
(24)
(25) 0001919
Figure 6-1

ENGINE
1 Valve Cover Nut
2 Valve Cover Nut O-Ring CAUTION
3 Crankcase Breather Cover Identify all parts and their location using
4 Diaphragm Spring an appropriate method. It is important
5 Diaphragm Plate
6 Crankcase Breather Diaphragm
(non-turbocharged engines only)
0000080en
7 Oil FIll Cap
8 Valve Cover Gasket
2. Disconnect the electrical wire from the intake air
9 Rocker Arm Shaft Spring
10 Valve Adjusting Screw Lock Nut
heater (Figure 6-2, (1)).
11 Valve Adjusting Screw
12 Rocker Arm
13 Rocker Arm Shaft
14 Rocker Arm Shaft Aligning Stud (1)
15 Support Bolt
16 Rocker Arm Shaft Support
17 Valve Cap
18 Valve Keepers
19 Spring Retainer
20 Valve Spring
21 Valve Stem Seal
22 Valve Guide
23 Cylinder Head
24 Intake Valve
25 Exhaust Valve
26 Cylinder Head Gasket Figure 6-2
27 Fuel Injector Retainer
28 Washer
29 Fuel Injector Retainer Bolt
30 Fuel Injector Nozzle Protector
31 Fuel Injector Nozzle Seat
32 Push Rod
33 Crankcase Breather Components
34 Valve Cover
Disassembly of 2-Valve Cylinder

Head
Prepare a clean, flat working surface on a
workbench large enough to accommodate the
cylinder head assembly. Discard all gaskets,
O-rings and seals. Use new gaskets, O-rings and
seals on reassembly of the cylinder head.
1. Drain the coolant from the engine into a suitable
container. See Drain, Flush and Refill Cooling
System With New Coolant on page 5-35.

ENGINE
3. Disconnect the coolant hoses from the cold 5. Remove the exhaust manifold bolts
start device (Figure 6-3, (1)) on the fuel (Figure 6-4, (4)) and nuts (Figure 6-4, (5)).
injection pump. Remove the exhaust manifold (Figure 6-4, (6))
and the exhaust manifold gasket
(Figure 6-4, (7)).
6. Remove the coolant pump. See Disassembly of
(1) Engine Coolant Pump on page 8-10.
7. Remove the high-pressure lines and fuel
injectors from the cylinder head. See Removal
of Fuel Injectors on page 7-31.
Removal of Valve Cover

1. Remove the valve cover nuts (Figure 6-5, (1)).
2. Remove the O-ring (Figure 6-5, (2)) on each
valve cover nut.
0002087A (1)
(2)
Figure 6-3
4. Remove the intake manifold bolts
(Figure 6-4, (1)). Remove the intake manifold
(Figure 6-4, (2)). Discard the intake manifold
gasket (Figure 6-4, (3)). (3)
(5)
(4) (4)
0001920
(5)
Figure 6-5
(6) 3. Remove the valve cover (Figure 6-5, (3)) and
(7)
the valve cover gasket (Figure 6-5, (4)).
(2) (3)
0001682
(1)
Figure 6-4

ENGINE
Removal of Rocker Arm Assembly
(7)
1. Remove the bolts (Figure 6-6, (1)) that retain (6)
the rocker arm shaft supports. (1)
(2)
2. Remove the rocker arm shaft assembly from
the cylinder head.
Note: Identify the push rods so they can be (3)
(4)
reinstalled in their original locations.
3. Remove the push rods and identify for
installation. (5)
0001951
Figure 6-7
(1)
3. Remove the valve adjusting screw
(Figure 6-7, (6)) and the lock nut
(Figure 6-7, (7)) from the rocker arms.
Removal of Cylinder Head

1. Loosen the cylinder head bolts following the
sequence shown in (Figure 6-8).
(2)
8 14 5
0001950 2 12 9 3
(1)
Figure 6-6 4 10 11 1
6 13 7
Disassembly of Rocker Arm Assembly

1. Remove the rocker arm shaft alignment stud (2)
(Figure 6-7, (4)) from support (Figure 6-7, (5)).
7 16 14 6
1 9 18 12 4
Note: The rocker arm shaft fits tightly in the
(1)
rocker arm supports. Clamp the support 3 11 17 10 2
in a padded vise. Twist and pull out on 5 13 15 8
the rocker arm shaft to remove. Reverse 0001864
this process when you reinstall the 1 Cooling Fan End

rocker arm shaft into the supports. 2 Camshaft Side
2. Slide the rocker arm shaft (Figure 6-7, (3)) out Figure 6-8
of the rocker arm supports (Figure 6-7, (5)),
springs (Figure 6-7, (1)), and rocker arms
(Figure 6-7, (2)).
Note: Mark the rocker arms so they can be
reinstalled with the original matching
valve and pushrod.

ENGINE
2. Remove the cylinder head bolts
(Figure 6-9, (1)).
3. Lift the cylinder head away from the cylinder
block. Discard the cylinder head gasket
(Figure 6-9, (2)). Position the cylinder head on
the work bench to prevent damage to the
combustion surface.
0000191
(1) Figure 6-10

4. Remove the valve keepers (Figure 6-11, (2)).
5. Slowly release the tension on the valve spring.
6. Remove the spring retainer (Figure 6-11, (3))
and valve spring (Figure 6-11, (4)).
(1)
(2)
(3)
(4)
(2) (5)
(6)
0001690
Figure 6-9
0001684
Removal of Intake / Exhaust Valves Figure 6-11

1. Place the cylinder head on the work bench with
7. Repeat the procedure with all remaining valves.
the combustion side down.
Note: If the valves are to be reused, identify
2. Remove the valve cap (Figure 6-11, (1)) and
them so they can be installed in their
keep with the valve it was installed on.
original location.
3. Using the valve spring compressor tool,
compress one of the valve springs 8. Turn the cylinder head so the exhaust port side
(Figure 6-10). faces down. Remove the intake and exhaust
valves (Figure 6-11, (6)) from the cylinder
head.
9. Remove the valve stem seals
(Figure 6-11, (5)).

ENGINE
Removal of Valve Guides Cleaning of Cylinder Head
Note: Removal of the valve guides should be Components
postponed until inspection and
measurement procedures have been
performed. See Inspection of Valve
A WARNING
Guides on page 6-39.
1. If the valve guides were not within
specifications, use a drift pin and hammer to
drive the valve guides (Figure 6-12, (1)) out of
the cylinder head. FUME / BURN HAZARD!
(1) cleaners, primers, sealants and
sealant removers.
or serious injury.
0000014en
Thoroughly clean all components using a non-

metallic brush and an appropriate solvent. Each
part must be free of carbon, metal filings and other
001689
debris.
Figure 6-12
Inspection of Cylinder Head
Components
Visually inspect the parts. Replace any parts that
are obviously discolored, heavily pitted or otherwise
damaged. Discard any parts that do not meet its
specified limit.
CAUTION
0000119en

ENGINE
3. Use a feeler gauge to measure the gap
CAUTION (Figure 6-13). See Push Rod on page 6-8 for
Any part determined to not meet the the service limit.
current rate of wear, should be replaced
0000120en
Inspection of Push Rods

Push Rod Bend
Determine if the bend of the push rods are within
the specified limit. 0000204
1. Place the push rods on a flat inspection block or Figure 6-13

layout bed.
Inspection of Rocker Arm Assembly
2. Roll the push rods until a gap can be observed
between a portion of the push rod and the Rocker Arm Shaft Hole Diameter
surface of the block or layout bed. Use a test indicator and micrometer to determine if
the inside diameter of all the rocker arm support
brackets and the rocker arms (Figure 6-14) are
within the specified limits. See Rocker Arm and
Shaft on page 6-9 for the service limit.
Inspect the contact areas (Figure 6-14, (1)) for
excessive wear or damage.
(1)
(1)
0001916
Figure 6-14

ENGINE
Rocker Arm Shaft Outside Diameter Inspection of Cylinder Head
Use a micrometer to measure the rocker arm shaft
Cylinder Head Distortion
diameter. Measure at each rocker arm location in
two directions 90 apart (Figure 6-15). See Rocker Place the cylinder head flat and inverted
Arm and Shaft on page 6-9 for the service limit. (combustion side up) on the bench. Use a straight
edge and a feeler gauge to measure cylinder head
distortion (Figure 6-17). Measure diagonally and
along each side. See Cylinder Head on page 6-6
for the service limit.
0001952
Figure 6-15
0000192
Inspection of Valve Guides Figure 6-17

Visually inspect the valve guides for distortions, If distortion exceeds the service limit, resurface or
scoring or other damage. replace the cylinder head. Remove only enough
Note: Measure the valve guides while they are material to make the cylinder head flat, but do not
installed in the cylinder head. remove more than 0.008 in. (0.20 mm).
Use a telescoping gauge and micrometer to Inspection of Intake and Exhaust Valves
measure the inside diameter at each end of the Visually inspect the intake and exhaust valves.
valve guide. Measure in three places and 90 apart Replace any valves that are obviously discolored,
(Figure 6-16). See Intake / Exhaust Valve and heavily pitted or otherwise damaged.
Guide on page 6-7 for the service limit. Replace
valve guides if not within specification. Valve Stem Diameter
Use a micrometer to measure the valve stem
diameter. Measure the valve stem near the
combustion end and near the opposite end
(Figure 6-18, (1)). See Intake / Exhaust Valve and
0001869
Guide on page 6-7 for the service limit.
Figure 6-16
(1)
0000197
Figure 6-18

ENGINE
Valve Stem Bend
Place the valve stem on a flat inspection block or
layout bed. Roll the valve until a gap can be
observed between a portion of the valve stem and
the surface of the block or bed. Use a feeler gauge
to measure the gap (Figure 6-19). See Intake /
Exhaust Valve and Guide on page 6-7 for the
service limit.
0001755
Figure 6-21
Valve Face and Valve Seat

Always check the clearance between the valve and
valve guide before grinding or lapping the valve
seats. See Intake / Exhaust Valve and Guide on
0000199 page 6-7 for the service limit. If the clearance
exceeds the limit, replace the valve and / or valve
Figure 6-19
guide to bring the clearance within the limit.
Valve Recession Roughness or burrs will cause poor seating of a
Note: The valve guides must be installed to valve. Visually inspect the seating surfaces of each
perform this check. valve and valve seat to determine if lapping or
Insert the valves into their original locations and grinding is needed.
press them down until they are fully seated. Use a Visually inspect all valve faces and valve seats for
depth micrometer (Figure 6-20) to measure the pitting, distortion, cracking, or evidence of
difference between the cylinder head gasket overheating. Usually the valves and the valve seats
surface and the combustion surface of each can be lapped or ground to return them to
exhaust and intake valve (Figure 6-21). See serviceable condition. Severely worn or damaged
Cylinder Head on page 6-6 for the service limit. components will require replacement.
Coat the valve seat with a thin coat of bluing
compound. Install the valve and rotate it to
distribute bluing onto the valve face. The contact
pattern should be approximately centered on the
valve face (Figure 6-22, (1)) and even in width.
0000193
Figure 6-20

ENGINE
If the valve or seat require grinding, lap the valve
after grinding. Lap the valve face to the valve seat
using a mixture of valve lapping compound and
engine oil.
Be sure to thoroughly wash all parts to remove all
grinding powder or compound.
Inspection of Valve Springs

Inspect the valve springs. If damage or corrosion is
seen, or if measurements exceed the specified
(1) limits, replace the springs.
Fractures
Check for fractures on the inside and outside
0001691B
portions of the springs. If the valve spring is
Figure 6-22 fractured, replace the valve spring.
Also visually inspect the valve seat for even Corrosion

contact. Check for corrosion of the spring material caused
by oxidation.
Light cutting can be performed by the use of a
hand-operated cutter (Figure 6-23, (3)). Squareness
Use a flat surface and a square to check each
(1) spring for squareness (Figure 6-24). See Valve
150 40 Spring on page 6-9 for the service limit.
(3)
(2)
0001862
Figure 6-23
The valve seat diameter can be adjusted by top-
grinding with a 150 stone to make the seat
diameter smaller, and bottom-grinding using a 40
stone to make the seat diameter larger. Once the
0000201
seat location has been corrected, grind and lap the
seat angle (Figure 6-23, (1)) to specification. See Figure 6-24
Cylinder Head on page 6-6 for specifications.
Free Length
Grind the valve face and / or valve seat only Use a caliper to measure the length of the spring
enough to return them to serviceable condition. (Figure 6-25). See Valve Spring on page 6-9 for
Grinding is needed if the valve and the valve seat the service limit.
do not contact correctly. Check the recession after
grinding.

ENGINE
2. Immediately after removing the valve guides
from the freezer, insert the valve guides
(Figure 6-26, (1)) in their proper positions.
2
3
1
4
0
5
9
(1)
6
8
7
0000200
Figure 6-25
Reassembly of Cylinder Head 001689
Use new gaskets, O-rings and seals for the

Figure 6-26
reassembly of the cylinder head.
3. Finish installing the valve guides
IMPORTANT
(Figure 6-27, (1)) into the cylinder head to the
Liberally oil all components during
proper height (Figure 6-27, (3)) using the valve
reassembly to prevent premature wear or
guide installation tool (Figure 6-27, (2)). See
damage.
Intake / Exhaust Valve and Guide on page 6-7.
Reassembly of Valve Guides
1. The valve guides are installed into the cylinder (2)
head with an extremely tight press fit. Before
installing the valve guides, place the valve
guides in a freezer for at least twenty minutes
This will cause the valve guides to contract, (3)
making it easier to install the valve guides into
place. (1)
0001756A
Figure 6-27

ENGINE
Reassembly of Intake and Exhaust Valves 3. Place the cylinder head assembly on its
exhaust port side.
IMPORTANT
4. Place all the valves (Figure 6-30, (6)) in their
Always install new valve stem seals. The
proper location in the cylinder head.
exhaust seals can be identified by having
yellow paint. Ensure they are installed in the
(1)
correct locations.
(2)
1. Oil the lip of the valve stem seal
(3)
(Figure 6-28, (2)). Using the valve stem seal
installation tool (Figure 6-28, (1)), install a new (4)
valve stem seal on each of the valve guides (5)
(Figure 6-28, (3)).
(1)
(6)
(2)
0001684
(3)
Figure 6-30
5. Place the cylinder head on the workbench with
0001873
the combustion side down to install the valve
springs. Install the valve spring
Figure 6-28 (Figure 6-30, (4)) and the spring retainer
2. Measure the distance (Figure 6-29, (1)) from (Figure 6-30, (5)).
the cylinder head to valve stem seal to ensure 6. Using the valve spring compressor tool,
proper clearance (Figure 6-29, (2)) between compress the valve spring.
the guide and the seal. See Intake / Exhaust 7. Insert the valve keepers (Figure 6-30, (2)) and
Valve and Guide on page 6-7. slowly release the tension on the valve spring.
Install the valve cap (Figure 6-30, (1)). Repeat
the steps on all the remaining valves.
(2)
(1)
0001874
Figure 6-29

ENGINE
Reassembly of Cylinder Head 3. Lightly oil the threads of the cylinder head bolts
1. Carefully clean both the combustion surface of (Figure 6-31, (1)). Tighten the bolts to the
the cylinder head and the top surface of the specified torque in two steps as shown in the
cylinder block. Then place a new cylinder head chart below. Tighten in the sequence shown in
gasket (Figure 6-31, (2)) on the cylinder block. (Figure 6-32). See Special Torque Chart on
page 6-23 for specification.
2. Position the cylinder head on the cylinder head
gasket. First Step 1/2 of final torque
Second Step Final torque
(1)
4. Insert the push rods in their respective
positions.
(2)
7 1 10
13 3 6 12
(1)
11 5 4 14
9 2 8
(2)
12 3 5 13
18 10 1 7 15
(2) (1)
16 8 2 9 17
14 6 4 11
0001875
1 Fan End
2 Camshaft Side
Figure 6-32
Reassembly of Rocker Arm Reassembly

0001690 Note: Ensure the lubrication holes
(Figure 6-33, (1)) in the rocker arm shaft
Figure 6-31 are oriented correctly with respect to the
rocker arms (Figure 6-33, (2)).
(2)
(1)
(1) 0001914
Figure 6-33

ENGINE
1. Lubricate the rocker arm shaft. Slide the rocker 6. Tighten the rocker arm shaft alignment studs.
arm supports (Figure 6-34, (5)), springs 7. Adjust the valve clearance. See Measuring and
(Figure 6-34, (1)) and rocker arms Adjusting Valve Clearance on page 6-62.
(Figure 6-34, (2)) onto the shaft.
Note: The rocker arm shaft fits tightly in the Reassembly of the Valve Cover
rocker arm supports. Clamp the support 1. Lightly grease a new valve cover gasket
in a padded vise. Twist and push on the (Figure 6-35, (4)). Place the gasket in the
rocker arm shaft to reinstall. groove of the valve cover (Figure 6-35, (3)).
Note: To properly align the rocker arm shaft 2. Place the valve cover on the cylinder head.
with the rocker arm shaft supports, first 3. Be sure new O-rings (Figure 6-35, (2)) are
reinstall a rocker arm support installed on the valve cover nuts. Reinstall and
(Figure 6-34, (5)) having a hole for the tighten the valve cover nuts (Figure 6-35, (1)).
shaft alignment stud (Figure 6-34, (4)).
4. Reinstall the exhaust manifold using a new
Align the hole in the rocker arm shaft and
gasket. Tighten the bolts to the specified
the hole in the rocker arm support.
torque.
Reinstall the alignment stud.
(1)
(7) (2)
(6)
(1)
(2)
(3) (3)
(4)
(5) (4)
0001920
Figure 6-35
0001951
5. Reinstall the intake manifold using a new
Figure 6-34
gasket. Tighten the bolts to the specified
Note: Figure 6-34 shows components for one torque.
cylinder. Components for all remaining 6. Reinstall the fuel injectors. See Installation of
cylinders are assembled in the same the Fuel Injectors on page 7-37.
order.
7. Reinstall the high pressure and the return fuel
2. Place the rocker arm shaft assembly onto the injection lines. See Installation of the Fuel
cylinder head. Injectors on page 7-37.
3. If removed, reinstall the valve adjusting screws 8. Reinstall the engine coolant pump. See
(Figure 6-34, (6)) and the lock the nuts Reassembly of Engine Coolant Pump on
(Figure 6-34, (7)). page 8-11.
4. Align the push rods with their respective rocker 9. Reinstall the coolant hoses on the cold start
arms. device on the fuel injection pump.
5. Reinstall and tighten the rocker arm shaft 10. Reinstall the alternator. See Installation of
retaining bolts to the specified torque. Alternator on page 12-16.

ENGINE
4-VALVE CYLINDER HEAD

4-Valve Cylinder Head Components
(1)
(2)
(3)
(4) (5)
(36)
(6)
(7)
(35)
(8)
(34)
(9)
(11) (12)
(10)
(33)
(14) (15)
(31) (13)
(30) (32)
(29)
(28)
(27) (16)
(26)
(24)
(25)
(23) (17)
(18)
(22)
(19)
(21)
(20) 0001861
Figure 6-36

ENGINE
1 Crankcase Breather Cover
2 Diaphragm Spring CAUTION
3 Diaphragm Cup Identify all parts and their location using
4 Crankcase Breather Diaphragm an appropriate method. It is important
5 Oil Fill Cap
6 Valve Cover Nut
7 Valve Cover Nut O-Ring
8 Valve Cover Gasket 0000080en
9 Support Bolt
10 Rocker Arm Shaft Support
2. Remove the high pressure fuel injection lines
11 Wave Washer (Figure 6-37, (1)). See Removal of Fuel
12 Fuel Injector Retainer Bolt Injectors on page 7-31.
13 Valve Adjusting Screw (Primary)
14 Valve Adjusting Screw Lock Nut (Primary)
15 Rocker Arm Shaft Aligning Stud
16 Fuel Injector Retainer (1)
17 Valve Stem Seal
18 Valve Guide
19 Cylinder Head
20 Intake Valve
21 Exhaust Valve
22 Cylinder Head Gasket
23 Fuel Injector Nozzle Protector
24 Fuel Injector Nozzle Seat (3)
25 Valve Spring
26 Valve Bridge Guide
27 Spring Retainer
28 Valve Keepers
29 Valve Bridge
30 Valve Bridge Seat (2)
31 Valve Adjusting Screw Lock Nut 0001876
(Secondary)
32 Valve Adjusting Screw (Secondary) Figure 6-37
33 Push Rod
34 Rocker Arm Shaft CAUTION
35 Crankcase Breather Components
36 Valve Cover Remove or install the high-pressure fuel
Disassembly of 4-Valve Cylinder possible. Disassembling the
high-pressure fuel injection lines from
Head the retainers or bending any of the fuel
Prepare a clean, flat working surface on a lines will make it difficult to reinstall the
workbench large enough to accommodate the fuel lines.
cylinder head assembly. Discard all gaskets, 0000047en
O-rings and seals. Use new gaskets, O-rings and
seals on reassembly of the cylinder head. 3. Disconnect the fuel return hose
(Figure 6-37, (2)) from the cylinder head.
1. Drain the coolant from the engine into a suitable
4. Disconnect the hoses (Figure 6-37, (3)) from
container. See Drain, Flush and Refill Cooling
the cold start device on the fuel injection pump.
System With New Coolant on page 5-35.

ENGINE
5. Remove the turbocharger-to-intake manifold Removal of Valve Cover
hose (Figure 6-38, (1)) (if equipped). Note: The high pressure fuel injection lines and
6. Disconnect the electrical wire from the intake air valve cover grommets must be removed
heater (Figure 6-38, (12)). prior to removing the valve cover. See
7. Remove the intake manifold bolts Removal of Fuel Injectors on page 7-31.
(Figure 6-38, (11)). Remove the intake 1. Remove the high-pressure fuel lines.
manifold (Figure 6-38, (10)). Discard the intake
manifold gasket (Figure 6-38, (9)). 2. Use a flat-blade screwdriver (Figure 6-39) to
remove the fuel injection line grommets
8. Disconnect the turbocharger oil supply (Figure 6-40, (1)) from the valve cover
(Figure 6-38, (2)) and the return lines (Figure 6-40, (3)) and fuel injectors
(Figure 6-38, (4)) (if equipped). (Figure 6-40, (2)). There is a notch at the 3
9. Remove the exhaust manifold bolts oclock position in the valve cover opening to
(Figure 6-38, (7)). Remove the exhaust insert the screwdriver.
manifold (Figure 6-38, (6)) with the
turbocharger attached. Discard the exhaust
manifold gasket. (Figure 6-38, (5)).
(2)
(3) (6)
(1)
(7) Figure 6-39
(5) 3. Remove the valve cover nuts (Figure 6-40, (4)).
(4)
4. Remove the O-ring (Figure 6-40, (5)) on each
valve cover nut.
(12)
(11) (8)
(10) (9)
0001860
Figure 6-38
10. Remove the engine coolant pump. See
Disassembly of Engine Coolant Pump on
page 8-10.

ENGINE
Removal of Rocker Arm Assembly
(3) 1. Remove the fuel injectors from the cylinder
head. See Removal of Fuel Injectors on
(4) page 7-31.
(5) 2. Remove the bolts (Figure 6-41, (1)) that retain
the rocker arm shaft supports to the cylinder
head.
3. Remove the rocker arm and shaft assembly
from the cylinder head.
(2)
(6) Note: Identify the push rods and valve bridges
(1) so they can be installed in their original
locations.
4. Remove the push rods (Figure 6-41, (2)).
5. Remove the valve bridge assemblies
(Figure 6-41, (3)). Remove the seat
(Figure 6-41, (4)) from each valve bridge.
6. Identify all parts so that they will be reinstalled
in their original locations.
(1)
0001877
Figure 6-40
5. Remove the valve cover (Figure 6-40, (3)).
Discard the valve cover gasket (4)
(Figure 6-40, (6)). (3)
(2)
6. Inspect and clean the crankcase breather
assembly. See Inspect Crankcase Breather
000187
Figure 6-41

ENGINE
Disassembly of Rocker Arm Assembly Removal of Cylinder Head
Note: Identify the rocker arms so they can be 1. Loosen the cylinder head bolts following the
reinstalled with the original matching sequence shown in (Figure 6-43).
valve and pushrod.
(2)
1. Remove the rocker arm shaft alignment studs 8 14 5
(Figure 6-42, (5)) from the rocker arm shaft 2 12 9 3
supports (Figure 6-42, (6)). (1)

4 10 11 1
2. Slide the supports, wave washers 6 13 7
(Figure 6-42, (7)), rocker arms

(Figure 6-42, (8)), and fuel injector retainers
(Figure 6-42, (4)) off the rocker shaft (2)
(Figure 6-42, (1)), leaving these parts in order 1
7
9
16
18
14
12
6
4
on the bench surface. (1)
3 11 17 10 2
5 13 15 8
(1)
0001864
(3) 1 Cooling Fan End

2 Camshaft Side
(2)
(4) (5)
Figure 6-43
2. Remove the cylinder head bolts
(Figure 6-44, (1)).
3. Lift the cylinder head away from the cylinder
block. Discard the cylinder head gasket
(8) (Figure 6-44, (2)). Place the cylinder head on
(7) the work bench to prevent damage to the
(6)
0001866 combustion surface.
Figure 6-42
Note: Figure 6-42 shows components for one
cylinder. Components for all remaining
cylinders are assembled in the same
order.
3. Remove the valve adjusting screw
(Figure 6-42, (2)) and the lock nut
(Figure 6-42, (3)) from the rocker arms.

ENGINE
3. Remove the valve keepers (Figure 6-46, (1)).
(1) 4. Slowly release the tension on the valve spring.
5. Remove the spring retainer (Figure 6-46, (2)),
valve spring (Figure 6-46, (3)).
(1)
(7) (2)
(6)
(3)
(4)
(2)
(5)
0001872
0001867
Figure 6-44
Figure 6-46
Removal of Intake and Exhaust Valves
6. Repeat the procedure with all the remaining
1. Place the cylinder head on the work bench with valves.
the combustion side down.
Note: If the valves are to be reused, identify
2. Using the valve spring compressor tool, them so they can be installed in their
compress one of the valve springs original location.
(Figure 6-45).
7. Remove the injector nozzle protectors
(Figure 6-46, (6)) and the seats
(Figure 6-46, (7)).
8. Turn the cylinder head so the exhaust port side
faces down. Remove the intake and exhaust
valves (Figure 6-46, (5)) from the cylinder
head.
0000191
9. Remove the valve stem seals
(Figure 6-46, (4)).
Figure 6-45

ENGINE
Removal of Valve Guides Thoroughly clean all components using a non-
Note: Removal of the valve guides should be metallic brush and an appropriate solvent. Each
postponed until inspection and part must be free of carbon, metal filings and other
measurement procedures have been debris.
performed. See Inspection of Valve
Guides on page 6-54.
Components
1. Using a drift pin and hammer, drive the valve
guides (Figure 6-47, (1)) out of the cylinder Visually inspect the parts. Replace any parts that
head. are obviously discolored, heavily pitted or otherwise
damaged. Discard any parts that do not meet its
(1) specified limit.
CAUTION
0000119en
0001868 CAUTION
Figure 6-47 Any part determined to not meet the
Cleaning of Cylinder Head service, as determined from the state of
Components current rate of wear, should be replaced
A WARNING 0000120en
FUME / BURN HAZARD!

sealant removers.
or serious injury.
0000014en

ENGINE
Inspection of Push Rods
Push Rod Bend
1. Place the push rods on a flat inspection block or
layout bed.
2. Roll the push rods until a gap can be observed
between a portion of the push rod and the (1)
surface of the block or layout bed. (1)
3. Use a feeler gauge to measure the gap
(Figure 6-48). See Push Rod on page 6-8 for
0001916
the service limit.
Figure 6-49
Rocker Arm Shaft Outside Diameter

Use a micrometer to measure the rocker arm shaft
diameter (Figure 6-50). Measure at each rocker
arm location in two directions 90 apart
(Figure 6-50). See Rocker Arm and Shaft on
page 6-9 for the service limit.
0000204
Figure 6-48
Inspection of Rocker Arm Assembly

Rocker Arm Shaft Hole Diameter
1. Use a telescoping gauge and micrometer to
determine if the inside diameter of all the rocker
arm support brackets and the rocker arms
(Figure 6-49) are within the specified limits.
See Rocker Arm and Shaft on page 6-9 for the
service limit.
0001952
2. Inspect the contact areas (Figure 6-49, (1)) for
excessive wear or damage. Figure 6-50

ENGINE
Inspection of Valve Guides If distortion exceeds the service limit, resurface or
replace the cylinder head. Remove only enough
Valve Guide Inside Diameter material to make the cylinder head flat, but do not
Visually inspect the valve guides for distortions, remove more than 0.008 in (0.20 mm).
scoring or other damage.
Inspection of Intake and Exhaust Valves
Note: Measure the valve guides while they are
Visually inspect the intake and exhaust valves.
installed in cylinder head.
Replace any valves that are obviously discolored,
Use a telescoping gauge and micrometer to heavily pitted or otherwise damaged.
measure the inside diameter at each end of the
valve guide. Measure in three places and 90 apart Valve Stem Diameter
(Figure 6-51). See Intake / Exhaust Valve and Use a micrometer to measure the valve stem
Guide on page 6-7 for the service limit. Replace the diameter. Measure the valve stem near the
valve guides if not within specification. combustion end and near the opposite end
(Figure 6-53, (1)). See Intake / Exhaust Valve and
Guide on page 6-7 for the service limit.
(1)
0001869
Figure 6-51
0000197

Figure 6-53
Cylinder Head Distortion
Place the cylinder head flat and inverted
(combustion side up) on the bench. Use a straight
edge and feeler gauge to measure cylinder head
distortion (Figure 6-52). Measure diagonally and
along each side. See Cylinder Head on page 6-6
for the service limit.
0000192
Figure 6-52

ENGINE
Valve Stem Bend
Place the valve stem on a flat inspection block or
layout bed. Roll the valve until a gap can be
observed between a portion of the valve stem and
the surface of the block or bed. Use a feeler gauge
to measure the gap (Figure 6-54). See Intake /
Exhaust Valve and Guide on page 6-7 for the
service limit.
0001755
Figure 6-56
Valve Face and Valve Seat

Always check the clearance between the valve and
valve guide before grinding or lapping the valve
seats. See Intake / Exhaust Valve and Guide on
0000199
page 6-7 for the service limit. If the clearance
exceeds the limit, replace the valve and/or valve
Figure 6-54
guide to bring the clearance within the limit.
Valve Recession Roughness or burrs will cause poor seating of a
Note: The valve guides must be installed to valve. Visually inspect the seating surfaces of each
perform this check. valve and valve seat to determine if lapping or
Insert the valves into their original locations and grinding is needed.
press them down until they are fully seated. Use a Visually inspect all valves faces and valve seats for
depth micrometer (Figure 6-55) to measure the pitting, distortion, cracking, or evidence of
difference between the cylinder head gasket overheating. Usually the valves and valve seats can
surface and the combustion surface of each be lapped or ground to return them to serviceable
exhaust and intake valve (Figure 6-56). See condition. Severely worn or damaged components
Cylinder Head on page 6-6 for the service limit. will require replacement.
0000193
Figure 6-55
Note: 2-Valve cylinder head is shown. 4-Valve
cylinder head is similar.

ENGINE
Coat the valve seat with a thin coat of bluing Grind the valve face and/or valve seat as necessary
compound. Install the valve and rotate to distribute to return them to serviceable condition. Grinding is
bluing onto the valve face. The contact pattern needed if the valve and valve seat do not contact
should be approximately centered on the valve face correctly. Check the valve margin and valve
(Figure 6-57, (1)) and even in width. recession after grinding.
If the valve or seat require grinding, lap the valve
after grinding. Lap the valve face to the valve seat
using a mixture of valve lapping compound and
engine oil.
Be sure to thoroughly wash all parts to remove all
grinding powder or compound.
Inspection of Valve Springs

Inspect the valve springs. If damage or corrosion is
(1) seen, or if measurements exceed the specified
limits, replace the springs.
Fractures
0001691B
Check for fractures on the inside and outside
Figure 6-57 portions of the springs. If the valve spring is
fractured, replace the valve spring.
Also visually inspect the valve seat for even
contact. Corrosion
Light cutting can be performed by the use of a Check for corrosion of spring material caused by
hand-operated cutter (Figure 6-58). oxidation.
Squareness
(1) Use a flat surface and a square to check each
150 40 spring for squareness (Figure 6-59). See Valve
Spring on page 6-9 for the service limit.
(3)
(2)
0001862
Figure 6-58
Valve seat diameter can be adjusted by top-
grinding with a 150 stone to make the seat
diameter smaller, and bottom-grinding using a 40
stone to make the seat diameter larger. Once the
seat location has been corrected, grind and lap the
seat angle (Figure 6-58, (1)) to specification. See 0000201
Cylinder Head on page 6-6 for specifications. Figure 6-59

ENGINE
Free Length Reassembly of Cylinder Head
Use a caliper to measure the length of the spring Use new gaskets, O-rings, and seals on
(Figure 6-60). See Valve Spring on page 6-9 for reassembly of the cylinder head.
the service limit.
IMPORTANT
Liberally oil all components during
reassembly to prevent premature wear or
damage.
Reassembly of Valve Guides

2
3
1
4
0
1. The valve guides are installed into the cylinder
5
9
6
8
7
head with an extremely tight press fit. Before
installing the valve guides, place the valve
guides in a freezer for at least twenty minutes
This will cause the valve guides to contract,
making it easier to install the valve guides into
0000200 place.
Figure 6-60 2. Immediately after removing the valve guides
from the freezer, insert the valve guides
Inspection of Valve Bridges (Figure 6-62, (1)) in their proper positions.
Visually inspect the contact surface at both ends of
the valve bridge (Figure 6-61, (2)) for excessive (1)
wear or mushrooming.
Remove and inspect the seat (Figure 6-61, (1)).
Measure the diameter of the valve bridge guide pin
bore in the valve bridge and guide pin
(Figure 6-61, (3)). See Rocker Arm and Shaft on
(1)
(2) 0001868
Figure 6-62
(3)
Figure 6-61

ENGINE
3. Finish installing the valve guides 2. Measure the distance (Figure 6-65, (1)) from
(Figure 6-63, (1)) into the cylinder head to the the cylinder head to the valve stem seal to
proper height (Figure 6-63, (3)) using the valve ensure proper clearance (Figure 6-65, (2))
guide installation tool (Figure 6-63, (2)). See between the guide and seal. See Intake /
Intake / Exhaust Valve and Guide on page 6-7. Exhaust Valve and Guide on page 6-7.
(2)
(2)
(3) (1)
(1)
0001756A
Figure 6-63 0001874
Figure 6-65
Reassembly of Intake and Exhaust Valves
3. Place the cylinder head assembly on its
IMPORTANT exhaust port side.
Always install new valve stem seals. The
exhaust valve seals can be identified by 4. Place all the valves (Figure 6-66, (5)) in their
having yellow paint. Ensure they are proper location in the cylinder head.
installed in the correct locations.
(1)
1. Oil the lip of the valve stem seal (7) (2)
(Figure 6-64, (2)). Using the valve stem seal (6)
installation tool (Figure 6-64, (1)), install a new (3)
valve stem seal on each of the valve guides (4)
(Figure 6-64, (3)).
(1)
(5)
(2) 0001867
(3) Figure 6-66

5. Place the cylinder head on the workbench with
the combustion side down. Install the valve
spring (Figure 6-66, (3)) and spring retainer
0001873
(Figure 6-66, (2)).
Figure 6-64
6. Using the valve spring compressor tool,
compress the valve spring.

ENGINE
7. Insert the valve keepers (Figure 6-66, (1)) and (2)
slowly release the tension in the valve spring.
7 1 10
Repeat the steps on all the remaining valves. 13 3 6 12
(1)
Reassembly of Cylinder Head 11
9
5
2
4
8
14
1. Carefully clean both the combustion surface of

the cylinder head and the top surface of the
cylinder block. Then place a new cylinder head (2)
gasket (Figure 6-67, (2)) on the cylinder block. 12 3 5 13
18 10 1 7 15
2. Position the cylinder head on the on the cylinder (1)
head gasket. 16 8 2 9 17
14 6 4 11
0001875
(1) 1 Fan End

2 Camshaft Side
Figure 6-68
Reassembly of Rocker Arm Assembly

1. Reinstall the valve bridges (Figure 6-69, (3)) in
their original locations and ensure each seat
(Figure 6-69, (4)) is in place.
2. Insert the push rods (Figure 6-69, (2)) in their
original locations.
(1)
(2)
0001872 (4)
Figure 6-67 (3)
(2)
3. Lightly oil the threads of the cylinder head bolts
(Figure 6-67, (1)). Tighten the bolts to the
specified torque in two steps as shown in the
chart below. Tighten in the sequence shown in
(Figure 6-68). See Special Torque Chart on
page 6-23 for specification.
0001871
First Step 1/2 of final torque
Second Step Final torque Figure 6-69

ENGINE
IMPORTANT Note: To properly align the rocker arm shaft
The wave washers (Figure 6-70, (2)) must with the rocker arm shaft supports, first
be installed with the bow facing the rocker reinstall one of the end rocker arm
arms (Figure 6-70, (1)). supports (Figure 6-72, (6)) with a hole
for the shaft alignment stud
(Figure 6-72, (5)). Align the hole in the
(1)
(2) rocker arm shaft and the hole in the
rocker arm support bracket. Reinstall the
alignment stud.
(1)
(3)
0001878
(2)
(4) (5)
Figure 6-70
IMPORTANT
Ensure the lubrication holes
(Figure 6-71, (1)) in the rocker arm shaft
are oriented correctly with respect to the
rocker arms (Figure 6-71, (2)). (8)
(7)
(6)
(2) 0001866
Figure 6-72
(1) Note: Figure 6-72 shows components for one
cylinder. Components for all remaining
cylinders are assembled in the same
order.
4. Position the rocker arm assembly on a flat
surface. Reinstall the alignment studs
(1) 0001914 (Figure 6-72, (5)).
Figure 6-71 5. Place the rocker arm shaft assembly onto the
cylinder head.
3. Lubricate the rocker arm shaft. Slide the rocker
6. If removed, reinstall the valve adjusting screws
arm supports (Figure 6-72, (6)), wave washers
(Figure 6-72, (2)) and lock nuts
(Figure 6-72, (7)), rocker arms
(Figure 6-72, (3)).
(Figure 6-72, (8)), and fuel injector retainers
(Figure 6-72, (4)) onto the shaft. 7. Align the push rods with their respective rocker
arms.
8. Reinstall and tighten the rocker arm shaft
retaining bolts to the specified torque.
9. Tighten the rocker arm shaft alignment studs.
10. Adjust the valve clearance.
11. Reinstall the fuel injectors. See Installation of
the Fuel Injectors on page 7-37.

ENGINE
Reassembly of the Valve Cover 9. Reinstall the high pressure and fuel return lines.
1. Lightly grease a new valve cover gasket See Installation of the Fuel Injectors on
(Figure 6-73, (6)). Place the gasket in the page 7-37.
groove of the valve cover (Figure 6-73, (3)). 10. Reinstall the coolant pump. Reassembly of
2. Place the valve cover on the cylinder head. Engine Coolant Pump.
3. Be sure new O-rings (Figure 6-73, (5)) are 11. Reinstall the alternator. See Installation of
installed on the valve cover nuts. Reinstall and Alternator on page 12-16.
tighten the valve cover nuts (Figure 6-73, (4)). 12. Reconnect the turbocharger oil supply and
drain lines.
13. Reconnect the air intake hose.
(3)
(4)
(5)
(2)
(6)
(1)
0001877
Figure 6-73
4. Reinstall the fuel injector grommets
(Figure 6-73, (1)).
5. Reinstall the exhaust manifold using a new
gasket. Tighten the bolts to specification.
6. Reinstall the intake manifold using a new
gasket. Tighten the bolts to specification.
7. Reconnect the fuel injector return hose and fuel
injection pump coolant hoses.
8. Reinstall the high-pressure fuel line grommets
into the valve cover.

ENGINE
MEASURING AND ADJUSTING If there is no valve clearance, and the cylinder

is at TDC of the compression stroke, extreme
VALVE CLEARANCE wear, or damage to the cylinder head or valves
Measure and adjust while the engine is cold. may be possible.
If adjusting each cylinder individually, the
Notes:
cylinder to be adjusted first does not have to be
The No. 1 piston position is on the flywheel end the No. 1 cylinder. Select and adjust the
of the engine, opposite the radiator. The firing cylinder where the piston is nearest to the top
order is 1-3-2 for 3-cylinder engines and dead center after turning. Make adjustment for
1-3-4-2 for 4-cylinder engines. the remaining cylinders in the order of firing by
3-cylinder engines fire every 240 of crankshaft turning the crankshaft each time.
rotation. To decrease the number of rotations required
4-cylinder engines fire every 180 of crankshaft to check all cylinders, other cylinders can also
rotation. be checked as indicated in the chart below.
Valve clearance of both the intake and exhaust Example: On a 3-cylinder engine, with the No. 1
valves can be checked with the piston for that piston at TDC on the compression stroke (both
cylinder at top dead center (TDC) of the valves closed), the valves indicated on the top line
compression stroke. When a piston is at TDC of the chart can be adjusted without rotating the
of the compression stroke, both rocker arms crankshaft. To adjust the remaining two valves,
will be loose and the cylinder TDC mark on the rotate the crankshaft until the No. 1 piston is at TDC
flywheel will be visible in the timing port of the on the exhaust stroke (exhaust valve only open).
flywheel housing.
3-Cylinder Engines
Cylinder No. 1 2 3
Valve Intake Exhaust Intake Exhaust Intake Exhaust
No. 1 Cylinder at TDC

Compression
No. 1 Cylinder at TDC Exhaust
4-Cylinder Engines
Cylinder No. 1 2 3 4
Valve Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust

Compression

Compression

ENGINE
2-Valve Cylinder Heads
1. Remove the valve cover. See Removal of Valve (2)
Cover on page 6-48.
Note: If adjusting each cylinder individually, the
cylinder to be adjusted first does not
have to be the No. 1 cylinder. Select and
adjust the cylinder where the piston is
nearest to the top dead center after
turning, and make adjustment for other
cylinders in the order of firing by turning
the crankshaft.
(1)
2. Rotate the crankshaft clockwise as seen from
the coolant pump end, to bring No. 1 piston to Figure 6-75
TDC on the compression stroke while watching
6. Insert a feeler gauge of the correct thickness
the rocker arm motion and timing grid on the
(Figure 6-76, (1)) (see Adjustment
flywheel. (Position where both the intake and
Specifications on page 6-6) between the rocker
exhaust valves are closed.)
arm and valve cap. Turn the valve adjustment
3. Insert a feeler gauge (Figure 6-74, (1)) screw to adjust the valve clearance so there is a
between the rocker arm and valve cap, and slight drag on the feeler gauge when sliding it
record the measured valve clearance. (Use the between the rocker arm and the valve cap. Hold
data for estimating the wear.) the adjusting screw while tightening the valve
adjusting screw lock nut (Figure 6-75, (1)).
(1) Recheck the clearance.
Note: There is a tendency for the clearance to
decrease slightly when the lock nut is
tightened. It is suggested that you make
the initial clearance adjustment slightly
on the loose side before tightening the
lock nut.
(1)
0001782A
Figure 6-74
4. If adjustment is required, proceed to the next
step.
Figure 6-76
5. Loosen the valve adjusting screw lock nut
(Figure 6-75, (1)) and valve adjusting screw 7. Apply oil to the contact surface between the
(Figure 6-75, (2)) on the rocker arm and check adjusting screw and push rod.
the valve for inclination of the valve cap,
8. Rotate the crankshaft. Measure and adjust the
entrance of dirt, or wear.
valves on the next cylinder. Continue until all
the valves have been measured and adjusted.

ENGINE
4-Valve Cylinder Heads IMPORTANT
Do not loosen or tighten the valve adjusting
The 4-valve cylinder head operates two valves with
screw lock nut without holding the valve
a single rocker arm by employing a valve bridge
bridge. Always hold the valve bridge using a
(Figure 6-77, (1)) between the two valves
wrench to prevent bending of the valve
(Figure 6-77, (2)). Clearance (Figure 6-77, (4))
stems.
between the valve bridge and valves must be set
before adjusting the clearance (Figure 6-77, (5)) 4. Loosen the valve bridge adjusting screw lock
between the rocker arm (Figure 6-77, (3)) and nut (Figure 6-78, (1)) while holding the bridge
valve bridge. (Figure 6-78, (3)) with a wrench
(Figure 6-78, (2)).
(5) (3)
(1) (1)
(4)
(3)
(2) (2) (2) 0001917A
Figure 6-78
0001918B
5. To assure the valve bridge contacts the rear

Figure 6-77
valve, apply light, downward (Figure 6-79, (4))
1. Remove the valve cover. See Removal of Valve finger pressure on the valve bridge
Cover on page 6-48. (Figure 6-79, (3), and loosen the valve bridge
adjusting screw (Figure 6-79, (1)), until there is
Note: If adjusting each cylinder individually, the
visible clearance (Figure 6-81, (2)) between the
cylinder to be adjusted first does not
adjusting screw and the front valve.
have to be the No. 1 cylinder. Select and
adjust the cylinder where the piston is 6. To assure the valve bridge has equal contact
nearest to the top dead center after with the front and rear valves, apply light
turning, and make adjustment for other downward (Figure 6-79, (4)) pressure on the
cylinders in the order of firing by turning valve bridge (Figure 6-79, (3), adjust the valve
the crankshaft 180 each time. bridge adjusting screw ((Figure 6-79, (1)),
(Figure 6-81, (1))) so there is zero
2. Rotate the crankshaft clockwise as seen from 0 clearance (Figure 6-81, (2)) between the
the coolant pump end, to bring No. 1 piston to adjusting screw and the front valve.
TDC on the compression stroke while watching
the rocker arm motion and the timing grid on the (1)
flywheel. (Position where both the intake and (4)
exhaust valves are closed.)
3. Make sure there is clearance (Figure 6-77, (5))
between the valve bridge (Figure 6-77, (1)) and
the rocker arm (Figure 6-77, (3)). (3)
(2) 0001917C
Figure 6-79

ENGINE
7. Tighten the lock nut (Figure 6-80, (1)), while
(2)
holding the valve bridge (Figure 6-80, (3)) with
a wrench (Figure 6-80, (2)). Verify that the
valve clearance (Figure 6-81, (2) is zero 0.
(1)
(3)
.006 (1)
(2) 0001917A .152 m
m
Figure 6-80
(1) 0003566
(3)
Figure 6-82
9. If adjustment is required, proceed to the next
step.
(2)
10. Loosen the valve adjusting screw lock nut
(Figure 6-83, (5)) and valve adjusting screw
(Figure 6-83, (4)) on the rocker arm
0001918D (Figure 6-83, (3)) and check the clearance gap
Figure 6-81 (Figure 6-83, (2)) for evidence of dirt or wear.
Note: There is a tendency for the clearance to
Note: There is a tendency for the clearance to decrease slightly when the lock nut is
decrease slightly when the lock nut is tightened. It is suggested that you make
tightened. It is suggested that you make the clearance adjustment is made
the initial clearance adjustment is made slightly on the loose side before
slightly on the loose side before tightening the lock nut.
tightening the lock nut.
11. Adjust the valve clearance (Figure 6-83, (2)) by
8. To adjust the actual valve clearance between turning the adjusting screw (Figure 6-83, (4))
the rocker arm and the valve bridge, insert a until there is a slight drag on the feeler gauge
feeler gauge (Figure 6-82, (1)) of the correct when sliding it between the rocker arm and the
thickness (See Adjustment Specifications on valve bridge.
page 6-6) between the rocker arm
(Figure 6-82, (2)) and valve bridge
(Figure 6-82, (3)). Record the results and use
this value as an indication of wear.

ENGINE
(3)
(4)
(1) (2) (5)
0001918
Figure 6-83
12. Hold the adjusting screw (Figure 6-83, (4))
while tightening the valve adjusting screw lock
nut (Figure 6-83, (5)). Recheck the clearance.
13. Apply oil to the contact surface between the
adjusting screw and push rod.
14. Rotate the crankshaft to measure and adjust
the set of valves. Continue until all valves are
measured and adjusted.

ENGINE

ENGINE
CRANKSHAFT AND CAMSHAFT COMPONENTS

(6)
(1)
(5)
(7)
(3) (4)
(2)
(41)
(40)
(8)
(9)
(39) (10)
(8)
(38)
(37) (11)
(35) (12)
(36) (13)
(34) (14)
(32)
(33) (17)
(29) (16)
(31) (15)
(30) (18)
(19)
(20)
(21)
(22)
(28) (23)
(24)
(25)
(27) (26)
0001963
Figure 6-84

ENGINE
1 Cylinder Block
2 Camshaft Bushing CAUTION
3 Gear Case (3TNV94 - 4TNV106) Identify all parts and their location using
4 Dowel (2 used) an appropriate method. It is important
5 O-Ring
6 Front Plate (3TNV82 - 4TNV88)
7 Gear Case Cover (3TNV82 - 4TNV88)
0000080en
8 Front Crankshaft Seal
9 Gear Case Cover (3TNV94 - 4TNV106)
If the engine will be completely disassembled, the
10 Tappets
11 Camshaft
following preliminary steps should be performed:
12 Camshaft Gear Key 1. Disconnect the battery cables at the battery.
13 Camshaft End Plate
Always disconnect the negative (-) cable first.
14 Camshaft Gear
15 Idler Gear Shaft 2. Remove the throttle cable, electrical
16 Idler Gear Bushing connections, intake and exhaust system
17 Idler Gear connections, and fuel supply lines from the
18 Oil Pickup O-Ring engine.
19 Oil Pickup
3. Remove the alternator. See Removal of
20 Crankshaft
21 Parallel Pin
Alternator on page 12-12.
22 Crankshaft Gear Key 4. Drain the engine coolant from the radiator and
23 Crankshaft Gear cylinder block. See Drain, Flush and Refill
24 Crankshaft Pulley Cooling System With New Coolant on
25 Main Bearing Inserts page 5-35. Remove the cooling system
26 Main Bearing Cap components from the engine.
27 Oil Pan
28 Thrust Bearings 5. Remove the engine from the machine. Mount
29 Flywheel the engine to a suitable engine repair stand
30 Connecting Rod Cap having adequate weight capacity.
31 Connecting Rod Bearing Inserts
32 Connecting Rod A CAUTION
33 Wrist Pin Bushing
34 Circlip Be sure to secure the engine solidly to
35 Wrist Pin prevent injury or damage to parts due to
36 Piston the engine falling during work on the
37 Oil Ring engine.
38 Second Compression Ring 0000009en
39 Top Compression Ring
40 Crankshaft Rear Seal 6. Clean the engine by washing with solvent, air or
41 Crankshaft Rear Seal Housing steam cleaning. Carefully operate so as to
prevent any foreign matter or fluids from
Disassembly of Engine entering the engine or any fuel system or
Prepare a clean, flat working surface on a electrical components remaining on the engine.
workbench large enough to accommodate the 7. Drain the engine oil into a suitable container.
engine components. Discard all used gaskets, Remove the oil filter.
O-rings and seals. Use new gaskets, O-rings and 8. Remove the cylinder head. See 2-Valve
seals on reassembly of engine. Cylinder Head on page 6-32 or 4-Valve Cylinder
Head on page 6-46.

ENGINE
9. Remove the fuel injection pump from the gear
case / front plate only if it must be sent out for
repair, or will interfere with other procedures
such as hot tank cleaning. If the fuel injection
pump does not need to be repaired, leaving it
mounted to the timing gear case or plate will
eliminate the need to re-time it during
reassembly. See Fuel Injection Pump on
page 7-16.
10. Remove the starter motor. See Removal of
Starter Motor on page 11-10.
Disassembly of Camshaft and Timing (1)
Components 0001641A
Discard all gaskets, O-rings and seals. Use new Figure 6-85
gaskets, O-rings and seals on reassembly of the
camshaft and timing components. Checking Timing Gear Backlash
Prior to removing the timing gears, measure the
Removal of Timing Gear Case Cover gear backlash and determine the gear wear.
1. Remove the bolt and washer retaining the Check the backlash between each pair of mating
crankshaft pulley. gears (Figure 6-86). If not within specification,
IMPORTANT replace both mating gears. See Timing Gear
Use care not to damage the threads in the Backlash on page 6-12 for service limits.
end of the crankshaft when removing the Note: Do not allow the gear being checked to
crankshaft pulley. move axially as excess end play could
2. Remove the crankshaft pulley using a gear cause a false reading.
puller.
(1)
3. Remove the bolts that retain the gear case (2)
cover to the cylinder block and oil pan.
4. Remove the gear case cover (Figure 6-85, (1)). B B
C C
A
(7) A
(3)
(6) (4)
(5) 0001709A
1 Fuel Injection Pump Drive Gear

2 Camshaft Drive Gear
3 Auxiliary Drive Gear (Optional)
4 Crankshaft Drive Gear
5 Direction of Rotation
6 Oil Pump Drive Gear (4TNV94L - 4TNV106)
7 Idler Gear
Figure 6-86

ENGINE
Note: 3TNV82A - 4TNV88: The oil pump is
driven directly by flats on the crankshaft
drive gear hub.
Measuring Idler Gear-to-Crankshaft Gear

Backlash (2)
1. Install a dial indicator as shown in Figure 6-87.
(3)
(1)
0001728A
Figure 6-88
2. Do not remove the crankshaft gear unless it is
damaged and requires replacement. If the gear
must be removed, remove it using a gear puller.
3. Removal of the camshaft gear requires the
0002086 camshaft be removed and placed in a press. Do
Figure 6-87 not remove the camshaft gear unless it or the
camshaft is damaged and requires
2. Rotate the idler gear back and forth to check replacement. See Removal of Camshaft on
the idler gear-to-crankshaft gear backlash. The page 6-73.
total indicator reading is the backlash. Record
the measurement. CAUTION
Measuring Idler Gear-to-Camshaft Gear Do not loosen or remove the four bolts
Backlash retaining the fuel injection pump drive
gear to the fuel injection pump hub. Do
1. Drive a small wooden wedge between the not disassemble the fuel injection pump
crankshaft gear and idler gear to prevent the drive gear from the hub. Correct fuel
idler gear from rotating. injection timing will be very difficult or
2. Install the dial indicator to read the camshaft impossible to achieve.
gear backlash. Rotate the camshaft drive gear 0000031en
against the idler gear to measure the backlash.
Record the measurement. 4. Do not remove the fuel injection pump drive
gear unless absolutely necessary to avoid
3. Check the idler gear-to-fuel injection pump
damage to the gear or pump. Do not loosen or
drive gear backlash in the same manner as the
remove the four bolts (Figure 6-89, (3))
camshaft drive gear. Record the measurement.
retaining the pump drive gear to the hub. Only
Removal of Timing Gears remove the nut (Figure 6-89, (1)) and washer
(Figure 6-89, (2)), leaving the hub attached to
1. Remove the bolts from the idler gear shaft the gear. Remove the pump drive gear and hub
(Figure 6-88, (1)). Remove the idler gear shaft, as an assembly using a gear puller.
idler gear (Figure 6-88, (2)) and bushing
(Figure 6-88, (3)).

ENGINE
(3)
(1)
(2)
0000162A
(1)
Figure 6-89
Removal of Oil Pan

1. Invert the engine (oil pan up) on the engine
stand.
2. Remove the oil pan (Figure 6-90, (1)). 0001695A
Figure 6-90

ENGINE
3. Remove the oil pickup tube (Figure 6-91, (1)) (2)
and O-ring (Figure 6-91, (2)).
60
50 70
40 80
30 90
20 0
10
(1)
0002085A
Figure 6-92
Method B: Use a feeler gauge to measure the
(2)
clearance between the thrust plate
(1) (Figure 6-93, (1)) and front camshaft bearing
(Figure 6-93, (2)). See Thrust Bearing on
0001696A (1)
Figure 6-91
(2)
Removal of Camshaft
1. Before removing the camshaft, check the
camshaft end play.
Method A: Install a dial indicator
(Figure 6-92, (1)) on the cylinder block. Move
the camshaft (Figure 6-92, (2)) back and forth
to measure the end play. Record the
measurement. See Camshaft on page 6-10 for 0001710B
the service limit.
Figure 6-93

ENGINE
2. Remove the two bolts (Figure 6-94, (3)) Removal of Gear Case or Front Plate
retaining the camshaft thrust plate Note: The camshaft must be removed before
(Figure 6-94, (1)). the gear case / front plate can be
removed. See Inspection of Camshaft on
page 6-84.
(2) (5) 1. TNV94 - TNV106: Remove the oil pump.

Note: It is not necessary to remove the fuel
(1) injection pump from the gear case / front
plate to remove the gear case / front
(3) (4) plate. If the fuel injection pump does not
need to be repaired, leaving it mounted
to the timing gear case / front plate will
eliminate the need to re-time it during
0001966
assembly. See Fuel Injection Pump on
page 7-16.
Figure 6-94
2. Remove the bolts (Figure 6-95, (4)).
3. Rotate the engine in the engine stand so that
3. Remove the gear case (Figure 6-95, (1)) or
gravity causes the tappets (Figure 6-94, (5)) to
front plate from the cylinder block. Thoroughly
drop away from the camshaft lobes.
clean all old sealant from the mating surfaces.
Note: Rotate the camshaft at least two turns to
4. Inspect and measure the camshaft bushing.
bump any sticking tappets away from
See Camshaft on page 6-10 for the service
the camshaft.
limit. If damaged or worn beyond service limits,
4. Slowly pull the camshaft (Figure 6-94, (2)) remove the camshaft bushing
assembly out of the engine being careful not to (Figure 6-95, (3)).
damage the front camshaft bushing. 5. TNV94 - TNV106: Remove two O-rings
Note: If the engine is not installed on an engine (Figure 6-95, (2)).
repair fixture, stand the engine upright on
the flywheel end mounting flange. Rotate
the camshaft at least two turns to bump
the tappets out of the way to prevent the
tappets from interfering with the removal
of the camshaft.
(3) (1)
Note: The tappets are mushroom shaped and
must be removed from inside the engine
crankcase.
(4)
5. Remove the tappets. Mark the tappets so they
can be reinstalled in the same location.
6. Remove the camshaft drive gear
(2)
(Figure 6-94, (4)) only if the gear or camshaft 0001737B
require replacement. Use a knife-edge puller
and a press to remove the gear. The gear is a Figure 6-95
shrink-fit and will need to be heated to
356 - 392F (180 - 200C) to remove.

ENGINE
6. TNV84 - TNV88: Remove the O-ring 1. Using a feeler gauge, measure the connecting
(Figure 6-96, (2)) and dowels rod side clearance as shown (Figure 6-97).
(Figure 6-96, (5)). See Connecting Rod on page 6-21 for the
standard limit. If the measurement is out of
specification, replace the crankshaft,
connecting rod, or both.
(3)
(1)
(2) (4)
(5 )
0002016
Figure 6-96
0000219
Disassembly of Crankshaft and Figure 6-97

Piston Components 2. Measure bearing oil clearance prior to removing
the pistons and connecting rods to determine
Removal of Pistons extent of wear. Record the measurements.
CAUTION
assemblies, and connecting rod
assemblies together to be returned to
the same position during the
reassembly process. Label the parts
using an appropriate method.
0000088en
IMPORTANT
Engines with high operating hours may
have a ridge near the top of the cylinders
that will catch the piston rings and make it
impossible to remove the pistons. Use a
suitable ridge reamer to remove ridges and
carbon prior to removing the pistons.
Note: Pistons can fall from cylinder block if the
engine is inverted. Rotate the engine so
the connecting rods are horizontal before
removing the connecting rod caps.

ENGINE
IMPORTANT (g) Repeat with remaining connecting rods.
Mark the connecting rod caps and
connecting rods so the caps and connecting IMPORTANT
rods stay together. Do not allow the connecting rod to contact
the crankshaft journal during piston
(a) Remove the bearing cap. Do not remove the removal. Damage to the bearing journal
bearing inserts at this time. may result.
(b) Wipe oil from the bearing insert and 3. Use a wooden dowel against the connecting
crankshaft journal surfaces. rod and tap the piston / connecting rod
(c) Place a piece of PLASTIGAGE assembly out of the cylinder.
(Figure 6-98, (1)) along the full width of the 4. Mark the cylinder number on the piston and
bearing insert. connecting rod.
5. Remove the bearing inserts (Figure 6-100, (2)).
(1) 6. Remove the compression rings
(Figure 6-100, (3)) from the piston using a
piston ring expander.
7. Remove the oil ring (Figure 6-100, (4)) from the
piston using a piston ring expander.
0001898
(3)
Figure 6-98
(4)
IMPORTANT (5)
Do not rotate the crankshaft when using
PLASTIGAGE. A false reading may result. (9) (6)
(5)
(d) Reinstall bearing cap and tighten to
specification. See Special Torque Chart on
page 6-23. (8)
(e) Remove bearing cap. (7)
(f) Compare the width of the flattened
PLASTIGAGE to the graduation marks on (2)
the package (Figure 6-99, (1)). The mark
(1)
that most closely matches the width of the
flattened PLASTIGAGE will indicate the
bearing oil clearance.
0001960
Figure 6-100
8. Remove the circlips (Figure 6-100, (5)) from
(1) the wrist pin.
9. Remove the wrist pin (Figure 6-100, (6)) and
connecting rod (Figure 6-100, (8)) from the
piston (Figure 6-100, (9)).
0001899
10. Repeat the steps until all pistons are removed
Figure 6-99 and dissembled.

ENGINE
Removal of Crankshaft Method B: Use a feeler gauge to measure the
1. Remove the flywheel (Figure 6-101, (1)) from clearance (Figure 6-103, (3)) between the
the crankshaft. thrust bearing (Figure 6-103, (1)) and
crankshaft (Figure 6-103, (2)). Record the
2. Remove the bolts from the rear oil seal measurement. See Thrust Bearing on
assembly (Figure 6-101, (2-3)). Remove the page 6-14 for the service limit.
assembly from the engine.
(2)
(3)
(1)
(1)
(2)
(3) 0001962
Figure 6-103
0001707A
Figure 6-101
3. Before removing the main bearing caps,
measure the crankshaft end play. Use either of
the following two methods.
Method A: Install a dial gauge
(Figure 6-102, (1)) on the cylinder block. Move
the crankshaft (Figure 6-102, (2)) in and out to
measure the end play. Record the
measurement.
(1)
(2)
0001961
Figure 6-102

ENGINE
4. Remove the main bearing caps
(Figure 6-104, (3)). Be sure to note the (1)
markings on the main bearing caps, or mark
them yourself, so they can be reinstalled in the
same order as they were removed. Do not
remove the bearing inserts at this time.
Note: The arrows on the main bearing caps
point to the flywheel end of the engine. 0001898
Figure 6-105
IMPORTANT
Do not rotate the crankshaft when using
PLASTIGAGE. A false reading may result.
(c) Reinstall bearing caps and tighten to
page 6-23.
(d) Remove bearing caps.
(e) Compare the width of the flattened
(2) PLASTIGAGE to the graduation marks on
the package (Figure 6-106, (1)). The mark
that most closely matches the width of the
flattened PLASTIGAGE will indicate the
bearing oil clearance.
(1)
(1)
(3)
0001752A
Figure 6-104 0001899
5. Measure bearing oil clearance prior to removing Figure 6-106

the crankshaft to determine extent of wear. 6. Remove the crankshaft from the engine.
Record the measurements.
7. Remove the bearing inserts (Figure 6-104, (1))
(a) Wipe oil from the bearing insert and and thrust bearings (Figure 6-104, (2)).
crankshaft journal surfaces.
Note: Do not remove the crankshaft gear
(b) Place a piece of PLASTIGAGE unless the gear or crankshaft are
(Figure 6-105, (1)) along the full width of damaged and require replacement.
each bearing insert.

ENGINE
8. If necessary, remove the crankshaft gear 2. Apply a continuous bead of ThreeBond Liquid
(Figure 6-107, (1)), parallel pin Gasket No. 1212, Yanmar Part No. 977770-
(Figure 6-107, (2)) and key (Figure 6-107, (3)). 01212 to the outside diameter of a new oil seal
If using a gear puller, be careful not to damage (Figure 6-108, (2)), and install in the gear case
the threads in the end of the crankshaft. cover. Apply lithium grease to the lip of the seal.
(2)
(3)
(1)
0001731A
(1)
Figure 6-107
Inspection of Crankshaft and

Camshaft Components (2)
A WARNING 0001735A
Figure 6-108
3. Remove the rear oil seal (Figure 6-109, (3))
from the seal housing (Figure 6-109, (2)).
4. Apply a continuous bead of ThreeBond Liquid
FUME / BURN HAZARD! Gasket No. 1212, Yanmar Part No. 977770-
Always read and follow safety related 01212 to the outside diameter of a new oil seal
precautions found on containers of (Figure 6-109, (2)), and install in the housing.
hazardous substances like parts Apply lithium grease to the lip of the seal.
sealant removers.
(2)
or serious injury.
0000014en (3)
Thoroughly clean all components using a brush (1)

and appropriate solvent. Each part must be free of
carbon, gasket material, metal filings and other
debris.
Replacement of Crankshaft Oil Seals

1. Remove the seal (Figure 6-108, (2)) from the
cover (Figure 6-108, (1)). 0001707A
Figure 6-109

ENGINE
Measure Crankshaft Bearing Oil Clearance On an engine with high hours, the pistons rings
Oil clearance should be checked during should be replaced and the cylinder honed (See
disassembly to determine the extent of wear, and Honing and Boring on page 6-85) or replaced.
during assembly to ensure long engine life. The The piston should be replaced as necessary.
same procedure is done for both connecting rods 1. Clean piston ring grooves using a piston ring
and main bearings. groove cleaning tool. Follow manufacturers
instructions for correct operation.
Inspection of Cylinder Block
2. Wash the pistons in an appropriate solvent
1. Ensure that oil passages are clear and using a soft brush.
unobstructed.
3. Visually inspect each piston for cracks. Pay
2. Check for discoloration or evidence of cracks. If particular attention to the ring lands between
a fracture is suspected, use the color check the piston ring grooves.
method or the Magnaflux method to determine
if the cylinder block is fractured. 4. Measure the diameter of the piston skirt at 90
to the wrist pin bore as shown (Figure 6-111).
3. Inspect cylinders for roundness, taper, or Measurements must be taken at a specified
evidence of scoring. Collect and record the distance (Figure 6-111, (1)) from the bottom of
measurements. Consider honing, reboring or the piston, based on engine model. Record the
replacing the cylinder block if the measurements. See Piston on page 6-15 for
measurements are not within specification. specifications.
Take measurements at three places
(Figure 6-110) (a, b, c), and in two directions (d
and e) in each cylinder.
a 20 mm
(3/4 in.)
d
e
b (1)
c
20 mm
(3/4 in.)
0000230B 0000235
Figure 6-111
Figure 6-110
5. Subtract the piston measurement from the
Inspection of Pistons, Piston Rings and greatest measurement acquired during cylinder
Wrist Pin inspection (see Inspection of Cylinder Block on
page 6-80) to obtain piston-to-cylinder
Notes:
clearance. Record the measurements. See
On an engine with low hours, the pistons, piston Piston on page 6-15 for specifications.
rings may be reused if they are found to be within 6. Measure the diameter of the wrist pin bore on
specifications. The pistons and piston rings must both sides of the piston (Figure 6-112). See
be reinstalled in the same cylinders from which Piston on page 6-15 for specifications. Record
they were originally removed. the measurements.

ENGINE
0000237
0001892
Figure 6-112
7. Measure the outside diameter of the wrist pin in Figure 6-114
three places and at 90 (Figure 6-113). See
Piston on page 6-15 for specifications. Record
the measurements.
0001889
Figure 6-113
8. Using a micrometer, measure the thickness of
each piston ring. See Piston Ring on page 6-17
for specifications. Record the measurements.
Notes:
On an engine with low hours, the pistons,
piston rings and cylinders may be reused if they
are found to be within specifications.
On an engine with high hours, the pistons rings
should be replaced and the cylinder honed
(see Honing and Boring on page 6-85) or
replaced. The piston should be replaced as
necessary.
9. Place each compression piston ring in the
groove as shown (Figure 6-114). Use a feeler
gauge to measure the clearance between the
piston ring and the piston ring land. Record the
measurements. See Piston Ring on page 6-17
for specifications. Replace the piston if not
within specification.

ENGINE
10. To measure piston ring end gap, insert each
compression piston ring (Figure 6-115, (1)),
one at a time, into the cylinder. Use a piston
with the piston rings removed to slide the ring
into the cylinder bore until it is approximately
1.18 in. (30 mm) (Figure 6-115, (2)) from the
bottom of the bore. Remove the piston.
Measure the end gap (Figure 6-115, (3)) of
each piston ring. Record the measurements.
See Piston Ring on page 6-17 for (1)
specifications.
(2)
0001724A
Figure 6-116
2. Place the connecting rod bearing inserts into
the connecting rod and connecting rod cap.
Install the rod cap and tighten the bolts to the
(1) specified torque.
(2) 3. Measure the inside diameter. See Crankshaft
on page 6-13 for specifications.
Inspection of Tappets
(3) 1. Inspect the tappet contact surfaces for
0001964 abnormal wear (Figure 6-117, (1)). Normal
Figure 6-115 wear will be even as shown in
(Figure 6-117, (2)). Slight surface defects can
Note: Always check the piston ring end gap
be corrected using an oilstone.
when installing new piston rings. See
Piston Ring on page 6-17 for
specifications. Use a piston ring end gap
filing tool to adjust the piston ring end
gap on new piston rings.
11. Repeat the above steps for each cylinder and
piston assembly.
Inspection of Connecting Rod

1. Measure the wrist pin bushing bore using a (1) (2) 0001725
bore gauge (Figure 6-116, (1)). Replace the
Figure 6-117
bushing if not within specifications. If the
bushing has been removed, measure the inside
diameter of the connecting rod small end
(Figure 6-116, (2)). See Connecting Rod on
page 6-21 for specifications.

ENGINE
2. Measure the outside diameter of the tappet 4. Use the color check method or Magnaflux to
stem (Figure 6-118, (1)). See Tappet on inspect the crankshaft for cracks. Replace the
page 6-22 for the service limit. crankshaft if evidence of fractures are found.
5. Measure the outside diameter of each crankpin
(Figure 6-120, (2)) and main bearing journal
(Figure 6-120, (1)). See Crankshaft on
page 6-13 for specifications. Take
measurements at several places around each
bearing surface. If not within specification, grind
the journals and install undersize bearings, or
replace the crankshaft.
(1)
0001726A
Figure 6-118
3. Measure the tappet bores in the cylinder block.
See Tappet on page 6-22 for the service limit.
Inspection of Crankshaft
1. Place the crankshaft end journals
(Figure 6-119, (4)) on V-blocks.
2. Place a dial indicator (Figure 6-119, (3)) on a
center main bearing surface.
(2) R
(1)
R
(1)
(3) (2) 0001733A
Figure 6-120
(4) (4) 0000232A
Figure 6-119
3. Rotate the crankshaft and observe runout. See
Crankshaft on page 6-13 for specifications.

ENGINE
Inspection of Camshaft (3)
1. Use V-blocks and a dial indicator to check
camshaft bend (Figure 6-121). Place the
indicator on the center bearing journal. (2)
(1)
0001713A
Figure 6-123
0001711
Inspection of Camshaft Bushing and Bores
Figure 6-121 1. Measure the I.D. of the front bushing and the
remaining bores in the cylinder block. See
2. Rotate the camshaft and observe the runout. Camshaft on page 6-10 for specifications.
See Camshaft on page 6-10 for specifications.
2. If the camshaft bushing is not within
3. Measure the height of each lobe specification, replace it using the appropriate
(Figure 6-122, (1)). See Camshaft on service tool. If the remaining bores are not
page 6-10 for specifications. within specification, the cylinder block will
require replacement as there are no bearing
inserts used.
(1)
Inspection of Idler Gear and Shaft
1. Measure the outside diameter
(Figure 6-124, (1)) of the idler gear shaft
(Figure 6-124, (2)). See Idler Gear Shaft and
Bushing on page 6-12 for specifications.
0001712A
2. Measure the inside diameter
Figure 6-122 (Figure 6-124, (3)) of the idler gear bushing
(Figure 6-124, (4)). See Idler Gear Shaft and
4. Measure the diameter of the gear end
Bushing on page 6-12 for specifications.
(Figure 6-123, (1)), intermediate
(Figure 6-123, (2)), and flywheel end
(Figure 6-123, (3)) bearing journals. See (4)
Camshaft on page 6-10 for specifications.
(1) (3)
(2)
0001714A
Figure 6-124

ENGINE
Honing and Boring
CAUTION
Pistons must move freely in the cylinders while
maintaining adequate compression and oil sealing.
If the cylinder walls are scuffed, scored,
out-of-round, or tapered beyond specifications,
rebore and hone to restore cylinders to usable
motion.
condition. Slight imperfections can be corrected by
0000090en
honing alone.
1. Boring - Significant cylinder damage may be (1)
corrected by boring the cylinder to an oversize
dimension. Refer to the appropriate parts
catalog for available oversize pistons and piston
rings.
Boring a cylinder should always be done in a
properly equipped machine shop.
A bored cylinder should always be finished with
a hone to properly prepare the cylinder surface
so the new piston rings will seat properly.
After the cylinder has been bored and honed, 0000248A
install the appropriate oversize pistons and Figure 6-125
piston rings.
2. Honing - Minor cylinder imperfections may be Use a 50:50 mixture of diesel fuel and engine
corrected by using a rigid cylinder hone oil as a honing fluid.
(Figure 6-126, (1)). Be sure not to exceed the Use a 300-grit hone at 300 - 1200 rpm
maximum cylinder bore specification. (Figure 6-126).
Deglazing - A used cylinder that did not require
(1)
boring or honing, should always be deglazed with
a ball hone (Figure 6-126, (2)) before installing (2)
new piston rings. This will properly prepare the
cylinder surface to allow new piston rings to seat
properly.
Note: When honing a cylinder, with either a
ridged hone or a ball hone 0000249B
(Figure 6-125, (1)), move the rotating
hone up and down in the cylinder bore to Figure 6-126
accomplish a 30 to 40 crosshatch
pattern (Figure 6-125). This will provide IMPORTANT
the ideal surface for the proper seating of Solvents will not adequately remove honing
new piston rings. residue, resulting in premature piston and
ring wear. Always wash cylinders using hot,
soapy water.

ENGINE
When honing is completed, wash the cylinder
block with hot water and soap. The cylinder wall (3)
is adequately cleaned when a white rag wiped
(4)
in cylinder comes out clean. Use brushes to
clean all passages and crevices. Rinse with hot (5)
water and dry with compressed air. Apply clean (9) (6)
engine oil to all steel surfaces to prevent (5)
rusting.
Reassembly of Crankshaft and (8)

Piston Components (7)
Notes:
(2)
Proceed slowly. Make no forced assemblies
unless a pressing operation is called for. All (1)
parts must be perfectly clean and lightly
lubricated when assembled.
0001960
Use new gaskets, seals and O-rings during
assembly. Figure 6-127
Liberally apply clean engine oil to all internal 3. Reinstall one circlip (Figure 6-127, (5)) into the
parts during assembly. piston. Ensure the circlip is securely seated in
All fasteners should be tightened to a given the groove.
torque. If a special torque is not provided in the
Special Torque Chart on page 6-23, tighten to IMPORTANT
standard torque specifications. See Tightening The piston and connecting rod must be
Torques for Standard Bolts and Nuts on assembled with the correct orientation.
page 4-45. When correctly assembled, the
identification mark (Figure 6-128, (1))
Reassembly of Pistons stamped into the top of the piston will be on
1. Select the parts needed to reassemble the the same side of the connecting rod as the
piston and connecting rod for one cylinder. match marks (Figure 6-128, (3)) stamped
into the connecting rod and connecting rod
2. If removed, install a new wrist pin bushing cap. When installed in the cylinder, the
(Figure 6-127, (7)) using a press and the embossed mark (Figure 6-128, (2)) cast
appropriate service tool. Be sure to align the oil into the beam of connecting rod will face the
holes. flywheel end of the engine.
Note: The actual appearance of the match
marks will vary but they will always be in
the same locations.

ENGINE
(6) (1)
(1)
ML844V
(2)
(5)
(2) (3)
(4)
E106 R
0001967
0002090 1 Fuel Injection Pump Side of Engine

2 Piston Identification Mark
3 Embossed Mark on Connecting Rod
(3)
4 Rod and Cap Match Marks
5 Flywheel End of Engine
6 Camshaft Side of Engine
80 80
Figure 6-129
0002089 5. Lubricate and reinstall the wrist pin
Figure 6-128 (Figure 6-130, (3)) through the piston and
connecting rod.
4. Place the connecting rod into the piston. The
6. Reinstall the second circlip (Figure 6-130, (4))
match marks (Figure 6-129, (4)) on the
and ensure it is securely seated in the groove.
connecting rod and cap must be on the same
side as the identification mark
(3)
(Figure 6-129, (2)) on the top of the piston.
(4)
(5)
(9) (6)
(5)
(8)
(7)
(2)
(1)
0001960
Figure 6-130

ENGINE
Note: If installing new piston rings the end gap
must be checked and adjusted as (1)
necessary. See Inspection of Pistons,
Piston Rings and Wrist Pin on page 6-80
for specifications. Use a piston ring end
(2)
gap filing tool to adjust the piston ring
end gap on new piston rings.
(3)
Note: Reinstall the top and second piston rings
with the stamped makers mark
(Figure 6-131, (1)) facing the top of the
piston. The makers mark may vary in (4)
appearance but will always be located on 0001722B
the top surface of the piston ring Figure 6-132

adjacent to the piston ring gap. The oil
ring and oil ring expander can be 10. Stagger the piston ring end gaps at 120
installed either side up. intervals (Figure 6-133, (1, 2, 3)). Do not
position the top piston ring end gap in line with
(1) the wrist pin.
(1)
0000225A
Figure 6-131 (2)
IMPORTANT (3)
Always use a piston ring installation tool
(expander) when installing piston rings.
Never attempt to install piston rings by
hand.
7. Reinstall the oil ring expander
(Figure 6-132, (4)). Reinstall the oil ring
(Figure 6-132, (3)) with the end gap at 180
from the expander end gap.
0001968
8. Reinstall the second compression ring
(Figure 6-132, (2)). This ring is identified by its 1 Top Compression Ring End Gap
dark color and tapered face profile. 2 Second Compression Ring End Gap
3 Oil Ring End Gap
9. Reinstall the top compression ring
(Figure 6-132, (1)). This ring is identified by its Figure 6-133
silver color and barrel-shaped face profile.
IMPORTANT
The oil ring expander (Figure 6-132, (4))
end gap must be located 180 from the oil
ring (Figure 6-132, (3)) end gap.

ENGINE
Installation of Crankshaft 6. Rotate the crankshaft to assure it turns freely.
1. If removed, reinstall the keys and timing gear on 7. Apply ThreeBond Liquid Gasket No. 1212,
the crankshaft. Yanmar Part No. 977770-01212 to the mounting
2. Reinstall new bearing inserts flange of the seal housing (Figure 6-135, (2)).
(Figure 6-134, (1)) and thrust bearing 8. Align the seal housing with the two dowel pins.
(Figure 6-134, (2)) in the cylinder block and 9. Reinstall seal housing and seal assembly.
main bearing caps. Apply a liberal coat of clean
engine oil to the bearings and crankshaft 10. Reinstall the flywheel (Figure 6-135, (1)) and
journals. tighten the bolts to the specified torque. See
Special Torque Chart on page 6-23 for
3. Place the crankshaft into the engine. specifications.
IMPORTANT
The main bearing caps are numbered and
have arrows for proper positioning. The (2)
No. 1 cap is at the flywheel end. The arrows
point toward the flywheel end of the engine. (3)
4. Reinstall the main bearing caps (1)

(Figure 6-134, (3)).
5. Apply a light coat of clean engine oil to the
bearing cap bolts and tighten the bolts to the
specified torque in two stages (1/2 then full
torque). See Special Torque Chart on
0001707A
Figure 6-135
Installation of Pistons
IMPORTANT
Do not allow the connecting rod to contact
the crankshaft journal during piston
installation. Damage to the crankshaft
bearing journal may result.
(2)
1. Lubricate the piston, piston rings, and cylinder
with clean engine oil or assembly lubricant.
(1)
(3)
0001752A
Figure 6-134

ENGINE
2. Rotate the crankshaft so the crankpin for the 4. Carefully reinstall the piston and rod assembly.
piston being installed is near bottom dead Be sure the match marks (Figure 6-137, (4))
center. stamped into the connecting rod and cap, and
the identification mark (Figure 6-137, (2))
IMPORTANT stamped into the piston top are facing the fuel
Ensure the piston ring gaps are located injection pump side (Figure 6-137, (1)). The
correctly (Figure 6-136). embossed mark cast into the connecting rod
beam (Figure 6-137, (3)) will be facing the
(1) flywheel end of the engine (Figure 6-137, (5)).
(6) (1)
(2)
(3)
(2)
(5)
(3)
(4)
0001967
0001968
1 Fuel Injection Pump Side of Engine
1 Top Compression Ring End Gap 2 Piston Identification Mark
2 Second Compression Ring End Gap 3 Embossed Mark on Connecting Rod
3 Oil Ring End Gap 4 Rod and Cap Match Marks
Figure 6-136 5 Flywheel End of Engine
6 Camshaft Side of Engine
3. Using a piston ring compressor, compress the
Figure 6-137
piston rings.
IMPORTANT
The piston and connecting rod must be
installed with the correct orientation. When
installed correctly, the identification mark
(Figure 6-137, (2)) stamped into the top of
the piston will be on the same side of the
engine as the fuel injection pump
(Figure 6-137, (1)) and the embossed mark
(Figure 6-137, (3)) cast into the connecting
rod beam will face the flywheel end of the
engine (Figure 6-137, (5)).

ENGINE
5. Reinstall the bearing inserts (Figure 6-138, (1))
in the connecting rod and cap.
6. Apply a liberal coat of clean engine oil to the
bearing inserts and crankshaft journal.
7. Apply a light coat of clean engine oil to the rod
(3) (1)
cap bolts. Reinstall the connecting rod cap
(Figure 6-138, (2)). Tighten the connecting rod
bolts to the specified torque in two stages (1/2
then full torque). See Special Torque Chart on
(4)
(2)
0001737B
Figure 6-139
4. TNV84 - TNV88: Reinstall the dowels
(Figure 6-140, (5)) and a new O-ring
(Figure 6-140, (2)).
(1)
(2)
(3)
(1)
0001965
Figure 6-138
8. Reinstall the remaining pistons in their
respective cylinders. (2) (4)
(5 )
Reassembly of Camshaft and Timing
Components 0002016
Figure 6-140
Installation of Gear Case or Front Plate
5. Reinstall the gear case (Figure 6-139, (1)) or
1. If removed, install a new camshaft bushing
front plate (Figure 6-140, (1)). Tighten the bolts
(Figure 6-139, (3)) using the appropriate
to the specified torque.
service tool.
2. Apply a continuous bead of ThreeBond Liquid Installation of Camshaft
Gasket No. 1212, Yanmar Part No. 977770- Note: The gear housing or front plate must be
01212 to the mounting area of the gear case or reinstalled prior to installing the
front plate. Be sure to circle each bolt hole. camshaft. See Installation of Gear Case
3. 4TNV94 - 4TNV106: Install two new O-rings or Front Plate on page 6-91.
(Figure 6-139, (2)) in the cylinder block.

ENGINE
1. If removed, reinstall the camshaft end plate Installation of Timing Gears
(Figure 6-141, (1)), key, and timing gear 1. Set the No. 1 piston to top dead center.
(Figure 6-141, (4)) onto the camshaft using a
press. 2. Rotate the camshaft until the mark
(Figure 6-142, (C)) is approximately at the
Note: Heat the gear to 356 - 392F 9 oclock position.
(180 - 200C) and press onto the end of
the camshaft. (1)
(2)
2. Rotate the cylinder block so that gravity will
keep the tappets (Figure 6-141, (5)) in place
and out of the way of the camshaft lobes when B B
C C
the camshaft is being reinstalled.
A
Note: If the engine is not installed on an engine (7) A
(3)
repair fixture, stand the engine upright on
the flywheel end mounting flange. (6) (4)
(5) 0001709A
Note: The tappets are mushroom shaped and
must be installed from inside the engine 1 Fuel Injection Pump Gear
crankcase. 2 Camshaft Gear
3 Optional Accessory Drive Gear
3. Lubricate the tappets with clean oil or assembly
4 Crankshaft Gear
lube. Reinstall the tappets in their respective 5 Direction of Rotation
locations in the cylinder block. Push the tappets 6 Oil Pump Gear
fully into the tappet bores so they will not 7 Idler Gear
interfere with the installation of the camshaft.
Figure 6-142
4. Lubricate the camshaft (Figure 6-141, (2)) with
clean engine oil or assembly lube. Slowly insert 3. Lubricate the idler gear (Figure 6-143, (2)),
the camshaft through the front of the engine. bushing (Figure 6-143, (3)) and idler gear shaft
5. Reinstall and tighten the cap screws (Figure 6-143, (1)) with clean engine oil.
(Figure 6-141, (3)).
(2) (5)
(2)
(1)
(3)
(3) (4) (1)
0001966 0001728A
Figure 6-141 Figure 6-143

6. If removed, reinstall the fuel injection pump. 4. Align the timing gears as shown in
Adjust the fuel injection timing the engine after (Figure 6-142).
installation. See Adjusting Fuel Injection Timing
on page 7-30.

ENGINE
5. Reinstall the idler gear and idler gear shaft. Be IMPORTANT
sure the oil hole in the bushing is facing toward 4TNV94L: Use the crankshaft pulley
the top of the engine. installation tool (Figure 6-145, (3)) when
6. Ensure all three timing marks reinstalling the pulley (Figure 6-145, (1)).
(Figure 6-142, (A, B, C)) are aligned. The tool will guide the pulley hub and
protect the front seal (Figure 6-145, (2))
7. When all gears are properly aligned, tighten the
from damage.
idler gear retaining bolts to specified torque.
See Special Torque Chart on page 6-23 for
specifications. (1)
(2)
Installation of Gear Case Cover
Gasket No. 1212, Yanmar Part No. 977770-
01212 to the mounting area of the gear case
cover (Figure 6-144, (1)). Be sure to circle the
bolt holes.
IMPORTANT
3TNV84 - 4TNV88 engines: Be sure to
align the flats on the oil pump with the flats (3)
on the crankshaft gear when installing the
gear case cover.
2. Reinstall and tighten the gear case cover bolts.
0002133
Figure 6-145
4. Reinstall the washer and bolt. Tighten the bolt
to the specified torque. See Special Torque
Chart on page 6-23 for specifications.
(1)
0001641A
Figure 6-144
3. Reinstall the crankshaft pulley.

ENGINE
Installation of Oil Pan Final Reassembly of Engine
1. Reinstall the oil pickup tube (Figure 6-146, (1)) 1. Reinstall the starter motor.
using a new O-ring (Figure 6-146, (2)).
2. Reinstall the cylinder head. See Reassembly of
Cylinder Head on page 6-44 for the 2-valve
cylinder head or 6-59 for the 4-valve cylinder
head.
3. Reinstall the engine in the machine.
4. Reconnect the fuel and coolant lines.
5. Reinstall the alternator.
6. Reconnect and adjust the throttle cable.
7. Reconnect all electrical connections.
(2)
8. Fill the engine with oil and coolant.
(1)
9. Reconnect the battery cables, negative (-) cable
last.
0001696A
Figure 6-146
Gasket No. 1212, Yanmar Part No.
977770-01212 to the mounting surface of the oil
pan (Figure 6-147, (1)). Be sure to circle each
bolt hole.
3. Reinstall the oil pan and tighten the bolts
securely.
(1)
0001695A
Figure 6-147

Section 7
FUEL SYSTEM
Page
Introduction...................................................................................... 7-5
Fuel Injection Pump................................................................... 7-5
Stop Solenoid ............................................................................ 7-6
Cold Start Device....................................................................... 7-7
Trochoid Fuel Pump .................................................................. 7-7
Fuel System Specifications ............................................................. 7-8
Special Torque Chart................................................................. 7-8
Test and Adjustment Specifications .......................................... 7-8
Special Service Tools...................................................................... 7-9
Measuring Instruments.................................................................... 7-9
Fuel System Diagram.................................................................... 7-10
Fuel System Components ............................................................. 7-12
2-Valve Cylinder Head............................................................. 7-12
4-Valve Cylinder Head............................................................. 7-14
Fuel Injection Pump....................................................................... 7-16
Removal of Fuel Injection Pump.............................................. 7-16
Installation of Fuel Injection Pump........................................... 7-21
Checking and Adjusting Fuel Injection Timing .............................. 7-26
Determining the Fuel Injection Timing Specification................ 7-26
Checking Fuel Injection Timing ............................................... 7-27
Adjusting Fuel Injection Timing................................................ 7-30

FUEL SYSTEM
Fuel Injectors.................................................................................. 7-31
Removal of Fuel Injectors......................................................... 7-31
Testing of Fuel Injectors ........................................................... 7-33
Disassembly and Inspection of Fuel Injectors .......................... 7-35
Adjusting Fuel Injector Pressure .............................................. 7-36
Reassembly of Fuel Injectors ................................................... 7-37
Installation of the Fuel Injectors................................................ 7-37

FUEL SYSTEM
BEFORE YOU BEGIN

A WARNING
SERVICING Never inject fuel toward you. Since the
fuel is injected at high pressure from
A WARNING the nozzle, it may penetrate the skin,
resulting in injury.
Never inject fuel toward a fire source.
Atomized fuel is highly flammable and
may cause a fire or burn skin.
0000028en
service it. A WARNING
servicing it. This could result in a
serious injury. FUME / BURN HAZARD!
back long hair, and keep your hands,
sealant removers.
or serious injury.
or serious injury.
0000014en
0000010en
A WARNING
equipment.
or serious injury.
0000006en

FUEL SYSTEM
A CAUTION CAUTION
NEVER remove or attempt to remove
FLYING OBJECT HAZARD! been made at the factory to meet all
ALWAYS wear eye protection when then sealed.
compressed air or high-pressure NEVER attempt to make any
water. Dust, flying debris, compressed adjustments to these sealed
air, pressurized water or steam may adjustment screws. If adjustments are
injure your eyes. required, they can be made only by a
Failure to comply may result in minor ensure the injection pump continues
or moderate injury. to meet all applicable emissions
0000003en regulations and then replace the
tamper-proof seals.
A CAUTION Tampering with or removing these
Warranty.
0000146en
CAUTION
PINCH HAZARD! Never use a steel wire brush to clean
Carefully rotate the alternator toward the fuel injectors. Damage to the nozzle and
cylinder block while loosening the other components is likely to result.
V-belt. Failure to comply may result in 0000172en
minor or moderate injury.

0000014en CAUTION
equipment.
0000159en

FUEL SYSTEM
CAUTION INTRODUCTION
Remove or install the high-pressure fuel This section of the Service Manual describes the
injection lines as an assembly whenever procedures necessary to remove, install, and time
possible. Disassembling the the MP fuel injection pump and its associated
high-pressure fuel injection lines from system components. This fuel injection pump is
the retainers or bending any of the fuel representative of the fuel injection pumps used on
lines will make it difficult to reinstall the other TNV DI model engines.
fuel lines.
Fuel Injection Pump
0000047en
Note: If the MP fuel injection pump itself
requires servicing, it must be taken to an
CAUTION authorized Yanmar FIE (Fuel Injection
After marking the position of the pump Equipment) repair facility.
drive gear, do not rotate the engine
crankshaft. Rotating the crankshaft will
CAUTION
cause the fuel injection pump to become
misaligned. NEVER remove or attempt to remove
0000048en
CAUTION fuel injection pump and governor
Do not loosen or remove the four bolts assembly. These adjustments have
retaining the fuel injection pump drive been made at the factory to meet all
gear to the fuel injection pump hub. Do applicable emissions regulations and
not disassemble the fuel injection pump then sealed.
drive gear from the hub. Correct fuel NEVER attempt to make any
injection timing will be very difficult or adjustments to these sealed
impossible to achieve. adjustment screws. If adjustments are
0000031en required, they can be made only by a
CAUTION ensure the injection pump continues
Do not rotate the crankshaft with the
injection pump removed.
tamper-proof seals.
0000083en
Tampering with or removing these
CAUTION Warranty.
Each pressure adjusting shim removed 0000146en
or added changes the pressure
threshold by approximately 275 psi
(1.9 MPa, 19 kgf/cm2). Adding adjusting
shims increases the threshold pressure.
Removing adjusting shims reduces the
pressure threshold.
0000081en

FUEL SYSTEM
Stop Solenoid
The MP fuel injection pumps are equipped with a
stop solenoid that controls the fuel flow inside the
fuel injection pump.
With the starter switch in the OFF position, no
current flows to the stop solenoid and the solenoid
plunger is extended holding the fuel injection pump
fuel rack in the closed position and not allowing
fuel to flow through the injection pump and to the
engine.
0000038
When the starter switch is turned to the start
Figure 7-1 position, the pull coil (36.5 Amp draw / white wire)
inside the solenoid is activated and pulls the
The following describes the features of the MP fuel
solenoid plunger into the solenoid. This releases
injection pump, manufactured by Yanmar.
the fuel injection pump fuel rack, allowing fuel to
The fuel injection pump is a very important flow through the injection pump and allowing the
component of the engine. It is capable of making engine to start and run.
very precise fuel delivery adjustments according to
When the starter switch is returned to the ON or
the varied loads applied to the engine.
RUN position, the pull coil no longer receives
All of the fuel injection pump components are very current and the hold coil (0.5 Amp draw / red wire)
precisely machined. It is extremely important to inside the solenoid is activated. The hold coil
follow good service practices and maintain holds the solenoid plunger in the RUN position,
cleanliness when servicing the fuel injection pump. allowing fuel to continue flowing and he engine to
continue running.
The Yanmar MP Mono-Plunger Fuel Injection
Pump is a distributor type pump which consists of a To stop the engine, the key switch is turned to the
single fuel supply plunger, a distributor shaft, a OFF position. Current no longer flows to the stop
hydraulic head and a pump housing. The hydraulic solenoid hold coil, and the solenoid plunger
head has a delivery valve for each cylinder. The extends and moves the injection pump fuel rack to
fuel injection pump housing contains a governor the closed position, shutting off the fuel flow and
and an internal camshaft. stopping the engine.
The fuel is pressurized by the up and down motion Failure of the stop solenoid could result in the
of the camshaft-driven single plunger. It is then engine not starting, the engine stopping suddenly,
distributed to the proper fuel injector by the rotating the engine not continuing to run with the key switch
distributor shaft. returned to the ON or RUN position, or the engine
failing to stop when the key switch is turned to the
There are two versions and sizes of the MP Fuel OFF position. Use a multimeter or continuity light to
Injection Pump. The smaller of the two pumps, the check for 12V at the stop solenoid connector in the
MP2 pump, is used on the 3TNV82A - 4TNV88 correct sequence.
model engines. The larger pump, the MP4 pump,
which has a larger single plunger and a more
aggressive cam profile, is used on the
4TNV94L - 4TNV106T model engines.

FUEL SYSTEM
Cold Start Device Trochoid Fuel Pump
The Yanmar TNV model engines are equipped with Note: The trochoid fuel pump located on the
a cold start device (CSD). side of the MP fuel injection pump is not
a fuel supply pump. The function of this
The cold start device is located in the upper section pump is to raise the pressure of the fuel
of the fuel injection pump and is connected to the supplied by the electric fuel supply pump
engines cooling system. to the internal fuel pressure required by
The cold start device improves engine starting at the MP fuel injection pump.
lower temperatures. At engine cooling system The use of an electric fuel supply pump is required
temperatures below 41F (5C), the cold start on all TNV model engines with the MP fuel injection
device advances the fuel injection timing and pump.
slightly increases the fuel injection volume.
For approximately the first 5 minutes of operation,
the idle speed of the engine will be slightly
elevated.
CAUTION
equipment.
0000159en
When the cold start device is activated, you may

notice a slight increase in the exhaust smoke of
the engine during engine warm-up.

FUEL SYSTEM
FUEL SYSTEM SPECIFICATIONS

Special Torque Chart
Lubricating Oil Application
Component Tightening Torque
(Thread Portion and Seat Surface)
29 ftlb
Fuel Injector Retainer Bolt (39.2 Nm; Not Applied
4 kgfm)
3TNV82A
58 - 65 ftlb
to Not Applied
(78 - 88 Nm; 8 - 9 kgfm)
Fuel Pump Drive 4TNV88
Gear Nut 83 - 91 ftlb
4TNV94 to
(113 - 123 Nm; Not Applied
4TNV106T
11.5 - 12.5 kgfm)
22 - 25 ftlb
High-Pressure Fuel Injection Line Nuts (29 - 34 Nm; Not Applied
3.0 - 3.5 kgfm)
69 - 87 inlb
Fuel Return Line Bolts (7.8 - 9.8 Nm; Not Applied
0.8 - 1.0 kgfm)
17 - 21 ftlb
Fuel Injection Pump Mounting Nuts (23 - 28 Nm; Not Applied
2.3 - 2.9 kgfm)
30 - 33 ftlb
Fuel Injector Nozzle Case Nut (39.2 - 44.1 Nm; Not Applied
4 - 4.5 kgfm)
22 - 26 ftlb
3TNV82A to
4TNV88
Fuel Injection Pump Plunger 3.1 - 3.6 kgfm)
Plug 30 - 33 ftlb
4TNV94 to
4TNV106T
4.1 - 4.6 kgfm)
Test and Adjustment Specifications

Engine Injector ID
Model Fuel Injector Pressure Fuel Injection Timing
Class mark*
3133 - 3278 psi
3TNV82A - 4TNV88 CL V (21.6 - 22.6 MPa;
220 - 230 kgf/cm2 See Checking and Adjusting Fuel
3TNV82A - 4TNV88 VM 2843 - 2988 psi Injection Timing on page 7-26
W (19.6 - 20.6 MPa;
4TNV106, 4TNV106T ALL 200 - 210 kgf/cm2
Note: Fuel injector pressures given are for used parts. New injectors (5 hours operation or less) will read
approximately 725 psi (5 MPa; 51 kgf/cm2) higher.
* All DI injectors have 3 letters with the first letter starting with a V or W.

FUEL SYSTEM

No. Tool Name Application Illustration
For tightening nuts and bolts to the specified

1 Torque Wrench Locally Available
torque
0000840
Used in conjunction with a slide hammer to

Fuel Injector Yanmar Part No.
2 remove the fuel injectors (2-valve cylinder
Removal Tool 129470-92305
heads)
MEASURING INSTRUMENTS
For observing injection spray pattern of fuel

1 Fuel Injector Tester Locally Available injection nozzle and measuring injection
OFF
P-
OFF
E-
ON AG
-G
pressure
Mituotoyo 2050SB -
Dial Indicator* Check and adjust fuel injection timing
Locally Available
2
0000831
Mituotoyo 303613 -
Extension Rod*
Locally Available
(M14) TNV82-88 -
Yanmar Part No.
158090-51831
Fuel Injection Pump
3 Mount dial indicator to fuel injection pump
Plunger Adapter* (M16) TNV94-106 -
Yanmar Part No.
158090-51841
0002690
Plunger Adapter Yanmar Part No.

4 Clamps stem of dial indicator in plunger adapter.
Clamp 23000-013000
0002691
* These special service tools may also be available as an MP Fuel Injection Pump Special Tool Set, under a
different part number, in territories serviced by Yanmar America and Yanmar Europe. Contact your authorized
Yanmar dealer or distributor for details.

FUEL SYSTEM
FUEL SYSTEM DIAGRAM

(5) (20)
(21)
(4)
(18)
(17)
(19)
(16)
(3) (22)
(15)
(2)
(17)
(13) (14)
(11)
(1) (12)
(10)
(6)
(9)
(8)
(7)
0000034B
1 Diesel Fuel Tank 12 Engine Crankcase

2 Fuel Filter / Water Separator 13 Tappet
3 Electric Fuel Pump 14 High Pressure Gallery
4 Fuel Filter 15 Overflow Orifice
5 Air Bleed Orifice 16 Accumulator
6 Fuel Supply Line 17 Timer Piston
7 Low Pressure Gallery 18 Mono-Plunger
8 Pressure Control Valve 19 Distributor Shaft
9 Trochoid Pump 20 Fuel Return Line
10 Oil Seal 21 High-Pressure Fuel Injection Lines
11 Fuel Injection Pump Cam 22 Fuel Injector
Figure 7-2

FUEL SYSTEM

FUEL SYSTEM
FUEL SYSTEM COMPONENTS

2-Valve Cylinder Head
(16 )
(1)
(2)
(3)
(15 )
(14 )
(4)
(13)
(18)
(12) (10)
(17)
(9)
(8)
(11) (5)
(7)
(19) (6)
0002128
Figure 7-3

FUEL SYSTEM
1 High-Pressure Fuel Injection Lines 9 Coolant Lines for Cold Start Device
2 Fuel Return Line 10 Fuel Injection Pump Insulator
3 Fuel Injector 11 Fuel Injection Pump
4 Front Plate or Timing Gear Case 12 Rear Fuel Injection Pump Support
5 Gear Case Cover 13 Fuel Filter / Water Separator
6 Fuel Injection Pump Drive Gear Nut 14 Electric Fuel Supply Pump
7 Lock Washer 15 Fuel Filter
8 Fuel Injection Pump Drive Gear Assembly 16 Fuel Filter Housing
(DO NOT remove or loosen the four bolts 17 Stop Solenoid
that fasten the injection pump drive gear to 18 Cold Start Device (CSD)
the injection pump drive gear hub!) 19 Trochoid Fuel Pump

FUEL SYSTEM
(18)
(1)
(2)
(3)
(5)
(4)
(17)
(16)
(6)
(15)
(12)
(20)
(14)
(19)
(11)
(10) (7)
(13)
(21) (9)
(8)
0002017
Figure 7-4

FUEL SYSTEM
1 High-Pressure Fuel Injection Lines 11 Coolant Lines for Cold Start Device
2 Fuel Return Line 12 Fuel Injection Pump Insulator
3 Return Line-to-Cylinder Head Bolt 13 Diesel Fuel Injection Pump
4 Fuel Injector 14 Rear Fuel Injection Pump Support
5 Injection Line Grommet 15 Fuel Filter / Water Separator
6 Front Plate or Timing Gear Case 16 Electric Fuel Supply Pump
7 Gear Case Cover 17 Fuel Filter
8 Fuel Injection Pump Drive Gear Nut 18 Fuel Filter Housing
9 Lock Washer 19 Stop Solenoid
10 Fuel Injection Pump Drive Gear Assembly 20 Cold Start Device (CSD)
(DO NOT remove or loosen the four bolts 21 Trochoid Fuel Pump
that fasten the injection pump drive gear to
the injection pump drive gear hub!)

FUEL SYSTEM
FUEL INJECTION PUMP CAUTION

Removal of Fuel Injection Pump Remove or install the high-pressure fuel
1. Loosen the cooling fan V-belt. possible. Disassembling the
2. Remove the engine coolant fan guard (if high-pressure fuel injection lines from
equipped), engine coolant fan (Figure 7-5, (2)), the retainers or bending any of the fuel
spacer (Figure 7-5, (3)) if equipped, V-pulley lines will make it difficult to reinstall the
(Figure 7-5, (4)) and cooling fan V-belt fuel lines.
(Figure 7-5, (1)). 0000047en
7. Finish loosening all the fuel line nuts and

remove the high-pressure fuel lines as an
assembly being careful not to bend any of the
fuel lines. Be sure to protect the fuel system
from contamination by covering all open
(3) (2) connections.
8. Disconnect the coolant lines from the cold start
device (Figure 7-6, (3)) on the fuel injection
pump. Plug the open ends of the lines to
minimize leakage and prevent contamination.
(1)
9. Disconnect the fuel return lines from the fuel
return fitting (Figure 7-6, (2)). Plug the open
ends of the lines to minimize leakage and
(4) prevent contamination.
0000163A
Figure 7-5
3. Close any fuel valves in the fuel supply line.
4. Place a drain pan under the fuel injection pump
to catch any spillage.
(1)
5. Remove the high-pressure fuel injection lines
as an assembly (Figure 7-6, (1)). (4)
Note: To prevent rounding the fuel line nuts (3)
always use a line or flare nut wrench.
When loosening the fuel line nuts,
always hold the fuel injection pump (2)
delivery valves with a back up wrench
to prevent loosening of the delivery
valves.
6. First loosen the fuel line nuts at the fuel
injectors and then at the fuel injection pump. 0002094
Figure 7-6

FUEL SYSTEM
10. Remove the fuel supply line (Figure 7-6, (4)).
Plug the open end of the line to minimize
leakage and prevent contamination.
11. Remove the throttle cable from the fuel injection
pump. (1)
12. Separate the stop solenoid wiring connector
(Figure 7-7, (2)).
13. Remove the rear fuel injection pump bracket(s)
(Figure 7-7, (1)) from the fuel injection pump.
Note: Configuration of the fuel injection pump
rear brackets may vary depending upon
engine model.
(2) 0000593B
Figure 7-8
15. Remove the fuel injection pump drive gear
cover (Figure 7-9, (1)) from the gear case
cover (Figure 7-9, (2)).
(1) Note: The fuel injection pump drive gear cover
is secured with an adhesive sealant. Use
a gasket scraper to separate the fuel
injection pump cover from the gear case
cover.
(2) (2)
0000153A
Figure 7-7
14. Disconnect the lube oil line (Figure 7-8, (1))
and the clamp (Figure 7-8, (2)) from the pump.
IMPORTANT
Take care to not damage or bend the oil
line. In some applications, it may be
preferable to remove the complete oil line
assembly from the engine before
proceeding.
(1)
Note: On models 3TNV82-4TNV88, the fuel 0002039
injection pump drive gear cover is
retained to the gear case cover by 4 Figure 7-9
bolts. On models 4TNV94-4TNV106, the
cover is larger and retained by 7 bolts. Note: TNV82-88 shown.

FUEL SYSTEM
16. To position the fuel injection pump for easier On TNV94 - 106 model engines, the idler gear
removal and installation, install a dial indicator is visible. Make a reference mark
(see Checking and Adjusting Fuel Injection (Figure 7-11, (1)) across both the fuel injection
Timing on page 7-26) into the injection pump pump drive gear and the idler gear.
plunger opening. Using a wrench on the
crankshaft pulley bolt, rotate the crankshaft until
the dial indicator shows that injection pump
plunger is at the bottom of it's stroke.
17. To aid in reassembly, make reference marks on
the fuel injection pump drive gear, and on either
the gear case cover or idler gear.
CAUTION
After marking the position of the pump
(1)
drive gear, do not rotate the engine
crankshaft. Rotating the crankshaft will
cause the fuel injection pump to become
misaligned.
0000048en Figure 7-11
On TNV82-88 model engines, the idler gear is

not visible. Make a reference mark on the fuel CAUTION
injection pump drive gear (Figure 7-10, (1)) Do not loosen or remove the four bolts
and a matching mark on the bore of the gear retaining the fuel injection pump drive
case opening (Figure 7-10, (2)). gear to the fuel injection pump hub. Do
not disassemble the fuel injection pump
drive gear from the hub. Correct fuel
injection timing will be very difficult or
impossible to achieve.
0000031en
18. Do not loosen or remove the four bolts

(2) (Figure 7-12, (3)) retaining the pump drive gear
to the hub. Only remove the single drive gear
nut (Figure 7-12, (1)) and washer
(Figure 7-12, (2)), leaving the hub attached to
the gear.
(1)
0000575
0000575A
Figure 7-10

FUEL SYSTEM
Note: On TNV82 - 88 models the injection
pump drive gear will remain captured in
the gear case. On TNV94 - 106 models,
the injection pump drive gear can be
removed through the gear case cover
opening.
(3)
21. Once the fuel injection pump drive gear and
hub assembly has popped loose from the
tapered fuel injection pump drive shaft, carefully
(1)
remove the drive gear nut (Figure 7-14, (1))
and lock washer (Figure 7-14, (2)).
(2)
0000162A
Figure 7-12
19. Hold the gear train using a large socket wrench (1)
on the crankshaft pulley nut. Loosen the fuel
injection pump drive gear retaining nut
(Figure 7-12, (1)) and turn it out to the end of
the fuel injection pump shaft. (2)
20. Remove the pump drive gear and hub as an
0000162B
assembly using an appropriate two-bolt gear
puller (Figure 7-13). Figure 7-14
22. Locate the mark stamped into the upper outside
mounting boss of the fuel injection pump.
Highlight this mark and make a corresponding
mark on the gear case or front plate
(Figure 7-15, (1)).
(1)
0000574
Figure 7-13 0000593

0000593A
Figure 7-15

FUEL SYSTEM
Note: Some model engines may require the
(1)
intake manifold and fuel injection pump
insulator (Figure 7-16, (2)) be removed
to access the inner fuel injection pump
(Figure 7-16, (1)) retaining nuts.
(2)
(1)
0002047
Figure 7-17
CAUTION
Do not rotate the crankshaft with the
injection pump removed.
0000263A
0000083en
25. If the fuel injection pump requires servicing, it

Figure 7-16
must be sent to an authorized Yanmar FIE
23. If required, remove the intake manifold and fuel repair facility for repair and calibration, or
pump insulator to access the fuel injection replaced with a new fuel injection pump.
pump mounting nuts.
Note: The MP2 fuel injection pumps
(TNV82 - 88 model engines) are
fastened to the gear case with three (3)
studs and nuts. The MP4 fuel injection
pumps (TNV94 - 106 model engines) are
fastened to the gear case with four (4)
studs and nuts.
24. Remove the fuel injection pump
(Figure 7-16, (1)). For purposes of future
injection timing purposes, record the fuel
injection pump timing index number located on
the boss on the engine side (back) of the of the
fuel injection pump (Figure 7-17, (1)).

FUEL SYSTEM
If additional assistance is needed in locating the
CAUTION engine timing index number see To Locate an
NEVER remove or attempt to remove Authorized Yanmar Industrial Engine Dealer or
the tamper-proof devices from the Distributor: on page 2-4 and follow the instructions
full-load fuel adjusting screw or the to locate an authorized Yanmar industrial engine
high-speed throttle limit screw on the dealer or distributor for assistance.
Note: Treat the timing index number as if it has
a decimal point (68 = 6.8).
been made at the factory to meet all
(1)
then sealed.
NEVER attempt to make any
adjustments to these sealed
adjustment screws. If adjustments are
required, they can be made only by a
ensure the injection pump continues
Figure 7-18
tamper-proof seals.
Tampering with or removing these 1. Align the pump drive gear with the idler gear
devices may void the Yanmar Limited using the reference marks made earlier.
Warranty. TNV82 - 88 model engines (Figure 7-19, (1)).
0000146en
TNV94 - 106 model engines (Figure 7-20, (1)).
Installation of Fuel Injection Pump

IMPORTANT
If installing a new or recalibrated fuel
injection pump, locate and record the timing
index number located on the pump housing
boss on the engine side of the new or (1)
recalibrated fuel injection pump
(Figure 7-18, (1)). This number will be used
to calculate and adjust the final fuel injection
timing.
Note: If either or both of the fuel injection
pumps do not have a timing index
number, note the injection pump ID
(example: XK42) on the injection pump
0000575
0000575B
ID label.
Figure 7-19
To locate the timing index number for the engine
being serviced use the Timing Index Chart under
FIE Specs on the Yanmar Distributor Website
(http://distributor.yanmar.co.jp).

FUEL SYSTEM
Note: Ensure the tapered surface of the fuel
injection pump shaft is clean and dry.
4. Align the key on the fuel injection pump shaft
with the keyway in the fuel injection pump drive
gear hub. Reinstall the fuel injection pump into
the fuel injection pump drive gear and gear
housing. Reinstall the pump retaining nuts
finger tight.
(1) 5. Reinstall the fuel injection pump drive gear lock
washer (Figure 7-22, (2)) and nut
(Figure 7-22, (1)). Do not lubricate the threads
of the nut or shaft. Hold the crankshaft pulley
bolt with a socket wrench and tighten the drive
0002096
gear nut to the specified torque. See Special
Figure 7-20 Torque Chart on page 7-8.
2. If installing the fuel injection pump on an engine

with the front gear case cover removed, the fuel
injection pump drive gear can be aligned with
the idler gear by aligning the stamped marks
(A, B, C) on the fuel injection pump drive gear,
idler gear, and crankshaft drive gear. Ensure all
three timing marks (Figure 7-21, (A, B, C)) are
aligned.
(1)
(2) (1)
B B
C C
A (2)
(7) A
(3) 0000162B
(6) (4) Figure 7-22

(5) 0001709A
1 Fuel Injection Pump Drive Gear If reinstalling the original fuel injection pump:
2 Camshaft Drive Gear
Align the reference marks (Figure 7-23, (1))
3 Auxiliary Drive Gear (Optional)
previously made on both the fuel injection
4 Crankshaft Drive Gear
5 Direction of Rotation pump mounting flange and gear case or front
6 Oil Pump Drive Gear (4TNV94L - 4TNV106) plate.
7 Idler Gear
Figure 7-21
3. Install a new O-ring on the pump mounting
flange. Apply grease to the O-ring to hold it in
place during installation of the injection pump.

FUEL SYSTEM
If installing a new fuel injection pump:
Reinstall the timing grid sticker, provided with
the new fuel injection pump, onto the back of
the gear case / front plate (Figure 7-24). Align
the standard mark (Figure 7-24, (1)) with the
reference mark (Figure 7-24, (2)) made on the
gear case during disassembly.
(1)
0000593
0000593A
Figure 7-23
Tighten the fuel injection pump retaining nuts
to specification. See Special Torque Chart on
page 7-8.
(2)
(1)
0002139
Figure 7-24

FUEL SYSTEM
Calculate the difference between the timing The above calculated difference indicates that
index numbers (Figure 7-25, (1)) of the fuel the replacement fuel injection pump is to be
injection pump that you removed and the installed at +0.5 (advanced) from the Standard
replacement fuel injection pump. See Mark (Figure 7-26, (1)) on the timing sticker.
Calculation Example below.
(1)
(3)
(1)
+0.5
+1.0
(2)
0002047
Figure 7-25
Adjusting the fuel injection timing to
0002124A
compensate for the difference in pump timing
index numbers: Figure 7-26
Calculation Example In this case, rotate the top of the fuel injection
Timing Index Number pump away from the cylinder block until the mark
on the outside upper mounting boss
Original injection pump= 6.8
(Figure 7-27, (1)) of the fuel injection pump
Replacement injection pump= 7.3
aligns with the +0.5 mark on the timing sticker.
Difference= +0.5
If the difference between the timing index

numbers is a positive number, the fuel injection
pump mounting position must be advanced
(Figure 7-26, (2)) (rotated away from the
engine) as compared to the standard mark
(Figure 7-26, (1)) by the calculated positive
amount, adjust the fuel injection pump to the
calculated value.
If the difference between the timing index
numbers is a negative number, the
replacement injection pump must be retarded
(Figure 7-26, (3)) (rotated toward the engine) (1) 0002125A
by the calculated negative amount.

Figure 7-27
Each mark on the timing sticker represents
0.5 timing change.

FUEL SYSTEM
Tighten the fuel injection pump mounting nuts to
page 7-8.
6. Reinstall the rear bracket(s) (Figure 7-28, (1))
to the fuel injection pump. Tighten the rear
support bolts.
(1)
Note: Configuration of the fuel injection pump
rear brackets may vary depending on the
model.
(1) (2) 0000593B
Figure 7-29
9. Apply ThreeBond Liquid Gasket No. 1212,
Yanmar Part No. 977770-01212, or equivalent
sealant to the sealing surface of the pump
(2)
cover. Install the pump cover and tighten the
cover bolts.
10. Reconnect the fuel return lines, fuel supply line
0000153A
and coolant lines to the fuel injection pump.
Figure 7-28
11. Reinstall the fuel injection high-pressure lines.
7. Reconnect the throttle linkage and the stop Tighten the nuts to specification. See Special
solenoid connector (Figure 7-29, (2)). Torque Chart on page 7-8.
8. Reconnect the lube oil line (Figure 7-29, (1)) IMPORTANT
and clamp (Figure 7-29, (2)). When reinstalling a new or repaired fuel
injection pump, it is important to add engine
oil to the fuel injection pump to provide
lubrication for initial start-up. Add 5-7 oz
(150-200 cc) of clean engine oil to the fuel
injection pump at the fill plug located in the
upper outside section of the governor
housing.

FUEL SYSTEM
12. If equipped, verify the fuel injection pump 16. Prime the fuel system. See Priming the Fuel
insulator (Figure 7-30, (2)) is not damaged. System on page 4-12.
Reinstall the insulator and intake manifold if 17. Operate the engine and check for fuel and
previously removed. coolant leaks.
CHECKING AND ADJUSTING

(2)
FUEL INJECTION TIMING
(1) Determining the Fuel Injection Timing
Specification
1. Locate and record the fuel injection pump
timing index number (Figure 7-33, (1)) stamped
into the boss on the engine side of the fuel
injection pump housing (Figure 7-32, (1)). Treat
this number as though there is a decimal point
0000263A between the two digits. i.e. 68 = 6.8
Figure 7-30 (1)

13. Reinstall the coolant pump V-pulley
(Figure 7-31, (4)), spacer (Figure 7-31, (3)) (if
equipped) and engine coolant fan
(Figure 7-31, (2)).
(3) (2) 0000040B
Figure 7-32
(1)
(1)
(4) 0000163A
Figure 7-31
14. Reinstall the cooling fan V-belt
(Figure 7-31, (1)). Adjust it as described in
Check and Adjust Cooling Fan V-Belt on
page 5-21.
0002047
15. Reinstall the cooling fan guard (if equipped).
Figure 7-33

FUEL SYSTEM
2. Using the FIR number for the engine being Checking Fuel Injection Timing
serviced use the Fuel Injection Reference (FIR)
Chart under FIE Specs on the Yanmar Note: Some fuel may drain from the fuel
Distributor Website injection pump during this process. Make
(http://distributor.yanmar.co.jp). provisions to contain any such spillage.
The FIR number is determined by the complete 1. Turn off the fuel valve in the fuel supply hose
engine model number. The engine model and the fuel return hose.
number is located on the engine nameplate 2. Clamp shut the fuel injection pump fuel return
(Figure 7-34). hose leading to fuel filter (Figure 7-35, (1)).
(1)
3TNV82A - DSA (2)
kW
3000
1.33 l
06532
0002132
0002087
Figure 7-34
Figure 7-35
EXAMPLE: The following example is for an engine
model 3TNV82A-DSA. IMPORTANT
Clean the top of the fuel injection pump to
Find the engine model number in the FIR chart. prevent any contamination when the fuel
Locate and record the FIR number (The FIR injection pump plunger plug is removed.
number for this engine is 4).
3. Remove the forward fuel injection pump plunger
Insert the numbers you have recorded into the plug (Figure 7-35, (2)) on the top of the fuel
following equation: injection pump.
(Fuel Injection Pump Timing Index Number X 2) 4. Install a dial indicator adapter and clamp into
+ FIR Number = FIT (Fuel injection Timing in the pump plunger opening.
Degrees)
(6.8 X 2) = 13.6 + 4 = 17.6 Fuel injection

Timing
Record the calculated fuel injection timing
specification.

FUEL SYSTEM
Note: Use the Yanmar part no. 158090-51831
M14 adapter for the MP2 fuel injection (1)
pumps (TNV82 - 88 model engines) or
Yanmar part no. 158090-51841 for the
M16 adapter used on the MP4 fuel
injection pumps (TNV94 - 106 model
engines) and Yanmar part no. 23000-
013000 plunger adapter clamp
(Figure 7-36, (1)).
(1)
0002069
Figure 7-37
Note: The following references to the direction-
of-rotation are facing the coolant pump
end of the engine and are adjusted by
turning the crankshaft pulley.
6. Using a wrench on the crankshaft pulley bolt,
rotate the crankshaft in a clockwise direction
0002068A
while looking through the flywheel inspection
Figure 7-36 port (Figure 7-38, (1)). Rotate the crankshaft
until the injection timing marks on the flywheel
5. Install a dial indicator (Figure 7-37, (1)), are visible.
Mitutoyo No. 2050SB or equivalent, with a
30 mm extension, Yanmar part no.
158090-51870 or Mitutoyo No. 303613, into the
adapter. Secure with the Yanmar part no.
23000-013000 plunger adapter clamp
(Figure 7-36, (1)) at approximately the mid-
point of its travel.
00020
(1)
Figure 7-38
7. Typical flywheel markings are as shown in
(Figure 7-39, (1)).
Note: A typical flywheel will have multiple
timing grids depending on the number of
cylinders. Any grid can be used to check
the fuel injection timing.

FUEL SYSTEM
The flywheel shown in Figure 7-39 is for a EXAMPLE: If the distance between the two
Yanmar Standard Specification DI engine. longer marks is approximately 2.0 cm and the
Flywheels used on some OEM Specific DI distance from the TDC mark is approximately
engines may be marked differently. You should 4.0 cm, the answer is approximately 2. This
contact that specific OEM for information on the indicates there is 10 (2 x 5) between the TDC
identification of the timing marks. mark and the first longer mark on the timing
grid. That means the first longer mark on the
timing grid indicates 10 BTDC, the second
(3) longer mark indicates 15 BTDC and the third
timing mark indicates 20 BTDC. If the answer
(2)
(4) is 3, that indicates there is 15 (3 x 15)
between the TDC mark and the first longer
(1) mark and that the first longer mark indicates
14
15 BTDC with the second and third longer

(5)
marks indicating 20 BTDC and 25 BTDC
respectively.
0002071 8. Highlight the timing reference mark
(Figure 7-40, (2)) on the flywheel housing or
1 10 BTDC (Before Top Dead Center) engine back plate (Figure 7-41, (2)). Highlight
2 15 BTDC the TDC (Top Dead Center) mark
3 20 BTDC
(Figure 7-40, (1)) on the flywheel.
4 Direction of Rotation
5 TDC (Top Dead Center) 9. Highlight the target timing mark
(Figure 7-41, (1)) on the flywheel as calculated
Figure 7-39
in Determining the Fuel Injection Timing
Note: The TDC (Top Dead Center) mark can Specification on page 7-26.
be identified by the cylinder numbers
stamped near the TDC mark on the
flywheel.
(1)
If you are uncertain as to the timing degree (2)
designation of the timing marks on the flywheel
timing grid, you can determine the timing degree
1 4
designation by measuring the timing grid.

First measure the distance between two of the
longer marks on the timing grid. (They are 5
apart.) Then measure the distance from the
TDC mark to the first longer mark on the
timing grid. Divide that measurement by the 0002065
distance between the two longer marks. The
resulting answer will tell you how many Figure 7-40
degrees there are between the TDC mark and
the first longer mark.

FUEL SYSTEM
13. If the injection timing is correct, remove the dial
indicator and adapter. Replace the pump
plunger plug and its copper gasket and tighten
(1)
to specifications. Replace the flywheel
(2)
inspection port cover. Open the fuel supply
valve and remove the clamp from the fuel
supply hose and the fuel return hose.
14. Prime the fuel system. Operate the engine and
check for leaks.
Adjusting Fuel Injection Timing

If the timing marks did not align when performing
0002066
the Checking Fuel Injection Timing on page 7-27,
the following steps must be performed to properly
time the engine.
(2) 1. Leave the dial indicator installed in the fuel

injection pump. Do not disturb the reading on
(1)
the dial indicator.
2. Rotate the flywheel until the target timing mark
(Figure 7-42, (1)) and the timing reference
mark (Figure 7-42, (2)) on the flywheel housing
or back plate are aligned.
IMPORTANT
Do not rotate the crankshaft during the
0002142 remainder of this procedure.
Figure 7-41
10. Rotate the crankshaft counter-clockwise until
the dial indicator shows that the injection pump (1)
plunger is at the bottom of its stroke. Rock the (2)
crankshaft back and forth slightly to confirm a
point where the dial indicator shows no
movement. Zero the dial indicator.
11. Slowly rotate the crankshaft clockwise until the
dial indicator shows a pump plunger lift of
2.5 mm (0.098 in.).
12. Check the position of the flywheel target timing
mark (previously determined) (Figure 7-41, (1)) 0002066
in relation to the timing reference mark
(Figure 7-41, (2)) on the flywheel housing or Figure 7-42
engine back plate. If the two marks are aligned,
the fuel injection timing is correct. If the marks
do not align, the fuel injection timing must be
adjusted. See Adjusting Fuel Injection Timing
on page 7-30.

FUEL SYSTEM
3. Note the reading on the dial indicator 9. Tighten the fuel injection pump mounting nuts
(Figure 7-43, (1)). If the reading is less than and rear bracket(s).
2.5 mm (0.098 in.), the fuel injection timing is 10. Remove the dial indicator and adapter. Replace
retarded. If the dial indicator reading is greater the plug in the pump plunger opening and
than 2.5 mm (0.098 in.), the fuel injection timing tighten it to specification. If removed, install the
is advanced. intake manifold and pump insulator. Tighten the
high-pressure injection line nuts to
(1)
specification. Open the fuel supply valve,
remove the clamp from the fuel return line and
prime the fuel system. Operate the engine and
check it for leaks.
FUEL INJECTORS
Removal of Fuel Injectors
1. Close any fuel valves in the fuel supply line.
0002069 2. Remove the high-pressure fuel injection lines
as an assembly (Figure 7-44, (1)).
Figure 7-43
(1)
Note: Some model engines require the intake
manifold and fuel injection pump
insulator be removed to access the inner
fuel injection pump retaining nuts.
4. Loosen the nuts fastening the fuel injection
pump to the gear case or front plate. Loosen
the rear bracket(s) on the fuel injection pump.
Note: Loosening the high-pressure injection
line nuts on the fuel injection pump may
make rotating the pump easier.
5. Rotate the fuel injection pump until the dial
indicator reads 2.5 mm (0.098 in.).
6. To advance the injection timing, rotate the top
of the fuel injection pump away from the engine.
7. To retard the injection timing, rotate the top of
the fuel injection pump toward the engine.
8. When the dial indicator reads 2.5 mm
(0.098 in.) of pump plunger lift and the target 0000154A
timing mark on the flywheel aligns with the
reference mark on the flywheel housing or Figure 7-44
engine back plate, the injection timing is
correct.

FUEL SYSTEM
Note: To prevent rounding the fuel line nuts
always use a line or flare nut wrench.
When loosening the fuel line nuts,
always hold the fuel injection pump
delivery valves with a back up wrench (3)
to prevent loosening. (1)
(4)
Loosen the fuel line nuts at the fuel injectors
and then at the fuel injection pump.
CAUTION
possible. Disassembling the
high-pressure fuel injection lines from
the retainers or bending any of the fuel
fuel lines.
(2) 0002092A
0000047en
Figure 7-45
Finish loosening all the fuel line nuts and
remove the high-pressure fuel lines as an 6. Remove the fuel injector.
assembly being careful not to bend any of the Note: The fuel injectors can usually be
fuel lines. Be sure to protect the fuel system removed by manually pulling them out of
from contamination by covering all open the fuel injector wells. If the fuel injectors
connections. cannot be manually removed, use the
3. Remove the return fuel hoses (Figure 7-45, (1)) fuel injector removal tool, Yanmar Part
from one side of each fuel injector. No. 129470-92305, and a slide-hammer
4. Remove the bolts and washers that secure the puller (Figure 7-46).
fuel injector retainers (Figure 7-45, (2)) to the Attach a slide-hammer puller to the fuel injector
cylinder head. removal tool using a 3/8-16 puller rod.
5. Remove the fuel injector retainer.

FUEL SYSTEM
(2)
(1)
(3)
(4)
(5)
(6)
0000815
Figure 7-46
Tap the fuel injector out of the cylinder head
using the slide hammer. Figure 7-47
7. Remove the injector nozzle protector
(Figure 7-45, (3)) and seat (Figure 7-45, (4)) Note: The fuel injectors can be removed by
from the cylinder head. manually pulling them out of the fuel
injector wells.
8. Repeat the steps to remove the remaining fuel
injectors. 6. Remove the injector nozzle protector
(Figure 7-47, (5)) and seat (Figure 7-47, (6))
4-Valve Cylinder Head from the cylinder head. Discard both items.
1. Close any fuel valves in the fuel supply line. 7. Repeat steps to remove the remaining fuel
2. Remove the valve cover. See Removal of Valve injectors.
Cover on page 6-34.
Testing of Fuel Injectors
3. Remove the injector return line
(Figure 7-47, (1)). Be careful not to bend the
line.
CAUTION
4. Remove the fuel injector mounting clamp bolts
fuel injectors. Damage to the nozzle and
(Figure 7-47, (2)). Lift the injector mounting
other components is likely to result.
clamps (Figure 7-47, (3)) away from injector.
0000172en
5. Remove the fuel injector (Figure 7-47, (4)) from
the cylinder head. 1. Thoroughly clean the fuel injector nozzle using
clean diesel fuel and a brass wire brush.

FUEL SYSTEM
2. Visually inspect the fuel injectors and nozzle
protectors for deposits or damage. Clean, repair
or replace as necessary.
Note: Test the fuel injector using an injection OFF
P-
nozzle tester. Operate the tester ON

-G
O
AG
FF
E-
following the information provided by the

tester manufacturer. Use clean, filtered
fuel or FIE calibration fluid for the test.
3. Using the correct adapter, connect a fuel
injector to a nozzle tester. Aim the fuel injector Figure 7-48
into a suitable container to catch the fuel spray.
4. Pump the operating lever of the tester slowly,
observing the pressure reading at the point
A WARNING where the fuel injector begins spraying fuel
Never inject fuel toward you. Since the (Figure 7-48).
fuel is injected at high pressure from
See Figure 7-51 for injector ID location.
the nozzle, it may penetrate the skin,
resulting in injury. See Test and Adjustment Specifications on
Never inject fuel toward a fire source. page 7-8 for correct pressure readings.
Atomized fuel is highly flammable and Note: The opening pressure of a new fuel
may cause a fire or burn skin. injector will be approximately 725 psi
0000028en (5 MPa; 51 kgf/cm2) higher than one that
has been operated for five hours or
A CAUTION longer.
5. Pump the operating lever slowly to hold the
pressure steady at a point just below the
opening pressure and hold it for 5 seconds.
Observe the injector to see that it is sealing
properly and is not dripping. If fuel leaks from
the return line fitting, check that the nozzle case
FLYING OBJECT HAZARD! nut is tight. Service or replace the injector if fuel
continues to leak from either the return line
ALWAYS wear eye protection when fitting or nozzle.
compressed air or high-pressure
water. Dust, flying debris, compressed
injure your eyes.
or moderate injury.
0000003en

FUEL SYSTEM
6. Pump the operating lever more rapidly to (1)
repeatedly pop the injector and observe the
spray pattern. The pattern should be a very fine
(2)
uniform spray (Figure 7-49). If a dripping or an
uneven pattern is seen (Figure 7-50), service
or replace the injector. (3)
(4)
(5)
(6)
(7)
0001336A
Figure 7-49 (8)
(9)
(10)
1 Fuel Return Passage

2 Injector ID Location
0001337A 3 Injector Body
4 Pressure Adjusting Shims
Figure 7-50 5 Spring
If the fuel injector fails any of these tests, it should 6 Spring Seat
be serviced or replaced as necessary. If the 7 Valve Stop Spacer
8 Nozzle Valve
pressure is outside specified limits, adjust the
9 Nozzle Body
pressure. See Adjusting Fuel Injector Pressure 10 Nozzle Case Nut
on page 7-36.
Figure 7-51
Disassembly and Inspection of Fuel
2. Place the fuel injector in a soft-jawed vise with
Injectors the nozzle pointing up.
3. Remove the nozzle case nut.
CAUTION
4. Carefully remove the injector from the vise.
fuel injectors. Damage to the nozzle and 5. Turn the injector over and remove the nozzle
other components is likely to result. body, nozzle valve, valve stop spacer, nozzle
spring seat, nozzle spring, and shims.
0000172en
1. Clean carbon from used injectors using clean

diesel fuel. Hardened deposits or varnish can
be cleaned using a brass wire brush.

FUEL SYSTEM
6. Inspect the sealing surfaces (Figure 7-52, (2)) Adjusting Fuel Injector Pressure
between the valve stop spacer and nozzle body
for nicks or scratches. Check the contact area The fuel injectors open when pressure reaches a
between the valve stop spacer and the nozzle predetermined pressure threshold. They close
valve (Figure 7-52, (1)) for scoring, or pitting. when the pressure is reduced below that threshold.
Use a magnifier glass to inspect the area. The pressure threshold can be adjusted by adding
or removing shims (Figure 7-54, (3)).
(1)
(1)
(2)
(2)
(3)
(4)
(5)
0001333A
0002093
Figure 7-52 (6)
(7)
7. Perform a nozzle valve slide test:
(a) Wash nozzle body and valve in clean diesel (8)
fuel.
(b) While holding the nozzle body vertical, pull (9)
the nozzle valve about 2/3 of the way out
(Figure 7-53).
(c) Release the valve. It should fall smoothly to (10)
its seat by its own weight.
0002093
1 Fuel Return Passage

2 Injector ID Location
3 Injector Body
4 Pressure Adjusting Shims
5 Spring
6 Spring Seat
7 Valve Stop Spacer
8 Nozzle Valve
9 Nozzle Body
10 Nozzle Case Nut
0001332A
Figure 7-54
Figure 7-53 The injection pressure will change by
8. Replace the fuel injector assembly if it fails any approximately 275 psi (1.9 MPa; 19 kgf/cm2) for
inspection. every 0.1 mm (0.004 in.) in shim thickness.

FUEL SYSTEM
See the parts catalog for available shims. Installation of the Fuel Injectors
CAUTION 2-Valve Cylinder Head

Each pressure adjusting shim removed 1. Reinsert a new nozzle seat (Figure 7-55, (4))
or added changes the pressure and nozzle protector (Figure 7-55, (3)) in the
threshold by approximately 275 psi cylinder head for each injector.
(1.9 MPa, 19 kgf/cm2). Adding adjusting 2. Reinstall a O-ring on to each injector body.
shims increases the threshold pressure. 3. Reinsert each fuel injector into the cylinder
Removing adjusting shims reduces the head.
pressure threshold.
4. Reinstall the fuel injector retainers
0000081en
(Figure 7-55, (2)) and torque the retaining bolts
1. Disassemble the fuel injector assembly. See to specification.
Disassembly and Inspection of Fuel Injectors 5. Reinstall the fuel return hoses
on page 7-35. (Figure 7-55, (1)), one on each side of each
2. Remove or add adjusting shims as needed. injector.
3. Reassemble the fuel injector assembly. See 6. Reinstall the fuel high-pressure fuel line
Reassembly of Fuel Injectors on page 7-37. assembly and tighten the nuts using a line or
flare nut wrench.
4. Retest the fuel injector. See Testing of Fuel
Injectors on page 7-33. If the injector cannot be
adjusted to the appropriate pressure, discard
the fuel injector.
Reassembly of Fuel Injectors (3)

(1)
(4)
1. Secure the injector in a soft-jawed vise with the
nozzle end up.
2. Reinstall the shims, nozzle spring, nozzle
spring seat, valve stop spacer, nozzle valve,
and nozzle body.
3. Reinstall the nozzle case nut. Tighten it to
page 7-8.
(2) 0002092A
Figure 7-55
8. Operate the engine and check for fuel and
coolant leaks.

FUEL SYSTEM
4-Valve Cylinder Head 8. Operate the engine and check for fuel and
1. Reinsert a new nozzle seat (Figure 7-56, (6)) coolant leaks.
and nozzle protector (Figure 7-56, (5)) in the
cylinder head for each injector.
2. Reinstall a O-ring on to each injector body.
3. Reinsert each fuel injector (Figure 7-56, (4))
into the cylinder head.
4. Reinstall the fuel injector retainers
(Figure 7-56, (3)) and torque the retaining bolts
(Figure 7-56, (2)) to specification.
5. Reinstall the fuel injector return line assembly
using new gaskets on each side of the injector
line screws.
6. Reinstall the fuel high-pressure fuel lines to
each injector and tighten the nuts using a line
or flare nut wrench.
(2)
(1)
(3)
(4)
(5)
(6)
0002088
Figure 7-56

Section 8
COOLING SYSTEM
Page
Introduction...................................................................................... 8-6
Cooling System Diagram................................................................. 8-6
Engine Coolant Pump Components ................................................ 8-7
Engine Coolant System Check........................................................ 8-8
Engine Coolant Pump ..................................................................... 8-8
Removal of Engine Coolant Pump ............................................ 8-8
Disassembly of Engine Coolant Pump .................................... 8-10
Cleaning and Inspection .......................................................... 8-10
Reassembly of Engine Coolant Pump..................................... 8-11
Installation of Engine Coolant Pump ....................................... 8-11

COOLING SYSTEM

COOLING SYSTEM
BEFORE YOU BEGIN

A WARNING
SERVICING
A DANGER
service it.
SCALD HAZARD! NEVER leave the key in the key switch

NEVER remove the radiator cap if the Someone may accidentally start the
engine is hot. Steam and hot engine engine and not realize you are
coolant will spurt out and seriously servicing it. This could result in a
burn you. Allow the engine to cool serious injury.
the radiator cap. If you must service the engine while it
Tighten the radiator cap securely after back long hair, and keep your hands,
you check the radiator. Steam can other body parts and clothing away
spurt out during engine operation if from moving / rotating parts.
the cap is loose.
ALWAYS check the level of the engine or serious injury.
coolant by observing the reserve tank. 0000010en

serious injury.
0000002en
A WARNING
A WARNING
FUME / BURN HAZARD!

BURN HAZARD! hazardous substances like parts
Wait until the engine cools before you cleaners, primers, sealants and
drain the engine coolant. Hot engine sealant removers.
Failure to comply could result in death or serious injury.
or serious injury. 0000014en
0000016en

COOLING SYSTEM
A WARNING A CAUTION
BURN HAZARD!
PINCH HAZARD!
is still hot, stay clear of the hot engine Carefully rotate the alternator toward the
oil to avoid being burned. cylinder block while loosening the
V-belt. Failure to comply may result in
ALWAYS wear eye protection. minor or moderate injury.
Failure to comply could result in death 0000014en
or serious injury.
0000011en
CAUTION
Only use the engine coolant specified.
A CAUTION Other engine coolants may affect
buildup of rust and scale and / or
shorten engine life.
FLYING OBJECT HAZARD! the surrounding area before you
ALWAYS wear eye protection when remove the cap.
servicing the engine and when using NEVER mix different types of engine
compressed air or high-pressure coolants. This may adversely affect the
water. Dust, flying debris, compressed properties of the engine coolant.
air, pressurized water or steam may 0000006en
injure your eyes.
Failure to comply may result in minor CAUTION
or moderate injury.
If the engine coolant pump must be
0000003en
replaced, replace the engine coolant
pump as an assembly only. Do not
attempt to repair the engine coolant
pump or replace individual components.
0000041en

COOLING SYSTEM
CAUTION
Use a new special O-ring between the
engine coolant pump and the joint. Be
sure to use the special O-ring for each
engine model. Although the O-ring
dimensions are the same as a
commercially available O-ring, the
material is different.
0000042en

COOLING SYSTEM
INTRODUCTION
This section of the Service Manual describes the procedures necessary to service the 4TNV84 engine
coolant pump. This engine coolant pump is representative of the coolant pumps used on other TNV model
engines. For specific part detail, see the parts catalog for the engine you are working on.
COOLING SYSTEM DIAGRAM

(1)
(2)
(3)
(4)
(7)
FULL
LOW
(6)
(5)
0000573A
1 Cylinder Head 5 Coolant Recovery Tank

2 Thermostat 6 Engine Oil Cooler*
3 Engine Coolant Pump 7 Cylinder Block
4 Radiator
* Not standard on all models.
Figure 8-1

COOLING SYSTEM
ENGINE COOLANT PUMP COMPONENTS
(1)
(2)
(3)
(5)
(4)
(8)
(7)
(6)
(9)
(12)
(10)
(11)
(13)
0000031A
1 Thermostat Cover 8 Gasket

2 Thermostat Cover Gasket 9 Engine Coolant Pump Gasket
3 Thermostat 10 V-Belt
4 Thermostat O-Ring 11 Engine Coolant Pump V-Pulley
5 Special O-Ring 12 Spacer
6 Engine Coolant Pump 13 Engine Coolant Fan
7 Temperature Switch
Figure 8-2

COOLING SYSTEM
ENGINE COOLANT SYSTEM 1. Before removing the engine coolant pump or

thermostat, it will be necessary to drain the
CHECK engine coolant. Drain the coolant into a clean
Check the engine coolant system for leakage. container if the coolant is to be reused.
Otherwise, properly dispose of the coolant.
1. With the radiator properly filled, install a cooling
2. Remove the radiator cap (Figure 8-4, (1)).
system tester (Figure 8-3, (1)).
3. Remove the drain plug or open the drain cock
(Figure 8-4, (1)) at the lower portion of the
radiator and drain the coolant.
(1)
(1)
0000577A
Figure 8-3
FULL
LOW
2. Apply 10.8 - 14.8 psi (75 - 105 kPa; 0.75 - 1.05

kgf/cm) to the cooling system. If the pressure
reading drops, the engine coolant system is
leaking. Identify the source of the leak and
repair it.
(2) 0000074A
ENGINE COOLANT PUMP Figure 8-4

Removal of Engine Coolant Pump 4. Drain the coolant from the engine block.
Verify the condition of the engine coolant pump On models equipped with an oil cooler, remove
before disassembling it from the engine. Check the the coolant hose (Figure 8-5, (1)) at the oil
engine coolant pump shaft bearing for abnormal cooler.
noise, sticking, excessive play and water leakage.
Replace the coolant pump if any of these conditions
are present.
CAUTION
If the engine coolant pump must be
replaced, replace the engine coolant
pump as an assembly only. Do not
attempt to repair the engine coolant
pump or replace individual components.
0000041en
IMPORTANT
Make sure the engine and engine coolant (1) 0001579B
are not hot. Figure 8-5

COOLING SYSTEM
On models not equipped with an oil cooler,
remove the coolant drain plug (Figure 8-6, (1))
from the engine block.
(2) (1)
(4)
(1)
(3)
0000163B
0000027B
Figure 8-7
Figure 8-6
7. Disconnect the coolant hoses and the
5. Loosen the alternator mounting bolts. Loosen temperature switch lead wire from the engine
and remove the V-belt and rotate the alternator coolant pump.
away from the engine and out of the way.
8. Remove the engine coolant pump
A CAUTION (Figure 8-7, (4)). Discard the gasket.
PINCH HAZARD!
Carefully rotate the alternator toward the
cylinder block while loosening the
0000014en
6. Remove the engine coolant fan guard (if

equipped), engine coolant fan (Figure 8-7, (1)),
spacer (Figure 8-7, (2)) and engine coolant
pump V-pulley (Figure 8-7, (3)).

COOLING SYSTEM
Disassembly of Engine Coolant
Pump (3) (1)
1. Remove the thermostat cover (Figure 8-8, (1)).
Discard the gasket.
(2)
(1)
(4) (2)
(3) 0000577A
Figure 8-9
2. Place the temperature switch and an accurate
thermometer (Figure 8-9, (3)) in engine
coolant.
3. Slowly increase temperature of the fluid using
an external heat source.
4. The temperature switch is operating properly if
the continuity light or ohmmeter indicates
continuity when the fluid temperature reaches
225F - 235F (107C - 113C).
0000267A
Thermostat
Figure 8-8 1. Check for proper operation of the thermostat.
2. Remove the thermostat (Figure 8-8, (2)). Place the thermostat (Figure 8-10, (1)) and an
Discard the O-ring. Remove the temperature accurate thermometer (Figure 8-10, (2)) in
switch (Figure 8-8, (3)) and gasket warm water.
(Figure 8-8, (4)). Discard the gasket.
Cleaning and Inspection (2)
Temperature Switch
1. Check for proper operation of the temperature
switch. Connect a continuity light or ohmmeter
(1)
to the temperature switch. Connect one lead to
the terminal of the switch (Figure 8-9, (1)) and
the other lead to the metal portion of the switch
(Figure 8-9, (2)).
0000577A
Figure 8-10
2. Slowly increase the temperature of the water
using an external heat source.

COOLING SYSTEM
3. The thermostat is operating properly if it starts
to open at the temperature value stamped on
the flange of the thermostat, and fully opens as
(2)
the temperature of the water is increased.
Radiator Cap (5) (1)

1. Check for proper operation of the radiator cap.
Install the radiator cap (Figure 8-11, (1)) on a
cooling system tester.
(4)
(3)
(1)
0000577A
Figure 8-11
0001623A
2. Apply 10.8 - 14.8 psi (75 - 105 kPa; 0.75 - 1.05
Figure 8-12
kgf/cm) to the radiator cap. The radiator cap
relief valve must open within the specified 2. Reinstall the thermostat cover
range. (Figure 8-12, (2)) and a new gasket. Tighten
the thermostat cover bolts.
Reassembly of Engine Coolant Pump
3. Reinstall the temperature switch
1. Reinstall the thermostat (Figure 8-12, (1)) and (Figure 8-12, (3)) and a new gasket
a new O-ring. (Figure 8-12, (4)).
Installation of Engine Coolant Pump

1. Position the engine coolant pump on the engine
and install a new gasket. Install a new special
O-ring (Figure 8-12, (5)) on assembly between
the engine coolant pump and the joint.
CAUTION
Use a new special O-ring between the
engine coolant pump and the joint. Be
sure to use the special O-ring for each
engine model. Although the O-ring
dimensions are the same as a
commercially available O-ring, the
material is different.
0000042en

COOLING SYSTEM
2. Reinstall the engine coolant pump bolts. 6. Reinstall the V-belt. Tighten the V-belt to the
Tighten the bolts. proper tension. See Check and Adjust Cooling
3. Inspect and reinstall the coolant hoses and the Fan V-Belt on page 5-21.
temperature switch lead wire. 7. Reinstall and tighten the drain plug or close the
4. Reinstall the engine coolant pump V-pulley drain cock in the radiator. Reinstall and tighten
(Figure 8-13, (1)), spacer (Figure 8-13, (2)) the engine block drain plug or reconnect the
engine coolant fan (Figure 8-13, (3)) and coolant hose at the oil cooler.
engine coolant fan guard (if equipped). 8. Fill the radiator and engine with engine coolant.
See Drain, Flush and Refill Cooling System
With New Coolant on page 5-35.
CAUTION
Only use the engine coolant specified.
(2) (3) Other engine coolants may affect
buildup of rust and scale and / or
shorten engine life.
remove the cap.
(1)
0000163C
Figure 8-13 coolants. This may adversely affect the
properties of the engine coolant.
5. Inspect the condition of the V-belt. There must 0000006en
be clearance (Figure 8-14, (1)) between the
V-belt and the bottom of the pulley groove. If
there is no clearance (Figure 8-14, (2))
between the V-belt and the bottom of the pulley
groove, replace the V-belt.
(2)
(1)
0000584
Figure 8-14

Section 9
LUBRICATION
SYSTEM
Page
Introduction...................................................................................... 9-5
Oil Pump Service Information.......................................................... 9-5
Lubrication System Diagram ........................................................... 9-8
Checking Engine Oil Pressure ........................................................ 9-9
Trochoid Oil Pump........................................................................... 9-9
3TNV82A to 4TNV88 Oil Pump Components............................ 9-9
Disassembly of Oil Pump ........................................................ 9-10
Reassembly of Oil Pump ......................................................... 9-12
Trochoid Oil Pump......................................................................... 9-13
4TNV94L/98/106 Oil Pump Components ................................ 9-13
Disassembly of Oil Pump ........................................................ 9-14
Reassembly of Oil Pump ......................................................... 9-15

LUBRICATION SYSTEM

LUBRICATION SYSTEM
BEFORE YOU BEGIN

A WARNING
SERVICING
A WARNING
BURN HAZARD!
ENTANGLEMENT HAZARD! as the muffler, exhaust pipe,
Stop the engine before you begin to turbocharger (if equipped) and engine
service it. block during operation and shortly
seriously burn you.
servicing it. This could result in a Failure to comply could result in death
serious injury. or serious injury.
0000015en
back long hair, and keep your hands, A WARNING
or serious injury.
0000010en
FUME / BURN HAZARD!

sealant removers.
or serious injury.
0000014en

LUBRICATION SYSTEM
A CAUTION CAUTION
Only use the engine oil specified.
coverage, cause internal engine
engine life.
ALWAYS wear eye protection when clean the oil cap / dipstick and the
servicing the engine and when using surrounding area before you remove
compressed air or high-pressure the cap.
injure your eyes.
or moderate injury.
0000003en
0000005en
A CAUTION
If any oil pump component clearance CAUTION
If the oil pump must be replaced, replace
it as an assembly only. Do not replace
0000015en
individual components.
0000030en

LUBRICATION SYSTEM
INTRODUCTION
This section of the Service Manual describes the procedures necessary to service the 3TNV82A to
4TNV88, and 4TNV94L/98/106 Trochoid oil pumps.
See Replace Engine Oil and Engine Oil Filter on page 5-27 for engine oil and engine oil filter replacement
procedures.
OIL PUMP SERVICE INFORMATION

Engine Oil Pressure - All Models
Model at Rated Engine rpm at Low Idle Speed
3TNV82A, 3TNV84, 3TNV84T, 42 - 57 psi
3TNV88, 4TNV84, 4TNV84T, (0.29 - 0.39 MPa;
4TNV88, 4TNV94L, 4TNV98 2.96 - 3.98 kgf/cm2)
57 - 71 psi
4TNV98T (0.39 - 0.49 MPa;
3.98 - 5.00 kgf/cm2)
45 - 71 psi
4TNV106 (CL),
(0.31 - 0.49 MPa;
4TNV106T (CL)
3.16 - 5.00 kgf/cm2) All Models
8.8 psi (0.06 MPa; 0.6 kfg/cm2) or greater
With balancer:
49 - 64 psi
(0.34 - 0.44 MPa;
3.47 - 4.49 kgf/cm2)
4TNV106 (VM),
4TNV106T (VM)
Without balancer:
57 - 71 psi
(0.39 - 0.49 MPa;
3.98 - 5.00 kgf/cm2)
Outer Rotor Outside Clearance - All Models

Reference
Model Standard Limit
Page
Check Outer
0.0047 - 0.0083 in. 0.0118 in. Rotor Outside
(0.12 - 0.21 mm) (0.30 mm) Clearance on
4TNV88
page 9-14
0.0039 - 0.0061 in. 0.0098 in. Check Outer
(0.100 - 0.155 mm) (0.25 mm) Rotor Outside
0.0039 - 0.0065 in. 0.0098 in. Clearance on
4TNV106, 4TNV106T page 9-14
(0.100 - 0.165 mm) (0.25 mm)

LUBRICATION SYSTEM
Outer Rotor Side Clearance - All Models
Reference
Page
Check Outer
0.0008 - 0.0028 in. 0.0047 in. Rotor Side
(0.02 - 0.07 mm) (0.12 mm) Clearance on
4TNV88
page 9-12
0.0020 - 0.0039 in. 0.0059 in. Check Outer
(0.05 - 0.10 mm) (0.15 mm) Rotor Side
(0.03 - 0.12 mm) (0.17 mm)
Outer Rotor to Inner Rotor Tip Clearance - All Models

Reference
Page
Outer Rotor to
0.0063 in. Inner Rotor Tip
(0.16 mm) Clearance on
4TNV88
page 9-11
0.0063 in. Outer Rotor to
(0.16 mm) Inner Rotor Tip
0.0063 in. Clearance on
(0.16 mm)
Inner Rotor and Gear Boss Clearance - 3TNV82A to 88

Standard
Standard Standard Reference
Item Parts Clearance
Dimension Clearance Page
Limit
2.0886 - 2.0925 in.
Gear Boss Diameter
Inside Clearance of (53.05 - 53.15 mm) 0.012 - 0.020 in. 0.024 in.
Inner Rotor 2.1043 - 2.1083 in. (0.3 - 0.5 mm) (0.6 mm) Check Inner
Rotor Diameter Rotor and
(53.45 - 53.55 mm)
Gear Boss
Width Across Flat of 1.9468 - 1.9587 in. Clearance on
Inner Rotor Width Gear Boss (49.45 - 49.75 mm) 0.008 - 0.024 in. 0.028 in. page 9-12
Across Flat
Width Across Flat of 1.9665 - 1.9705 in. (0.2 - 0.6 mm) (0.7 mm)
Clearance
Rotor (49.95 - 50.05 mm)

LUBRICATION SYSTEM
Rotor Shaft Clearance - 4TNV94L to 4TNV106T
Reference
Page
0.5110 - 0.5126 in. 0.5138 in.
Gear Case Bearing I.D.
(12.980 - 13.020 mm) (13.05 mm)
4TNV94L, 4TNV98, 0.5100 - 0.5108 in. 0.5096 in.
Rotor Shaft O.D.
4TNV98T (12.955 - 12.975 mm) (12.945 mm)
0.0014 - 0.0026 in. 0.0041 in. Check Rotor
Rotor Clearance
(0.035 - 0.065 mm) (0.105 mm) Shaft
Gear Case Bearing I.D. page 9-15
(13.00 - 13.02 mm) (13.05 mm)
0.5100 - 0.5104 in. 0.5096 in.
4TNV106, 4TNV106T Rotor Shaft O.D.
(12.955 - 12.965 mm) (12.945 mm)
0.0014 - 0.0026 in. 0.0041 in.
Rotor Clearance
(0.035 - 0.065 mm) (0.105 mm)

LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM
Oil Filter
Turbocharger*
Bypass Valve
Oil Cooler* Fuel

Injection Pump
Oil Pressure
Switch
Cylinder Body - Main Gallery

Pressure
Regulator Valve
Idle Gear Camshaft Crank
Oil Pump Shaft Bearing Journal
Piston Cooling Rocker Arm Crank Pin

Oil Suction Pipe Nozzles* Bearing
Strainer
Rocker Arm
Tappet
Cam Face
Oil Pan
0000042
Figure 9-1
Note: Items marked * are not standard equipment on all models.

LUBRICATION SYSTEM
CHECKING ENGINE OIL TROCHOID OIL PUMP

PRESSURE
3TNV82A TO 4TNV88 Oil Pump
Perform an engine oil pressure check if there is any
indication of low oil pressure such as the oil
Components
pressure indicator is on or the oil pressure gauge On these model engines, the oil pump is located
indicates low oil pressure. SeeEngine Oil inside the front gear case cover and is driven by a
Pressure - All Models on page 9-5. boss on the front crankshaft gear. You must remove
the front gear case cover to gain access to the oil
1. Disconnect the wire lead from the oil pressure pump.
switch or sending unit (Figure 9-2, (1)).
(1)
(2) (5) (6)
(1) (3)
(4)
0000028B
0000075A
Figure 9-2
2. Remove the oil pressure switch. 1 Crankshaft
2 Oil Pump Cover
3. Install a mechanical oil pressure gauge in the 3 Oil Pressure Regulator
oil pressure switch port. 4 Gear Case Cover
4. Start the engine: 5 Outer Rotor
6 Inner Rotor
If the mechanical oil pressure test gauge
indicates good oil pressure, replace the faulty Figure 9-3
oil pressure switch or sending unit, or faulty
machine oil pressure gauge in instrument
panel.
If the mechanical oil pressure test gauge
indicates low oil pressure, troubleshoot the
lubrication system to locate the cause of the
low oil pressure. See Troubleshooting Charts
on page 14-7. Repair as necessary.

LUBRICATION SYSTEM
Disassembly of Oil Pump (1) (2)
CAUTION
0000030en
1. Remove the engine cooling fan guard (if

equipped), engine cooling fan (Figure 9-4, (3)),
spacer (Figure 9-4, (2)), engine coolant pump
V-pulley (Figure 9-4, (1)) and V-belt.
0001625
Figure 9-5
4. Remove the oil pump cover (Figure 9-5, (1))
(2) (3)
from the gear case cover.
5. Remove the outer rotor (Figure 9-6, (2)) and
inner rotor (Figure 9-6, (1)) from the gear case
cover.
(2)
(1)
(1)
0000163C
Figure 9-4
2. Remove the crankshaft pulley and gear case
cover. See Removal of Timing Gear Case
Cover on page 6-70.
3. Remove the seven oil pump cover
(Figure 9-5, (1)) screws (Figure 9-5, (2)). 0001626
Note: The oil pump cover screws are installed

Figure 9-6
using a liquid thread lock. It may be
necessary to use a localized heat
(small propane torch) and an
impact-type screwdriver or air tool to
remove these screws.

LUBRICATION SYSTEM
6. Remove the oil pressure regulator valve Record the measurement(s) and seeOuter Rotor
(Figure 9-7, (1)) from the oil pump cover Outside Clearance - All Models on page 9-5 for
(Figure 9-7, (2)). the service limits.
(1)
(2)
(2)
(1) 0001151A
Figure 9-8
0001642
Outer Rotor to Inner Rotor Tip Clearance
Figure 9-7
Determine the outer rotor to inner rotor tip
Cleaning and Inspection clearance. Insert a feeler gauge between the top of
an inner rotor tooth (Figure 9-9, (1)) and the top of
Wash the oil pump cover, the oil pressure regulator
an outer rotor tooth (Figure 9-9, (2)) and measure
valve, the oil pump cavity and the inner and outer
the clearance.
rotors. Inspect the parts for wear or damage.
Replace as necessary.
Note: If the oil pump cavity is damaged, the
gear case cover must be replaced.
A CAUTION
(1)
0000015en
(2) 0001150A
Check Outer Rotor Outside Clearance
Figure 9-9
1. Reinstall the outer and inner rotors. The dots on
the rotor faces must face up. Make sure that Record the measurement(s) and seeOuter Rotor to
the pilot on the back of the inner rotor fits into Inner Rotor Tip Clearance - All Models on page 9-6
the bore of the oil pump cavity and the top for the service limits.
surface of the inner rotor is flush with the top
surface of the outer rotor.
2. Determine the outside clearance of the outer
rotor. Insert a feeler gauge between the outer
rotor (Figure 9-8, (1)) and the gear case oil
pump cavity (Figure 9-8, (2)).

LUBRICATION SYSTEM
Check Outer Rotor Side Clearance Record the measurement(s) and see Inner Rotor
Determine the side clearance of the outer rotor and Gear Boss Clearance - 3TNV82A to 88 on
across the pump cavity. While pressing down on page 9-6 for the service limits.
the outer rotor, measure the depression using a
depth micrometer (Figure 9-10).
Reassembly of Oil Pump
1. Lubricate the outer rotor (Figure 9-12, (1)),
inner rotor (Figure 9-12, (2)) and pump bore in
10
25 20 15
the gear case cover with clean engine oil.
(5)
(3)
(1)
0001152
(2)
Figure 9-10
Record the measurement(s) and see Outer Rotor
Side Clearance - All Models on page 9-6 for the
service limits.
(4)
Check Inner Rotor and Gear Boss 0000044A
Clearance
Figure 9-12
Using appropriate measuring instruments, measure
the outside dimensions of the crankshaft gear boss 2. Reinstall the outer rotor in the gear case. The
and the inside dimensions of the inner rotor dot mark on the face of the outer rotor must
(Figure 9-11). face up toward the oil pump cover.
3. Reinstall the inner rotor into the gear case cover
(5) with the dot mark also facing up. Make sure that
the pilot on the back side of the inner rotor fits
(3) into the bore in the gear case cover and the top
surface of the inner rotor is flush with the top
surface of the outer rotor.
4. Reinstall the oil pressure regulator valve into
the oil pump cover. Apply LOCTITE 242 (red)
to the valve plug. (Follow LOCTITE package
(1) (6) instructions.)
(4)
(2) 5. Reinstall the oil pump cover (Figure 9-12, (3)).
0000076A
Apply LOCTITE 290 (green) or LOCTITE 262
1 Crank Gear (red) to the oil pump cover screws. (Follow
2 Inner Rotor LOCTITE package instructions.) Tighten the
3 Inside Width Across Flats of Inner Rotor
pump cover screws to 61 13 inlb
4 Overall Inside Diameter of Inner Rotor
(6.9 1.5 Nm, 0.7 0.15 kgfm).
5 Outside Width Across Flats of Gear Boss
6 Overall Outside Diameter of Gear Boss
Figure 9-11

LUBRICATION SYSTEM
6. Reinstall the gear case cover and crankshaft TROCHOID OIL PUMP
pulley. See Installation of Gear Case Cover on
page 6-93. 4TNV94L/98/106 Oil Pump
7. Reinstall the engine coolant pump V-pulley
Components
(Figure 9-13, (1)), spacer (Figure 9-13, (2)),
engine cooling fan (Figure 9-13, (3)) and The oil pump on these model engines is located in
engine cooling fan guard (if equipped). the front gear case and is driven by the same gear
train that drives the camshaft and fuel injection
pump. You must remove the front gear case cover
to gain access to the oil pump.
(2) (3)
(1)
(2)
(5)
(3)
(1) (4) 0000043A

0000163C
1 Gear Case Housing
2 Outer Rotor
Figure 9-13
3 Inner Rotor
8. Reinstall the V-belt. Tighten the V-belt to the 4 Cover Plate
proper tension as described in Check and 5 Drive Gear
Adjust Cooling Fan V-Belt on page 5-28. Figure 9-14

LUBRICATION SYSTEM
Disassembly of Oil Pump
CAUTION
(1)
0000030en
Remove the engine cooling fan guard (if equipped),

engine cooling fan (Figure 9-15, (3)), spacer
(Figure 9-15, (2)), engine coolant pump V-pulley (2) 0000049D
(Figure 9-15, (1)) and V-belt. Figure 9-16
Cleaning and Inspection

Wash the oil pump, oil pressure regulator and oil
(2) (3) pump cavity. Inspect for wear or damage. Replace
as necessary.
A CAUTION
0000015en
(1) Check Outer Rotor Outside Clearance

0000163C
Figure 9-15 Determine the outside clearance of the outer rotor.

Insert a feeler gauge between the outer rotor
1. Remove the crankshaft pulley and the gear (Figure 9-17, (1)) and gear case oil pump cavity
case cover. See Removal of Timing Gear Case (Figure 9-17, (2)).
Cover on page 6-70.
2. Remove the oil pump assembly bolts. Remove (1)
(2)
the oil pump assembly (Figure 9-16, (1)) from
the gear case housing (Figure 9-16, (2)).
0000045A
Figure 9-17
Record the measurement(s) and see Check Outer
Rotor Outside Clearance on page 9-11 for the
service limits.

LUBRICATION SYSTEM
Outer Rotor to Inner Rotor Tip Clearance Check Rotor Shaft Clearance
Determine the outer rotor to inner rotor tip Determine the rotor shaft clearance. Measure the
clearance. Insert a feeler gauge between the top of outside diameter of the rotor shaft
an inner rotor tooth (Figure 9-18, (1)) and the top (Figure 9-20, (1)) and the bore diameter in the gear
of an outer rotor tooth (Figure 9-18, (2)) and case housing (Figure 9-20, (2)).
measure the clearance.
Calculate the difference between the two
measurements to determine the clearance.
(1)
(2) (1)
0001153A
Figure 9-18 (2)

0000047A
Record the measurement(s) and seeOuter Rotor to
Inner Rotor Tip Clearance on page 9-11 for the Figure 9-20
service limits. Record the measurement(s) and seeRotor Shaft
Clearance - 4TNV94L to 4TNV106T on page 9-7
Check Outer Rotor Side Clearance
for the service limits.
Determine the side clearance of the outer rotor
across the pump cavity. Measure the depression Reassembly of Oil Pump
using a depth micrometer (Figure 9-19, (1)).
1. Lubricate the outer rotor and pump bore in the
gear case with clean engine oil.
(1)
2. Reinstall the outer rotor in the gear case
housing. The punch mark (Figure 9-21, (1)) on
the end of the outer rotor must face away from
the gear case housing (Figure 9-21, (2)).
0001615A
1
Figure 9-19 0000048A
Record the measurement(s) and seeCheck Outer Figure 9-21

Rotor Side Clearance on page 9-12 for the service
limits.

LUBRICATION SYSTEM
3. Reinstall the oil pump assembly
(Figure 9-22, (1)) into the gear case housing
(Figure 9-22, 2). Tighten the bolts to specified
torque.
(1)
(2) 0000049D
Figure 9-22
4. Reinstall the gear case cover and crankshaft
pulley. See Installation of Gear Case Cover on
page 6-93.
5. Reinstall the engine coolant pump V-pulley
(Figure 9-23, (1)), spacer (Figure 9-23, (2)),
engine cooling fan (Figure 9-23, (3)) and
engine cooling fan guard (if equipped).
(2) (3)
(1)
0000163C
Figure 9-23
6. Reinstall the V-belt. Tighten the V-belt to the
proper tension as described in Check and
Adjust Cooling Fan V-Belt on page 5-21.

Section 10
TURBOCHARGER
Page
Before You Begin Servicing .......................................................... 10-3
Introduction.................................................................................... 10-5
Specifications ................................................................................ 10-5
Turbocharger Service Information ........................................... 10-5
Troubleshooting............................................................................. 10-6
Excessive Exhaust Smoke ...................................................... 10-6
Generates White Smoke ......................................................... 10-7
Sudden Oil Decrease .............................................................. 10-7
Decrease in Output.................................................................. 10-7
Poor (Slow) Response (Starting) of Turbocharger .................. 10-7
Abnormal Sound or Vibration .................................................. 10-7
Turbocharger Components ........................................................... 10-8
Turbocharger Component Functions........................................... 10-10
Theory of Operation............................................................... 10-11
Compressor Side Sealing Mechanism .................................. 10-11
Waste Gate Modulation ......................................................... 10-11
Washing Procedure..................................................................... 10-12
Periodic Inspection ...................................................................... 10-13
Visual Inspection ................................................................... 10-13
Inspection of Rotor Rotation .................................................. 10-13
Inspection of Rotor Play ........................................................ 10-13
Removal of Turbocharger...................................................... 10-13
Checking Rotor Play.............................................................. 10-14
Waste Gate Valve Test.......................................................... 10-14
Waste Gate Actuator Leak Test ............................................ 10-15
Installation of Turbocharger................................................... 10-15

TURBOCHARGER

TURBOCHARGER
BEFORE YOU BEGIN

A WARNING
SERVICING Never apply over 40 psi (2.8 kgf/cm) to
the waste gate actuator.
A WARNING 0000026en
A CAUTION
service it.
Someone may accidentally start the ALWAYS wear eye protection when
engine and not realize you are servicing the engine and when using
servicing it. This could result in a compressed air or high-pressure
serious injury. water. Dust, flying debris, compressed
injure your eyes.
back long hair, and keep your hands, Failure to comply may result in minor
other body parts and clothing away or moderate injury.
from moving / rotating parts. 0000003en

or serious injury. CAUTION
0000010en For maximum engine life, Yanmar
A WARNING engine down, you allow the engine to
will allow the engine components that
operate at high temperatures, such as
the turbocharger (if equipped) and
exhaust system, to cool slightly before
the engine itself is shut down.
FUME / BURN HAZARD!
0000008en
sealant removers.
or serious injury.
0000014en

TURBOCHARGER
CAUTION
Avoid damage to the turbocharger or the
engine. Do not spray blower wash fluid
or water too quickly.
Use short strokes from a spray bottle to
inject blower wash fluid or water into the
turbocharger.
Spraying too much wash fluid or water,
or spraying too quickly will damage the
turbocharger.
0000063en
CAUTION
Do not allow any material to fall into the
oil lines or the oil inlet and outlet ports
of the turbocharger.
0000064en
CAUTION
If the waste valve does not meet
specifications, replace the turbocharger
or have it repaired by a qualified repair
facility.
0000078en

TURBOCHARGER
INTRODUCTION
This section of the Service Manual describes the servicing of the RHF5, RHB31 and RHB51 model
turbochargers.
SPECIFICATIONS
Turbocharger Service Information
3TNV84T (CL,
4TNV106T
Applicable Engine Model (application) VM) 3TNV84T (VM) 4TNV98T
(CL, VM)
4TNV84T (CL)
Turbocharger Model RHB31 RHB51 RHF5 RHF5
Turbocharger Specification Standard (w/waste gate)
Turbine Type Radial flow
Blower (Compressor) Type Centrifugal
Lubrication External lubrication
Maximum Continuous Allowable Speed 250,000 180,000
Maximum Continuous Allowable Gas Inlet
750F (399C)
Temperature
5.4 lb 9.2 lb 10.3 lb 10.3 lb
Weight (Dry)
(24 N; 2.4 kgf) (41 N; 4.2 kgf) (46 N; 4.7 kgf) (46 N; 4.7 kgf)
Note: VM application is provided with the waste gate.

TURBOCHARGER
TROUBLESHOOTING
The following troubleshooting procedures apply to problems identified as turbocharger related. Consider all
other troubleshooting possibilities before cleaning or removing the turbocharger.
Excessive Exhaust Smoke

Cause Corrective action
Clogged air cleaner element Clean or replace the air cleaner element
Blocked air intake port Correct the condition
Leak from a joint in intake line Correct the condition

1. Compressor impeller dirty
1. Wash the impeller blades.
2. Deposit of impurities in oil sticking on the turbine side seal
2. Repair the turbocharger. Send to a qualified repair facility.
portion to make turbine revolution heavy
3. Sticking bearing:
3a. Repair turbocharger. Send to qualified repair facility.
3a. Insufficient lubrication or clogged lubrication piping
3b. Inspect the lubricating oil line for problem. Correct the
3b. Excessively high oil temperature
condition and replace lubricating oil.
3c. Repair the turbocharger. Send to a qualified repair
3c. Unbalanced rotating part
facility.
3d. Improper operation of the machine. Refer to the
3d. Insufficient warming up or sudden stop from loaded
Operation Manual.
operation (no-load operation)
4. Contact or breakdown of turbine wheel or blower vane: 4a. Inspection and repair of each engine part
4a. Excessive revolution 4b. Inspection and repair of each engine part
4b. Excessive exhaust temperature rise 4c. Clean the air cleaner and engine compartment. Repair
4c. Foreign matter within turbocharger the turbocharger. Send to a qualified repair facility.
4d. Repair the turbocharger. Send to a qualified repair
4d. Worn bearing facility.
4e. Repair the turbocharger. Send to a qualified repair
4e. Incorrect assembly of turbocharger facility.

Exhaust system gas leak prior to the turbocharger. Condition
Inspect the exhaust system for leaks. Correct the condition.
will decrease turbocharger revolutions.
Deformed or clogged exhaust pipe. Condition will decrease
Correct the condition.
turbocharger revolutions.

TURBOCHARGER
Generates White Smoke
Clogged or deformed oil return pipe causing oil flow to the Correct the condition
blower on the turbine side
Excessive bearing wear causing abnormal wear or damage of
the seal ring Repair the turbocharger. Send to a qualified repair facility.
Sudden Oil Decrease

Excessive bearing wear causing abnormal wear or damage of
Repair turbocharger. Send to qualified repair facility.
the seal ring
Decrease in Output
Gas leak from any part in exhaust piping Correct the condition
Air leak from discharge side of blower Correct the condition
Clogged air cleaner element Clean or replace the air cleaner element
Damaged turbocharger Repair the turbocharger. Send to a qualified repair facility
Poor (Slow) Response (Starting) of

Turbocharger
Hard carbon deposit on the turbine side (wheel sealing portion)
Repair the turbocharger. Send to a qualified repair facility
causing abnormal revolution of the turbine shaft
Incomplete combustion Correct the condition
Abnormal Sound or Vibration

Excessively narrowed gas path due to clogged nozzle in the
turbine wheel chamber or reverse flow of blower discharge in Repair the turbocharger. Send to a qualified repair facility
acceleration (generally called surging)
Contact rotating part Repair the turbocharger. Send to a qualified repair facility

Loosened intake, exhaust or oil pipe connection with the
Correct the condition
turbocharger
Damaged bearing, contact between rotating part and adjacent
part, or chipping of the turbine wheel or blower vane due to Repair the turbocharger. Send to a qualified repair facility
foreign matter within the turbocharger
Unbalanced rotating part Repair the turbocharger. Send to a qualified repair facility

TURBOCHARGER
TURBOCHARGER COMPONENTS
Note: The following illustration is provided for informational purposes only. Yanmar does not offer individual
service parts for turbochargers. If the turbocharger is worn or damaged, it should be replaced or
repaired by a qualified repair facility.
(12)
(15)
(14) (8) (7)
(13) (9)
(4)
(5)
(11) (3) (22)
(2) (23)
(20) (21)
(28)
(10) (29)
(24)
(27)
(6)
(19)
(1) (29)
(14)
(13)
(17)
(18) (26)
(16) (32)
(25) (31) (30)
0000078A
Figure 10-1

TURBOCHARGER
1 Turbine Shaft 17 Bolt
2 Thrust Bearing 18 Lock Plate
3 Oil Thrower 19 Bearing Housing
4 Seal Ring 20 Retaining Ring
5 Seal Ring 21 Bolt
6 Seal Ring (Turbine Side) 22 Bolt
7 Lock Nut 23 Lock Washer
8 Impeller 24 Heat Protector
9 Seal Plate 25 Liquid Gasket
10 Journal Bearing 26 Waste Gate Actuator
11 Thrust Bearing 27 Hose
12 Compressor Housing 28 Adapter
13 Flanged Bolt 29 Clip
14 Spring Washer 30 Retaining Ring
15 Clamp 31 Waste Gate Valve
16 Turbine Housing 32 Link Plate

TURBOCHARGER
TURBOCHARGER COMPONENT FUNCTIONS

D
(13) (14) (12) (15) (8) (9) (10) (17)
B C
(19)
(18)
F
(2)
(11) (1) (20) (3) (5) (16) (6) (4) (7)
A 0000077A
1 Turbine Shaft 11 Turbine Housing

2 Oil Thrower 12 M6 Hex Bolt
3 Turbine Side Seal Ring 13 Turbine Side Clamp
4 Seal Plate 14 Lock Washer
5 Journal Bearing 15 Bearing Housing
6 Thrust Bearing 16 Retaining Ring
7 Compressor Housing 17 M3 Countersunk Flat-Head Bolt
8 M5 Hex Bolt 18 Compressor Wheel
9 M5 Spring Washer 19 Shaft End Nut
10 Compressor Side Clamp 20 Heat Protector
A. Exhaust Gas Inlet D. Air Outlet

B. Exhaust Gas Outlet E. Oil Inlet
C. Air Inlet F. Oil Outlet
Figure 10-2

TURBOCHARGER
Theory of Operation Bearings
Normally aspirated engines produce horsepower Thrust Bearing
that is limited by the atmospheric pressure of the A thrust force is continuously imposed on the
induction air. The turbocharger is an exhaust gas turbine shaft during engine operation. A thrust
pressure driven device that adds to the bearing prevents the shaft from moving laterally
atmospheric pressure, resulting in a boost in under this thrust force.
pressure at the combustion chambers. This
substantially increases the amount of fuel that can Radial Bearing
be injected into the combustion chambers, while A floating radial bearing moves with the turbine
maintaining the proper fuel-to-air ratio. A slight shaft as oil films form on the inside and outside
parasitic loss is imposed on the engine because of bearing surfaces. The bearing slipping speed is
added back pressure in the exhaust system. That slower than the turbine shaft speed, resulting in
loss is offset by horsepower gains. The net result is higher dynamic stability and reduced mechanical
substantially increased overall horsepower over noise.
normally aspirated engines.
Lubrication
The turbocharger consists of two main
components: The oil pump delivers oil from the engine to the
turbocharger for cooling and lubrication of the
Turbine bearings. As oil leaves the turbocharger, it is
Compressor returned to the engine.
Turbine Compressor Side Sealing Mechanism

The turbine is driven by exhaust gas pressure from A seal ring and a seal plate form a double wall
the engine and is coupled to a shaft on the structure at the rear of the compressor impeller.
compressor side of the turbocharger. The seal ring and seal plate prevent Intake air and
oil leakage.
Exhaust gas velocity is accelerated at the nozzle
portion in the turbine housing where the Waste Gate Modulation
cross-sectional area is reduced. As exhaust passes
Excessive boost pressure that cannot be
over the turbine impeller at high linear velocity, the
accommodated by the engine can damage the
turbine shaft is rotated at proportionally high rpm.
turbocharger. The waste gate is a component that
Compressor monitors intake boost pressure on the compressor
side and diverts exhaust gases around the
The compressor is driven by a shaft on the turbine turbocharger turbine. The amount of exhaust gas
side of the turbocharger and increases the diverted is varied to limit turbine rpm and maintain
induction air pressure at the intake manifold. the intake pressure equal to, or less than the
The compressor impeller draws induction air into specified maximum level. This improves the
the turbocharger, compresses it and directs it into response to load variation in the low to medium rpm
the engine at high pressure. range and minimizes black smoke.
A seal ring and heat insulating plate thermally Waste Gate Control
isolate heat energy, at the turbine side, from the A mechanical pressure sensor in the outlet of the
bearings and the induction air, at the compressor compressor side of the turbocharger opens and
side. closes the waste gate to maintain the specified
intake pressure at the intake manifold.

TURBOCHARGER
WASHING PROCEDURE
Note: Inspection, cleaning and repair of the
internal turbocharger components must
be performed by a qualified repair facility.
The washing procedure described in this section is
intended to clean the impeller on the compressor
only if the engine loses rpm, seems sluggish or has
insufficient boost pressure. The process does not
require disassembling any portion of the
turbocharger.
Since washing is quick and easy, perform this
procedure before considering replacement.
1. Start the engine and allow it to reach the
0000860
normal operating temperature.
Figure 10-3
CAUTION
3. Continue to operate the engine under the same
Avoid damage to the turbocharger or the
load for three to four minutes.
engine. Do not spray blower wash fluid
or water too quickly. 4. While the engine is still operating at normal load
(75 - 80% of maximum), slowly and evenly
Use short strokes from a spray bottle to spray 2 - 3 oz (60 - 90 cc) of clean water over a
inject blower wash fluid or water into the period of ten to fifteen seconds into the air inlet.
turbocharger.
5. Continue to operate the engine under the same
Spraying too much wash fluid or water, load for at least ten minutes to completely dry
or spraying too quickly will damage the the air intake system and turbocharger.
turbocharger.
6. Test the engine performance. If engine
0000063en
performance has not improved, repeat steps 2
2. While the engine is operating at normal load through 6. If the engine performance does not
(75 - 80% of maximum), slowly and evenly improve after executing the washing process
spray 2 - 3 oz (60 - 90 cc) of blower wash fluid three times, replace the turbocharger or have it
over a period of ten to fifteen seconds into the repaired by a qualified repair facility.
air inlet (Figure 10-3).

TURBOCHARGER
PERIODIC INSPECTION
Inspect the turbocharger at regularly scheduled intervals.
Inspection interval
Application
200 hours 400 hours 500 hours 800 hours 1000 hours 2000 hours
First 6 First 12 Every 24
Construction Equipment months months months
or 500 hrs or 1000 hrs or 2000 hrs
First 6 First 12 Every 24
Farm Equipment months months months
or 200 hrs or 400 hrs or 800 hrs
Engine Oil and Filter Replacement Based on engine operation manual
Visual Inspection Inspection of Rotor Play

1. Check for indications of oil leaks at the oil inlet To inspect the rotor, the turbocharger must be
and outlet lines. Repair or replace the oil lines removed. Inspect for maximum rotor end play and
as needed. run-out limits before reinstalling.
2. Inspect the air inlet connection to the
turbochargers turbine side for cracks or broken
Removal of Turbocharger
hardware. Repair or replace the connection as 1. Shut down the engine and allow the
needed. turbocharger to cool. Remove the exhaust
3. Inspect the exhaust outlet connection to the outlet connection from the turbocharger
turbochargers compressor side for cracks or housing.
broken hardware. Repair or replace the 2. Remove the air inlet connection from the
connection as needed. turbocharger housing.
Inspection of Rotor Rotation CAUTION

1. With the engine cool and not operating, Do not allow any material to fall into the
manually rotate the rotor. Smooth rotation is oil lines or the oil inlet and outlet ports
normal. Any catching or resistance to rotation is of the turbocharger.
an indication of abnormal operation. Replace 0000064en
the turbocharger or have it repaired by a
qualified repair facility. 3. Remove the inlet and outlet oil lines from the
turbocharger. Plug the lines and ports with tape
2. Start the engine.
to prevent contamination. Discard the sealing
3. After the engine reaches normal operating washers and O-rings. Inspect the oil lines and
temperature, place a stethoscope firmly against replace if damaged.
the turbocharger case.
4. Remove the turbocharger mounting nuts from
4. Increase the rpm gradually. A high-pitched the mounting studs. Lift the turbocharger from
sound, occurring at intervals of two or three the engine and place it on a clean, level working
seconds, is an indication of abnormal operation. surface.
Replace the turbocharger or have it repaired by
5. Discard the turbocharger exhaust manifold
a qualified repair facility.
gasket.

TURBOCHARGER
Checking Rotor Play
Note: If rotor play measurements are not within specification, replace the turbocharger assembly or have it
repaired by a qualified facility.
Standard Dimension Wear Limit

Rotor Play
RHF5 RHB31 RHB51 RHF5 RHB31 RHB51
0.0011 - 0.0024 in. 0.0009 - 0.0021 in. 0.0012 - 0.0024 in. 0.0044 in. 0.0028 in. 0.0035 in.
End Play
(0.03 - 0.06 mm) (0.022 - 0.053 mm) (0.03 - 0.06 mm) (0.09 mm) (0.07 mm) (0.09 mm)
0.0031 - 0.0051 in. 0.0024 - 0.0037 in. 0.0031 - 0.0051 in. 0.007 in. 0.0047 in. 0.0067 in.
Run-out
(0.08 - 0.13 mm) (0.061 - 0.093 mm) (0.08 - 0.13 mm) (0.17 mm) (0.12 mm) (0.17 mm)
To Check Rotor End Play:

1. Set up a dial indicator as shown (Figure 10-4). (1)
(2)
2. Manually move the rotor end-to-end while
observing indicated readings. Replace the (4)
turbocharger if end play measurements are
outside specified limits. See table above.
(1)
(2)
(3)
(3)
0000081A
Figure 10-5
Waste Gate Valve Test

0000080A
Before reinstalling the turbocharger, verify the
operation of the waste gate valve. Poor waste gate
Figure 10-4 operation will adversely affect the engine
To Check Rotor Run-out: performance.
1. Set up a dial indicator as shown (Figure 10-5).

CAUTION
2. Manually rotate the rotor while observing
indicated limits. Replace the turbocharger if If the waste valve does not meet
run-out measurements are outside specified specifications, replace the turbocharger
limits. See table above. or have it repaired by a qualified repair
facility.
0000078en

TURBOCHARGER
1. Connect a hand-operated air pump to the waste If the pressure reading is equal to or greater
gate actuator pipe (Figure 10-6, (1)). The pump than 15.9 psi (0.11 MPa; 1.1 kgf/cm2), the
should be equipped with a 30 psi (0.21 MPa; waste gate actuator is not leaking and is
2.21 kgf/cm2) pressure gauge operating properly.
(Figure 10-6, (2)), and a pressure release valve If the pressure reading is less than 15.9 psi
to release any pressure pumped into the (0.11 MPa; 1.1 kgf/cm2), the waste gate
system. (Similar pumps are used to check for actuator is leaking. Replace the turbocharger
leaks in marine gear cases.) or have it repaired by a qualified repair facility.
A WARNING Installation of Turbocharger

Never apply over 40 psi (2.8 kgf/cm) to 1. Pour 2 oz (60 cc) of clean engine oil in the oil
the waste gate actuator. inlet port at the top of the turbocharger. Rotate
0000026en the compressor wheel to ensure the shaft
bearings are lubricated.
2. Flush the oil lines to ensure that they are free of
containments.
3. Put a new turbocharger exhaust manifold
gasket in place and reinstall turbocharger on
the exhaust manifold.
(1 4. Apply anti-seize compound to the turbocharger
(2) mounting studs.
5. Reinstall the mounting nuts. Torque the nuts to
the specified torque.
6. Install new sealing washers and O-rings and
reinstall the inlet and outlet oil lines to the
turbocharger.
(3) 00001617
CAUTION
Do not allow any material to fall into the
Figure 10-6
oil lines or the oil inlet and outlet ports
2. Apply 17 psi (0.12 MPa; 1.2 kgf/cm2) to the of the turbocharger.
waste gate actuator (Figure 10-6, (3)) circuit. 0000064en
Observe if the waste gate valve is open fully. If

7. Reinstall the air inlet connection to the
the waste valve does not open fully, replace the
turbocharger turbine housing.
turbocharger or have it repaired by a qualified
repair facility. 8. Reinstall the exhaust connection to the
turbocharger compressor housing.
Waste Gate Actuator Leak Test
Allow the pressure, 17 psi (0.12 MPa; 1.2 kgf/cm2)
to remain in the circuit for one minute. After one
minute, observe the pressure reading.

TURBOCHARGER

Section 11
STARTER MOTOR
Page
Introduction.................................................................................... 11-5
Starter Motor Information .............................................................. 11-5
3TNV82A to 4TNV88 - Standard and Optional........................ 11-5
Starter Motor Specifications .......................................................... 11-7
Starter Motor Troubleshooting....................................................... 11-8
Starter Motor Components ............................................................ 11-9
Starter Motor ............................................................................... 11-10
Removal of Starter Motor ...................................................... 11-10
Disassembly of Starter Motor ................................................ 11-10
Cleaning and Inspection ........................................................ 11-12
Reassembly of Starter Motor................................................. 11-17
Check Pinion Projection Length ............................................ 11-18
No-Load Test......................................................................... 11-19
Installation of Starter Motor ................................................... 11-20

STARTER MOTOR

STARTER MOTOR
BEFORE YOU BEGIN

A WARNING
SERVICING
A WARNING
SHOCK HAZARD!
ENTANGLEMENT HAZARD! equipped) or disconnect the negative
electrical system.
service it.
Check the electrical harnesses for
cracks, abrasions, and damaged or
0000009en
or serious injury.
0000010en
FUME / BURN HAZARD!
sealant removers.
or serious injury.
0000014en

STARTER MOTOR
A CAUTION CAUTION
The starter motor is water-proofed
according to JIS D 0203, R2 which
protects the motor from rain or general
cleaning. Do not use high-pressure
wash or submerse the starter motor in
water.
FLYING OBJECT HAZARD! 0000055en
ALWAYS wear eye protection when

servicing the engine and when using CAUTION
compressed air or high-pressure Use a specialized battery charger to
water. Dust, flying debris, compressed recharge a battery with a voltage of
air, pressurized water or steam may 8 volts or less. Booster starting a battery
injure your eyes. with a voltage of 8 volts or less will
Failure to comply may result in minor generate an abnormally high voltage
or moderate injury. and destroy electrical equipment.
0000056en
0000003en
CAUTION
The starter motor can be damaged if
operated continuously longer than
10 seconds while performing the
no-load test.
0000034en
CAUTION
Make sure that the combined total
resistance of the battery cable in both
directions between the starter motor
indicated on the wiring diagram. The
starter motor will malfunction or break
down if the resistance is higher than the
specified value.
0000054en

STARTER MOTOR
INTRODUCTION
This section of the Service Manual covers the servicing of the starter motor. Yanmar Part No. 129900-
77010 is standard equipment on 4TNV94-98 model engines and is used in this section to show the service
procedures for a representative starter motor. For specific part detail, see the Yanmar Parts Catalog for the
engine you are working on.
STARTER MOTOR INFORMATION

3TNV82A to 4TNV88 - Standard and Optional
YANMAR Mfg. No Load Loaded
Part Mfg. Part Specification Terminal Amperag Terminal Amperag
Number Number rpm Torque rpm
Voltage e Draw Voltage e Draw
87 in.-lb
129129- 228000- DC12V-1.6 hp
Denso 11.5 90A MAX 3000 8 280 Max (9.81Nm; 900
77010 0251 (1.2 kW)
1.0 kgf/m)
117 in.-lb
129407- 228000- DC12V-1.9 hp
Denso 11.5 90A MAX 3000 8.5 350 Max (13.2 Nm; 1000
77010 3732 (1.4 kW)
1.4 kgf/m)
74 in.-lb
129608- S114- DC12V-1.9 hp
Hitachi 11 90A MAX 2700 8.4 250 Max (8.3 Nm; 1000
77010 817A (1.4 kW)
0.9 kgf/m)
134 in.-lb
129242- S114- DC12V-2.3 hp
Hitachi 11 90A MAX 2300 8 370 Max (15.1 Nm; 880
77010 883 (1.7 kW)
1.5 kgf/m)
97 in.-lb
129136- DC12V-3.1 hp 140A
Hitachi S13-332 11 4100 7.7 400 Max (11.0 Nm; 1400
77011 (2.3 kW) MAX
1.1 kgf/m)
269 in.-lb
129612- S25- DC24V-5.3 hp 100A
Hitachi 24 3500 18 400 Max (30.4 Nm; 1000
77011 166A (4.0kW) MAX
3.1 kgf/m)

STARTER MOTOR
4TNV94L to 4TNV106T - Standard and Optional
YANMAR Mfg. No Load Loaded
Part Mfg. Part Specification Terminal Amperag Terminal Amperag
Number Number rpm Torque rpm
Voltage e Draw Voltage e Draw
97 in.-lb
129900- DC12V-3.1 hp 140A
Hitachi S13-204 11 4100 7.7 400 Max (11.0 Nm; 1400
77010 (2.3 kW) MAX
1.1 kgf/m)
60 in.-lb
129940- DC12V-4.0 hp 160A
Hitachi S14-102 12 3600 10.85 300 Max (6.9 Nm; 2000
77010 (3.0 kW) MAX
0.7 kgf/m)
130 in.-lb
119131- DC24V-4.8 hp
Hitachi S24-13 23 90A MAX 3100 20.2 250 Max (14.7 Nm; 1300
77010 (3.5 kW)
1.5 kgf/m)
130 in.-lb
129900- DC24V-4.8 hp
Hitachi S24-14 23 90A MAX 3100 20.2 250 Max (14.7 Nm; 1300
77030 (3.5 kW) Wet
1.5 kgf/m))
97 in.-lb
129910- S13- DC12V-3.1 hp 140A
Hitachi 11 4100 7.7 400 Max (11.0 Nm; 1400
77022 2050 (2.3 kW) Wet MAX
1.1 kgf/m)

STARTER MOTOR
STARTER MOTOR SPECIFICATIONS

Yanmar Part Number 129900-77010
Nominal Output 3.0 hp (2.3 kW)
12.1 lb
Weight
(5.5 kg)
Revolution Direction (As Viewed From Pinion) Clockwise
Engagement System Magnetic Shift
Terminal Voltage / Current 11 V / 140 A max
No-load
Revolution 4100 rpm (min-1)
Terminal Voltage / Current 2.5 V / 1050 A max
Loaded 18 ft-lb
Torque
(24.5 Nm; 2.5 kgf/m) minimum
Clutch System Overrunning
Pinion Projection Voltage at 212F (100 C) 8.6 V max
Pinion DP or Module / Number of Teeth M3/9
Difference (O-ring, Oil Seal) Dry (none)
Application Standard
Spring Force 7.868 lbf (35 N; 3.6 kgf)
Brush Standard 0.591 in. (15 mm)
Height
Limit 0.354 in. (9 mm)
Magnetic Series Coil Resistance 0.27 W at 68F (20C)
Switch Shunt Coil Resistance 0.60 W at 68F (20C)
Standard 1.437 in. (36.5 mm)
Outside Diameter
Limit 1.398 in. (35 mm)
Commutator Run-Out
Limit 0.008 in. (0.2 mm)
Standard 0.020 - 0.031 in. (0.5 - 0.8 mm)
Insulation Depth
Limit 0.008 in. (0.2 mm)
Armature Run-Out
Limit 0.008 in. (0.02 mm)
Armature Front 6903DDU
Bearing Armature Rear 608DDU
Nominal Number
Type Pinion Front 60004DDU
Pinion Rear 6904DDU
Pinion Projection Length (Length L) 0.012 - 0.059 in. (0.3 - 1.5 mm)

11-8
Is the shift lever at NO Move shift lever to Is battery fully charged NO Charge or replace battery.
NEUTRAL position? NEUTRAL position. and terminals clean? Clean terminals.
YES
Engine does not start? Inspect wiring up to magnetic switch
Is starter motor magnetic and repair if necessary.
NO Key switch
STARTER MOTOR
switch actuating sound

YES heard? Safety relay
Magnetic switch assembly
NO NO Electrical connections
Does engine crank? Is starter motor operating? YES
YES
Adjust / pinion projection length.
Inspect shift lever for deformation,
Pinion and ring gear NO return spring for fatigue and pinion
meshing normal? for sliding.
YES Repair meshing between pinion and
ring gear or replace as needed.
YES
Connect M terminal of starter NO Inspect brush and replace if worn.
Pinion roller clutch or motor directly to battery. If brushes are not worn, replace armature
reduction gear damaged. Does starter motor operate? assembly.
Inspect and replace.
YES
Magnetic switch assembly If starter motor becomes wet, replace magnetic switch
contact defective. Repair assembly even if function is normal.
or replace.
STARTER MOTOR TROUBLESHOOTING
NO
(slow revolution) NO
Is revolution normal? Is battery fully charged Charge or replace battery. If a problem occurs:
and terminals clean? Clean terminals. Immediately disconnect battery negative terminal.
YES YES
Inspect fuel system. Is the engine oil NO Engine does not stop
Replace engine oil.
viscosity correct? even when key switch is
turned OFF.
YES

Does engine turn when YES Repair or replace Repair or replace key switch, starting
starter motor is replaced? starter motor. motor relay or magnetic switch assembly.
Slow Revolution
Inspect condition of engine.
0000102
STARTER MOTOR
STARTER MOTOR COMPONENTS

(13)
(12) (14)
(11)
(10)
(9)
(8)
(7)
(6)
(5)
(4)
(23)
(3)
(2)
(1) (15)
(18)
(22)
(21)
(19)
(20)
(17)
(16) 0000103A
1 Pinion Shaft 13 Magnetic Switch Assembly (Solenoid)

2 M4 Bolts (3 used) 14 Cover
3 Bearing Retainer 15 M6 Bolts (2 used)
4 Pinion Clutch Assembly 16 Armature Assembly
5 Return Spring 17 Field Coil Assembly
6 Pinion Stop 18 Positive (+) Brushes
7 Retaining Ring 19 Negative (-) Brushes
8 Gear Housing 20 Brush Holder Assembly
9 Shift Lever 21 Rear Cover
10 Torsion Spring 22 M5 Through Bolts (2 used)
11 Plunger 23 M4 Bolts (2 used)
12 Dust Covers (Shims)
Figure 11-1

STARTER MOTOR
STARTER MOTOR (1)
A WARNING
SHOCK HAZARD!
equipped) or disconnect the negative 0002126
battery cable before servicing the Figure 11-2

electrical system.
Check the electrical harnesses for Disassembly of Starter Motor
cracks, abrasions, and damaged or 1. Loosen the M8 nut from the magnetic switch
corroded connectors. ALWAYS keep (solenoid) assembly (Figure 11-3). Disconnect
the connectors and terminals clean. the wire from the magnetic switch.
or serious injury.
0000009en
Note: While starter motor design varies

between models, the basic repair
procedures are the same. The following
procedures are typical and may differ
from the stater being serviced.
Removal of Starter Motor

1. Disconnect the battery cables at the battery,
negative (-) cable first. 0000104
2. Remove the electrical wires from the magnetic Figure 11-3

switch assembly. 2. Remove the two M4 bolts (Figure 11-4, (1))
3. Remove the starter mounting bolts securing the rear cover (Figure 11-4, (2)) to the
(Figure 11-2, (1)). Remove the starter motor brush holder assembly (Figure 11-4, (3)).
from the flywheel housing.

STARTER MOTOR
(7) (1)
(4)
(1)
(2) (3)
0000107A
Figure 11-6
(6) (5) (3) (2) 6. Pull the armature assembly (Figure 11-6, (3))
0000105A
out from the field coil assembly
Figure 11-4 (Figure 11-6, (2)).
3. Remove the two M5 through bolts 7. Remove the two M6 bolts (Figure 11-7, (1))
(Figure 11-4, (4)). Separate the rear cover retaining the magnetic switch assembly
(Figure 11-4, (2)), field coil assembly (Figure 11-7, (2)) to the gear housing. Remove
(Figure 11-4, (5)) with the armature assembly the magnetic switch assembly, dust cover(s)
(Figure 11-4, (6)) from the gear housing (Figure 11-7, (3)) and torsion spring
(Figure 11-4, (7)). (Figure 11-7, (4)) from the gear housing.
4. Pull the brush springs up using a brush spring (1)
puller. On the negative (-) side, bring the brush
spring into contact with the side of the brush for
lifting from the commutator surface. On the
positive (+) side, remove the brush from the (2) (4)
brush holder assembly (Figure 11-5, (1)).
(3)
0000108A
Figure 11-7
8. Disassemble the dust cover (Figure 11-8, (3))
and shift the lever (Figure 11-8, (4)) from the
(1) gear housing.
0000106A
(1)
Figure 11-5
5. Remove the brush holder assembly
(Figure 11-6, (1)) from the armature assembly
(Figure 11-6, (3)).
(2)
0000109A
Figure 11-8

STARTER MOTOR
9. Remove the three M4 bolts (Figure 11-9, (1))
(4)
securing the bearing retainer assembly (1)
(Figure 11-9, (2)) to the gear housing. Remove
the bearing retainer assembly from the gear (5)
housing. (2)
(3)
(2)
0000112A
Figure 11-11
(3)
Cleaning and Inspection
Armature
(1)
Commutator Surface Inspection
0000110A If the commutator surface is rough, polish the
surface with a #500 to #600 emery cloth
Figure 11-9
(Figure 11-12).
10. Remove the pinion clutch assembly
(Figure 11-9, (3)) from the bearing retainer
assembly.
11. Using a flat-blade screwdriver, remove the
retaining ring (Figure 11-10, (1)) from the shaft
of the pinion.
(1)
0000117
Figure 11-12
Measure Commutator Outside Diameter

0000111A Measure the commutator outside diameter
(Figure 11-13). Replace the armature if the
Figure 11-10
measurement is less than the limit.
12. Disassemble the pinion stop
(Figure 11-11, (3)), return spring
(Figure 11-11, (4)), pinion clutch assembly
(Figure 11-11, (1)), and pinion shaft
(Figure 11-11, (5)).

STARTER MOTOR
Armature Coil Continuity Test
Check for continuity between the commutator
segments using a multimeter (Figure 11-15). The
multimeter should indicate continuity.
0000113
Figure 11-13
See Starter Motor Specifications on page 11-7 for
the service limit.
0000114
Measure Commutator Insulation Depth
Figure 11-15
Measure the depth of the insulating material
(Figure 11-14, (1)) between commutator segments If the multimeter does not indicate continuity,
(Figure 11-14, (2)). If the depth measures less replace the armature.
than the limit, use a hacksaw blade
(Figure 11-14, (3)) to remove the insulating Armature Coil Insulation Test
material until the depth is within the limit. Check for continuity between a commutator
segment and the shaft or armature using a
A normal commutator condition is indicated in multimeter (Figure 11-16). The multimeter should
(Figure 11-14, (4)). An abnormal commutator not indicate continuity.
condition is indicated in (Figure 11-14, (5)).
(3)
(2)
(1)
0000115
Figure 11-16
(5) (4) If the multimeter indicates continuity, replace the
0000118
armature.
Figure 11-14
the service limit.

STARTER MOTOR
Measure Armature and Commutator Run-Outs Field Coil Insulation Test
Measure the armature core run-out and the Check for continuity between the field coil terminal
commutator run-out using a dial indicator and the yoke using a multimeter (Figure 11-19).
(Figure 11-17). Replace the armature if either of The multimeter should not indicate continuity.
the measurements is less than the limit.
If the multimeter indicates continuity, replace the
field coil assembly.
0000116
Figure 11-17
See Starter Motor Specifications on page 11-7 for 0000120
the service limit.
Figure 11-19
Field Coil
Measure Brush Length
Field Coil Continuity Test Measure the length of the brush (Figure 11-20).
Check for continuity between the field coil terminals Replace the brush if the length is less than the limit.
using a multimeter (Figure 11-18). The multimeter
should indicate continuity.
If the multimeter does not indicate continuity,
replace the field coil assembly.
0000121
Figure 11-20
0000119 the service limit.
Figure 11-18

STARTER MOTOR
Magnetic Switch Series Coil Continuity Test
If the starter motor becomes wet, replace the Check for continuity between the S and M
magnetic switch even if the magnetic switch terminals using a multimeter (Figure 11-22). The
assembly function is normal. multimeter should indicate continuity.
Shunt Coil Continuity Test If the multimeter does not indicate continuity,
replace the magnetic switch.
Check for continuity between the S terminal and
the switch body using a multimeter (Figure 11-21).
The multimeter should indicate continuity.
If the multimeter does not indicate continuity,
0000125
Figure 11-22
Coil Resistance Test

0000124 the service limit.
Figure 11-21

STARTER MOTOR
Contact Continuity Test Slide the pinion clutch assembly on the shaft. It
Depress the plunger at the bottom of the magnetic should slide smoothly on the shaft (Figure 11-25).
switch. Check for continuity between the B and Rust, too much grease or damage could prevent
M terminals using a multimeter (Figure 11-23). the pinion clutch from sliding smoothly. If the pinion
The multimeter should indicate continuity. clutch assembly does not slide smoothly, clean the
shaft and pinion clutch assembly or replace the
If the multimeter does not indicate continuity, damaged component.
0000128
Figure 11-25
0000126 Ball Bearing Inspection
Figure 11-23 Rotate each ball bearing while holding the pinion
clutch assembly (Figure 11-26). Replace the ball
Pinion Clutch Assembly bearing if it does not rotate smoothly or has
excessive play.
Pinion Clutch Assembly Inspection
Manually rotate the pinion clutch assembly in the
drive direction (Figure 11-24). It should rotate
freely in the drive direction and is locked by turning
it in the opposite direction. Replace the pinion
clutch assembly if the results are different.
0000129
Figure 11-26
0000127
Figure 11-24

STARTER MOTOR
Reassembly of Starter Motor (3)
1. Apply appropriate starter bendix grease (obtain
locally) to the pinion shaft. Reassemble the
pinion shaft (Figure 11-27, (5)), pinion clutch (2)
(1)
assembly (Figure 11-27, (1)), return spring
(Figure 11-27, (4)) and pinion stop
(Figure 11-27, (3)). Reinstall the retaining ring
(Figure 11-27, (2)) in the groove in the pinion
shaft. Slide the piston stop over the retaining (5)
ring.
(4)
(4)
0000268
(1)
(5) Figure 11-28
(2) 5. Reassemble the magnetic switch assembly to
(3) the gear housing. Pry the pinion away from the
gear housing to allow installation of the
0000112A magnetic switch assembly (Figure 11-29).
Figure 11-27
2. Reinstall the pinion clutch assembly into the
bearing retainer assembly.
3. Reinstall the bearing retainer assembly and
pinion assembly to the gear housing. Reinstall
and tighten the three M4 bolts.
4. Apply a small amount of high temperature
lithium grease (obtain locally) to the sliding
portions of the shift lever (Figure 11-28, (1)). 0000131
Reassemble the torsion spring
Figure 11-29
(Figure 11-28, (2)), shift lever and dust cover(s)
(Figure 11-28, (3)), plunger (Figure 11-28, 4) 6. Secure the magnetic switch assembly to the
and magnetic switch assembly gear housing using the two M6 bolts.
(Figure 11-28, (5)).

STARTER MOTOR
7. Carefully install the armature assembly 12. Reinstall the two M4 through bolts
(Figure 11-30, (1)) into the field coil assembly (Figure 11-32). Securely tighten the through
(Figure 11-30, (2)). bolts. Reconnect the wire to the magnetic
switch assembly. Tighten the M8 nut. Reinstall
the cover over the connection.
(1)
(2)
0000269
Figure 11-30
8. Position the brush springs in brush holders
(Figure 11-31). Reinstall the brushes in the
brush holders. Reversing the brushes will cause 0000104
the starter motor to turn backwards.

Figure 11-32
Check Pinion Projection Length

1. Connect the positive (+) lead from a battery to
the S terminal.
2. Connect the negative (-) lead to the M
terminal.
3. Lightly pull the pinion away from the gear
housing.
4. Turn the switch ON and measure the pinion
0000106 moving distance L in the thrust direction
Figure 11-31 (Figure 11-33). Perform this test within 10
seconds. See Starter Motor Specifications on
9. Carefully install the brush holder assembly to page 11-7 for the service limit.
the armature assembly.
10. Reinstall the field coil assembly with the
armature assembly to the gear housing.
11. Reinstall the rear cover to the brush holder
assembly. Securely tighten the two bolts.
0000132
Figure 11-33

STARTER MOTOR
5. If the measured L dimension is outside the
standard range, adjust the dust covers to obtain
the standard range. Dust covers (3)
(6 )
(Figure 11-34, (1)) are available in 0.020 in (0.5 (8 ) (1 )
mm) and 0.031 in (0.8 mm) thicknesses.
M
(2 )
(7 )
(1)
(5 )
(4 )
0002127A
Figure 11-35
3. Connect a wire lead between the mounting
base of the starter motor (Figure 11-35, (4))
and the battery negative terminal
0000133
(Figure 11-35, (5)).
Figure 11-34 4. Connect a voltmeter (Figure 11-35, (7)) to the
battery negative (-) terminal (Figure 11-35, (5))
No-Load Test and the main positive (+) battery terminal
(Figure 11-35, (3)) on the starter motor.
Test the characteristics of the starter motor by
performing a no-load test. 5. Install a switch (Figure 11-35, (6)) in a circuit
between the battery positive (+) terminal
(Figure 11-35, (2)) and the starter magnetic
CAUTION switch (solenoid) terminal (Figure 11-35, (8))
The starter motor can be damaged if on the starter motor.
operated continuously longer than 6. Use a suitable tachometer to monitor the rpm of
10 seconds while performing the the starter.
no-load test.
7. Turn the switch to the ON position. Monitor the
0000034en
rpm, amperage draw and voltage. For test
1. Secure the starting motor in a vise or other specifications, see 3TNV82A to 4TNV88 -
suitable fixture. Standard and Optional and 4TNV94L to
4TNV106T - Standard and Optional on
2. Connect an ammeter (Figure 11-35, (1)) in
page 11-5 for the appropriate starter motor.
series between the battery positive (+) terminal
(Figure 11-35, (2)) and the main positive (+)
terminal (Figure 11-35, (3)) on the starter
motor.
Note: The ammeter and all wire leads used in
this test must have a capacity equal to or
greater than the amperage draw
specification for the starter motor being
tested.

STARTER MOTOR
Installation of Starter Motor
1. Reinstall the starter motor to the flywheel
housing.
2. Reinstall the starter mounting bolts
(Figure 11-36, (1)). Tighten the bolts to
specification. See Tightening Torques for
Standard Bolts and Nuts on page 4-45.
(1)
0002126
Figure 11-36
3. Reconnect the electrical wires to the magnetic
switch assembly (solenoid). Be sure to place
the cover over the battery positive (+) cable
connection.
4. Reconnect the battery cables at the battery.

Section 12
ALTERNATOR
Page
Introduction.................................................................................... 12-6
Dynamo and Alternator Information .............................................. 12-6
3TNV82A to 4TNV106T - Standard and Optional
Dynamos ................................................................................. 12-6
3TNV82A to 4TNV106T - Standard and Optional
Alternators ............................................................................... 12-6
Alternator Specifications................................................................ 12-7
Dynamo Specifications.................................................................. 12-7
Alternator Troubleshooting ............................................................ 12-8
Alternator Components ................................................................. 12-9
Alternator Wiring Diagram ........................................................... 12-10
Alternator Standard Output ........................................................ 12-11
Alternator .................................................................................... 12-12
Removal of Alternator............................................................ 12-12
Disassembly of Alternator...................................................... 12-12
Reassembly of Alternator ...................................................... 12-14
Installation of Alternator......................................................... 12-16
Dynamo Component Location..................................................... 12-17
Dynamo Wiring Diagram ............................................................. 12-18
Operation of Dynamo .................................................................. 12-18
Dynamo Standard Output ........................................................... 12-19
Testing of Dynamo ...................................................................... 12-20
Testing Stator Coil Continuity ................................................ 12-20
Testing Stator Coil Short-to-Ground ...................................... 12-20
Testing Dynamo Regulated Output ....................................... 12-20

ALTERNATOR
Dynamo........................................................................................ 12-20
Removal of Dynamo............................................................... 12-20
Disassembly of Dynamo......................................................... 12-21
Reassembly of Dynamo ......................................................... 12-21
Installation of Dynamo............................................................ 12-22

ALTERNATOR
BEFORE YOU BEGIN

A WARNING
SERVICING
A WARNING
SHOCK HAZARD!
ENTANGLEMENT HAZARD! equipped) or disconnect the negative
electrical system.
service it.
cracks, abrasions, and damaged or
0000009en
or serious injury.
0000010en
BURN HAZARD!
block during operation and shortly
seriously burn you.
or serious injury.
0000015en

ALTERNATOR
A WARNING A CAUTION
FUME / BURN HAZARD!

PINCH HAZARD!
precautions found on containers of Carefully rotate the alternator toward the
hazardous substances like parts cylinder block while loosening the
cleaners, primers, sealants and V-belt. Failure to comply may result in
sealant removers. minor or moderate injury.
0000014en
or serious injury.
0000014en
CAUTION
A CAUTION
NEVER permit anyone to operate the

engine or driven machine without proper
training.
FLYING OBJECT HAZARD! Read and understand this Operation

Manual before you operate or service
ALWAYS wear eye protection when the machine to ensure that you follow
servicing the engine and when using safe operating practices and
compressed air or high-pressure maintenance procedures.
air, pressurized water or steam may Machine safety signs and labels are
injure your eyes. additional reminders for safe operating
and maintenance techniques.
or moderate injury. See your authorized Yanmar industrial
engine dealer or distributor for
0000003en
additional training.
0000002en
CAUTION
Do not short-circuit the charging system
between alternator terminals IG and L.
Damage to the alternator will result.
0000035en

ALTERNATOR
CAUTION CAUTION
Do not connect a load between Using a non-specified V-belt will cause
alternator terminals L and E. Damage to inadequate charging and shorten the
the alternator will result. belt life. Use the specified belt.
0000036en 0000052en
CAUTION CAUTION
Do not remove the positive (+) battery Agricultural or other chemicals,
cable from alternator terminal B while especially those with a high sulfur
the engine is operating. Damage to the content, can adhere to the IC regulator.
alternator will result. This will corrode the conductor and
0000037en result in battery over-charging (boiling)
and charging malfunctions. Consult
Yanmar before using the equipment in
CAUTION such an environment or the warranty is
Do not turn the battery switch OFF while voided.
the engine is operating. Damage to the 0000053en
alternator will result.
0000038en
CAUTION
Do not use a high-pressure wash
CAUTION directly on the alternator. Water will
Do not operate the engine if the damage the alternator and result in
alternator is producing unusual sounds. inadequate charging.
Damage to the alternator will result. 0000049en
0000039en
CAUTION
Do not reverse the positive (+) and
negative (-) ends of the battery cable.
The alternator diode and stator coil will
be damaged.
0000050en
CAUTION
When the battery indicator goes out, it
should not come on again. The battery
indicator only comes on during
operation if the alternator fails or if the
V-belt breaks. However, if an LED is
used in the battery indicator, the LED
will shine faintly during normal
operation.
0000051en

ALTERNATOR
INTRODUCTION
This section of the Service Manual describes the servicing of the dynamos and alternators. Yanmar Part
No. 129423-77200 alternator is used in this section to show the service procedures for the representative
alternator. Yanmar Part No. 171301-77201 dynamo is used in this section to show the service procedures
for the representative dynamo. For specific part detail, see the Parts Catalog for the engine you are working
on.
DYNAMO AND ALTERNATOR INFORMATION

3TNV82A to 4TNV106T - Standard and Optional Dynamos
YANMAR Part Number Mfg. Mfg. Part Number Specification
171301-77201 Kokusan GP8138 DC12V-15A
119910-77200 Kokusan GP9191 DC12V-20A
3TNV82A to 4TNV106T - Standard and Optional Alternators

YANMAR Part Number Mfg. Mfg. Part Number Specification
119620-77201 Denso 100211-4531 DC12V-40A
129423-77200 Denso 101211-1170 DC12V-40A with Pulse
129961-77200 Denso 101211-2591 DC12V-55A
119626-77210 Denso 101211-2951 DC12V-55A with Pulse
129612-77290 Hitachi LR180-772 DC12V-80A with Pulse
129900-77240 Hitachi LR235-705 DC24V-35A with Pulse

ALTERNATOR
ALTERNATOR SPECIFICATIONS
Nominal Output (13.5 Volts Heat) 40 Amps
Weight 6.17 lb (2.8 kg)
Revolution Direction (As Viewed From Pulley) Clockwise
Rating Continuous
Battery Voltage 12 Volts
Rated Revolution 5000 rpm (min-1)
Operating Range 1350 - 18000 rpm (min-1)
Grounding Characteristics Negative (-) Side of Circuit
Integrated Regulator IC Regulator
Outside Diameter of Pulley 2.724 in. (69.2 mm)
Belt Shape Type A
DYNAMO SPECIFICATIONS
Nominal Output 20 Amps
Weight 3.97 lb (1.8 kg)
Revolution Direction (As Viewed From Pulley) Clockwise
Rating Continuous
Battery Voltage 12 Volts
Rated Revolution 3500 rpm
Operating Range 1400 - 6600 rpm
Grounding Characteristics Negative (-) Side of Circuit
Integrated Regulator IC Regulator
A-Belt 2.56 in. (65 mm)
Outside Diameter of Pulley
Special M-Belt 2.28 in. (58 mm)
Belt Shape Type A or Type Special M

12-8
Turn key switch ON. OFF Disconnect harness L terminal Ground drive machine side OFF Replace the battery indicator.
Does battery indicator and IG terminal at alternator L terminal. Does battery Battery indicator is available from
ALTERNATOR
turn ON? indicator turn on? driven machine manufacturer.
ON ON Inspect rotor assembly and

brushes.
Start Engine.
Inspect or replace V-belt.

Battery indicator ON. Inspect alternator.
At idle, does battery Battery indicator flashes. Inspect diode positive (+) side.
indicator turn OFF?
Battery indicator
OFF is dim.
Increase engine speed to
1500 rpm. Turn light switch ON.
ALTERNATOR TROUBLESHOOTING
Battery voltage minus

L terminal voltage is Excessive voltage drop between
greater than 0.5 volt. BAT and batt ( + side) terminal.
Does battery indicator Battery indicator With engine idling,
come ON? is dim. measure voltage at L
terminal and at battery.
Battery voltage minus Check condition of L terminal.
L terminal voltage is Inspect diode negative (-) side.
OFF less than 0.5 volt.
With engine running at 1500
rpm, measure voltage at Battery voltage greater
than 15.5 volts. Replace regulator.
battery.
Battery voltage
is between 13 With engine idling, Does battery indicator ON Inspect auxiliary diode.
and 15 volts. turn light switch ON. come ON?
OFF

Notes: Not abnormal.
1) Use a fully charged battery
2) DC voltmeter: 0 to 30 V, 0.5 class
3) The check method is also applicable to the bench test
ALTERNATOR
ALTERNATOR COMPONENTS
Yanmar Part No. 129423-77200 alternator is used in this section to show the service procedures for the
representative alternator. For specific part detail, see the Parts Catalog for the engine you are working on.
14
12 13
10 11
8 9
6
5
29
4
3 7 19
2
16 18
1 17
25
15 28
27
26
24
23
22 0000255
21
20
1 Nut 17 Insulation Bushing
2 Pulley 18 Spring (2 used)
3 Collar 19 Brush Holder
4 Front Frame Housing 20 Rear Frame Housing
5 Stator Assembly 21 Bolt (2 used)
6 Stud (2 used) 22 Holder
7 Front Frame Housing Bearing 23 IC Regulator Assembly
8 Bearing Cover 24 Bolt (2 used)
9 Bearing Cover Bolt (4 used) 25 Bolt
10 Rotor Assembly 26 Brush (2 used)
11 Rear Frame Housing Bearing 27 Bolt
12 Bearing Cover 28 Rear Cover
13 Thrust Washer 29 Bolt (3 used)
14 Thrust Washer
15 Nut (2 used)
16 Nut
Figure 12-1

ALTERNATOR
ALTERNATOR WIRING DIAGRAM
IG 1
IG P
B
PI P L
2
F
IC
L
3 3
0.5F
B
4A
E T
5 6
1 Key Switch 4 Battery

2 Charge Lamp (3.4 Watts Max.) 5 Alternator Assembly
3 Load 6 IC Regulator Assembly
Figure 12-2
CAUTION CAUTION
Do not short-circuit the charging system Do not remove the positive (+) battery
between alternator terminals IG and L. cable from alternator terminal B while
Damage to the alternator will result. the engine is operating. Damage to the
0000035en alternator will result.
0000037en
CAUTION
Do not connect a load between
alternator terminals L and E. Damage to
the alternator will result.
0000036en

ALTERNATOR
ALTERNATOR STANDARD OUTPUT
Output Current
60
Cold
50
13.5 Volts, Constant Ambient

Temperature at 77F (25C)
Hot
40
30
20
10
0 1 2 3 4 5 6 7 8
Alternator RPM (x10 min)
Figure 12-3

ALTERNATOR
ALTERNATOR 4. Remove the nut (Figure 12-4, (2)) from the

gear case stud. Remove the alternator.
A WARNING
SHOCK HAZARD!
2 1
0000264
equipped) or disconnect the negative
battery cable before servicing the Figure 12-4
electrical system.
Disassembly of Alternator
cracks, abrasions, and damaged or 1. Remove the nut (Figure 12-5, (1)) from the
corroded connectors. ALWAYS keep shaft of the rotor assembly. Remove the pulley
the connectors and terminals clean. (Figure 12-5, (2)).
or serious injury.
0000009en
Removal of Alternator
1. Disconnect the electrical wires from the
alternator.
2. Loosen the V-belt.
A CAUTION
2
1 0000256
PINCH HAZARD! Figure 12-5

Carefully rotate the alternator toward the
cylinder block while loosening the
0000014en
3. Remove the V-belt adjuster from the alternator

bolt (Figure 12-4, (1)).

ALTERNATOR
2. Remove the three bolts (Figure 12-6, (1)) 5. Remove the bolts retaining the holder
retaining the rear cover (Figure 12-6, (2)) to the (Figure 12-7, (2)) to the rear frame housing.
rear frame assembly. Remove the holder.
6. Remove the nut (Figure 12-7, (3)) retaining the
insulation bushing (Figure 12-7, (4)). Remove
the insulation bushing.
7. Remove the two bolts (Figure 12-8, (1)) and
3 1 two nuts (Figure 12-8, (2)) securing the rear
frame housing to the front frame housing.
4 2
5
1
0000257A
Figure 12-6
3. Remove the brush holder (Figure 12-6, (3)).
0000265A
Remove the brush springs (Figure 12-6, (4))
and brushes (Figure 12-6, (5)). Figure 12-8
4. Remove the bolt retaining the regulator 8. Using a press, remove the rotor assembly
assembly (Figure 12-7, (1)) to the holder (Figure 12-9, (1)) from the front frame housing
(Figure 12-7, (2)). (Figure 12-9, (2)) and rear frame housing
(Figure 12-9, (1)).
3 3
1
4
1
2
100266A
Figure 12-9
0000258A
Figure 12-7

ALTERNATOR
9. Remove the stator assembly
(Figure 12-10, (1)) from the front frame
housing.
4
3
2
3 1
0000260A
1 Figure 12-11
Reassembly of Alternator
0000259A
1. If removed, reinstall the two trust washers
(Figure 12-12, (3)) and bearing cover
Figure 12-10 (Figure 12-12, (2)) in the rear frame housing.
Lubricate the outside diameter of a new bearing
10. If it is necessary to replace the bearing (Figure 12-12, (1)). Press the bearing into the
(Figure 12-10, (2)) in the front frame housing, rear frame housing.
remove the four bolts (Figure 12-10, (3))
securing the plate (Figure 12-10, (4)) to the
front frame housing. Remove the plate. Use a
puller to remove the bearing. Discard the
bearing.
11. If it is necessary to replace the bearing
(Figure 12-11, (1)) in the rear frame housing, 3
use a puller to remove. Discard the bearing. 2
Remove the bearing cover (Figure 12-11, (2)) 1
and two thrust washers (Figure 12-11, (3)).
0000260A
Figure 12-12

ALTERNATOR
2. If removed, lubricate the outside diameter of a 5. Align the front frame housing with the rear
new front frame housing bearing. Press the frame housing. Reinstall the two bolts
bearing (Figure 12-13, (2)) into the front frame (Figure 12-15, (1)) and two nuts
housing. Reinstall the plate (Figure 12-13, (4)) (Figure 12-15, (2)).
to the front housing. Tighten the four bolts
(Figure 12-13, (3)). 2
1
3
0000265A
1 Figure 12-15
6. Reinstall the insulation bushing
0000259A (Figure 12-16, (4)) and nut (Figure 12-16, (3)).
Figure 12-13
3. Position the stator assembly (Figure 12-13, (1)) 3
on the front frame housing studs. 1
4
4. Lubricate the shaft of the rotor assembly
(Figure 12-14, (1)). Press the rotor assembly
into the front frame housing (Figure 12-14, (2))
and rear frame housing (Figure 12-14, (3)).
1
2
2
0000258A
Figure 12-16
7. Reassemble the regulator assembly
(Figure 12-16, (1)) to the holder
100266A
(Figure 12-16, (2)).
Figure 12-14

ALTERNATOR
8. Reinstall the brush holder (Figure 12-17, (3)), Installation of Alternator
springs (Figure 12-17, (4)) and brushes
(Figure 12-17, (5)). 1. Position the alternator on the gear case.
Loosely reinstall the nut (Figure 12-19, (2)) on
9. Reattach the regulator assembly and holder to the gear case stud and the V-belt adjuster bolt
the rear frame housing. (Figure 12-19, (1)).
3 1
2 1
0000264
Figure 12-19
4 2
5 2. Reconnect the electrical wires to the alternator.
Tighten the nuts to 15 - 20 in.-lb (1.7 - 2.3 Nm;
17-23 kgfm).
3. Reinstall the V-belt. Tighten the V-belt to the
0000257A
Figure 12-17 Adjust Cooling Fan V-Belt on page 5-28.
4. Start the engine. Listen for any unusual sounds
10. Reinstall the rear cover (Figure 12-17, (2)) to from the alternator.
the rear frame housing with three bolts
(Figure 12-17, (1)). CAUTION
11. Reassemble the pulley (Figure 12-18, (2)) and Do not operate the engine if the
nut (Figure 12-18, (1)) to the shaft of the rotor alternator is producing unusual sounds.
assembly. Tighten the nut. Damage to the alternator will result.
0000039en
5. Verify that the charge indicator is ON while the

engine is operating. If the charge indicator is
not ON, repair the problem before operating the
engine.
2
1 0000256
Figure 12-18

ALTERNATOR
DYNAMO COMPONENT LOCATION

Yanmar Part No. 171301-77201 dynamo is used in this section to show the service procedures for the
representative dynamo. For specific part detail, see the Parts Catalog for the engine you are working on.
(1)
(2)
(3)
(4)
(7)
(5)
(8) (9)
(6) (10)
(11) (12)
(13)
(14)
0002140
1 Rear Cover 8 Spacer

2 Nut 9 Stator Assembly
3 Lock Washer 10 Front Bearing (2 used)
4 Flat Washer 11 Flat Washer
5 Rear Bearing 12 Flywheel Assembly
6 Output Wire and Connector 13 Pulley Half
7 Plate 14 Through Bolt
Figure 12-20

ALTERNATOR
DYNAMO WIRING DIAGRAM
(3)
(5) (6)
(2) (4)
(1)
0002137
1 Dynamo
2 IC Regulator Assembly
3 Key Switch
4 Charge Lamp (3.4 Watts Max.)
5 Battery
6 Load
Figure 12-21
OPERATION OF DYNAMO
The dynamo consists of a series of permanent
magnets that rotate around a stationary stator coil.
The magnets are attached to the flywheel which is
rotated via the engine cooling fan drive belt. The
resultant output is an AC (alternating current)
signal. The AC is converted to DC (direct current) in
the IC Regulator. The IC Regulator outputs
charging DC current to the battery.

ALTERNATOR
DYNAMO STANDARD OUTPUT
0002138
Figure 12-22

ALTERNATOR
TESTING OF DYNAMO DYNAMO

Use a circuit tester or multimeter to perform the
following tests.
Removal of Dynamo
1. Disconnect the output wire connector from the
Testing Stator Coil Continuity dynamo.
1. Disconnect the dynamo output wire connector. 2. Loosen the V-belt.
2. Connect one meter lead to each of the stator
wire terminals and read the meter. A CAUTION
Results: The meter reading should indicate
continuity. If continuity is not indicated, the windings
are open and the stator must be replaced.
Testing Stator Coil Short-to-Ground

1. Disconnect the dynamo output wire connector. PINCH HAZARD!
2. Test continuity between each stator wire Carefully rotate the alternator toward the
terminal and engine ground. cylinder block while loosening the
Results: The meter reading should infinity. If the V-belt. Failure to comply may result in
meter reading indicates continuity, the windings are minor or moderate injury.
shorted to ground and the stator must be replaced. 0000014en
Testing Dynamo Regulated Output 3. Remove the V-belt adjuster from the dynamo
bolt (Figure 12-23, (1)).
1. Test and record the battery voltage with the
engine not running. 4. Remove the nut (Figure 12-23, (2)) from the
gear case stud. Remove the dynamo.
2. Start the engine and operate it at normal
operating rpm.
3. Again, check the battery voltage with the engine
running.
Results: The meter reading with the engine
running must be higher than with the engine not
running.
If results are not correct, test the stator for
(1) 0002141
continuity and shorts to the ground. (2)
Check the charging system wiring. Figure 12-23
If no problems are found in previous checks,
replace the IC regulator.

ALTERNATOR
Disassembly of Dynamo 4. Remove the screws (Figure 12-26, (1)) and the
stator assembly (Figure 12-26, (2)).
1. Remove the rear cover (Figure 12-24, (1)).
5. Remove the rear bearing (Figure 12-26, (3)).
2. Remove the nut (Figure 12-24, (2)), lock
washer (Figure 12-24, (3)), and flat washer
(3)
(Figure 12-24, (4)).
(1)
(2)
(3)
(4)
(2)
(1)
0002145
Figure 12-26
0002143
Figure 12-24 Reassembly of Dynamo

1. Reinstall the rear bearing (Figure 12-27, (3)).
3. Remove the through bolt (Figure 12-25, (1)),
pulley half (Figure 12-25, (2)), flywheel 2. Reinstall the stator (Figure 12-27, (2)) and
(Figure 12-25, (3)), flat washer screws.
(Figure 12-25, (4)), bearings
(Figure 12-25, (5)), and spacer (3)
(Figure 12-25, (6)).
(6) (2)
(5)
(4) (1)
(3)
(2)
(1)
0002145
Figure 12-27
0002144
Figure 12-25

ALTERNATOR
3. Reinstall the front bearings (Figure 12-28, (5)) Installation of Dynamo
and spacer (Figure 12-28, (6)).
1. Position the dynamo on the gear case. Loosely
4. Reinstall the flat washer (Figure 12-28, (4)), reinstall the nut (Figure 12-30, (2)) on the gear
flywheel (Figure 12-28, (3)), pulley half case stud and the V-belt adjuster bolt
(Figure 12-28, (2), and through bolt (Figure 12-30, (1)).
(Figure 12-28, (1)).
(6)
(5)
(4)
(3)
(2) (1) 0002141
(2)
(1)
Figure 12-30
2. Reconnect the dynamo output wire connector.
0002144 3. Reinstall the V-belt. Tighten the V-belt to the
Figure 12-28
Adjust Cooling Fan V-Belt on page 5-28.
5. Reinstall the flat washer (Figure 12-29, (4)), 4. Start the engine. Listen for any unusual sounds
lock washer (Figure 12-29, (3)), and nut from the alternator.
(Figure 12-29, (2)). Tighten the nut to the
specified torque. CAUTION
6. Reinstall the rear cap (Figure 12-29, (1)). Do not operate the engine if the
alternator is producing unusual sounds.
(1) Damage to the alternator will result.
(2)
(3) 0000039en
(4)
5. Verify that the charge indicator is ON while the
engine is operating. If the charge indicator is
not ON, repair the problem before operating the
engine.
0002143
Figure 12-29

Section 13
ELECTRIC WIRING
Page
Electric Wiring Precautions .......................................................... 13-3
Electrical Wire Resistance ............................................................ 13-4
Battery Cable Resistance.............................................................. 13-5
Electrical Wire Sizes - Voltage Drop ............................................. 13-6
Conversion of AWG to European Standards................................. 13-7

ELECTRIC WIRING

ELECTRIC WIRING
ELECTRIC WIRING CAUTION

PRECAUTIONS Removing the battery cables or the
Failure to follow these precautions may result in the battery while the engine is operating
failure of an electrical component and the loss of may cause damage to the current limiter
warranty coverage on that item as well as related depending on the electrical equipment
items. Make sure that all users read and being used. This situation could cause
understand these precautions. loss of control of output voltage. The
continuous high voltage of 23-24 volts
(for 5000 rpm dynamo) will damage the
CAUTION current limiter and other electrical
Do not reverse the positive (+) and equipment.
negative (-) ends of the battery cable. 0000058en
The alternator diode and stator coil will
be damaged.
0000050en
CAUTION
Reversing the battery cable connections
at the battery or on the engine will
CAUTION destroy the SCR diode in the current
When the battery indicator goes out, it limiter. This will cause the charging
should not come on again. The battery system to malfunction and may cause
indicator only comes on during damage to the electrical harnesses.
operation if the alternator fails or if the 0000059en
V-belt breaks. However, if an LED is
used in the battery indicator, the LED
will shine faintly during normal
operation.
0000051en
CAUTION
Make sure that the combined total
resistance of the battery cable in both
directions between the starter motor
indicated in the Battery Cable
Resistance chart in the Electric Wiring
Section of this manual. The starter
motor will malfunction and fail if the
resistance is higher than the specified
value.
0000057en

ELECTRIC WIRING
ELECTRICAL WIRE RESISTANCE

Metric Ohms / Foot
AWG
Nominal mm Resistance
20 0.5 0.009967
18 0.8 0.006340
16 1.25 0.004359
14 2 0.002685
12 3 0.001704
10 5 0.001073
8 8 0.000707
6 15 0.000421
4 20 0.000270
2 30 0.000158
1 40 0.000130
0 (1/0) 50 0.000103
00 (2/0) 60 0.000087
000 (3/0) 85 0.000066
0000 (4/0) 100 0.000051
Wiring voltage drop should not exceed 5% [0.05] x 12 Volts = 0.6 Volts.
Voltage Drop = Current [Amps] x Length of Wire [Feet] x Resistance per Foot
Example:
Current draw of 100 Amps x 3 feet of 4 AWG wire
100 Amps x 3 Feet x 0.000270 = 0.08 Volts [Voltage Drop]

ELECTRIC WIRING
BATTERY CABLE RESISTANCE

Maximum Total Battery Cable Length
(Positive Cable + Negative Cable + a*)
AWG mm 12V Starter Motor Output
Less Than 2.68 HP (2 kW) Greater Than 2.68 HP (2 kW)
m ft m ft
6 15 1.5 4.75 N/A N/A
4 20 2.3 7.4 N/A N/A
2 30 3.8 12.6 2.3 7.5
1 40 4.6 15.3 2.8 9.2
0 (1/0) 50 5.9 19.5 3.5 11.6
00 (2/0) 60 7.0 22.8 4.2 13.7
000(3/0) 85 9.3 30.5 5.6 18.3
0000 (4/0) 100 11.9 39.0 7.1 23.4
00000 (5/0) 125 N/A N/A 8.3 27.3
000000 (6/0) 150 N/A N/A 10.1 33.3
Note: Total allowable resistance of the complete battery cable circuit (positive cable + negative cable + a*)
(a*: Resistance () of a battery switch or other electrical equipment having high resistance).
Note: For starter motors of less than 2.68 HP (2 kW): the total resistance must be less than 0.002 . For
starter motors of greater than 2.68 HP (2 kW): the total resistance must be less than 0.0012 .

ELECTRIC WIRING
ELECTRICAL WIRE SIZES - VOLTAGE DROP

Total Length of conductor from source of current to device and back to source (in feet)
current on
circuit in 10 15 20 25 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170
amps
12 Volts Wire Size (AWG)
5 18 16 14 12 12 10 10 10 8 8 8 6 6 6 6 6 6 6 6
10 14 12 10 10 10 8 6 6 6 6 4 4 4 4 2 2 2 2 2
15 12 10 10 8 8 6 6 6 4 4 2 2 2 2 2 1 1 1 1
20 10 10 8 6 6 6 4 4 2 2 2 2 1 1 1 0 0 0 2/0
25 10 8 6 6 6 4 4 2 2 2 1 1 0 0 0 2/0 2/0 2/0 3/0
30 10 8 6 6 4 4 2 2 1 1 0 0 0 2/0 2/0 3/0 3/0 3/0 3/0
40 8 6 6 4 4 2 2 1 0 0 2/0 2/0 3/0 3/0 3/0 4/0 4/0 4/0 4/0
50 6 6 4 4 2 2 1 0 2/0 2/0 3/0 3/0 4/0 4/0 4/0
60 6 4 4 2 2 1 0 2/0 3/0 3/0 4/0 4/0 4/0
70 6 4 2 2 1 0 2/0 3/0 3/0 4/0 4/0
80 6 4 2 2 1 0 3/0 3/0 4/0 4/0
90 4 2 2 1 0 2/0 3/0 4/0 4/0
100 4 2 2 1 0 2/0 3/0 4/0
24 Volts
5 18 18 18 16 16 14 12 12 12 10 10 10 10 10 8 8 8 8 8
10 18 16 14 12 12 10 10 10 8 8 8 6 6 6 6 6 6 6 6
15 16 14 12 12 10 10 8 8 6 6 6 6 6 4 4 4 4 4 2
20 14 12 10 10 10 8 6 6 6 6 4 4 4 4 2 2 2 2 2
25 12 12 10 10 8 6 6 6 4 4 4 4 2 2 2 2 2 2 1
30 12 10 10 8 8 6 6 4 4 4 2 2 2 2 2 1 1 1 1
40 10 10 8 6 6 6 4 4 2 2 2 2 1 1 1 0 0 0 2/0
50 10 8 6 6 6 4 4 2 2 2 1 1 0 0 0 2/0 2/0 2/0 3/0
60 10 8 6 6 4 4 2 2 1 1 0 0 0 2/0 2/0 3/0 3/0 3/0 3/0
70 8 6 6 4 4 2 2 1 1 0 0 2/0 2/0 3/0 3/0 3/0 3/0 4/0 4/0
80 8 6 6 4 4 2 2 1 0 0 2/0 2/0 3/0 3/0 3/0 4/0 4/0 4/0 4/0
90 8 6 4 4 2 2 1 0 0 2/0 2/0 3/0 3/0 4/0 4/0 4/0 4/0 4/0
100 6 6 4 4 2 2 1 0 2/0 2/0 3/0 3/0 4/0 4/0 4/0

ELECTRIC WIRING
CONVERSION OF AWG TO EUROPEAN STANDARDS

Conductor Size Conductor Diameter Conductor Cross-sectional Area
(AWG) (mm) (mm2)
25 0.455 0.163
24 0.511 0.205
23 0.573 0.259
22 0.644 0.325
21 0.723 0.412
20 0.812 0.519
19 0.992 0.653
18 1.024 0.823
17 1.15 1.04
16 1.29 1.31
15 1.45 1.65
14 1.63 2.08
13 1.83 2.63
12 2.05 3.31
11 2.30 4.15
10 2.59 5.27
9 2.91 6.62
8 3.26 8.35
7 3.67 10.6
6 4.11 13.3
5 4.62 16.8
4 5.19 21.2
3 5.83 26.7
2 6.54 33.6
1 7.35 42.4
0 (1/0) 8.25 53.4
00 (2/0) 9.27 67.5
000(3/0) 10.40 85.0
0000 (4/0) 11.68 107.2
00000 (5/0) 13.12 135.1
000000 (6/0) 14.73 170.3
2
1.1 circular mil (CM) @ 0.0005067 mm

ELECTRIC WIRING

Section 14
TROUBLESHOOTING
Page
Special Service Tools.................................................................... 14-3
Troubleshooting By Measuring Compression Pressure ................ 14-4
Compression Pressure Measurement Method ........................ 14-4
Quick Reference Table For Troubleshooting ................................ 14-6
Troubleshooting Charts .................................................................. 14-7
Wiring Diagram............................................................................ 14-19

TROUBLESHOOTING

TROUBLESHOOTING
For measuring compression pressure

Yanmar Gauge Set Part No. TOL-97190080
0000849
Adapter for direct injection 2-valve cylinder head

Yanmar Adapter Part No. 119802-92950
130
Compression Gauge Kit
0000850
Adapter for direct injection 4-valve cylinder head for

4TNV94L/98/98T
165
0000851
Adapter for direct injection 4-valve cylinder head for

4TNV106(T)
179
0000852

TROUBLESHOOTING
TROUBLESHOOTING BY 3. Turn off the fuel supply valve in the fuel supply
line. Disconnect the fuel injection pump stop
MEASURING COMPRESSION solenoid at the connector. This prevents the fuel
PRESSURE injection pump from injecting fuel during
compression testing.
Compression pressure drop is one of the major
causes of increasing blow-by gas (engine oil 4. Before installing the compression gauge
contamination or increased engine oil consumption (Figure 14-1, (1)) adapter, crank the engine
as a resultant phenomenon) or starting failure. The with the stop solenoid disconnected for a few
compression pressure is affected by the following seconds to clear the cylinder of any residual
factors: fuel.
5. Install a nozzle seat at the tip end of the
1. Degree of clearance between the piston and compression gauge adapter. Install the
cylinder compression gauge and the compression
2. Degree of clearance at the intake / exhaust gauge adapter at the cylinder to be measured.
valve seat 6. Crank the engine until the compression gauge
3. Gas leak from the nozzle gasket or cylinder reading is stabilized.
head gasket
The pressure will drop due to increased parts wear.
Pressure drop reduces the durability of the engine.
A pressure drop may also be caused by a
scratched cylinder or piston, dust entrance from the
1
dirty air cleaner element or a worn or broken piston
ring. Measure the compression pressure to
determine the condition of the engine.
Compression Pressure Measurement

Method
1. Warm up the engine.
Figure 14-1
2. Stop the engine. Remove the high-pressure fuel
injection lines as an assembly from the engine. 7. After performing the compression check
Remove the fuel injector from the cylinder to be remove the compression gauge and
measured. See Removal of Fuel Injectors on compression gauge adapter from the cylinder.
page 7-31. Reinstall the fuel injector, high-pressure fuel
injection lines, and reconnect the stop solenoid.
CAUTION See Reassembly of Fuel Injectors on
page 7-37.
injection lines as an assembly whenever 8. Turn on the fuel supply valve and reconnect the
possible. Disassembling the injection pump stop solenoid.
high-pressure fuel injection lines from 9. Prime the fuel system. Check for leaks. Test the
the retainers or bending any of the fuel engine.
fuel lines.
0000047en

TROUBLESHOOTING
Standard Compression Pressure (Reference Value)
Compression Pressure
Engine Model at 250 rpm (250 min-1) Deviation Between Cylinders
Standard Limit
443 - 473 psi 340 - 370 psi
3TNV82A
(3.06 - 3.26 MPa; 30 - 32 kgf/cm) (2.35 - 2.55 MPa; 24 - 26 kgf/cm)
3TNV84 455 - 485 psi 355 - 385 psi
4TNV84 (3.14 - 3.34 MPa; 32 - 34 kgf/cm) (2.45 - 2.65 MPa; 25 - 27 kgf/cm)
3TNV84T 411 - 441 psi 340 - 370 psi
4TNV84T (2.84 3.04 MPa; 29 - 31 kgf/cm) (2.35 - 2.55 MPa; 24 - 26 kgf/cm) 29 - 43 psi
3TNV88 (0.2 - 0.3 MPa; 2 - 3 kgf/cm)
4TNV88
4TNV94L
483 - 513 psi 384 - 414 psi
4TNV98
(3.33 - 3.53 MPa; 34 - 36 kgf/cm) (2.65 - 2.85 MPa; 27 - 29 kgf/cm)
4TNV98T
4TNV106
4TNV106T
Engine Speed and Compression Pressure (Use for Reference)
3TNV88
4TNV88
4TNV94L
4TNV98
569 psi 4TNV98T
(4 MPa)
(40 KgF/cm2) 3TNV84
4TNV106
4TNV106T
498 psi 4TNV84
(35 KgF/cm2)
427 psi
(30 KgF/cm2) (3 MPa)
356 psi
(25 KgF/cm2) 3TNV82A
3TNV84T
284 psi
4TNV84T (2 MPa)
(20 KgF/cm2)
200 250 300 350 400

Engine speed (min-1)
Figure 14-2

TROUBLESHOOTING
Measured Value and Troubleshooting
When the measured compression pressure is below the limit value, inspect each part by referring to the
table below.
No. Item Cause Corrective Action

Clogged element Clean the element.
1 Air Cleaner Element Broken element
Replace the element.
Defect at element seal portion
2 Valve Clearance Excessive or no clearance Adjust the valve clearance.
3 Valve Timing Incorrect valve clearance Adjust the valve clearance.
Replace the gasket.
4 Cylinder Head Gasket Gas leak from gasket Retighten the cylinder head bolts to the specified
torque.
Intake / Exhaust Valve Sticking valve Replace the intake / exhaust valve.
5 Gas leak due to worn valve seat

Valve Seat or foreign matter trapped in Lap the valve seat.
valve
Piston
Gas leak due to scratching or
6 Piston Ring Perform honing and use an oversized part.
wear
Cylinder
QUICK REFERENCE TABLE

FOR TROUBLESHOOTING
The following table summarizes the general trouble
symptoms and their causes. If any trouble symptom
occurs, take corrective action before it becomes a
serious problem so as not to shorten the engine
service life.

Troubleshooting Charts TNV DI Service Manual TROUBLESHOOTING
Troubleshooting Charts
Poor
High Knocking Sound During Combustion

Insufficient Engine Engine Air
Trouble Symptom Starting Problem Exhaust Engine Oil
Engine Output Surging Coolant Intake
Color
Difficulty in Returning to Low Speed

Engine Starts
During
But Stops Exhaust Color
Work
Soon.
Excessive Fuel Consumption
Excessive Oil Consumption

Uneven Combustion Sound
Excessive Engine Vibration
Exhaust Temperature Rise

Exhaust
Abnormal Engine Sound
Low Water Temperature

Smoke
Excessive Blow-by Gas

During Work Operation
Engine Does Not Start.
Dilution by Diesel Fuel

Corrective Action Reference Page
Low Oil Pressure
Pressure Drop
Pressure Rise
Oil with Water
During Idling
Cause
Overheat
Ordinary
White
White
Black
Black
Much
None
Little
See Measuring and Adjusting Valve
Improper Intake / Exhaust Valve Clearance O O O O O O Adjust the Valve Clearance.
Clearance on page 6-62.
See Valve Face and Valve Seat on
page 6-40 for 2 valve head or Valve
Compression Leakage from Valve Seat O O O O O O O O Lap the Valve Seat.
Face and Valve Seat on page 6-40 for 4
valve head.
Correct or Replace Intake / See Removal of Intake / Exhaust
Engine System
Intake / Exhaust Valve Seizure O O O O O O O O O O O

Exhaust Valve. Valves on page 6-36.
See Removal of Cylinder Head on
Cylinder Head Gasket Blowout O O O Replace the Gasket.
page 6-50.
See Reassembly of Pistons on
Seized or Broken Piston Ring O O O O O O O O O O O O Replace the Piston Ring.
page 6-85.
Perform Honing and Use Oversize
Worn Piston Ring, Piston or Cylinder O O O O O O O See Honing and Boring on page 6-84.
Parts.
See Inspection of Crankshaft on
Seized Crankpin Metal or Bearing O O O O O O O Repair or Replace.
page 6-82.
Improper Arrangement of Piston Ring Joints O O O O Correct the Ring Joint Positions.
page 6-85.

TROUBLESHOOTING Troubleshooting Charts

Troubleshooting Charts TROUBLESHOOTING
Poor

Color

Engine Starts
During
Work
Soon.


Exhaust

Smoke


Low Oil Pressure
Pressure Drop
Pressure Rise
Oil with Water
During Idling
Cause
Overheat
Ordinary
White
White
Black
Black
Much
None
Little
Reverse Assembly of Piston Rings O O O O Reassemble Correctly.
page 6-85.
See Inspection of Crankshaft on
Worn Crankpin and Journal Bearing O O O O O O Measure and Replace.
page 6-82.
Engine System - Continued
See Torque for Bolts and Nuts on

Loose Connecting Rod Bolt O O O Tighten to the Specified Torque.
page 6-23.
Foreign Matter Trapped in Combustion See Disassembly of Engine on
O O O O Disassemble and Repair.
Chamber page 6-68.
See Checking Timing Gear Backlash
Excessive Gear Backlash O Adjust Gear Meshing.
on page 6-69.
See Inspection of Valve Guides on
Worn Intake / Exhaust Valve Guide O O O Measure and Replace.
page 6-39.
See Check and Adjust the Governor
Governor Adjusted Incorrectly O O O O O Make Adjustment. Lever and Engine Speed Control on
page 5-28.
Improper Open / Close Timing of Intake / See Measuring and Adjusting Valve
O O O O O O Adjust the Valve Clearance.
Exhaust Valves Clearance on page 6-62.


Poor

Color

Engine Starts
During
Work
Soon.


Exhaust

Smoke


Low Oil Pressure
Pressure Drop
Pressure Rise
Oil with Water
During Idling
Cause
Overheat
Ordinary
White
White
Black
Black
Much
None
Little
See Washing Procedure on
Fouled Blower O O Wash the Blower.
Turbocharger
page 10-12.
See Waste Gate Valve Test on
Waste Gate Malfunction O O Disassemble and Inspect.
page 10-14.
Worn Radial Bearing O O Disassemble and Inspect. See Radial Bearing on page 10-11.
See Disassembly of Engine Coolant

Excessive Radiator Cooling O O O Replace Thermostat.
Pump on page 8-10.
Engine Coolant System
Replace Thermostat or Check for Pump on page 8-10 or Check and

Insufficient Radiator Cooling O O O
Loose Fan Belt. Adjust Cooling Fan V-Belt on
page 5-21.
Check Water Leakage from Engine See Engine Coolant System Check on
Insufficient Engine Coolant Level O O O
Coolant System. page 8-8.
Cracked Water Jacket O O O Repair or Replace.
Pump on page 8-10.
See Check and Adjust Cooling Fan V-
Stretched Fan Belt O O O Adjust the Belt Tension.
Belt on page 5-21.
Defective Thermostat O O O O Check or Replace.
Pump on page 8-10.


Poor

Color

Engine Starts
During
Work
Soon.


Exhaust

Smoke


Low Oil Pressure
Pressure Drop
Pressure Rise
Oil with Water
During Idling
Cause
Overheat
Ordinary
White
White
Black
Black
Much
None
Little
See Engine Oil Specifications on
Incorrect Engine Oil O O O O O O Use Correct Engine Oil.
page 4-13.
See Disassembly of Oil Pump on
Engine Oil System Leakage O O Repair.
page 9-10.
Engine Oil System
Insufficient Delivery Capacity of Trochoid See Disassembly of Oil Pump on

O Check and Repair.
Pump page 9-10.
See Replace Engine Oil and Engine Oil
Clogged Engine Oil Filter O O Clean or Replace.
Filter on page 5-19.
See Disassembly of Oil Pump on
Defective Pressure Regulating Valve O Clean, Adjust or Replace.
page 9-10.
Insufficient Engine Oil Level O O Add Correct Engine Oil. See Adding Engine Oil on page 4-15.
See Checking Engine Oil on

Overfilled Engine Crankcase O Check Engine Oil
page 4-14.


Poor

Color

Engine Starts
During
Work
Soon.


Exhaust

Smoke


Low Oil Pressure
Pressure Drop
Pressure Rise
Oil with Water
During Idling
Cause
Overheat
Ordinary
White
White
Black
Black
Much
None
Little
Stop Solenoid Failure O O Check and Replace See Stop Solenoid on page 7-6.
See Checking and Adjusting Fuel

Too Early Timing of Fuel Injection Pump O O O O Check and Adjust.
Injection Timing on page 7-26.
See Checking and Adjusting Fuel
Too Late Timing of Fuel Injection Pump O O O O O O Check and Adjust.
Injection Timing on page 7-26.
See Diesel Fuel Specifications on
Incorrect Diesel Fuel O O O O O O Use Correct Fuel Oil.
page 4-10.
See Drain Fuel Filter / Water
Water in Fuel System O O O O O O O Draining the Fuel Filter.
Separator on page 5-23.
See Clean Fuel Filter / Water
Clogged Fuel Filter O O O Clean or Replace.
Separator on page 5-33.
See Priming the Fuel System on
Air in Fuel System O O O Bleed the Air.
Fuel System
page 4-13.
Clogged or Cracked Fuel Line O O O Clean or Replace.
Check the Fuel Tank Cock, Fuel

Insufficient Fuel Supply to Fuel Injection Pump O O O Filter, Fuel Line, and Fuel Feed
Pump.
Uneven Injection Volume from Fuel Injection See Testing of Fuel Injectors on
O O O O O O O O O Check and Adjust.
Pump page 7-33.
See Testing of Fuel Injectors on
Excessive Fuel Injection Volume O O O O O O O Check and Adjust.
page 7-33.
See Testing of Fuel Injectors on
Poor Spray Pattern from Fuel Injection Nozzle O O O O O O O O O Check and Adjust.
page 7-33.
Foreign Matter Trapped in the
See Fuel System Components on
Priming Failure O Valve Inside the Priming Pump
page 7-12.
(Disassemble and Clean).
Clogged Strainer at Feed Pump Inlet O Clean the Strainer.


Poor

Color

Engine Starts
During
Work
Soon.


Exhaust

Smoke


Low Oil Pressure
Pressure Drop
Pressure Rise
Oil with Water
During Idling
Cause
Overheat
Ordinary
White
White
Black
Black
Much
None
Little
See Clean Air Cleaner Element on
Air / Exhaust Gas System
Clogged Air Filter O O O O O Clean Air Filter.

page 5-29.
Engine Used at High Temperatures or at High Study Output Drop and Load
O O O O O
Altitude Matching.
Clogged Exhaust Pipe O O O O Clean Exhaust Pipe.
Starting Motor Defect O Repair or Replace Stater Motor. See Starter Motor on page 11-10.
Electrical System
See Removal of Alternator on

Alternator Defect O Repair or Replace Alternator.
page 12-12.
Open-Circuit in Wiring O Repair Open Circuit.
Battery Voltage Drop O Inspect and Change the Battery. See Check Battery on page 5-24.


Electrical Wiring TNV DI Service Manual WIRING DIAGRAM
Electrical Wiring
Note: The following wiring diagram is representative of a common installation using a Yanmar engine. The actual installation may be equipped with a variety of electrical components and wiring harnesses. Contact the machine
manufacturer for specific information.
KEY SWITCH* 30A

FUSE*
EMERGENCY
STOP
SWITCH*
Items marked with * are

not provided by Yanmar.
0000864A

WIRING DIAGRAM Electrical Wiring

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TNV DI Service Manual

ii TNV DI Service Manual

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TNV DI Service Manual 1-1

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1-2 TNV DI Service Manual

TNV DI Service Manual 2-1

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2-2 TNV DI Service Manual

YANMAR LIMITED WARRANTY

How Long is the Warranty Period?

What the Engine Owner Must Do:

TNV DI Service Manual 2-3

To Locate an Authorized Yanmar Industrial Engine Dealer or Distributor:

What Yanmar Will Do:

What is Not Covered by this Warranty?

2-4 TNV DI Service Manual

Retail Purchaser Registration

TNV DI Service Manual 2-5

EMISSION SYSTEM WARRANTY

YANMAR CO., LTD. LIMITED EMISSION CONTROL SYSTEM

Manufacturers Warranty Period:

Engine Type Warranty Period by Number of Years or Hours of Operation

2-6 TNV DI Service Manual

TNV DI Service Manual 2-7

Owners Warranty Responsibilities:

2-8 TNV DI Service Manual

TNV DI Service Manual 3-1

This Page Intentionally Left Blank

3-2 TNV DI Service Manual

TNV DI Service Manual 3-3

FIRE AND EXPLOSION HAZARD!

EXPLOSION HAZARD! FIRE AND EXPLOSION HAZARD!

3-4 TNV DI Service Manual

FIRE AND EXPLOSION HAZARD! FIRE AND EXPLOSION HAZARD!

TNV DI Service Manual 3-5

FIRE AND EXPLOSION HAZARD!

dried grass close to the engine during

FIRE AND EXPLOSION HAZARD!

3-6 TNV DI Service Manual

FIRE AND EXPLOSION HAZARD!

FIRE AND EXPLOSION HAZARD!

TNV DI Service Manual 3-7

SEVER HAZARD! EXHAUST HAZARD!

3-8 TNV DI Service Manual

when you are working near moving /

TNV DI Service Manual 3-9

HIGH-PRESSURE HAZARD! ENTANGLEMENT HAZARD!

SHOCK HAZARD! BURN HAZARD!

3-10 TNV DI Service Manual

BURN HAZARD! A WARNING

To prevent possible eye injury, always

TNV DI Service Manual 3-11

COOLANT HAZARD! PINCH HAZARD!

3-12 TNV DI Service Manual

TNV DI Service Manual 3-13

to operate the engine.

3-14 TNV DI Service Manual

TNV DI Service Manual 3-15